SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Starter Motor Removal
In order to remove the starter motor you will need to remove the muffler and exhaust header pipe. Refer to the Exhaust Removal topic for more information.
Disconnect the starter motor cable from the starter motor terminal using a 10 mm wrench. Be careful not to turn the starter motor terminal.
Loosen the two starter motor bolts using a 10 mm wrench.
Pull the starter motor free from the reduction gear housing.
Inspect the starter motor O-ring for damage. Replace as needed. Clean and lubricate this O-ring with a small amount of engine oil upon reassembly. Clean the starter motor and crankcase mounting posts to insure a good ground upon reinstallation.
Starter Motor Disassembly
Pay particular attention to the alignment marks on the outside of the starter. This will help you when it is time for reassembly.
Using a #2 Phillips head screwdriver, remove both retaining screws from the starter.
Remove the starter end cover on the brush assembly side. Note the location of the shims.
Remove the other end cover. Check that the bearing spins freely and that the seal is in good condition – replace either as needed. Note the location of the tab washer.
Inspect the O-rings that are located on each end of the starter motor for wear or damage – replace as needed.
Pay particular attention to how the brush plate tab is aligned with the housing notch – you will need to align both upon reassembly.
Remove the terminal stud nut with a 10 mm wrench and remove the terminal stud. Note the location of the phenolic (plastic) washers.
Remove the brush plate assembly.
Remove the armature from the starter motor housing. This armature is not from the Kawasaki KLR650, but it looks similar.
Remove the positive brushes.
Inspect the positive brush holder rubber grommet on the starter motor – replace as needed.
Clean all of the starter motor parts with aerosol electrical contact cleaner and a lint free cloth.
Starter Motor Inspection
Brush Length
Measure the maximum length of the brushes with a caliper and compare your measurements with specification.
brush length is no less than 6 mm)
Brush Springs
Check that the brush springs apply tension to the brushes and that the brushes move in the brush holders smoothly. Replace any worn or damaged brushes.
Armature
If the commutator is discolored use 400 grit sandpaper or emery cloth on it prior to testing. Be sure to clean any carbon dust out of the grooves between each segment. Using a pair of verniers, measure the diameter of the commutator. If the measurement is less than specification, replace the starter motor assembly as a unit.
commutator diameter is no less than 27 mm)
Using a digital multimeter set to Ohms of resistance, touch one meter lead to any one commutator strip and touch the other meter lead to all of the other commutator strips one by one. Polarity of the meter leads does not matter. There should be continuity for all of the readings, if any readings show no continuity the armature must be replaced.
Using a digital multimeter set to Ohms of resistance, touch one meter lead to any one commutator strip and touch the other meter lead to the steel shaft of the armature. Polarity of the meter leads doesn’t matter, and you only need to check one of the commutator strips. There should be no continuity, if there is the armature must be replaced.
Brush Plate
Inspect the brush plate by using a digital multimeter set to Ohms of resistance to check the continuity between the negative brushes and the metal plate. Replace the brush plate if there is no continuity.
Use a digital multimeter set to Ohms of resistance and check the continuity between the positive brush holder and the metal plate. There should be no continuity, if there is the brush plate must be replaced.
Positive Brush
Install the positive brushes in the starter motor body. Use a digital multimeter set to Ohms of resistance to check the continuity between the positive brushes and the terminal stud. Replace the positive brushes if there is no continuity.
Using a digital multimeter set to Ohms of resistance, check the continuity between the starter motor body and the terminal stud. There should be no continuity, if there is the positive brushes must be replaced.
Starter Motor Reassembly
Slide the armature into the starter motor body with the commutator end next to the terminal stud. The magnets will pull the armature into position.
Place the shims and tab washer in their original positions. The tabs must fit in between the webbing of the end cover.
Slide the brushes back into the holders on the brush plate and place the brush plate back into position. Make sure the small locating tab at the very bottom of the photo fits into its slot.
Place both end caps in position, making sure the two large O-rings are in place. The groove cast into the brush side end cap in the photo on the right must fit around the large metal tab sticking out of the brush plate.
Install the two long Phillips head screws and tighten them securely. Turn the armature with your hand, it should turn with some resistance, if it doesn’t turn at all the starter motor will have to be taken apart again to see what is binding.
Slide the starter motor into position and tighten the two mounting bolts to specification.
starter motor bolt torque: 9.8 N-m or 87 in-lb
Reconnect the starter motor cable and tighten the nut securely, making sure not to turn the terminal stud.
Install the protective rubber boot over the terminal.