Kawasaki KLE500 (2004) [360/401] Starter motor brush length

16-46 ELECTRICAL SYSTEM

Electric Starter System

•

Make sure that the marks [A] on the covers and yoke

housing align with each other.

•

Tighten the through bolts.

Torque - Starter Motor Through Bolts: 6.9 N·m (0.7 kgf·m,

65 in·lb)

Brush Inspection

•

Measure the length [A] of each brush.

If any is worn down to the service limit, replace the brush

plate assembly [B].

Starter Motor Brush Length

Standard: 12.0 ∼ 12.5 mm (0.47 ∼ 0.49 in.)

Service Limit: 8.5 mm (0.34 in.)

Brush Spring Inspection

•

Check that the brush springs are in place and will snap

the brushes firmly into place.

If not, reinstall or replace the spring.

Commutator Cleaning an d Inspection

•

Smooth the commutator s urface [A] if necessary with fine

emery cloth [B], and clean out the grooves.

•

Measure the diameter [A] of the commutator [B].

Replace the starter motor with a new one if the commu-

tator diameter is less than the service limit.

Commutator Diameter

Standard: 28 m m (1.10 in.)

Service Limit: 27 mm (1 .06 in.)