Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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Electric Starter System
• Align the line [A] marked on the yoke with the through bolt
hole [B].
ELECTRICAL SYSTEM 16-51
Brush Inspection
• Measure the length [A] of each brush.
If any is worn down to the service limit, replace the carbon
brush holder assembly [B] and the terminal bolt assembly
[C].
Starter Motor Brush Length
Standard: 12 mm (0.47 in.)
Service Limit: 8.5 mm (0.33 in.)
Commutator Cleaning and Inspection
• Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.
• Measure the diameter [A] of the commutator [B].
If the commutator diameter is less than the service limit,
replace the starter motor with a new one .
Commutator Diameter
Standard: 28 mm (1.10 in.)
Service Limit: 27 mm (1.06 in.)
Armature Inspection
• Using the × 1 Ω hand tester range, measure the resistance
between any two commutator segments [A].
Special Tool - Hand Tester: 57001–1394
If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
• Using the highest hand tester range, measure the resistance
between the segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.