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

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16-52 ELECTRICAL SYSTEM
Electric Starter System
NOTE
○Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with the hand tester. If all other starter motor
and starter motor circuit components check good, but
the starter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.
Brush Lead Inspection
• Using the × 1 Ω hand tester range, measure the resistance
as shown.
[A] Terminal Bolt and Positive Brush
[B] Brush Plate and Negative Brush
Special Tool - Hand Tester: 57001–1394
If there is not close to zero ohms, the brush lead has
an open. Replace the terminal bolt assembly and/or the
brush holder assembly.
Brush Plate and Terminal Bolt Inspection
• Using the highest hand tester range, measure the resistance
as shown.
[A] Terminal Bolt and Brush Plate
[B] Terminal Bolt and Right–hand End Cover
Special Tool - Hand Tester: 57001–1394
If there is any reading, the brush holder assembly and/or
terminal bolt assembly have a short. Replace the brush
holder assembly and the terminal bolt assembly.
Starter Relay Inspection
• Remove the battery negative (–) cable from the battery
negative (–) terminal (see Battery Removal).
Remove the right side cover.
• Pull out the starter relay.
Disconnect the connector [A]
• Disconnect the starter motor cable [B] and battery positive
(+) cable [C] from the starter relay [D].
CAUTION
The battery positive (+) cable with the rubber cap is
connected directly to the battery positive (+) terminal
even when the ignition switch off, so take care
not to short the removed cable to chassis ground.