Book Excerpt: 1987-2002 Kawasaki EX500, GPZ500S, Ninja 500R Repair Manual
ELECTRICAL SYSTEM
ELECTRIC STARTER
The starter circuit includes the starter button, starter relay, battery and starter motor. Figure 9 illustrates the typical starter circuit.
(For Removal/Installation, refer to Chapter Four).
DISASSEMBLY/REASSEMBLY
Starter motor repair is generally a job for electrical shops or a Kawasaki dealer. The following procedure describes how to check starter brush condition.
Referring to Figure 10, disassemble the starter motor.
Measure the length of each brush with a vernier caliper (Figure 11). If the length is less than specified in Table 1, it must be replaced. Replace the brushes as a set even though only one may be worn to this dimension.
Inspect the commutator. The mica in a good commutator is below the surface of the copper bars. On a worn commutator, the mica and copper bars may be worn to the same level. See Figure 12. If necessary, have the commutator serviced by a dealer or electrical repair shop.
REAR SUSPENSION
This chapter includes repair and replacement procedures for the rear wheel, drive chain and rear suspension components.
Tables 1-3 are at the end of the chapter.
REAR WHEEL: REMOVAL/INSTALLATION
Support the bike so that the rear wheel clears the ground.
Remove the cotter pin, then disconnect the torque link (Figure 1) at the rear brake. Then remove the rear brake adjuster nut (Figure 2).
Loosen the drive chain adjusting locknuts and adjuster bolts (A, Figure 3).
Remove the cotter pin, rear axle nut and washer (B, Figure 3).
