Starter Motor Rebuild

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Miles
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Starter Motor Rebuild

Post by Miles »

Hello folks,

Excuse my ignorance but after searching around on the forum for abit I couldn’t find any information about taking the starter motor apart.

I remember years ago coming across a guide for it but no such luck.

Much appreciated if anyone could send me in the right direction

Thanms
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banner001
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Re: Starter Motor Rebuild

Post by banner001 »

I know of the same guide, think the pictures are long gone.

I've done it before, and it was a giraffe, as you have to get all 4 carbon brushes past the commutator.

You can use toothpicks or thin crocodile clips to hold them back on reassembly, but it's very difficult still.

Word to the wise, when I did mine it never worked properly afterwards, had to buy another one
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003
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Miles
zxr400 oc member
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Posts: 498
Joined: Wed Apr 30, 2008 11:00 pm
My Bike: ZXR 400 L3
Location: Bangor, Northern Ireland

Re: Starter Motor Rebuild

Post by Miles »

Not a problem, thanks for the reply Banner.

Did you get a new motor from somewhere or was it 2nd hand?

Obv Kwak don’t do them anymore (along with original coil packs, hence my other posts about changing to stick coils but I think stick coils will fry the Igniter due to their secondary resistance and feeding a pulse back into the igniter)
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banner001
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Re: Starter Motor Rebuild

Post by banner001 »

2nd hand one from ebay.

I was trying to sort out my starting issues, and thought it might be the motor...turns out that new battery leads and a much higher cranking battery (175cca!) fixed it...
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003
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Miles
zxr400 oc member
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Posts: 498
Joined: Wed Apr 30, 2008 11:00 pm
My Bike: ZXR 400 L3
Location: Bangor, Northern Ireland

Re: Starter Motor Rebuild

Post by Miles »

Ah yes I happen to own a set of you’re much improved battery leads.

Maybe a higher cranking battery will help as well
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banner001
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Re: Starter Motor Rebuild

Post by banner001 »

Standard battery is YTX9-BS, which is 135CCA

Motabat battery is MB9U, which is 140CCA

Yuasa YT12A-BS battery is awesome, and 175CCA - this is what i have on my bike, and its awesome!
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003
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Miles
zxr400 oc member
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Posts: 498
Joined: Wed Apr 30, 2008 11:00 pm
My Bike: ZXR 400 L3
Location: Bangor, Northern Ireland

Re: Starter Motor Rebuild

Post by Miles »

Is the YT12A-BS a straight swap banner or did you need to lift the battery up to reach the cables etc?
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banner001
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Re: Starter Motor Rebuild

Post by banner001 »

Straight swap, it's the same dimensions as the oem, and the terminals are in the same place
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003
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