As with quite a few, I have been plagued by hot starting issues since I got my bike with it barely turning over when hot and causing me to have to bump start when hot.
So I fitted the bigger cables, had no effect.
Tuned the bike several times. Made a small improvement but the issue still persisted.
So I took the starter off and stripped it down, I found the back bush near the brushes had some play in it and the front thrust washer had some heat scores on it. Basically nothing shouting massive issues.
So I thought I would try another starter motor. After ordering a new second hand one, I was looking at trying to buy new (not available) but I came across new ZZR600 ones that looked the same with the same 10spline shafts.
I found an auction site special for £20 inc delivery so worth a punt.
When it came I checked it against the original and the collar and the rear fixings are identical but the diameter was about 1/4 bigger. So I tried it anyway. It fitted and wow what a difference. It now starts Very quickly and when very hot too.
Starter motor from 1997 ZZR600
Denzo starter
Part no. 21163-1211
228000-1820
12v
Worth getting a set of uprated cables if you fit the bigger motor as standard ones will cause issues and get hot.
I can’t say if there’s any issues with using the above but I am trying it out myself. I hope the above will be useful to others but I can’t be responsible if it causes issues for other people just sayin what I have done and it works for me.
IMO the starter as fitted from factory is a bit light on power and as soon as wear sets it then things that’s when it becomes a problem, looking at my starter it looks like a combo of the tail bush wear and the front thrust washer taking a heavy load is causing it to loose power so when things are hot and tight then it can’t overcome the friction of the engine.
Permanent fix for hot starting problem (starter motor)
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