Kawasaki Z400 - Service manual > Electric  Starter System

Starter Motor Removal

NOTICE

Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.

• Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Frame Bracket Bolts [A] Right Frame Bracket [B]
• Slide back the rubber cap [A] and remove the starter motor cable terminal nut [B].
• Remove: Starter Motor Mounting Bolts [C] Starter Motor [D]

Starter Motor Installation

NOTICE

Do not tap the starter motor shaft or body. Tapping the shaft  or body could damage the motor.

When installing the starter motor, clean the starter motor legs [A] and crankcase [B] where the starter motor is grounded.

• Replace the O-ring [A] with a new one and apply grease to the O-ring.
• Install the starter motor on the crankcase and tighten the starter motes mounting bolts.

Torque - Starter Motor Mounting Bob: 9.8 Nm (1.0 kgf*m, 87 in*lb)

• Connect the starter motor cable [A] to the starter motor [B] as shown.
• Tighten:

Torque -Starter Motor Cable Terminal Nut: 9.8 Nm (1.0 kgf-m, 87 in*lb)

• Slide the rubber cap to the original position.
• Install the removed parts (see appropriate chapters).

Starter Relay Inspection

• Remove: Battery Case Cover (see Battery Case Cover Removal in the Frame chapter) Bolt [A]

• Slide the dust cover [A] and remove the starter relay terminal bolts [B].
• Disconnect the connector [C].
• Remove the starter relay [D] from the bracket.

• Connect a tester [A] and 12 V battery [B] to the starter relay [C] as shown

*If the relay does not work as specified, the relay is defective.

Replace the relay.

Testing Relay Criteria: When battery Is connected →0 When battery Is disconnected →

• Installation is the reverse of removal.
• Tighten:

Torque - Starter Relay Terminal Bolts: 3.6 N*m (0.37 kgf*m, 32 In-lb)

Electric Starter Circuit

1. Ignition Switch
2.  Engine Stop switch
3. Starter Button
4. Gear Position Sensor
5.  ECU
6. Side Stand Switch
7. Engine Ground
8. Battery
9.  Main Fuse 30 A
10. Starter Relay
11. Starter Motor
12.  Frame Ground (4)
13.  Frame Ground (2)
14. Fuse Box (1)
15. Ignition Fuse 10 A
16. Relay Box
17.  Starter Circuit Relay
18. Starter Lockout Switch

See also: