TOPIC:

I've got two starters both with bad armatures. Kawasaki.com doesn't list the armatures as separate parts. So there's no part number and no way to look up what fits what (at least that I can tell).

Does anybody know if the armatures for the electric starters in different years/models are at all interchangeable? Or were they pretty specific for each model?

There's an armature for a KZ250 on ebay that's tempting me. The photo looks about right. Unfortunately the seller says they won't take measurements (too many requests and not enough staff).

What's bad about the armatures and from what bike?

79 kz750. The armatures are physically damaged.

Starter Solenoid/Motor Checkout Procedure

Some simple steps to determine what is working and what's not:

1.Fully charge and test the battery(most bike shops can load test the battery, and then use a floating ball hydrometer to check specific gravity in the charged cells).

2.Clean all battery terminals of corrosion.

3.Tighten all starting related connections(Positive RED(+) battery terminal, Negative BLACK(-)terminal) and from the terminal to the engine case. All connections must be clean and tight. If the cables feel “Crunchy” when flexed, they may have corrosion inside the insulation, requiring replacement.

4.Clean the cable from the starter solenoid to the starter motor.

5.Clean and check the "bullet connectors" going to the coil side of the starter solenoid.

6.Try again to start the bike, keep in mind some Kawasaki’s have a clutch interlock to prevent cranking the engine while it’s in gear, so the clutch lever must be squeezed.

7.If no luck, go to step #8

8.Wearing eye protection, bridge with pliers or a screwdriver the two heavy duty(large)terminals on the solenoid. If the bike cranks, your solenoid may be bad.

9. If the starter won’t turn over, one of several things has happened; The starter motor has seized due to brushes binding up, lack of lubrication in the bushings of the motor, the battery is weak , the engine has seized or it could be a combination of any of the above. Some websites for starter motor rebuild kits are:

A. www.psep.biz/store/mitsuba_starter_motors_page_2.htm

B. www.nationsautoelectric.com/Kawasaki.html

C. www.whitedogbikes.com/cat--Kawasaki-Star...-Starter-Motors.html

D. www.ricksmotorsportelectrics.com/starters.php

E. www.dbelectrical.com/

F. http://.www.nationsautoelectric.com/Kawasaki.html

10.The dealer may want $$$ for a new solenoid, but take your old one along and visit the nearest riding lawn mower shop. They have solenoids for about $15 that with a little work will fit. Be aware that the new solenoid from the lawn mower shop may require a ground wire for it to work.

11. I’d recommend upgrading from the existing battery cables to at least 6 gauge welding cables.
They are available in two colors(RED and BLACK) have more flexibility due to being constructed with finer conductors, and will fit in tighter areas.

12. The welding cable is sold by the foot, so take careful measurements or bring your old cables along. Most battery shops might be able to supply the cable too, so call to find out. The battery shop should be able to crimp/swage on the end of the welding cable the terminal ends or lugs using either a dedicated crimping machine or a tool that looks like a bolt cutter that has special dies to terminate the cable.

MFolks, thanks for the troubleshooting tips, but I know what's wrong here. Here are some pics of my starter motor.
kzrider.com/forum/2-engine/593938-a-ques...ists?start=20#633554

I bought an untested, used replacement on ebay hoping to scavenge the armature only to find it was physically damaged too.

So nobody knows if any of these armatures are interchangeable? I wonder why Kawasaki didn't give them part numbers.

Hey man, I hope its way too late to help you, (I mean I hope you spent the last three months riding your bike and not cursing the starter. ) Anyway, i just picked up a 250 for a song and it had a bad starter in it too. The more i looked at it the more familiar it looked so went out to my pile of parts bikes and fished out the starter off an old 197? KZ400. I had to pop the ends off both starters and swap them but in about 15 minutes all together I had a working starter ready to bolt on. Now all I need to do is source the tube that goes inside the oil filter, (thanks to the previous owner) and button her up and see if shell runs.

Thanks! Been riding and mastering the art of the kick start. I've aquired a new starter thanks to a generous kzr member but it needs some work and I haven't gotten around to it yet.