2003 Kawasaki KLF250 Service Manual., Page 279Get this manual
ELECTRICAL SYSTEM 16-37 Electric Starter System
the diameter [A] [B] Measure the starter motor of theacommutator the commuReplace with new one if tator diameter is less than the service limitCommutator Diameter Standard: Service Limit: 28 mm (1.10 in,) 27 mm (1.06 in,)
Armature Inspection
1 range Using the xbetween any of the hand tester, measure the resistance two commutator segments [A]If there is high resistance or no reading () between any two segments, winding is openReplace the starter motorUsing the highest range of the hand tester, measure the resistance between the segments and the shaft [B]If there is any reading at all, the armature has shortReplace the starter motor
Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand testerIf all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with new oneStarter Motor Brush Length