82 KZ1100 starter rebuild

No riding until I rebuild this 35 year old starter.
Was thinking about the Honda starter upgrade, but 12 bucks is closer to my budget right now

Armature isn't too bad. Incut a few thousandths, but seen worse

Looks like the bushing was running dry. Check for slop.
Steve

What is the depth of the mica between commutator plates? I'm wondering for mine if a rebuild will fix my problem, and if yours has the same problem.

Thanks,
Matt

kzrider.com/forum/4-electrical/609001-st...ble-83-kz1100#788468

M_a_t_t wrote: What is the depth of the mica between commutator plates? I'm wondering for mine if a rebuild will fix my problem, and if yours has the same problem.

Thanks,
Matt

kzrider.com/forum/4-electrical/609001-st...ble-83-kz1100#788468

Wow, Matt, that sure let the smoke out of the brushes. The brush holder is charred white from heat. Like Steve said, it looks like the bushings are toast. and the armature was dragging, and cooked it hard. I don't even see any mica between the segments, although it has to be there, somewhere There was a thread a while back on some rebuild kits with 4 brush holders and bushings. I don't remember where, eBay, I think.

Turn that armature and and see if it works. I was taught in college to use a "growler" and a hacksaw blade to check the armature,.. 40 years ago, so I'm a little foggy on the exact procedure.. I don't happen to have one laying around, myself, as I am sure you don't either. Maybe an auto electric place near you can turn it and check it for you.

I bought the 12 dollar rebuild kit off ebay.
It came with new bearings, bushings, brushes and all the hardware.
It took me a little while to figure out a way to hold the springs back on the brushes while I slid the armature back in.
The armature isn't in perfect shape, not much micah between those pickup coils.
Bearings and shaft are still pretty close, not much slop.
Starts better now than at any time since I bought it this past January.
Very happy to be riding again today!
Thank you all for your suggestions and concerns!
It's very helpful and appreciated!

To remove the bushing from the end cap, fill it with grease and use the shaft as a drift carefully tapping on it until it comes out. If the bushing is too far gone you will need a larger bolt/rod as a drift. Even a little slop can make the starter bind.
Steve