KZ 440 Starter Issue

Ok guys, got the very stubborn starter motor open and now I'm trying to rebuild. No wonder this old girl went bad. It was DISGUSTING inside that old starter. Tons of blank gunk went everywhere when I popped it open! I'm stuck on something that's got me scratching my head...

I bought a Caltric KZ 440 Starter motor rebuild kit and I've found that the bracket for the brushes isn't the same as the OEM. The OEM bracket retained the brushes when I removed it, but the Caltric one has different cuts to where the brushes won't stay in their slots with the springs. Maybe the Caltric kit is designs for the commutator in the middle to retain the brushes? Has anyone used a Caltric kit to rebuild?

Just an update on this... I was overthinking things on that Caltric starter kit! I got it to work after all. Rebuilt the starter, wired it up to the bench and it lives! Fires hard and fast. Another step forward. Next I'll put the bike together and see if she will get close to cranking.

Another update-

She lives! Put the bike back together enough for a test. Using a little starter spray with the carbs off, the bike fired up and ran! Now to get the carbs, tank and clutch back together.

Hoping I'll have a video of the first ride for you guys soon. Thanks for all the help. I'd highly recommend anyone who is thinking about trying to rebuild a starter go for it. It was a first time experience for me, but u learned a lot and hope I'll be able to save a lot of bucks doing this in the future!

Congratulations! One big hurdle conquered!!

Just a quick update- thanks for all the help guys. I've got a KZ that's running like she is NEW!

Since my last update I've put the starter in, rebuilt the carbs, cleaned up the clutch and even checked the ignition timing. She is purring and I've put 200 miles on her just this week! Still some work to do, the Tachometer needs replaced (started making a little buzzing sound here and there and the needle bounces) and I need to get a decent seat, but she is rideable and a really fun little bike.

Thanks again for the help guys, a KZ440 lives on thanks to all the support from you guys! And to think the PO was sending her to a junkyard.... Best 150 bucks I ever spent!

You could try lubricating the tachometer drive cable before replacing the instrument.