Starter Motor Brushes for Kawasaki FR600V

Starter Motor Brushes for Kawasaki FR600V

Blog Article

Engine and Starter Motor Overview

• Displacement: 603 cc


• Power output: 22.5 HP (16.8 kW)


• Starter motor specifications: 12V, typically with a 9-tooth pinion gear and a solenoid-activated design.

Brush Specifications and Compatibility

• Material: Carbon-graphite composite with 40–50% copper content for optimal conductivity in high-current applications (up to 300 amperes during cranking).


• Dimensions:
  
  
  
  • Length: 22–24 mm
  
  
  • Width: 10–12 mm
  
  
  • Thickness: 8–10 mm
  
  
  
  


• OEM Part Numbers: Common original equipment part numbers include:
  
  
  
  • 21151-7037 (Kawasaki genuine brush set)
  
  
  • 21151-7041 (for later FR600V models)
  
  
  
  


• Aftermarket Equivalents: Compatible aftermarket brushes often carry cross-reference numbers such as:
  
  
  
  • ST-1234 (generic lawn equipment starter brush)
  
  
  • BR-600V (manufacturer-specific replacement)
  
  
  
  

Signs of Worn Brushes in FR600V Starters

• Intermittent Starting: The engine fails to crank consistently, especially in cold conditions.


• Arcing Noise: Visible sparks or a buzzing sound from the starter motor during engagement.


• Reduced Cranking Speed: The starter turns more slowly than normal, indicating poor electrical contact.


• Physical Wear: Brushes worn below 50% of their original length (e.g., less than 10 mm from the initial 22 mm).


• Commutator Damage: Scoring or blackening on the commutator segments, caused by worn brushes.

Replacement and Maintenance Guide

1. 
   
   Tools Required:
   
   
   
   
   • Socket set (10–14 mm)
   
   
   • Screwdrivers (flathead and Phillips)
   
   
   • Multimeter (for electrical testing)
   
   
   • Feeler gauge (to check brush spring tension)
   
   
   
   


2. 
   
   Step-by-Step Replacement:
   
   
   
   
   • Disconnect the battery negative cable to prevent electrical accidents.
   
   
   • Locate the starter motor on the FR600V engine (typically mounted near the flywheel housing).
   
   
   • Remove the starter motor mounting bolts and electrical connections (solenoid wire and ground cable).
   
   
   • Open the brush end cap of the starter motor, usually secured by clips or screws.
   
   
   • Remove the worn brushes by detaching the pigtail wires and releasing the brush springs.
   
   
   • Inspect the commutator for damage; use fine-grit sandpaper (400-grit) to smooth minor imperfections.
   
   
   • Install new brushes, ensuring the pigtail wires are correctly soldered or clamped.
   
   
   • Reassemble the starter motor and test for proper engagement (bench test recommended before reinstallation).
   
   
   
   


3. 
   
   Maintenance Tips:
   
   
   
   
   • Clean the commutator with isopropyl alcohol after brush replacement to remove debris.
   
   
   • Check brush spring tension (should be 1.8–2.5 N) using a spring scale to ensure consistent contact.
   
   
   
   

OEM vs. Aftermarket Brushes

• 
  
  OEM Brushes (Kawasaki)
  
  
  
  
  • Advantages: Guaranteed fit, matched to original design specifications, and compatible with warranty requirements.
  
  
  • Disadvantages: Higher cost (typically $15–$25 per set) and potential availability delays.
  
  
  
  


• 
  
  Aftermarket Brushes
  
  
  
  
  • Advantages: Lower cost ($8–$15 per set), wider availability from third-party suppliers.
  
  
  • Considerations: Ensure the aftermarket product lists compatibility with Kawasaki FR600V starters and meets or exceeds OEM performance standards (e.g., conductivity and wear resistance).
  
  
  
  

Where to Source Brushes for FR600V Starters

• Kawasaki Dealers: Authorized dealers carry genuine OEM brushes, ideal for warranty repairs. Use the Kawasaki dealer locator to find nearby service centers.


• Outdoor Power Equipment Retailers: Stores like Tractor Supply Co. or local lawn mower repair shops often stock aftermarket brushes for popular engines like the FR600V.


• Online Marketplaces: Websites such as Amazon, eBay, or specialized parts stores (e.g., Jack’s Small Engines) offer brush sets with shipping options.


• Industrial Supply Sites: For bulk orders or heavy-duty replacements, platforms like Starter Stock provide technical specifications and compatibility guides for FR600V starter components.

Relevant Website and Resources