How to install starter motor on kz250 motorcycle

It is generally possible to remove the starter motor on a 1998 Harley FXSTC (EVO) without removing the oil tank. However, it may be necessary to remove other parts or components in order to access the starter motor.
To remove the starter motor on a 1998 Harley FXSTC (EVO), you will need to follow these steps:

1. Disconnect the negative battery cable. This will prevent any electrical accidents while working on the starter motor.
2. Remove the starter motor cover, if applicable. This is typically located on the side of the engine near the starter motor.
3. Disconnect the electrical connections to the starter motor. This includes the starter solenoid wire and the starter motor wire.
4. Remove any fasteners that hold the starter motor in place. These are typically bolts or screws that hold the starter motor to the engine or frame.
5. Carefully lift the starter motor off of the motorcycle.

It's important to be careful when removing the starter motor to avoid damaging the motor or the motorcycle. If you are unsure of how to remove the starter motor or if you encounter any difficulties, it may be best to consult a mechanic or the motorcycle's service manual for further guidance.

https://www.google.com gives a number of sites with manuals for sale.

Example below:

https://www.z1enterprises.com/motorcycles/kawasaki/kz250/maintenance-parts/manuals-books.html

Hello Pam, the controllers on the Kawasaki, KLT 250 Prairie, 1983-1985 are suppose to be the same...i have never swapped a CDI controller on the older KZ 250's, so i can not advise if another unit would work. I did however locate a new replacement for your bike. Here is the link.
I hope this helps & good luck with your bike.
http://cgi.ebay.com/ebaymotors/CDI-box-Kawasaki-KZ250-1980-1983-KZ-250-/250839194546?pt=Motors_ATV_Parts_Accessories&hash=item3a672e5bb2

Tap on the starter gently with a plastic hammer while holding the starter button. If the starter works now you need starter brushes. The brushes are about the only replacement part available on Japanese motorcycle starters. Unbolt the power cable to the starter, take off the two bolts holding the starter to the case, and pull the starter out of the motor. Now you can take off the end cap to inspect the brushes. Installation is reverse order. bench test the starter before reinstalling. If the spline of the starter does not mesh with the spline hole of the gear in the motor, rotate the starter enough so the splines line up or power the motor to move the position of the spline and try again. If you have an Ohm meter you can easily test the armature. You should have continuity between every other contact. But no continuity between adjacent contacts. If there is anything other than brushes wrong with the starter you will have to replace the assembly.

Hi,,if the starter is turning,and not the motor,,then the gear on the starter is not engaging.

I yes install a new Battery evry 2 years , The battery since to loose the apm, Juse, and can damage u starter, is cheaper to replace the battery,,

Try downloading at this site: http://www.trippycolor.com/1980-kawasaki-kz250-manual.html

The starter motor sits on top of the engine cases behind the left two cylinders (as you sit on the bike)
If you look at your engine from the left, look between the cases and the carbs and you will see it. It bolts to the top of the cases right about in the middle, and plugs into the cases behind the left crankcase cover.
The parts microfiche does not do a good job showing where the starter motor sits.

http://www.babbittsonline.com/pages/parts/viewbybrand/default.aspx

If you go through the steps of putting in your brand, motorcycle, year and finding your model, then select the crankcase option, where you see reference #27 is where the starter motor nose cone is installed in the cases. If you look towards the center of the cases behind where the cylinders are, right between where #2 and #3 would be, you can see one of the castings sticking up that is used for mounting the starter motor to the cases. Also, in the small diagrams at the top of the page, the left diagram shows a short line extending perpendicularly down from the row of cylinder holes, just to the right of the #2 cylinder, that is another view of where your starter motor attaches to the cases.

hi yamafam,

below is the link that will show you the factory settings of the KZ250

http://www.zedder.com/Info/81%20KZ250-D2%20CSR.htm

regards