How do I remove the starter motor from my Honda G400 electrical generator?

it seems like your ignition switch may not be removing the ground while in the starting position try removing the ground wire from key switch if it turns over and start with key replace switch assy.

Hi there! 1) Check battery with a load tester and recharge / replace if necessary 2) Check the ignition switch for loose wires or if the switch is okay 3) Remove the starter and try to run it against a piece of wood ( Have you seen the wooden hammer handle of an auto electrician?) If you can stop it then the motor needs repair/replacement it is often cheaper to replace than repair it excluding labour!! 4) Check ringear on the flywheel and the pinnion of the starter motor for binding and wear. Keep these tips in mind for your Automobiles too

Follow the specific instructions in the Factory Service Manual. Step 1 - Remove the heavy wire from the starter solenoid. Either end will suffice. Step 2 - Remove the chrome cover over the starter. Step 3 - remove the screws that hold the starter motor in place. Step 4 - Lift the starter motor out of the engine. NOTE: removing the carbs may make this step simpler. The "business" end of the starter should come out of the splined starter clutch gear. If you have trouble removing the starter from the clutch gear, you may need to remove the left side stator cover to gain access to the starter clutch and chain. The exploded parts diagram is available HERE Kawasaki Motorcycle Parts 1982 KZ1000 J2 STARTER MOTOR STARTER CLUTCH...

hi
I think the problem is on when the key is turn to rotate and to engage the starter motor and it at this point that the cable curring the current on to the starter motor it then the fuse gets blown , in my opinion this cable is shortening across the chassis causing the fuse to blow, or when it get to the starter solenoid a faulty solenoid absorbs accessed electric current causing the fuse to blow

REMOVAL & INSTALLATION
(see Figures 2, 3, 4, 5, 6 and 7)

1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3. If necessary for access, remove the splash shield.
4. If equipped, unfasten the flywheel inspection cover bolts and remove the cover.
5. Label and detach the electrical connectors from the starter.

Fig. 2: Unfasten the starter motor electrical connections. You may want to tag them first to avoid confusion



Fig. 3: Exploded view of the starter motor electrical connections

1. It may allow more room it you remove the right side cooling fan.
2. Remove the starter-to-engine bolts, then carefully lower the starter from the vehicle.

Fig. 4: The starter is attached to the engine with 2 mounting bolts (see arrows)



Fig. 5: Unfasten the front mounting bolt (1) and remove any necessary shims (2), noting their locations for installation



Fig. 6: Unfasten the long starter mounting bolt, then remove the starter motor from the vehicle


Before installing the starter motor, make sure the electrical terminals are secure by tightening the nuts next to the cap on the solenoid battery terminal and on the "S" terminal. If these terminals are not tight in the solenoid cap, the cap may be damaged during installation of the electrical connections and cause premature starter failure.



Fig. 7: Exploded view of the starter motor mounting - 1987-97 vehicles


To install:
Note the location of any shims so they may be replaced in the same positions upon installation.

1. Place the starter in position, then install the starter-to-engine bolts and tighten to 32 ft. lbs. (43 Nm).
2. Attach the electrical connectors to the starter, as tagged during removal. Tighten as follows:
1. Tighten the nut on the solenoid battery terminal to 12 ft. lbs. (16 Nm).
2. On the SD-250 and SD-255 models, tighten the nut on the "S" terminal to 22 inch lbs. (2.5 Nm).
3. If removed, install the flywheel inspection cover and secure with the retaining bolts. Tighten the flywheel cover bolts to 62 inch lbs. (7 Nm).
4. If removed, install the splash shield.
5. Carefully lower the vehicle.
6. Connect the negative battery cable.

Hope helps (remember rated and comment his).

REMOVAL & INSTALLATION
(see Figures 2, 3, 4, 5, 6 and 7)

1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3. If necessary for access, remove the splash shield.
4. If equipped, unfasten the flywheel inspection cover bolts and remove the cover.
5. Label and detach the electrical connectors from the starter.
   

Fig. 2: Unfasten the starter motor electrical connections. You may want to tag them first to avoid confusion



Fig. 3: Exploded view of the starter motor electrical connections

1. It may allow more room it you remove the right side cooling fan.
2. Remove the starter-to-engine bolts, then carefully lower the starter from the vehicle.

Fig. 4: The starter is attached to the engine with 2 mounting bolts (see arrows)



Fig. 5: Unfasten the front mounting bolt (1) and remove any necessary shims (2), noting their locations for installation



Fig. 6: Unfasten the long starter mounting bolt, then remove the starter motor from the vehicle

Before installing the starter motor, make sure the electrical terminals are secure by tightening the nuts next to the cap on the solenoid battery terminal and on the "S" terminal. If these terminals are not tight in the solenoid cap, the cap may be damaged during installation of the electrical connections and cause premature starter failure.



Fig. 7: Exploded view of the starter motor mounting - 1987-97 vehicles

To install:


Note the location of any shims so they may be replaced in the same positions upon installation.

1. Place the starter in position, then install the starter-to-engine bolts and tighten to 32 ft. lbs. (43 Nm).
2. Attach the electrical connectors to the starter, as tagged during removal. Tighten as follows:
   
1. Tighten the nut on the solenoid battery terminal to 12 ft. lbs. (16 Nm).
2. On the SD-250 and SD-255 models, tighten the nut on the "S" terminal to 22 inch lbs. (2.5 Nm).
   


3. If removed, install the flywheel inspection cover and secure with the retaining bolts. Tighten the flywheel cover bolts to 62 inch lbs. (7 Nm).
4. If removed, install the splash shield.
5. Carefully lower the vehicle.
6. Connect the negative battery cable.

Hope helps (remember rated and comment this).

1. Disconnect the negative battery cable.
   
2. Raise and support the vehicle safely.
   
3. If necessary for access, remove the splash shield.
   
4. If equipped, unfasten the flywheel inspection cover bolts and remove the cover.
   
5. Label and detach the electrical connectors from the starter.
   

Unfasten the starter motor electrical connections. You may want to tag them first to avoid confusion


Exploded view of the starter motor electrical connections

2. It may allow more room it you remove the right side cooling fan.
   
4. Remove the starter-to-engine bolts, then carefully lower the starter from the vehicle.
   

The starter is attached to the engine with 2 mounting bolts (see arrows)


Unfasten the front mounting bolt (1) and remove any necessary shims (2), noting their locations for installation


Unfasten the long starter mounting bolt, then remove the starter motor from the vehicle

Before installing the starter motor, make sure the electrical terminals are secure by tightening the nuts next to the cap on the solenoid battery terminal and on the "S" terminal. If these terminals are not tight in the solenoid cap, the cap may be damaged during installation of the electrical connections and cause premature starter failure.


Exploded view of the starter motor mounting - 1987-97 vehicles

To install:
Note the location of any shims so they may be replaced in the same positions upon installation.

1. Place the starter in position, then install the starter-to-engine bolts and tighten to 1 ft. lbs. (43 Nm).
   
2. Attach the electrical connectors to the starter, as tagged during removal. Tighten as follows:
   
   1. Tighten the nut on the solenoid battery terminal to 12 ft. lbs. (16 Nm).
      
   2. On the SD-250 and SD-255 models, tighten the nut on the "S" terminal to 22 inch lbs. (2.5 Nm).
      
3. If removed, install the flywheel inspection cover and secure with the retaining bolts. Tighten the flywheel cover bolts to 62 inch lbs. (7 Nm).
   
4. If removed, install the splash shield.
   
5. Carefully lower the vehicle.
   
6. Connect the negative battery cable.
   

ELECTRIC START WILL BE MOUNTED BETWEEN THE POWER UNIT AND THE GAS MOTOR IF YOU TAKE THE OUTER COVERS OFF YOU SHOULD BE ABLE TO SEE IT IT WILL LOOK LIKE A MINI CAR STARTER IF YOU NEED MORE HELP I MAY BE ABLE TO GET SCHEMATICS FOR YOU BUT I WOULD NEED MOTOR INFO MODEL BRAND SERIAL #S AND FROM THE POWER UNIT ALSO

Sorry, I don;t have a solution but do you have a good coil from one of those you would like to sell?

1. Disconnect the negative battery cable.
   
2. Raise and support the vehicle safely.
   
3. If necessary for access, remove the splash shield.
   
4. If equipped, unfasten the flywheel inspection cover bolts and remove the cover.
   
5. Label and detach the electrical connectors from the starter.
   

Unfasten the starter motor electrical connections. You may want to tag them first to avoid confusion
Exploded view of the starter motor electrical connections
Click to Enlarge

1. It may allow more room it you remove the right side cooling fan.
   
2. Remove the starter-to-engine bolts, then carefully lower the starter from the vehicle.
   

The starter is attached to the engine with 2 mounting bolts (see arrows)
Unfasten the front mounting bolt (1) and remove any necessary shims (2), noting their locations for installation
Click to Enlarge Unfasten the long starter mounting bolt, then remove the starter motor from the vehicle
Before installing the starter motor, make sure the electrical terminals are secure by tightening the nuts next to the cap on the solenoid battery terminal and on the "S" terminal. If these terminals are not tight in the solenoid cap, the cap may be damaged during installation of the electrical connections and cause premature starter failure.