When I prepair to remove the starter Should I make line up marks/
or are thair line up marks to remove and install Need an anser before I start
This starter must be rebuilt The battery and salanoid are or and the starter cut off is ok It cranks too slow if any at all
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This procedure is for 200 Kawasaki Prairie 400
1:on the flywheel cover, remove the pull starter asembley so you can turn the engine over by using a wrench. on that same side, remove the timing inspection plug. it will be on teh side of teh flywheel cover, and have a large flat blade screwdriver mark or allen hole you use to unscrew it.
2:with the inspection plug removed, slowley turn the engine untill you see a "F" and a line. from there, rotate the engine very slowley untill you see a "T." JUST after the "T" there is a line. you want the mark inside the inspection plug hole to line up with that line after the "T."
3: with the bottom end now timed, you will install the cam into the head. when you set the camshaft into the head, do so with the lobes pointing directly down. after the cam is installed, then install the cam sprocket and make sure the lines on it are directly left to right. the lines will end up lining up with the level surface of the cylinder head surface. ater you have installed the cam and sprocket, look again at the inspection hole in the flywheel cover to recheck that the bottom end is still on time.
4: once the cam is installed, and the sprocket is installed on it, you will see the lobes point down, and the cam sprocket lines are from side to side. then yo uwant to install teh cy;inder head cover.
5after the head cover is installed, install the cam chain tensioner, and slowley rotate the engine to ensure the valves and piston do not contact. USE HAND TOOLS TO ROTATE ENGINE, NOT ELECTRIC STARTER!! the electric starter will cause damage if the timing is off.
Section 03-06: Starting System
1996 Mark VIII Workshop Manual
REMOVAL AND INSTALLATION
WARNING: WHEN SERVICING STARTER MOTOR (11002) OR PERFORMING ANY MAINTENANCE IN THE AREA OF THE STARTER MOTOR, NOTE THE HEAVY GAUGE INPUT LEAD CONNECTED TO THE STARTER SOLENOID (11390) IS HOT AT ALL TIMES. MAKE SURE THE PROTECTIVE CAP IS INSTALLED OVER THE TERMINAL AND IS REPLACED AFTER SERVICE.
Disconnect the battery ground cable (14301). Refer to Section 14-01 .
Raise the vehicle on a hoist. Refer to Section 00-02 .
CAUTION: When disconnecting hardshell connector at S-terminal, grasp the plastic shell and pull off. Do not pull on wire. Be careful to pull straight off to prevent damage to the connector and S-terminal. If any part of the connection is damaged, replace the damaged components.
Disconnect starter cable and push-on connector from starter solenoid.
2-4 hrs, depends on experience, you need metric sockets and wrench set, hydraulic jack or any jack. screwdrivers (flats and phillips) $100+ us dollars for a new starter, with core return. Disconnect your negative battery cable, on your battery. Disconnect wirings at your starter: ignition wires, and power cable. !!! Important for the electrical wiring !!! (take pictures, or mark it where goes back, for reference when putting it back together) Three bolts holds the starter, two medium length bolt and one extra long bolt (this the long bolt goes thru your front engine mount). one of the bolts is double nutted, first nut secures a cover shroud over your starter,, second holds the starter. You need to jack the engine up slightly to relieve pressure off the long bolt when removing, also to prevent engine from dropping when long bolt is removed. when all bolts are removed starter should come out easily. install new starter in reverse order, take pictures, mark all hardware make sure they go back in the same place, mark or take pictures of your wiring before disconnecting.
Disconnect the negative, then the positive battery cable. Drain the crankcase and the cooling system into suitable containers.
Drain and recycle the engine coolant.
Properly relieve the fuel system pressure.
NOTE: If your vehicle is equipped with air conditioning, refer to Section 1 for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components. CAUTION Never open, service, or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. In addition, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.
Mark the position of the hood on the hinges and remove the hood. Disconnect the battery ground cables from the cylinder block.
Remove the air intake duct and the air cleaner.
Disconnect the upper radiator hose from the thermostat housing and the lower hose from the water pump. Disconnect the oil cooler lines from the radiator.
Remove the bolts attaching the radiator fan shroud to the radiator. Remove the radiator. Remove the fan, belt pulley, and shroud.
Remove the alternator bolts and position the alternator aside.
Disconnect the oil pressure sending unit wire from the sending unit. Disconnect the fuel lines; refer to Section 5.
Disconnect the accelerator cable from the throttle body. Disconnect the throttle valve rod/cable. Disconnect the cruise control cable, if equipped.
Disconnect the throttle valve vacuum line from the intake manifold, if equipped. Disconnect the transmission filler tube bracket from the cylinder block.
Disconnect the air conditioning lines and electrical connectors at the compressor; refer to Section 6. Plug the lines and the compressor fittings to prevent the entrance of dirt and moisture.
Disconnect the power steering pump bracket from the cylinder head. Remove the drive belt. Position the power steering pump aside in a position that will prevent the fluid from leaking.
Disconnect the power brake vacuum line from the intake manifold.
Disconnect the heater hoses from the heater tubes. Disconnect the electrical connector from the coolant temperature-sending unit.
Remove the transmission-to-engine upper bolts.
Disconnect the wiring harness at the two 10-pin connectors.
Raise and safely support the vehicle. Disconnect the starter cable from the starter and remove the starter.
Disconnect the muffler inlet pipes from the exhaust manifolds. Disconnect the engine mounts from the chassis. Disconnect the downstream thermactor tubing and check valve from the right exhaust manifold stud, if equipped.
Disconnect the transmission cooler lines from the retainer and remove the transmission inspection cover..
Match mark the converter and flywheel with a dab of paint to ease installation. Disconnect the flywheel from the converter and secure the converter assembly in the transmission. Remove the remaining transmission-to-engine bolts.
Lower the vehicle and then support the transmission. Attach suitable engine lifting equipment and hoist the engine.
Raise the engine slightly and carefully pull it from the transmission. Carefully lift the engine out of the engine compartment. Avoid bending or damaging the rear cover plate or other components. Install the engine on a workstand.
Attach the engine lifting equipment and remove the engine from the workstand.
Lower the engine carefully into the engine compartment. Make sure the exhaust manifolds are properly aligned with the muffler inlet pipes.
Start the converter pilot into the crankshaft. Align the paint mark on the flywheel to the paint mark on the torque converter.
Install the transmission upper bolts, making sure the dowels in the cylinder block engage the transmission.
Install the engine mount-to-chassis attaching fasteners and remove the engine lifting equipment.
Raise and safely support the vehicle. Connect both muffler inlet pipes to the exhaust manifolds. Install the starter and connect the starter cable.
Remove the retainer holding the torque converter in the transmission. Attach the converter to the flywheel. Install the converter housing inspection cover and install the remaining transmission attaching bolts.
Remove the support from the transmission and lower the vehicle.
Connect the wiring harness at the two 10-pin connectors.
Connect the coolant temperature sending unit wire and connect the heater hoses. Connect the wiring to the metal heater tubes and the engine coolant temperature, air charge temperature and oxygen sensors.
Connect the transmission filler tube bracket. Connect the manual shift rod and the retracting spring. Connect the throttle valve vacuum line, if equipped.
Connect the accelerator cable and throttle valve cable. Connect the cruise control cable, if equipped.
Connect the fuel lines and the oil pressure sending unit wire.
Install the pulley, water pump belt and fan/clutch assembly.
Position the alternator bracket and install the alternator bolts. Connect the alternator and ground cables. Adjust the drive belt tension.
Unplug and connect the refrigerant lines and connect the electrical connector to the compressor.
Install the power steering drive belt and power steering pump bracket. Connect the power brake vacuum line.
Place the shroud over the fan and install the radiator. Connect the radiator hoses and the transmission oil cooler lines. Position the shroud and install the bolts.
Connect the heater hoses to the heater tubes. Fill the cooling system. Fill the crankcase with the proper type and quantity of engine oil. Adjust the transmission throttle linkage.
Connect the positive and then the negative battery cables. Start the engine and bring to normal operating temperature. Check for leaks. Check all fluid levels.
Install the air intake duct assembly. Install the hood, aligning the marks that were made during removal.
Have a MVAC certified evacuate and charge the air conditioning system.
disconnect batt,remove the 3 starter mounting bolts and ground cable(should be connected to one of the mounting bolts),disconnect the 2 wires on the starter.install new starter and then reconnect batt.