Starter System Armature Components and Details Starter Reassembly NOTE: Always use a new retainer. Do not reuse old retainers that have been removed. NOTE: Correctly installed, center pivot section of drive lever will be fl ush or below machined surface of housing. 1. Apply drive lubricant to armature shaft splines. Install drive pinion onto armature shaft. 2. Install and assemble stop collar/retainer assembly. a. Install stop collar down onto armature shaft with counter bore (recess) up. b. Install a new retainer in larger (rear) groove of armature shaft. Squeeze with a pliers to compress it in groove. c. Slide stop collar up and lock it into place, so recess surrounds retainer in groove.
If necessary, rotate pinion outward on armature splines against retainer to help seat collar around retainer. 3. Install offset thrust (stop) washer so smaller offset of washer faces retainer/collar. 4. Apply a small amount of oil to bearing in drive end cap, and install armature with drive pinion. 5. Lubricate fork end and center pivot of drive lever with drive lubricant. Position fork end into space between captured washer and rear of pinion. 6. Slide armature into drive end cap and at same time seat drive lever into housing. 7. Install rubber grommet into matching recess of drive end cap. Molded recesses in grommet should be out, matching and aligned with those in end cap. 8.
Install frame, with small notch forward, onto armature and drive end cap. Align notch with corresponding section in rubber grommet. Install drain tube in rear cutout, if it was removed previously. 9. Install fl at thrust washer onto commutator end of armature shaft. 10. Starter reassembly when replacing brushes/brush holder assembly: a. Hold starter assembly vertically on end housing, and carefully position assembled brush holder assembly, with supplied protective tube, against end of commutator/armature. Mounting screw holes in metal clips must be up/out. Slide brush holder assembly down into place around commutator, and install positive (+) brush lead grommet in cutout of frame.
Protective tube may be saved and used for future servicing. Starter reassembly when not replacing brushes/ brush holder assembly: a. Carefully unhook retaining caps from brush assemblies. Do not lose springs. b. Position brushes back in their slots so they are fl ush with I.D. of brush holder assembly. Insert brush installation tool (with extension), or use tube described above from a prior brush installation, through brush holder assembly, so holes in metal mounting clips are up/out. 1. Clean and inspect commutator (outer surface). Mica insulation must be lower than commutator bars (undercut) to ensure proper operation of commutator. 2. Use an ohmmeter set to Rx1 scale.
Touch probes between 2 different segments of commutator, and check for continuity. Test all segments. Continuity must exist between all or armature is bad. 3. Check for continuity between armature coil segments and commutator segments. There should be no continuity. If continuity exists between any 2 armature is bad. 4. Check armature windings/insulation for shorting. Shift Fork Check that shift fork is complete, and pivot and contact areas are not excessively worn, cracked, or broken. Brush Replacement 4 brushes and springs are serviced as a set. Use a new Kohler brush and spring kit if replacement is necessary. 1. Perform steps 1-5 in Starter Disassembly. 2.
Remove screws securing brush holder assembly to end cap (plate). Note orientation for reassembly later. Discard old brush holder assembly. 3. Clean component parts as required. 4. New brushes and springs come preassembled in a brush holder with a protective sleeve that will also serve as an installation tool. 5. Perform steps 10-13 in Starter Reassembly sequence. If starter has been disassembled, installation must be done after armature, drive lever, and frame are installed. 36 KohlerEngines.com 66 690 01 Rev. C A B A Commutator O.D. B Mica Insulation C E D C Insulation Check D Armature Coil E Continuity Check