Starter System Solenoid Shift Starter Components Starter Disassembly NOTE: Do not reuse old retainer. NOTE: Do not soak armature or use solvent when cleaning. Wipe clean using a soft cloth, or use compressed air. 1. Remove hex nut and disconnect positive (+) brush lead/bracket from solenoid terminal. 2. Remove screws securing solenoid to starter. 3. Unhook plunger pin from drive lever. Remove gasket from recess in housing. 4. Remove thru (larger) bolts. 5. Remove commutator end plate assembly, containing brush holder, brushes, springs, and locking caps. Remove thrust washer from inside commutator end. 6. Remove frame from armature and drive end cap. 7.
Remove drive lever pivot bushing and backing plate (if equipped) from end cap. 8. Take out drive lever and pull armature out of drive end cap. 9. Remove thrust washer from armature shaft. 10. Push stop collar down to expose retaining ring. 11. Remove retainer from armature shaft. Save stop collar. 12. Remove drive pinion assembly from armature. 13. Clean parts as required. Inspection Drive Pinion Check and inspect following areas: ● Pinion teeth for abnormal wear or damage. ● Surface between pinion and clutch mechanism for nicks or irregularities which could cause seal damage. ● Check drive clutch by holding clutch housing and rotating pinion. Pinion should rotate in only 1 direction.
Brushes and Springs Detail When power is applied to starter electric solenoid moves drive pinion out onto drive shaft and into mesh with fl ywheel ring gear. When pinion reaches end of drive shaft it rotates fl ywheel and cranks engine. When engine starts and start switch is released, starter solenoid is deactivated, drive lever moves back, and drive pinion moves out of mesh with ring gear into retracted position. Inspect both springs and brushes for wear, fatigue, or damage. Measure length of each brush. Minimum length for each brush is 7.6 mm (0.300 in.). Replace brushes if they are worn, undersize, or condition is questionable. 66 690 01 Rev.
C KohlerEngines.com 35 H I J G K F L E M D N C O P B Q R S A T U A Tube B Washer C Armature D Drive E Stop F Retaining Ring G Collar H Drive End Cap I Screw J Plunger K Spring L Lever M Plate N Plug O Solenoid P Frame and Field Q Brush Holder R Nut S Commutator End Plate T Screw U Bolt A A Wear Limit Length