Starter System
61
66 690 14 Rev. A
KohlerEngines.com
NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool-down period between
starting attempts. Failure to follow these guidelines can burn out starter motor.
NOTE: If engine develops su
ffi
cient speed to disengage starter but does not keep running (a false start), engine
rotation must be allowed to come to a complete stop before attempting to restart engine. If starter is engaged
while
fl
ywheel is rotating, starter pinion and
fl
ywheel ring gear may clash and damage starter.
NOTE: If starter does not crank engine, shut o
ff
starter immediately. Do not make further attempts to start engine until
condition is corrected.
NOTE: Do not drop starter or strike starter frame. Doing so can damage starter.
NOTE: Battery must be tested and con
fi
rmed acceptable prior to troubleshooting starter system. Follow battery or
OEM battery testing procedures.
Engines in this series use solenoid shift starters.
Troubleshooting-Starting Di
ffi
culties
Condition
Possible Cause
Conclusion
Starter does not energize.
Battery
Check speci
fi
c gravity of battery and battery state of charge. If
low, recharge or replace battery as necessary.
Wiring
Clean corroded connections and tighten loose connections.
Replace wires in poor condition and with frayed or broken
insulation.
Starter Switch
or Solenoid
By-pass switch or solenoid with a jumper wire. If starter
cranks normally, replace faulty components. Consult with
OEM electrical system service procedures for OEM related
component diagnostics. Perform solenoid test procedure.
Starter energizes but turns
slowly.
Battery
Check speci
fi
c gravity of battery and battery state of charge. If
low, recharge or replace battery as necessary.
Transmission
or Engine
Make sure clutch or transmission is disengaged or placed
in neutral. This is especially important on equipment with
hydrostatic drive. Transmission must be exactly in neutral to
prevent resistance which could keep engine from starting.
Check for seized engine components such as bearings,
connecting rod, and piston.
SOLENOID SHIFT STARTERS
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.
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.
