Kohler COMMAND CV11, Service Manual

Page: 56 / 148

7.2
Section 7
Retractable Starter
Rope Replacement
The rope can be replaced without complete starter
disassembly.
1. Remove the starter from the engine blower
housing.
2. Pull the rope out approximately 12" and tie a
temporary (slip) knot in it to keep it from retracting
into the starter. See Figure 7-3.
Figure 7-3. Removing Starter Handle.
3. Remove the rope retainer from inside the starter
handle. Untie the single knot and remove the rope
retainer and handle.
4. Hold the pulley firmly and untie the slip knot. Allow
the pulley to rotate slowly as the spring tension is
released.
5. When all spring tension on the starter pulley is
released, remove the rope from the pulley.
6. Tie a single knot in one end of the new rope.
7. Rotate the pulley counterclockwise (when viewed
from pawl side of pulley) until the spring is tight.
(Approximately 6 full turns of pulley.)
8. Rotate the pulley clockwise until the rope hole in
pulley is aligned with rope guide bushing of starter
housing.
NOTE: Do not allow the pulley/spring to unwind.
Enlist the aid of a helper if necessary, or
use a C-clamp to hold the pulley in
position.
9. Insert the new rope through the rope hole in
starter pulley and rope guide bushing of housing.
See Figure 7-4.
Figure 7-4. Installing Rope.
10. Tie a slip knot approximately 12" from the free
end of rope. Hold the pulley firmly and allow it to
rotate slowly until the slip knot reaches the guide
bushing of housing.
11. Slip the handle and rope retainer onto the rope.
Tie a single knot at the end of the rope. Install the
rope retainer into the starter handle.
12. Untie the slip knot and pull on the handle until the
rope is fully extended. Slowly retract the rope into
the starter.
When the spring is properly tensioned, the rope
will retract fully and the handle will stop against
the starter housing.
Pawls (Dogs) Replacement
The starter must be disassembled to replace the
starter pawls. A pawl repair kit is available which
includes the following components:
Pawl Repair Kit
Description
Qty.
Pawl Retainer
Center Screw
Pawl (Dog) Spring
Brake Spring
Starter Pawl (Dog)
Brake Washer
Washer 1
1
2
1
2
1
1
Keep Pulley
from Rotating
Rope Guide
Bushing
Rope Hole
in Pulley
Slip Knot
Handle
Knot
Rope Retainer