Kohler Command PRO CS, Service Manual

Page: 86 / 162

8.30
Section 8
Electrical System and Components
5. Assemble the end cap assembly to the starter,
inserting the commutator below the brushes and
gently guiding the end of the armature shaft into
the bushing within the end cap, against the brush
spring tension. See Figure 8-53.
Figure 8-53. Installing End Cap Assembly.
6. Align all scribe marks and install the thru bolts
with O-Rings. Torque the bolts to 5.3 N·m
(48 in. lb.) . See Figure 8-54.
Figure 8-54. Torquing Thru Bolts.
7. Attach the starter lead from the solenoid to the
stud and add the lock washer and outer hex jam
nut to secure. Hold the lower jam nut from
turning with a wrench while tightening the top
nut, to prevent damaging the internal
components. See Figure 8-55.
Reinstall the protective boot over the connection.
If the solenoid was removed from the starter,
reinstall it at this time, and connect the starter
lead to the lower large terminal. See Figure 8-56.
Figure 8-55. Assembling Starter Lead.
Figure 8-56. Installing Solenoid Connections.
8. Apply a light film of molybdenum disulfide to
the splines of armature shaft and install the drive
pinion, spring, and spring holder.
9. Push the spring holder down and install a new
retaining ring into the groove of the armature
shaft. Squeeze it with a pliers to compress it into
the groove. It must fit into the recess in the end of
the spring holder.
10. Install the starter back onto the engine. Refer to
Section 11 Reassembly.