Kohler COMMAND PRO CS10, Service Manual

Page: 81 / 154

8.27
Section 8
Electrical System and Components
8
Brush Replacement
The brushes in the starter are part of the starter frame.
The brush kit, Kohler Part No. 52 221 01-S, contains
four replacement brushes and springs. If replacement
is necessary, all four brushes should be replaced.
1. Remove brushes from brush holder, and remove
brush holder from frame.
2. Cut the brush lead wire at the edge of the post
with a pair of nippers.
3. File off burrs on the post.
4. The replacement brushes have a solid portion on
them which should be crimped on the post.
5. Solder the crimped portion to the post.
6. Replace the brush holder in the frame and place
the brushes in the brush holder. Reinstall the
springs.
Starter Service
Clean drive lever and armature shaft. Apply Kohler
electric starter drive lubricant (Part No. 52 351 01-S) to
lever and shaft.
Starter Reassembly
1. Install the drive pinion onto the armature shaft.
2. Slide the stop collar onto the armature shaft below
the retaining ring groove. Make sure the recessed
side of the stop collar is ‘‘up’’.
3. Position a new retainer in the groove of armature
shaft, and carefully tighten with a pliers to secure.
NOTE: Always use a new retainer. Do not nick
or damage armature shaft.
4. Use an open end wrench and slide the stop collar
up until the recessed section encases the
retaining ring and locks the collar into position.
See Figure 8-51.
Figure 8-51. Lock Collar around Retaining Ring.
5. Install the thrust washer onto the armature shaft
and lightly lubricate the end of the shaft with drive
lubricant.
6. Position the lubricated drive lever around the drive
pinion assembly and insert the assembly into the
drive end cap. Seat the ‘‘pivot’’ section of drive
lever into the corresponding section within the
housing. See Figure 8-52.
Figure 8-52. Installing Armature.