Starter System
46
32 690 01 Rev. D
KohlerEngines.com
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 head 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
A
A
Wear Limit Length
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.
Armature
Components and Details
A
B
A
Commutator O.D.
B
Mica Insulation
D
E
C
C
Insulation Check
D
Armature Coil
E
Continuity Check
1. Clean and inspect commutator (outer surface). Mica
insulation must be lower than commutator bars
(undercut) to ensure proper operation of
commutator.
2. Use an ohmmeter set to Rx1 scale. Touch probes
between 2 different segments of commutator, and
check for continuity. Test all segments. Continuity
must exist between all or armature is bad.
3. Check for continuity between armature coil
segments and commutator segments. There should
be no continuity. If continuity exists between any 2
armature is bad.
4. Check armature windings/insulation for shorting.
Shift Fork
Check that shift fork is complete, and pivot and contact
areas are not excessively worn, cracked, or broken.
Brush Replacement
4 brushes and springs are serviced as a set. Use a new
Kohler brush and spring kit if replacement is necessary.
1. Perform steps 1-5 in Starter Disassembly.
2. Remove screws securing brush holder assembly to
end cap (plate). Note orientation for reassembly later.
Discard old brush holder assembly.
3. Clean component parts as required.
New brushes and springs come preassembled in a
brush holder with a protective sleeve that will also
serve as an installation tool.
4. Perform steps 10-13 in Starter Reassembly
sequence. If starter has been disassembled,
installation must be done after armature, drive lever,
and frame are installed.
