Starter System
44
32 690 01 Rev. D
KohlerEngines.com
INERTIA DRIVE ELECTRIC STARTERS
Inertia Drive Electric Starter Components
A
B
C
D
E
F
G
H
I
J
A
Commutator End Cap
with Brushes
B
Frame
C
Armature
D
Drive End Cap
E
Drive Nut (Collar)
F
Drive Pinion
G
Anti-Drift Spring
H
Spring Retainer
I
Retaining Ring
J
Dust Cover
When power is applied to starter, armature rotates. As
armature rotates, drive pinion moves out on drive shaft
splines and into mesh with flywheel ring gear. When
pinion reaches end of drive shaft, it rotates flywheel and
cranks engine.
When engine starts, flywheel rotates faster than starter
armature and drive pinion. This moves drive pinion out
of mesh with ring gear and into retracted position. When
power is removed from starter, armature stops rotating
and drive pinion is held in retracted position by anti-drift
spring.
Drive Service
If drive pinion is worn, or has chipped or broken teeth, it
must be replaced.
1. Rubber dust cover has a molded lip on inside that
snaps over a lip on front of drive pinion. Turn drive
pinion clockwise until it reaches fully extended
position. While holding it in extended position, grasp
tip of dust cover with a pliers or vise grip and pull it
free from pinion.
2. Grasp spring retainer with a pliers and push it toward
starter, compressing anti-drift spring to expose
retaining ring.
3. Remove retaining ring from armature shaft using
either a retaining ring pliers or snap ring removal
tool, as described in Steps 4, and 5. Do not reuse
old retainer.
4. Holding spring retainer in retracted position,
assemble inner halves of removal tool around
armature shaft with retaining ring in inner groove.
Slide collar over inner halves to hold them in
position.
5. Thread center screw into removal tool until you feel
resistance. Use a wrench (1-1/8" or adjustable) to
hold base of removal tool. Use another wrench or
socket (1/2" or 13 mm) to turn center screw
clockwise. Resistance against center screw will tell
you when retaining ring has popped out of groove in
armature shaft.
6. Remove drive components from armature shaft,
paying attention to sequence. If splines are dirty,
clean them with solvent.
7. Splines should have a light film of lubricant.
Lubricate as necessary with Kohler starter drive
lubricant. Reinstall or replace drive components,
assembling them in reverse order they were
removed.
Retaining Ring Installation
1. Position retaining ring in groove in one of inner
halves. Assemble other half over top and slide on
outer collar.
2. Be certain drive components are installed in correct
sequence onto armature shaft.
3. Slip tool over end of armature shaft, so retaining ring
inside is resting on end of shaft. Hold tool with one
hand, exerting slight pressure toward starter. Tap top
of tool with a hammer until you feel retaining ring
snap into groove. Disassemble and remove tool.
4. Squeeze retaining ring with a pliers to compress it
into groove.
5. Assemble inner halves with larger cavity around
spring retainer. Slide collar over them and thread
center screw in until resistance is felt.
6. Hold base of tool with a 1-1/8" wrench and turn
center screw clockwise with a 1/2" or 13 mm wrench
to draw spring retainer up around retaining ring. Stop
turning when resistance increases. Disassemble and
remove tool.
7. Reinstall dust cover.
