Starter System
47
32 690 01 Rev. D
KohlerEngines.com
Starter Reassembly
NOTE: Always use a new retainer. Do not reuse old
retainers that have been removed.
NOTE: Correctly installed, center pivot section of drive
lever will be flush or below machined surface of
housing.
1. Apply drive lubricant to armature shaft splines. Install
drive pinion onto armature shaft.
2. Install and assemble stop collar/retainer assembly.
a. Install stop collar down onto armature shaft with
counter bore (recess) up.
b. Install a new retainer in larger (rear) groove of
armature shaft. Squeeze with a pliers to
compress it in groove.
c. Slide stop collar up and lock it into place, so
recess surrounds retainer in groove. If necessary,
rotate pinion outward on armature splines against
retainer to help seat collar around retainer.
3. Install offset thrust (stop) washer so smaller offset of
washer faces retainer/collar.
4. Apply a small amount of oil to bearing in drive end
cap, and install armature with drive pinion.
5. Lubricate fork end and center pivot of drive lever
with drive lubricant. Position fork end into space
between captured washer and rear of pinion.
6. Slide armature into drive end cap and at same time
seat drive lever into housing.
7. Install rubber grommet into matching recess of drive
end cap. Molded recesses in grommet should be
out, matching and aligned with those in end cap.
8. Install frame, with small notch forward, onto
armature and drive end cap. Align notch with
corresponding section in rubber grommet. Install
drain tube in rear cutout, if it was removed
previously.
9. Install flat thrust washer onto commutator end of
armature shaft.
10. Starter reassembly when replacing brushes/brush
holder assembly:
a. Hold starter assembly vertically on end housing,
and carefully position assembled brush holder
assembly, with supplied protective tube, against
end of commutator/armature. Mounting screw
holes in metal clips must be up/out. Slide brush
holder assembly down into place around
commutator, and install positive (+) brush lead
grommet in cutout of frame. Protective tube may
be saved and used for future servicing.
Starter reassembly when not replacing brushes/
brush holder assembly:
a. Carefully unhook retaining caps from brush
assemblies. Do not lose springs.
b. Position brushes back in their slots so they are
flush with I.D. of brush holder assembly. Insert
brush installation tool (with extension), or use
tube described above from a prior brush
installation, through brush holder assembly, so
holes in metal mounting clips are up/out.
c. Install brush springs and snap on retainer caps.
d. Hold starter assembly vertically on end housing,
and carefully place tool (with extension) and
assembled original brush holder assembly onto
end of armature shaft. Slide brush holder
assembly down into place around commutator,
install positive (+) brush lead grommet in cutout
of frame.
11. Install end cap onto armature and frame, aligning
thin raised rib in end cap with corresponding slot in
grommet of positive (+) brush lead.
12. Install thru bolts and brush holder mounting screws.
Torque bolts to 5.6-9.0 N·m (49-79 in. lb.) and brush
holder mounting screws to 2.5-3.3 N·m
(22-29 in. lb.).
13. Hook plunger behind upper end of drive lever and
install spring into solenoid. Insert mounting screws
through holes in drive end cap. Use these to hold
solenoid gasket in position, then mount solenoid.
Torque screws to 4.0-6.0 N·m (35-53 in. lb.).
14. Connect positive (+) brush lead/bracket to solenoid
and secure with nut. Torque nut to 8-11 N·m
(71-97 in. lb.). Do not overtighten.
