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Starter System
KohlerEngines.com 20 690 01 Rev. F
Starter Disassembly
1. Remove drive components following instructions for
servicing drive.
2. Remove nut and insulating washer from positive (+)
brush lead stud.
3. Remove thru bolts and recessed nuts.
4. Remove commutator end cap and lift out brush
carrier assembly with brushes and springs.
5. Remove drive end cap, then pull armature with
thrust washer and wave washer (if equipped) out of
starter frame.
Brush Replacement
1. Remove nut and insulating washer from positive (+)
brush lead stud.
2. Remove thru bolts and captured hex nuts.
3. Remove commutator end cap, then pull brush carrier
assembly out of frame.
Commutator Service
Clean commutator with a coarse, lint free cloth. Do not
use emery cloth.
If commutator is badly worn or grooved, turn it down on
a lathe or replace armature.
Starter Reassembly
1. Place wave washer, followed by thrust washer onto
drive shaft of armature.
2. Insert armature into starter frame. Magnets will hold
it in place.
3. Align holes with spaces between magnets and install
drive end cap onto front of frame.
4. If brush assembly is not being replaced, position
springs and brushes within their pockets in carrier;
move them to retracted position, and install carton
staples to retain them. Replacement brushes come
pre-assembled in carrier housing, retained with two
carton staples.
5. Hold brush holder assembly with positive brush lead
stud up. Align molded sections with corresponding
cutouts in starter frame and slide brush carrier
assembly into place. Commutator will push carton
staples out as brush assembly is inserted.
6. Position commutator end cap over brush assembly,
aligning holes for stud terminal and thru bolts.
7. Install thru bolts and hex nuts. Torque to 3.3-3.9 N·m
(30-35 in. lb.).
8. Install insulating washer and hex fl ange nut onto
positive (+) brush lead stud. Make sure stud is
centered and does not touch metal end cap. Torque
hex fl ange nut to 2.2-4.5 N·m (20-40 in. lb.).
After installation and connection of starter lead,
torque outer nut to 1.6-2.8 N·m (12-25 in. lb.), do not
over torque.
9. Lubricate drive shaft with Kohler bendix starter drive
lubricant. Install drive components following
instructions for servicing drive.