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8.22
Section 8
Electrical System and Components
8. The outward travel of the drive pinion is controlled
by a snap ring, installed in a groove in the
armature shaft, and a two-piece stop collar. The
snap ring fits into a recess in the pinion (lower)
stop collar, which locks it in the groove (see Figure
8-45). The thrust receiving (upper) stop collar has
a projecting flange, which rests on the snap ring,
and it serves as a thrust washer to protect the
front armature bushing in the drive end cap.
Figure 8-45. Stop Collars and Retainer.
Side the thrust receiving stop collar off the end
of the armature shaft. Place the open end of a
13 mm or 1/2" deep socket over the end of the
armature shaft, so the end of the socket is against
the top of the pinion stop collar. Tap the other end
of the socket with a small hammer of soft head
mallet to separate the collar from the snap ring.
See Figure 8-46.
Figure 8-46. Separating the Pinion Stop Collar from
the Retainer.
9. Remove and discard the snap ring, then slide the
pinion stop collar off of the armature shaft.
10. Remove the pinion from the splines.
Brush Replacement
The brushes in the starter are part of the starter frame.
Brush kit 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 side cutters.
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
Every 500 hours of operation (or annually, whichever
comes first), solenoid shift starters must be
disassembled, cleaned and relubricated. Apply Kohler
solenoid shift starter lubricant (Part No. 52 357 02-S)
to lever and shaft. Failure to do so could result in an
accumulation of dirt or debris that might prevent the
engine from starting and could cause damage to the
starter or flywheel. Service may be necessary more
frequently under dusty or dirty conditions.
Starter Reassembly
1. Apply new drive lubricant (Kohler Part No.
52 357 02-S) to the armature shaft splines and
drive lever. Install the pinion onto the splines.
2. Slide the pinion stop collar onto the armature shaft
with the recessed side up. Install a new snap ring
in the armature shaft groove. Squeeze it with a
pliers, to seat/compress it in the groove.
3. Clamp a Vise-Grip
®
or other locking jaw pliers onto
the pinion, between the drive gear and the clutch.
Turn the pinion out on the splines until it contacts
the pinion stop collar and pushes it up into position
around the snap ring. Slide the thrust receiving
stop collar onto the armature shaft with the flange
toward the snap ring. Apply a coating of drive
lubricant to the stop collars.
4. Reassemble the remaining components of the
starter in reverse order from disassembly.
Thrust Receiving
Stop Collar
Pinion Stop
Collar
Armature Snap Ring Pinion
Shaft
Plastic
Hammer
1/2" (13 mm)
Deep Socket
Pinion Stop
Collar