Kohler K91 Service Manual page 66

1 . Remove the starter from engine .
�
CAUTION: Spring Under Tensionl
Do not remove the center screw of the starter until
the tension of recoil spring has been released. Re­
moving the center screw before releasing spring
tension, or improper starter disassembly can cause
the sudden and potentially dangerous release of the
recoil spring. Follow these instructions carefully to
ensure personal safety and proper starter disassem­
bly. Make sure adequate face protection is worn by
all persons in the area.
2 . Pull the rope out approximately 1 2 " and tie a
temporary (slip) knot in it to keep it from re­
tracting into starter. Refer to Figure 7-1 2 .
3 . Remove the rope retainer from inside hand l e .
Untie t h e knot a n d remove t h e retainer and
handle .
Slip Knot
Fig u re 7- 1 2 . Removi ng Handle.
4 . Rotate the pulley counterclockwise until the
notch in pulley is next to the rope guide bush­
ing .
5 . Hold the pulley fi rmly to keep it from turning .
Untie the slip knot and pull the rope through
the bushing .
6 . Place the rope into the notch i n pulley. This
will keep the rope from interfering with the
starter housing leg reinforcements as the pul­
ley is rotated (step 7) .
7 . Hold the housing and pu lley with both hands.
Release pressure on the pul ley and allow it to
rotate slowly as the spring tension is released .
Be sure to keep the rope in the notch . Refer
to Figure 7-1 3 .
7 . 8
Fig u re 7- 1 3 . Releasing Spring Tension.
8 . Make sure the spring tension i s fully released .
(The pulley should rotate easily in either direc­
tion . )
9 . When all spring tension o n the pul ley i s re­
leased , remove the center screw, 3/4 " DIA .
washer, and 1 /2 " DIA . washer .
1 0 . Carefully lift the pawl retainer from pul ley. Re­
fer to Figure 7-1 4 .
Nylon Spring
Retainer
Pawls
Figure 7- 1 4 . Removing Pawl Retainer, Pawls,
And Related Components.
NOTE : A small return spring and nylon spring re­
tainer (spacer) are located under the pawl re­
tainer . These parts are fragile and can be easily
lost or damaged . If necessary , use a small screw­
driver to loosen the spring retainer from the post
on pulley . Replace the spring if it is broken ,
stretched , or shows other signs of damage .
1 1 . Remove the 1 - 1 /8 " D I A . thrust washer, brake ,
return spring , nylon spring retainer, and pawls .
1 2 . Rotate the pulley clockwise 2 full turns. There
should be no resistance to this rotation . This
will ensure the pul ley is disengaged from the
recoil spring .
1 3 . Hold the pul ley into the starter housing and
invert starter so the pul ley is away from you r
face a n d others in t h e area .
1 4 . Rotate the pul ley sl ightly from side to side and
carefully separate the pul ley from the starter
housing . Refer to Fig u re 7-1 5 .
Pawl Retainer
1 - 1 /8 " D IA.
Washer