Kohler K91 Service Manual page 67

Figure Removing Pulley From Housing .
7-1 5.
If the pu lley and housing do not separate eas­
ily, the spring could be engaged with pulley , or
there is sti ll tension on the spring . Return the
pulley to the housing and repeat step 1 2 be­
fore separating the pul ley and housing .
1 5 . Only if it is necessary for the repair of starter ,
remove the spring from the starter housing as
instructed under " To Replace Recoil Spring . "
Do not remove the spring unless it is abso­
lutely necessary.
I nspection and Service
Carefully
1 . inspect the rope , starter pawls ,
housi ng , center screw , center shaft, spring
and other components for wear or damage.
2 . Replace all worn o r damaged components .
Use only genuine Kohler replacement parts
specified in the Parts Manual . All components
shown in Figure 7- 1 1 are available as service
parts. Do not use nonstandard parts.
3 . Carefully clean all old grease and dirt from
starter components . Lubricate the spring , cen­
ter shaft , and certain other components as
specified in these instructions with any com­
mercially available beari ng grease .
To Replace Rope
The starter must be completely disassembled to
replace the rope .
1 . Remove the starter from engine .
2 .
Disassemble starter as instructed i n steps 2
through 1 4 u nder " Disassembly . "
3 . Remove the 4 Phill ips head screws securing
the pul ley and sheave . Separate the pulley and
sheave and remove the old rope . Refer to Fig­
u re 7-1 6 .
Figure Replacing Rope.
7- 1 6.
4 . Position the new rope i n the notch i n the pulley
and around the rope lock post .
NOTE : Use only a genuine Koh ler replacement
rope which is designed for this starter. Using rope
of the incorrect diameter and/or type will not lock
properly in the pulley.
5 . Install the sheave to the pulley and install the 4
Phillips head screws . Use care not to strip or
cross-thread the threads in p ulley.
6 . Inspect the pul ley t o make sure the sheave is
securely joi ned to the pulley. Pull firmly on the
rope to make sure it is securely retained in the
pul ley.
To Replace Recoil S p ring
�
CAUTION: Spring Under Tension!
Do not attempt to pull or pry the recoil spring from
the housing. Doing so can cause the sudden and
potentially dangerous release of the spring from the
housing. Follow these instructions carefully to en­
sure personal safety and proper spring replacement.
Make sure adequate face protection is worn
throughout the following procedure.
1 . Carefully note the position of the spring in the
housing . Also refer to Figure 7- 1 7 . The new
spring must be installed in the proper position
- it is possible to install it backwards in the
housing .
2 .
Place the housing o n a flat wooden su rface
with the recoil spring and center shaft down
and away from you .
3 . Grasp the housing by the top so that your fin­
gers are protected . Do not wrap your fingers
around the edge of the housing .
7 . 9