Kohler K91 Service Manual page 69

starter housing leg reinforcements as the pul­
ley is rotated later during reassembly.
4 . I nstall t h e pu lley onto the center shaft .
If the pulley d oe s not fully seat , it is resting on
the inner center s pring coil . Rotate the pul ley
s l ightly from side to side while exerting slight
downward pressure . This should move the in­
ner spring coil out of the way and allow the
pulley to drop i nto position .
The p ulley is i n position when the center shaft
is flush with the face of the pulley .
wind the p u l l ey a n d recoil spring at this time.
5 . Install the starter pawls i nto the appropriate
pockets in the pulley. Refer to Figure 7-2 1 .
Figure 7-2 1 . I nstalling Pawls, Pawl Retainer,
And Related Components.
6 . Sparingly lubricate t h e u nderside of the 1 - 1 /8 "
DIA . washer with g rease and install it over the
center shaft . Make sure the threads i n center
shaft remain clea n , d ry, and free of g rease or
o i l .
7 . Sparingly l u b ricate the i nsides of the " legs " of
the brake spider with g rease . Install the brake
to the retainer.
8 . Install t h e small return ring to t h e pawl re­
tainer. Make sure it is positioned properly.
9 .
Position the pawl retainer and return spring
n ext to the small post o n pulley . Instal l the
free loop of the return spring over the post .
Install the nylon spring retainer over the post .
1 0 . Invert the pawl retai ner over the pawls and
center hub of pulley . Take g reat care not to
damage or unhook the return spring . Make
sure the pawls are positioned in the slots of
pawl retainer.
1 1 . As a test , rotate the pawl retainer slightly
clockwise . Pressure from the return s pring
should be felt . I n addition , the pawl retainer
should return to its original position when re­
leased . If no spring pressure is felt or the re­
tainer does n ot ret urn , the spring is damaged ,
un hooked , or improperly assem bled . Repeat
steps 8, 9, and 1 0 to correct the problem .
1 2 . Sparingly
3 /4 " DIA. washer in the center of pawl re­
tainer. Make sure the th reads in center shaft
remain clea n , dry, and free of grease or oil .
Do not
1 3 . Apply a small amount of Loctite #27 1 to the
threads of center screw. I nstall the center
screw to center shaft . Torque screw to 55/70
in. l b .
1 4 . Rotate the pulley counterclockwise (when
viewed from the pawl side of p u lley) until the
spring is tight. (Approxi mately 4 full turns of
pulley . ) Make sure the fully extended rope is
held i n the notch i n pulley to p revent i nterfer­
ence with the housing leg reinforcements . Re­
fer to Figure 7-22 .
Keep Rope
In Notch
1 5 . Rotate the p u lley clockwise until the notch is
aligned with the rope guide bushing of hous­
ing .
NOTE : Do not allow the pulley/spring to u nwind .
Enlist the aid of a helper, or use a c-clamp to
hold p ul ley in positio n .
1 6 . Insert t h e free end o f rope through rope guide
bushin g . Tie a temporary (slip) knot approxi­
mately 1 2 " from the free end of the rop e .
1 7 . Hold the pu lley firm ly with thumbs and allow
the pul ley to rotate
reaches the rope guide bushing of housing .
Refer to Figure 7-23 .
lubri cate the 1 /2 " DIA . washer and
Figure 7-2 2 . Tensioning S p ri n g .
slowly until the slip knot
7. 1 1