Kohler K91 Service Manual page 90

4. Reinstall the brush holder and new stud termi­
nal with positive (+) brushes into end cap .
Secure with the fiber washer, plain washer,
split lock washer, and hex nut.
CAUTION : To prevent electric arcing, make sure
the stud terminal and braided brush
leads do not touch the end cap .
5 . I nstall the new negative (-) brushes and se­
cure with the self-tapping screws.
6 . I nstall the brush springs and brushes into the
pockets i n brush holder. Make sure the cham­
fered sides of brushes are away from the
spring s .
NOTE : Use a brush holder tool t o keep the
brushes in the pockets. A brush holder tool can
easily be m ade from thin sheet meta l . Refer to
Figure 8-24 .
B r u s h H o l d e r Tool I n stalled
Over Bru s h e s A n d End Cap
Fig u re 8-24. Brush Holder Tool .
Commutator Service
Clean the commutator with a coarse, lint free
clot h . Do not use emery cloth . If the commutator
is badly worn or grooved, turn down on a lathe, or
replace the armature .
Reassembly
1 . Insert the armature into the starter frame.
Make sure the magnets are closer to the drive
shaft end of armature . The magnets will hold
the armature inside the fram e .
2 .
Install the thrust washer and drive end cap .
Make sure the match marks on end cap and
frame are alig ned . Refer to Figure 8-2 5 .
8 . 20
Commutator
End Cap
Figure 8-25. Starter Assembly Match Marks.
Install the brush holder tool to keep the
3 .
brushes i n the pockets of commutator end
cap. Refer to Figure 8-24.
4. Install the commutator end cap to armature
and starter frame . Firmly hold the drive end
cap and commutator end cap to the starter
frame. Remove the brush holder tool .
Make sure t h e match marks o n e n d cap and
5 .
frame are aligned . Refer to Figure 8-25 . I nstall
the thru bolts .
6 . Insta ll the drive pinion , dust cover spacer,
anti-drifting spring . stop gear spacer, stop
nut , and dust cover. Refer to " Starter Drive
Service . ..
NOTE : If the, engine being serviced is equipped
with special shouldered cap screws and lock wash­
ers for mounting , make sure these same parts are
used for reinstalling the starter. These special
parts ensure alignment of the pinion and ring gear.
Wound-Field Bendix Drive Starter Service
NOTE: In the event of a false start (engine starts
but fails to keep running) the engine must be al­
lowed to come to a complete stop before the
starter is re-engaged . If the flywheel is still rotat­
ing when the starter is engaged , the pinion and
ring gear may be damaged .
NOTE : Do not crank the engine for longer than
seconds . A 60-second cool-down period must be
allowed between starting attempts. Failure to fol­
low this procedure could result in starter burnout.
NOTE : If the engine being serviced is a Model
K 1 6 1 or K 1 8 1 and has special shouldered cap
screws and lock washers for mounting , make sure
these same parts are used for reinstalling the
starter. These special parts ensure alignment of
the pinion and ring gear.
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