Kohler K9J Service Manual page 62

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CAUTION: Spring Under Tension!
Do not remove the center screw of the starter when
replacing pawls. Removal of the center screw can
cause the sudden and potentially dangerous release
of the recoil spring. It is not necessary to remove
the center screw when making this repair.
2. Carefully note position of the pawls, pawl
springs, and retaining rings before disassem-
bly. (Components must be assembled cor-
rectly for proper operation.) Refer to Figure
7-4.
3. Remove the retaining rings, pawls, and pawl
springs from pawl pins on pulley.
4. Clean pins and lubricate with any commercially
available bearing grease.
5. Install new pawl springs, pawls, and retaining
rings. When properly installed, the pawl
springs will hold the pawls against the pawl
cam.
NOTE: Make sure the snap rings are securely
seated in grooves of pawl pins. Failure to seat the
snap ring can cause pawls to dislodge during op-
eration.
6. Pull rope to make sure pawls operate properly.
7. Install starter to engine as instructed under
"To Install Starter."
To Replace Rope
The rope can be replaced without complete starter
disassembly.
Figure 7-4. Starter Pawls.
1. Remove the starter from engine.
2. Pull the rope out approximately 12" and tie a
temporary (slip) knot in it to keep it from re-
tracting into starter. Refer to Figure 7-5.
7.4
3. Remove the rope retainer from inside handle.
Untie the knot and remove the retainer and
handle.
4. Hold the pulley firmly with thumb and untie the
slip knot. Allow the pulley to rotate slowly as
the spring tension is released. Refer to Figure
7-6.
5. When all spring tension on the starter pulley is
released, remove old rope from pulley.
6. Tie a single knot in one end of new rope.
7. Rotate the pulley counterclockwise (when
viewed from pawl side of pulley) until the
spring is tight. (Approx. 6 full turns of pulley).
8. Rotate the pulley clockwise until the rope
pocket is aligned with the rope guide bushing
of housing.
NOTE: Do not allow pulley/spring to unwind. Enlist
the aid of a helper if necessary, or use a c-clamp to
hold pulley in position.
Figure 7-5. Removing Handle.
Figure 7-6. Releasing Spring Tension.
9. Insert the new rope into the rope pocket of
pulley and through rope guide bushing in hous-
ing. Refer to Figure 7-7.