Kohler K9J 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. Install the new negative (-) brushes and se-
cure with the self-tapping screws.
6. Install the brush springs and brushes into the
pockets in brush holder. Make sure the cham-
fered sides of brushes are away from the
springs.
NOTE: Use a brush holder tool to keep the
brushes in the pockets. A brush holder tool can
easily be made from thin sheet metal. Refer to
Figure 8-24.
Brush Holder Tool Installed
Over Brushes And End Cap
Figure 8-24. Brush Holder Tool.
Commutator Service
Clean the commutator with a coarse, lint free
cloth. 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 frame.
2. Install the thrust washer and drive end cap.
Make sure the match marks on end cap and
frame are aligned. Refer to Figure 8-25.
8.20
Commutator
End Cap
Figure 8-25. Starter Assembly Match Marks.
3. Install the brush holder tool to keep the
brushes in 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.
5. Make sure the match marks on end cap and
frame are aligned. Refer to Figure 8-25. Install
the thru bolts.
6. Install 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 1 0
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
K161 or K181 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.