Starter System - Kohler HD Series Service Manual

Starter System

NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between
starting attempts. Failure to follow these guidelines can burn out starter motor.
NOTE: If engine develops suffi cient speed to disengage starter but does not keep running (a false start), engine
rotation must be allowed to come to a complete stop before attempting to restart engine. If starter is engaged
while fl ywheel is rotating, starter pinion and fl ywheel ring gear may clash and damage starter.
NOTE: If starter does not crank engine, shut off starter immediately. Do not make further attempts to start engine until
condition is corrected.
NOTE: Do not drop starter or strike starter frame. Doing so can damage starter.
Engines in this series use inertia drive electric starters and/or retractable starters. Inertia drive electric starters are not
serviceable.
Some HD electric starters use brake switch for an interlock (on ground). When bail is held down, switch in brake
assembly completes circuit of ground for starter. If there is a no crank situation, cause could be brake assembly,
battery, key switch, wiring harness, fuse (if equipped), or starter itself.
Troubleshooting-Starting Diffi culties
Condition Possible Cause
Starter does not
energize.
Starter Switch
or Brake Assembly
Starter energizes
but turns slowly.
Drive Unit (if equipped)
Electric Starting System Tests (Without Brake
Assembly)
NOTE: Battery must be fully charged. If low, recharge or
replace battery as necessary.
1. Test battery on unit.
a. Connect a DC voltmeter across battery terminals
and read battery voltage (key switch OFF).
b. Turn key switch to start position and read battery
voltage again. Turn switch OFF.
Condition
Voltage less than 12 volts. Charge or replace battery.
Battery voltage should not
fall below 9 volts during
cranking.
2. Use a known, good, fully-charged battery and
jumper cables to test starter motor. Be sure drive
unit is in neutral and blade is off (if equipped with a
blade brake clutch assembly (BBC).
38
Battery Check battery state of charge. If low, recharge or replace battery as
necessary.
Wiring Check fuse condition (if equipped).
Clean corroded connections and tighten loose connections.
Replace wires in poor condition and with frayed or broken insulation.
Check switch operation. Replace faulty components.
Battery Check battery state of charge. If low, recharge or replace battery as
necessary.
Wiring Check for corroded connections, poor ground connection.
Self-propelled Make sure drive unit is disengaged or in neutral. This is especially
important on equipment with a self-propelled drive unit. Drive unit
or must be in neutral to prevent resistance which could keep engine from
Engine starting.
Check for seized engine components such as bearings, connecting rod,
and piston.
Conclusion
If it does, battery may be
faulty or there may be a
short in starting circuit.
KohlerEngines.com
Conclusion
Disconnect starter wire from application. Connect
one end of positive (+) jumper cable to bullet
terminal of red starter wire and connect other end to
positive (+) terminal of battery.
Connect one end of negative (-) jumper cable to
negative terminal of battery. Touch other end of
negative (-) jumper cable to a bare surface on
crankcase or to starter housing.
Condition
Starter engages and
begins to crank.
Starter does not crank.
Conclusion
Key switch is faulty, or
there is a wiring problem
to/from key switch. Check
wiring and test key switch
circuits.
Replace starter.
14 690 10 Rev. --