Retractable Starters - Kohler HD Series Service Manual

Starter System

RETRACTABLE STARTERS

Uncoiling Spring can cause severe injury.
Wear safety goggles or face protection when
servicing retractable starter.
Retractable starters contain a powerful, recoil spring
that is under tension. Always wear safety goggles
when servicing retractable starters and carefully follow
instructions in Retractable Starter for relieving spring
tension.
Retractable Starter Components
A
B
C
D
E
F
G
H
A Housing
C Pulley
E Drive Pawl (Dogs)
G Drive Plate
I Grommet
K Starter Rope
M Hex Flange Nut
40
WARNING
M
I
J
K
L
B Recoil Spring
D Drive Pawl Springs
F Pulley Spring
H Center Screw
J Starter Handle
Double Left-Hand
L
Knot
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Remove Starter
NOTE: Whenever possible, an impact wrench should be
used to loosen nuts securing retractable starter.
1. Remove nuts securing starter to blower housing.
2. Remove starter assembly.
Rope Replacement
NOTE: Do not allow pulley/spring to unwind. Enlist aid
of a helper if necessary.
Rope can be replaced without complete starter
disassembly.
1. Remove starter assembly from engine.
2. Pull rope out approximately 12 in. and tie a
temporary (slip) knot in it to keep it from retracting
into starter.
3. Pull knot end out of handle, untie knot, and slide
handle off .
4. Hold pulley fi rmly and untie slipknot. Allow pulley to
rotate slowly as spring tension is released.
5. When all spring tension on starter pulley is released,
remove rope from pulley.
6. Tie a double left-hand knot in one end of new rope.
7. Rotate pulley counterclockwise to pre-tension spring
(approximately 4 full turns of pulley).
8. Continue rotating pulley counterclockwise until rope
hole in pulley is aligned with rope guide bushing of
starter housing.
9. Insert unknotted end of new rope through rope hole
in starter pulley and rope guide bushing of housing.
10. Tie a slipknot approximately 12 in. from free end of
rope. Hold pulley fi rmly and allow it to rotate slowly
until slipknot reaches guide bushing of housing.
11. Insert starter rope through starter handle and tie a
double, left-hand knot at end of starter rope. Insert
knot into hole in handle.
12. Untie slip knot and pull on starter handle until starter
rope is fully extended. Slowly retract starter rope into
starter assembly. If recoil spring is properly
tensioned, starter rope will retract fully and starter
handle will stop against starter housing.
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