Drive Pinion; Brush Replacement; Starter Service; Shift Fork - Kohler CH940-CH1000 Service Manual

Inspection

Drive Pinion

Check and inspect following areas:
a. Pinion teeth for abnormal wear or damage.
b. Surface between pinion and clutch mechanism
for nicks, or irregularities which could cause seal
damage.
c. Check drive clutch by holding clutch housing and
rotating pinion. Pinion should rotate in one
direction only.
Brushes and Springs
A
D
E
Wear Limit Length
A
Mica Insulation
C
Armature Coil
E
Inspect both springs and brushes for wear, fatigue,
or damage. Measure length of each brush. Minimum
length for each brush is 7.6 mm (0.300 in.). Replace
brushes if they are worn undersize, or their condition is
questionable.
Armature
1. Clean and inspect commutator (outer surface). Mica
insulation must be lower than commutator bars
(undercut) to ensure proper operation of
commutator.
2. Use an ohmmeter set to Rx1 scale. Touch probes
between two different segments of commutator, and
check for continuity. Test all segments. Continuity
must exist between all or armature is bad.
3. Check for continuity between armature coil
segments and commutator segments. There should
be no continuity. If continuity exists between any
two, armature is bad.
4. Check armature windings/insulation for shorting.
62 690 01 Rev. C
B
C
F
Commutator O.D.
B
Insulation Check
D
Continuity Check
F
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Shift Fork

Check that shift fork is complete, and pivot and contact
areas are not excessively worn, cracked, or broken.

Brush Replacement

Brushes and springs are serviced as a set (4). Use
a new Kohler Brush and Spring Kit, if replacement is
necessary.
1. Perform Steps 1-5 in Starter Disassembly.
2. Remove two screws securing brush holder assembly
to end cap (plate). Note orientation for reassembly
later. Discard old brush holder assembly.
3. Clean component parts as required.
4. New brushes and springs come preassembled in a
brush holder with a protective sleeve that will also
serve as an installation tool.
5. Perform Steps 10-13 in Starter Reassembly
sequence. Installation must be done after armature,
drive lever, and frame are installed, if starter has
been disassembled.

Starter Service

Clean drive lever and armature shaft. Apply Kohler
electric starter drive lubricant (Versilube G322L or Mobil
Temp SHC 32) to lever and shaft. Clean and check other
starter parts for wear or damage as required.
Starter Reassembly
NOTE: Always use a new retainer. Do not reuse old
retainers which have been removed.
NOTE: Correctly installed, center pivot section of drive
lever will be fl ush or below machined surface of
housing which receives backup washer.
1. Apply drive lubricant to armature shaft splines. Install
drive pinion onto armature shaft.
2. Install and assemble stop collar/retainer assembly.
a. Install stop collar down onto armature shaft with
counter bore (recess) up.
b. Install a new retainer in larger (rear) groove of
armature shaft. Squeeze with a pliers to
compress it in groove.
c. Slide stop collar up and lock it into place, so
recess surrounds retainer in groove. If necessary,
rotate pinion outward on armature splines against
retainer to help seat collar around retainer.
3. Install offset thrust (stop) washer so smaller offset of
washer faces retainer/collar.
4. Apply a small amount of oil to bearing in drive end
cap, and install armature with drive pinion.
5. Lubricate fork end and center pivot of drive lever
with drive lubricant. Position fork end into space
between captured washer and rear of pinion.
6. Slide armature into drive end cap, and at same time
seat drive lever into housing.
7. Install backup washer, followed by rubber grommet,
into matching recess of drive end cap. Molded
recesses in grommet should be out, matching and
aligned with those in end cap.
Electrical System
45