Solenoid Test Procedure - Kohler CH940-CH1000 Service Manual

Electrical System
8. Install frame, with small notch forward, onto armature and drive end cap. Align notch with corresponding section in
rubber grommet. Install drain tube in rear cutout, if it was removed previously.
9. Install fl at thrust washer onto commutator end of armature shaft.
10. Starter reassembly when replacing Brushes/Brush Holder Assembly:
a. Hold starter assembly vertically on end housing, and carefully position assembled brush holder assembly, with
supplied protective tube, against end of commutator/armature. Mounting screw holes in metal clips must be up/
out. Slide brush holder assembly down into place around commutator, and install positive (+) brush lead
grommet in cutout of frame. Protective tube may be saved and used for future servicing.
Starter reassembly when not replacing Brushes/Brush Holder Assembly:
a. Carefully unhook retaining caps from over each of brush assemblies. Do not lose springs.
b. Position each of brushes back in their slots so they are fl ush with I.D. of brush holder assembly. Insert Brush
Installation Tool (with extension), or use tube described above from a prior brush installation, through brush
holder assembly, so holes in metal mounting clips are up/out.
c. Install brush springs and snap on four retainer caps.
d. Hold starter assembly vertically on end housing, and carefully place tool (with extension) and assembled
original brush holder assembly onto end of armature shaft. Slide brush holder assembly down into place
around commutator, install positive (+) brush lead grommet in cutout of frame.
11. Install end cap onto armature and frame, aligning thin raised rib in end cap with corresponding slot in grommet of
positive (+) brush lead.
12. Install two thru bolts, and two brush holder mounting screws. Tighten bolts to torque specifi cations. Tighten brush
holder mounting screws to torque specifi cations.
13. Hook plunger behind upper end of drive lever, and install spring into solenoid. Insert three mounting screws
through holes in drive end cap. Use these to hold solenoid gasket in position, then mount solenoid. Tighten
screws to torque specifi cations.
14. Connect positive (+) brush lead/bracket to solenoid and secure with hex nut. Tighten nut to torque specifi cations.
Do not overtighten.

Solenoid Test Procedure

Solenoid Shift Style Starters
Disconnect all leads from solenoid including positive brush lead attached to lower stud terminal. Remove mounting
hardware and separate solenoid from starter for testing.
Test 1 Solenoid Pull-In Coil/Plunger Actuation Test
*NOTE: DO NOT leave 12 volt test leads connected to
solenoid for any time over what is necessary for
performing each of individual tests. Internal
damage to solenoid may otherwise occur.
Use a 12 volt power supply and two test leads. Connect
one lead to fl at spade S/start terminal on solenoid.
Momentarily* connect other lead to lower large post
terminal.
When connection is made solenoid should energize
(audible click), and plunger retract. Repeat test several
times. If solenoid fails to activate, it should be replaced.
Test 3 Solenoid Hold-In Coil Function Test
Connect one 12 volt test lead to fl at spade S/start
terminal on solenoid, and other lead to body or mounting
surface of solenoid. Then, manually push plunger In
and check if Hold-In coil holds plunger retracted. Do
not allow test leads to remain connected to solenoid
for a prolonged period of time. If plunger fails to stay
retracted, solenoid should be replaced.
46
Test 2 Solenoid Pull-In Coil/Contact Continuity Test
Use an ohmmeter set to audible or Rx2K scale, and
connect two ohmmeter leads to two large post terminals.
Perform preceding test (1) and check for continuity.
Ohmmeter should indicate continuity, if no continuity
is indicated solenoid should be replaced. Repeat test
several times to confi rm condition.
Test 4 Solenoid Hold-In Coil/Contact Continuity Test
Use an ohmmeter set to audible or Rx2K scale, and
connect two ohmmeter leads to two large post terminals.
Perform preceding test (3) and check for continuity.
Meter should indicate continuity. If no continuity is
indicated, solenoid should be replaced. Repeat test
several times to confi rm condition.
KohlerEngines.com 62 690 01 Rev. C