Remove Starter; Rope Replacement; Pawls (Dogs) Replacement; Install Starter - Kohler XT-6 Service Manual

Starter System

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 firmly 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 firmly 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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Pawls (dogs) Replacement

1. Install a clamp to hold pulley in starter housing and
prevent it from rotating.
2. Unscrew center screw and lift off drive plate.
3. Note positions of pawls and pawl springs before
removing. Remove parts from pulley.
4. Install pawl springs and pawls into pawl slots of
pulley. All parts must by dry.
5. Position drive plate over pawls, aligning actuating
slots in place with raised sections on each drive
pawl. Torque center screw to 5-6 N·m (44-54 in. lb.).
6. Remove clamp and pull starter rope out part way to
check operation of pawls.

Install Starter

1. Place starter onto studs protruding from blower
housing. Start nuts onto studs, but do not tighten.
2. Pull starter handle out until pawls engage in drive
cup. Hold handle in this position and torque nuts to 8
N·m (71 in. lb.).
KohlerEngines.com 14 690 01 Rev. G