Kohler KT17 Service Manual

SECTION 6
ELECTRICAL SYSTEMS AND COMPONENTS
BRUSH REPLACEMENT AND
COMMUTATOR SERVICE
The starter must be completely disassembled to
service brushes and commutator. Refer to Figure
6-10 and proceed as follows:
1. Remove
drive pinion unit (see "Drive Assem-
bly" for correct procedure).
2. Remove thru bolts.
3.
Separate end cap from armature.
NOTE: Brush springs will probably fall out
when brushes pull free of commutator.
4. Clean commutator with a coarse, lint-free cloth
- if badly worn or grooved, turn down on lathe.
5. Replace brushes as follows: The positive brush-
es are part of the terminal stud assembly. To
replace, remove nuts, and pull stud out thru
inside of end cap. Insert new stud terminal-
brush unit after transferring insulation bush-
ing from old unit. To replace insulated (negative)
brushes, simply remove capscrew and lock
washer. Always use new brushes and springs.
Assemble brushes with chamfered side away
from springs. Keep brush leads away from
contact with metal of end cap.
6. To keep brushes in position so that they will fit
over the commutator as the end cap is reinstall-
ed, use a brush holder tool as shown in Figure
6-11. It can easily be cut out of thin sheet metal.
7. Line-up bench marks on both end caps with
those on the motor frame, insert thru bolts and
tighten.
DRIVE ASSEMBLY
If drive pinion is badly worn, has chipped or
broken teeth, it must be replaced. Replacement
drive kits are available from your Kohler parts
supplier.
It is not necessary to disassemble the starting
motor to remove or reinstall the pinion or the
retaining nut. Refer to Figure 6-10 and proceed as
follows:
1. Hold the drive pinion in a vise with soft jaws
40
Sheet Metal Brush
Holder Tool
Brush Holder
In Place
Over Brushes and End Cap
Figure 6-11. Brush Holder Tool
while turning the nut on or off. The armature
will turn with the nut only until the pinion stops
against internal spacers.
CAUTION: Do not overtighten vise as this
could distort the shape of the
p1n1on.
2. Remove the drive pinion stop nut and the drive
parts in the order shown.
3. Clean the drive shaft splines with a good com-
mercial solvent, dry thoroughly and apply a
small amount of Kohler electric starter drive
lubricant - available from your Kohler parts
supplier.
4. Apply a small amount of Loctite #271 to the
drive pinion stop nut threads and assemble
drive parts in reverse order of disassembly.
Torque pinion stop nut to 160 in. lbs.
(Some field reports have indicated drive assembly
problems were nothing more than gummed as-
sembly components. When cleaning, make certain
step 3 is followed.)
RING GEAR
WARNING: Do not attempt to replace the flywheel
ring gear. Kohler no longer provides
the ring gear as a serviceable part.
Replace
the flywheel if the ring gear is
damaged.

Kohler KT17 Specifications

General

Brand	Kohler
Model	KT17
Category	Engine
Language	English