Kohler MAGNUM M18

SECTION 8
ELECTRICAL SYSTEM AND COMPONENTS
NOTE: If the engine develops sufficient speed to dis-
engage the starter but does not keep running
{a “false start”), the engine rotation must be
allowed to come to a complete stop before
attempting to restart the engine. If the starter
is engaged while the flywheel is rotating, the
starter pinion and flywheel ring gear may
clash. This can damage the starter.
NOTE: If the starter does not crank the engine, shut-
Off the starter immediately. Do not make fur-
ther attempts to start the engine until the con-
dition is corrected. Do not jump start using
another battery. Using batteries larger than
those recommended can bum out the starter
motor.
NOTE: Do not drop the starter or strike the starter
frame. Doing so can damage the ceramic
permanent magnets.
Troubleshooting Guide
Starter Drive Service
Every 500 operating hours or annually (whichever
comes first), clean and lubricate the drive splines of
the starter, If the drive pinion is badly wom, or has
chipped or broken teeth, it must be replaced.
It is not necessary to disassemble the starter to ser-
vice the drive components. Refer to Figure 8-17 and
Service drive as follows.
1. Hold the drive pinion in a vise with soft jaws when
removing and installing the stop nut. The arma-
ture wili rotate with the nut only until the drive pin-
ion stops against internal spacers.
NOTE: Do not overtighten the vise as this can
distort the drive pinion.
2. Remove the dust cover, stop nut, stop gear
spacer, anti-drift spring, dust cover spacer, and
drive pinion.
3. Clean the drive shaft splines with solvent. Dry the
splines thoroughly.
Problem Possible Fault Correction
1. Clean corroded connections and tighten loose connections.
Wiring 2. Replace wires in poor condition and with frayed or broken insulation.
STARTER Starter Switch Bypass the switch or solenoid with a jumper wire-if starter cranks normally, replace
FAILS or the faulty parts.
TO ENERGIZE Solenoid
Battery Check specific gravity of battery. If tow, recharge or replace battery as necessary,
Battery Check specific gravity of battery. If low, recharge or replace battery as necessary.
Brushes Check for excessively dirty or worn brushes and commutator. Clean using a coarse
cloth (not emery paper). Replace brushes if excessively or unevenly worn.
STARTER Make sure the clutch or transmission is disengaged or placed in neutral. This is
ENERGIZES especially important on equipment with hydrostatic drive. The transmission must
BUT TURNS Transmission be exactly in neutral to prevent resistance which could keep the engine from
SLOWLY or starting.
Engine Check for seized engine components such as the bearings, connecting rod, and
piston.
4. Apply a small amount of Kohler electric starter
drive lubricant (Part No. 52 357 01) to splines.
NOTE: Kohler starter drive lubricant (Part No.
52 357 01) must be used on all Kohler
electric starter drives. The use of other
lubricants can cause the drive to stick or
bind.
5. Apply a small amount of Loctite& No. 271 to stop
nut threads,
6. Reinstall the drive pinion, dust cover spacer, anti-
drift spring, stop gear spacer, and stop nut.
Torque stop nut to 160 In. Ib. Instalt the dust
cover.
Disassembly
1. Remove the dust cover, stop nut, stop gear
spacer, anti-drift spring, dust cover spacer, and
drive pinion. Refer to "Starter Drive Service."
2. Remove the thru bolts.
3. Remove the drive end cap and thrust washer.
8.14