Kohler Command PRO CV730 [51/92] Starter system
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Kohler Command PRO CV730 [51/92] Starter system

Kohler Command PRO CV640 [51/92] Starter system
Starter System
24 690 07 Rev. J
KohlerEngines.com 51
Retaining Ring Installation
1. Position retaining ring in groove in one of inner
halves. Assemble other half over top and slide on
outer collar.
2. Be certain drive components are installed in correct
sequence onto armature shaft.
3. Slip tool over end of armature shaft, so retaining ring
inside is resting on end of shaft. Hold tool with one
hand, exerting slight pressure toward starter. Tap top
of tool with a hammer until you feel retaining ring
snap into groove. Disassemble and remove tool.
4. Squeeze retaining ring with a pliers to compress it
into groove.
5. Assemble inner halves with larger cavity around
spring retainer. Slide collar over them and thread
center screw in until resistance is felt.
6. Hold base of tool with a 1-1/8 wrench and turn
center screw clockwise with a 1/2 or 13 mm wrench
to draw spring retainer up around retaining ring. Stop
turning when resistance increases. Disassemble and
remove tool.
7. Reinstall dust cover.
Starter Disassembly
1. Remove drive components following instructions for
servicing drive.
2. Locate small raised line on edge of drive end cap.
On starters with style A commutator end caps, it will
be aligned with a pre-marked line on starter frame.
Frame is not pre-marked on starters with style B end
caps. Place a piece of masking tape on frame and
mark a line on tape in line with raised line on end
cap.
3. Remove thru bolts.
4. Remove commutator end cap with brushes and
brush springs (style A). Style B end caps remove as
a separate piece with brushes and carrier remaining
in frame.
5. Remove drive end cap.
6. Remove armature and thrust washer (if equipped)
from inside starter frame.
7. Remove brush/carrier assembly from frame (style B
starters).
Brush Replacement
Style A
NOTE: Use a brush holder tool to keep brushes in
pockets. A brush holder tool can easily be made
from thin sheet metal.
1. Remove brush springs from pockets in brush holder.
2. Remove self-tapping screws, negative (–) brushes,
and plastic brush holder.
3. Remove nut and fi ber washer from stud terminal.
Remove stud terminal with positive (+) brushes and
plastic insulating bushing from end cap.
4. Install insulating bushing on stud terminal of new
positive (+) brushes. Install stud terminal into
commutator end cap. Secure stud with fi ber washer
and screw.
5. Install brush holder, new negative (–) brushes, and
self-tapping screws.
6. Install brush springs and brushes into pockets in
brush holder. Make sure chamfered sides of brushes
are away from brush springs.
Style B
Starters with style B end caps have brushes in a plastic
carrier housing, separate from end cap. Replacement
brushes come preassembled in carrier housing, retained
with two carton staples.
Commutator Service
Clean commutator with a coarse, lint free cloth. Do not
use emery cloth.
If commutator is badly worn or grooved, turn it down on
a lathe or replace starter.
Starter Reassembly
1. Place thrust washer (if equipped) over drive shaft of
armature.
2. Insert armature into starter frame. Make sure
magnets are closer to drive shaft end of armature.
Magnets will hold armature inside frame.
3. Install drive end cap over drive shaft. Make sure
match marks on end cap and starter frame are
aligned.
4. Style A commutator end caps:
Install brush holder tool to keep brushes in pockets
of commutator end cap.
Align match marks on commutator end cap and
starter frame. Hold drive end and commutator end
caps fi rmly to starter frame. Remove brush holder
tool.
Style B commutator end caps:
If brush assembly is not being replaced, position
brushes in their pockets in carrier. Move them to
retracted position, and install carton staples to retain
them.
Align terminal stud block with notch in starter frame
and slide brush/carrier assembly into frame.
Commutator will push carton staples out as brush
assembly is installed. Position end cap over brush
assembly, so holes for thru bolts are aligned with
those in brush carrier.
5. Install thru bolts and tighten securely.
6. Lubricate drive shaft with Kohler starter drive
lubricant. Install drive components following
instructions for servicing starter drive.

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