Kohler Command PRO EFI propane PCV680 [61/96] Starter system

6124 690 31 Rev. D KohlerEngines.com

Starter System

b. Position 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 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.

4.0-6.0 N·m (35-53 in. lb.).

14. Connect positive (+) brush lead/bracket to solenoid and secure with nut. Torque nut to 8-11 N·m (71-97 in. lb.). Do

not overtighten.

Solenoid Tests

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 occur.

Disconnect all leads from solenoid including positive brush lead attached to lower stud terminal. Remove mounting

hardware and separate solenoid from starter for testing.

To test solenoid pull-in coil/plunger:

Actuation

2. Perform solenoid pull-in coil/plunger actuation test and check for continuity. Ohmmeter should indicate continuity.

Repeat test several times.

To test solenoid hold-in coil:

Function

1. Connect a 12 volt test lead to fl at spade S/start terminal on solenoid and other lead to body or mounting surface

of solenoid.

2. Manually push plunger IN and check if coil holds plunger retracted. Do not allow test leads to remain connected to

solenoid for a prolonged period of time.

Continuity

1. Use an ohmmeter set to audible or Rx2K scale, and connect 2 ohmmeter leads to 2 large post terminals.