Service and Repairs

51
Starter System
17 690 01 Rev. L KohlerEngines.com
4. Use a known, good, fully-charged battery and
jumper cables to test starter motor. Be sure
transmission is in neutral and PTO is OFF.
Remove heavy lead from post terminal on starter.
Connect one end of positive jumper cable to post
terminal and connect other end to positive terminal
of battery.
Connect one end of negative jumper cable to
negative terminal of battery. Touch other end of
negative jumper cable to a bare surface on
crankcase or to starter housing.
Condition Conclusion
Relay engages and starter
begins to crank.
Key switch is faulty, or
there is a wiring problem
to/from key switch. Check
wiring and test key switch
circuits with an ohmmeter.
5. Disconnect leads from starter relay and remove it
from starter for testing.
a. Set an ohmmeter on Rx1 scale and zero meter.
Connect one ohmmeter lead to terminal of blue
lead from relay. Connect other ohmmeter lead to
relay mounting bracket.
Condition Conclusion
Meter reading less than
3.4 ohms, or an open
circuit is indicated (infi nity
ohms).
Relay is faulty and must
be replaced.
b. With ohmmeter still on Rx1 scale, connect leads
to two large post terminals. Meter should indicate
an open circuit (infi nity ohms, no continuity).
c. Leave ohmmeter leads connected to large
terminals. Connect a jumper lead from positive
terminal of battery to terminal of blue relay lead.
Connect another jumper lead from negative
terminal of battery to relay mounting bracket.
Condition Conclusion
When circuit is completed,
applying 12 volts to
energizing coil, an audible
click should be heard as
relay engages, and
ohmmeter should then
indicate continuity
between large terminals.
Results are other than
indicated, replace relay.
INERTIA DRIVE ELECTRIC STARTERS
WARNING
Accidental Starts can cause severe injury or
death.
Disconnect and ground spark plug lead(s)
before servicing.
Before working on engine or equipment, disable
engine as follows: 1) Disconnect spark plug lead(s). 2)
Disconnect negative (–) battery cable from battery.
Type I Starter CH395, CH440
A
B
A
Round Boot on
Top of Starter
B
Relay (Solenoid)
is Serviced
Type II Starter CH440
C
D
C
Square Boot at
Front of Starter
D
Relay (Solenoid)
is Serviced