Kohler Various Reference manual

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DATE REVISEDDATE ISSUED
MODEL
NO.
PRINTED IN U.S.A. ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
Service
Bulletin
Starter Warranty Policy
Due to the increase in starter warranty claims we will be requiring some simple testing be performed when
replacing a starter under warranty. Listing a starter as the defective part you will be requested to enter the results
from the test below in the parts information box. By performing these test procedures you will expedite the
warranty claim review on starters. Any starter warranty claim submitted without completing these tests will be
rejected and returned.
This new policy has been put in place and will be enforced beginning April 1, 2011.
Below we have provided the testing procedures and questions that will be required. Also included with each
starter is an installation instruction that outlines the testing procedure.
Starter Warranty Test Procedures
NOTE: Please perform the following testing as near to the conditions during failure (i.e. in the morning when
cold, a hot restart, or as close to the description of failure provided by the customer).
WARNING
Explosive Fuel can cause res
and severe burns.
Do not ll the fuel tank while the
engine is hot or running.
Gasoline is extremely ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated,
unoccupied buildings, away from sparks or ames. Do not ll the fuel tank while the engine is hot or running, since spilled fuel
could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use
gasoline as a cleaning agent.
CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
Never touch electrical wires or components while the engine is running. They can be sources of electrical shock.
Before Starting
• Disable ignition system: disconnect the spark plug lead from the spark plug, then ground the spark plug lead
to the engine block using mechanical means. Refer to the correct engine service manual if necessary.
• Battery voltage should be tested and must be at 12.4 VDC or higher. Do not proceed if battery voltage is less
than 12.4 VDC as battery should be charged.
(OVER)

2
• Test meter leads before use. (Set meter to Ohms and check for resistance reading of less than 0.5 Ohm.)
• If available, use clamping meter leads to assist with testing.
• Set meter to next highest voltage scale that includes 12 VDC.
• When taking readings, allow the meter to stabilize before recording. The reading should stabilize after 3 to 5
seconds. If reading continues to drop while cranking, stop the test and perform a battery load test.
Solenoid Shift Starter Warranty Test Procedures
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Test #1
Battery Voltage Test (Static)
DVOM
Battery
NOTE: Touch meter
leads to actual battery
terminals.
VDC
Test #2
Voltage Drop Across Battery (Cranking)
DVOM
Battery
VDC
Test #3
Voltage Drop Across Starter (Cranking)
NOTE: Use starter
end plate as test
point.
DVOM
Starter
VDC
Test 1 Conclusions
• If baery voltage is above 12.4
VDC continue to Test 2.
• If voltage is below 12.4 VDC,
charge baery and retest.
• If baery will not hold a charge
it should be replaced before
continuing the test or replacing
the starter.
Test 2 Conclusions
• If baery cranking voltage is
above 9.0 VDC continue to
Test 3.
• If baery cranking voltage is
below 9.0 VDC you should
check the baery by using
a load tester. Also check for
external engine load.
Test 3 Conclusions
• If the dierence between test
2 and test 3 is greater than 1
VDC check all positive and
negative electrical connections
for corrosion and/or loose
fasteners in the starter circuit.
• If additional starter testing
is necessary, refer to proper
service manual for complete
troubleshooting information.

3
Inertia Drive Starter Warranty Test Procedures
Test 1 Conclusions
• If baery voltage is above 12.4
VDC continue to Test 2.
• If voltage is below 12.4 VDC,
charge baery and retest.
• If baery will not hold a charge
it should be replaced before
continuing the test or replacing
the starter.
Test 2 Conclusions
• If baery cranking voltage is
above 9.0 VDC continue to Test
3.
• If baery cranking voltage is
below 9.0 VDC you should
check the baery by using
a load tester. Also check for
external engine load.
Test 3 Conclusions
• If the dierence between test
2 and test 3 is greater than 1
VDC check all positive and
negative electrical connections
for corrosion and/or loose
fasteners in the starter circuit.
• If additional starter testing
is necessary, refer to proper
service manual for complete
troubleshooting information.
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Test #1
Battery Voltage Test (Static)
DVOM
Battery
NOTE: Touch meter
leads to actual battery
terminals.
VDC
Test #2
Voltage Drop Across Battery (Cranking)
DVOM
Battery
VDC
Test #3
Voltage Drop Across Starter (Cranking)
NOTE: Use starter
end plate as test
point.
DVOM
Starter
VDC
Warranty Claim Instructions
1. Create claim in warranty system as normal.
2. Once the starter part number is placed in the defective part box the questions listed below will display in the
section shown as a Parts Message. Enter the results of the testing in the Parts Information box.
• Baery voltage measured?
• Voltage across baery during cranking?
• Voltage across starter during cranking?
• Was the testing above performed under the conditions that failure was observed? (Yes/No)
3. Finish warranty claim as normal.