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)

• 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

+ -

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.

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

• 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.

+ -

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.

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