[mikeinri]

Tried the GS6500's starter again today, was turning the engine. I stopped letting it turn before it started.

Got the shroud off, verified that the bendix was stuck in the up position. Maybe normal if the engine doesn't start?

After taking the pic, with the shroud still off, I tried again, and let the engine start. The bendix retracted normally.

Running:

After running:

I called Ace Armature, they recommended cleaning it, and leaving it dry (do NOT lube it with anything, as that will collect dirt given that it's a lawn tractor).

I then grabbed the bendix gear with my fingers, and is seems to move up and down freely (I was expecting some resistance from a spring?).

Anyway, I'll try cleaning it up after this next rain cloud goes by. Probably won't be cutting the grass until tomorrow.

Mike

 

[mikeinri]

This is a SV725-0013 Kohler Courage engine. The service manual shows a spring to hold the bendix gear down. I wonder if that's also broken?

I don't recall playing with it after getting it back the last time it was repaired, so I suppose it's possible that they never reinstalled it, and it's not really necessary?

Mike

 

[mikeinri]

Here's an interesting video, apparently there have been at least three upgrades to the starter design over the years (and mine is the oldest one)...

Mike

 

[mikeinri]

Well, I wanted to run the engine for a few minutes to warm up the oil before draining it while I work on the starter, but...

...it's stuck in the up position, and while the starter motor is spinning, the bendix gear ("drive pinion" per Kohler manual above) is NOT.

Pulled the starter, verified that the drive nut (collar) was stuck, holding the gear up:

I was able to tap the drive nut/collar with a hammer, and that allowed everything to slide back down.

I played with it a little, the spring seems to be working, but the collar keeps binding when it gets to the top of the shaft / spirals. To my untrained eye, it looks like there's worn metal on the inner part of that collar.

The Kohler manual says to disassemble, clean and lube. Disassembly requires a special tool (which is NLA online), and the lube is a Kohler part (no clue what it really is).

I'm taking it to the Armature shop tomorrow. If all else fails, I'll upgrade to a new generation starter. Those are $200+ online.

I have full confidence in Ace Armature, so I doubt it'll come to that...

Mike

 

[mikeinri]

...and I found the problem (or it found me???)...

After removing the starter, I started cleaning up around the engine, and found this sitting on the tractor frame:

Pic of the rebuild kit (gear is top center of this pic), the black material is supposed to go all around the base of the bendix gear.

It's hard rubber, so I'm assuming it's a bumper / spacer. Being missing, is allowing the collar to rise too high.

You can see remnants of it on the bottom of my old gear.

Obviously, this is more than a clean / lube job at this point...

Mike

 

[tomw0]

If you can get the gear with the rubber collar(bump stop?) you should be in business once again. Ten years isn't bad IMO, but more would be nice.
If the kit listed is available, I think I'd go that way vs a new one. A rebuild/repair kit seems to be the answer that will get the starter functional. I think I would take it apart(partially, anyway) and clean the insides, wipe off the armature, clean the brushes and holders, inspect the brush tension springs(I bet brushes are available that will fit - perhaps Stens, etc), and put a little lube into the bushings after cleaning. Starters on OPE generally get used a lot less than automotive, and are close in the type/style/class of the parts used in their manufacture. IOW, they don't design new parts to be flimsier and to wear out sooner, AFAIK.
tom

 

[mikeinri]

Thanks Tom. It's at the armature shop, they're going to replace the bendix gear, not sure if they'll tear into the whole thing. I'm hoping that they have the part in stock and finish it today.

Should have stuck with my original plan and brought it to them Saturday morning, LOL.

I did chat with the owner, he agreed that they've changed the design over the years. He's seen the second generation, but not the third generation (maybe that's a good sign?).

He also agreed that by welding the nut onto the shaft, it might make it difficult (or impossible) to service those (third generation). Who knows?

Mike

 

[mikeinri]

Not done today...

Mike

 

[mikeinri]

Of course, last Wednesday (while we were dropping off our son at the baseball village in Cooperstown, NY), the armature shop called to tell me the starter was ready (back in RI)...

Got back from our trip last night, and I picked it up this morning. Probably won't get it installed until tomorrow (due to expected rain after work this evening).

New gear, but it doesn't look like they opened the main case. $30. Perfect!

Pic of the fixed starter...

...just realized that you can't really see the base of the gear, with the rubber(?) ring. I'll get better pics tomorrow.

Mike

 

[mikeinri]

Better pics, works perfectly.

Mike