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Posted by David Kirk on Thursday, June 12, 2003 - 08:50 PM:
I must admit that I had starting problems this winter with my K-301 AQS HR (hot-rodded) engine. This seeemed mostly due to the additional drag imposed by the larger charge pump that is part of the hydraulics package that I installed earlier in the year. The result was the engine just wouldn't crank fast enough to self-sustain. It would fire, kick the bendix out and not keep running.
Recently I came across a starter for a newer, vertical shaft Kohler that is exactly the same physical size as the K-series starter. Only major difference is the new model is flange mounted while the K-series is a side mount.
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Disassembly of the new starter revealed that the wire diameter on the armature windings was .050 versus .046 on the original. Also, the new one had epoxy on the windings for better retention. Two comparison pictures to follow.
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Measuring the pinion gear travel and number of teeth revealed that both were identical. Thus, it seemed rather straight forward to put all the newer parts into the old starter frame and wind up with something that would give a little more cranking effort.
The first and foremost modification was removing the flanges from the aluminum front bearing plate. This was chucked up in the lathe and turned to a 3.030 diameter, same as the other, stamped steel plate.
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Another improvement in the newer starter is the bendix drive pinion has a friction clutch such that false starts are eliminated or greatly reduced. The pinion and driver are a two-piece component versus the older style single piece.
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I decided to use the old style rear bearing plate so the new brush holder and brushes were transferred over. Everything was totally interchangeable.
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With that done, assembly was next. I use the popsickle stick method of holding the brushes down, then lowering the armature down into position over the sticks.
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Then the frame is lowered over the armature while doing some fancy fingerwork. The sticks are then pulled out and weight and magnetism hold everything in place.
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The front bearing plate is slid into position and bolted up with the newer, slightly longer bolts. The pinion gear and return spring is retained by a snap ring and collar arrangement rather than the older style threaded nut.
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All that's left is to snap the plastic dust cover in place, mount on the engine, and try it.
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Well I'm happy to say that this super-starter works GREAT! It spins the engine over at a noticeably faster rate yielding instant light-offs. It also is much quieter and has a nicer, precision sound versus the original, "grind some for me" racket that reminded me of an old school bus I used to ride as a kid. The thicker front bearing plate poses no installation problems and everything clears and fits fine.
Winter and cold weather will be the real test. I think it will perform with gusto.<!-/quote-!><hr size=0></blockquote>
Here is photo number 9558.jpg:
If you must see the photos let me know and I'll send 'em out. I'll be heading home in a minute or two so I will not be around to respond until Monday.
Bryan, you want a Word Document with the photos inserted into their proper place for making another page?