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I am replacing armature on a kohler starter 2009811-s and I am having trouble holding the 4 brushes in so I can put the armature in the end piece. How do they do that thanks.

You have to keep them retracted while slipping them over the armature.
I've used small diameter wire to do this.
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There is no holes to put a wire in to hold the brushes back

I've seen the procedure on You Tube.
Give it a search.

can you use strips of thin cardboard or plastic cut from something to help hold them back? Do the brush holders have small holes in them for a sturdy toothpick or something?

There is no holes in the brush plate

You Have to make 4- square bottom "U" shaped stiff wire clips to hold the brushes back and allow them to slip past the commutator. There are example online. Don't fight or force anything because you can easily chip the tips on the brushes or damage the commutator.

The larger paper clips work good (the big star shaped ones) to make the clips or an old throttle/choke cable wire.

I saw the video using u shaped pieces but there is no holes to put them in to hold the brushes in.

tim4 said:

I saw the video using u shaped pieces but there is no holes to put them in to hold the brushes in.

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Apparently you will have to drill holes in bottom plate so you can hold brushes in with a couple of wires. It is a real pain.

Can you provide a coupe of pictures of you brush end cap parts? I feel like we are trying to instruct by brail here.

I already drilled 4 holes in the end cap that has the brush holders on it thanks.

Were you able to get it back together then?

I have to glue a magnet on the case.

Use 3M yellow adhesive, but I think you are going through a lot of headaches for such a cheap starter.

I'm thinking them little people with the little hands and fingers and Big Head did not have any trouble installing the brushes super fast, probably women on the assembly line.

I am going to buy one from amazon they are around 50.00 thanks for all the sugestions.

thinking about all that has been said. This is informative only. Starter armatures run a tight clearance. This is true for many motors. If the armature expands it will drag on the field coils. It sounds like this is what happened to this starter. Also some starters are self supporting while others need a bushing in the bell housing to support the nose end of the starter. If this starter is one of those, a worn bushing can cause the armature to drag on the field coils. I don't know if this is one of those or not.

The starter has bushings on both ends nothing else supports the armature.

tim4 said:

The starter has bushings on both ends nothing else supports the armature.

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Remember, it wasn’t that many years ago that starters, alternators, etc. were rebuilt locally. I mean, some still are but very few. People remove and replace most times. An aftermarket starter price is really reasonable. However, the OEM starters are usually 3 times and up, the cost of aftermarket.

I'm still one of the few in my area that will replace a simple broken plastic Bendix gear on a starter for a customer. Of course there are many who are just cheap price shoppers so they go for the poor quality aftermarket starters. Most don't want to fuss with the pesky spring clip design.

I have a small collection of reconditioned starters that I keep on hand. If the armature has not been smoked, I would rather recondition an original

Auto Doc's said:

I'm still one of the few in my area that will replace a simple broken plastic Bendix gear on a starter for a customer. Of course there are many who are just cheap price shoppers so they go for the poor quality aftermarket starters. Most don't want to fuss with the pesky spring clip design.

I have a small collection of reconditioned starters that I keep on hand. If the armature has not been smoked, I would rather recondition an original

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I do the same.

A guy that swapped in new starters for customers gave me a big pile of starters sometime back and I've reconditioned several of them that just needed a Bendix gear or Brush kit.

He also gave me a big pile of carbs, several were the OEM types carbs Briggs and Nikki's.

tim4 said:

I am replacing armature on a kohler starter 2009811-s and I am having trouble holding the 4 brushes in so I can put the armature in the end piece. How do they do that thanks.

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Do this.....get a sheet and a flashlight.....sit under the sheet on a solid floor because those springs will launch to God knows where sometimes. I "lost" one spring but knew the last thing it hit was metal after bouncing off the ceiling and eventually found it in the top of my tool chest.

Work in pairs....helps to have the case clamped vertically in a vice as well.....and insert two opposite brushes and use a small flat tip screwdriver to push the compressed springs into place on opposite sides. A strip of duct tape over each may help retain the installed pair. Then work carefully on the other two opposite pairs replacing springs. It's almost like you need three hands to do this. Can be done it's just fiddly work.

Just you a socket with a opening bigger then the armature, put it inside brushes and push into place.