Kohler Command CH20 Service Manual page 44

Electrical System
Test Ignition Modules and Connections (Smart-
Spark only)
™
NOTE: Resistance values apply only to modules that
have been on a running engine. New service
modules may have higher resistance until they
have been run.
1. Remove blower housing from engine. Inspect wiring
for any damage, cuts, bad crimps, loose terminals,
or broken wires.
2. Disconnect leads from ignition module(s) and clean
all of terminals (male and female) with aerosol
electrical contact cleaner to remove any old
dielectric compound, dark residue, dirt, or
contamination. Disconnect spark plug leads from
spark plugs.
3. Remove one mounting screw from each ignition
module. If mounting screws are black, remove them
both and discard. Look in mounting hole with a
fl ashlight and use a small round wire brush to
remove any loose rust from laminations inside
mounting hole.
4. Use a digital ohmmeter to check resistance values
and compare them to ignition module resistance
table. When testing resistance to laminations, touch
probe to laminations inside screw hole, as some
laminations have a rust preventative coating on
surface which could alter resistance reading.
Condition
All resistance values are within
ranges specifi ed in table.
At least 1 resistance value is not
within ranges specifi ed in table.
5. Check and/or adjust ignition module air gap(s). An air gap of 0.28/0.33 mm (0.011/0.013 in.) must be maintained
under all three legs of ignition module(s). Checking/adjusting should be performed with parts at room temperature.
Condition
Module was not loosened or
replaced.
Module was loosened or replaced.
a. Adjust ignition module air gap.
1. Turn fl ywheel magnet away from module position.
2. Attach module to mounting legs, pull it away from fl ywheel, and tighten screws to hold it temporarily.
3. Rotate fl ywheel so magnet is centered under module.
4. Position a 0.30 mm (0.012 in.) feeler gauge between magnet and all three legs of module. Ignition module
air gap is critical to proper system performance. Do not attempt to set it with a business card or folded
microfi che card. Use feeler gauge specifi ed.
5. Loosen mounting screws, allow magnet to pull module down against feeler gauge, and retighten mounting
screws.
6. Rotate fl ywheel to remove feeler gauge, position magnet back under module, and recheck that specifi ed
gap, minimum of 0.28 mm (0.011 in.), exists under each leg of module. When you are certain gap is correct,
torque module mounting screws to 4.0 N·m (35 in. lb.). Repeat these 6 steps to set other ignition module.
6. Reattach lead wires to ignition module(s), noting if resistance is felt, indicating a snug fi t between male and female
terminals. If any connections do not feel snug, disconnect lead, lightly pinch female terminal with a pliers, and
recheck fi t.
7. When integrity of all connections has been verifi ed, retest for spark.
44
Ignition Module Resistance Table
24 584 03
24 584 11
(1 11/16 in. High)
Test
(Use Digital
Ohmmeter)
24 584 03
24 584 11
(1 11/16 in. H)
24 584 15-S
(2 1/16 in. H)
24 584 36-S
(2 1/16 in. H)
Possible Cause
Ignition Module Gap
Ignition Module
Possible Cause
Ignition Module Air Gap
Ignition Module
KohlerEngines.com
or
4
2 1
2 1
3
From No. From No.
1 to 4 2 to 4
945 to 149 to
1175 ohms 166 ohms
890 to 119 to
1175 ohms 136 ohms
590 to 183 to
616 ohms 208 ohms
Conclusion
Check and adjust ignition module
gap.
Ignition module is faulty and should
be replaced.
Conclusion
Check that specifi ed air gap is
present under all three legs. If gap is
correct, reinstall second mounting
screw removed earlier and recheck
gap after tightening.
Adjust ignition module air gap.
24 584 15-S
or
24 584 36-S
(2 1/16 in. High)
From No.
3 to 4
3750 to
7000 ohms
5600 to
9000 ohms
8000 to
40,000 ohms
24 690 30 Rev. G