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Electrical System
Troubleshooting -- Electric Ignition System
Check Ignition System
NOTE: If engine starts or runs during any of testing, you may
need to ground kill lead to shut it down. Because you
have interrupted kill circuit, it may not stop using
switch.
Isolate and Verify Trouble is Within Engine
1. Locate connectors where wiring harnesses from engine
and equipment are joined. Separate connectors and
remove white kill lead from engine connector. Rejoin
connectors and position or insulate kill lead terminal so it
cannot touch ground. Try to start engine to verify whether
reported problem is still present.
Test for Spark
NOTE: If two testers are available, testing can be performed
simultaneously for both cylinders. However, if only one
tester is available, two individual tests must be
performed. Side not being tested must have spark plug
lead connected or grounded. Do not crank engine or
perform tests with one spark plug lead disconnected
and not grounded, or permanent system damage may
occur.
1. With engine stopped, disconnect one spark plug lead.
Connect spark plug lead to post terminal of spark tester
and attach tester clip to a good engine ground.
2. Crank engine over, establishing a minimum of 550-600
RPM, and observe tester(s) for spark.
3. Repeat spark test on opposite cylinder if cylinders are
being tested individually.
Check for Timing Advance
1. Make a line near edge of fl ywheel screen with a marking
pen, chalk, or narrow tape.
2. Connect an automotive timing light to cylinder that had
good spark.
3. Run engine at idle and use timing light beam to locate line
on screen. Draw a line on blower housing next to line on
screen. Accelerate to full throttle and watch for movement
of line on screen relative to line on blower housing. If both
cylinders had good spark, repeat test on other cylinder.
Test Ignition Modules and Connections
1. Remove blower housing from engine. Inspect wiring for any
damage, cuts, bad crimps, loose terminals, or broken wires.
Check that connections are oriented properly on terminals
of modules.
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. Using a multi-meter, check that a proper ground is
established between ground (black) lead of DSAI module
(closest to spark plug lead), and a known good ground
location on engine.
4. Turn key switch to ON position and check for 12 volts at
center/power (red) lead terminal of DSAI module. Use
same ground location for multi-meter as in checking for
timing advance.
34
Test
KohlerEngines.com
Conclusion
If problem goes away, electrical system on
equipment is suspect. Check key switch, wires,
connections, safety interlocks, etc.
If problem persists, condition is associated with
ignition or electrical system of engine. Leave kill
lead isolated until all testing is completed.
Identify white kill lead of engine wiring harness
connector. Establish a connection to a known
good ground location. Engine should kill
completely. If not, or only one cylinder is affected,
test ignition modules and connections but also
check white kill lead connection for affected DSAI
module.
If both cylinders have good spark but engine runs
poorly, or existing plug condition or appearance is
questionable, install new spark plugs, and retest
engine performance. If problem persists, check for
timing advance.
If one cylinder had good spark but other cylinder
had no spark, or intermittent spark, test ignition
modules and connections.
If there was spark on both cylinders but power is
suspect, check for timing advance.
If line on screen moved away from line on blower
housing during acceleration, DSAI ignition module
for cylinder being tested is working properly. If
it didn't move away, test ignition modules and
connections.
If you were able to check timing on both cylinders,
lines you made on blower housing should be
90° apart. If not, test ignition modules and
connections.
If all tests are OK and module has no spark or
fails to advance, replace affected module.
If any of tests are bad; determine cause and fi x as
required, then retest.
62 690 01 Rev. C
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Troubleshooting
