Kohler Courage SV710-740 Service Manual page 67

The CD ignition systems are designed to be trouble
free for the life of the engine. Other than periodically
checking/replacing the spark plugs, no maintenance
or timing adjustments are necessary or possible.
Mechanical systems do occasionally fail or break
down however, so the following troubleshooting
information is provided to help you get to the root of
a reported problem.
Reported ignition problems are most often due to
poor connections. Before beginning the test procedure,
check all external wiring. Be certain all ignition-related
wires are connected, including the spark plug leads.
Be certain all terminal connections fit snugly. Make
sure the ignition switch is in the RUN position.
NOTE: The CD ignition systems are sensitive to
excessive load on the kill lead. If a customer
complains of hard starting, low power,
or misfire under load, it may be due to
excessive draw on the kill circuit. Perform the
appropriate test procedure.
The following procedures are provided for
troubleshooting ignition problems on
DSAM or Smart-Spark
you to isolate and pinpoint the failed component(s).
• Hand Tachometer
• Tester* (Kohler Part No. 24 455 02-S)
• Automotive Timing Light
• Multi-Meter (Digital)
• Spark Plug Gap 0.76 mm (0.030 in.)
• Ignition Module Air Gap 0.28/0.33 mm
(0.011-0.013 in.), 0.30 mm (0.012 in.) nominal
*NOTE: Ignition tester (Kohler Part No.
24 455 02-S), must be used to test ignition
on these engines. Use of any other tester can
result in inaccurate findings.
equipped engines, to allow
Battery on unit must be fully charged and
properly connected before making any of
these tests (a battery that is hooked up or
charged backward will crank the engine,
but it won't have spark). Be sure drive
is in neutral and all external loads are
disconnected.
1. Locate the plug connectors where the wiring
harnesses from the engine and equipment are
joined. Separate the connectors and remove the
white kill lead from the engine connector. Rejoin
the connectors and position or insulate the white
kill lead terminal so it cannot touch ground. Try
starting the engine to verify whether the reported
problem is still present.
NOTE: If the engine starts or runs during any of
the testing, you may need to ground the
kill lead to shut it down. Because you have
interrupted the kill circuit, it may not stop
using the switch.
a. If the problem is gone, the electrical system
on the unit is suspect. Check the key switch,
wires, connections, safety interlocks, etc.
b. If the problem persists the condition is
associated with the ignition or electrical
system of the engine. Leave the kill lead
isolated until all testing is completed.
1. With the engine stopped, disconnect one spark
plug lead. Connect the spark plug lead to post
terminal of spark tester (Kohler Part No.
24 455 02-S), and attach tester clip to a good
engine ground.
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. The side
not being tested must have the spark plug
lead connected or grounded. Do not crank
the engine or perform tests with one spark
plug lead disconnected and not grounded or
permanent system damage may occur.
2. Crank the engine over, establishing a minimum of
550-600 RPM, and observe tester(s) for spark.