7.5
Section 7
Electrical System and Components
7
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.
Test Procedure for Standard (Fixed Timing) CD
Ignition System
Isolate and verify the trouble is within the engine
ignition system.
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 kill
lead terminal so it cannot touch ground. Try to
start** the engine to verify whether the reported
problem is still present.
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.
**
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.
2. Test for spark on both cylinders with Kohler
ignition tester (see Section 2). Disconnect one
spark plug lead and connect it to the post
terminal of the tester. Connect the clip to a good
ground, not to the spark plug. Crank the engine
and observe the tester spark gap. Repeat the
procedure on the other cylinder. Remember to
reconnect the first spark plug lead.
a. If one side is not firing, check all wiring,
connections, and terminations on that side. If
wiring is okay, replace ignition module and
retest for spark.
b. If the tester shows spark, but the engine
misses or won’t run on that cylinder, try a
new spark plug.
c. If neither side is firing, recheck position of
ignition switch and check for shorted kill
lead.
Battery Charging System
General
Most engines are equipped with a 15, 20, or 25 amp
regulated charging system. See Figures 7-5, 7-6, 7-7,
and 7-8.
NOTE:
Observe the following guidelines to avoid
damage to the electrical system and
components:
• Make sure the battery polarity is correct. A
negative (-) ground system is used.
• Disconnect the rectifier-regulator plug and/or the
wiring harness plug before doing any electric
welding on the equipment powered by the
engine. Also, disconnect all other electrical
accessories in common ground with the engine.
• Prevent the stator (AC) leads from touching or
shorting while the engine is running. This could
damage the stator.
