Electrical System
3362 690 01 Rev. C KohlerEngines.com
Troubleshooting CD Ignition Systems
NOTE: CD ignition systems are sensitive to excessive load on kill lead. If a customer complains of hard starting, low
power, or misfi re under load, it may be due to excessive draw on kill circuit. Perform appropriate test
procedure.
Isolate and verify trouble is within engine ignition system.
Troubleshooting -- CD Ignition Systems
Test Conclusion
1. Locate plug 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.
1. If problem is gone, electrical system on unit 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.
2. Test for spark on both cylinders with Kohler ignition
tester. Disconnect one spark plug lead and connect
it to post terminal of tester. Connect clip to a good
ground, not to spark plug.
Crank engine and observe tester spark gap. Repeat
procedure on other cylinder. Remember to reconnect
fi rst spark plug lead.
2. If one side is not fi ring, check all wiring, connections,
and terminations on that side. If wiring is okay,
replace ignition module and retest for spark.
If tester shows spark, but engine misses or won’t run
on that cylinder, try a new spark plug.
If neither side is fi ring, recheck position of ignition
switch and check for shorted kill lead.
Test Procedure for DSAI Ignition Systems
NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate
fi ndings. 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 engine, but it won’t have spark). Be certain drive is
in neutral and all external loads are disconnected.
A
Kill Switch/
Off Position of
Key Switch
B Air Gap
C Flywheel D Magnet
E Ignition Modules F Spark Plug
A
B
C
D
E
F
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