8.4
Section 8
Electrical System and Components
Troubleshooting Guide
Ignition and Oil Sentry™ Systems
Before testing, be certain all electrical leads are connected and crankcase oil is at the point of overflowing the
filler neck.
Problem Test Conclusion
1. Disconnect the cap from the spark plug and
attach it to the terminal end of spark tester
Kohler Part No. 25 455 01-S. Attach tester
spring clip to a good ground, not to the spark
plug. Turn ignition/key switch ‘‘on’’ and
crank the engine while observing the firing
tip of the tester.
1. If tester is firing, ignition system is good.
Install a new spark plug and try to start
engine. If it still will not start, check other
possible causes (fuel, compression, etc.). If
tester does not fire, go to step 2.
Engine Will
Not Start
2. On electric start engines, remove the starter
cover panel. Locate the black/white kill lead
coming from the ignition module inside the
blower housing. Disconnect the bullet
connector where the kill lead plugs into the
harness. Repeat the spark test (step 1).
2. If spark is now present, check for a shorted lead
in the kill circuit or a faulty switch (step 7). If
there is still no spark, go to step 3.
3. Trace the blue lead from the Oil Sentry
™
control module. Disconnect the bullet
connector where it joins the lead from the Oil
Sentry
™
float switch (black with gray sleeve).
Repeat spark test again.
3. If spark is now present, the control module or
float switch is faulty. Test the control module
(step 4) and the float switch (step 5). If there is
still no spark, test the ignition module (step 6).
4. Connect a jumper lead from the blue lead
terminal to a bare spot on the crankcase
(ground). Turn the ignition switch ‘‘on’’,
crank the engine, and observe the red LED
indicator lamp.
a. If the indicator lamp was not flashing,
trace the black (manual start models) or
black/white (electric start models) lead
from the ignition switch. Separate the
bullet connector where the switch lead
joins the double red harness lead. Crank
the engine, again observing the red LED
indicator lamp.
4. If the indicator lamp flashes during cranking,
the control module is functioning, proceed to
step 5. If the lamp was not flashing initially but
did flash in step 4a, the control module is good,
but the ignition switch is probably faulty. Test
the float switch (step 5) and the ignition switch
(step 7).
5. Set an ohmmeter to the Rx1 scale and zero the
meter. Connect one ohmmeter lead to the Oil
Sentry
™
float switch lead (black with gray
sleeve) and touch the other lead to a bare spot
on the crankcase (ground). Drain the oil from
the crankcase and repeat the test.
a. If continuity was indicated with and
without oil above, check if the insulation
has been scraped off the float switch lead.
b. With the float switch removed, connect
one ohmmeter lead to the float switch lead
terminal and connect the other lead to
mounting bracket. Test resistance with the
switch in the normal position and
inverted.Repeat test 2 or 3 times in each
direction.
5. With the oil at the proper level, no continuity
should have been indicated. After the oil was
drained, continuity should have been indicated.
If test results are other than specified, remove
the closure plate from the engine and remove
the float switch for further testing (5a and 5b).
a. If the lead wire is bare, allowing it to short,
repair with electrical tape or replace float
switch.
b. Switch continuity should be as indicated in
Figure 8-3. If not, replace it.
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