KOHLER Courage twin cylinder Wont START , NO SPARK . How To FIX and UPDATE the IGNITION SYSTEM

[Music] well good morning folks from Jeff's little engine service I have a good one for you today that was quite a mystery but we solved it let me show you what we have so it's a craftsman lawnmower DGS 6500 and it has one of these piece-of-crap kohler 26 horsepower twin cylinder courage engines and we have determined that there is no spark to it so we don't have spark so after doing a little bit of research I learned that there was a service bulletin put out on these that they've changed the ignition systems so you have to buy a conversion kit to fix this no sparking problem whether it be the spark advance module that's not working or one of these coils that's not working you have to buy the whole kit to update it back to a magneto style ignition where you don't have to have 12 volts running to it for it to work you just have to have the magnet on the flywheel zooming past the coils which creates the spark so to get to those components we're going to have to take off this engine cover first thing and this conversion kit its top-secret information only I know about it and one other guy that lives on the East Coast and they have to keep us separated in case something happens to one of us so keep that in mind you're getting some top-secret information so let's go ahead and take this engine cover off so we can see what the heck we're dealing with here okay so I think that's the 8-millimeter there good old Kohler they seem to use all metric take off your fuel pump here and I'll check under here to see if we have any I can take off the air filter here I don't see any mounting bolts down in the mayor actually that might be able just to stay into place while you take this off so I see two bolts in the front here both ten millimeters okay oops I have one more back there I gotta get that's another one of these eight millimeters and another 8-millimeter here and there's one tucked back in here just like on the other side man colors are a piece of crap you guys will hear me say that more than once today these replacement parts are not cheap either I think this kit is about $100 while we have this cover off it'll be a good time to change that starter motor to okay let's see here I think I'm gonna have to take this thing off and it looks like it just kind of pops out of there just be careful you can break these little plastic pieces but they do just pop right off this is how I'm doing I'm just sticking a screwdriver right in there and oops broke one there we go whatever call it as a crap alright looks like we did it there we go so just look at all this nonsense that Koehler puts in here I mean usually you just have one wire going to the coil they decided to put four so the conversion kit basically consists of two new coils you could see we have a coil over there too and that's it so I'm not sure how I'm supposed to wire this thing once these coils are out of here hopefully there'll be some damn directions in this conversion kit to tell me how to rewire this thing these engineers should be ashamed of themselves time to go back to school boys they barely even connected these wires when they're plugging it in there so that's what I'm talking about Koehler is a piece of crap and you have some more fine workmanship on this side on this side you can see there they left about a half inch of wire hanging out as well see this starter gear is about to fall off check that out not good and luckily the ring gear hasn't been damaged yet from that gear flopping around on there so that's good oh it is damaged brutal yeah see he's missing teeth already on his flywheel that is not good so just doing some investigating here the green wires both go to ground so so yeah the green wires go to ground they both make it over here both go into this harness both go into this connector and then they both go out and this part grounds on the carburetor and the other side you can't see here it grounds on the head and this is the kill switch and the white is the kill switch and the same thing white from over here goes and it goes into this connector where they meet and so that's normally would be your kill wire or what when you turn it off it would ground that wire and then we have the red here and then the red wires are the power that comes into these piece-of-crap units so this ignition system has to have 12 volts coming from the battery into it for it to function correctly and this conversion kit we're getting is going to eliminate that so you'll just have coils on each side and then a ground wire you won't have to have 12 volts going to the coil for them to work just when this magnet here spins by the coils it creates the spark now that's a proper ignition system that's the way lawn mowers have been doing it for decades I don't know why Kohler thought they needed to change things up and this component here I think it's a voltage regulator because I could see the wires co it looked like they go up underneath to the stator so I think that that's what that is if it's not all confirmed and from what I understand some of these bolder ones with this system actually have a spark advance module somewhere this one is a 2006 or 2007 model I believe and look I don't see any other electrical component on here other than these two coils in this regulator rectifier so I got this kit from Kohler apparently this is the part number and you can look inside here and and if you look see it comes with a couple of brand new coils or Magneto's whatever you want to call in a little wiring harness and thank goodness some directions they're not written down very well as far as an explanation but I think we can figure it out first thing we're going to have to do is just remove these coils and they call this version these RDS AI modules apparently there's a DSA M module set up to I think those are the ones that have the separate spark advance unit on them but for this one we're just going to disconnect the wires and we can take these old coils off now looks like that might be an eight-millimeter there it's been raining pretty hard out here the past week or two that's the garbage man dumping out all my beer bottles I actually insane the neighbors beer bottles okay so just like that we can remove the coils and you'll see the cables kind of there's a little slot for the cables to go you'll want to save the mounting bolts but you can throw these pieces of junk away and you see the cables and there's actually a spot that the cable routes down through there a little slot in the metal so there's not a left or right coil but it does say to install it with the flat side the way Koehler puts it out towards me so I would assume that it's that way I'm going to go ahead and clean off these posts here just because it's important for the coil to be grounded well so let's clean those up so just have a little sanding block here much better you can see this flywheel is missing some teeth which is not good guy waited too long to get a new starter motor and there he is folks he's trying to ruin my video right there I just kidding I like the garbage man he's a good guy okay now that that nonsense is gone we can get back to making a video here so the coil gap is 0.25 millimeters or point zero zero nine inches so that would be nine thousandths of an inch so there we go it's the one we want and we'll just put it between the coil and the magnet where there we go so you just that's where you want so that's where you'll want to check the gap right at the magnet and just make sure you have it nine thousands you can do it this way the magnet holds it in place it's kind of tricky though because if you tighten this side down too tight you're not able to move this side to adjust it so you kind of have to go back and forth however you need to do it to make it work call that good and let's go back and check the other side make sure we're still good there that's a pretty tight gap on this coil Briggs are usually gap at 12 see now this side is too tight so I'll back it off and readjust and go back and forth until I get it right okay I had to turn off my camera and cuss my way through it but eventually I got these coils on and gapped correctly I ended up gapping them at ten thousandths because every time I tried at nine and tightened him down they would be too tight so I ended up using the ten thousandths feeler gauge to do this every time I locked them tighten down the screws with the nine thousandths dealer gage and rechecked they were too tight for whatever reason so I used the ten thousandths and that seemed to get these gaps right where I want them and these bolts right here you will tighten down to 35 to 55 inch pounds trust me you don't want to over tighten them because if they break you're screwed so the next thing that it says to do is connect the wiring harness here to the coils and it shows this way so Bend that tab up a little bit put on that side put on this side and then they tell you to zip tie this wire down to the plastic manifold here so it stays out of the way so we'll do that well it looks like I'm about out of large zip ties so I will have to put two small ones together so let's go ahead and start right here all right so let's go ahead and anchor down this right here besides a little easier to get to things actually I think I'm gonna hold off because they tell you to zip-tie all this extra onto there too so I'm going to wait till I figure out what to do there so the wires here that go to the main wiring harness you can see there's a red one and a white one the red one was the 12-volt power into the old system and the white one is essentially the kill wire now don't get it confused with this other white one that go just goes to the other plug here so you'll want to cut this one so you'll want to cut this white wire that goes to this plug connector you'll want to cut it as close as you can to the connector and then of course you want to strip a little bit off so you can put the new connector on here oh nice they actually have zip ties in the kit here but once I can say good job Kohler anyways so here we are yeah there's the wire I cut this is the connector that comes in the kit I'm gonna put it on here and then crimp it down I don't know why they have that all right yep we're good so then you hook this up to the new wiring harness that you just installed looks like they don't have he's supposed to fold it up or something all that thing is doing is preventing me from finishing the job so I'm going to cut that box chata here so then at this point you'll want to zip-tie this stuff down here to get it out of the way I'll tuck this connector down here and I think we'll be able to go back together and test this thing out so there's our starter motor first thing we'll want to do is disconnect the power that goes to it so it looks like this is an 11 millimeter bolt or nut boy that starter motor is in bad shape look at how it's wiggling around on there okay and it looks like those are ten millimeter bolts and there's one under here look at you can see that chipped tooth right there this flywheel gear has like three chipped teeth and none of them are in a row so it's still functioning and the customer says that he wants me just to fix it like this so he can run it for another year if possible so the old starter motor was working so I'm assuming a new one will work better Wilson all right hopefully this will be easy and I went ahead and ordered an aftermarket one I don't normally use aftermarket parts this one was half the price of a Kohler one which was the Kohler one was like a hundred and forty hundred and fifty dollars this one I got for about $70 and it's through DB electric off of Amazon and I've purchased their equipment before and it seems to be pretty good so I purchased it again every once in a while you can get lucky with aftermarket parts if you find a good aftermarket company with quality parts you can you can stick with it all right let's cinch this baby down not too tight and bust these Auerbach I think I'll fire this thing up without the engine cuz we're on just so what we can see what's what's going on with it make sure everything's fixed before we put it back together all right so we'll hook up the spark plug here and do the one on the other side put the spark plug in over here I want to be careful starting the engine without the cover on make sure all the wires are out of the way all right folks keep our fingers crossed hopefully we can fire this baby up all right let's test this baby out [Music]

Channel: Jeff's Little Engine Service

Views: 116,619

Rating: 4.4948239 out of 5

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Id: uoUAxylM2sY

Length: 26min 55sec (1615 seconds)

Published: Sun Nov 24 2019