Kohler Engine Weak Spark

[chevy4wd]

Recently picked up a NAMCO Express, with a 20hp Kohler Engine (I'm just about ready to slap my 24hp Honda in it). So the other day, I was replaced the coupler, rebuilt the carb. and tried to fire it up with no luck. I checked to see if I had spark, used the spark plug tester and on one side there was spark and the other had none. I replace the ignition module and now both sides have a spark. Although the spark plug tester lights up, it seems dim. I then pulled the spark plug out and grounded it to see if I can see the color of the spark, but no spark either side. I thought the spark plugs went bad so I bought 2 to replace, but again no spark. I put the spark plug tester on and attached the spark plug, and grounded it... the spark plug tester lit up (dim) and no spark at the spark plug. Any help would be greatly appreciated.

 

[ccclean]

Are the battery and regulator/rectifier good?

 

[chevy4wd]

Battery is good, how do you test the rectifier?

 

[Ara Klujian]

Have tried to tighten the plug clamps inside the boots? Maybe they are not snapping on the plug tip.

 

[ccclean]

Battery is good, how do you test the rectifier?

You can see if it’s charging by putting an amp meter on the battery terminals while running.

Since that’s not an option you can take it off and look at it and see if it’s burned or damaged in some way.
Also, make sure it’s getting 12v when Keyed.
Koehler have had problems with them going.

 

[The Magician]

I'm thinking its the rectifier. Let us know how you corrected the problem

 

[Ara Klujian]

Have you tested the voltage and continuity going to the coils? If the primary voltage is lower than 12.6 volts you get weak spark and or no spark. I would test the rectifier and recheck the battery.

 

[chevy4wd]

Up date.... Replaced the rectifier and now no spark to the spark plug wire, (I may have to replace it back with the old one... at least the spark plug tester showed some kind of spark)... my next step is to take off the fly wheel and see if the magnets came off, I'm told that Kohler is notorious for this... Wish me luck!!

 

[chevy4wd]

Took off the fly wheel and all the magnets were in place, next I checked the Stator to see if it was bad.. leads was not grounding out. I put everything back together and gave it a try... Finally I got a bright light on the spark plug tester and grounded the sparkplug and got a white spark!! progress, but only for 5 minutes. As I was tinkering with the wiring (the previous owner was no electrician nor apprentice) this is a wiring nightmare! while trying to figure out what wire went where and what wire did what, I guess I wiggled something loose, again no spark! Going to redo the wiring and see if I can figure this thing out, it seems like a simple fix.