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matt nolen
New member
Username: Matt
Post Number: 2
Registered: 10-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Tuesday, October 23, 2007 - 03:11 pm: | 
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I recently purchased a 1999 Max with a 20 hp kohler engine. It does not run. I have replaced the ignition module and the spark plugs are still not getting any juice. The fly wheel is a little rusty, will that matter? It turns over fine and I believe I have the solonoid hooked up correctly but still no spark. please help. |
Dennis F. Saskowski
Advanced Member
Username: Sasko
Post Number: 125
Registered: 07-2005
Rating: N/A
Votes: 0 (Vote!) | | Posted on Tuesday, October 23, 2007 - 03:47 pm: |
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Matt, rust on fly wheel if heavy might be a factor. also check air gap from pick up to fly wheel kinda tricky with magnetic field. I set gap using about .003/.005 more just letting the coil pick up rest against the shims /fly wheel. tighten then pull out and ck again for correct gap ,seems to fall to the correct gap.If you have plastic gap gauges thats even better.Have coils checked at a shop if problem still exists.I'm sure you checked the ground strap the factory installs from the frame to the engine support table jumping the rubber mount.I run a ground right from batt. ground to motor. |
Dennis F. Saskowski
Advanced Member
Username: Sasko
Post Number: 126
Registered: 07-2005
Rating: N/A
Votes: 0 (Vote!) | | Posted on Tuesday, October 23, 2007 - 05:52 pm: |
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Matt, ck. 1 more thing, in the wire loom feeding the top of the motor there might be a green wire wth a 1/4'' spade connector going to nowhere if thats touching the block its killing the ignition. That wire is for the oil sentry if your motor is not equiped with it and it grounds out motor will not fire. |
matt nolen
New member
Username: Matt
Post Number: 3
Registered: 10-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Wednesday, October 24, 2007 - 01:44 pm: |
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Dennis thanks for the help. I do have oil sentry protection. I have checked the ground strap and it is secure. I also have the battery grounded to the solenoid base. I need to check the wire for the oil sentry to see if any chaffing exists. Is there a wiring diagram for the solenoid so I can make sure i have it properly wired. thanks for all your help. |
Dennis F. Saskowski
Advanced Member
Username: Sasko
Post Number: 127
Registered: 07-2005
Rating: N/A
Votes: 0 (Vote!) | | Posted on Wednesday, October 24, 2007 - 03:08 pm: |
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Matt go to www. kohler plus .com. it is site used by dealers and guests can get on off peak. It gives access to shop manuals,parts blow up views etc. and if you got a big computer you can download a shop manual.I think I used the wiring diagram once to double check my ignition switch connection which is a lot different than a motorcycle or auto. |
matt nolen
New member
Username: Matt
Post Number: 4
Registered: 10-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Wednesday, October 24, 2007 - 03:32 pm: |
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Once again, Thank You. |
matt nolen
New member
Username: Matt
Post Number: 5
Registered: 10-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Thursday, October 25, 2007 - 12:49 pm: |
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 ok I have put new ignition module, checked oil sentry for ground, cleaned little rust off fly wheel,and checked the grounds on frame and starter solenoid. What are my next moves. I am still not getting a spark to my plugs. I have taken out the spark plugs and grounded them while cranking the engine. still no spark. could it be a rectifier or regulator? Is there a way to check it. |
Dennis F. Saskowski
Advanced Member
Username: Sasko
Post Number: 128
Registered: 07-2005
Rating: N/A
Votes: 0 (Vote!) | | Posted on Monday, October 29, 2007 - 06:02 pm: |
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Sounds like you covered it all. Highley unlikely both coils are dead. back track to all your connections,use continuity tester to see if a circut is open or broken wire.Regulator is just for charging system.Did you look at ignition wiring schematic? |
Sean Ridlon
Junior Member
Username: Wasillabilly
Post Number: 16
Registered: 09-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Wednesday, October 31, 2007 - 11:01 am: |
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I am having trouble getting my Max right. I have headlights on, heated throttle cable functioning, winch working, but a dead ignition when I turn the key. What would you replace next?
Clue: I already replaced the solinoid and the starter. |
Dennis F. Saskowski
Advanced Member
Username: Sasko
Post Number: 132
Registered: 07-2005
Rating: N/A
Votes: 0 (Vote!) | | Posted on Wednesday, October 31, 2007 - 11:41 am: |
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Check all of the above mentioned post first. I don't randomly replace things unless I exhaust all simple possibilites.Ended up with more money in my pocket and less good spare parts in my garage. |
Sean Ridlon
Junior Member
Username: Wasillabilly
Post Number: 17
Registered: 09-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Saturday, November 03, 2007 - 12:52 pm: |
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Ok, I re-grounded everything and if I by-pass the starter and cable (btw.. new) the new starter fired right up. I think I still have an issue in here to fix, but at least the wife can see it is running  . |
Sean Ridlon
Junior Member
Username: Wasillabilly
Post Number: 18
Registered: 09-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Saturday, November 03, 2007 - 12:56 pm: |
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Oops, in my last post I ment to say "I bypassed the solinoid and battery cable TO the starter with a jumper cable". I have juice as far as the relay it seems. |
pgjeepster
Member
Username: Pgjeepster
Post Number: 20
Registered: 05-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Saturday, November 03, 2007 - 10:08 pm: |
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Did you replace the ignition switch? sounds like the signal/power is not getting to the solinoid. To check this run a hot wire to the "s" position on the solinoid, if it clicks/engages then it's your ignition switch. |
matt nolen
New member
Username: Matt
Post Number: 6
Registered: 10-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Sunday, November 04, 2007 - 10:29 pm: |
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Does anyone have an ignition wiring schematic, or where can I find one?
1999 max iv |
pgjeepster
Member
Username: Pgjeepster
Post Number: 21
Registered: 05-2007
Rating: N/A
Votes: 0 (Vote!) | | Posted on Sunday, November 04, 2007 - 11:10 pm: |
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A small engine repair shop should have the wiring for this, I got mine from a local shop just brought in my old unit , he cross matched it and sold me the new switch with a detailed diagram of the wiring. The switch should have the letters on the spades that you connect to eg; "M" for the mag, "S" for the start position on the solinoid, "L" accessories or lights,"B" for battery and so on. |
Dennis F. Saskowski
Advanced Member
Username: Sasko
Post Number: 136
Registered: 07-2005
Rating: N/A
Votes: 0 (Vote!) | | Posted on Monday, November 05, 2007 - 08:50 pm: |
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Matt sent wiring diagram to your e-mail posted in your profile,couldn't down load to 6x6,unable to shrink. Again it could be found in the shop manual available on www.kohler plus.com sec. 8 electrical. Let me know if you got it. Dennis |
Shop Talk: Tech Tips and Q&A section