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Kohler: Sudden loss of spark


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  #1  
Old 11-26-2018, 01:55:43 PM
Tbirddillon Tbirddillon is offline
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Default Kohler: Sudden loss of spark

Model 3.5A21 with a Wico XH2006 magneto. So I've had this plant running under light load previously with no issues and decided to do a full load test and see how much fuel it will consume. About 6 minutes into running and trying to make adjustments to the rpm it suddenly shut off. I checked fuel removed all load and started hand cranking to find out I lost spark. I recently replaced the condenser about a month ago any ideas what could be wrong?
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Old 11-26-2018, 02:35:51 PM
Vanman Vanman is offline
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Default Re: Sudden loss of spark

I have heard that new condensers- like most new things- are not well made anymore. That would be my first place to check.
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Old 11-26-2018, 02:53:29 PM
Zephyr7 Zephyr7 is offline
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Default Re: Sudden loss of spark

Check that the wires and connections are all good, especially any that you had to move while replacing the condensor. Sometimes a wiggle to a wire is enough to cause a fracture and eventual failure of a connection. Iíve seen many little crimp lugs that break after one bend due to brittle fracture in the metal.

Bill
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Old 11-26-2018, 08:26:10 PM
jack0 jack0 is offline
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Default Re: Sudden loss of spark

So you are hand cranking to start this set?

I would first lift the ground wire off the mag and try it.
If it starts, its not a mag issue.
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Old 11-26-2018, 10:02:27 PM
Tbirddillon Tbirddillon is offline
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Default Re: Sudden loss of spark

Yea I'm hand cranking it right now. The ground wire has been disconnected. I'll need to test the new condenser to see if suddenly went bad.
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Old 12-03-2018, 12:06:19 AM
Tbirddillon Tbirddillon is offline
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Default Re: Kohler: Sudden loss of spark

So, update: the other day I decided to start tinkering with the engine to see what was going on. I noticed that only cylinder 1 was getting spark, I pulled the cap off and everything looked good. I didn't have my volt meter to check anything and stopped there. Tonight I decided to swap wires to see if my new ones were the issue and all of a sudden it's got spark to all 4 cylinders. Now it gets odd, after about 5 minutes or so coolant starts pouring out of the cap. I shut the engine down and everything looks ok, no oil in the coolant and vice versa. I pulled the rad cap off, started her up, top off the coolant, put the cap on, and let it run. I got a little overflow from the the tube and that was it. I let it run about ten minutes everything appeared well, so I shut it down. Any idea what might be going on?
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Old 12-03-2018, 02:45:53 AM
Vanman Vanman is offline
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Default Re: Kohler: Sudden loss of spark

I suppose it's possible that there was a bit too much coolant in it to start with. When it gets warm and expands, the excess will be pushed out once the pressure rating of the cap is reached. The next time it cools it will draw in air to deplace the lost coolant, and from then on it should not burp any more out.
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Old 12-03-2018, 11:14:54 AM
Zephyr7 Zephyr7 is offline
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Default Re: Kohler: Sudden loss of spark

Might be some obstruction in the radiator so that the outlet flow from the engine canít circulate quickly enough. Iíd guess too much coolant first though, and thatís a lot easier to fix

Bill
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Old 12-03-2018, 12:41:43 PM
Vanman Vanman is offline
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Default Re: Kohler: Sudden loss of spark

Along the lines of restriction, these engines are known for rust and scale clogging the coolant passageways in the block, since water (alone) was commonly used as the coolant.
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Old 12-03-2018, 01:09:56 PM
Tbirddillon Tbirddillon is offline
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Default Re: Kohler: Sudden loss of spark

I thought of both of those possibilities and before i ran it i thoroughly flusged the block and radiator. Today I ran it for 45 minutes with no issues. What has me the most confused is the spark issue. I'll have to try another full load test again.
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