Kohler Command Ignition System Update.

[Onan18]

For any Command owners out there with an aging ASAM, DSAM, or DSAI ignition system Kohler has stepped up to the plate and is offering conversion kits to convert over to the MDI system for a very reasonable price. Here is what you need to do in order to convert an old CH with the ASAM to MDI. The process will be very similar for the CV engines as well as the ones equipped with the DSAM ignition.


Engine is on an Exmark Lazer Z but the process is more or less the same for all of them. Start by draining the oil, locate the oil fill for the engine.


On this model, it is the yellow cap on top of the valve cover.


Remove the cap so the engine can vent.

 

[Onan18]

Next locate the oil drain.


On this model, Exmark was nice enough to have the drain drop through the frame so it doesn't make a mess every time you change the oil.


All Sixteenths works good for removal.


Just let gravity do the work.

 

[Onan18]

Next you need to remove the rear guard. There are five bolts holding it on.


One here.


One here.


This one.


And that one.

 

[Onan18]

The fifth bolt is special.


It holds the PTO clutch support arm in place.


Here is the order that everything goes.


Guard off.

 

[Onan18]

Electrical now.


Start by unplugging the PTO.


And the engine harness.


Pull back on the boot to expose the terminal on the starter, unplug the yellow trigger wire.


The nut on the terminal is 1/2"


And off.

 

[Onan18]

PTO belt now.


Start by pulling the tension off of the spring loaded idler arm.


Slip the belt off of the fixed idler first.


Then the tensioner pulley.


And last the clutch.

 

[Onan18]

Shut the fuel off.


Disconnect the fuel line at the filter.


Here is how the throttle and choke cables go.


Disconnect them.


Also, put the oil fill cap back on after the engine is drained to avoid contamination getting into the crankcase.

 

[angelo c]

Great work Joe....as always. What is the issue with the ignition?

 

[Onan18]

Great work Joe....as always. What is the issue with the ignition?

The older ASAM, DSAM, and DSAI ignition systems are failure prone. Sometimes they quit working altogether and sometimes the timing advance feature fails and the engine runs poorly, no power. There are kits offered to convert these engines to a MDI (Briggs and Stratton calls it Magnatron) style ignition that is much more reliable.

 

[angelo c]

Ok. I'm watching now.... how do I tell which one I have ?

 

[Onan18]

There is a cover over the pump belt, it is held on with four bolts. Technically you don't have to remove it...


But it sure makes it easier.


Now to get the pump belt off.


Take a big pry bar and slide it between the idler arm and output shaft like so.


Pry back hard and slip the belt off of the left hand hydro pump pulley. Then you can snake it out.

 

[Onan18]

Ok. I'm watching now.... how do I tell which one I have ?

Have to look it up by the spec number of your engine. ASAM and DSAM have a brain box mounted on the fan shroud. DSAI has funny looking coils with no armature.

 

[Onan18]

Now to get the PTO clutch off. Start by removing the bolt, in theory it should just slide right off.


That almost never happens. So spray some penetrating oil in the hole, put a divot in the head of the bolt, and run it part of the way back in.


You are going to need an air hammer with a pointed bit.

Set the bit in the divot, place your free hand behind the clutch and put pressure on it.
Pull the trigger and the clutch will walk off.

 

[Onan18]

Next you need to remove the pivot bolt on the PTO idler arm.


You can just let it hang.



Had to get it out of the way so you can get to the engine mount bolts. Two on the left side..


And two on the right side.

 

[Onan18]

One of the engine mount bolts has the main ground cable attached to it.


And another has this other ground on it.


Engine off.


And on the bench.

 

[Onan18]

Loosen these two set screws.


And the pulley will slide off with a little bit (or a lot) of persuasion.


Remove these four bolts.


And the air intake screen along with it's spacer.

 

[Onan18]

The oil cooler is secured to the shroud with two bolts.


One here.


And one here. Remove them both so that the cooler can pull away.


You will also need to remove the two bolts holding the fuel pump on.

 

[Onan18]

There is a total of eight bolts holding the fan shroud on.


Two here.

Two more here.


One here.


Another down here.

 

[Onan18]

Unplug the voltage regulator.


There is a bolt hiding behind it and one more on this side of the engine.

 

[Onan18]

Here is the old ASAM module, the DSAM looks the same but functions on a different principle. Either one will be held on by two screws.


One on the top.


And one on the bottom.


Shroud off.


A shot of the ASAM system.