Kohler Command Ignition System Update.

[Onan18]

The fan just pulls off the flywheel at this point.


Four bolts hold the output shaft on.



It has to be removed so you can get to the flywheel bolt.

 

[Onan18]

The flywheel cannot come off with the coils bolted on, and they are being replaced anyways.


So off with you!


And you as well!


Now the flywheel can be removed.

 

[Onan18]

This unit came in not charging the battery and I diagnosed it with a bad stator. I documented the stator replacement as well but it is not part of the ignition system update.


Start by removing the two bolts that hold the stator on.


And you need to remove this baffle as well, two bolts.


Remove this clamp.

And the stator is out.

 

[Onan18]

Now grab the plug.


Turn it up and you will see that the terminals are stepped.


Take a small flat head screwdriver or pick and slide into the small steps on the two outer (white wires) terminals to release them.


And the terminals will pull out of the plug.

 

[Onan18]

New parts, it is foolish to be in this deep and not replace the crank seals.


Remove the flywheel key and pry the old seal out.


Drive the new seal into place.


Don't forget to reinstall the key.

 

[P.M.P.]

This is good stuff.
I have a gravely promaster 200 with a Kohler command on it. Not sure what ignition yet.

 

[Onan18]

Install the new stator being certain to route the wires into the channel in the block. Also reinstall the air baffle at this time.
Plug the new stator into the regulator connector. It doesn't matter which white goes where.

 

[Onan18]

Alright gang, finally getting down to the nitty gritty of this.


Here is the MDI conversation kit for a CH with the ASAM system. Consists of two new coils, a new kill wire, and a new flywheel. Not all of the kits come with a flywheel, I know for a fact that the DSAI kit does not. Kohler is comping the flywheel for the engines that need it. As a stand alone part a flywheel is well over $300.00 however this update kit cost $150.00 as of 06/2019.


Start by setting the new flywheel in place being certain that the key doesn't fall out. Reinstall and tighten the flywheel bolt at this time.


Next cut this zip tie.


And the other one.

 

[Onan18]

Unplug the fuel solenoid from the ASAM harness.


And unplug the switch 12 volt (Red) wire from the main engine harness to the ASAM.


Plug the switch 12 volt wire from the engine harness directly to the fuel solenoid.

 

[Onan18]

The ASAM is grounded to the engine block through this intake manifold bolt.


Remove the bolt, slide the wire out, and immediately reinstall the bolt with blue loctite and tighten well.


Disconnect the kill wire (white).


And the ASAM is out.

 

[Onan18]

Install the new coils being sure to set the air gap, a business card works well for this. Note the new coil has a static discharge wire on the high tension lead, be certain you ground it.


Once both coils are in place you can route the new kill wire provided in the kit.


The new kill wire uses a spade connector to tie into the harness. Some of the older engines (like this one) have a bullet connector on the harness. Not to worry though, simply cut the old connector off of the harness and strip back roughly 1/4" of insulation.


Now crimp on the new connector Kohler provided in the kit and plug everything up.


Tie everything neatly to the intake manifold with the new zip ties provided in the kit.

 

[Onan18]

The new flywheel is shaped differently than the old one so the fan needs to be modified. There are two of these tabs that indexed onto the old flywheel. They need to be removed, a pair of side cutters makes quick work of this.


Install the modified fan and at this point the job is more or less done. Reassembly from here is just the reverse of the tear down.


One last little touch, Kohler gives you a nice sticker to cover the hole in the shroud that the ASAM harness passed through.

 

[Onan18]

Hope this helps, if anyone has any questions or something to add please feel free.

 

[angelo c]

Holy fn chit....that's a lot of ......grief!!!

Joe. That stator winding was mud loaded. Do you think that might be an issue. Got to be as common a reason for failure then anything else.

Thanks for the play-by-play.

 

[Onan18]

Holy fn chit....that's a lot of ......grief!!!

Joe. That stator winding was mud loaded. Do you think that might be an issue. Got to be as common a reason for failure then anything else.

Thanks for the play-by-play.

I do believe so yes. I think what happens when they get caked up like that is the stator over heats and burns some of the insulation off of the windings. Once that happens game over.