Kohler V-Twin DSAI to MDI Ignition Upgrade

Step by Step!

Today we'll be working on a Craftsman DGS6500 riding lawn mower that has a #Kohler #Courage #SV735 engine.

One of the engine's ignition modules failed, and is no longer producing spark. This is a V-twin, so the engine will still run, but will only run on 1 cylinder.

You may notice a loss of power, and white or black smoke coming from the muffler or exhaust. This is due to unburnt fuel in the cylinder going into the exhaust.

In this video, I explain how these older DSAI ignition modules work, why they failed, and I'll also take you through the process of replacing them with Kohler's upgraded ignition magnetos.

Skip to 7:50 to show the wiring, and skip to 20:31 for the installation of the new ignition modules.

The old ignition system is called DSAI for Digital Spark Advanced Ignition, and we'll be upgrading them to a MDI system, which stands for Magneto Discharge Ignition.

This is a complete upgrade kit, which includes newer, solid state ignition coils that are superior in design to the older ignition system.

Unlike the older Ignition Modules, that required 12v, these newer ignition magnetos do not require 12v power.

Since the new ignition system doesn't require 12v, there are 2 ways you can install this kit.

1. Leaving the original ignition wiring harness attached.
2. Removing the original ignition wiring harness completely.

I show you how to do both ways in this video, as removing the wiring harness completely may require you to connect the Fuel Shut-Off Solenoid to a source of 12v.

Either way, we'll be wiring into the Red and White wire.

Note: some engines have the Red/White wires located near cylinder 1, and others may have them located near cylinder 2. The steps are the same.

Additionally, some engines will have a separate 12v power wire going to the Fuel Shut-Off solenoid, which means you can disregard those steps in the video.

Here are the part numbers for the upgrade kit for various Kohler V-twin engines, it covers both the Courage and Command engine models;

CH/CV740 - 25 707 03-S
CH/CV750 - 25 707 03-S

SV735/740/840 - 32 707 01-S

These kits upgrade the old Ignition Module part numbers;

CH/CV740, SV735, SV740: Previous Modules 24 584 52, 24 584 63 24 584 53, 24 584 64, 24 584 89, (Upgraded Module with Diodes 24 755 172-S)

CH/CV750: 24 584 90 (Upgraded Module with Diodes 24 755 173-S)

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[EliminatorPerformance]

If you'd like, you can skip to 7:50 to show the wiring, and skip to 20:31 for the installation of the new ignition modules.

[leviwynnyk]

This video explains what was almost impossible to find online. Thank you so much for making this video

[tihspidtherekciltilc]

By far the best no nonsense small engine repair channel there is.
End. Of. Story.

[WestonMorrisdoBrasil]

What a fabulous explanation of the history of the possible types of ignition modules that we may come across and how to upgrade to MDI. Well done!

[PatrickObrien-kh]

Excellent video. I just made my own wire harness rather than buying the Kohler kit . Followed your lead and it fired right up. Only have $70 dollars in this . Thank you.

[morelwhisperer]

This is perhaps the most clear and BS free video I've seen on youtube. Nice Work!

[emroseman]

You are a godsend. Mine were working just fine until mice chewed up one of the spark plug wires and I was trying to figure out what to do...

[andybecker]

I’m glad that my 1998 Craftsman GT3000 with the Command 23 Pro was before the DSAI fiasco. I just retired it running with 23 seasons of service.

[watermanone]

Nice job. I recently had a customer with that same issue and when I told him the cost of the new coils and the labor, he decided to trade the mower in to a dealer. He really got burned at the dealer and bought a new mower. They only gave him an allowence for $300 dollars for his old mower. It was in excellent condition except for the coil issue. Thanks for the video.

[nickluzzi]

As always great . You do nice work . You remind me of a electrical teacher I had in school 50 years ago . Direct and to the point . Thanks

[XxvxX]

Thank you. Easiest video I found to fix my Cub Cadet gt1554. After replacing the broken stator and flywheel I wanted to get rid of this junk design. Only puzzling part was of the two flywheels I have one is timed differently where the key is.

[macbirt]

One of the best instructional videos I've ever seen on YouTube.

[TefCom]

Great video. Not overly talkie talkie, and right on point!

[wcuflanker]

Thank you sir-just did this to a mower I bought for my parents . Awesome commentary and clear instructions! I really appreciate it!

[outlet]

Thank you for making a well-produced and informative video. Your video made this installation "So simple, a child could do it. I can't wait until my ten-year-old son returns from school.

[mikebradley]

Awesome video - to the point, no fluff love it!

[mitchellrinker]

Great Video 🤩 I picked up a used Craftsman, this exact mower actually .... ran great when I picked it up but after a few Laps around my property things quickly changed. !!!. I cannot wait to do this fix - thank you

[waynestefinashen]

As your number one fan i would like to thank you for taking the time that it took you to research all the information you have provided in this video and i especially liked the ending where you used the heat gun to check the temperature of both exhaust pipes to ensure both cylinders were running. That spare coil that is still good has some great $ value to someone that needs one eh?

[bernardsaberon]

Awesome video. Very concise and professional. Thank you so much. Brother and I are going into repair work and now know about the change over repair to new coil kit install. Again, thank you. Don't know what we would have done without these videos!

[mera.k.a]

Wow this is exactly the info I needed. I hit the jackpot with this video. Thanks so much!