Kohler 5E strange noise

[GirlyGirl1999]

Hey Group, searched for about an hour and couldn’t find a thread for this. Generator serviced last March, you can search my posts and read about that debacle.
Raw water pump coupler replaced and engine serviced.
Engine/Gen has run great all year
New $1M choke assembly last year as well
It has always made a soft clanking sound on startup that immediately went away.
Young man that helps me came down to help me adjust the choke a bit as it started a little hard.
While he was working he broke the governor spring that I did not see, it was very rusty, tried to start the Gen no good as you can imagine. He held it up and asked “is this important?”
I laughed and said yes.
Called Kohler and very nice guy took all my model and serial numbers, told me he had it, $12.00 for the spring $20.00 to send it to me. Oh Well
Same young man came back to install said spring, we had the service manual pulled up on the IPad to make sure we had it in the 60Hz hole.
All good, Gen started right up, carried the load no problem.
Fast forward to two weeks ago
Down on the boat to start all systems for their bi-weekly fluid and systems check.
Gen starts as normal makes the quick clank sound but then unloaded or loaded sounds like a pop-corn machine in the bilge ,not consistent like a rod knock. Immediately shut it down.
Good water flow, full oil, full coolant in the exchanger and overflow tank.
So, hoping it’s a loose shroud or maybe mounts, young man can’t come help for two more Saturday’s I will have him bilge dive to look for obvious loose stuff. Then run it for a minute, he is a fantastic auto tech at one of the local garages here, it’s how I found him. He’s experienced enough to listen for rod knock or spun bearings. Not so much the generator side, me either.

So, anything special to look for?
Plan is to look for anything loose
Take the plugs out and look for liquid
Head gasket?
Apart from that, call a Kohler tech (ugh )
Anyone have experience taking it (the GenSet) out without removing the port engine?
Sorry for the super log post but wanted to try to give detail and answer the common questions that come up.
Thanks Jon

 

[BillK2632]

Check the spark plugs. Those older Kohler are hard on them. I had a 5e in my 290 and only problem I ever had was spark plugs. It would make a terrible missing popping sound under load.

 

[Skybolt]

Is it a dull sounds or a sharper clanky sound not steady? If the later could be the starter bendix hanging up.

EDIT: you might be able to pull the gen (if needed) by removing the outside exhaust manifolds.

 

[GirlyGirl1999]

Is it a dull sounds or a sharper clanky sound not steady? If the later could be the starter bendix hanging up.

EDIT: you might be able to pull the gen (if needed) by removing the outside exhaust manifolds.

Super clanky, not consistent, starter never even crossed my mind. Thank you. Weather is supposed to get be good tomorrow, if I go down I’ll try to make a video/sound clip

 

[jmcdboater]

What about fuel flow? Possible obstruction in the line? Is there a separate file filter between the tanks and genset? Fuel pump?

 

[PlayDate]

Clanky is usually sheet metal. It might be a drive belt, a pulley or a loose panel.

 

[GirlyGirl1999]

Thanks Group, I don’t think its fuel, it will hold a load no problem, but always check everything right? Belt and sheet metal are at the top of the list but when I get my guy down there going to move the starter to the top of the list. Not going down today as the upstairs furnace has quit. Waiting on the HVAC guy now. It’s always something.