Starting Problems with Kohler 5E Generator

[320Bob]

The last two weeks I have had trouble starting my Kohler generator. I have to turn it over it 3 or 4 times before it will keep running on its own. When I first put the boat in the water in March, the generator would start the first time and keep running however it was emitting a lot of blue smoke until it warmed up. I had the marina look at it and a spring was disconnected I believe on the choke. After that, no blue smoke but would start the first time. Now all of sudden it won't stay running on the first try. My guess is the choke is not setting properly until the 3rd or 4th try but I'm no expert. What needs to be done? The generator was completely serviced over the winter including new plugs and has a new impellar.

 

[everthing's irie]

I had that problem. The linkage needed lubrication. It would crank on the first try if I moved the linkage by hand. So I lubricated it and it worked like a charm.

 

[320Bob]

I had that problem. The linkage needed lubrication. It would crank on the first try if I moved the linkage by hand. So I lubricated it and it worked like a charm.

Thanks for the tip. What did you use to lubricate the linkage? WD-40 or something else?

 

[AKBASSKING]

Thanks for the tip. What did you use to lubricate the linkage? WD-40 or something else?

Try this:

 

[320Bob]

Try this:

Thanks, I try to find some of this stuff. I also talked to my marina Service Manager and he said my starting problems could also be fouling plugs. Eventhough they were replaced over the winter, the generator was fogged so the oil often gets on the plug tips. He generally doesn't replace generator plugs until after it has been started and run for the spring to prevent this.

 

[Hampton]

It could very well be plugs. Remember, once you allow your genny to warm up for 1 - 3 minutes, load it up and keep it loaded to avoid fouling plugs or developing other issues associated with idling for too long. Running the A/C in the winter (heat mode) or summer loads it enough. Running A/C when it's comfy out is not enough load on the genny. If you need it on in these conditions, turn on the water heater as well as all of the normal small stuff (batt chargers, refrig's, charge your phone and camera batteries...).

 

[wvsundancer]

mine loves new plugs.. had to change on the 280 but well worth it

 

[AKBASSKING]

Thanks, I try to find some of this stuff. I also talked to my marina Service Manager and he said my starting problems could also be fouling plugs. Eventhough they were replaced over the winter, the generator was fogged so the oil often gets on the plug tips. He generally doesn't replace generator plugs until after it has been started and run for the spring to prevent this.

WM has it......

 

[Kreole Kid]

Be careful cranking too many times without closing the seacock or you'll have some water intrusion that will ultimately turn in to bent rods and valves.

Ask me how do I know that:smt013:smt013:smt013

 

[320Bob]

Be careful cranking too many times without closing the seacock or you'll have some water intrusion that will ultimately turn in to bent rods and valves.

Ask me how do I know that:smt013:smt013:smt013

I have been somewhat concerned about this since the manual says to close it after the first unsuccessful try. In my case the generator starts but just doesn't keep running until the third or fourth start then it is fine. So am I tempting the fates?

Hampton,
I run the generator whenever I take the boat out with the A/C, refrig, outlets and charger running to provide load. This potential plug fouling is really surprising to me since I have essentially the same V twin water cooled Kawasaki engine (25 HP vs 18 HP) in my JD lawn tractor. The plugs are never fouled when I change them each year. Similar Spring/Summer/Fall duration of use on both so what gives?

 

[Kreole Kid]

I'll let you know the extent of the damage tomorrow hopefully. But so far, I do have some damage to the rods and valves.:smt013

 

[320Bob]

I'll let you know the extent of the damage tomorrow hopefully. But so far, I do have some damage to the rods and valves.:smt013

Between hitting underground cables and water spritzing your generator internals I say you are having a run of Coon Ass bad luck!:smt089

 

[Chris R]

I hate these Kohlers. My was flawless for a year and a half, then has been crap ever since. I had a Kohler retailer mechanic at my boat on and off for almost 4 months. The factory would tell him to replace one thing, then another, then another. Original fault code was EC69.

Every module and sensor has been replaced. Get this, even the entire wiring harness. Finally, the ECM was replaced and it started acting normal again. Even with all that, it still takes two tries to start. And..it has new plugs.

 

[Hampton]

I have been somewhat concerned about this since the manual says to close it after the first unsuccessful try. In my case the generator starts but just doesn't keep running until the third or fourth start then it is fine. So am I tempting the fates?

Hampton,
I run the generator whenever I take the boat out with the A/C, refrig, outlets and charger running to provide load. This potential plug fouling is really surprising to me since I have essentially the same V twin water cooled Kawasaki engine (25 HP vs 18 HP) in my JD lawn tractor. The plugs are never fouled when I change them each year. Similar Spring/Summer/Fall duration of use on both so what gives?

Don't know. Souds like you're doing it right. Is it running rich? Choke stuck?

 

[jrcinnh]

...This potential plug fouling is really surprising to me since I have essentially the same V twin water cooled Kawasaki engine (25 HP vs 18 HP) in my JD lawn tractor. The plugs are never fouled when I change them each year. Similar Spring/Summer/Fall duration of use on both so what gives?

Generator use is tough on engines because they can't vary speed with load. In a mower or other normal use an engine can speed up or slow down to react to load. On a generator the engine must stay at one speed so that the electrical ouptut is always 60 hz (or 50). So at low load they really want to run slower but they can't, it's like running your car at high rpm in neutral. At high load they really want to run faster but again they are stuck. So they are tuned for a compromise and don't run well away from that point.

 

[320Bob]

Don't know. Souds like you're doing it right. Is it running rich? Choke stuck?

I think the choke is sticking since it seems to behave like it's not getting enough gas initially. By the 3rd or 4th start the choke seems to be finally set properly because the engine runs for a minute or so at slower rpm then it speeds up and stays there. I am going to spray some lubricant on the linkage this weekend and see if that helps like one other poster suggested.

 

[1stSeaRay]

I'll be interested to hear how this turns out, as my Kohler usually hard to start as you describe (when starting for the first time in a week or two) I had assumed that the fuel in the bowl was evaporating while in storage (as evidenced by the strong fuel smell in the bilge when its been in the 130º boat garage for a week or two) but maybe the choke isn't setting properly. It is usually much easier to start if its been run in the previous 24 hours.

 

[320Bob]

I'll be interested to hear how this turns out, as my Kohler usually hard to start as you describe (when starting for the first time in a week or two) I had assumed that the fuel in the bowl was evaporating while in storage (as evidenced by the strong fuel smell in the bilge when its been in the 130º boat garage for a week or two) but maybe the choke isn't setting properly. It is usually much easier to start if its been run in the previous 24 hours.

I guess the boating gods were smiling yesterday because the generator fired right up on the first try and keep running. The only thing I did differently from the past two weekends was to run the blower for 3-4 minutes before starting it. I question whether this had any effect but maybe after the two previous weeks of running it, the choke may now be working properly again.

 

[1stSeaRay]

I guess the boating gods were smiling yesterday because the generator fired right up on the first try and keep running. The only thing I did differently from the past two weekends was to run the blower for 3-4 minutes before starting it. I question whether this had any effect but maybe after the two previous weeks of running it, the choke may now be working properly again.

I had much better luck this past weekend as well. As part of my pre-departure routine, I manually operated the choke linkage on the generator (worked it back and forth several times, then left it in the closed position) The generator was much easier to start, I'll give the linkage a shot of lube next time and see if it stays fixed.

 

[firecadet613]

I've had a problem with my choke sticking on, so I just adjusted it. Maybe yours needs adjusting? Two philips head screws hold it down...