Surging Kohler 5E generator

[Prattbratt777]

Hello friends, I have a Beautiful 2000 see Ray Sundancer 290 with a Kohler 5E generator. The problem I'm having is that when my generator is running at idle it is surging trying to find a peaceful place to settle in. When she's under load she runs perfectly with no surging at all, but as soon as the AC kicks off, the surging begins all over again. She will continue to run but can't find that sweet spot at idle. I have checked the fuel filter and the fuel seems fine, clean and no water. I changed the spark plugs. Pulled off the stop solenoid and it was a little dirty. Cleaned it up, but the surging continues. Any suggestions? Likely a carburetor issue?

 

[Fred]

I had the same issue on my 320DA.
A carb rebuild kit and cleaning fixed it permanently.

 

[Prattbratt777]

Thanks, Lucky Dog. Did you do it yourself or did you have it done by a repairman? Was it a simple repair or complicated to get to?

 

[gerryb]

sounds like a carb problem. The 5e is known to get gummed-up rather easily. Sometimes you can fix it by shooting generous amounts of gumout into the carb through all the hose nipples.

 

[Prattbratt777]

Thanks! I'll give that a try before tearing the carb down.

 

[Fred]

Thanks, Lucky Dog. Did you do it yourself or did you have it done by a repairman? Was it a simple repair or complicated to get to?

Easy and cheap do it yourself repair. In my case carb spray alone did not work.

 

[scoflaw]

Carb spray isn't going to get to the fuel jets. Might try some seafoam in the spin on fuel filter first for an attempt at a quick fix.

 

[MancaveII]

It's a do it yourself project, but you can also buy a rebuilt one for under $100.

 

[Prattbratt777]

Where could I find a rebuilt for under $100?

 

[electricaldoctor]

Perhaps the governor needs tweaking?

 

[Jeremygavin]

I had the same exact problem and I tried rebuilding mine but it didn't fix the problem. New carb 2 years ago ($250) and purrs like a kitten ever since.

 

[Prattbratt777]

Thanks for all of your Insight. Looks like it may be a carburetor replacement. However, yesterday as I was working on the boat I noticed that the linkage from the carburetor to the electric choke was not remaining open. If I held the linkage open she purred like a kitten but as soon as I let go of the linkage it began surging again. Possibly the electric choke needs to be replaced?

 

[scoflaw]

Bingo

 

[JimFromMD]

I feel your pain. I fought with a surging 5E for 2 years. Replaced everything I could replace on my own (spin on filter, in line filter, fuel pump, solenoid, carb cleaner, mixed in some seafoam) to no avail. Then I called in a professional from the local SR tech shop. They cleaned the carb, adjusted the valve clearances, helped a little but not really. Finally called in a Kohler trained tech. He cleaned the carb, needle, jets, solenoid and seemed to have it going fine. Of course that happened just at the end of the season as I was putting the boat down for the winter without ever getting to see the results in person. I started it up in the spring and the same thing was going on. The tech was dumbfounded. He ended up replacing the original carb with a new fresh-from-the-factory-box carb and it ran ok for about a month with varying weekend use. Then it started again... This time the issue was that it would run for 30-mins to an hour and then surge wildly and then stall. Wouldn't start back up right away but if I waited a 5-20 mins it would. Had the tech back out and what he found was that the plastic float in the new carb had a burr on the side of the hinge from manufacturing. It was preventing the float from dropping back down to let more fuel in. End result was that it would run for as long as it could on the fuel in the bowl (short under heavy load, longer under light load) then quit. Eventually the float would drop under its own weight in an empty bowl, and let fuel back in, and the cycle would start again. The tech replaced with yet another new carb under warranty and it's been fine since. Cannot tell you how frustrating it was figuring out what the issue was. If I had it to do again, I'd go direct to a tech, and save myself the headaches. I have some videos of what the generator was doing if you want to see (2nd link). Cant believe I had three threads going at various times dealing with this. Did I mention frustrating :smt013

http://clubsearay.com/showthread.php/52406-Surging-Stalling-Generator

http://clubsearay.com/showthread.php/59166-Finally-solved-the-genny-surging-and-starting-problem

http://clubsearay.com/showthread.php/60203-Surging-Bogging-Kohler-5E-Generator-Water-in-gas


Two Other threads with more food for thought.
http://clubsearay.com/showthread.php/60726-kohler-5kw-running-issues
http://clubsearay.com/showthread.php/61970-kohler-generator-issues

 

[Prattbratt777]

Thanks. Nice to know I'm not alone on this issue. I'm posting a couple of YouTube videos that I took of the surging. You'll notice that what appears to be the linkage from the automatic choke to the carburetor is moving back and forth. That's me manually moving it. If I manually open the choke, she runs perfectly, but as soon as I let go of that linkage the choke closes (I guess) and it starts surging again. This is what makes me believe perhaps it has to do with the automatic choke instead of the carburetor. Any thoughts on this?
https://youtu.be/Rp6AeWP1New
https://youtu.be/2oLaTBybP2U

 

[JimFromMD]

Thanks. Nice to know I'm not alone on this issue. I'm posting a couple of YouTube videos that I took of the surging. You'll notice that what appears to be the linkage from the automatic choke to the carburetor is moving back and forth. That's me manually moving it. If I manually open the choke, she runs perfectly, but as soon as I let go of that linkage the choke closes (I guess) and it starts surging again. This is what makes me believe perhaps it has to do with the automatic choke instead of the carburetor. Any thoughts on this?
https://youtu.be/Rp6AeWP1New
https://youtu.be/2oLaTBybP2U

That seems very similar if not exactly like what my 5E was doing. I didn't get the same result with the choke fully closed, but if I held it part way it would slow the surging or completely settle. I wish I had a definitive answer for you, but the new carb (or 2 new carbs in my case, with the faulty new one) solved it. I did hear about folks with choke issues, but not sure. Its been a while since I looked at my videos, but take a look. I think I showed manipulating the choke some.

Side note, you can get 5E parts from here or any local kohler dealer... If you are inclined to try a <$150 experiment and open to changing the carb yourself.
http://www.partsfortechs.com/asapcart/page.html?chapter=0&id=25

 

[Curtiss]

2004 sundancer 280 with Kohler 5e. I can't get the carburetor out. I've got problems getting the linkage unhooked. I was able to get the spring but not the larger ones. I was hoping that when carb started to come up I would get the angle to get them out of the hole but I can't get the carb up and out. I've unhooked everything I can see including the hoses and gas line. I can lift it up about 1/2 inch or so but it's like something is holding it from the bottom or the left side above the coolant overflow. It's a tight spot and I must be missing something.

 

[sweet revenge]

i had the same issue with mine. turnout to be the fuel line was collapsing inside after running. replaced fuel line issue reolved.

 

[Captain_CGC]

Thanks. Nice to know I'm not alone on this issue. I'm posting a couple of YouTube videos that I took of the surging. You'll notice that what appears to be the linkage from the automatic choke to the carburetor is moving back and forth. That's me manually moving it. If I manually open the choke, she runs perfectly, but as soon as I let go of that linkage the choke closes (I guess) and it starts surging again. This is what makes me believe perhaps it has to do with the automatic choke instead of the carburetor. Any thoughts on this?

Hi

Where you able to resolve this issue, if so, could you please share what you did. My generator does exactly what yours is doing. What I have done so far.

1. New Plugs
2. New Carburetor (OEM)
3. New Impeller
4. New Fuel filters
5. New Fuel pump
6. New hoses

I'm amazed that all this has done nothing to resolve the issue. I've adjusted the fuel/air mixture screw, but that does not make and difference in the operation of the engine.

Thanks.

Carlos

 

[B4tn]

@Captain_CGC did you figure it out? The mechanic working on mine is stumped. He has done all the same new carb, fuel filter, pump, plugs, etc and it runs great load or no load for about 30 minutes then the idle hunts and and it dies. I’m curious about the float with a burr on it and the fuel line collapsing.