replace the sprak plugs every 20 hours

 

I think he meant 200 but I also recall seeing threads on lubricating the choke linkage. Try a search (it seems to work better now) and you should find quite a few threads identifying the same problem. Good luck.

 

I replaced the plugs as suggested and for the most part it fixed the problem. I believe though this is more of a bandage rather than a fix. I have owned this same genset before on another boat and it worked without any problems. I have called the Kohler rep and they are going to visit my boat. I'll keep you posted with what we find. Thanks again for your comments.

 

Have you changed the fuel filter along with the plugs? I don't know what the differences between my 5E and your 5CE units are but mine works like a champ. I also changed out the coolant, oil filter and switched to full synthetic oil before this season.

 

I believe the problem is with your choke linkage, sounds like it needs to be adjusted and lubricated.

 

I mistyped I have a 5E. I tried lubricating the linkage. I do believe though you are in the right area......carb/choke. I have had one of these before so I know how they are suppose to run. They are coming out Friday I'll let you know what they find. Thanks for the suggestions.

 

There are two screws on the choke assembly. Loosen them slightly and turn it to lessen the amount of choke that is applied, and it should fix the issue.

What lake in IN are you on?

 

We are in Lake Monroe in Bloomington, IN - Four Winds Marina.

The Kohler guys were here today. All they did was replace the plugs, which is what I did a few days ago using exactly what the factory manual said to use. KOHLER said that the factory spece'd plug let the engine run too cold therefore causing the plugs to foul. Instead of using a BPR4 they used a BPR6. The tech said for the two hours they were there running the generator that it never had a problem as he loaded and unloaded the genny. I hope it works as they said but if they send me a bill for a couple hundred bucks it is not going to go well ON THE PHONE

 

Well for the first time in four years that I have owned the boat the generator finally runs the way it suppose to. By using a slight larger plug the genny runs great.

 

I read On another forum that using a hotter running plug would reduce plug fouling. Looks like that is what the Kohler guys think also. I may do the same when I replace my plugs.

 

Well the generator saga continues........after running generator for 20 hours with new plugs without a problem it stopped and will not restart. I was running generator last weekend for about an hour and it just died. The starter will run but it is like their is no gas. Talked to kohler rep today and he says there is a solnoid in the carborator bowl that shuts off gas if generator turns upside down. He says he typically see this problem when varnish accumulates on valve and causes it to stay shut. Told me to remove 12 v from solnoid then connect 12v from starter to solonoid If I hear a click then it is working and that I should test fuel pump the same way. If it is valve then I need to take valve out and clean with cleaner.

 

Well after downloading the service manual for the genny and a lot of conversations I found that the fuel pump stop working. Since I didn't get the boat out last year and left it in storage I have had to replace a number of rubber check valves this season. Not knowing for sure but I bet there is a rubber item in the fuel pump. Well I'm back up and running.

 

My gen has 9 hours on it and it just started surging last weekend. I find it hard to believe the plugs would be bad, but I will check them. I called a Kohler service center and the tech thinks it could be just a small governor adjustment. We will see who is right.

 

The BPR6 is a hotter plug. Won't foul like a colder plug can (BPR4).

How often are you changing your impeller? It's a 5 minute job on a $28 part, and two years is too long to go. I've added it to my annual service checklist...

 

Changed plugs yesterday to a hotter range plug, problem SOLVED! Called Kohler tech and told him what I did, he said "yea that's what we would try first". 4$ dollars Autozone.

 

I would check NGKs website - I thought their heat ranges were opposite of what were used to. BPR4 is hotter than BPR6, but my memory is cloudier than it used to be. Also kohler had a problem w/ choke pull-off piston getting stuck in its bore causing rich running, fouled plugs, surging under load. The fix was replace complete choke housing and linkage, Not that expensive but took a while to duplicate customers complaint. lost money on the first one, but made it up on all after that. Good luck

 

Changed the plugs on my 5E for the surging issue, it helped but the problem was not solved. Purchased a new carb for 213.00 changed it in 15 mins, no surging at all! Ran for 15 hours since and still no surging, Surging was a fuel issue.

 

According to this info from the NGK website, the BPR 5 and 6 are COLDER than the BPR4 unless I am misunderstanding somthing?

View attachment 24857

 

JoeyD and Aquaaddiction - you guys are correct...hmmm.

AC plugs are hotter with a higher number. A colder plug works better on an engine that is heavily loaded, and a warmer plug works better on a lightly loaded or idling engine...Maybe that's why the BPR6ES' are working better than the BPR4ES'....

Let me look on mine this weekend and see what the plugs are. It runs with no problems.

 

I was having problems with my generator a few years ago. I was getting an EC72 error. Chris in Texas tipped me off that the a potential problem with the main power relay. I spoked to Kohler and they confirmed there were some problems with the relay. I purchased a relay for about $5.00 and installed it myself. My problems went away. The relay is about 1inch square that looks like small black fuse block that you would plug into a fuse panel on your car. It sitst behind the control panel.


Looks like this (this is not the actual Kohler relay)

Re: Kohler 5ecd Generator shuts down - EC72

Hello All,

Just to let you know I have had the EC72 on a reoccurring basis. Would run then stop suddenly and show EC72. Would clear it and restart after a while would do it again. Kept progressively getting quicker and quicker to the point it wouldn't start, would try to start but then show EC72 right away.

1st fix by Kohler guys was to replace the K5 Main power relay. From the factory it was a cheap made in china no-name 30A relay. Was replaced by Bosch relay. The reason was the relay contacts were getting burnt and carbon build up on it, and wasn't getting power to the ECU on the back of the genny, it also started affecting the fuel pump at the end.

The 2nd time I got the EC72 about 5 months later, it was narrowed down to the 120 Ohm resister on the CAN bus, located closest to the front starboard side of the genny. A new resister was soldered into place and has worked like a champ ever since.

Hope this helps,
Chris

​

 

I was having problems with my generator a few years ago. I was getting an EC72 error. Chris in Texas tipped me off that the a potential problem with the main power relay. I spoked to Kohler and they confirmed there were some problems with the relay. I purchased a relay for about $5.00 and installed it myself. My problems went away. The relay is about 1inch square that looks like small black fuse block that you would plug into a fuse panel on your car. It sitst behind the control panel.


Looks like this (this is not the actual Kohler relay)
View attachment 24858


Re: Kohler 5ecd Generator shuts down - EC72

Hello All,

Just to let you know I have had the EC72 on a reoccurring basis. Would run then stop suddenly and show EC72. Would clear it and restart after a while would do it again. Kept progressively getting quicker and quicker to the point it wouldn't start, would try to start but then show EC72 right away.

1st fix by Kohler guys was to replace the K5 Main power relay. From the factory it was a cheap made in china no-name 30A relay. Was replaced by Bosch relay. The reason was the relay contacts were getting burnt and carbon build up on it, and wasn't getting power to the ECU on the back of the genny, it also started affecting the fuel pump at the end.

The 2nd time I got the EC72 about 5 months later, it was narrowed down to the 120 Ohm resister on the CAN bus, located closest to the front starboard side of the genny. A new resister was soldered into place and has worked like a champ ever since.

Hope this helps,
Chris

​

Hi Chris I have same problem with my genny. Where did you order the k5 relay and the 120 ohm resistor? Thanks very much!

 

Vince - is yours a 5E or a 5CE?

 

Not sure. I zoomed in on my PC and it looks like it is a 5ECD ? Can you tell from the pic?

[/QUOTE]

 

looks like a 5ECD to me, my 2006 5E doesn't have the LED display

 

Hi Chris

you stated that it was narrowed down to the 120 Ohm resister on the CAN bus, located closest to the front starboard side of the genny. A new resister was soldered into place and has worked like a champ ever since., was this wiring harnest 120 Ohm resister under the muffler are on the back side of the Genny? where was this resistor?

 

First off, with ngk plugs the lower the number the hotter the plug and yes the engine does run better with 1 notch hotter plug.
Second off, the aluminum used to mfg the carb is susceptible to corrosion due to moisture and the symptom is surging which can only be resolved with replacing the carb.