Kohler 5E Cold Start Up

[Stray Cat]

Anyone experienced this one?

After an overnighter on the hook, I fired up the 5E the next morning. The automatic choke seems to stick and chokes the hell out of the motor to the point where it is nearly flooded. The motor runs on one cylinder trying to overcome the choke. If I move the choke linkage open by hand the motor cleans out and runs perfect.

If the main engines have been run, and it is warm in the bilge, the gen pops right off on two cylinders and all is good. It only balks on cold starts.

All that said, I changed the fuel filter last fall, and replaced the plugs with the NGK it came with, gapped per the manual, and sprayed the choke linkage with a light oil. The linkage moves freely.

It worked perfect last year...any ideas?

 

[280 SeaRay]

On cold starts... the 5E does indeed... hack and cough... it has since new..... takes about 30-45 seconds on cool mornings... then the choke lets go (almost sounds like it "resets" itself and then sounds normal)...... you will also notice that you are not getting a full 120v when it is hacking and coughing. How can you tell it is only running on only 1 cylinder? Or does it just seem/sound like it does?

I freaked out the first couple of times... then realized the thing is just a lawnmower painted white.... :smt001

The SR techs told me they all act this way.... it may be worth a call to Kohler.... I am thinking that it may be a default to get her running.... as you are 100% right on the money.... does not do this if warm.

 

[Stray Cat]

Jeremy, based on the hacking and coughing, it only sounds like it is running on 1 cylinder....during this period it smokes like a Lawnboy too! :smt043 We didn't really get into overnighting with the boat last year until the weather warmed up perhaps thats why we didn't notice it.

I presumed a Kawasaki had better behavior. I didn't give it 45 seconds to see if it snapped out of it...I started cussing instead :smt043

 

[280 SeaRay]

it does indeed sound awful at startup... reminds me of a poorly tuned dirt bike or something.... and yes there is a bit of smoke..... especially if you forget to "excercise the generator weekly" as the manual says.... we had a cool night friday night this last weekend... where the temp dropped off into the mid-50's and she kicked and screamed for about 45 seconds when I started her up.... but as soon as that choke quits.... puuuurrrrs like a kitten....

oil analysis says everything is awesome at the last oil change... I inspected the plugs... and they were clean.... and not fouled any..... my only complaint... is that the impeller had a nearly broken vane at 35 hours.... I expected to get at least 50 hours....

I really dig the oil drain seacock... I wish the engines had that type of setup at the end of the remote drain hoses....

 

[Presentation]

I just want to say ‘thank you’ for the above. I lean more each time I read posts here at CSR.

Once warmed up is the noise level lower then the noise level of say one engine at idle?

Does it come standard with a sound shield?

 

[MLauman]

Does it come standard with a sound shield?

$500 option. :smt013

Once warmed up is the noise level lower then the noise level of say one engine at idle?

No such thing as 'idle'. The 5E is supposed to run at 3600rpm at ALL times, regardless of load. That's one reason they tend to foul plugs when there's not enough load on them.

 

[Bridog]

On cold starts... the 5E does indeed... hack and cough... it has since new..... takes about 30-45 seconds on cool mornings... then the choke lets go (almost sounds like it "resets" itself and then sounds normal)...... you will also notice that you are not getting a full 120v when it is hacking and coughing.... does not do this if warm.

Mine also has the same problems at cold start ups. Once the engine compartment is warm everthing is fine.

 

[Stray Cat]

Once warmed up is the noise level lower then the noise level of say one engine at idle?
Does it come standard with a sound shield?

Presentation I really think the genny is pretty quiet in our boat. There is a lot of insulation on the bulkhead. Plus you have the bilge blower running when the genny is running also...I think the sound shield would hinder the ease of access to inspecting things also. The exhaust noise is hardly noticeable.

I emailed Kohler last night to get their input...I checked the manual for hacking and coughing and didn't see it listed :grin:

 

[280 SeaRay]

I agree with Stray Cat.... the noise from the 5E is barely noticable from the cockpit.... I can hear the bilge blowers(fans) more than the genset... or the exhaust...

From the cabin it is a bit more noisy... but the it is a pretty constant hum (once the choke lets go)

Stray Cat.... please let me know what Kohler says.... I am sure that the tech writers choose to exclude hacking and coughing...hehehheehe


Presentation.. The sound shield does not come standard on the 5E with the 280.... however like mentioned I think it would hinder accessibility..... from the cockpit the genset is barely noticable to the point where I forget it is on.... I remember once I get into the cabin. Is the genset the same noise as a single engine fire.... umm.... probably more noisy as the genset is not nearly as smooth.... plus the exhaust is wrapped around half of the engine compartment before exiting above the waterline. The engine exhaust has a very quick route overboard to underwater discharge.

hope this helps.

 

[Presentation]

......hope this helps.

Yes, and thank you! :thumbsup:

 

[Stray Cat]

Jeremy - My reply from Kohler refered me to call my local distributor...I can understand where they are coming from. I'll address the huffing and puffing with them and post an update...

 

[280 SeaRay]

I really think it is the nature of the animal.... but it will be interesting to hear the explaination. :smt001

 

[Presentation]

Jeremy - My reply from Kohler refered me to call my local distributor...I can understand where they are coming from. I'll address the huffing and puffing with them and post an update...

As you are making your huffing and puffing sounds along with your hacking and coughing make sure you add some visual animation. Tray shaking your hands and head like a crazed rabid dog. It’s a multimedia world and you need to help convey your situation as completely as possible. Actually, adding a fart would help too. :smt043

 

[280 SeaRay]

:smt043 :lol: :smt043

 

[Stray Cat]

I spoke to the Kohler service tech for my area, there may be a cure for the cough-do-to-cold on the 5E and it aint Smith Bros. or Vicks!

I'll share what he said to do, though I have not yet taken a screwdriver to mine yet. (But will try a hand at it this weekend)

The reason for the cold start hacking - The vacuum pull on the choke does not have enough force to overcome the bimetal spring on the choke. This causes a temporary flooding condition on a cold start until the engine sputters long enough to build some heat and vacuum into it. Once there is some heat in the engine, the vacuum pull off has enough pull force to over come the spring and open the choke. Then engine runs smooth. The bimetal spring in the choke reacts to heat in the genny's engine or the ambient warmth of the bilge from running the main engine(s). On a warm start, there is less tension on the spring and the vacuum pull off works fine

Solution - Take some of the tension off the spring. Locate the square black cap with two screws on it. The choke linkage will be connected to it. There should be an arrow on the black cap that either points to "rich or lean" (the tech couldn't remember which it is) Since the engine is running too rich on a cold start, you want to make a slight lean adjustment to the choke.

Slightly lossen both screws (don't remove them!) and rotate the black cap in the LEAN direction about a 1/4 inch and tighten the screws. This takes some of the tension off the spring. Adjustment to the choke should only be made when the bilge and the genny engine is cool / cold. Then start the genny to see how much affect you've made. Its not an exact science, so you may need to tweek it slightly until you get it.

"Automatic Chokes" on automotive engines were adjusted this way when I was kid back in the 60's and 70's...

I'm posting a pic of my 5E so you can get an idea where the magic black cap is....its easy to find, left of the radiator cap.

Wish me luck...I'll let you know how it works.

 

[roosevelt14]

I also have had the same problem !! I did turn the black dial to lean did help a little but I now just open it by hand, it is a pain to open the engine hatch but at least I don't smog my self to death!!! let alone my neighbors!!

 

[Stray Cat]

Well gang, no joy :smt009 I looked over the magic black cap and the choke assembly and couldn't find either a "lean or rich" mark anywhere on it....I presumed the correct way to lean it would be CCW but didn't risk messing it up.

I started it up after the mains were run, and she ran like a champ. I am going to see if I can find a 5E service manual that may offer more detail on the subject...

 

[brian thomas]

My last and current boats both did it with the Kohlers. I tried adjusting the choke on the previous boat with no luck. If it stuck on and ran rough I shut it down and got in the bilge and started it with the rocker switch. As soon as it starts I just barely touch the choke linkage and the choke pops off and it runs perfect. Bad by design. There is a wire to the bimetal coil but it must take too long to heat up with only 12 volts.

 

[njmello]

I put a 'night-light' in a rarely used recepticle and leave it on as a 'reminder' that the gen is running.