Kohler 5E surging under load

[firecadet613]

Kohler 5E, surging under a light load every 30 seconds or so. Taking the load off stops the surging.

59 hours on the '07 (I've put 40 on in the two years I've had it). New plugs last year.

Has anyone experienced this and resolved it?

https://youtube.com/shorts/nb3yp1arAlg?feature=share

 

[Wanderer 290]

I had similar symptoms with surging not under load. Did try it with a load because I feared frying the voltage reg. And/or appliances.
I tried rebuilding the carb to no avail.
The resolution was a new carb.
I did source the carb through Kawasaki directly and saved $100 vs buying it through kohler..

 

[Little Ducky]

I had surging on my 4kW and found the spring that was on the carb linkage had detach.

Once reconnected it's rock steady.

Lets hope it's this simple.

 

[firecadet613]

I had surging on my 4kW and found the spring that was on the carb linkage had detach.

Once reconnected it's rock steady.

Lets hope it's this simple.

All looks good, was able to move them all around, the RPMs changed and the unit recovered quickly back to its normal speed.

Frustrating and not good as I know surging under load is bound to cause a voltage spike and damage something.

That said, we made it back to the dock and our A/C compressor isn't wanting to kick on. It's trying to cycle every 30 or so seconds...so I may have found my "surge". Need to run it with the water heater on vs the A/C and see what happens.

 

[KevinC]

I had similar symptoms with surging not under load. Did try it with a load because I feared frying the voltage reg. And/or appliances.
I tried rebuilding the carb to no avail.
The resolution was a new carb.
I did source the carb through Kawasaki directly and saved $100 vs buying it through kohler..

Which carburetor was it? - I was also looking into this for my 2004 Kohler 5e. Was it a direct replacement? I know the engines are Kawasaki.

-Kevin

 

[Wanderer 290]

Which carburetor was it? - I was also looking into this for my 2004 Kohler 5e. Was it a direct replacement? I know the engines are Kawasaki.

-Kevin

Yes the carb was the exact same carb that was originally on the generator.
Replaced it 3 years ago and running fine now.
I’ll look for the invoice and part number later today.

 

[KevinC]

Yes the carb was the exact same carb that was originally on the generator.
Replaced it 3 years ago and running fine now.
I’ll look for the invoice and part number later today.

Thanks - it will save a bunch of research for myself and others.

-Kevin

 

[Wanderer 290]

I found the Kawasaki part #
15004-0773
For my kohler 5e year
Kawasaki 2cylinder Fd501d
I believe I ordered it from
Jacks small engine parts but not 100% certain

 

[KevinC]

I found the Kawasaki part #
15004-0773
For my kohler 5e year
Kawasaki 2cylinder Fd501d
I believe I ordered it from
Jacks small engine parts but not 100% certain

View attachment 107534

Thanks, I will verify if I have the FD501D on my Kohler.
Did you need to get a gasket or was it included in the kit?
Was it a simple swap out - any gotchas ?

-Kevin

 

[Wanderer 290]

I do not recall on the gasket.

And no gottachs. Bolt up and go. Swapped a couple parts from carb to card but it is the exact carb as installed from the factory.
No adjustments necessary and as the enclosed instructions state it is preadjusted.

last but not least DO NOT use FUEL with ETHANOL unless you plan on buying a new carb every year.

 

[KevinC]

I do not recall on the gasket.

And no gottachs. Bolt up and go. Swapped a couple parts from carb to card but it is the exact carb as installed from the factory.
No adjustments necessary and as the enclosed instructions state it is preadjusted.

last but not least DO NOT use FUEL with ETHANOL unless you plan on buying a new carb every year.

Unfortunately I am limited by what fuel is available at the docks
I will look into other options including running my winterization off a highly stablized tank or even draining the bowl.

Thanks again!
-Kevin

 

[Wanderer 290]

Unfortunately I am limited by what fuel is available at the docks
I will look into other options including running my winterization off a highly stablized tank or even draining the bowl.

Thanks again!
-Kevin

 

[Wanderer 290]

As The first step of winterizing I disconnect the electrical connection to the fuel pump while the generator is running with no load and let it run until it shuts off which empties the fuel system.

 

[KevinC]

As The first step of winterizing I disconnect the electrical connection to the fuel pump while the generator is running with no load and let it run until it shuts off which empties the fuel system.

My only problem with that is that I have to run antifreeze through the raw water system. Once the fuel runs out I would not be able to do that and timing it would be impossible.

-Kevin

 

[Wanderer 290]

My only problem with that is that I have to run antifreeze through the raw water system. Once the fuel runs out I would not be able to do that and timing it would be impossible.

-Kevin

Your generator doesn’t have heat exchanger ?
If it does the raw water side and muffler is very easy to drain in its entirety.

 

[Craig]

Your generator doesn’t have heat exchanger ?
If it does the raw water side and muffler is very easy to drain in its entirety.

Most certainly does have a heat exchanger. Thats why it draws in seawater and get pumped out the exhaust to cool the engine. It is drainable but most just run antifreeze through to winterize.

 

[KevinC]

Your generator doesn’t have heat exchanger ?
If it does the raw water side and muffler is very easy to drain in its entirety.

Yes, but I like to run A/F from the strainer straight through to the exhaust. It assures no water being trapped anywhere to cause freeze damage.

-Kevin

 

[KevinC]

My Kohler manual supplement shows I have the FD501D and Amazon has this carb (via third party) so going to order it and hopefully the surging will go away. Worth a shot for this price.

-Kevin

 

[Wanderer 290]

My Kohler manual supplement shows I have the FD501D and Amazon has this carb (via third party) so going to order it and hopefully the surging will go away. Worth a shot for this price.

-Kevin

Please keep the forum informed. Thanks

 

[firecadet613]

Closing this out as the generator ran fine yesterday for 4 hours. Turns out my "surging" was due to my A/C Compressor being locked up and it trying to kick on every 30 seconds.

New A/C unit and the gen is back to just purrring...