Kohler 5eCD won't turn over

[Stray Current]

Can you tell me if this 3 wire is normal. Each of the black wires are exposed in the flex tube. And the connectors doesn't seem like something a manufacturer would use. Do i need to reassess the whole electrical system? Lol.

Mine is also all ripped apart in my garage at the moment. I haven’t really looked at the harness yet, but I don’t remember seeing any bare copper.

Some generators that use MPUs for speed sensing will have a static bleed off wire in the harness to the unit coil, but I don’t believe that is the case on the crank position sensor on these

 

[Stray Current]

Yeah, that looks awfully wonky and not oem for sure

I see your AVR for battery charging melted too. I made a 105 degree Celsius pigtail for it in 2021 and it burned up too when my AVR melted again in August 23 but it was fine until the AVR failed. Redid the same

im tired and perhaps a wee bit tipsy so I will see if I can dig out the schematic and pinout tomorrow

 

[TimmyD]

Thank you and i really appreciate your help with this. These pictures help a lot

 

[TimmyD]

View attachment 158668View attachment 158669View attachment 158670View attachment 158671View attachment 158672View attachment 158673View attachment 158674View attachment 158675View attachment 158676Yeah, that looks awfully wonky and not oem for sure

I see your AVR for battery charging melted too. I made a 105 degree Celsius pigtail for it in 2021 and it burned up too when my AVR melted again in August 23 but it was fine until the AVR failed. Redid the same

im tired and perhaps a wee bit tipsy so I will see if I can dig out the schematic and pinout tomorrow

View attachment 158668View attachment 158669View attachment 158670View attachment 158671View attachment 158672View attachment 158673View attachment 158674View attachment 158675View attachment 158676Yeah, that looks awfully wonky and not oem for sure

I see your AVR for battery charging melted too. I made a 105 degree Celsius pigtail for it in 2021 and it burned up too when my AVR melted again in August 23 but it was fine until the AVR failed. Redid the same

im tired and perhaps a wee bit tipsy so I will see if I can dig out the schematic and pinout tomorrow

Can you identify this part for me please?

 

[Stray Current]

That is the SCR. It is responsible for regulating the generator output from field flash to the AVR and not related to starting issues.

pm me your email and I’ll send you the service manual and parts manual

 

[TimmyD]

View attachment 158668View attachment 158669View attachment 158670View attachment 158671View attachment 158672View attachment 158673View attachment 158674View attachment 158675View attachment 158676Yeah, that looks awfully wonky and not oem for sure

I see your AVR for battery charging melted too. I made a 105 degree Celsius pigtail for it in 2021 and it burned up too when my AVR melted again in August 23 but it was fine until the AVR failed. Redid the same

im tired and perhaps a wee bit tipsy so I will see if I can dig out the schematic and pinout tomorrow

Could you identify this part as well? I can't find it in my parts diagrams.

 

[Stray Current]

Could you identify this part as well? I can't find it in my parts diagrams.

That’s the oxygen sensor. It’s in there somewhere because I ordered one back in 2019

 

[TimmyD]

I found the Oxygen sensor in the parts manual. It was under engine not electrical.

I got the starter cleaned up and will start to move the crank. Now Im back to compression release or too high compression. The starter will go as far as the compression. If I move the crank past the compression it will turn it again until the next compression. I've checked the valves. They appear to be set. They all move and the rods are in place. I followed the instructions to check them and they were already at spec.