2013 kohler generator 5ekd??Backfires and stutters

unikguy

hello everyone. I have the above generator on my 2013 360ec. Since day one it has backfired and stutters. I have had 2 service tech to try to resolve the problem and so far it has been not resolved.

The flame arrester is pretty burned from i guess the backfiring. I have yet to have used this generator because of this issue. Now the tech wants to take apart to get to the pistons and see if anything wrong with the pistons.

Anyone out there that has had a similiar problem and would share the findings.

I dont like the fact that a brand new generator has to be taken apart to the pistons. Not very pleased. Its almost 2 years and still no resolution to the problem. I am not happy i paid big bucks for this option and not been able to use it.

 

thanks

 

raybo3

Very stupid question. Did anyone change the plugs? These Genny's eat plugs like candy. I had almost the same problem and changed the plugs and it still did not run. I change them again and it ran like a top. Good luck and keep us posted...

Hamdog

I second what raybo3 says. Those generators eat plugs like Popeye eats spinach. I even figure in one new set a season in my boat budget. The symptoms you describe are dead on what happens when the plugs go bad OR are not properly gapped.

Good Luck!!

Hamdog

Black_Diamond

The evil 5e series.     I'll '3rd' on the plugs..even if they look good, replace.  I change annually and carry a spare pair.  Note there are (2) plugs on this model.  Use the correct NGK series too, some places will try to interchange with the lawn mower engine plugs (short nose) based on the engine (marine genset uses the long nose). 

Also, try running it from a 1 gallon gas can with premium gas and an overload of gumout or similar (use a separate fuel line from the can to the fuel pump) to help clean out the fuel system.

CrewLounge

I"ll 4th the plugs. I got rid of the NGK plugs when mine did that. Runs great on Champion for two years now

Black_Diamond

Search on here for Kohler and you'll find several threads on the 5e series and all the mischief they cause.

212rowboat

Kawasaki oughta stay out of generator engines, huh?

For you fellers out of warranty, check out MSD, and liven up your ignition heat.. basically you intercept the charge and blast it to upwards of 45~50k vdc.. doing this will allow for a much wider gap on the plugs, which ensures more positive ignition... A matter of fact, NOT gapping the plugs will ensure they don't last long...... Which, uh, may be the case already present in those engines.. you'll not know until you pull them and read them.

When you guys pull and replace the plugs, what do the tips look like? Rich or lean? Worn electrodes or polished white insulators? Just a curiosity is why I'm asking..

Black_Diamond

Drew, they often look perfect, no wear or 'bad' colors. Thus the replace regardless of condition and it works.

 

I'm not sure how you would add a MSD on the Kawasaki engine?  It uses 2 coils and loops back to the controller.

Capt Ron

I would start by looking at the fuel injection electronics... the heart and soul of the genny.. if it isn't working properly, the genny will not either. I assume it is still under warranty, the technicians should try changing out the electronics first, I doubt the problem has anything to do with pistons since you haven't used it... which is why I doubt it is the spark plugs. If changing the electronics doesn't do it, maybe the cam timing chain might have been installed incorrectly. More likely the electronics IMO.

Dream_Inn

Wow, first off sorry to hear the troubles are still going on.  I can't believe two years and not fixed, I'd probably have that entire unit pulled and out at this point  (I can't imagine not having my generator!!).  ok, now, after some of the obvious mentioned, I'd agree with Ron.  I had issues on my 7.3 that was some from the fuel injectors.  I also had some when it didn't start that was a rocker that was too tight (operating on one cylinder).  For yours, if not fuel injectors or anything fuel related, then electronics.  They should've swapped a few boards by now and checked the fuel pressure.

212rowboat

You intercept the signal and generate a more powerful one with the msd.

unikguy

thank you all for thoughts and comments. i also emailed randy rinker and waiting to see what suggestion he may have. i believe i have been patient enough with this.

I will recommend to the tech all the suggestions that were made here.

 

at this point, yes i agree, just replace the unit and give a working one.

 

thanks

 

Black_Diamond

If can talk them into replacing, pay the upcharge and install a Westerbeke.

pilotmanfran

Oh yeah............plugs. I can't keep enuf spares.

Hope it's that simple

grinner

What state are you in? Most have lemon laws that cover a piece of equipment that has never performed to specs for usually up to 2 years.

I have the FL statute, if you want that. It is 672.608

You basically have an attorney write a letter to the boat manufacturer and the dealer saying that the boat has never performed as spec'd because the generator has never worked. The statute allows you to return the boat and the original sales price is returned. Usually, you give them 30 days to perfect the item or you return the boat. Trust me, they will fix your generator.

Black_Diamond

I know on mine there was a 5 year warranty, time to call them on it to replace. I should have with mine at the time. Hoping my repairs last fall work this summer!!

unikguy

i am waiting to hear from a tech and rinker to see what can be done. I hope I will be able to use it on this 3rd season of boating. lol

Black_Diamond

I'd skip the tech and work with RInker to get it replaced.  I know on my 342 you have to pull the engine to get it out, so it's $$$ to replace.  If it's not working now, it never will (correctly), 10 years and mine has never operated even close to reliable (minutes to maybe 1 hour).  I've certainly found some bugs: plugs, electric fuel pump connection.  I went full press on replacing parts late last summer with some hope of fixing it, (knocking on wood) as of last fall I had it running by leaving the service cover off the sound enclosure.  Go figure.

Black_Diamond

I'd skip the tech and work with RInker to get it replaced.  I know on my 342 you have to pull the engine to get it out, so it's $$$ to replace.  If it's not working now, it never will (correctly), 10 years and mine has never operated even close to reliable (minutes to maybe 1 hour).  I've certainly found some bugs: plugs, electric fuel pump connection.  I went full press on replacing parts late last summer with some hope of fixing it, (knocking on wood) as of last fall I had it running by leaving the service cover off the sound enclosure.  Go figure.

Dream_Inn

There is also a sensor that detects CO and will shut off.  I went thru about a month or so of troubleshooting on mine and thats what a Kohler tech said.  I had a slight leak from the riser area that well, supposedly made the CO sensor go off after taking the boat for a ride.  But there other items on the list as well.  But, it is something else you can check.