Kohler 5e......what else do I need to change??

DanD2

Soo many posts about problems with this generator. Having surging issues with mine...does it with or without a load. Here's what I've done, changed plugs, cleaned spark arrestor, changed fuel separator, put on brand new carb, put on brand new fuel pump.....What am I missing here guys?

On a side note.....I have a good used carb and fuel pump for sale!

Black_Diamond

Surging is a lean running issue. Have you checked both cylinders are firing?  It will run on one till you load it. 

DanD2

Both plugs looked the same so I just assumed they were firing. I'll check for spark on both tomorrow. It surges even under load.

Black_Diamond

The electric choke can be an issue too. Did you replace it or reuse it?  Are you running without the sound cover service door on?

DanD2

The electric choke was new year before last and it moves without any hang ups. Any manual manipulation of the choke does not help the surging. I've always run it with the cover on without issues, cover has been off while I've been troubleshooting it and it doesn't make a difference.

Black_Diamond

So moving the choke makes no difference in the surging?  Usually closing it some helps. I would look for a vacuum leak. Run the engine and spray some starting fluid around the intake manifold, if it accelerates you found the leak. It is running lean for some reason. You might pull the anti-diesel valve out and make sure it is clean and working. They do fail and would cause a lean running engine too. 

DanD2

I'll try the starter fluid trick to see if I can find a leak. Anti-diesel valve is new.

zaverin1

I would also say that it could be the choke
vacuum leak
or fuel delivery
i worked on my friends same gen model last year.
rebuilt the car and had to adjust it under load.
put a new impeller in it 
then had to replace the choke
his boat came from the salt so choke was rusted shut.
also make sure all tension springs are there and installed properly.
if not it wills surge.
easy way is to unhook the choke and manually open the butterfly to see if it levels out.
Make sure fuel pickup is not clogged and still there.
since it used a regular nylon tube that fits into the tank it sits so wen you are 1/4 tank gen will not start. That way it will give you fuel to start engines and get more fuel.
on that note carefully unscrew the gen pickup and inspect the pickup tube.
fuel pump is low pressure so if it fell off or has cracks it will starve the gen for fuel. On my buds boat I took the hose off and by manually starting the gen put the hose to my lip to check for suction.
had strong pull so it eliminates the pump
when I checked the fuel pickup there it was. Cracked tube that was partially broke.
there is no filter on it since they have a inline fuel filter.

Black_Diamond

Get rid of the filter that screws into the fuel pump and use a good in line type.