Kohler 5E Generator Thermostat

aero3113 · March 2020

I got the thermostat, heat exchanger, coupler and impeller in today. Everything went in with no issues. The hand pump worked perfect to bleed the coolant. Before I started I removed the reservoir and dumped/cleaned it out. I also removed and cleaned up the all of the grounds and power wires, gave them a coat of terminal protector. Hopefully tomorrow I’ll replace the plugs and get the sound shield back on. Once I start it up and run it, I’ll change the oil and filter. Hope the pictures help.

Image: https://us.v-cdn.net/5020499/uploads/editor/mf/2qsngyd4qul8.jpeg

aero3113 · March 2020

I’ll also try and get the fuel filter changed out tomorrow.

reneechris14 · March 2020

Awesome i love pictures

YYZRC · March 2020

I can’t wait to follow your lead (as usual)! My box of Kohler parts arrived today.

aero3113 · March 2020

Awesome @YYZRC ! I saw that kit online.

YYZRC · March 2020

Honestly I’m somehow most excited about the box itself - it will be great for safety equipment!

aero3113 · March 2020

Yes, I just picked up a box like that at Harbor Freight for my safety items. Will definitely come in handy.

https://www.harborfreight.com/Tactical-AmmoUtility-Box-64113.html

Dream_Inn · March 2020

YYZRC said:

Honestly I’m somehow most excited about the box itself - it will be great for safety equipment!

I bought that kit many years ago. I use the box to keep most of my spare maintenance parts.

rasbury · March 2020

So what is this kit you speak of?
My frame and pan for the Genny is about to turn into dust...just about to the point to just get it out of there...

aero3113 · March 2020

They should’ve made the pan out of composite, luckily mine is in good shape. I see the new AC units have composite pans.

aero3113 · March 2020

Changed out the plugs and fuel filter. I’m not sure if the correct plugs were in there, huge difference with the electrode compared the the new ones. The new ones are BPR4ES (6587) the old ones were PGR5A-11 (3537). Or were the old ones just worn out?The fuel filter is in such a bad location, but doable.

Liberty44140 · March 2020

The old ones were definitely the more pointed plugs and not worn, but I think they were not correct, the new ones are the right code. Nice work on the fuel filter, I eliminated mine because I had one mounted to the wall..... per BDs advice....

right plug:

https://www.amazon.com/gp/aw/d/B000CSIS54?psc=1&ref=ppx_pop_mob_b_asin_title

aero3113 · March 2020

If anyone is replacing the fuel filter, loosen the clamp for the fuel line at the barb. Do not remove the hose. Use a wrench to back the barb out of the filter letting it spin in the hose, then remove the filter. To install, spin the filter on the barb fitting by hand then screw the filter in the generator. Tighten the barb fitting some then snug the filter down and then snug the barbed fitting and tighten the clamp. Also use pipe sealant on the threads. Hope I didn’t confuse you!

aero3113 · March 2020

Thanks @Liberty44140

Black_Diamond · March 2020

I got rid of that in-line filter. PITA to get at. Just use an inline Racor filter now.

aero3113 · March 2020

Yea, eventually I might add a spin on filter.

Spyderweb · March 2020

@aero3113 Fantastic photos! I don’t have the mechanic background that so many of you have on this site. But I’m learning so much from reading here, and the pictures add so much. Certainly gives me the confidence to do a little more of the work than I might have done otherwise.

Regarding your spark plugs, I did change mine the 1st year and the old ones were even more pointed than yours. Felt I was really doing something good there.

aero3113 · March 2020

Thanks @Spyderweb , pictures definitely help understand things. I take them for myself for future reference, I have a dedicated 330 photo album. Makes sense to share them!

YYZRC · March 2020

Echoing Spyder’s thoughts and appreciation for the great photos and tips. Can’t wait to tackle this!

reneechris14 · March 2020

The plugs with the point are Iridium plugs. Iridium is a mineral that is very high on the hardess scale. They don't foul out as easy.

YYZRC · March 2020

rasbury said:

So what is this kit you speak of?
My frame and pan for the Genny is about to turn into dust...just about to the point to just get it out of there...

https://www.partsfortechs.com/asapcart/index.php?main_page=product_info&products_id=433

rasbury · March 2020

Nice little kit!

YYZRC · March 2020

What did you gap the plugs to?

Liberty44140 · March 2020

I’ve always bought NKG for the 5e and never gapped them

aero3113 · March 2020

Look at page 32, I gapped them to around .025-.026 .

http://www.sailing.com.br/loja/manual/5-7.3op.pdf

aero3113 · March 2020

They were over .028 out of the box.

Black_Diamond · March 2020

The NGK’s last longer IMO. BPR4ES is correct.

aero3113 · March 2020

That’s good to know @Black_Diamond , I’ve read that the generator likes to go through plugs.

rasbury · March 2020

I need to check the hours on mine but I've had pretty good luck...

YYZRC · March 2020

Lame question of the day - how do I get the sound shield off?! I removed the two bolts from the top panel (at the rear edge) and the single bolt from each end (near the top edge). Do I need to get rough with it?

Thanks!

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