Kohler 5E Generator Battles to start and surges when running.

[Captain_CGC]

Greetings.

I'd really appreciate some advice on my Kohler 5E generator.

My generator was spitting fuel out the air intake when running, it was also surging. Clearly spitting fuel into the engine bay is a major safety hazard.

I removed the carburetor and found that it was all clogged up and decided to buy a brand new one.

I installed the new carburetor and the engine battles like crazy to start, once running, it surges, more accurately it hunts to stay at operating RPM.

I need to spray a ton on starter fluid into the carburetor before the engine starts.

I've searched the internet for answers, and mosts state to set the fuel air mixer, which I've done or at least I think I have. I cannot find a single diagram that shows what the different screws on the carb are. I think I'm adjusting the correct one, it's the screw with a black plastic cap on it just below the throttle linkage.

The manual for the carb states, that it's all preset at the factory, and offers no guidelines on how to set it if it requires adjustment. I'm sure that it should not be necessary to buy a new carburetor whenever it needs minor adjustment.

I've replaced everything there is to replace (plugs, carb, oil, impeller etc.) on the generator. I did not replace the electric fuel shut-off valve.

I'd appreciate any advice on adjusting the generator and getting it to running properly. I'll even pay for advise, it should not be so hard to get a simple engine to run properly.

Thank you in advance.

Carlos.

 

[alldodge]

Is the choke staying full open and not moving when its surging?

 

[Captain_CGC]

Hi

Yes, the choke stays fully open. the throttle is opening and closing.

I replaced the fuel pump today with a 4 psi pump, similar to OEM. The generator now occasionally starts without needing starter fluid, so that seems like progress.

I'm amazed that a simple 2 cylinder engine can be a source of so much frustration.

As stated in my first post, I installed a brand new carburetor and was expecting it to run well. I removed the carburetor today and opened it up, as expected everything looks new and I don't see anything visibly faulty.

I adjusted the fuel/air mixture screw, but it seems to make little or no difference whenever I make adjustments. Which is weird because adjusting the mixture typically results a noticeable change in engine operation..

I appreciate the help.

Regards.

Carlos

 

[alldodge]

I have a kohler Gen and its hard to start, but for the most part its because I never use it. Start it up at least once a season to get oil flowing and that's it

Have read several threads about brand new carbs being bad. One guy on the searay forum went thru 3 carbs by a kohler Tech before they fixed his issue. Most all cases the surging or hunting is caused by the carb not flowing fuel correctly

Do see your posting to that forum as well

 

[Captain_CGC]

Thanks for responding. I also suspect a bad carb. I've done everything recommended by those with similar problems. I'm wondering if there is not a generic carb that one can use for this generator.

This is very frustrating.

Take care.

 

[Alumarine]

Can you not clean your original carb?

 

[vroom ZOOM]

spitting fuel out the carb almost seems like a valve issue. Had a genny where the valve guide was so worn that the cylinder pressure would go back out the carb. Might not hurt checking compression IMO.