Kohler 7.3E Won't Start

[jsurfwhite]

I had my 2000 356 Aft Deck out for a cruise, with the generator running when we left the dock. Back to dock, generator was not running. Remote switch would not start it. The switch on the unit started it long enough to confirm I had cooling water. After that, the switch would not do anything. When I pulled the hatch, I noticed water on the underside of the hatch. I started the starboard engine, and raw water was spraying the engine compartment from a broken hose clamp at the heat exchanger. Replaced clamp, cleaned engine compartment, started troubleshooting generator, following Kohler service manual. I have 12v at starter switch, continuity at the switch, but LED2 does not energize when I press the start button. Manual says to replace the circuit board. Checking to see if I missed anything before I buy the board. I did not have the enclosure around the unit, so I suspect water got into the control box.

[KeithS]

When you say you have 12v at the starter switch, that switch is actually switching 12v- not 12v+. Is that what you checked for? An unusual but important difference. If water sprayed around, undo the big round multi-pin plug on the back of the black controller box and make sure you don't have corrosion in there. It is not a waterproof connection.

[tomschauer]

check a couple things before you buy the $200+ circuit board. You say it wont start, does it crank? If so, make sure your fresh water (anti freeze) is full, also make sure your oil is full. if you are a pint low on oil, these units will not start.

[jsurfwhite]

Update on my problem with starting my Kohler generator. I replaced the circuit board, and the generator started. All LED's are displaying properly. I still have an issue with it running rich. Under power load, it will stall. I can push the auto choke lever and it smooths out, but returns to the rich condition when I release it. Any thoughts on adjusting, repairing the auto choke? Thanks.

[KeithS]

If you look closely at the black round choke cover, you will see an arrow that says "lean". Loosen the two hold down screws and turn it just a 1/4" at a time to see if that helps. Do it when the generator is cold and un-plug either one of the push on terminals to keep the electric heater element from messing with your adjustment. Make an adjustment, start the generator and see if it works, if not try another 1/4"
There is a vacuum assisted choke pull off that sometimes gets sticky from corrosion, but to check that you would need to remove that black cover. The issue then becomes trying to reassemble properly because there is a bi-metal spring that has to engage a slot just right.
The proper way according to Kohler would be to remove the whole front cover assembly and adjust the choke with a 1/8" gap open when cold. Easier to use the trial and error 1/4" at a time method.

[jsurfwhite]

Tried rotating the choke cover to more lean setting. Found that the vacuum hose is not pulling the choke lever off. There is a slide that goes into a small cylinder that the vacuum hose connects to. That slide appears to be stuck, or there is not enough vacuum to pull it. Not sure where to go from here.

[KeithS]

Stuck piston on the choke pull-off is pretty common. You will have to remove the black cover, paying close attention to which way the bi-metal spring is coiled and how it slides into the notch of the linkage. Then spray lots of whatever your favorite lubricant is. CRC, WD-40 or whatever. I prefer Boeshield T-9, but anything will work. Manually move the piston back and forth until it moves freely. In extreme cases I have had to pry that piston out and wirebrush it. I don't usually waste a lot of time repairing things like this but for a while the choke assembly was not available and the repair kit had an insane $670 price.

[jsurfwhite]

I lubricated the choke lever piston to free it up. Did the trick. I lined up the spring with the notch on lever. Think I got that right. Started cold, however, it was about 90 degrees today. Now on to the sputtering starboard engine. I suspect my fuel separator has water in it. Engine starts fine, will run at low speed, but cannot get above 3000 rpm.