89 Kohler genset won’t start

[CptBacardi]

I have the heat exchanger. I’m on my way now. I’ll check fluid levels, sensor connections, and perform a reset. Will report back in about an hour.

[CptBacardi]

Well crap. I verified it’s a 7.5R23 relay model, not solid state. Oil level is fine. Water level is fine. Connections appear ok. Battery is weaker now. It won’t start.

[CptBacardi]

I assume that if I am seeing at least a weak and intermittent indication of spark coming from the magneto to the spark plugs via the in-line spark tester bulb that the controller “C” relay is giving the OK for the engine to start and run, right?

[ColRon]

The “C” relay energizes the starter and the choke. The “CR” Relay has contacts that are normally closed that grounds the magneto that open and normally open contacts that closed to energize the voltage regulator, temp and oil pressure circuits. Check page 5-7 for the starting sequence. Page 5-4 has your voltage checks and where to check.

My understanding is that the Kohler L654 is a pretty robust engine and was used in several differing generator models. While it could be your magneto, some of the threads I’ve read on it on a vintage generator site, it is not common.

A word of caution, close your raw water valve before you turn over the engine a lot, as you are pumping water whenever the engine turns. In turn this water must exit via the exhaust system and without the engine running that water can back up and enter the engine through the exhaust valves.

That said, I would first pull the number one plug and with it removed and grounded, I would check for spark at the plug itself. If you’re getting a spark at the plug, then check each one. If they are all getting spark then it’s likely there nothing wrong with the ignition system.

You said earlier that the plugs were dry when you pulled them. It makes me wonder if it is getting fuel. If the problem were ignition related, I would expect wet plugs.

I wish I had an engine manual for the L654 engine...if it is determined that it is a purely ignition issue you will like need one to do any repairs/testing for the magneto.

[ColRon]

I just found an Engine service manual. Here is the link:
https://drive.google.com/folderview?id= ... sp=sharing

[CptBacardi]

Thanks ColRon. I did notice some fuel on top of the mechanical fuel pump, but I didn’t investigate further. We got “marina’ed” so I closed it up. As time allows I’ll continue with it. Thank you for your help and the link to the manual. I promise I’ll follow up with updates.

[CptBacardi]

I think I need to replace the fuel pump, but I can’t find one online. Any ideas or links?

[bud37]

What leads you to the pump being bad ? Before you go any further make sure the needle valve in the carb is not stuck shut, have a look in the float bowl to see if any fuel.

Those pumps are completely rebuildable, but where to get one or a kit is a good question....the l654 engine has been around for a long time in lots of different machinery. Have you checked with any local generator dealers, not just marine .

I will add, your dry plugs usually shows a no fuel condition. Have a look at the fuel line from the tank to the pump, check for kinks, leaks etc.

[ColRon]

I agree with Bud37, check everything first. If it is your fuel pump, the repair kit for the pump is Kohler part # 241197 and is no longer available, unless you find some NOS somewhere. From a quick check it appears that they now have an electrical fuel pump replacement kit. Part #GM73506 for marine sets. The GM66011 is for RV applications.

[AnamCara]

Just an FYI, If the problem lies in the magneto, contact Mainley Magneto's in Maine, the have the parts and service and are much cheaper than going thru kohler. Good Luck