Hello....i have several problems and questions. All related to my Kohler Confident 5 generator. Just bought the rv the generator is on a few weeks ago, so I have limited use and knowledge with it. It ran like a charm the first week, only occasionally shutting down randomly while we were driving down the road. This last weekend, it shut off several times on the first leg of the trip, only to fire right back up (basically). Then the next day on the return trip it ran for a while, then shut off. Then when it started it only would run for 15-30 seconds, then shut off. We stopped starting it after we realized it would not stay running. Then when we returned home I went outside to start it and it would crank for 5 seconds, maybe less, and then let out a loud squawking noise. Sounded to me like maybe it was the starter not disengaging from the fly wheel? Does that sound right. It seemed like it was maybe about to start when this would happen, but thats hard to tell with how loud the squawk was. My second part I need to figure out is if I need to take the genny out of the rv. There is a silver line that is apparently holding wires and I'm not sure how to disconnect them. Also, where can I get an air filter for this generator, and does it use a fuel pump, and where is it located. Thanks

I believe that this had the magnum 20 HP engine on it. If so this is the service manual for just the engine: http://www.kohlerengines.com/onlinecatal...

This engine has a mechanical fuel pump and is located in the top of the engine. Just follow the fuel line backward from the carb. The fuel pump is the next connection away from the carb.



THe service manual for the genset appears to be TP-5394.pdf I have not downloaded it yet as it is quite slow here at the moment. (3%) Let me know if the link below does not work.



http://www.partsfortechs.com/pdf/kohler/4ckm_and_5ckm_serv_man_tp5394.pdf



As far as the starter goes... I know I said NOT to do this but.. use some 30 wt oil on the bearings (they are brass oilite) I am reluctant to tell you to take the starter apart as the brushes will break if you have never done it before.



Going to send this off for now so you will have the links. Ask any questions you wish anytime. We will get this up and going again.



Kelly I believe that this had the magnum 20 HP engine on it. If so this is the service manual for just the engine: http://www.kohlerengines.com/onlinecatalog/pdf/tp_2204_b.pdf
This engine has a mechanical fuel pump and is located in the top of the engine. Just follow the fuel line backward from the carb. The fuel pump is the next connection away from the carb.

THe service manual for the genset appears to be TP-5394.pdf I have not downloaded it yet as it is quite slow here at the moment. (3%) Let me know if the link below does not work.

http://www.partsfortechs.com/pdf/kohler/4ckm_and_5ckm_serv_man_tp5394.pdf

As far as the starter goes... I know I said NOT to do this but.. use some 30 wt oil on the bearings (they are brass oilite) I am reluctant to tell you to take the starter apart as the brushes will break if you have never done it before.

Going to send this off for now so you will have the links. Ask any questions you wish anytime. We will get this up and going again.

Kelly

The starter is a breeze to disassemble. The problem is getting the brushes held back out of the way to slide the armature back in. The whole thing comes apart by removing 2 through bolts and popping off the end caps after unhooking the main positive lead. The engine manual link I sent you has the starter break down on page 84. (TP-2204) I checked the generator service manual and it just says use the engine manual. Neither one is specific on starter repair. If you have any mechanical abilities at all you can take the starter apart. The hard part is carefully getting the brushes over the armature slip ring. The whole process to take it apart.. clean and lube it is less than 15 minutes. The bearings are in the end caps for this starter. Since the bearing are in the end caps it means the bearings are pretty thin. You can probably get by with just lubricating the bearings with turbine oil. Turbine oil is a paraffin based oil and you can get it in the form of Zoom-Spout Oiler that is in most hardware and appliance parts stores (<-cheap) or Union 76 turbine oil at automotive stores (<-expensive) Lubricate the bendix also (<-the geared piece)

You can take it somewhere to have this done but I would bet they would charge $30 - 50 to do it. Most store front lawn more repair shops will fix these starters.



Kelly
The starter is a breeze to disassemble. The problem is getting the brushes held back out of the way to slide the armature back in. The whole thing comes apart by removing 2 through bolts and popping off the end caps after unhooking the main positive lead. The engine manual link I sent you has the starter break down on page 84. (TP-2204) I checked the generator service manual and it just says use the engine manual. Neither one is specific on starter repair. If you have any mechanical abilities at all you can take the starter apart. The hard part is carefully getting the brushes over the armature slip ring. The whole process to take it apart.. clean and lube it is less than 15 minutes. The bearings are in the end caps for this starter. Since the bearing are in the end caps it means the bearings are pretty thin. You can probably get by with just lubricating the bearings with turbine oil. Turbine oil is a paraffin based oil and you can get it in the form of Zoom-Spout Oiler that is in most hardware and appliance parts stores (<-cheap) or Union 76 turbine oil at automotive stores (<-expensive) Lubricate the bendix also (<-the geared piece)
You can take it somewhere to have this done but I would bet they would charge $30 - 50 to do it. Most store front lawn more repair shops will fix these starters.

Kelly