Hi All,

I have a 1987 Barth with a Kohler generator. It is marked as a 593R, Model 4.5CKM21-RV, Serial # 194350. It was running this spring and when we changed the oil we put new spark plugs in. The problem is that when you press the start switch the starter motor runs but does not engage the gas engine. I am looking for any help I can get to find out how to repair it or get a replacement part.

Regards,

Jim

Sometimes a Kohler starter just needs a little clean and lube to the starter drive. I don't have a picture of your gen in my head, but you might be able to squirt a light lube like LPS1, CRC 2-26, or similar in there without removing anything.

Be sure all connections are clean, tight and bright. Be sure there is a heavy ground wire from a starter mount bolt to the MH chassis. Lots of starter problems go away with a really good ground.

Does it do any better when a start is attempted at the start switch right on the genset?

Also, with starters the old adage, "Don't force it - get a bigger hammer" applies. Have someone engage the starter while another taps on the side of the starter; sometimes this is enough to free up the solenoid. But as bill h suggest, first check the electrical connections.

Usually, Percussive Therapy is just a one-time fix, but it will get you going until you can do a proper repair.

Our BAE 146s had 4 jet engines with a Lucas electric starter for each. I was a Boy Scout and replaced every starter that needed the hammer whenever I had time. It turned out that the new ones were equally in need of the hammer, so I quit replacing them.

I have a starter like that in my 4WD right now. About every hundred times. Lifetime warranty, but new ones get that way, too. In this case, it is not a solenoid problem, as the voltage drop can be observed. But no rotation.

quote:

Originally posted by bill h:
Usually, Percussive Therapy is just a one-time fix, but it will get you going until you can do a proper repair.

Our BAE 146s had 4 jet engines with a Lucas electric starter for each. I was a Boy Scout and replaced every starter that needed the hammer whenever I had time. It turned out that the new ones were equally in need of the hammer, so I quit replacing them.

Lucas: "Prince of Darkness". The hammer thingy will get it going so's you can lubricate the solenoid, but in most cases, the starter has to come off, be disassembled, and the solenoid cavity cleaned and lubed (I recommend Super Lube Grease). The problem is that solenoids tend to rust easily unless used frequently.

The solenoid does indeed need disassembly to properly clean and lube. My original response to the OP related to the starter drive, which often sticks on the shaft and can often be cleaned and lubed with spray. If the solenoid plunger sticks, it is unlikely that the contacts will allow current to flow to the starter itself. Jim's starter is spinning, so we can assume the solenoid is traveling to the end of its stroke to make the washer bridge the two contacts. But a spinning motor means it is most likely that the starter pinion teeth are not engaging or the sprag is slipping. I have not gone inside a Kohler sprag, but my BMW motorcycle gets crabby about starting if it gets a gummed-up sprag. Squirt therapy is often the fix. However, a full-travel plunger usually also means pinion engagement, so we are back to the sprag. But squirting is still worth trying. Hope springs eternal.

Rusty,perhaps your gen is more like Jim's, and you could advise on squirting. Mine is a 7.5, and may be configured a little differently, but it has fairly good access for little spray tubes. It needed a shot when I bought it, and every two years or so since.

My thanks to all who have replied. Bill you are correct, it's not an electrical problem but mechanical. Squirting sounds like the next step and if that does not work..I suspect the only thing to do is take the starter motor apart..ugh !!

Jim

quote:

Originally posted by JMF:
and if that does not work..I suspect the only thing to do is take the starter motor apart..ugh !!

Jim

Think positively..............if you do take it apart and make things right, it will be good for another 20 years. I would guess that the contacts inside the solenoid would benefit from a little dressing with a file, too. Sometimes you can turn them around to expose unpitted metal for better contact.

Hi All,

Good News, the generator is working. Just needed a little more cleaning of the starter motor. Off to Boothbay Maine for the weekend.

Thanks for all the help,

Jim

Get a little lobstah, ayuh!

quote:

Originally posted by JMF:
Hi All,

I am looking for any help I can get to find out how to get a replacement part.

Regards,

Jim

Oh, yeah............neat place for generator parts