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Old 16-10-2019, 07:51   #1
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NEEDED - AFTER MARKET STARTER 4 KOHLER 5 E Generator

KOHLER GENERATOR
MODEL 5 E Marine- gas
year built 2002
Needs - Starter # 359924
Electric engine is a Kawasaki 2 cylinder # FD501D-DS04
Hour meter 255

Boat is a twin gas engine power cruiser
Generator mounted under deck , along side port engine
Impossible too get too with port engine blocking it
Primary use 2 run A/C under way or on hook .
I stay at marinas.
Started often maintained best I could until one day, cloud of black smoke
coming from engine room Scary,
Looked like boat was on fire . Coming from generator
Unable too check further with engine blocking .

Recently Port engine was pulled. Access too pull generator
Lots of rust , Crank Frozen , Starter dead
Removed starter , it had the same smoke smell . .
After a weeks soaking generators fly wheel turns
Why did crank freeze ?? water entered piston , freezing taking out
starter or both had failure same time ??
Finding a starter has been a challenge
Kohler & Onan stopped making gas generators years ago
Parts scarce , Costly No after market
Rebuilding spending 5 thousand on a generator never used ,
buying new ?? 10 thousand .
If I need a generator a portable Honda would fire up a 9000 BTU -a/c
Lot cheaper ,
Curious to see if I can get generator running .
I did locate a Kohler Dealer starter . $ 499.00 not spending
that much money too test .
Seeking a cheap o China after market
Spoke with a number of on line small engine supply. They offer
thousands of starters for every engine except the Kohler marine .
No numbers crossing over
Anybody have knowledge ?
Will hit lawn mower shops ,
Ebay- presently nothing
NAPA is knowledgeable , might be able too match up
Will contact alternator / starter rebuilding shops providing they
can get parts too rebuild .

HAVE U HUGGED YOUR BOAT TODAY ??
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Old 16-10-2019, 08:01   #2
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Re: NEEDED - AFTER MARKET STARTER 4 KOHLER 5 E Generator

I have some experience with "after market" starters. I was running the service department of a charter company and had a couple of starters on Yanmars die. I thought I was so very clever I found replacements for $125 instead of ~$500 OEM

None of them lasted more than 3 months. On one the housing shattered sending fragments of metal into the flywheel housing of the engine. Cost us $1000's to rip it apart and pull out all the bits.

Cheap Chinese crap. Just say NO.
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Old 16-10-2019, 08:45   #3
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Posts: 74
Re: NEEDED - AFTER MARKET STARTER 4 KOHLER 5 E Generator

Thanks for getting back , YES I KNOW , a concern . If I get
generator working , once back in place I have zero access too back too replace
a in expensive starter . It will get wet ,
I am testing and a cheap o would work for that purpose
Might not be worth fixing gen set .
I had similar issues with electric fuel pumps cells on Volvo Penta ,
Pumps are Carter
VOVLO PENTA list $ 900.00 each - when I first got boat wanted too keep
everything as it should . After 1 year , one pump , crapped out .
Good thing I had dealer install , Volvo Covered . Other pump got 3 years .
Might think your getting a better product cause it says Volvo , all about the bucks , Says Volvo , possibly made in China ? who knows
Not paying $1800 again .

In the mean while I purchased Cheap O China exact Volvo Penta fuel pump
cells , look identical except the aluminum not as heavy $ 189.00 each on Amazon . After a year , SO FAR SO GOOD .
I have the heavier duty Volvo Penta ,will install new cells so I will have back up
I just called a alternator / starter rebuilder that worked on a old collector car
I had years ago .
He said bring it over , he can rebuild most
If this guy can rebuild with same casing solves present and long term .
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Old 16-10-2019, 17:17   #4
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Re: NEEDED - AFTER MARKET STARTER 4 KOHLER 5 E Generator

Alternator shop had one sitting on his shelf
Rebuilt ,
He did say that particiar starter is a hard find .
This guy does quality work .
Gave him my old one .

Fresh gas , water running thru , charged battery , keep your fingers
crossed it fires up ,
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Old 16-10-2019, 21:19   #5
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Location: Tacoma, Washington, USA
Boat: Casacde 36
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Re: NEEDED - AFTER MARKET STARTER 4 KOHLER 5 E Generator

Try DB Electrical, on line. Yep they're Chinese but my Yanmar has been operating one for 5 years now, and we live aboard, and cruise, our boat for 4 to 5 months per year.
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Old 17-10-2019, 03:14   #6
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Re: NEEDED - AFTER MARKET STARTER 4 KOHLER 5 E Generator

DB was one of the companies contacted , along with Jacks small engines
plus 2 others ,
Took a chance on one, from DB, received , ng .
Just received return label
Few I spoke with over the phone , very nice, try too help but only
work off of numbers , Challenging ,
As I said I did find one sitting on a shelf at my local alternator/ starter
rebuilding shop ,
Installing hopefully today
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Old 17-10-2019, 11:38   #7
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Re: NEEDED - AFTER MARKET STARTER 4 KOHLER 5 E Generator

Observation: When installing the starter, I did notice that the mounting flange did not have a small cut out that the original had. It's not really a cut out, more of a small indentation of the flange edge. Doing a trial fit, I noticed that it bore hard against the pipe that feeds oil to the overhead gear also. So....I got out my trusty angle grinder and changed the profile slightly, testing the clearance with a piece of cardboard. Maybe this interference caused the nose cone to fail?
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