1990 Winnebago Warrior Kohler generator

[brianokeefe]

Hi All,

My 1990 Warrior has a Kohler generator. It has not had any maintenance since I bought the RV used (73K miles). The gen ran fine until one night it just quit. It turns over fine and fast but never fires. I'm going to replace the plug but it may be a fuel issue (clogged line, carb, etc). The plug is easy to access and replace but the fuel issue would be much harder because of access. Any brilliant ideas?

Many thanks!!!

[brianokeefe]

Well I tried everything that I can do diagnostically. I finally took the RV to a service shop. The tech is just amazed at how inaccessible the gen-set is and that simple things are just not able to be gotten to without pulling the entire unit. Now that is frustrating. I can see the fuel pump but can't get to it and that may be the problem as there is no fuel odor even when choked. I'd install a new one if I could access it. Pulling the set looks almost as impossible. I have the installation manual but even getting to anchor bolts/nuts is ridiculous. The tech said a minimum of $500 but if he could at least access the fuel line he could determine fuel supply but even he can't! What a ridiculous set up.
So I think I'll keep an eye out for a stand alone generator that I can just set off and plug into if I need to. I rarely need the gen. so even not having one isn't the end of the world. I have an inverter and solar charger so maybe that will be enough for my simple needs.
Thanks for all the input!

[brianokeefe]

Well, the oil and gas weren't a fix. I need to manually reset the oil level switch. The PDF manual I downloaded states this and also has a completely unreadable photo of the switch location. I cannot find the switch and have no idea where it is. Any help out there?

Many thanks

[brianokeefe]

Well, I still need to find that reset button. It's in the PDF version of the manual but the photo is too poor to actually use it for help. But apparently that reset must be done if the generator stops working due to a low oil level, which mine had.

[TyroneandGladys]

Sounds strange but some times to get my generator to start I have to have the RV running

[Gjac]

Based on what you did already I would remove the spark plug and check for spark, no spark ohm out coil. Your Koehler may have points, check gap and also check gap from the coil to the magneto with a match book cover. If you have spark remove hose going to carb an crank genset, does gas squirt out? If not remove line from fuel pump intake that comes from your main gas tank and connect a piece of hose there to. draw from a gallon gas can. If you try these simple things and post back you will be able to narrow down your problem.

[brianokeefe]

changed spark plug, added oil, gassed up and no firing after many times turning it over. Is there some sort of reset?

[brianokeefe]

I'm sure that's it-I hope. But it seems the most reasonable

Thanks

[DrewE]

I'm almost willing to bet money that the 1/8 tank of gas is the whole problem you're having. Obviously it's a good idea to have the oil at the proper level, as is doing whatever other maintenance is reasonably needed.

[brianokeefe]

Found the manual so I should be good to do the maintenance and then fuel and oil up and I'll bet she works!

[brianokeefe]

it's a Kohler 2.5 25CZ

[brianokeefe]

Thanks all,
I'm looking for a manual now. The oil is low and I only have 1/8 tank of gas! I'll fill the oil once I get the manual. I want to replace the plug, no problem there. Accessing the filters looks like a pain so far.
So I do need a good maintenance session as I've written, this RV sat for 2 years unused, unopened in Houston. The plastics are cracked and breaking but I can repair those. I've already repaired the fridge and furnace (twice). Now the water pump isn't pumping though I did pump it dry for the season and left all the faucets open. Would that make some sensor not start the pump?
Thanks again. It's a learning curve!

[Matt_Colie]

I would be willing to bet that there is a manual on-line that you can download. Then you can catch up on the maintenance. I don't even know what model and spec it is or I might just venture an opinion where to start.

Matt

[brianokeefe]

I'll check the oil. I wouldn't know where the pressure switch is.

Thanks

[DrewE]

Perhaps a silly question, but is your gas tank low? Motorhomes are often set up so that the generator fuel intake is at approximately the 1/4 full height in the gas tank so that you can't strand yourself by running completely out of gas running the generator. It's not always a precise level.

It's also possible that the fuel pickup tube in the tank fell off or developed a hole and you aren't getting gas for that reason. It also would not hurt to check the fuel pump for the generator (it presumably has one) and typical small engine repair things.