Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Electrical System, Overheats, Unit is noisy, Battery will not

Engine (Continued)

Problem	Possible Cause	Corrective Action
Overheats	Improper cooling	Check intake and outlet openings. Check
		coolant level and pressure cap. Check raw
		water strainer.
	Thermostat defective	Replace
	Sea strainer clogged	Clean sea strainer
	Carburetor adjustment too lean	Adjust carburetor mixture
	Engine ignition timing incorrect	Adjust timing
Unit is noisy	Exhaust system leak	Check exhaust system
	Exhaust system not securely installed	Check for loose parts
	Broken or damaged vibromounts	Check vibromounts
	No installation clearance (unit hits craft	Check clearances
	structure or compartment)
	No compartment sound insulation	Install approved insulation
	Excessive vibration engine/ generator	See authorized Kohler service
	(internal imbalance)	dealer/distributor
	Loose or vibrating sheet metal	Check shrouds

Electrical System

Problem	Possible Cause	Corrective Action
Battery will not	Loose or corroded connections	Clean and tighten connections
charge
	Sulfated or worn-out battery	Check electrolyte level and specific gravity
		(batteries with filler caps only)
	Defective battery charging system	Check charging system
	Battery charging fuse blown	Replace fuse. If fuse blows again see
		authorized Kohler service dealer/distributor
Starter does not	Loose or corroded connections	Clean and tighten loose connections
work properly
	Low battery output	Check electrolyte level and specific gravity
		(batteries with filler caps only). Check
		battery voltage.
	Defective starter solenoid	Replace starter solenoid
	Defective start/stop switch	Replace switch
	Defective wiring	Check wiring
Starter cranks	Low battery output	Check electrolyte level and specific gravity
slowly		(batteries with filler caps only)
	Too heavy viscosity lube oil	Use proper viscosity oil
	Loose or corroded wiring	Clean and tighten loose connections
	High starter current draw	Rebuild or replace starter
	Battery cable undersize	See Installation Section--Electrical
		Systems

TP-5695 12/93 Troubleshooting 4-3