Kohler 7000 oil leak

[Keyair]

Digging about on my computer and I found this short video that clearly shows the issue and why the pipe was leaking!!!

[bkahler]

Originally Posted by Keyair

Steve,

Did you look at the possibility of adding a Street Elbow in place of the plug so the drain point would be pointing down? Or is it too close to the outer shell to do so?

Also, how did you manage to tighten the section of pipe that connects directly to the block? Is there room to turn a wrench in there?

I do like the idea of using the leveling jacks to assist in draining the oil

Brad

[bkahler]

Originally Posted by Keyair

While I am here, anyone know where this rubber pipe on the side of the carb, under the linkage, center of pic should go or be connected to?

Steve,

Just noticed your question. It reminds me of an overflow hose but I'm not sure. When I get home this evening I'll look at mine and see if it has the same hose and if it does I'll see where it goes.

Brad

[Keyair]

Its possible that you would have space...
I planned to put a long funnel in a drain can, and tuck the edge under the drain...

Just remember that the whole thing is sprung to isolate the genset running vibration, and it might hit something... mostly when starting and stopping.
I have since spotted my genset hits the front fan shroud on the drawer slide sometimes, so will have to add a spacer somewhere...
You can almost see it here...
Will have to space the genset tray up, or the slide out away from it... again, it only hits when starting/stopping.

[Keyair]

That pipe...
I pulled it off... to look... and guess what... it is attached to the throttle butterfly shaft... stupid I thought.... what is the point of that!
But wait....
What if the throttle shaft is worn and leaking air at that point....
Maybe a knowledgable tech knows that putting a bit of rubber pipe over, acts as a seal...
Oh boy...

[bkahler]

Originally Posted by Keyair

Its possible that you would have space...
I planned to put a long funnel in a drain can, and tuck the edge under the drain...

Just remember that the whole thing is sprung to isolate the genset running vibration, and it might hit something... mostly when starting and stopping.
I have since spotted my genset hits the front fan shroud on the drawer slide sometimes, so will have to add a spacer somewhere...
You can almost see it here...
Will have to space the genset tray up, or the slide out away from it... again, it only hits when starting/stopping.

I don't have the clearance issue. My generator is set slightly inside the drawer slides so there is no interference. However you have a good point about the generator rocking when it starts and stops. I believe I'll just do what you did and use a pipe plug. No sense complicating matters any more than they need to be

Brad

[bkahler]

Originally Posted by Keyair

That pipe...
I pulled it off... to look... and guess what... it is attached to the throttle butterfly shaft... stupid I thought.... what is the point of that!
But wait....
What if the throttle shaft is worn and leaking air at that point....
Maybe a knowledgable tech knows that putting a bit of rubber pipe over, acts as a seal...
Oh boy...

Interesting. I'll have to keep that in mind for my Triumph SU carburetors

[Keyair]

Oh, on tightening the first pipe section...
1/ Be carefull... the starter solenoid is right there, and if you are stupid enough to forget to disconnect or isolate the chassis battery, you can get a nice healthy spark....

2/ get a nice wind of PTFE pipe tape on both ends of the first pipe length and screw it in the crank case by hand.
Then assemble this part...


Like this...
and screw it on as an assembly... this will tighten both onto the pipe..


Then disassemble the outer part... there was just enough space to ge a adjustable wrench on the large hex...
Then assemble the rest of the pieces as an assembly and that split piece allowes you to put it all back as one..
Then just tighten the large hex and its good to go!

I have to add a spacer between the dipstick tube support bracket and genset body yet as its spaced to the right a little more than originally...
You can see the gap here...

[bkahler]

I managed to complete the oil fill piping mod that Keyair pioneered on his Kohler generator. Using his parts list I went to the local Ace hardware and bought the needed supplies.

Using his pictures as a guide I removed the old filler piping using a sawzall. The cutting went a lot easier than I expected.



As you can see there is an oily mess underneath the generator. And to think that area was spotless back in 2006 after I mounted the generator on drawer slides. In 6 years of mostly just sitting with very little run time on the generator it leaked this badly



One thing I realized AFTER installing the 4" pipe with the coupling attached is 4" wasn't long enough for my genset. It was about 1/2" to short. Not sure why mine would end up being different that Steve's but it was. After looking at it for a while I realized that I could turn the Street Elbow around and use a close nipple between the coupling and the elbow. This pushed the Street Elbow out just about 1/2" which worked perfect, which meant I didn't have to run back to the hardware store

So for anyone else contemplating this mod (highly recommended) I would suggest verifying the length needed before installing the pipe. Once I had it installed I could not get it removed because I couldn't get a wrench on it.



I did have to make one other mod as well. In the Tee where the pipe plug is installed I had to cut a section of the Tee off as it was to close to the metal pan. By sawing off about 1/4" of the Tee there was enough clearance. The plug itself is sitting high enough above the flange that it doesn't make contact even when starting and stopping.



Hopefully this mod permanently solves the oil leak problem. One problem resolved, now about 200 more to go

Brad

[Keyair]

Awesome Brad!
You did the drawer slide mod which I copied... glad to give back!

Was your pipe loose like mine???

[bkahler]

Originally Posted by Keyair

Awesome Brad!

Was your pipe loose like mine???

I'm not sure loose would be the best description, partially installed might be more appropriate

[Keyair]

Originally Posted by bkahler

I'm not sure loose would be the best description, partially installed might be more appropriate

LOL...
Good stuff!
If the mod lasts another 25 years, I will be happy to be around to hear it!

[bkahler]

Originally Posted by Keyair

LOL...
Good stuff!
If the mod lasts another 25 years, I will be happy to be around to hear it!

It probably will but I doubt I'll be around that long...

[69skylark]

Super helpful thread.
I've got an 87 holiday rambler 33 imperial with the 7k kohler gennie. Bought it 6 years ago with 31k miles. Spent a lot of hours under her over the years but it's my favorite Rv. This is my 6th. I've had class C's, a diesel pusher and a B but the rambler has been the best and the most fun. Anyway when I first bought it I had to do the usual new fuel pump and rebuild carb to get the gennie going. Low hours and runs like a champ. But for some reason always leaked some oil. I realized last year the oil fill was loose in the crankcase. I just finished the solution you guys described. Perfect! No leaks and still runs like a champ. Thank you!!
See pic