Poor coolant maintenance most likely.Only 63 hours.... Begs the question, why would someone be drilling out a core plug on a motor with only 63 hours on it.... :shrug:
The generator has a few years in it and the water pump was changed as well as the freeze plug directly behind the pump was also replaced most likely at the same time. Both the pump and plug were not painted kohler yellow unlike the rest of the motor. Exactly why the freeze plug was replaced??? Good question. Could be as Birken Vogt suggests - poor coolant maintenance resulting in the freeze plug to rust and leak, so the pump and plug were replaced at the same time and the mechanic accidently drilled too far? Aside form the damage and the mess, all the parts of the motor look new. The crank is in perfect condition. No signs of wear or anything abnormal. Starter works like new. The ring gear on the flywheel shows absolutely no signs of wear. It all looks new. It would be the perfect motor that anyone would want if there was no damage.Only 63 hours.... Begs the question, why would someone be drilling out a core plug on a motor with only 63 hours on it.... :shrug:
No worse than the four year old 25kW Generac standby set I took out of a $1.5M home in Terre Haute, IN due to the cost of replacing a failed ignition module. Generac charged around $2000 for the module, and once we factored in the expense of travel time, mileage and repair time we were close to 50% of the cost of a new unit.What is the future of this Kholer? I have plans to use the outdoor enclosure for one of the other sets, and dismantled the rest of it. Whatever is junk such as the block will be brought to the recycling scrap yard. Other parts such as the injector pump, starter, alternator, and whatever will be inspected and stored away until someone needs a part that I have. Parts such as the meters will be used in my future projects to cut down on costs.
That's about it! It is a shame that one little mistake by a tech (or who ever decided to remove the freeze plug) can cause catastrophic failure in a matter of seconds by drilling too far and through the cylinder wall. It was an expensive and unfortunate situation for the original owner of this Kohler, but as they say, "Sh1T HapPenS".