KOHLERGHGINES Single Cylinder Engine SERVICE MANUAL K91, K141, K161, K181, K241, K301, K321, K341 =,SECTION 1. SECTION 2, SECTION 3. SECTION 4. SECTION 5, SECTION 6. SECTION 7. SECTION 8. SECTION 9. SECTION 10. Disassembly .. SECTION 11. Inspection and Repair .. SECTION 12. Reassembly .. CONTENTS General Information Special Tools Periodic Maintenance Troubleshooting . .. Air Cleaner And Air Intake System Fuel System And Governor .. Retractable Starters Electrical Systems And Components .. Automatic Compression ReleaseGENERAL INFORMATION SAFETY INFORMATION For Your Safety! SECTION 1 These safety precautions should be followed at all times. Failure to follow these safety precautions could result in serious injury to yourself and others. AA WARNING AWARNING & 4 WARNING Expioave Ful ‘oan eaute tres and severe Stop eng beloe ing Rotating Parte can cause severe injury, Sy away wee erg is in opeaton Hot Pars ean cause severe buns Do not tuch eng wile poerang oust to" stopcng WARNING: Explosive Fu Gasoline is extremely flammable ‘and its vapors can explode if ig- nited. Store gasoline only In ap- proved containers, in well. ventilated, unoccupied buildings, away from sparks or flames. Do not {ill the fuel tank while the engine is ‘hot or running, since spilled fue! ‘could ignite if it comes in contact with hot parts or sparks from ignl- ton. Do not start the engine near spilled fuel, Never use gasoline as a cleaning agent. Keep hands, feet, half, and clothing ‘away from all moving parts 10 pre- vent injury. Never operate the en- gine with covers, shrouds, or guards removed, WARNING: Hot Parts! Engine components can get ex. tremely hot from operation. To pre- vent severe burns, do not touch these areas while the engine is run- ning—or immediately after itis tumed off. Never operate the engine with heat shields or guards removed. 14[A WARNING| Prao% (WARNING AA\WARNING an ea [aecentar Stare Joon cause sovere nury Joreath. bisceanect ec run spark pup oa bat tare, WARNING: Accidental Starts! Before servicing the engine or equipment, always alsconnect the ‘spark plug lead to prevent the en- gine from starting accidentally. Ground the lead to prevent sparks that could cause fires. Make sure the equipment is in neutral CAUTION: Electrical Shock! ‘Never touch electrical wires or ‘components while the engine is running. They can be sources of electrical shock WARNING: Overspeed Is. a Hazardous! ‘Do not tamper with the governor setting. Overspeed is hazardous and could cause personal injury. A WARNING: Flammable Solvents! Carburetor cleaners and solvents are extremely flammable. Keep sparks, flames, and other sources of ignition away from the area. Fol- Jow the cleaner manufacturer's warnings and instructions on its: proper and sate use. Never use gasoline as a cleaning agent. 12 Carbon wononide fatndeg or Seat Do at pert ena @ Saris Roa i batoroe can cause severe ry Jorerge on n wot vertiation Resour oan WARNING: Lethal Exhaust Gases! Engine exhaust gases contain poi- ‘sonous carbon monoxide. Carbon ‘monoxide is odoriess, colorless, ‘and can cause death it inhaled. ‘Avoid inhaling exhaust fumes, and ‘never run the engine in @ closed building or confined area. WARNING: Spring Under Tension! Retractable starters contain a pow- ety, fat wire recoll spring that is. under tension, Do not remove the Center screw from the starter unti the spring tension is released. Re- ‘moving the center screw before re- leasing spring tension, or improper startor oisassembly, can cause the sudden and potentially dangerous release of the spring. Always wear safety goggles when servicing retractable starters —full face protection is recommended. To ensure personal safety and Proper starter disassembly and reassembly, follow the procedures in this section carefully. WARNING: Dangerous Acid, Explosive Gases! Battories contain sutturic acid. To Prevent acid bums, avoid contact with skin, eyes, and clothing. Bat- teries produce explosive hydrogen ‘gas while being charged. To pre- vent @ fire or explosion, charge bat- terles only in well-ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batter- jes out of the reach of children. Re- move all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure al! switches are OFF. If ON, a spark will occur at the ground cable ter- minal which could cause an explo- sion if hydrogen gas or gasoline vapors are present.ENGINE IDENTIFICATION NUMBERS When ordering parts, or in any communications: The engine identification numbers appear on a de- involving an engine, siways give the model, speci- cal (or decals) affixed to the engine blower hous- fication and serial number of the engine. ing. Refer to Figure 1-1. The si numbers Is shown below: AA /kontenaiae (roms) —* oo ; Biceeeeee tp e Figure 1-1. Location of Engine Identification Decal. A. MODEL NO. vermen Gees = Spocta O1 Pen Ko. PT @ 7 chen moset 4 & - Generator Appteston P = burp Modal = Gilt Model R = Reduction Gear Single 8 = Elctrc stat iSeries Engine Displacement Cylinder T - Retractable Start (Ga. in) SF = Electr start And Retractable St ep ~ Electric Plant 8. SPEC NO. Engine Model Code. code 60 1245 fet, 34 nie FA i 2 0 % ° Variation of 7 Basle Engine n C. SERIAL NO. E-172482] 9076430 10026692 7501807591 u u Ly u ‘A etter Fret Two Dit /1t | Frat Thee Digte /# | Fret Two Digts / I Ten Seven Omit Nurbor | Elm Dot Number | _ Digt Nuber 7% 1966 70191950 100-109 1980 18 1985 8 i866 pas 1970 Hots tse 18 (986 c 1987 foes tart tzo-t29 $982 17 Seer o toe fea tor 130-129 toe te 1569 © 1980 sess 1998 Mo-t4s tot 13 1889 foe. t974 150-159 1988 201900 jor 1878 at toot ise 1978 22 1992 foe 1997 23 1099 so t9re be i968 S50 1978 251995 Remaining digits are @ factory code, Figure 1-2. Engine Identification Decals. 1.3OIL RECOMMENDATIONS Using the proper type and weight of oil in the engine crankcase and in the gear reduction unit is extreme- ly Important, as is checking oil daily and changing oil regularly. Failure to use the correct oil or using dirty oll causes premature engine wear and failure. Oil Type Use high-quality detergent oil of API (American Pe- troleum Institute) Service Class SF or SG. Select the viscosity based on the air temperature at the time of operation as shown in the table. Recommended SAE Se | a cz EEE oe eo a RANE EXPECTE Straight 30-weight oil is preferred. SAE 10W-30 and 10W-40 are not recommended above 32°F (0°C). Using these oils substantially increases oil ‘consumption and combustion chamber deposits. NOTE: Using other than Service Class SF or SG oil ‘or extending oil change intervals longer than recommended could cause engine damage which is not covered by the engine warranty, A logo or symbol on oil containers identifies :he APt service class and SAE viscosity grade. Check Oil Level Check oil lover BEFORE EACH USE. Check gear reduction uniot oil level by removing the drain plug on the lower part of the cover. Gi level should be up to the bottom of the plug hole. If oil level is low, remove the vented plug at the tep of the cover, add cil until it reaches the bottom of the drain plug hole, and replace drain plug and vented plug. NOTE: Do not operate the engine with the oil level below the “L" mark ar over the “F* mark on the dipstick. Read level Remove from block Place on shoulder Bayonet Push down on tube Read level Figure 1-3. Dipsticks And Oil Fill Tubes.Change Oil For a new engine, change oil after the first 6 hours of operation. Change oil every 25 hours of operation thereafter. For an overhauled engine or one rebuilt with a new shortblock or miniblock, use straight 30-weight Service Class SF or SG oil for the first 5 hours of operation. Change the oil after this initial run-in period. Refill with Service Class SF or SG oll as specified in the table. Change oil every 2 operat- ing hours thereafter. FUEL RECOMMENDATIONS & waswinc: explosive rue Gasotine may be present inthe carburetor and fuol system. Gasoline is extremely flammable and it can explode ignited. Keep sparks, open flames, and other sources of ignition away from the engine. Dis- ‘connect and ground the spark plug lead to prevent the possibility of sparks from the ignition system. General Recommendations Purchase gasoline in small quantities and store in clean, approved containers. A container with a ca- pacity of 2 gallons or less with a pouring spout is recommended. Such a container is easier to handle and helps eliminate spoilage during refueling Do not use gasoline left over frarn the previous sea- son, to minimize gum deposits in your fuel system and to insure easy starting. Do not add oil to the gasoline. Do not overfill the fuel tank, Leave room for the fuel to expand. Fuel Type For best results, use only clean, fresh, unleaded ‘gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 80 octane minimum. Unleaded gasoline is recommended, as it leaves less combustion chamber deposits. Leaded gaso- line may be used in areas where unleaded is not available and exhaust emissions are not regulated Be aware however, that the cylinder head will re- quire more frequent service. Gasoline/Alcohol blends Gasohol (up to 10% ethy! alcohol, 90% unleaded gasoline by volume} Is approved as a fuel for Kohler engines. Other gasoline/aicono! blends are nat ap- proved. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 18% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether biends are not approved. OIL REFILL QUANTITIES (U.S. STANDARD QUARTS) kot 1a, K161, K181 k241, K301, K321, K34t K241A, K301A, K321A, K341A 1/2 Quart 1 Quart 2 Quarts 1 Quart" {After rafiling, always check oil level —- DO NOT OVERFILL) * A-type oil pan capacity varies from 1 to 1-3/4 quarts, On these add 1 quart of oil, check level, then add oil as necessary to bring up to full level. Figure 1-4. 1.5as ar a us. awa Coane La cRanxsHarT| : crunoen ae a none a RET ee eee fee ese ea eco a a vewrmon ass aes co vom ams | nas | a [sms os 5.08 |_araw ara | oo oan by of [| co a, nng 84 Gare oa || ae 8 awe i. Case * incladas Kit 1.8 Figure 1-5. Engine Speci ns And Tolerances.nonsePowen vox new 8 10 712, 14, 16, Eine Mode [connecTine|POStH0ok2 RODSO_|Cepscrews ‘SPARK PLUGS ruywuees |_NUT RETAINING | “Screw GOVERNOR BUSHING | mmm | Tien be, worm be ‘onass |_Metal = To Pein oe SCREEN | “pies = = oat ‘aumioum | = = on, | ee a BK, [eastiron | 20 Sue emees shoot metwo| = = mone wanrowoscrewmur| —— | — if = CAMSHAFT NUT = = = TON REALE FL = are rrr OUTING EES ‘USE STANDARD TOROUE SETTINGS WHEN SPECIE VALUES ARE NOT SPECIFIED. ‘1 Dram PLUGS (ira Assembly) : iy oO oO @ Figure 1-6. Torque Values & Sequences For Fasteners. 17SECTION 2 SPECIAL TOOLS SPECIAL SERVICE TOOL KIT NO, 3211-A These quality tools are designed to help you per- form specific disassembly, repair and reassembly procedures. By using tools designed for the job, you can service engines easier, faster and safer! in addition, you'll increase your service capabilities and customer satisfaction by decreasing engine down time. The Special Service Too! Kit No. 3211-A can be ‘ordered complete as shown in Figure 2-1 or the tools can be ordered individually. Contact your Kohler Engine Distributor for price and availabilty. Figure 2-1. Special Service Tool Kit 24VALVE SERVICE TOOLS TOOL NO. & NAME ‘APPLICATION ILLUSTRATION VALVE SEAT PULLERS 11726 11913 Removal of valve seats, Use 11918 adapter, 3222 slide hammer & 11915 forcing screw FORCING SCREW Used with valve seat mw 11915 pullers 11726 & 11919 ‘ADAPTER Used to connect valve seat pullers 19918 to slide hammer VALVE SEAT INSTALLER weit 11812 Used to install intake and exhaust seats. Use with 4747 handle 9222 SLIDE HAMMER 14799 Weight 12244 Slide Bolt Provides pulling force for valve seat and guide removal. Use 4747 handle. 3268 VALVE GUIDE REMOVAL KIT 11838 Stud 3 1/2" 32100 Stud 2 1/2" 11800 Adapter 0917 Nut 12008 Nut Used to pull vaive guides with 3222 slide hammer 9224 VALVE GUIDE INSTALLER KIT 412325 Driver 11763 Driver 11770 Gage 11771 Gage Used to install valve guides to proper depth. Use 11763 driver with 11770 & 11771 depth gages REAMERS (Valve Guide) 11843 5/16! 11844 11 To ream valve guides SEAL AND BEARING INSTALLERS 3228 SEAL INSTALLER KIT. 11782 Seal Installer 11783 Seal Installer 11784 Seal Installer 11785 Seal Installer 11786 Seal Installer 19787 Seal installer 11790 Seal instal 11791 Seal Installer 11792 Seal Installer 11793 Seal Installer Used to install seals without damage and to proper depth. Use 11795 handle with installers 11795 Handle 22SEAL AND BEARING INSTALLERS TOOL NO. & NAME ‘APPLICATION ILLUSTRATION 9242 SEAL PROTECTOR SLEEVE KIT 1202075" 12021 1.00 12022 1.25 12126 1.12 12127 150 12128 1.44 Used on crankshaft when installing seals to prevent damage 9241 BEARING INSTALLING KIT 12014 Ins. (Crank Bushing) 12018 ins. (Cam Bushing) 12016, 12017, 12018 & 12109, Brg. Installers. Used to install & remove engine bearings and bushings. 93226 FLYWHEEL PULLER KIT 12485 Puller witarcing screw 5108 Bolt - 1/4" wiwasher @) 12505 Bolt - 10-24 wiwasher (2) 12504 Bolt - 3/8" wiwasher (2) 12506 Storage Bag OTHER APPLICATIONS Used to remove flywheels and bearing plates from engine FLYWHEEL STRAP WRENCH 10357 Used to hold flywheel for nut removal OFFser wrench Used 0 rmove & stall inde (> 11797 Wrench 1/2" barrel retaining nuts f eo wrench a6 f FEELER CAGE Use o 20 pum eve gear — inet sesh ont onincer gine c rine oace Ueda told batance gaan ined |] Tis Ting Gage ettinmenasnneerame, | | | SCRAPER Used to scrape machined surfaces 11762 without damage eH) HANDLE Used with bearing installers, slide 4747 Handle hammer, and valve seat instaliers TOOL BOARD AND HOOK SET 12033, Used to store and identity tools ‘SEE FRONT PAGE 2.324 KIT NO. 3211-A TOOL USAGE CHART PART NO & NAME VALVE TOOLS ‘MODEL (" K" SERIES) 11726 Valve Seat Puller 11913 Valve Seat Puller 11915 Forcing Screw 71978 Adapter 11811 Valve Seat Installer 11812 Valve Seat Installer © . . ° "elele ee) Ki01 S . . . . 3222 Siide Hammer, 3268 Vaive Guide Removal KI 12325 Valve Guide Drive 11763 Valve Guide Driver (di ‘elele) [elele| [elKaa elele T1770 Valve Guide Depin Gage [11771 Valve Guide Depth Gage. 11843 Valve Guide Reamer 5/16" . 11844 Valve Guide Reamer 1/2” *KT19 engines prior BEARING AND SEAL ‘0 Series 72074 Installer — Grank Bushing 72075 installor — Cam Bushing 712016 Installer — Bearing T2017 installer — Bearing (PTO) T2018 Installer — Bearing 12079 installer — Bearing T1782 Installer — Seal (PTO) 11763 Installer — Seal (Flywheel of [11785 installer — Seal (PTO) [74786 Installer — Seal (Flywheel T1767 installer — Seal (PTO) 0 11790 Installer — Seal (Flywheel [11791 installer — Seal (PTO) 0 11792 Installer — Seal (Flywheel D 71173 Install (Flywheel) 1175 Handle — installer Seal _[e|@ [elle ejele 12020 Seal Si USE AS REQUIRED [12021 Seal Sleeve : USE Ag REQUIRED 12022 Seal Sleeve USE AS AEGUIRED 12126 Seal Sleeve USE AS REGUIRED 12127 Seal Sleeve USE AS AEGUIRED 12126 Seal Sleeve USEAg REgUIRED MISCELLANEOUS TOOLS T0567 Flywheel Strap Wrench "ele ]elele lee [11787 Offset Wrench [4923 Offset Wrench S167 11767 Feeler Gauge-Cra [10355 Tirning Too! (alance Gear) 11782 Scraper la7ar Drive Handle faa [3226 Fiywheet Pullor Kit — NOTE: K141 requires same tools as K161.Digital Tachometer Digital Engine Analyzer Thermocouples Digital Voltmeter Digital Thermomet Slack Tube Manometer Carrying Cai Figure 2-2. Engine Analysis Kit The Kohler Engine Analysis Kit contains a selection of instruments which will enable you to measure critical items that relate to engine performance. You will find many uses for these instruments — from basic crankcase vacuum checks to sophisti- cated application tests ‘The kit includes the following: ty. | Description Digital Voltmeter Digital Tachometer Digital Thermometer Digital Engine Analyzer Slack Tube Manometer @ Ft. Lead With Plug 14 mm Spark Plug Thermocouple Head Bolt Thermocouple Oil Sump Thermocouple 1/4" x 1/8" Bushing 3/8" x 1/8" Bushing 4/2" x 1/8" Bushing 3/4" x 1/8" Bushing Tube With Fittings Carrying Case Plain Thermocouple ‘The voltmeter, tachometer, thermometer and en- gine analyzer feature state of the art electronic Circuitry and digital readouts. Guidelines for using the instruments and for testing are incuded. Using the instruments in the kit you will be able to: WH Measure temperatures of ~ spark plug base gasket/cylinder head bolt # oil sump. air into flywheel and carburetor. 1M Measure engine speed (RPM) IM Measure crankcase vacuum and exhaust system back pressure. 1M Measure voltage. Measure charging system current. Mi Moasure electric starter current (Amp) draw. The Engine Analyzer Kit can be ordered complete as shown, or the instruments can be ordered ind vidually. Contact your Kohler Distributor for price and availabilty, 25SECTION 3 PERIODIC MAINTENANCE REQUIRED MAINTENANCE These required maintenance procedures should be performed at the frequency steted in the table: Required Maintenance Frequency Check Oil Level. Clean Grass Screen Clean/Replace Fuel Filter . Clean Foam Precieaner Change Oi : Check Optional Reduction Gear Unit ... : Clean Cooling Fins and External Surfaces ... Clean Paper Air Gleaner Element . Check Spark Plug ....-.- Check Valve-To-Tappet Clearance . Clean Cylinder Head end ‘Combustion Chamber" Service Starter Motor Drive . - Dally <++ Dally* ‘As Required seeeeeseessees 25 Hours! eater andi ieee 26 Houra: + 50 Hours + 50 Hours* 100 Hours* = 100 Hours = 500 Hours +++ 800 Hours** Annually or 500 Hours * Perform these meintenence procedures more frequently when engine is operated under ‘extremely dusty and diny conditions. "* 250 Hours when leaded gasoline is used. B wasn: scciserta start Before servicing the engine or equipment, always remove the spark plug to prevent the engine from ‘starting accidentally. Ground the lead to prevent ‘sparks that could cause fires. CHECK OIL LEVEL The importance of checking and maintaining the proper oil level in crankcase cannot be overem- phasized, Check oll BEFORE EACH USE as follows: Make sure the engina is stopped, laval, and is oo! so the oil has had time to drain into the sump. Clean the area around oil fill cap/dipstick be- fore removing to keep dirt, grass clippings, etc., out of the engine. Remove oil fil cap/dipstick; wipe oil off. Rel sett dipstick and push it all the way down into tube. Remove dipstick and check the level. On engines with threaded type piug dipstick, shoulder plug on top of hole to observe level. a4The oil level should be up to, but not over, the ““F* mark on the dipstick. Refer to Figure 3- Figure 3-1. Oil Level Range. . Add the proper type of oil if the level is low. ‘Always check the level with dipstick before adding more of. CAUTION: Never operate the engine with the oil level below “L* mark or over "F* mark on dip- stick. CHANGE OIL For a new engine, change oil after the first 5 hours of operation. Changs oil every 26 operating hours thereafter. For an overhauled engine or those rebullt with a new shortblock or miniblock, Use straight 30-woight Service Class SF or SG oil for the first 5 hours of operation. Change the oil after this initial run-in period. Change oil every 25 hours thereafter. Drain ol! while the engine is still ‘warm from operation. The oil will flow freely and carry away more impurities. Change oil as follows: Remove the oil drain plug and dipstick. Tilt the ‘engine slightly towards the drain hole to obtain better drainage. 2. Reinstall the drain plug. Make sure it is tight ‘ened securely. 3. Fill with new oil of the proper type to the “F™ ‘mark on the dipstick. Always check the level on dipstick before adding more oil. Make sure the engine is level when filing and checking oil. SERVICE AIR CLEANER K-Series engines are equipped with a high-density paper air cleaner element. Some specifications are also equipped with an cited foam precioaner which surrounds the paper element. Refer to Fig- ure 3-2. Precleaner lf so equipped, wash and recil the precleaner ‘every 25 operating hours (more often under ox- tremely dusty, dirty conditions). 1. Remove precieaner from paper element. Wash the precleaner in warm water with detergent. 2. Rinse precieaner thoroughly until all traces of dotergent are oliminated, Squeeze out excess water (do not wring). Allow precieaner to air ary. 3. Saturate precieaner in clean, fresh engine oil ‘Squeeze out excess oil, 4, Reinstall precleaner over paper element. Paper Element Every 100 hours of operation (more often under ex- tremely dusty or diny conditions), check the paper ‘element. Replace the element as necessary. 1. Remove the precleaner (i so equipped), element cover, and paper element. 2. Repiace a dirty, bent, or damaged element with a genuine Kohler element. Handle new ele- ments carefully; do not use of the sealing sur- faces are bent or damaged NOTE: Do not wash the paper element or use com- pressed air as this will damage element. 3. Reinstall the paper element. 4. install the precteaner (cleaned and oiled) over the paper element. 5. Install the air cleaner cover and wing nut, Tight en wing nut. Make sure element is sealed tight- ly against air cleaner bese, Inspect Air Cleaner Components Whenever the air cleaner cover Is removed, or serv- ing the element or precleaner, check the following ‘components: Air Cleaner Base ~ Make sure it is secured tightly to carburetor and Is not bent or damaged. Element Cover and Element Cover Nut ~ On K18t New Look engines only, meke sure element cover Is not bent or damaged. Check that element cover Nut is secured tightly to seal element between air cleaner base and element cover. Tighten nut to 50 in. Ib. torque. Breather Tube ~ Make sure it is sealed tightly in air cleaner base and breather cover. 3.2Figure 3-2. Alr Cleaner Components, NOTE: Damaged, worn, or loose air cleaner com- ponents could allow unfitered air into the engine causing premature wear and failure. Replace all damaged or worn components. CLEAN AIR INTAKE/COOLING AREAS To ensure proper cooling, make sure the grass screen, cooling fins, and other external surfaces. of engine are kept clean at all times. Every 50 operating hours (more often under extremely dusty, dirty conditions), remove the blower hous- ing and other cooling shrouds. Clean the cooling fins and external surfaces as necessary. Make sure the cooling shrouds are reinstalled. Refer to the “Disassembly” and “Reassembly” sections for cooling shroud removal and installation proce- dures. NOTE: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or col- ing shrouds removed will cause engine damage dus to overheating. CHECK SPARK PLUG Every 100 operating hours, remove the spark plug, check its condition, and reset gap or replace with new plug as necessary. Refer to Figure 3-3 Wire Gauge Spark Plug. a = Ground Electrode Figure 3-3. Servicing Spark Plug. - Before removing spark plug, clean the area around the base of plug to keep dirt and de- bris out of engine. ”. Remove the plug and check its condition. Re- place the plug if worn or if rouse is question- able. 3.3NOTE: Do not clean the spark plug in a machine using abrasive grit. Soe grit could remain in spark plug and enter the engine causing extensive wear and damage. 3. Check gap using a wire feeler gauge. Adjust gap by carefully bending the ground electrode. 4, Reinstall spark plug into cylinder head. Torque plug to 18/22 ft. Ib. ‘SERVICE OPTIONAL REDUCTION GEAR UNIT (On engines equipped with a reduction gear unit, check the oil level in unit every 50 operating hours. Refer to Figure 3-4. Vented Olt or am uewen, Drain Plug (Ol Level Check) Figure 3-4. Reduction Gear Unit. 1. Remove the plug on the lower part of gear unit cover, With engine level, the oil should be up to the bottom of the plug hole. 2. To add oll, remove the vented fil plug at the top of the unit. Use the same type of oil as used in the engine crankcase. 3. Reinstall and tighten the plugs securely. CHECK FUEL FILTER Some engines are equipped with an in-line fuel filtor. Visually inspect the fiter periodically, Re- place when dirty with a genuine Kohler filter. Refer to Figure Figure 3-5. In-line Fuel Filter. SERVICE STARTER MOTOR DRIVE Every 500 operating hours or annually (whichever occurs first), clean and lubricate the drive splines of the Bendix-drive electric starter motor. 1. Remove starter from crankcase. (Refer to ap- propriate “Disassembly” section.) 2. Remove dust cover, stop nut, stop gear spacer, spring, dust cover spacer, and drive pinion. 3. Clean the drive shaft splines with solvent. Dry solvent thoroughly. 4. Apply a small amount of Kohler electric starter drive lubricant (Part No. 52 357 01) to splines. NOTE: Kohler starter drive lubricant (Part No. 2 367 01) must be used on all Kohlor electric starter drives. The use of other lubricants can cause the drive to stick or bind, 5. Apply a small amount of Loctitet® No. 271 to stop nut threads. Assemble drive parts in r verse order of removal. Torque stop nut to 160 in. tb. 6. Reinstall starter to crankcase. (Refer to appro- priate “Reassambly” section.) CLEAN CYLINDER HEAD AND COMBUS- TION CHAMBER Every 500 operating hours (250 hours when leaded gasoline is used), remove cylinder head and clean combustion chamber. Refer to Figure 3-6, 3.4Figure 3-6. Cleaning Cylinder Head And Combustion Chamber. 1. Remove the cylinder head baffle and cylinder head. 2. Clean away combustion deposits using a ‘wooden or piastic scraper. 3. Reinstall the cylinder head using a new gasket. Torque the cylinder head fasteners in se- quence to the values spacified in Figure 3-7, CHECK VALVE-TO-TAPPET CLEARANCE Every 500 operating hours, remove breather/valve cover and check valve-to-teppet clearance with a flat fecler gauge. Refer to Figure 3-8. The engine must be cold when checking this clearance. 1, Remove the air cleaner assembly, carburetor, ‘and breather assembly. (Refer to appropriate "Disassembly" section.) 2. Position the crenkshatt so the piston is at top ‘of compression stroke (eam has no effect on tappets) K161, K181 * 15-20 ft. Ibs. K301, K321 25-30 ft. Ibs. K341 19 25-30 ft. Ibs. 6 | Os ©2 Figure 3-8. Measuring Valve-To-Tappet Clearance * Includes 141 Figure 3-7. Cylinder Head Fastener Tightening Sequence.3, Measure valve-to-tappet clearance with a flat fooler gauge. ‘On Model K91, K141, K161, K181 ~ if the clearance is too small, remove the valves and grind the valve stems until the correct ciear- ance is obtained. Make sure valve stems are ‘ground perfectly flat and smooth. Model Intake Valve Exhaust Valve Kot .005"/.008" 011"/.015" 161, ki@1 | .006"/.008” .017"/.019" 241, K301 | .008"/.010" .0177/.019" 321, K341 Figure 3-9. Valve Clearances If clearance is too lerge, replace the valves and recheck clearance. NOTE: Large clearances can also be reduced by grinding the vaives and/or valve seats. Refer to the "Inspection And Rapair/Reconditioning” section for valve specifications. On Models K241, K301, K321, K341 ~ Adjust the clearance by turning the adjusting screw on tap- pots. Refer to Figure 3-9. ‘Adjusting Serew Figure 3-10. Adjusting Valve-To-Tappet Clearance - Models K241 Through K341, 3.6 STORAGE If the engine will be out of service for approxi- mately two months or more, use the following storage procedure. 1. Change the oil when engine is still warm from operation. Refer to “Change Oil.” 2. Change the oil in reduction gear unit, if so equipped. Refill with the same oil as used in engine crankcase for season of operation. Re- fer to “Service Optional Reduction Gear Unit.” Run engine for a few minutes to distribute ‘clean oil throughout engine. 3. Drain the fuel tank and fuel system (or run ‘engine until fuel tank and fuel system are empty). 4, Remove the spark plug. Add one tablespoon of engine cil into the spark plug hole. Install plug, by do not connect plug lead. Crank the engine two or three revolutions. 5. Remove the spark plug. Cover the spark plug hole with thumb and turn engine over until the piston is at the top of its stroke (pressure against thumb is greatest). Reinstall plug, but do not connect piug lead. 6. Clean the exterior surfaces of engine. Spread a light film of oil over any exposed metal sur- faces of engine to prevent rust. 7. Store the engine in a clean, dry place.SECTION 4 TROUBLESHOOTING TROUBLESHOOTING GUIDE When trouble occurs, be sure to check the simpie ‘causes which, at first, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. ‘Some common causes of engine troubles are listed below. Use this as a guide to locate trouble causing factors. Engine Cranks But Will Not Start 1. Empty fuel tank. 2. Fuel shutoff vaive closed. 3. Clogged fuel line. 4. Spark plug lead disconnected. 5. Keyswitch or kill switch in "off" position. 6. Faulty spark plug. 7. Faulty ignition. 8. Dirt oF wator in fuel system. Engine Starts But Does Not Keep Running Restricted fuel tank vent. Dirt or water in fuel system. Faulty choke or throttle controls/cables. Loose wires or connections shorting ignition to ground. 5. Carburetor improperly adjusted. 6. Faulty cylinder head gasket. 7. Faulty fuel pump. Engine Starts Hard 1. Hydrostatic transmission not in neutral/PTO drive is engaged. Loose wires or connections. Dirt or water in fuel system. Clogged or restricted fuel lines. Faulty choke or throttle controls/cabies. Faulty spark plug. Carburetor improperly adjusted. Incorrect valve-to-tappet clearance. 9. Low compression. 10. Fauity ACR mechanism. Engine Will Not Crank 1. Hydrostatic transmission is not in neutral/PTO drive is engaged. PrNOPPED Pree EaeD Battery is discharged. Safety interlock switch Is “engaged”. Loose or faulty wires or connections. Faulty keyswitch or ignition switch. Faulty electric starter/starter solenci Retractable starter not engaging in drive cup. Seized internal engine components. Engine Funs But Misses ie 2. 3 6. Dirt or wator in fuel system. Spark plug lead loose. Loose wires or connections intermittently short- ing ignition to ground. Carburetor improperly adjuste Engine overheating. Incorrect vaive-to-tappet clearance. Engine Will Not Idle 1 2 3 4 5. 6 7 Idle speed adjusting screw improperiy set. Dirt or water in fuel systern. Idle fuel adjusting screw improperiy set Fuel tank vent restricted. Faulty spark plug. Incorrect valve-to-tappet clearance. Low compression. Engine Overheats 1 Grass screen, cooling fins or shrouding clogged. Excessive engine load. Low crankcase oil level. High crankcase oil level. Carburetor improperiy adjusted. Engine Knocks 1 2. Low crankcase oil level. Excessive engine load. Engine Loses Power Low crankcase oil level High crankcase cil level. Restricted air cleaner element. Dirt or water in fuel system. Excessive ongine load. Engine overheating. Faulty spark plug. Carburetor improperly adjusted. aa9, Low compression. Engine Uses Excessive Amount of Oil 1. Incorrect oil viscosity or type. 2. Clogged or improperly assembled breather system. 3. Worn or broken piston rings. 4. Wor cylinder bore. 5. Wor valve stems and/or guides. EXTERNAL ENGINE INSPECTION 1. Before cleaning or disassembling the engine, check its external appearance and condition. This inspection can give clues to what might bbe found inside the engine (and the cause) once It is disassembied. Check for buildup of dirt and debris on the crankcase, cooling fins, grass screen and other external surfaces. Dirt or debris in these areas are causes of overheating (Check for obvious fual and cil leaks and dam- aged components. Excessive oll leakage can indicate a clogged or improperly assembled breather, worn or damaged seals and gaskets ‘oF loose or improperly torqued fasteners. Cl Check the air cleaner cover, element cover and air cleaner base for damage or indications of improper fit or seal. Check the air cleaner element. Look for holes, tears, cracked or damaged sealing surfaces or other damage that could allow dirt to enter the engine. Also note if the element Is clogged or restricted. These conditions could indicate that the air cleaner has been underserviced. Check the carburetor throat for dirt, Dirt in the throat is further indication that the air cleaner is not functioning properly. Check the oil fevel. Note if the oil level is, within the operating range on the dipstick, or if it is low or overfilled. Check the condition of the oil. Drain the oi into a container ~ it should flow freely. Check for metal chips and other foreign particles. NOTE: It is good practice to drain oil at a location away from the workbench. Be sure to allow ample time for complete drainage. Sludge is a natural by-product of combustion; a ‘small accumulation is normal. Excessive sludge formation could indicate that the oll has not been changed as recommended, an Incorrect type or ‘weight of oil has been used, over-rich carburetor settings or weak ignition, to name a few. CLEANING THE ENGINE After inspecting the external condition of the en- gine, clean it thoroughly before disassembling. Also clean individual components as the engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that quickly remove grease, oil and grime from engine parts. When such a cleaner is used, follow the manufacturer's instructions carefully. Make sure all races of the cleaner are removed before the engine is reassembled and placed in opera- tion. Even smail amounts of these cleaners quickly break down the lubricating properties of engine oil. BASIC ENGINE TESTS Fuel System Test To determine if fuel is getting to the carburetor, disconnect the fuel line at inlet to carburetor ~ if fuel does not flow out of line, check system back to tank for clogged lines, wrong (unvented) filler cap, blocked fitter screen, faulty fuet pump, etc. If fuel is getting as far as the carburetor, remove the spark plug, crank engine and check for fuel inside combustion chamber. if no fuel is present here, check for faulty carburetor. Ignition System Test To determine if the ignition system is good, re- move the spark plug and place plug with side electrode against cylinder head then crank engine at sufficient speed to produce a good spark. If a sharp, snappy spark is noted, this eliminates the ignition system components as the cause, al- though the ignition timing could be off. I no spark or a weak spark is produced, check the ignition system further. If points are pitted, don’t attempt to service them - replace points in bad shape. Dirty points may be cleaned. A bad condenser will cause premature failure of points. Check the breaker push rod for evidence of bind- ing or sticking ~ replace as needed. Condenser can be tested on commercial tester per tester manufacturer's instructions, Check Ignition coil on coll tester for continuity. Crankcase Vacuum A partial vacuurn should exist in the crankcase when the engine is operating at normal tempera- tures. Prossure in the crankcase (usually caused by a clogged or improperly assembled breather} can cause oil to be forced out at oil seals, gas kets or other available spots. Crankcase vacuum is best measured with a slack tube manometer. The manometer included in the 42Kohler Engine Analysis Kit is recommended. Refer to the "Special Tools" section for more informa- tion. Crankcase Vacuum Test To test crankcase vacuum with the manometer: 1 Insert the stopper hose into the ail fil hole. Leave the other vent of the manometer open to the atmosphere. Make sure the shutoff clamp is closed. Start the engine and run at high speed (3200 to 3600 RPM), Open the clamp and note the water level in the tube. The level in the engine side should be 6 to 10 inches above the level in the open NO CRANKCASE VACUUI side. If there is no vacuum (level in engine side is the same as in open side) or a positive pressure (level in open side is higher than in engine side) check for the conditions in the following table. engine. Compression Test Because these engines are equipped with an auto- matic compression release mechanism (ACR), It is difficult to obtain an accurate compression read- ing. To check the condition of the combustion chamber and related mechanisms, physical inspection and a crankcase vacuum test are recommended. IM/PRESSURE IN CRANKCASE Possible Cause Solution ‘Crankcase breather clogged or inoperative. ‘Seals and/or gaskets leaking. Loose or improperly torqued fasteners. Piston biowby or leaky valves. (Confirm by inspecting components.) Restricted exhaust. 1. Disassemble breather, clean parts thoroughly, reassemble, and recheck pressure. 2. Replace all worn or damaged seals and gaskets. Make sure fasteners are tightened securely. Use appropriate torque values and sequences when necessary, 3, Recondition piston, rings, cylinder bore, valves, and valve guides. 4, Replace restricted muttler/exhaust system. Figure 4-1. MeasuRe OFFExENCE BETWEEN COLLIS. Figure 4-2. “ U" Tube Manometer 43 Close the shutoff clamp before shutting off theSECTION 5 AIR CLEANER AND AIR INTAKE SYSTEM K series engines are equipped with a high-density AIR CLEANER SERVICE Paper air cleaner element. Engines of some speci- fications are also equipped with an oiled foam Precleaner precleaner that surrounds the paper element. Re- for to Figure 5-1 IF $0 equipped, wash and re-cil the precleaner every 25 operating hours (more often under ex- tremely dusty or dirty conditions) 1. Wash the precieaner in warm water and deter- AIR CLEANER DISASSEMBLY sen 1, Remove the wing nut and air cleaner cover. 2. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out ex- 2. Remove the precieaner (if so equipped), pa- cess water (do not wring). Allow precleaner to per element and seal ary |. Saturate the preciearer with clean, fresh en- 3, Remove the base screws, air cleaner base, ee bake oo gine oil. Squeeze out excess oil. gasket and hose. 4. Reinstall the precleaner over the paper ele- ment. Figure 5-1. Air Cleaner Assembly ~ Exploded View. 5APaper Element Every 100 operating hours (more often under ex- tromoly dusty or dity conditions) chock the papor element. Replace the element as follows: 1. Remove the precleaner {if so equipped), ele- ‘ment cover nut, element cover and paper ele- ment, Replace a dirty, bent or damaged element with a new genuine Kohler element. Handle new elements carefully; do not use if surfaces are bent or damaged. NOTE: Do not wash the paper element or use compressed air as this will damage the element 3. Reinstall the paper element. 4, Install the precleaner (cleaned and oiled) over the paper element. 5, Install the air cleaner cover and wing nut. Tighten wing nut. Make sure element is sealed tightly against air cleaner base. Inspect Air Cleaner Components Whenever the air cleaner cover is removed, or when servicing the paper alement or precleaner, check the following components: 1. Air Cleaner Base ~ Make sure it is secured tightly to carburetor and is not bent or dam- aged. lement Cover and Element Cover Nut - On K181 New Look engines only, make sure ele- ‘ment cover is not bent or damaged. Check that element cover nut is secured tightly to seal element between air cleaner base and ‘element cover. Tighten nut to 50 in. tb. torque, Refer to Figure 5-2. 3. Breather Tube ~ Make sure it is sealed tightly in the air cleaner base and breather cover. NOTE: On Model K181 New Look engines of cer- tain specifications, the element cover may contact the breather tube, making it impossible to maintain crankcase vacuum. To prevent this problem, cut ‘the end of the breather tube that protrudes through the air cleaner base at approximately a 45 degree angle. Optional Precleaner Air Cleaner Cover Cover Nut ‘wing Nut ‘Ale Cleaner Base Figure 5-2. K181 New Look, Air Cleaner Assembly. 5.2NOTE: Damaged, worn or loose air cleaner com- ponents could allow unfitered air into the engine causing premature wear and failure. Replace all damaged or worn components OPTIONAL OIL BATH AIR CLEANER If the engine has an oil bath type air cleaner, clean and service it after every 25 hours of opera- tion or more frequently if conditions warrant. Refer to Figure 5-3. 1. Remove the cover, lift the element out of the bowl and drain the oll from the bowl. 2. Thoroughly wash bowl and cover in clean sok vent. Swish the element in the solvent and al- low it to dry. NOTE: Do not use compressed air to dry the ele- ment. The filtering material could be damaged. 3. Lightly re-oil the element with engine oil. 4. Inspect base and cover gaskets. Replace if damaged. 5. Install base gasket and place filter on air horn. 6. Add engine oil to filter and fill to the OIL LEVEL, mark. 7. Install fiter element, cover gasket and cover, Secure with wing nut finger tight only. COOLING AIR INTAKE SYSTEM Effective cooling of an air cooled engine depends (on an unobstructed flow of air over the cooling fins. Air is drawn into the cooling shroud by fins located on the flywheel. The blower housing, cool- ing shroud, air screen covering the flywheel and cooling fins on the cylinder and cylinder head must be Kept clean and unobstructed at all times. Never operate the engine with the blower housing or cooling shroud-removed. These devices direct air flow over the cooling fins, NOTE: Some engines use a plastic grass screen and some use metal. The two are not nterchange- able unless other modifications are made to the engine. OIL LEVEL Figure 5~: Optional Oil Bath Air Cleaner. 5.3SECTION 6 FUEL SYSTEM AND GOVERNOR FUEL SYSTEM - GASOLINE ‘Tho typical gasoline fuel system and related com- ponents include the fuel tank with vented cap, shutoff vaive with screen, in-line fuel filter, fuel pump (some models), carburetor and intercon necting fuel tine. Operation The fuel from the tank is moved through the screen and shutoff valve, in-line filter and fuel lines by the fuel pump (if so equipped) or gravity. Fuel enters the carburetor float bow! and is moved into the carburetor body where it is mixed with air The fuel-air mixture is drawn into the combustion chamber where it is compressed, then ignited by the spark plug. ‘Troubleshooting Use the following procedure to check that fuel is reaching the combustion chamber. BD. was0inc: expose Foot Gasoline may be present in the carburetor and fuel system. Gasoline is extremely flammable end it can explode if ignited. Keep sparks, open flames, and other sources of ignition away from the engine. Dis- connect and ground the spark plug lead to prevent the possibilty of sparks from the ignition system. Test Conclusion 1. Cheek for the following? ‘A. Make eure the tank contains fuel. 1B, Make eure the fuel eap vent is open, C. Make eure the fuel shutott valve is open, 2. Cheek for fuel in the combustion chamber. ‘A. Disconnect the spark plug lead, B. Close the choke on carburetor. C. Crank the engine several times. 1D. Remove the spark plug and check for fuel st tb If there ts fuel at tip of spark plug, fuel is reaching the com- Bustion chamber’ IF there 1s no fuel at tp of spark plug, chock for fuel from the. fuel tank, (Tost 3) 3. Check for fuel flow from tank to fu pump. A. Remove fuel Ine from inet fitting at fuel pump. 8, Hold tine below bottom of tank. Open shutoff Vave and observe flow. It fuel does flow trom line, check for fauity fuel pump. (Tost 4). If fuel does not flow from ine, check for clogged fuel tank vont, shutoff valve sereen, and fuel ins {If the fust tank cap vent does net allow ak to escape from the tank, modify the vent for proper operation by cutting 1182" to 1/16" off the bottom. Refer to Figure 6-1 ‘4. Check operation of fuel pump |A, Remove fuel ine from init fiting at carburetor BB. Crank engine sevoral times and observe flew. Titus! dows not flow from tne, check for clogged fuel tne. HF Ine Is unobstructed, fuel pump ts faulty and must be re- placed If tuo! does flow from fuel Ine, the carburetor probably Is faulty. Refer to the “Carbureter” portion af this section. 61cut oft ws2"-4716" Figure 6-1. Fuel Tank Cap. ("New Look” Only) FUEL TANK Engine-mounted fuel tanks on K series engines are constructed of steel. They are fitted with a vented cap. The venting properties of the cap should be checked regularly. A clogged vent can cause pressure buildup in the tank, which could result in fuel spraying from the filler when the cap is loosened, it can also cause a partial vacuum in the tank, stopping the engine. Fuel Shutoff Valve ‘Some engines are equipped with a fuel shutoff valve with a wire mesh screen. On engines without a shutoff vaive, a straight outlet fitting is used. The wire mesh prevents relatively large particles in the tank from reaching the carburetor. The shutoff valve permits work on the fuel system without the need for draining the tank. FUEL FILTER ‘Some engines covered by this manual may be ‘equipped with a see-through inline fuel filter. When the interior of the filter appears to be dirty, It should be replaced. FUEL PUMP: All K series engines except the K91 have provi- sions for mounting a mechanically operated fuel Pump. If no fuel pump is mounted on these en- gines, a cover is placed over the pump mounting ad on the crankcase. Older fuel pumps have a metal body. Later mod- ‘els have a body made of plastic. The plastic body better insulates the fuel from the hot engine, mini- mizing the chance of vapor lock. Operation The mechanical fuel pump is operated by a lever that rides on the engine camshaft. The lever transmits a pumping action to the flexible dia- phragm inside the pump body. The pumping ac- tion draws fuel in through the inlet check valve on the downward stroke of the diaphragm. On the upward stroke, the fuel is forced out through the outlet check valve. Refer to Figure 6~ poem PUM COVER NALYE GASKET SS oe wave vauve seasne “8 27 vauve seni ° Pune vaLVE~“ § VALVE RETAINERS VALVE PLATE SCREW uve eco“ NATO MARC Figure 6-2. Mechanical Fuel Pump. Removal 1. Disconnect the fuel lines from the inlet and outlet fittings of the pump. Remove the filister head sems screws, flat washers, fuel pump and gasket. 3. If required, remove the fittings from the pump body. Repair Plastic bodied fuel pumps are not serviceable and ‘must be replaced when faulty. Replacement pumps are available in kits which include the pump, mounting gasket and plain washers. Installation 4. Fittings ~ Apply a small amount of Permatex® Aviation Perm A Gasket (or equivalent gasoline resistant thread sealant) to fittings. Turn fi tings into pump six full turns; continue turning fittings in the same direction until desired di- rection is reached. 2. Install new gasket, fuel pump, flat washers, lock washers and filister head sems screws. Refer to Figure 6-3. 6.2Gasket lain Washer (2) \ pstume ‘Mounting Flange {*” Fillister Head Sems Screws (2) Figure 6-3. Installing Fuel Pump. NOTE: Make sure that the fuel pump lever is posi- tioned above the camshait. Damage to the fuel pump and severe damage to the engine could re- sult if the lever is positioned below the camshaft, Make sure that the flat washers are installed next to the mounting flange to prevent damage from the lock washers. If a metal bodied pump was replaced by a plastic bodied pump, make sure that the old thick gasket is discarded and the new thin gasket is used. 3. Torque screws to 37 ~ 45 in. /Ib. Connect fuel lines to inlet and outlet fittings. CARBURETOR - GASOLINE B. warswine: expoaive Fue Gasoline may be present in the carburetor and fuel system. Gasoline is extremely flammable and it can ‘explode if ignited. Keep sparks, open flames, and other sources of ignition away from the engine. Dis connect and ground the spark plug lead to prevent the possibility of sparks from the ignition system. Adjustment The carburetor is designed to deliver the correct fuel/air mixture to the engine under all operating conditions. Carburetors are set at the factory and normally do not need adjustment. If the engine ‘exhibits conditions like those found in the table that follows, it may be necessary to adjust the carburetor: In general, turning the adjusting needles in (clock wise) decreases the supply of fuel to the carbure- tor. This gives a /eaner fuel-to-air mixture. Turning the adjusting needies out (counterclockwise) in- creases the supply of fuel to the carburetor. This aives a richer fuel-to-air mixture. Setting the nee- dies midway between the lean and rich positions will usually give the best results. Adjust the carbu- retor as follows: 1. With the engine stopped, turn the low idle fuel adjusting needle in (clockwise) until it bottoms. lightly. NOTE: The tip of the low idle fuel and high idle fue! adjusting needies are tapered to critical dimensions. Damage to the needles and the seats in carburetor body will result if the needles are forced. 2. Preliminary Settings: Turn the adjusting needles ‘out (counterclockwise) from lightly bottomed according to the table shown in Figure 6-4. 3. Start the engine and run at half throttle for five to ten minutes to warm up. The engine must be warm before making final settings (Steps 4, 5, 6, and 7) 4. High Idle Fuel Needle Setting: This adjustment is required only for adjustable high idle (main) jot carburetors. If the carburetor is a fixed main jet type, go to step 5. Place the throttle into the “fast” position. If possi- ble, place the engine under load. Turn the high idle fuel adjusting needie out (coun- terclockwise) from the preliminary setting until the engine speed decreases (rich). Note the position of the needle. Now turn the adjusting needie in (clockwise). The engine speed may increase, then it will decrease as the needle Is turned in (lean). Note the position of the needle. Set the adjusting needle midway between the rich and lean settings. See Figure 6-! 5. Low Idle Speed Setting: Place the throttle con- trol into the “idle” or “slow” position. Set the low idle speed to 1200 rpm* (+ or - 75 rpm) by turning the low idle speed adjusting screw in of out. Check the speed using a tachome- ter. NOTE: The actual low idle speed depends on the application. Refer to the equipment manufacturer's instructions for specific low idle speed settings. The recommended iow idle speed for Basic En- gines is 1200 rpm. To ensure best results when setting the low idle fuel needie, the low idle speed must not exceed 1500 rpm. 6.3PRELIMINARY SETTINGS - K-SERIES MODELS KOHLER ADJUSTABLE JET ___WALBRO FIXED JET Low Idle High Idle Low idle kot 1-1/2 tums 2 tums NOT APPL. NOTE: Refer to publica Kia1 1-1/2 tums 3 turns NOT APPL. tion TP2377B Carburetor K161" 1-1/2 tums 3 turns NOT APPL. Reference Manual for kte1* 1-1/4 turns 2 turns 2-172 turns paaltionall Infonmston kat 2-1/2 turns 2 tums 1-1/4 turns: k301 2-1/2 turns 2 turns 1-1/4 turns 324 2-1/2 turns 3-1/4 turns 1-1/2 turns 341 2-1/2 turns 3-1/2 turns 1 tun * Includes “New Look" Models Figure 6-4. Pral 6. Low Idle Fuel Needle Setting: Place the throttle into the “idle” or “slow” position, Turn the low idle fuel adjusting needle out (coun- terclockwise) from the preliminary setting until the ‘engine speed decreases (rich). Note the position of the needle. Now turn the adjusting needle in (clockwise). The ‘engine speed may increase, then it will decrease as the needie is tumed in (lean). Note the position of the needie. Sot the adjusting needle midway between the rich and lean settings. See Figure 6-5. 7. Recheck the low idle speed using a tachome- tor, Readjust the speed as necessary. Lean apa 1 Rich —-~—| Figure 6-5. Optimum Low Idle Fue! Setting. Disassembly (Refer to Figure 6-7) 1. Remove the bow! retaining screw, retaining screw gasket and fuel bowl. inary Low Idle And High Idle Fuel Not 2. le Settings. Romove the float pin, float, fuel inlet needle, baffle gasket and bow! gasket. Remove the fuel inlet seat and inlet seat gas- ket. Remove the idle fuel and main fuel adjust- ing needles and springs. Remove the idle speed adjusting screw and spring. Further disassembly to remove the throttie and choke shafts is recommended only if these arts are to be replaced. Refer to “Throttle ‘and Choke Shaft Replacement” later in this section Figure 6-6. Kohler-Built Adjustable Jet Carburetor. 64Cleaning WARNING: Flammable Solvents! By _ Latburetor cleaners and solvents are extremely flammable. Keep sparks, flames and other sources of ignition away from the area. Follow the cleaner manufacturer's warnings and instructions on its proper and safe use. Never use gasoline as a clean- ing agent. All parts should be carefully cleaned using a car- buretor cleaner (such as acetone). Be sure all gum deposits are removed from the following ar- eas: Carburetor body and bore; especially the areas where throttle plate, choke plate and shafts are seated. Float and float hinge. Fuel bowl. Idle fuel and “off-idle” ports in carburetor bore, ports in main fuel adjusting needle and main fuel seat. NOTE: These areas can be cleaned using a piece of fine wire in adcition to cleaners. Be careful not to enlarge the ports or break the cleaning wire within the ports. Blow out all passages with compressed air. NOTE: Do not submerge carburetor in cleaner or solvent when fiber or rubber seals are installed. The cleaner may damage trese seals. Inspection 1. Carefully inspect all components and replace those that are worn or camaged. 2. Inspect the carburetor body for cracks, holes and other wear or damage. 3. Inspect the float for den's or holes. Check the float hinge for weer and missing or damaged float tabs. 4. Inspect the inlet needie and seat for wear or grooves. 5. Inspect the tips of the rain and idle fuel ad- justing needies for wear or grooves. Inspect the throttle and choke shafts and plate assemblies for wear or excessive play. Main Fuet Needle ¥ Idle Speed Screw spring Spring ¢ a Carburetor Fuel Intet SER Needle (> Float Fuel Bow! "| Bow! Retaining. 1 —"By—__Bow! Retaining ane ‘Screw Gasket Figure 6-7. Kohier-Built Adjustable Jet Carburetor ~ Exploded View. Choke Plate Modification The choke action has been changed on production carburetors to reduce the chances of over chok- ing. On production carburetors now used on the 321 and K341, both relief holes in the choke plate have been enlarged to 11/32” while on the 241 and K301, one relief hole is now 11/32" and the other is 3/16". If you find that the relief holes are smaller than this, enlarge them to these di- mensions. NOTE: When redrilling the holes, take the neces- sary precautions to prevent chips from entering the engine. Repair Always use new gaskets when servicing and rein- stalling carburetors. Several repair kits, which in- clude the gaskets and other components, are 65avalable. Always refer to the Parts Manual for the ‘engine being serviced to ensure that the correct, carburetor repair kits and replacement parts are ordered. Throttle And Choke Shaft Replacement To Replace Throttle And Choke Shafts Two kits are available that allow replacement of the carburetor throttle and choke shafts of Kohler carburetors. Refer to Figure 6-8. KTA7-KT18, Choke Shaft Bushing, (Choke Detent Ball -Spring—™ “s ‘Choke Shaft Busting Choke Piate (Reused) x 87/32" Brass Screws “Schoke shatt we \ coke tever ‘Roused) #2-56K7/52" or 93-4847/32" Brass Sorow #2-56x7/32" or #3-48x7/92" Brass Screw k91-K181, 1/2" Carb, ? Car #9-48x7/92" Brass Screws Lever 7 a Beh ‘Throttle Shatt/Lovor Assembly— 2 Styles For Modals ‘Torottle Shatt-4 Styles For Models K241-K341 & Throttle (Reusea) Throttle Shaft Bushing Throttle Plate (Reused) ‘installation Too! Bow! Gasket Figure 6-8. Throttle And Choke Shaft Replacement Kits. A srs: erent eye ry! Suitable eye protection (safety glasses, goggles, or face hood) should be worn for any procedure involv- Ing the use of compressed alr, punches, hammers, chisels, drills, or grinding tools. Disassemble Carburetor Refer to “Disassembly” at the beginning of this section. Remove Choke Plate and Choke Shaft; Transfer Choke Lever 1. To ensure correct reassembly, mark choke plate and carburetor body with a marking pen. Also take note of choke plate position in bore and choke lever position. 2. Carefully and slowly remove the screws secur- ing choke plate to choke shaft. Remove and ‘save the choke plate as it will be reused. 663. File off any burrs which may have been left on the choke shaft when the screws wore ro- moved. Place carburetor on workbench with choke side down. Remove choke shaft; the dotent ball and spring will fal! out. 4. Note the position of the choke lever with re- spect to the cut out portion of the choke shaft. 5. Carefully grind or file away the riveted portion of the shaft, Remove and save the choke lever; discard the old choke shaft. 6. Altach the choke lever to the new choke shaft from the kit. Make sure the lever is installed correctly as noted in step 4. Secure lever to choke shaft as follows: Models K91 - K181; Apply Loctite to threads of 1 #2-66 x 7/32” brass screw. Secure lover to shaft. Models K241 ~ K341; Apply Loctite to threads of 1 #3-48 x 7/32" brass screw. Secure lever to shaft. Remove Throttle Plate and Throttle Shaft; Transfer Throttle Lever To ensure correct reassembly, mark throttle plate and carburetor body with a marking pen. Also take note of the throttle plate position in the bore and the throttle lever position. 2. Carefully and siowly remove the screws secur- Ing the throttle plate to throttle shaft. Remove and save the throttle plate for reuse. 3. File off any burrs that may have been left on the throttle shaft when screws were removed. NOTE: Failure to remove burrs from the throttle shaft may cause permanent damage to carburetor body when shaft is removed. 4, Remove throttle shaft from carburetor body. Remove and discard the foam rubber dust seal from the throttle shaft. 5. Remove and transfer the throtile lever as fol- lows: Models K91 ~ K181 (1/2* Carb.); Carefully grind or filo away the riveted portion of the throttio shaft. Save the throttio shaft as it will be used to install the new throttle shaft bushing. Discard the throttle lever Models K241 ~ K341 (1 Carb.); 1a. Note the position of the throttle lever with re- spect to the cutout portion of the throttle shaft. b. Carefully grind or file away the riveted portion of the shaft, Remove the throttle lever. ©. Compare the old shaft with the new shafts in the kit. Select the appropriate new shaft and discard the old shatt. 4. Attach throttle lever to throttle shaft, Make sure lever is installed correctly as noted In step a. ©. Apply Loctite to threads of 1 42-66 x 7/32" brass screw (use #3-48 x 7/32” screw if shaft is 2-49/64" long. Secure lever to shaft Drill Choke Shaft Bores Using A Drill Press 1. Mount the carburetor body in a drill press vise. Keep the vise jaws slightly loose, 2. Install a deil bit of the following size in the ditt press chuck. Lower the bit (not rotating) through both choke shaft bores; then tighton vise. This ensures accurate alignment of the carburetor body with the drill press chuck. Models K91 - K181 (1/2" Cerb.); Use a 7/32" di ameter drill bit Models K241 — K341 (1" Carb.); Use a 1/4" di ameter drill bit. Refer to Figure 6-9. Figure 6-9. Aligning/Driling Carburetor Body. 3. Install a 19/64” drill bit in the chuck. Set drill Press to a low speed suitable for aluminum. Drill slowly to ensure a good finish. 4. Ream the choke shaft bores to a final size of 5/16", For best results use a plioted 5/16” reamer. 5. Blow out all metal chips using compressed air. ‘Thoroughly clean the carburetor body in carbu- rotor cleaner. 67Install Choke Shaft Bushings 1, Install screws in the tapped holes that enter the choke shaft bores until the screws bottom lightly. Refer to Figure 6-10. 2. Coat the outside surface of the kit-suppliog ‘choke shaft bushings with Loctite from the kit. Carefully press the bushings into the carbure- tor body using @ smooth-jawed vise. Stop pressing when bushings bottom against screws. Models K91 - K181 (1/2” Carb,); Make sure the bushing is pressed below the surface of the large choke shaft boss until the bushing bottoms against screw. 3, Allow Loctite to “set” for 5 to 10 minutes, then remove screws. Figure 6-10. Installing Choke Shaft Bushing: 4, Install new choke shaft in bushings. Rotate shaft and check that it does not bind. NOTE: If binding occurs, locate and correct the cause before proceeding. Use choke shaft to align bushings if necessary. 5, Remove choke shaft and allow Loctite to “set for an additional 30 minutes before proceed- ing. 6. Wipe away any excess Loctite from bushings ‘and choke shaft. Install Throttle Shaft Bushing 1. Make sure the dust seal counterbore in the carburetor body is thoroughly clean and free of chips and bur 2. Install a throttle shaft (without throttle lever) in carburetor body to use as @ pilot: Models K91 - K181 (1/2" Cerb.); Use the old throttle shaft removed previously. Models K141 - K341 (1” Carb.); Use one of the remaining new throttle shafts from the kit. 3. Coat the outside surface of the throttle shaft bushing with Loctite from the kit. Sip the bushing over the shaft. Using a vise and the installation tool from the kit, press the bushing into the counterbore unti it bottoms in the car- buretor body. Refer to Figure 6-11. Figure 6-11. Installing Throttle Shaft Bushing. 4, Allow the Loctite to “set” for 6 to 10 minutes, then remove the throttle shaft. 5. Install the new throttle shaft and lever in carbu- rotor body. Rotate the shaft and check that it does not bind. NOTE: if binding occurs, locate the cause and correct, bofore proceeding. Use throttle shaft to align bushing if necessary. 6. Remove the shalt and allow the Loctite to “sot” for an additional 30 minutes before pro- ceeding. 7. Wipe away all excess Loctite from bushing and throtie shaft. Install Detent Spring and Ball, Choke Shaft and Choke Plate 1. Install new detent spring and ball in carburetor body in the side opposite the choke lever. 2. Compress detent ball and spring and insert choke shaft through bushings. Make sure the choke lever is on the correct side of the car- buretor body. Refer to Figure 6-3. Attach choke plate to choke shaft. Make sure marks are aligned and plate is positioned prop- erly in the bore. Apply Loctite to threads of 2 #3-48 x 7/32" brass screws. Install screws so that they are slightly loose. 4. Operate the choke lever. Check that there is no binding between choke plate and carburetor bore. Loosen screws and adjust plate as nec- ‘essary; then tighten screws. Compress, C= "ane Spring Choke Shaft Figure 6-12. Installing Choke Shaft. Install Throttle Shaft and Throttle Plate 1. Install throttle shaft in carburetor with cutout portion of the shaft facing out. 2. Attach throttle piate to throttle shaft, Make sure marks are aligned and plate is positioned Properly in the bore. Apply Loctite to throads. of 2 #3-48 x 7/32” brass screws. Install screws so that they are slightly loose. 3. Apply finger pressure to throttle shaft to keep it firmly soated against pivot in carburetor body. Rotate the throttle shaft until the throttle plate fully closes the bore around its perime- ter; then tighten screws. 4. Operate the throttle lever and check that the throttle plate does not bind in the bore. Loosen screws and adjust piate if necessary; then tighten screws securely. Reassemble Carburetor Rofer to the following “Reassembiy” portion of this section. Reassembly Install the fue! inlot seat gasket and fuel inlet seat into carburetor body. Torque seat to 38/48 in. Ib. Install the fue! inlat needie into inlet seat. In- stall float and slide float pin through float hinge and float hinge towers on carburetor body. Sot float level: Invert carburetor so the flost {20 rests on the fuel inlet needle. There snoula be 11/64" (+~ 1/92") clearance between the machined surface of body and the free end of float. Bend the float tab with a smali screw- driver to adjust. Refer to Figure 6-13. Bend Tab To Adju ibe Inverted Carburetor Figure 6-13. Setting Float Level. Set float drop: Turn the carburetor over to its ormal operating position and allow float to drop to its towest level. The float drop should be limited 10 1=1/32" between the machined surface of body and the bottom of the free ‘end of float. Bend the float tab with a small screwdriver to adjust. Refer to Figure 6-14. Figure 6-14. Setting Float Drop.5. Check float-to-float hinge tower clearance: Invert the carburetor so the float tab rests on the fuel inlet needle. Insert a .010" feeler ‘gauge between float and float hinge towers. if the feeler gauge cannot be inserted, or there is interference between the float and towers, file the towers to obtain the proper clearance. Refer to Figure 6-15. 6. Install the bow! gasket and baffle gasket. Posi- tion baffle gasket so the inner edge is against the float hinge towers. 7. Install the fuel bow! so it is centered on the baffle gasket. Make sure the baffle gasket and bow! are positioned properly to ensure @ good seal. 8. Install the bow! retaining screw gasket and bowi retaining screw Torque screw to 50/60 in. Ib. 0.010" Feeler Gauge a (Both Sides) Float Hinge Towers Inverted Carburetor {On Carburetor Body) Figure 6-15. Checking Flost Clearance. 8. Install the idle speed adjusting screw and spring. Install the idle fuel and main fue! ad- justing needies and springs. Turn the adjusting needles clockwise until they bottom jightly. NOTE: The ends of adjusting needles are tapered to critical dimensions. Damage to needles and seats will result if needles are forced. 10. Reinstall the carburetor to the engine using a new gasket. 11. Adjust the carburetor as outlined under the “Adjustment” portion of this sect WALBRO FIXED/ADJUSTABLE CARBURETOR ‘This section covers the idle adjustment, disassem- bly, cleaning, inspection, repair, and reassembly of the Walbro-built, side draft, fixed/adjustable main jet carburetors. Idle Fuel Adjusting Needte ‘Adjusting Screw Figure 6-16. Fixed Main Jet Carburetor. Ba waswnc: rccttonta stanst Before servicing the carburetor, engine, or equip- ‘ment, always remove the spark plug leads to prevent the engine from staring accidentally. Ground the leads to prevent sparks that could cause fires. BD. waz0inc: expiosive Feet Gasoline maybe present nthe carburetor and te! system. GazoIne Is extremely fanmabe an ts vapors can explode if ignited. Keep sparks, open tame, and other sources of anton awey orn te area provent the possibly ots or exptosons. & wren: proven tye njry Suitable eye protecton (safely glasses, goggles, or face shield) should be worn for any procedure in- volving the use of compressed air, punches, ham- ‘mers, chisels, drills, or grinding tools.NOTE These wil be onaiher ine lap vas lever eof mounting ange a shown cron Date Code" Kohier Part No Throttle Lever/ Shaft Assembly Welch Plugs Choke Lever! Shalt Assembly Fuel Bow! Choke Detent Idle Speed Adjusting Ball And Spring Screw And Spring Mounting Flange Float Pin ap Float Fixed Main Fuel Jet “oltdte Throttle Plate Float Drop Port Adjusting Tab Limiting Tab (Non-Adjustable)| Ite Air Bleed Nozzle Air Bleed ‘Air Cleaner Mounting Surface late Fut Fuel Inlet Inlet Needle Figure 6-17. Major Components And Service Locations - Typical Fixed Jet Carburetor. 6.11‘TROUBLESHOOTING © Make sure the carburetor is securely fastened to the engine using gaskets in good condition, Hf engine troubles are experienced that appear to be fuel system related, check the following areas before adjusting or disassembling the carburetor. ee een een and all air cleaner components are fastened © Make sure the fuel tank is filled with clean, securely. fresh gasoline. © Make sure the ignition system, governor sys- tern, exhaust system, and throttle and choke controls are operating properly. © Make sure the fuel tank cap vent is not blocked and that it is operating properly. © Make sure fuel is reaching the carburetor. This includes checking the fuel shut-off valve, fuel It, after checking the items listed above, starting tank filter screen, in-line fuel fiter, fuel lines, problems or other conditions similar to those listed and fuel pump for restrictions or faulty compo- _in the following table exist, it may be necessary to nents as necessary. adjust or service the carburetor. Condition Possible Cause/Probable Remedy Idle fuel mixture oF 1. Engine starts hard, or le speed are improperly adjusted. Adjust the runs roughly or stalls at |" icle speed screw, then adjust idle fuel needle. idle speed. 2. Engine runs sich. 2a. Choke partially closed during operation. Check the choke lever and (Indicated by black, linkage to ensure choke is opening alter warm-up Sooty exhaust smoke, |p, iale tue! mature is improperly adjusted. Adjust ide fuel needle, ‘Speed and power, c. Float level set too high. With fuel bow! removed and carburetor in- ‘governor hunting, or verted, set exposed surface of float parallel with the bow! gasket reserve throtne surface of carburetor body ‘opening.) 4d, Dirt under fuel inlet needle. Remove needle. Clean needle and seat and blow with compressed air, ‘8. Bow! vent or air bleeds plugged. Remove fuel bowl, idle fuel adjust- ing needie, and woich plugs. Clean vent, ports, and air bleeds. Blow out all passages with compressed alr {. Fuel bowl gasket leaks. Remove fusl bowl and replace gasket. 4g. Leaky, cracked, or damaged float. Submerge float to check for leaks 3. 3a. Idle fuel mixture is improperly adjusted. Adjust idle fuel needle. (indicated by misfiring, b. Float level set too low. With fuel bowl removed and carburetor in- loss of speed and vorted, set exposed surtace of float parallel with the bow! gasket power, governor hunt- surface of carburetor body. 9. oF excessive throttle opening) «. Idle holes plugged; dirt in fuel delivery channels. Remove fuel bow, idle fuel adjusting needle, main fuel jet, and welch plugs. Clean all passages and blow out with comprossed air. 4. Fuel leaks from 4a. Float lovel set too high. See Remedy 20. carburetor. b. Dirt under fuel inlet needle. See Remedy 2d. ¢. Bowl vent plugged. Remove fue! bow! and clean bowl vent. Blow out with compressed air. 4. Float is cracked or damaged. Replace float. ©. Bow! retaining screw gasket damaged. Replace gasket. Bowl retaining screw is not tightened. Torque screw to specifications, 6.12Idle Speed ‘Adjusting Screw Adjusting Needle Figure 6-18. Fixed Main Jet Carburetor. Lean Adjust To Midpoint l Rich —— Figure 6-19. Carburetor Adjustment. CARBURETOR ADJUSTMENT NOTE: The tip of the low idle fuel and high ide fuel adjusting needles are tapered to critical di- mensions. Damage to the needles and the seats in carburetor body will result if the needles are forced. In general, turning the adjusting needles in (clock- wise) decreases the supply of fuel to the carbure- tor. This gives a leaner tue!-to-air mixturs. Turning the adjusting needles out (counterclockwise) in- creases the supply of fuel to the carburetor. This gives a richer fuel-to-air mixture. Setting the noodles midway between the lean and rich posi- tions will usually give the best results. Adjust the carburetor as follows: 1. With the engine stopped, turn the low idle fuel adjusting neadie in (clockwise) until it bottoms lightly. 2. Preliminary Settings: Turn the adjusting nee- dies out (counterclockwise) from lightly bot- tomed according to the table shown in Figure 6-20. 3. Start the engine and run at half throttle for five to ten minutes to warm up. The engine must be warm before making final settings (Steps 4, 5, 6, and 7). 4. High Idle Fuel Needle Setting: This adjustment is required only for adjustable high idle (main) jet carburetors. If the carburetor Is a fixed main Jet type, go to step 5. Place the throttle into the “fast” position. if possi- ble, place the engine under load. Turn the high idle fuel adjusting needle out (coun- terclockwise) from the preliminary setting until the ‘engine speed decreases (rich). Note the position of the needle. Now turn the adjusting needle In (clockwise). The engine speed may increase, then it wil decrease as the needle is turned in (lean). Note the position of the needle. Set the adjusting needle midway between the rich and lean settings. See Figure 6-21. 5. Low Idle Speed Setting: Place the throttle Control into the “idle” or “slow” position. Set the low idle speed to 1200 rpm* (+ or - 75 rpm) by turning the low idle speed adjusting screw in or out. Check the speed using a ta- chometer. *NOTE: The actual low idle speed depends on the application. Refer to the equipment manufacturer's instructions for specific low idle spoed settings. The recommended low idle speed for Basic En- gines is 1200 rpm. To ensure best results when setting the low idle fue! needa, the low idle speed must not exceed 1500 rpm. 6.13