Kohler K301 User's Manual
Contents
1. Figure 7 Servicing Spark Plug Battery Charging A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present On engines equipped with an alternator charging system disconnect plug from rectifier regulator prior to charging battery 10 Fuel Filter Some engines are equipped with an in line fuel filter Periodically inspect the filter and replace when dirty Use a genuine Kohler filter Reduction Gear Units On engines equipped with a reduction gear unit remove the oil plug on lower part of cover every 50 hours of operation to check oil level With the engine level the oil level of the unit should be up to the bottom of the oil plug hole To add oil remove the vented plug at the top of the unit Use the same weight and grade of oil as used in the engine crankcase Carburetor Troubleshooting and Adjustments NOTE Carburetor adjustments should be made only after the engine has warmed up Kohler K241 through K342. The engine identification numbers appear on decal or decals affixed to the engine shrouding Include letter suffixes if there are any Record your engine identification numbers on the identification label below Figure 4 for future reference REFER TO OWNER S MANUAL FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS FOR SALES AND SERVICE IN US CANADA CALL 1 800 544 2444 KOHLERENGJINES KOHLER CO KOHLER WI USA Figure 4 Engine Identification Label Operating Instructions Also read the operating instructions of the equipment this engine powers Pre Start Checklist e Check oil level Add oil if low Do not overfill e Check fuel level Add fuel if low e Check cooling air intake areas and external surfaces of engine Make sure they are clean and unobstructed e Check that the air cleaner components and all shrouds equipment covers and guards are in place and securely fastened e Check that any clutches or transmissions are disengaged or placed in neutral This is especially important on equipment with hydrostatic drive The shift lever must be exactly in neutral to prevent resistance which could keep the engine from starting A WARNING Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Cold Weather Starting Hints 1
3. Be sure to use the proper oil for the temperature expected See Figure 2 on page 4 2 Declutch all possible external loads 3 Set speed control at part throttle position 4 A warm battery has much more starting capacity than a cold battery 5 Use fresh winter grade fuel NOTE Winter grade gasoline has a higher volatility to improve starting Do not use gasoline left over from summer Starting 1 For a Cold Engine Place the throttle control midway between the slow and fast positions Place the choke control into the on position For a Warm Engine normal operating temperatures Place the throttle control midway between the slow and fast positions Place the choke into the off position 2 Start the engine as follows For Rope Start Engines Place the starting rope knot in the slot in starting pulley Wrap the rope around the pulley Pull the starter handle with a smooth steady motion For a Retractable Start Engine SLOWLY pull the starter handle until just past compression STOP Return starter handle pull firmly with a smooth steady motion to start Pull the handle straight out to avoid excessive rope wear from the starter rope guide Extend the starting rope periodically and check its condition If the rope is frayed have it replaced immediately by your Kohler Engine Service Dealer A WARNING Accidental Starts NOTE Do not crank the engine continuously for mo
4. 45 0 018 0 45 0 018 0 45 0 018 0 45 Spark PUG SIZE visina ER millimeters 14 eee Posen EE 14 Spark Plug NPE ae Champion RH10 or equivalent Breaker Point Gap Nominal inches millimeters 0 020 0 50 0 020 0 50 0 020 0 50 0 020 0 50 LIMITED 1 YEAR ENGINE WARRANTY We warrant to the original consumer that each new engine sold by us will be free from manufacturing defects in materials or workmanship in normal service for a period of one 1 year from date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or ata service facility designated by us of such part or parts as inspection shall disclose to have been defective EXCLUSIONS This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers WE SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but
5. approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season 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 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated Be aware however that the cylinder head will require more frequent service Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers of the engine
6. at increase the maximum engine speed angles exceeding 30 in any direction Overspeed IS hazardous and will void the Engine damage could result from insufficient engine warranty lubrication A WARNING Rope Starting Pulley is not NOTE If debris builds up on the grass screen or Do not use backup rope starting pulley as a drive other cooling air intake areas stop the engine pulley Using starting pulley as a drive could loosen immediately and clean Operating the engine flywheel fastener resulting in bodily harm with blocked or dirty air intake and cooling areas can cause extensive damage due to overheating Maintenance Instructions IN WARNING Accidental Starts Before servicing the engine or equipment always disconnect the spark plug lead to prevent the engine from starting accidentally Ground the lead fo prevent sparks that could cause fires Make sure the equipment is in neutral Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up Maintenance Required Fill fuel tank e Check oil level e Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary e Change oil iets cicada e Service precleaner element Every 50 Hours e Check gear reduction unit e Remove cooling shrouds and clean cooling areas e Replace air cleaner element E
7. not limited to labor costs or transportation charges in connection with the replacement or repair of defective parts ANY IMPLIED OR STATUARY WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is anyone authorized to make any in our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility For the facility nearest you consult your Yellow Pages or write Kohler Co Attn Engine Warranty Service Dept Kohler Wisconsin 53044 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 FORM NO TP 1346 C ISSUED 10 87 REVISED 8 97 MAILED LITHO IN U S A
8. of the engine are kept clean at all times Every 50 hours of operation more often under extremely dusty dirty conditions remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled NOTE Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating Check Spark Plug Every 100 hours of operation remove the spark plug check its condition and reset the gap or replace with a new plug as necessary Use a Champion type RH10 or equivalent spark plug 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 3 Check gap using a wire feeler gauge Spark plug gaps are as follows Battery Breakerless 035 Magneto margen 025 Gaseous Fuel Engines 018 Magneto Battery Only Adjust the gap as necessary by carefully bending the ground electrode See Figure 7 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 18 22 ft Ibs Wire Gauge Ground Electrode
9. wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock WARNING A A Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed California Proposition 65 Warning Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Safety Precautions Cont WARNING wes Ely iy WARNING WARNING Accidental Starts can cause severe injury or death Carbon Monoxide can cause severe nausea fainting or death Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Disconnect and ground spark plug lead before servicing Do not operate engine in closed or confined area Accidental Starts Lethal Exhaust Gases Explosive Gas Before servicing the engine or Engine exhaust gases contain Batteries produce explosive equipment always disconnect the poisonous carbon monoxide hydrogen gas while being charged spark p
10. 1 engines are equipped with one of two basic types of carburetors Kohler or Walbro fixed main jet or adjustable main jet The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The main fuel and idle fuel needles on adjustable jet carburetors are set at the factory and normally do not require further adjustment On fixed jet carburetors the low idle fuel needle is also set at the factory and normally does not need further adjustment The main fuel jet is calibrated and installed at the factory and is not adjustable NOTE K241 through K341 engines with fixed jet carburetors operating at altitudes above approximately 6000 ft may require a special high altitude main jet See your Kohler Engine Service Dealer for further information Troubleshooting If engine troubles are experienced that appear to be fuel system related check the following areas before adjusting the carburetor e Make sure the fuel tank is filled with clean fresh gasoline e Make sure the fuel tank cap vent is not blocked and that it is operating properly e If the fuel tank is equipped with a shutoff valve make sure it is open e lf the engine is equipped with an in line fuel filter make sure it is clean and unobstructed Replace the filter if necessary e Make sure fuel is reaching the carburetor This includes checking the fuel lines and fuel pump for restrictions or faulty c
11. DED SAE VISCOSITY GRADES 20 10 0 10 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Figure 2 Viscosity Grades Table Blower N Housing Figure 1 Typical Command Horizontal Shaft Engine Carburetor Spark Plug Cooling Shrouds As JE Starting Motor Oil Pan Oil Drain Straight 30 weight oil is preferred SAE 10W 30 oil is not recommended above 32 F Using this oil substantially increases oil consumption and combustion chamber deposits NOTE Using other than service class SG or SH oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 3 Figure 3 Oil Container Logo Refer to Maintenance Instructions beginning on page 7 for detailed oil check oil change and oil filter change procedures Fuel Recommendations IN WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean
12. KOHLER ent ines OWNER S MANUAL MODELS K241 K301 K321 amp K341 operating amp maintenance INSTTUCTIONS Congratulations You have selected a fine four cycle single cylinder air cooled engine Kohler designs long life strength and on the job durability into each engine making a Kohler engine dependable dependability you can count on Here are some reasons why e Kohler engines are easy to service All routine service areas like the points condenser air cleaner spark plug and carburetor are easily and quickly accessible e Parts subject to the most wear and tear like the cylinders crankshafts and camshaft are made from precision formulated cast iron Because the cast iron cylinders can be rebored these engines can last even longer e Every Kohler engine is backed by a worldwide network of over 10 000 distributors and dealers Service support is just a phone call away Call 1 800 544 2444 U S amp Canada for Sales amp Service assistance To keep your engine in top operating condition follow the maintenance procedures in this manual Safety Precautions To insure safe operations please read the following statements and understand their meaning Also refer to your equipment owner s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully IN WARNING Warning is used to indicate the presence of a hazard t
13. bic inch displacement and the number of cylinders Model K241A for example designates 24 cubic inch displacement 1 designates single cylinder The letter suffix designates a specific version as follows Suffix Designates A Oil Pan Type EP Generator Set P Pump Model Q Quiet Model R Gear Reduction S Electric Start T Retractable Start 14 Specifications Mode JED iaa KS0T senn KO int K341 POE ee inches millimeters 3 25 82 6 3 38 85 7 3 50 88 9 3 75 95 3 STOKE asbie inches millimeters 2 88 73 0 3 25 82 6 3 25 82 6 3 25 82 6 Displacement cubic inches cubic centimeters 23 9 391 29 1 476 31 3 512 35 9 588 Power 03600 RPM 4 horsepower kilowatts 10 7 5 1249 0 minister 14 10 4 2200 16 11 9 Approx Weight rrrnnrrrrnnrronnnnnrnnnnnnnnnn lbs kilograms 118 53 5 118 53 5 118 535 1 122 55 4 Oil Gapa iV ein EE U S pints liters 4 1 9 4 1 9 mn 4 TOn 4 1 9 Spark Plug Gap Magneto Ignition ssnnnnnnnnnnnnnnnnn inches millimeters 0 025 0 65 0 025 0 65 0 025 0 65 0 025 0 65 Battery Breakerless rrrrnnnnrrennnn inches millimeters 0 035 0 90 0 035 0 90 0 035 0 90 0 035 0 90 Gaseous Fueled Engines inches millimeters 0 018 0
14. dures Have your Kohler Engine Service Dealer do this work Possible Cause No improper Dirt In Dirty Incorrect Engine Dirty Air Faulty Problem Fuel Fuel Fuel Line Grass Screen Oil Level Overloaded Cleaner Spark Plug Will Not Start e Hard Starting Stops Suddenly Lacks Power o 9 Operates Erratically e Knocks or Pings Skips or Misfires Backfires a Overheats High Fuel Consumption 13 Storage If the engine will be out of service for two months or more use the following storage procedure 1 Clean the exterior surfaces of the engine 2 Change the oil and filter while the engine is still warm from operation See Change Oil on page 8 3 Change oil in reduction gear unit if so equipped Refill with the same oil as used in engine crankcase for season of operation See page 8 4 The fuel system must be completely emptied or the gasoline must be treated with a stabilizer to prevent deterioration If you choose to use a stabilizer follow the manufacturers recommendations and add the correct amount for the capacity of the fuel system Fill the fuel tank with clean fresh gasoline Run the engine for 2 3 minutes to get stabilized fuel into the carburetor To empty the system run the engine until the fuel tank and system are empty 5 Remove the spark plug Add one tablespoon of e
15. ely 4 Fill the crankcase with new oil of the proper type to the F mark on the dipstick Refer to Oil Type on page 4 Always check the level with the dipstick before adding more oil 5 Reinstall the oil fill cap or plug and tighten securely NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Service Precleaner and Air Cleaner Element This engine is equipped with a replaceable high density paper air cleaner element Some engines are also equipped with an oiled foam precleaner which surrounds the paper element See Figure 6 Base Plate Element Figure 6 Air Cleaner Housing Components Check the air cleaner daily or before starting the engine Check for buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air cleaner components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Service Precleaner Wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions 1 Remove the wing nut and air cleaner cover 2 Remove the precleaner from the paper element 3 Wash the precleaner in warm wate
16. hat can cause severe personal injury death or substantial property damage if the warning is ignored 71N CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the warning is ignored NOTE Note is used to notify people of installation operation or maintenance information that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others 4 WARNING Explosive Fuel can cause fires and severe burns Stop engine before filling fuel tank Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent WARNING Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed ki Electrical Shock can cause injury Do not touch
17. ich Note the position of the needle Now turn the adjusting needle 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 5 Low Idle Speed Setting Place the throttle control into the idle or slow position Set the low idle speed to 1200 RPM 75 RPM by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application refer to equipment manufacturer s recommendations The recommended low idle speed for basic engines is 1200 RPM To ensure best results when setting the low idle fuel needle the low idle speed must not exceed 1500 RPM 6 Low Idle Fuel Needle Setting Place the throttle into the idle or slow position Turn the idle fuel adjusting needle out counterclockwise 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 at the needle is turned in lean Note the position of the needle Set the adjusting needle midway between the rich and lean settings Adjust To Midpoint Rich Figure 8 7 Recheck idle speed using a tachometer Readjust speed as necessary 11 Walbro Carburetor Adjus
18. ipstick before adding more oil NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick F Mark Operating Range Figure 5 Oil Level Dipstick Oil Sentry Some engines are equipped with an optional Oil Sentry oil level monitor switch If the oil level drops below an acceptable level the Oil Sentry will either shut off the engine or activate a warning signal depending on the application NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to the F mark on the dipstick This includes engines equipped with Oil Sentry Change Oil For a new engine change oil after the first 5 hours of operation Thereafter change oil after every 25 hours of operation Change the oil while the engine is still warm The oil will flow freely and carry away more impurities Make sure the engine is level when filling checking or changing the oil Change the oil as follows 1 To keep dirt grass clippings etc out of the engine clean the area around the drain plug and dipstick before removing it 2 Remove the oil drain plug and dipstick Tilt the engine slightly towards the oil drain to obtain better drainage Be sure to allow ample time for complete drainage 3 Reinstall the drain plug Make sure it is tightened secur
19. lug lead to prevent the Carbon monoxide is odorless To prevent a fire or explosion engine from Starting accidentally colorless and can cause death if charge batteries only in well Ground the lead to prevent sparks inhaled Avoid inhaling exhaust ventilated areas Keep sparks open that could cause fires Make sure fumes and never run the engine in flames and other sources of the equipment ts in neutral a closed building or confined area ignition away from the battery at all times Keep batteries out of the reach of children Remove all Jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present Ignition Coil Air Filter Dipstick Oil Fill Plug Air Intake Screen NOTE Dipstick or oil fill plug is optional and may vary depending on engine specification Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG or SH Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMEN
20. ngine oil into the spark plug hole Install the plug but do not connect the plug lead Crank the engine two or three revolutions 6 Remove the spark plug Cover the spark plug hole with your thumb and turn the engine over until the piston is at the top of its stroke Pressure against thumb is greatest Reinstall the plug but do not connect the plug lead 7 Store the engine in a clean dry place Parts Ordering The engine Specification Model and Serial Numbers are required when ordering replacement parts from your Kohler Engine Service Dealer These numbers are found on the identification plate which is affixed to the engine shrouding Include letter suffixes if there are any See Engine Identification Numbers on page 5 Always insist on genuine Kohler parts All genuine Kohler parts meet strict standards for fit reliability and performance Major Repair Major repair information is available in Kohler Engine Service Manuals However major repair generally requires the attention of a trained mechanic and the use of special tools and equipment Your Kohler Engine Service Dealer has the facilities training and genuine Kohler replacement parts necessary to perform this service For Sales amp Service assistance call 1 800 544 2444 U S amp Canada or contact your Kohler Engine Dealer or Service Distributor they re in the Yellow Pages under Engines Gasoline Model Designation The model number designates the cu
21. o a complete stop Battery A 12 volt battery is normally used Refer to the operating instructions of the equipment this engine Before extending and checking the retractable starter powers for specific battery requirements rope remove the spark plug lead to prevent the engine from starting accidentally Make sure the equipment is in neutral If the battery charge is not sufficient to crank the engine recharge the battery see page 10 For an Electric Start Engine Activate the starter switch Release the switch as soon as the engine starts Operating Optional spark arrestor mufflers are available from your Kohler Engine Service Dealer Check your local laws and statutes regarding engine spark arrestor muffler requirements Angle of Operation This engine will operate continuously at angles up to WARNING Hot Parts 30 Check oil level to assure crankcase oil level is at Engine components can get extremely hot from the F mark operation To prevent severe burns do not touch these areas while the engine is running or Refer to the operating instructions of the equipment immediately after it is turned off Never operate the this engine powers Because of equipment design or engine with heat shields or guards removed application there may be more stringent restrictions regarding the angle of operation Engine Speed NOTE Do not tamper with the governor setting to NOTE Do not operate this engine continuously
22. omponents replace as necessary e Make sure the air cleaner element is clean and all air cleaner element components are fastened securely If after checking the items listed above the engine is hard to start runs roughly or stalls at low idle speed it may be necessary to adjust or service the carburetor Kohler Carburetor Adjustment 1 With the engine stopped turn the low and main fuel adjusting needles in clockwise until it bottoms lightly NOTE The tip of the idle fuel and main idle fuel adjusting needles 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 as follows Kohler Adjustable Jet tow idle 2 1 2 turns High Idle 2 turns 2 turns 3 1 4 turns 3 1 2 turns 2 1 2 turns 2 1 2 turns 2 1 2 turns 3 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before making final settings 4 Main Fuel Needle Setting This adjustment is required for adjustable main jet carburetors only If the carburetor is a fixed main jet type refer to Walbro adjustment Place the throttle into the wide open or fast position If possible place the engine under load Turn the main fuel adjusting needle out counterclockwise from the preliminary setting until the engine speed decreases r
23. r with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 Reinstall the precleaner over the paper element 6 When precleaner replacement is necessary always use genuine Kohler parts Service Paper Element l Every 100 hours of operation more often under extremely dusty or dirty conditions replace the element 1 Remove the precleaner if so equipped from the paper element 2 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 3 When servicing the air cleaner check the air cleaner base Make sure it is secured and not bent or damaged Also check the air cleaner cover seals and breather tube for damage or improper fit Replace all damaged air cleaner components 4 Reinstall the paper element air cleaner cover and wing nut Wing nut must be finger tightened to 1 2 to 1 full turn after nut contacts cover Do not overtighten 5 When air cleaner element replacement is necessary always use genuine Kohler parts Clean Air Intake Cooling Areas To ensure proper cooling make sure the grass screen cooling fins and other external surfaces
24. re than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor NOTE If the engine develops sufficient speed to disengage the starter but does not keep running a false start the engine rotation must be allowed to come to a complete stop before attempting to restart the engine If the start is engaged While the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the starter If the starter does not turn the engine over shut off starter immediately Do not make further attempts to start the engine until the condition is corrected Do not jump start using another battery refer to Battery below See your Kohler Engine service Dealer for trouble analysis 3 Fora Cold Engine Gradually return the choke control to the off position after the engine starts and warms ups Stopping 1 Remove the load by disengaging all PTO attachments 2 Move the throttle control to the slow or low idle position Allow the engine to run at idle for 30 60 seconds then stop the engine If the carburetor on the engine is equipped with a fuel solenoid move the throttle control back up between half and full throttle just before stopping the engine 3 Turn ignition switch off On engines so equipped press and hold stop button until engine comes t
25. the needle is turned in lean Note the position of the needle Back the needle out approximately 1 4 turn See Figure 10 for best main fuel performance Back out Appx 1 8 to 1 4 Figure 10 Optimum Main Fuel Setting 5 Low Idle Speed Setting Place the throttle control into the idle or slow position Set the low idle speed to 1200 RPM 75 RPM by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application Refer to the equipment manufacturer s instructions for specific low idle speed settings To ensure best results when setting the low idle fuel needle the low idle speed must not exceed 1500 RPM 6 Low Idle Fuel Needle Setting Turn the adjusting needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position of the needle Back the needle out approximately 1 8 to 1 4 turn See Figure 11 for best low idle fuel performance Figure 11 Optimum Low Idle Fuel Setting Troubleshooting When troubles occur be sure to check the simple causes which at first may seem to 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 in the following table Do not attempt to service or replace major engine components or any items that require special timing or adjustment proce
26. tment In general turning the adjusting needles in clockwise decreases the supply of fuel to the carburetor This gives a leaner fuel to air mixture Turning the adjusting needles out counterclockwise increases the supply of fuel to the carburetor Fuel Needle Main Fuel Needle Figure 9 NOTE The tip of the low idle fuel and main fuel adjusting needles are tapered to critical dimensions Damage to the needles and the seats in carburetor body will result if the needles are forced _ 1 With the engine stopped turn the adjusting needle s in clockwise until it bottoms ightly 2 Preliminary Settings Turn the adjusting needle s out counterclockwise from lightly bottomed as follows or to the rich side of adjustment Walbro Fixed Jet we 1 1 4 turns 1 1 4 turns 1 1 2 turns 1 turn Walbro Adjustable Jet dewide wanie 1 3 4 turns 1 1 8 turns 1 3 4 turns 1 1 8 turns 1 1 8 turns 1 1 4 turns 2 1 2 turns 1 1 4 turns 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 4 Main Fuel Needle Setting This adjustment is required only for adjustable main jet carburetors If the carburetor is a fixed main jet type disregard this setting Place the throttle into the fast position Turn the adjusting needle in clockwise The engine speed may increase then it will decrease as
27. very 100 Hours e Check spark plug condition and gap e Have bendix starter drive serviced gt e Have breaker points checked e Have ignition timing checked e Have valve and tappet clearance checked e Have cylinder head serviced 4 Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform this service 3Or annually whichever occurs first 4250 hours when leaded gasoline is used Daily or Before Starting Engine Annually or Every 500 Hours Check Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 To keep dirt grass clippings etc out of the engine clean the area around the oil fill tube dipstick before removing it 3 With threaded plug type dipstick remove and wipe oil off reinsert but do not turn plug in To check oil level shoulder plug on top of hole After checking again turn plug all the way into crankcase With extended oil fill tube and dipstick push dipstick all the way down in tube then take reading 4 If the level is low add oil of the proper type up to the F mark on the dipstick Refer to Oil Type on page 4 Always check the level with the d
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