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Single Cylinder Engine SERVICE MANUAL K9J, KJ4J, KJ6J, KJSJ

Contents

1. Bore x Siroke ff 2 375x2 008 2 938x2 500 2 938x2 750 3 251x2 875 3 375x3 250 3 5003 250 GENERAL Disptacement Cu In 8 86 15 94 18 64 23 85 29 07 27 39 Max Operating RPM C NN 3600 3800 3800 3600 3600 Shaft New 998 5001 4998 5001 4998 5001 oro 0 0 emm ame Am 4995 4996 End Play OVD 02 000 002 010 002 010 Sleeve 1 0 Installed oo T NEN End Play 005 020 005 010 005 010 005 010 005 010 005 010 005 010 E Pem F 001 0025 001 002 001 002 001 002 001 002 ae 03 005 005 025 0025 0025 0025 0007 0008 0006 0011 0006 0011 0003 0008 0003 0008 0003 0008 0003 0008 5630 5633 6255 6258 6255 6258 8596 8599 8757 8760 8757 8760 8757 8760 P 5841 9844 1 1811 1 1814 1 1611 1 1814 1 5745 1 5749 1 5745 1 5749 1 5745 1 5749 1 5745 1 5749 i j wearin 9841 1 1811 1 1811 1 5745 1 5745 15745 1 5745 A Round Sleeve as Max Taper Sleeve is panning i 2 REN fetes oa SS New Slesve Bearing I D MCN Nu AL a stalled 8 tM MENGE E cl New ECTEIMETIE ETT 4995 1 8000 14995 1 5000 1 4995 Max Wear Limit 1 1850 1 1850 1 4990 14990 ES 1 4990 gt Max Dut of Round 0005 0005 0005 0005 0005 o Max Taper Poot a Om wo aw End Play 004 023 002
2. d New 140 In Ibs Used 100 In Ibs 6 O1 3 K161 K181 CYLINDER K91 200 in Ibs 5 15 20 ft Ibs HEADO Qs Q2 K301 K321 25 30 ft Ibs V Os 2 QS K341 O Q 25 30 tt Ibs 3 Os Q2 O5 FLYWHEEL NUT RETAINING 40 50 ft Ibs 85 90 ft Ibs 50 60 ft Ibs 70 90 in Ibs 130 150 in Ibs 100 120 in Ibs a owe 9 000 00m9mm _Cast Iron _ Sheet Metal GOVERNOR BUSHING Grade 5 250 in Ibs Grade 8 350 in Ibs 35 ft Ibs 200 in Ibs 37 45 in Ibs 37 45 in Ibs USE STANDARD TORQUE SETTINGS WHEN SPECIFIC VALUES ARE NOT SPECIFIED ee CKNN NON METALLIC FUEL PUMP MOUNTING SCREWS OIL DRAIN PLUGS Oil at Assembly Tightening Torque Cast Iron or Steel 8 32 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 8 32 10 24 1 4 20 5 16 18 3 4 16 Aluminum 20 in 32 in 32 in 70 in B5 in 150 in 165 In 260 in 300 in 35 ft 45 ft 50 ft 70 ft 75 ft 100 ft 110 ft 140 ft 150 ft 200 ft Ib ib ib ic Ib Ib Ib Ib ib Ib Ib Ib Ib Ib Ib Ib Ib Ib Ib Ib 25 in 40 in 40 in 115 1N 140 in 250 in 270 in 35 ft 40 ft 55 ft 75 ft 8o ft 105 ft 125 ft 165 ft 180 ft 230 ft 245 ft 325 ft 20 in 32 in 70 in 150 in 20 in 32 in 7O in 150 in Ib
3. P Pd p nd STOP NUT 90 110 INCH LBS Figure 8 29 Permanent Magnet Starter Exploded View Failure Analysis Bendix Drive Starters ally in many instances the starter brushes will be welded or stuck in the brush holders Starter failures from overcranking or cranking with an abnormal parasitic load on the engine will display one or a number of the following signs Some of the frequent causes of abnormal parasitic load at cranking are mE Improper viscosity engine crankcase oil 1 The armature wire insulation or coating will ap pear discolored and may be swollen In many 2 Incorrect fluid in a direct coupled hydrostatic cases you may be able to detect an odor unit remember even in the idle or neutral from the burnt wire coating or see it oozing position a direct coupled hydrostatic pump will from the starter housing place a parasitic load on the engine at crank ing 2 One or a number of the armature windings may have wires or wire connections that have burnt in two Wires may have insulation miss 3 Malfunctioning or inoperative direct coupled clutch assembly ing or be partially fused together 4 Engaged accessory or drive clutch assembly 3 The starter brushes will show heavy surface Starter failures from overcranking or cranking galling and brush material transfer Addition against an abnormal parasitic load are not covered 8 23 by Kohler engine Warranty We would recommend that you identify t
4. Place the starter on the four screws make sure the centering pin engages the centerhole in the crankshaft and press into position Hold the starter with one hand and place the lock washers and nuts on the screws and tighten securely Reinstalling Starter On Engine b To align the starter place it on the blower housing in the desired position with the cen tering pin engaged in the center hole of the crankshaft If the centering pin is too short to reach the crankshaft use a pair of pliers and pull the pin out to the correct length SHARP EDGE Figure 7 2 Fairbanks Morse Starter Disassembly 7 2 2 Press the starter into position and install the four screws with lock washers and flat wash ers To Remove Starter 3 Hold the starter assembly in this centered po sition and securely tighten the four screws 1 Remove the five screws securing the starter assembly to blower housing STAMPED HOUSING MODELS To Install Starter A CAUTION Spring Under Tension Retractable starters contain a powerful flat wire re coil spring that is under tension Do not remove the 1 Install starter to blower housing using the five mounting screws Leave screws slightly loose center screw from the starter until the tension is re 2 Pull the handle out approximately 8 to 10 leased Removing the center screw before releas until the pawls engage in the drive cup Hold ing spring tension or improper starter disassembly the ha
5. Press the crankshaft into the rear bearing until the crankshaft gear is just above the camshaft gear but not in mesh with it Do not remove the balance gear timing tool at this time 4 Align the fifth 5th land marked on camshaft gear with the fifth 5th tooth marked on crankshaft gear Refer to Figure 12 22 Marked Tooth On Crankshaft Gear Marked Land On Camshaft Gear Figure 12 22 Aligning Camshaft Gear And Crankshaft Gear Press the crankshaft all the way into the rear bearing Make sure the camshaft and crank shaft gears mesh and the marks align while pressing 5 Remove the balance gear timing tool Check the timing of the crankshaft camshaft and balance gears The primary timing mark on crankshaft should align with the secondary timing mark on lower balance gear Refer to Figure 12 23 Figure 12 23 Crankshaft Gear Lower Balance Gear Alignment The primary timing mark on crankshaft should align with the timing mark on camshaft Re fer to Figure 12 24 12 7 If the marks do not align the timing is incorrect and must be corrected Upper Balance Gear Secondary Timing Mark i Crankshaft Primary Timing Mark 7th Land From A Timing Mark E PPA ESR AR NTE AGE E Camshatt Figure 12 26 Marking Land On Upper Balance Gear ae d Figure 12 24 Crankshaft Gear Camshaft Gear Alignment 2 Lubricate the rear bearing surface of crank shaft insert the PT
6. ee ee Size Grade 2 Grade 5 Grade 8 EP rrr T im Aluminum Pans m up 3 8 180 in Ib 120 in Ib 1 2 20 ft Ibs 13 ft ibs 3 4 25 ft Ibs 16 ft Ibs E X 708 1 20 25 ft Ibs 20 25 ft Ibs 165 in Ib 200 in 350 in 30 ft 50 ft 60 ft BO ft 105 ft 115 ft 165 ft 175 ft 230 ft 260 ft 330 ft 350 ft 470 ft 20 in 32 in 70 in 150 in Also Self Tapping Screws in lbs x 083 ft Ibs ft Ibs x 12 1n Ibs ft ibs x 1383 kgm ft Ibs x 1 35582 N m Conversions Lubricate with engine oil DO NOT overtorque loosen and retorque the hex nuts on Posi Lock connecting rods NEW Component directly from stock USED Component that was in a running engine Includes K141 Overtorque 20 loosen below torque value and retorque to final torque value Torque twice with minimum of one minute interval G 3 8 16 thread with hex head nut and fibre gasket Prior to Ser 23209832 45 55 ft ibs Figure 1 6 Torque Values amp Sequences For Fasteners 1 7 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 Serv
7. 1 1 2 turns 2 turns NOT APPL NOTE Refer to publica 1 1 2 turns 3 turns NOT APPL tion TP2377B Carburetor 1 1 2 turns 3 turns NOT APPL Reference Manual for 1 1 4 turns 2 turns 2 1 2 turns additional information 2 1 2 turns 2 turns 1 1 4 turns 2 1 2 turns 2 turns 1 1 4 turns 2 1 2 turns 3 1 4 turns 1 1 2 turns 2 1 2 turns 3 1 2 turns 1 turn Includes New Look Models Figure 6 4 Preliminary Low Idle And High Idle Fuel Needle Settings 6 Low Idle Fuel Needle Setting Place the throttle 2 Remove the float pin float fuel inlet needle into the idle or slow position baffle gasket and bowl gasket Turn the low idle fuel adjusting needle out coun 3 Remove the fuel inlet seat and inlet seat gas terclockwise from the preliminary setting until the ket Remove the idle fuel and main fuel adjust engine speed decreases rich Note the position ing needles and springs Remove the idle of the needle speed adjusting screw and spring Now turn the adjusting needle in clockwise The 4 Further disassembly to remove the throttle and engine speed may increase then it will decrease choke shafts is recommended only if these as the needle is turned in lean Note the position parts are to be replaced Refer to Throttle of the needle and Choke Shaft Replacement later in this section Set the adjusting needle midway between the rich and lean settings See Figure 6 5 7 Recheck the low idle speed using a ta
8. Inspection Scuffing and scoring of piston and cylinder wall occur when internal temperatures approach the melting point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very little wear takes place in the piston boss piston pin area If the original piston and connecting rod can be reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is included as part of the piston assembly if the pin boss in piston or the pin are worn or damaged a new piston assembly is required Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter the combustion chamber where it is burned along with the fuel High oil consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on piston causing rings to stick which results in rapid wear A worn ring usually 11 8 takes on a shiny or bright appearance Scratches on rings and piston are caused by abrasive mate rial such as carbon dirt or pieces of hard metal Detonation damage occurs when
9. GOVERNOR CROSS SHAFT gt Sy GOVERNOR ARM ONU boyi Ta DT LUI Figure 6 47 Initial Adjustment 6 30 GOVERNOR ARM GOVERNOR SPRING GOVERNOR ARM BRACKET SPEED CONTROL BRACKET HIGH SPEED STOP THROTTLE CONTROL Figure 6 48 Variable Speed Governor Initial Adjustment K241 K301 K321 K341 Initial adjustment for these models is essentially the same as for models K91 through K181 Refer to Figure 6 47 for parts description Throttle Wire Installation Install a throttle for variable speed applications as follows Refer to Figure 6 48 1 Mount the throttle control or throttle cable clamp on the blower housing as shown in Fig ure 6 48 2 Move the throttle control to the open position and place the end of the throttle wire through the hole in the pin on speed control bracket 3 Use a long nose pliers or similar tool to loop the end of the throttle wire around the pin Speed Adjustment A WARNING Overspeed Is Hazardous The maximum allowable speed for Models K241 through K341 is 3600 RPM no load Never tamper with the governor setting to increase the maximum speed Severe personal injury and damage to the engine or equipment can result if operated at speeds above the established maximum Adjust the governed speed of these models as follows Refer to Figure 6 48 1 Start the engine and allow a short warmup pe riod 2 Open the throttle fully and c
10. KOHLERENGMES Single Cylinder Engine SERVICE MANUAL K91 K141 K161 K181 K241 K301 K 321 K341 SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 SECTION 10 SECTION 11 SECTION 12 CONTENTS General Information cc en eee een RR Hk nnnm aras Special TOO IS 5 arse acr 9 renee sawn ou bene nee eae d opa hc 0 i eee Periodic Maintenance ccc cece eee ee eee nee Rr RR rra aat Troubleshooting cece ee ee eee eee eee ee eee etna Air Cleaner And Air Intake System Fuel System And Governor Retractable Starters Electrical Systems And Components Automatic Compression Release cccc cece eee teense nre DISasSembDi 665664265 92 9093 9 eee ee CR mdr aed Inspection and Repair s ehh hmm hahaha MCASSCINDIV asd ESCUR RSDCRCRACR R NSE EROR E RR eee eas ee ee we SECTION 1 GENERAL INFORMATION SAFETY INFORMATION For Your Safety These safety precautions should be followed at all times Failure to follow these safety precautions could result in serious injury to yourself and others A WARNING A WARNING Explosive Fuel can cause fires and severe burns Rotating Parts can cause severe injury Stay away while engine is in Stop engine before filling operation fuel tank WARNING Explosive Fuel WARNING Rotating Parts Gasoline is extremely flammable Keep
11. PRIMARY 10 PSI PRIMARY DIAPHRAGM SPRING AERE mee CHAMBER rem AH sa VALVE SPRING PRIMARY VALVE INLET SECONDARY 2 PSI SECONDARY DIAPHRAGM ac M BUTTON Figure 6 38 Two Stage Regulator Adjust the two stage regulator as follows 1 Turn the secondary adjustment counterclock wise as far as it will go Then turn it clockwise 3 turns 2 Connect a source of clean compressed air of at least 25 psi to the regulator inlet and de press primer button 3 times 3 Connect a 0 to 15 psi pressure gauge to the fuel outlet and press and hold the primer but ton The pressure gauge should read approxi mately 2 psi and hold steady at this reading If pressure rises slowly the primary valve is leaking and the regulator must be replaced If pressure remains constant proceed 4 Remove pressure gauge and cover outlet with a film of soap solution If a bubble forms the secondary valve is leaking 5 Slowly turn the secondary adjustment to the left until the bubble expands then to the right one complete turn to stop the leak If leaking persists replace the regulator GOVERNOR Engine speed governors in the K series of engines with the exception of the K91 are of the centrifu gal flyweight mechanical type The K91 utilizes a flyball The governor gear and flyweight mecha nism are contained within the crankcase The gov ernor gear is driven by a gear on the camshaft Operation In operation cen
12. SS yy NAN RS Figure 11 5 Valve Details Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check valves first After re moval clean valve head face and stem with power wire brush and then carefully inspect for defects such as warped valve head excessive corrosion or worn stem end Replace valves found to be in bad condi tion A normal valve and valves in bad condition are shown in the accompanying illustrations Normal Even after long hours of operation a valve can be reconditioned and reused if the face and margin are in good shape If a valve is worn to where the margin is less than 1 32 do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions 11 4 Bad Condition The valve depicted here should be replaced The head is warped the margin is dam aged and is too narrow These conditions could be attributed to excessive hours or a combination of poor operating conditions Leakage A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only Coking Coking is normal on intake valves and is not harmful If the seat is good the valve could be reused after cleaning Overheating An exhaust valve subject to over heating will have a dark discoloration in the area above the valve guid
13. Check the gap with a wire type feeler gauge Set the gap as shown in the following table by carefully bending the side electrode 4 Install the spark plug and torque to 18 to 20 ft Ib Spark Plug Specifications Inspect the spark plug as soon as it is removed from the engine The deposits on tip are a good indicator of the general condition of piston rings valves and carburetor Normal and faulty spark plugs are shown in Figures 8 10 through 8 14 Plug Part No 270321 S 41 132 06 41 132 02 235040 S 23504 1 S 41 132 02 235040 S 23504 1 S NOTE On gas fueled engines gap is 018 on all models 8 7 Figure 8 10 Normal Normal A plug taken from an engine operating under normal conditions will have light tan or gray deposits If the center electrode is not worn a plug in this condition may be gapped and re used Figure 8 11 Carbon Fouled Carbon Fouled Soft sooty black deposits indi cate incomplete combustion This is usually caused by overrich carburetor settings weak igni tion or poor compression Figure 8 12 Worn Worn On a worn plug the center electrode will be rounded and the gap will be eroded 010 or more beyond the correct gap Replace a worn spark plug Figure 8 13 Wet Fouled Wet Fouled Wetness is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by operating the engine without fully opening the choke after warmup Oil
14. Marking Tooth On Crankshaft timed the primary timing mark on the crank Gear shaft will now be aligned with the secondary timing mark on the lower balance gear Refer to Figures 12 9 and 12 17 Camshaft Locate the timing mark on cam shaft Starting with the land next to the timing mark count five 5 lands in a counterclock wise direction Mark the fifth land Refer to Figure 12 19 4 Install one 1 020 shim spacer and retaining ring rounded edge towards gear Check end 12 6 EA lt x i See ee Bs xm QUE 2 a E TOC S 31 E X 1 R n X My S402 us S E N 5th Land From A Camshaft Gear Ti ming Mark 4 Figure 12 19 Marking Land On Camshaft Gear 2 Align the primary timing marks on balance gears with the teeth on timing tool Insert the tool so it meshes with the gears Hold or clamp the tool against oil pan gasket surface of crankcase Refer to Figure 12 4 Balance Gear 3 Timing Tool Primary Timing Marks sud Teeth Vice Grips 7 Or Clamp Gasket Surface Timing Tool d Figure 12 20 Installing Balance Gear Timing Tool 3 Lubricate the rear bearing surface of crank shaft Insert the PTO end of crankshaft through the rear bearing Straddle the primary and secondary timing marks on crankshaft over the rear bearing oil drain Refer to Figure 12 21 Crankshaft Timing Marks i Figure 12 21 Aligning Crankshaft And Rear Bearing Oil Drain
15. Refer to Figure 7 5 Remove the rope retainer from inside handle and untie the knot to remove retainer and han dle Hold the pulley firmly with thumb and untie the slip knot Allow pulley to rotate slowly as the spring tension is released Refer to Figure 7 6 When all spring tension on the starter pulley has been released remove the rope from the pulley Remove the center screw washer pawl cam and brake spring Rotate the pulley clockwise 2 full turns This will ensure the pulley is disengaged from the spring Hold the pulley into starter housing and invert starter so the pulley is away from your face and away from others in the area Rotate the pulley slightly from side to side and carefully separate the pulley from the starter housing Refer to Figure 7 8 If the pulley and housing do not separate eas ily the spring could be engaged with the pul ley or there is still tension on the spring Re turn the pulley to the housing and repeat step 7 before separating the pulley and housing Note the position of the spring and keeper as sembly on the pulley Also refer to Figure 7 9 The spring and keeper assembly must be cor rectly positioned on pulley for proper opera tion Remove the spring and keeper assembly Figure 7 9 Position Of Spring And Keeper On Pulley 7 5 A CAUTION Spring Under Tension Do not remove the spring from the keeper Severe personal injury could result from sudden uncoil
16. To provide improved vibration reduc ing characteristics redesigned balance gear as semblies are being used in the K241 K301 K321 and K341 single cylinder engines These new bal ance gear assemblies Part No 45 043 03 are being used in engines with a Serial No of 1613600013 and later and for service replace ment Figure 12 12 shows the physical differences between the old and new style gear assemblies Crankshaft N Primary Camshaft i Timing Mark Figure 12 11 Aligning Crankshaft And Camshaft Timing Marks Because of the physical differences of the gear new procedures for installing the crankshaft and timing the balance gears crankshaft and cam shaft are required The following INSTALL CRANKSHAFT proce dures are broken down into four sections 1A OLD STYLE BALANCE GEAR ASSEMBLY WITH A BALANCE GEAR TIMING TOOL 1B OLD STYLE BALANCE GEAR ASSEMBLY WITHOUT A BALANCE GEAR TIMING TOOL 2A NEW STYLE BALANCE GEAR ASSEMBLY WITH A BALANCE GEAR TIMING TOOL 2B NEW STYLE BALANCE GEAR ASSEMBLY WITHOUT A BALANCE GEAR TIMING TOOL METHOD Figure 12 12 Old And New Style Balance Gear Assemblies 12 4 1A OLD STYLE BALANCE GEAR ASSEMBLY WITH A BALANCE GEAR TIMING TOOL 1 Align the primary timing marks of balance gears with the teeth on timing tool Insert tool SO it meshes with gears Hold or clamp tool against oil pan gasket surface Refer to Figure 12 13 Balance Gear P
17. and recheck pressure 2 Seals and or gaskets leaking Loose or 2 Replace all worn or damaged seals and gaskets improperly torqued fasteners Make sure fasteners are tightened securely Use appropriate torque values and sequences when necessary 3 Piston blowby or leaky valves Confirm by 3 Recondition piston rings cylinder bore valves inspecting components and valve guides 4 Restricted exhaust 4 Replace restricted muffler exhaust system Figure 4 1 V MEASURE DIFFERENCE BETWEEN COLUMNS Figure 4 2 U Tube Manometer 4 3 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 fer to Figure 5 1 If so equipped wash and re oil the precleaner every 25 operating hours more often under ex tremely dusty or dirty conditions 1 Wash the precleaner in warm water and deter AIR CLEANER DISASSEMBLY gent 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 precleaner if SO equipped pa cess water do not wring Allow precleaner to per element and seal dry 3 Saturate the precleaner with clean fresh en 3 Remove the base screws air cleaner base gine oil Squeeze out e
18. as these parts could become cracked or damaged Rope Start Models 1 Remove the grass screen retainer and wire mesh grass screen from rope pulley 2 Hold the flywheel with a strap wrench and loosen the hex cap screw Remove the hex cap screw plain washer rope pulley and spacer Remove the nylon grass screen from the fan Retractable Start Models 1 Hold the flywheel with a strap wrench and loosen hex cap screw securing flywheel to crankshaft Remove the hex cap screw plain washer and drive cup 2 Remove the grass screen from the drive cup Electric Start Models 1 Remove the grass screen from the fan 2 Hold the flywheel with a strap wrench and loosen hex cap screw or hex nut securing fly wheel to crankshaft Remove the hex cap screw or hex nut Remove plain washer On All Models 1 Flywheel is mounted on tapered portion of crankshaft Use of a puller is recommended for removing flywheel Bumping end of crank shaft with hammer to loosen flywheel should be avoided as this can damage crankshaft Refer to Figure 10 3 as TE QU N Figure 10 3 Removing Flywheel With A Puller NOTE Ignition magnet is not removable or service able Do not attempt to remove ignition magnet from flywheel Loosening or removing magnet mounting 10 3 screws could cause the magnet to come off dur ing engine operation and be thrown from the en gine causing severe injury Replace the flywheel
19. at its top The style C piston is to be installed with the notch facing the flywheel Partial Skirt with Raised Criss cross Pattern installation _ Direction identifier Notch Style C Piston The Style D piston has been used on the K181 K301 and K321 engines It can be identified by its partial skirt and rectangular recessed area around the piston pin bore In addition it has an installa tion direction identifier Fly which is stamped into the top of the piston The style D piston is to be installed with the arrow of the Fly mark pointing towards the flywheel l Partial Skirt Installation with Rectangular Direction Recess Identifier j Ne Style D Piston Piston Sizes All Styles In order to ensure a correct fit between piston and cylinder we utilize two cylinder bore sizes at the factory Cylinder blocks are honed to the Standard STD size or 003 075mm oversize with corre sponding pistons Blocks using the oversize are stamped on the cylinder head gasket surface with 003 It is essential that 003 oversize pistons are used in these blocks to prevent possible fail ure such as a noisy engine or eventual piston skirt cracking These pistons are available from Kohler Standard Service Rings should be used with both Standard and 003 oversize pistons Ring end gap will increase slightly when installed on 003 oversize pistons however sealing is maintained due to the ring design
20. bn TP 2379 ISSUED 4 90 REVISED 11 92 MAILED LITHO IN U S A
21. engine speed when a normal load is applied The internal governor mechanism is basically similar for all K series engines The external mechanism is different on the K241 through K341 models Be sure to follow the adjustment procedure for the model engine being serviced GOVERNOR SPRING BUSHING NUT SPEED CONTROL DISC THROTTLE BRACKET Y GOVERNOR ARM CROSS SHAFT DRIVE PIN Figure 6 39 Governor Components Make initial adjustment as follows 1 Loosen but do not remove the nut that holds the governor arm to the governor cross shaft 2 Grasp the end of the cross shaft with pliers and turn counterclockwise as far as possible The tab on the cross shaft will touch the rod on the governor gear assembly 3 Pull the governor arm away from the carbure tor as far as it will go then tighten nut holding governor arm to cross shaft cli O HEREDI ARM CROSS SHAFT Figure 6 40 Initial Adjustment Throttle Wire Installation In those applications where a throttle is to be con nected to the engine connect it as follows Refer to Figure 6 41 1 Bend the end of the throttle wire as shown in Figure 6 41 2 Place throttle control in open position Insert throttle wire in speed control disc hole nearest the throttle bracket 3 Install throttle cable clamp and bolt it to the throttle bracket 4 Remove drive pin from speed control disc and operate the throttle control rotating the disc
22. inlet Fitting POI Sih and LAG Plain Washers And Fillister Head t Figure 12 48 Installing Fuel Pump Torque the screws to 37 45 in Ib 2 Connect the fuel lines to fuel pump inlet and outlet fittings INSTALL EXTERNAL GOVERNOR COMPO NENTS AND THROTTLE CONTROLS 1 Install the throttle lever bracket spacer plain washer and hex cap screw 2 Install the governor spring to the governor arm Install the governor arm to the cross shaft Leave the palnut slightly loose as the governor arm and cross shaft will be adjusted after the carburetor and throttle linkage are installed INSTALL CARBURETOR AND THROTTLE LINKAGE 1 Install the fuel line and hose clamps 2 Install the gasket carburetor and slotted hex cap sems screws 3 Install the throttle linkage into the nylon inserts in the governor arm and carburetor throttle lever 4 Adjust the governor as instructed below 5 Refer to Fuel System And Governor section for carburetor adjustment procedure Governor Adjustment PREPARE THE ENGINE FOR OPERATION The governor cross shaft governor arm must be adjusted the engine is now completely reassembled Before every time the governor arm is loosened or removed starting or operating the engine be sure to do the from cross shaft following 1 Pull the govemor arm away from the carburetor as e 1 Make sure all hardware is tightened securely far as it will go 2 Grasp end of cross shaft with pliers
23. tion blow by Install Piston Rings NOTE Rings must be installed correctly Ring in stallation instructions are usually included with new ring sets Follow instructions carefully Use a pis ton ring expander to install rings Install the bottom oil control ring first and the top compression ring last POSI LOCK CONNECTING RODS Posi Lock connecting rods are used in some K Series engines On model K181 engines with the style D pistons refer to Piston and Rings Identifi cation earlier in this section the connecting rods have a narrower piston pin end than on the earlier style A Posi Lock connecting rods refer to Fig ure 11 13 Therefore the Posi Lock connecting rods used with the style D pistons are not inter changeabie with the Posi Lock connecting rods used with style A pistons Narrow Style D Piston Connecting Rod EE Connecting Rod Figure 11 13 Posi Lock Connecting Rods Inspection and Service Check bearing area big end for excessive wear score marks running and side clearances refer to Section 1 General Information Replace rod and cap is scored or excessively worn Service replacement connecting rods are available in STD crank pin size and 010 undersize The 010 undersize rod can be identified by the drilled hole located in the lower end of the rodshank re fer to Figure 11 14 Always refer to the appropri ate parts information to ensure the correct re placements are
24. 023 003 020 003 020 003 020 2 3755 2 3745 2 9380 2 9370 2 03802 8370 3 2515 3 2805 3 3755 9 3745 3 5005 3 4995 3 75054 7495 CYLINDER Diameler der 2 5 2924 2980 3 378 3 503 BORE 0 3 M3 003 003 003 Max Taper o5 03 02 0 002 002 CYLINDER HD Max Dul ot Flatness 00 03 003 003 00 Spark pee Ma RCJ 8 RCJ 8 RH 10 RH 10 RH 10 RH 10 g Battery 025 025 035 035 035 IGNITION Type Magneto 025 025 025 025 035 0 Gap poni 018 018 018 018 0t8 018 Nominal Point Gap 00 00 02 020 020 e O Service Replacement Ses 003 810 020 030 5B Thrust Face e 2 371 2 369 2 9297 2 9281 2 9297 2 9281 3 Pul 3 368 3 365 3 4041 3 4925 3 7425 3 74100 2c 0855 Mataa 2366 2 925 2 825 3 235 3 363 3491 3 PISTON asia 007 010 007 010 007 010 007 010 007 010 0070109 New Bore 007 017 007 017 007 017 010 020 010 020 010 020 010 020 End d Gap Ne 027 027 027 030 030 030 Max Ring Side Clearance J 006 8 O06 006 006 006 006 Service Replacement Sizes 93 010 020 030 Thrust Face a 2952 935336 33700 3 3693 3 4945 3 4938 2 0 0 0 Wen Timi 2H 3 367 349 EU ley Sich NN f 0034 0051 0045 0062 0050 0067 0030 0050 Ring New Bore ul 010 023 Pu 010 020 D 020 010 020 End Gan Used foem 039 9 030 i Max Rin
25. 3 If the regulator being adjusted is a Model KN open the lock off adjusting screw until air just starts flowing through the regulator 4 Turn the lock off adjusting screw in slowly until air flow stops NOTE A soap bubble test is a good way to check for complete shutoff If bubbles indicate that air is Still flowing turn the screw in one more full turn L VAPOR PRESSURE Approximate Values _ 80 Cc gt PRESSURE PST N IDLE ADJUSTMENT VIITTLTTIITI M VENT OR BALANCE LINE FUEL OUTLET Figure 6 34 Model F and F1 Secondary Regulators 6 23 PRIMER BUTTON LOCK OFF ADJUSTMENT Figure 6 35 Models S and SD Secondary Regulators NOTE The lock off adjusting screw may be used to adjust fuel flow while the engine is idling Never adjust at any speed above idle 5 If the regulator being adjusted is a Model S or SD depress the primer button for an instant This will allow air to flow through the regulator LOCK OFF ADJUSTMENT FUEL INLET 6 Check that air flow stops when the primer is released 7 f air flow does not stop completely loosen the adjustment screw lock nut and turn the adjust ment screw in until air flow stops then one more full turn 8 Repeat steps 5 through 7 until air flow stops every time 9 Tighten adjustment screw lock nut Primary Regulator The primary regulator provides initial control of the
26. 4 If fuel does not flow from line check for clogged fuel tank vent shutoff valve screen and fuel lines If the fuel tank cap vent does not allow air to escape from the tank modify the vent for proper operation by cutting 1 32 to 1 16 off the bottom Refer to Figure 6 1 If fuel does not flow from line check for clogged fuel line If line is unobstructed fuel pump Is faulty and must be re placed If fuel does flow from fuel line the carburetor probably Is faulty Refer to the Carburetor portion of this section 6 1 Cut Off 1 32 1 16 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 valve 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
27. Optional 70 Watt Lighting Spark Plug Breaker Flywheel Points Stator Black Optional 70 Watt Lighting Stator Condenser Coll Yellow 12 V Battery Figure 8 15 Wiring Diagram Electric Start Engines 1 25 Amp or 3 Amp Unregulated Battery Charging System 70 Watt Lighting TROUBLE ANALYSIS 10 AMP ALTERNATOR SYSTEM TEST WITH ENGINE RUNNING AT 3600 RPM NO LOAD CONDITION No Charge To Battery TEST A Disconnect B cable to positive terminal of battery Connect DC Voltmeter between B cable and ground Check DC voltage A 1 If above 14 volts A 2 If less than 14 volts but above 0 volts A 3 If 0 volts TEST B With B cable reconnected check B at terminal on rectifier regulator to ground with DC Voltmeter If 13 8 volts or higher place minimum load of 5 amps on battery to reduce voltage B 1 If charge rate Increases B 2 If charge rate does not Increase TEST C Unplug leads at rectifier regulator connect VOM multimeter across AC leads check AC voltage C 1 If less than 20 volts C 2 If more than 20 volts CONDITION Battery Continuously Charges At High Rate TEST D Check B to ground with DC Voltmeter D 1 If over 14 7 volts D 2 If under 14 7 volts Possible Fault Remedy A 1 Alternator system OK ammeter may be giving false reading Repair or replace ammeter A 2 Check for defective rectifler regulator TEST C A 3 C
28. 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 1 Fittings Apply a small amount of Permatex Aviation Perm A Gasket or equivalent gasoline resistant thread sealant to fittings Turn fit 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 fillister head sems screws Refer to Figure 6 3 Gasket Plain Washer 2 S Y Fuel Pump Mounting Flange y Fillister Head Sems Screws 2 Figure 6 3 Installing Fuel Pump NOTE Make sure that the fuel pump lever is posi tioned above the camshaft 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 4 Connect fuel lines to inlet and outlet fittings CARBURETOR GASOLINE A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and it can explode if ignited Keep sparks open flame
29. Refer to the equipment manufac turer s instructions for specific high speed set tings Check the operating speed with a tachome ter do not exceed the maximum To adjust high speed stop 1 Loosen the lock nut on high speed adjusting screw Refer to Figures 6 45 To Decrease To Increase x Speed High Speed zu Adiusting Screw E a drip uud Figure 6 45 High Speed Adjusting Screw 2 Turn the adjusting screw in or out until desired speed is reached Tighten the lock nut Recheck the speed with the tachometer read just if necessary SENSITIVITY ADJUSTMENT Governor sensitivity is adjusted by repositioning the governor spring in the holes in governor arm If set too sensitive speed surging will occur with a change in load If a big drop in speed occurs when normal load is applied the governor should be set for greater sensitivity The standard spring position is in the third hole from the cross shaft The position can vary de pending on the engine application Therefore make a note of or mark the spring position be fore removing it from the governor arm Refer to Figure 6 46 6 29 To increase sensitivity increase the governor spring tension by moving the spring towards the cross shaft NP COMPE To Increase Y i PE Sensitivity Governor Arm To decrease sensitivity and allow broader con trol decrease spring tension by moving the spring away from the cross shaft Em
30. Releasing Spring Tension 9 Insert the new rope into the rope pocket of pulley and through rope guide bushing in hous ing Refer to Figure 7 7 Rope Pocket f Rope Guide Bushing Figure 7 7 Installing Rope 10 Tie a slip knot approximately 12 from the free 11 12 end of rope Hold pulley firmly with thumb and allow pulley to rotate slowly until the temporary knot reaches the rope guide bushing in hous ing Slip the handle and rope retainer onto rope Tie a single knot at the end of rope and install rope retainer into handle Refer to Figure 7 5 Untie the slip knot in rope and pull the handle out until the rope is fully extended Slowly re tract the rope into the starter if the spring has been properly tensioned the rope will fully re tract until the handle hits the housing Disassembly Remove starter from engine A CAUTION Spring Under Tension Do not remove the center screw of the starter until the tension of recoil spring has been released Re moving the center screw before releasing spring tension or improper starter disassembly can cause the sudden and potentially dangerous release of the recoil spring Follow these instructions carefully to ensure personal safety and proper starter disassem bly Make sure adequate face protection is worn by all persons in the area Pull the rope out approximately 12 and tie a temporary slip knot in it to keep it from re tracting into starter
31. T 4 L High Throttle Speed Control Stop Figure 6 43 Centrifugal Flyweight Mechanical Governor Operation Centrifugal force acting on the rotating governor gear assembly causes the flyweights to move out ward as speed increases and inward s speed de creases As the flyweights move outward they force the regulating pin of the assembly to move outward The regulating pin contacts the tab on the cross shaft causing the shaft to rotate with changing speed One end of the cross shaft pro trudes through the side of the crankcase Through external linkage attached to the cross shaft the rotating action is transmitted to the throttle plate of carburetor When the engine is at rest and the throttle is in the fast position the tension of the governor 6 28 spring holds the throttle valve open When the en gine is operating governor gear assembly is rotat ing the force applied by the regulating pin against the cross shaft tends to close the throttle valve The governor spring tension and the force applied by the regulating pin are in equilibrium during operation holding the engine speed con stant When a load is applied and the engine speed and governor speed decreases the governor spring tension moves the governor arm to open the throttle plate wider This admits more fuel and re stores engine speed This action takes place very rapidly so a reduction in speed is hardly noticed As the speed reaches t
32. With fuel bowl removed and carburetor in verted set exposed surface of float parallel with the bowl gasket surface of carburetor body Idle holes plugged dirt in fuel delivery channels Remove fuel bowl idle fuel adjusting needle main fuel jet and welch plugs Clean all passages and blow out with compressed air Float level set too high See Remedy 2c b Dirt under fuel inlet needle See Remedy 2d Bowl vent plugged Remove fuel bowl and clean bowl vent Blow out with compressed air Float is cracked or damaged Replace float e Bowl retaining screw gasket damaged Replace gasket Bowl retaining screw is not tightened Torque screw to specifications In general turning the adjusting needles In clock wise decreases the supply of fuel to the carbure Idle Speed tor This gives a eaner fuel to air mixture Turning Adjusting Screw the adjusting needles out counterclockwise in creases the supply of fuel to the carburetor This gives a richer fuel to air mixture Setting the needles 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 needle in clockwise until it bottoms lightly 2 Preliminary Settings Turn the adjusting nee dles 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
33. a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using fuels with too low of an octane rating Pre ignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Pre ignition damage is often more se vere than detonation damage often a hole is quickly burned right through the piston dome Pre ignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon Abrasive Scratched Rings deposits blocked fins improperly seated valves or wrong spark park plug See Figure 11 10 for some common types of pis ton and ring damage Service K Series service replacement pistons are available in STD bore size and in 003 010 020 and 030 oversizes Replacement pistons include new piston ring sets and new piston pins Service replacement piston ring sets are also available separately for STD 003 same ring set for both sizes 010 020 and 030 oversized pistons Always use new piston rings when install ing pistons Never reuse old rings The cylinder bore must be deglazed before service ring sets are used Scored Piston and Rings Figure 11 10 Common Types Of Piston And Ring Damage Some important points to remember when servic i
34. are some isolated instances in which the equipment manufacturer supplies the entire fuel system for operation with gas Information on servicing these systems must be obtained from the equipment manufacturer Depending on the air temperature and the mixture of gasses in the tank pressure at the outiet of the tank can be as high as 180 to 200 psi Refer to Figure 6 33 Secondary Regulator The secondary regulators used on Kohler engines are compact single diaphragm types This type regulator accurately regulates the flow of gas to the carburetor and shuts the gas off automatically when the demand for gas ceases If the regulator fails it must be replaced or reconditioned by an authorized gas equipment repair shop Do not at tempt to repair a faulty regulator Secondary regulators used on Kohler engines re quire only one adjustment Ensign Models F or F1 regulators have an idle adjustment This adjust ment should be performed while the engine is run ning Refer to Figure 6 34 Garretson Model S SD and KN regulators have a lockoff or fuel control adjustment Use the follow ing procedure to make this adjustment Refer to Figures 6 35 and 6 36 NOTE The regulator should be mounted as close to vertical as possible and adjusted in the position in which it will be mounted on the engine 1 Connect regulator inlet to a source of clean compressed air not over 10 psi Do not con nect to a gas supply 2 Turn air supply on
35. charging system Is OK and battery was fuly charged If charge rate does not Increase when load Is applied test stator and rectifier regulator tests 2 and 3 eh is Remove connector from rectifler regulator If voltage is 28 volts or more stator Is OK arge With engine running at 3500 RPM measure Rectlfler regulator Is faulty Replace the rectl To AC voltage across stator leads using an AC fler regulator Battery voltmeter If voltage Is less than 28 volts stator Is prob ably faulty and should be replaced Test stator further using an ohmmeter test 3 3a With engine stopped measure the 3a If resistance is 0 064 0 096 ohms the stator Is resistance across stator leads using an OK ohmmeter If resistance Is Infinity ohms stator Is open Replace stator 3b With engine stopped measure the resis 3b If resistance Is Infinity ohms no continuity the tance from each stator lead to ground using stator Is OK not shorted to ground an ohmmeter If resistance or continuity Is measured the stator leads are shorted to ground Replace stator 1 With engine running at 3600 RPM measure 1 If voltage Is 14 7 volts or less the charging Battery voltage from B lead to ground using a DC system Is OK The battery Is unable to hold Continuously voltmeter charge Service battery or replace as neces Charges At 4 High Rate If voltage Is more than 14 7 volts the rectifier 8 16 regulator Is faulty Replace rectifier regulator
36. crankshaft until piston is at top 005 7 0097 0117 0157 dead center of compression stroke 006 008 017 019 K241 K301 008 010 017 019 2 Install the valves and measure the valve to K321 K341 tappet clearance using a flat feeler gauge Re fer to Figure 12 38 3 Adjust valve to tappet clearance as neces Sary On Models K91 K141 K161 and K181 If clearance is too small grind end of valve stems until correct clearance is obtained Make sure stems are ground perfectly flat and smooth Hold Valve Against Seat If clearance is too large replace the valves and recheck clearance NOTE Large clearances can also be reduced by grinding the valves and or valve seats Refer to the Inspection And Repair Reconditioning section for valve specifications Figure 12 39 Adjusting Valve To Tappet Clearance Figure 12 38 Measuring Valve To Tappet Clearance On Models K241 K301 K321 and K341 ad just valve to tappet clearance by turning the NOTE Valve faces and seats must be lapped in adjusting screw Mago ge t3 Refer to Figure before checking adjusting valve clearance Refer iem to the Inspection And Repair Reconditioning sec 4 On Models K91 K161 and K181 install the 12 tion valve springs close coils to top intake valve spring retainer exhaust valve rotator or retain Valve to tappet clearance er and valves Refer to Figure 12 40 12 13 Valve Spring Compressor Valve Sp
37. frame are aligned Refer to Figure 8 25 8 20 Commutator End Cap Match Marks SEE ri Match Marks Figure 8 25 Starter Assembly Match Marks 3 Install the brush holder tool to keep the brushes in the pockets of commutator end cap Refer to Figure 8 24 4 Install the commutator end cap to armature and starter frame Firmly hold the drive end cap and commutator end cap to the starter frame Remove the brush holder tool 5 Make sure the match marks on end cap and frame are aligned Refer to Figure 8 25 Instali the thru bolts 6 Install the drive pinion dust cover spacer anti drifting spring stop gear spacer stop nut and dust cover Refer to Starter Drive Service NOTE If the engine being serviced is equipped with special shouldered cap screws and lock wash ers for mounting make sure these same parts are used for reinstalling the starter These special parts ensure alignment of the pinion and ring gear Wound Field Bendix Drive Starter Service NOTE In the event of a false start engine starts but fails to keep running the engine must be al lowed to come to a complete stop before the starter is re engaged If the flywheel is still rotat ing when the starter is engaged the pinion and ring gear may be damaged NOTE Do not crank the engine for longer than 10 seconds A 60 second cool down period must be allowed between starting attempts Failure to fol low this procedure could result
38. free loop of the return spring over the post Install the nylon spring retainer over the post 10 Invert the pawl retainer over the pawls and center hub of pulley Take great care not to damage or unhook the return spring Make sure the pawls are positioned in the slots of pawl retainer 11 As a test rotate the pawl retainer slightly clockwise Pressure from the return spring should be felt In addition the pawl retainer should return to its original position when re leased If no spring pressure is felt or the re tainer does not return the spring is damaged unhooked or improperly assembled Repeat steps 8 9 and 10 to correct the problem 12 Sparingly lubricate the 1 2 DIA washer and 3 4 DIA washer in the center of pawl re tainer Make sure the threads in center shaft remain clean dry and free of grease or oil 13 Apply a small amount of Loctite 271 to the threads of center screw Install the center screw to center shaft Torque screw to 55 70 in Ib 14 Rotate the pulley counterclockwise when viewed from the pawl side of pulley until the spring is tight Approximately 4 full turns of pulley Make sure the fully extended rope is held in the notch in pulley to prevent interfer ence with the housing leg reinforcements Re fer to Figure 7 22 Keep Rope In Notch b EN Bw SS NIT Figure 7 22 Tensioning Spring 15 Rotate the pulley clockwise until the notch is aligned with the rope guide bushin
39. from idle to full speed Speed Adjustment A WARNING Overspeed Is Hazardous The maximum allowable speed for Model KS1 is 4000 RPM Models K161 and K181 are restricted to 3600 RPM maximum Never tamper with the gover nor setting to increase engine speed above these limits Severe personal injury and damage to the engine or equipment can result if the engine is oper ated at speeds above these maximums 6 27 Figure 6 41 After making an initial adjustment or connecting a throttle wire set speed adjustment as follows Re fer to Figure 6 42 1 Start the engine and allow a few minutes for warmup 2 Open the throttle to full speed and check en gine speed with a tachometer Speed should be approximately 4000 RPM for Model K91 and 3600 RPM for Model K161 or K181 3 If speed is not as required slightly loosen the bushing nut at the speed control disc 4 Move the throttle bracket counterclockwise to increase engine speed or clockwise to de crease speed 5 When proper speed is set tighten the bushing nut NOTE Do not use excessive force in tightening the bushing nut Excessive force could cause binding or stripping of threads DECREASE SPEED INCREASE SPEED Figure 6 42 Speed Adjustment Installing Throttle Governor New Look K181 Throttle Linkage bw Governor Arm Carburetor Throttle Lever Cross Shaft Flyweights Governor Gear Assembly Pin Governor Spring
40. 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 pad 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 6 2 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 2 g ASSEMBLY SCREW Q PUMP COVER SSS VALVE GASKET MATCH MARK GS PUMP VALVE P d VALVE srine E PUMP VALVE amp l EN VALVE etane BALE PLATE SCREW VALVE SPRING P DIAPHRAGM MOUNTING GASKET Pa WS ye KEK PUMP BODY SS 2 S MATCH MARK DIAPHRAGM Figure 6 2 Mechanical Fuel Pump Removal 1 Disconnect the fuel lines from the inlet and outlet fittings of the pump 2 Remove the fillister head sems screws flat washers fuel pump and gasket 3 If required remove the fittings from the pump body Repair
41. fuel under pressure as it comes from the fuel sup ply tank The inlet pressure for primary regulators should never exceed 250 psi The primary regula tor is adjusted for outlet pressure of approximately 6 ounces per square inch 11 W C If the regu lator does not function properly replace it or have it serviced by an authorized gas equipment shop Never attempt to service a faulty primary regulator Upon demand for fuel pressure drops on the out let side of the regulator diaphragm The gas inlet valve then begins to open allowing fuel to pass through the regulator to the secondary regulator As the need for more fuel increases the fuel inlet valve opens further allowing more fuel to pass Refer to Figure 6 37 Pressure may be adjusted by removing the bonnet cap and turning the spring tension adjustment with a large screwdriver Turning clockwise increases the pressure turning counterclockwise decreases DI APHRAGM RETAINING SCREW Figure 6 36 Model KN Secondary Regulator 6 24 a ADJUSTMENT HEEEEIEFP FUEL wur D DIAPHRAGM FUEL INLET Figure 6 37 Typical Primary Regulator Two Stage Regulator The two stage regulator used on Kohler engines is a double diaphragm type regulator designed for use with air cooled engines It combines primary and secondary regulation in one unit The regula tor fuel inlet is connected to the fuel tank Its out let is connected to the carburetor If the
42. 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 bowl gasket and baffle gasket Posi tion baffle gasket so the inner edge is against the float hinge towers 7 Install the fuel bowl so it is centered on the baffle gasket Make sure the baffle gasket and bowl are positioned properly to ensure a good seal 8 Install the bowl retaining screw gasket and bowl retaining screw Torque screw to 50 60 in Ib 0 010 Feeler Gauge Both Sides Necessary Float Hinge Towers Inverted Carburetor On Carburetor Body Figure 6 15 Checking Float Clearance 9 Install the idle speed adjusting screw and spring Install the idle fuel and main fuel ad justing needles and springs Turn the adjusting needles clockwise until they bottom ghtly 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 section 6 10 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 Needle Idle Speed
43. 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 plug lead Clean the exterior surfaces of engine Spread a light film of oil over any exposed metal sur faces of engine to prevent rust Store the engine in a clean dry place SECTION 4 TROUBLESHOOTING TROUBLESHOOTING GUIDE When trouble occurs be sure to check the simple 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 Empty fuel tank Fuel shutoff valve closed Clogged fuel line Spark plug lead disconnected Keyswitch or kill switch in off position Faulty spark plug Faulty ignition Dirt or water in fuel system OnN DOO 5 WD 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 mh UON 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
44. if magnet is damaged REMOVE STATOR 1 Remove the screws and stator REMOVE VALVES 1 Rotate the crankshaft until the piston is at top dead center of compression stroke both valves closed and piston flush with top of bore 2 Compress the valve springs with a valve spring compressor and remove the keepers Refer to Figure 10 4 Valve Spring Compressor Valves P Valve Springs me Intake Valve Exhaust Valve Spring Retainer Rotator Figure 10 4 Removing Valves 3 Remove the valve spring compressor then remove the valves intake valve spring lower retainer exhaust valve rotator valve springs and valve spring upper retainers NOTE Some models use a valve rotator on both valves REMOVE OIL PAN NOTE Make sure the piston is at top dead center in bore to prevent damage to oil dipper on con necting rod 1 Remove the hex cap sems screws oil pan and gasket 10 4 REMOVE CONNECTING ROD AND PISTON 1 Remove the connecting rod cap Refer to Figure 10 5 X Hex Nuts lt Figure 10 5 Removing Connecting Rod And Piston NOTE If a carbon ridge is present at top of bore use a ridge reamer tool to remove it before at tempting to remove piston 2 Carefully push the connecting rod and piston out top of bore REMOVE PISTON FROM CONNECTING ROD 1 Remove the retainer and wrist pin Separate the piston from the connecting rod Refer to Figure 10 6 Piston Wrist Pin Conn
45. is especially critical on gear reduction engines FRONT OIL SEAL LOCATION MAGNETO FLYWHEEL 3 AMP 10 AMP BREAKERLESS BATTERY ROTOR MAGNETO ALTERNATOR ALTERNATOR 1 32 1 32 Full In 1 32 1 32 1 32 1 32 1 2 1 2 1 2 12 1 2 1 2 1 2 12 1 2 1 2 1 2 With sleeve bearing drive seal in until it bottoms against shoulder REAR OIL SEAL DEPTH 1 32 for K91 through K181 1 8 for K241 through K341 Depth measured in from crankcase face at PTO end Figure 12 32 Measuring Crankshaft End Play 12 10 Figure 12 33 Installing Oil Seals Using Sleeves SLEEVE BEARING TYPICAL FLYWHEEL MAGNE TO TYPICAL SEAL PRESS SEAL DEPTH AGAINST SHOULDER BREAKERLESS TYPICAL BATTERY TYPICAL Figure 12 34 Front Oil Seal Location INSTALL OIL SEALS 1 Slide the appropriate seal sleeves over the crankshaft refer to the Special Tools sec tion Generously lubricate the lips of the oils seals with light grease Slide the oil seals over the sleeves Refer to Figure 12 33 2 Use the 711795 handle and appropriate seal drivers to install the front oil seals to the fol lowing depths Note that the front oil seal depth varies with en gine model and type of bearing plate used bearing plate configuration differs with type of ignition sys tem used these differences are shown in the cut away views in Figure 12 33 to help identify the various bearing plate types
46. m pJ a STARTING MOTOR SOLENOID Figure 8 22 Battery Ignition Interlock Bypass A WARNING Never return an engine to the owner with the safety interlock system removed or bypassed Great bodily harm or equipment damage could result Interlocks connected to an engine with a battery ignition system are bypassed simply by placing a jumper wire as shown in Figure 8 22 A WARNING Make sure all safety conditions have been observed before starting an engine with the interlocks bypassed The safety interlock system on manual start mag neto ignition engines is placed in the ignition sys tem The series connected interlock switches are connected to a solid state module that is con nected to the ignition system The module serves two functions It grounds the ignition system until all interlocks have closed and after the engine has started it prevents the ignition from grounding as the individual interlocks are opened in normal operation transmission placed in Drive PTO en gaged etc Refer to Figure 8 23 Brush Replacement Refer to Figure 8 23 Stud Terminal With Brush Springs N Positive Brushes Negative Brushes Self Tapping Negative Screws Brushes Brush Holder Figure 8 23 Commutator End Cap With Brushes 1 Remove the brush springs from the pockets in brush holder 2 Remove the self tapping screws and negative brushes 3 Remove hex
47. new gaskets when servicing and rein Stalling carburetors Repair kits are available which include new gaskets and other components These kits are described below Components such as the throttle and choke shaft assemblies throttle plate choke plate idle fuel needle main jet and others are available sepa rately Refer to the appropriate Parts Manual to ensure the correct carburetor repair kits and replacement parts are ordered REASSEMBLY Throttle Shaft Installation 1 4 Install the foam dust seal on throttle shaft In sert the throttle lever shaft assembly into car buretor body with the cutout portion of shaft facing the carburetor mounting flange Install the throttle plate to throttle shaft Make sure the plate is positioned properly in bore as marked and noted during disassembly the numbers stamped on plate should face the carburetor mounting flange Apply Loctite 609 to threads of 2 plate retaining screws Install screws so they are slightly loose Apply finger pressure to the throttle lever shaft to keep it firmly seated against pivot in carbu retor body Rotate the throttle shaft until the throttle plate fully closes the bore around its entire perimeter then tighten screws Refer to Figure 6 27 Apply Pressure When Tightening Screws Throttle Lever Shaft Assembly Figure 6 27 Installing Throttle Lever Shaft Operate the throttle lever check for binding between the throttle plate and ca
48. nut split lock washer plain wash er and fiber washer from the stud terminal Remove the stud terminal with positive brushes and plastic brush holder from end cap 8 19 4 Reinstall the brush holder and new stud termi nal with positive brushes into end cap Secure with the fiber washer plain washer split lock washer and hex nut CAUTION To prevent electric arcing make sure the stud terminal and braided brush leads do not touch the end cap 5 Install the new negative brushes and se cure with the self tapping screws 6 Install the brush springs and brushes into the pockets in brush holder Make sure the cham fered sides of brushes are away from the springs NOTE Use a brush holder tool to keep the brushes in the pockets A brush holder tool can easily be made from thin sheet metal Refer to Figure 8 24 Sheet Metal Brush Holder Tool 212 1 8 Brush Holder Tool Installed Over Brushes And End Cap Figure 8 24 Brush Holder Tool Commutator Service Clean the commutator with a coarse lint free cloth Do not use emery cloth If the commutator is badly worn or grooved turn down on a lathe or replace the armature Reassembly 1 Insert the armature into the starter frame Make sure the magnets are closer to the drive shaft end of armature The magnets will hold the armature inside the frame 2 Install the thrust washer and drive end cap Make sure the match marks on end cap and
49. on bearing plate INSTALL FLYWHEEL GRASS SCREEN AND DRIVE CUP OR ROPE START PULLEY A WARNING Damaging Crankshaft and Flywheel Could Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but also is a serious threat to the safety of persons nearby since broken fragments could be thrown from the engine Always observe and use the fol lowing precautions and procedures when installing the flywheel NOTE A Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean 12 14 dry and completely free of lubricants The presence of lubricants can cause the flywheel to be overstressed and damaged when the cap screw is torqued to specification Make sure square flywheel key is installed only in the flat area of keyway not in the rounded area The flywheel can become cracked or damaged if the key is installed in the rounded area of keyway Always use a flywheel strap wrench to hold flywheel when tightening flywheel fastener Do not use any type of bar or wedge between the cooling fins or flywheel ring gear as these parts could become cracked or damaged Do not use impact wrenches to install the fly wheel retaining nut as this may overstress the nut and crack the flywheel hub Do not reuse a flywheel if it has been dropped or damaged in any way Do make a through visual inspec
50. palnut Remove governor arm and spacer from cross shaft NOTE Loosening palnut or removing governor arm will disrupt governor arm to cross shaft adjust ment Readjustment will be required upon reas sembly 3 Remove the governor spring from the governor arm 4 Remove the hex cap screw plain washer spacer bracket and throttle lever REMOVE FUEL PUMP A WARNING Explosive Fuel 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 fromthe engine Dis connect and ground the spark plug lead to prevent the possibility of sparks from the ignition system 1 Disconnect the fuel line from the fuel pump inlet fitting 10 2 2 Disconnect the fuel line from the fuel pump outlet fitting Refer to Figure10 1 0 LIlXMFilister Head o Sems Screws Figure 10 1 Removing Fuel Pump 3 Remove the fillister head sems screws plain washers fuel pump and gasket REMOVE RETRACTABLE STARTER 1 Remove screws washers and the retractable starter assembly REMOVE ELECTRIC STARTER 1 Disconnect electrical connector s from back of keyswitch 2 Disconnect lead from electrical starter 3 Remove keyswitch panel 4 Remove hex cap sems screws which mount electric starter to engine 5 Remove electric starter REMOVE FUEL TANK A WARNING Explosive Fuel Gasoline may be present in the c
51. reduced compression results in an effective compression ratio of about 2 1 during cranking After the engine speed increases to about 600 RPM centrifugal force moves the flyweights to the position shown in Figure 9 2 In this position the tab on the larger flyweight drops into the recess in the exhaust cam lobe When in the recess the tab has no effect on the exhaust valve and the engine operates at full compression and full power Exhaust Valve Closed Camshaft Tab St Flyweights Tappet Spring Flyweights Figure 9 2 Automatic Compression Release ACR Running Position When the engine is stopped the spring returns the flyweights to the position shown in Figure 9 2 ready for the next start BENEFITS Because of the reduced compression pressures at cranking speeds several important benefits are obtained 9 1 e Manual starting rope start or retractable start is much easier Without ACR manual starting at full compression would be virtually impossible e Electric start models can use a starter and bat tery size that are practical for the applications in which these engines are used e ACR eliminates the need for a spark retard ad vance mechanism A spark retard advance mechanism would be required on engines with out ACR to prevent kickback that occurs when starting ACR eliminates this kickback making manual starting safer e The choke control setting is less critical
52. regulator fails to operate properly replace it or have it serv iced by an authorized gas equipment shop Never attempt to service a faulty regulator Vaporized fuel is admitted to the regulator at fuel tank pressure up to 250 psi Because the secon dary valve is closed engine not running the pressure on the internal side of the primary dia phragm builds up until the pressure overcomes the spring action on the opposite side of the dia phragm This primary diaphragm spring has suffi cient tension to require approximately 10 psi pres sure on the internal side of the diaphragm to counteract the opening force due to the spring When the pressure reaches this level the valve is closed preventing further pressure rise The secondary diaphragm acts against the secon dary valve spring Its action results from vacuum caused by the carburetor As the vacuum begins acting on the diaphragm the diaphragm is moved nearer to the center of the regulator opening the secondary valve until equilibrium is reached As more fuel is needed vacuum from the carburetor increases causing the secondary valve to open further When fuel is flowing pressure on the pri mary diaphragm is lowered slightly permitting the spring to open the primary valve in an attempt to bring the pressure back to 10 psi Refer to Figure 6 38 PRIMARY DIAPHRAGM SECONDARY ADJUSTMENT ATMOSPHERE CHAMBER Enc rem iL ese CHAMBER PRESSURE CHAMBER
53. sert dipstick and push it all the way down into tube Remove dipstick and check the level CHECK OIL LEVEL The importance of checking and maintaining the proper oil level in crankcase cannot be overem 4 On engines with threaded type plug dipstick phasized Check oil BEFORE EACH USE as follows shoulder plug on top of hole to observe level 3 1 The oil level should be up to but not over the F mark on the dipstick Refer to Figure 3 1 Operating Range Figure 3 1 Oil Level Range 5 Add the proper type of oil if the level is low Always check the level with dipstick before adding more oil 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 Change oil every 25 operating hours thereafter For an overhauled engine or those 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 Change oil every 25 hours thereafter Drain oil while the engine is still warm from operation The oil will flow freely and carry away more impurities Change oil as follows 1 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 prope
54. 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 Idle Fuel Adjusting Needle Figure 6 18 Fixed Main Jet Carburetor 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 Adjust To Midpoint 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 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 Figure 6 19 Carburetor Adjustment rpm by turning the low idle speed adjusting screw in or out Check the speed using a ta chometer CARBURETOR ADJUSTMENT NOTE The actual low idle speed depends on the application Refer to the equipment manufacturer s NOTE The tip of the low idle fuel and high idle instructions for specific low idle speed settings fuel adjusting needles are tapered to critical di The recommended lo
55. to Figure 10 10 Figure 10 8 Removal Of Bearing Plate With Puller 10 5 Stop Pin Copper Washer N Bushing Nut L Bearing Plate Side Cross Shaft Figure 10 10 Removing Tappets Figure 10 12 Removing Cross Shaft And Stop Pin NOTE The intake valve tappet is closest to the bearing plate side of crankcase The exhaust valve tappet is closest to the PTO side of crankcase REMOVE BALANCE GEARS 1 Remove the retaining rings shims balance gears with needle bearings shims and spac ers Refer to Figure 10 11 moe x3 J PE 4 LU P amp NOTE Extreme care must be taken when handling the new needle bearings or when removing bal ance gears containing the new bearings The needles are no longer caged and will drop out If this should occur the bearing case should be greased and the needles reset There are 27 indi vidual needles in each bearing Figure 10 13 Removing Governor Gear 2 Remove bushing nut and sleeve Remove cross shaft from inside crankcase REMOVE OIL SEALS 1 Remove the oil seals from the crankcase and bearing plate REMOVE BEARINGS 1 Press the bearings out of the bearing plate and crankcase Figure 10 11 Removing Balance Gears NOTE If the bearings have remained on the crank shaft remove bearing by using a puller REMOVE GOVERNOR GEAR AND CROSS SHAFT 1 Remove the stop pin copper washer gover nor gear and thrust washer Refer to Figures 10 1
56. 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 Viscosity Grades EMPERATURE RANGE EXPECTED BEFORE NEXT Oll CHANGE Straight 30 weight oil is preferred SAE 10W 30 and 10W 40 are not recommended above 32 F O C Using these oils substantially increases oil consumption and combustion chamber deposits I Shoulder of flange S uD l A WAAN ft AAEN ANANN EKARNAS NASAAN Read level Remove from block Place on shoulder 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 the API service class and SAE viscosity grade Check Oil Level Check oil lever BEFORE EACH USE Check gear reduction uniot oil level by removing the drain plug on the lower part of the cover Oil level should be up to the bottom of the plug hole If oil level is low remove the vented plug at the top of the cover add oil 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 or over the F mark on the dipstick Bayonet Push down on tube Read level Figure 1 3 Dipsticks And Oil Fill Tubes 1 4 Change
57. used Service Connecting Rod Service Connecting Rod Stan 0 010 Undersize 3 1 3 w 3 E LES E LX S r F e x x 3 3 2 x L1 f Figure 11 14 Standard And 010 Undersize Connecting Rods BALANCE GEARS AND STUB SHAFTS Most K321 and K341 K Series engines are equipped with a balance gear system K91 K161 and K181 engines do not have balance gears Some K241 and K301 engines are equipped with a balance gear system The system consists of two gears and spacer used to control end play mounted on stub shafts which are pressed into the crankcase The gears and spacers are held on the shafts with snap ring retainers The gears are timed with and driven by the engine crankshaft Inspection and Repair Use a micrometer and measure the stub shaft di ameter If the diameter is less than 4996 re place the stub shaft Use an arbor press to push old shaft out and new shaft in Refer to Figure 11 15 The stub shaft must protrude a specific distance above the stub shaft boss If the stub shaft boss is about 7 16 above the main bearing boss press the shaft in until it is 735 above the stub shaft boss On blocks where the stub shaft boss is only about 1 16 above the main bearing boss press shaft in until it is 1 110 above the stub shaft boss A 3 8 spacer must be used with the shaft which protrudes 1 110 Inspect the gears for worn or chipped teeth and for worn needle bearings Use an arbor press and driv
58. wire must protrude from beneath the rubber boot on the lead NOTE The preceding step is for timing lights using an alligator clip to connect to the spark plug If the light in use has a sharp prong on the spark plug lead simply penetrate the rubber boot with the prong and make contact with the spark plug lead metal connector 3 Connect one timing light lead to the wire wrapped around the spark plug terminal 4 Connect one timing light lead to the hot un grounded terminal of the battery 5 Connect the third timing light lead to engine ground 6 Start the engine and run it at 1200 to 1800 RPM 7 Aim the timing light at the timing sight hole The light should flash just as the S or SP mark is centered in the sight hole or is in line with the center mark on the bearing plate or blower housing 8 Iftiming is not as specified carefully remove the breaker point cover and slightly loosen the gap ad justing screw shift the breaker point plate until the timing mark is properly positioned and tighten the screw 9 Shut off the engine and replace the breaker point cover J7 PRIMARY CIRCUIT imm SECONDARY CIRCUIT IGNITION M 4 L L E J i4 BATTERY IGNITION ML P cor bka GROUND Battery Ignition System Operation The battery ignition system operates in a manner similar to the magneto system The major differ ence is that in the battery system
59. 161 and K181 If a hex head sems screw is used torque screw to 250 in Ib Install the grass screen 12 15 Models K241 K301 K321 And K341 Rope Start A Install the nylon grass screen B Install the spacer rope pulley plain washer and hex cap screw lubricate threads with oil Hold the flywheel with a strap wrench and torque hex cap screw to 35 40 ft Ib If a hex nut is used torque to 50 60 ft Ib C Install the wire mesh grass screen and grass screen retainer to rope pulley Retractable Start A Install the grass screen B Install the drive cup plain washer and hex cap screw lubricate threads with oil Hold the flywheel with a strap wrench and torque hex cap screw to 35 40 ft Ib if a hex nut is used torque to 50 60 ft Ib Electric Start A Install the plain washer and hex cap screw lu bricate threads with oil Hold the flywheel with a strap wrench and torque hex cap screw to 35 40 ft Ib If a hex nut is used torque to 50 60 ft Ib B Install the grass screen 3 For all models torque the grass screen fas teners to 70 140 in Ib for a metal grass screen and 20 30 in Ib for a plastic grass screen INSTALL BLOWER HOUSING 1 Install the spark plug lead and kill lead into the slots in the baffle 2 Install the remaining self tapping screws and the blower housing NOTE On some models the grass screen rnust be installed before installing the blower housing 3 Install push
60. 2 and 10 13 10 6 SECTION 11 INSPECTION AND REPAIR All parts should be thoroughly cleaned Dirty parts cannot be accurately gauged or inspected properly for wear or damage There are many commer cially available cleaners that quickly remove grease oil and grime accumulation from engine parts If such a cleaner is used follow the manu facturer s instructions carefully and make sure that all of the cleaner is removed before the engine is reassembled and placed in operation Even small amounts of these cleaners quickly break down the lubricating properties of engine oils Refer to TP 2150 A Guide to Engine Rebuilding for additional information Also available is TP 2159 Measurement Guide which you can use to record your inspection results FLYWHEEL Inspection Inspect the flywheel for cracks and the flywheel keyway for damage Replace flywheel if cracked Replace the flywheel the crankshaft and the key if flywheel key is sheared or the keyway is dam aged Inspect ring gear for cracks or damage Kohler no longer provides ring gears as a serviceable part Replace flywheel if the ring gear is damaged FLYWHEEL KEY Inspection Shearing has been reported specifically on engines with flywheel drives and battery ignition systems Check conditions such as overload ignition timing and spark plug gap when flywheel keyshearing oc curs Spark plug gap on battery ignition engines must be set as specified If impr
61. Electric Start Engine 30 Amp Regulated Battery Charging System Red 12 Volt Black Starter pm Flywheel Alternator Red Bat Lights Ammeter C9 pee eet rg Spark Plug Breaker i Points Switch Key Start D Coll Condenser Figure 8 20 Wiring Diagram Electric Start Engines 30 Amp Regulated Battery Charging System 30 Amp Stator Full Wave L Rectifier Black Red Figure 8 21 30 Amp Stator And Rectifier Regulator Troubleshooting Guide 30 Amp Regulated Battery Charging System Output tests should be made with engine running at 3600 RPM no load Battery must be fully charged Problem Test check resistance check resistance lead to ground Lo r M P7 L 22 2222 22 2 2 1 56 27 Vllulululuas ss NN Remove 4 Input leads from rectifler regulator Set ohmmeter on Rx1 scale and zero scale 1a Connect ohmmeter across red leads and Conclusion 1a Resistance should be 2 0 ohms 1b Connect ohmmeter across black leads and 1b Resistance should be 0 1 ohms 1c Measure the resistance from each stator 1c Resistance should be Infinity ohms no continuity Replace stator If specifled values are not Lamp off in one direction on when leads are reversed Diodes In regulator are good Replace rectifier regulator If lamp Indication Is the same In both directions 3 Chargin
62. ION MAINTENANCE INSTRUCTIONS ANB SAFETY INSTRUCTIONS AND SAFETY PRECAUTIONS PRECAUTIONS E HR COMPANY IK KOHLER COMPANY o eR WISE ONSIN USA KOHLER WISCONSIN USA C CENE 2 J identification Decal Figure 1 1 Location of Engine Identification Decal A MODEL NO Version Code A Special Oil Pan K 32 1 PT C Clutch Model G Generator Application P Pump Model Q Qulet Model Reduction Gear Approximate i Electric Start K Sends Engine Displacement Retractable Start Cu In ST Electric Start And Retractable Start 0 2 I EP Electric Plant B SPEC NO Engine Model Code Code Model 26 27 31 K91 BO 49 B 28 K161 K141 K181 K241 K301 K321 K341 Variation of Basic Engine C SERIAL NO E 172452 9076430 10026692 1501897591 LJ LJ L L A Letter First Two Digits If First Three Digits If First Two Digits If Ten Seven Digit Number Eight Digit Number Digit Number 100 109 110 119 120 129 130 139 140 149 150 159 Remaining digits are a 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 oi 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 Pe
63. If the battery fails to 3 10 15 and 30 amperes The 1 25 amp system accept a charge from the alternator charge it on is intended for battery charging only The 3 amp a battery charger and reinstall 8 9 Troubleshooting Guide 1 25 Amp Or 3 Amp Unregulated Charging System Optional 70 Watt Lighting NOTE Zero ohmmeters and voltmeters on each scale to ensure accurate readings Voltage test should be made with engine running at 3000 RPM no load Battery must be fully charged Problem No Charge To Battery No Lights With engine running at 3000 RPM measure voltage across battery terminals using a DC voltmeter Disconnect the charging lead from battery With engine running at 3000 RPM measure voltage from charging lead to ground using a DC voltmeter With charging lead disconnected from battery and engine stopped measure resistance from charging lead to ground using an ohmmeter Note reading Reverse the leads and measure resistance again In one direction the resistance should be Infinity ohms open circuit With the leads reversed some resistance should be measured about midscale on Rx1 range Cut the sleeving on the charging lead to ex pose the diode connections Measure the resistance from the stator side of diode to ground using an ohmmeter Disconnect the lighting lead from the wiring harness With engine running at 3000 RPM measure voltage from lighting lead to ground using an AC
64. L GEAR REDUCTION UNIT Removal 1 Drain lubricating oil from unit The reduction unit consists of a driven gear which is pressed on the power take off PTO shaft The drive gear is an integral part of the engine crank shaft The gear reduction on the K91 and K181 3 Remove four cap screws holding gear housing units is 6 1 The gear reduction on the K301 en to engine gine is 4 1 The PTO shaft is supported by two bearings one in the cover and the other in the housing Oil seals are provided at both ends of the shaft Refer to Figure 11 17 5 Remove old oil seals and install new seals flat side out in the gear housing and cover Remove four cap screws from gear housing and slide cover off along drive gear 4 Wash all parts and inspect shaft bushing and gear for wear Replace worn parts 11 13 Installation 1 Wrap piece of tape or roll paper around crank shaft gear to protect the oil seal slide housing over the shaft and attach to the block Two lock washers are used on the outside of hous ing and copper washers inside Tape or paper should be wrapped around the shaft to prevent the keyway from damaging 11 14 the cover oil seal Install the gasket s and reduction gear cover and tighten cap screws Adjust shaft end clearance to 001 006 inches by varying the total gasket thickness adding or removing gaskets as required Remove oil fill plug and oil level plug fill unit to the oil level hole Use the same g
65. Lower Balance Gear Secondary Timing Mark amp 3 EE ccm TY Crankshaft Primary 53 Timing Mark Upper Balance Gear Primary Timing Mark Figure 12 29 Aligning Lower Balance Gear And Crankshaft Install the lower balance gear to the stub shaft If properly timed the secondary timing mark on lower balance gear will now be aligned with the primary timing mark on crank shaft Refer to Figure 12 30 Figure 12 31 Crankshaft Gear Upper Balance Gear Alignment If the marks do not align the timing is incor rect and must be corrected INSTALL FRONT BEARING 6 Secure the lower balance gear to stub shaft using one 1 020 shim spacer and retaining 1 ring rounded edge towards gear Check end play of lower balance gear as instructed in INSTALL BALANCE GEARS Install the front bearing into the bearing plate using the 4747 handle and appropriate bear ing installer Refer to the Special Tools sec tion Make sure the bearing is bottomed fully and straight and true in the bore 12 9 INSTALL FUEL LINE AND WIRING HARNESS Js Position the fuel line and wiring harness if so equipped to crankcase Adjust the fuel line and wiring harness to their final positions just before securing the bearing plate to the crankcase INSTALL BEARING PLATE 1 The installation of bearing plate and gaskets can be made considerably easier with the use of two simple easy to make alignment guides Using 2 1 2 l
66. NTI DIESELING 45 435 01 BRACKET SOLENOID 45 126 05 a NUT JAM X 88 3 l LINKAGE NOTE Make sure tdle speed screw on carburetor has been turned counterclookwise until tt no longer contacta the throttle bracket thts allows the throttle plate to close fully Figure 6 31 Anti Dieseling Solenoid Automatic Chokes Thermostatic Type The automatic choke is a heat sensitive thermos tatic unit At room temperature choke lever will be set in a vertical position If engine should fail to start when cranked adjust choke lever by hand to determine if choke setting is too lean or too rich Once this has been established adjustment can be made to remedy situation Adjustment 1 Loosen adjustment lock screw on choke body This allows the position of adjustment to be changed 2 Moving adjustment bracket downward will in crease the amount of choking Upward move ment will result in less choking 3 After adjustment is made tighten adjustment lock screw Electric Thermostatic Type Remove air cleaner from carburetor to observe position of choke plate Choke adjustment must be 6 20 made on cold engine If starting in extreme cold choke should be in full closed position before en gine is started A lesser degree of choking is needed in milder temperatures Adjustment 1 Move choke arm until hole in brass shaft lines up with slot in bearings 2 Insert 43 drill 089 and push all the way down t
67. O end of crankshaft through the rear bearing Align the twelfth 12th tooth marked on crankshaft gear with the seventh 7th land marked on upper balance gear Re fer to Figure 12 27 2B NEW STYLE BALANCE GEAR ASSEMBLY WITHOUT A BALANCE GEAR TIMING TOOL NOTE The lower balance gear should be installed after 4he crankshaft has been installed PP Marked Tooth On Crankshaft Gear OE SP 36 1 Count and mark the teeth on the crankshaft A gear and the land notches between teeth on the upper balance gear as follows p Marked Land On 7 Upper Balance Gear Crankshaft Locate the primary timing mark La L a on crankshaft While looking at the PTO end of F crankshaft start with the tooth directly below timing mark and count twelve 12 teeth in a counterclockwise direction Mark the twelfth tooth Refer to Figure 12 25 Figure 12 27 Aligning Crankshaft Gear And Upper Balance Gear Press the crankshaft into the rear bearing until the crankshaft gear is just above the camshaft gear but not in mesh with it 3 Align the timing mark on camshaft with the primary timing mark on crankshaft NOTE To align the marks rotate the camshaft only do not rotate the crankshaft Rotating the Figure 12 25 Marking Tooth On Crankshaft crankshaft could cause the crankshaft gear to Gear come out of mesh and out of time with the wide band of teeth on upper balance gear Upper Balance Gea
68. Oil For a new engine change oil after the first 5 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 oil as specified in the table Change oil every 25 operat ing hours thereafter FUEL RECOMMENDATIONS A WARNING Explosive Fuel 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 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 frorn 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 countrie
69. P Single Cylinder Models Ignition problems and poor performance on these models are often the result of using an incorrect ignition coil spark plug or plug gap setting When replacing an ignition coil always use the genuine Kohler replacement Use of the correct spark plug and gap setting is also important The specified plug is a Champion H10 RH10 or equivalent gapped at 035 9mm Failure to follow these recommendations will result in erratic high speed ignition misfire or cutting out under load AC WINDING DIODE 2 ON STATOR SENSING COIL AND RESISTOR Breakerless Ignition System Operation The breakerless ignition system operates on the same general principle as the magneto system but does not use breaker points and conventional igni tion condenser to time the spark A trigger module containing solid state electronics performs the same function as the breaker points Refer to Fig ure 8 5 The breakerless system consists of four major components e ignition winding on alternator stator e Trigger module e Ignition coil assembly e Flywheel mounted trigger The ignition winding is separate from the other windings on the alternator stator It functions like the magneto winding The trigger module contains three diodes a resistor a sensing coil and mag net and an SCR a sort of electronic switch The ignition coil assembly includes a capacitor and a pulse transformer that serves the same purpose as the i
70. PM the charging system is OK and battery was and B lead connected measure the volt fully charged age from B at terminal on rectlfler regulator to ground using a DC voltmeter If charge rate does not Increase when load Is applied test stator and rectifier regulator If voltage Is 13 8 volts or more place a tests 2 and 3 minimum load of 5 Amps on battery to re duce voltage Observe ammeter NOTE Turn on lights If 60 watts or more Or place a 2 5 ohm 100 watt resistor across battery terminals Remove connector from rectifler regulator df voltage Is 28 volts or more stator Is OK With engine running at 3600 RPM measure Rectifler regulator is faulty Replace the rectl AC voltage across stator leads using an AC fler regulator voltmeter If voltage Is less than 28 volts stator Is probably faulty and should be replaced Test stator fur ther using an ohmmeter test 3 With engine stopped measure the resls If resistance Is 0 1 0 2 ohms the stator Is OK tance across stator leads using an ohmme ter if resistance Is Infinity ohms stator Is open Replace stator With engine stopped measure the reslis If resistance Is Infinity ohms no continuity the tance from each stator lead to ground stator Is OK not shorted to ground using an ohmmeter If resistance or continuity Is measured the stator leads are shorted to ground Replace stator With engine running at 3600 RPM measure f volta
71. Rear oil seal installa tion details are shown in Figure 12 34 INSTALL PISTON RING NOTE For detailed piston inspection and piston ring installation procedures refer to the Inspec tion And Repair Reconditioning section INSTALL PISTON TO CONNECTING ROD Style A Piston 1 Install wrist pin and retainers Style C And D Pistons NOTE Proper orientation of the piston to the con necting rod is extremely important Improper orien tation may cause extensive wear or damage 1 Orient piston and connecting rod so that the notch Style C piston or Fly symbol Style D piston on piston and the match mark on connecting rod are facing the same direction 2 Install wrist pin and retainers Refer to Figure 12 35 INSTALL PISTON CONNECTING ROD NOTE Proper orientation of the piston to the con necting rod is extremely important Improper orien tation may cause extensive wear or damage Piston Figure 12 35 Installing Piston To Connecting Rod Style D Piston Shown 1 Stagger the piston rings in their grooves until end gaps are 120 apart 2 Lubricate the piston and rings with engine oil Install the piston ring compressor around pis ton Refer to Figure 12 36 12 11 M _ Piston Ring Compressor Crankcase gp TT Installed Around Piston Arrow Must Point t Camshaft Towards Flywheel Figure 12 37 Installing Connecting Rod Cap Figure 12 36 Installing Pistons 5 Torque the c
72. Reassembly sections for cooling shroud removal and installation proce dures Ground Electrode NOTE Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cool ing shrouds removed will cause engine damage Figure 3 3 Servicing Spark Plug due to overheating 1 Before removing spark plug clean the area around the base of plug to keep dirt and de bris out of engine CHECK SPARK PLUG Every 100 operating hours remove the spark plug 2 Remove the plug and check its condition Re check its condition and reset gap or replace with place the plug if worn or if reuse is question new plug as necessary Refer to Figure 3 3 able 3 3 NOTE Do not clean the spark plug in a machine using abrasive grit Some 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 Oil Fill Plug N P IRE O0 Drain Plug Oil 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 oil remove the
73. Reconditioning Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Scoring of the Cylinder Wall Unburned fuel in se vere cases can cause scuffing and scoring of the cylinder wall As raw fuel seeps down the cylinder wall it washes the necessary lubricating oils off the piston and cylinder wall so that the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by local ized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If the cylinder bore is badly scored excessively worn tapered or out of round resizing is neces sary Use an inside micrometer to determine amount of wear see General Information Sec tion 1 then select the nearest suitable oversize of either 003 010 020 or 030 Resizing to one of these oversizes will allow usage of the available oversize piston and ring assemblies In itially resize using a boring bar then use the fol lowing procedures for honing the cylinder Honing While most commercially available cylinder hones can be used with either portable drills or drill presses the use of a low speed drill press is pre ferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute After instal
74. Replace Fuel Filter 00 ccc eee nnn As Required Clean Foam Precleaner ccc cece eee eee hh eee ee eee eens 25 Hours Change Oil s ME 62a ord tbr Rr de 9 93 9 P ra er Eae aetates e keke eas 25 Hours Check Optional Reduction Gear Unit ddl Allie obe bares ms ac ee coe nd ee dde aes 5O Hours Clean Cooling Fins and External Surfaces 9 9 4P eeclesie RR nme 50 Hours Clean Paper Air Cleaner Element 27 49 S eere mh hh m mm hh 100 Hours Check Spark Plug vax dice Ae ev RREERSRARY eh ewe eda eas 100 Hours Check Valve To Tappet Clearance eno leg Rm 500 Hours Clean Cylinder Head and Combustion Chamber 000 cece eee ee eee hh haha he 500 Hours Service Starter Motor Drive ccc ee eee eee eee eee eee anes Annually or 500 Hours Perform these maintenance procedures more frequently when engine is operated under extremely dusty and dirty conditions 250 Hours when leaded gasoline is used 1 Make sure the engine is stopped level and is A WARNING Accidental Starts cool so the oil has had time to drain into the Before servicing the engine or equipment always sump remove the spark plug to prevent the engine from 2L ae starting accidentally Ground the lead to prevent 2 Clean the area around oil fill cap dipstick be fore removing to keep dirt grass clippings Sparks that could cause fires etc out of the engine 3 Remove oil fill cap dipstick wipe oil off Rein
75. SCR is not switching prop erly in which case trigger module should be re placed IGNITION COILS Breakerless Type Ignition Coil Use an ohmmeter to test breakerless type coil assembly A Remove high tension lead from terminal on coil Insert one ohmmeter lead in coil terminal and the other to the coil mounting brack et A resistance of about 11 500 ohms should be indicated here B Connect one tester lead to the coil mounting bracket and the other to the ignition switch wire Continuity should not be indi cated here Replace ignition coil assembly if wrong results are obtained from either of these tests Magneto and Battery System Breaker Points Engine operation is greatly affected by breaker point condition and adjustment of the gap If points are burned or badly oxidized little or no current will pass The engine may not operate at all or may miss at high speed Size of the breaker point gap affects the amount of time the points are open and closed If the gap is set too wide they will open too early and close too late A defi nite period of time is required for the field to build in the ignition coil If the points are closed for too long or too short a period a weak spark will be produced by the coil Figure 8 8 shows the effects of too little and too much capacitance in the condenser Severe metal buildup on either contact indicates that the con denser is not properly matched to the rest of the system and should
76. TS 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 filter screen faulty fuel 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 If 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 Coil tester for continuity Crankcase Vacuum A partial vacuum should exist in the crankcase when the engine is operating at normal tempera tures Pressure in the crankcase usually caused by a clogged or i
77. X T Adjusting Screw ag Figure 6 16 Fixed Main Jet Carburetor WARNING Accidental Starts Before servicing the carburetor engine or equip ment always remove the spark plug leads to prevent the engine from starting accidentally Ground the leads to prevent sparks that could cause fires A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks open ffame and other sources of ignition away from the area to prevent the possibility of fires or explosions A WARNING Prevent Eye Injury Suitable eye protection safety 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 Trese will be e either tre top It rottie Date Code Kohler Part No lever side ef meunting f ange as s ewn cr on the beatem fuel bewi side of meunting flange Throttle Lever I m7 d Shaft Assembly Series Designation WETS gt A 3 74 Idle Fuel Adjusting 7 oe Needle And Spring 4 k ai 6G Y E Welch Plugs Choke Lever 3 hk eee Shaft Assembly ini Choke Plate Fuel Bowl e A Idle Speed Adjusting 1 i Md E Screw And Spring crew And Gasket Choke Detent Ball And Spring Mounting Flange Fuel Bowl Gasket En Float Pin Float Idle Fuel X Outlet Port Fix
78. al Use 4747 handle Used to pull valve guides with 3222 slide hammer Used to install valve guides to proper depth Use 11763 driver with 11770 amp 11771 depth gages To ream valve guides Used to install seals without damage and to proper depth Use 11795 handle with installers SEAL AND BEARING INSTALLERS 3242 SEAL PROTECTOR SLEEVE KIT Used on crankshaft when installing 12020 75 12021 1 00 seals to prevent damage 12022 1 25 12126 1 12 12127 1 50 12128 1 44 3241 BEARING INSTALLING KIT Used to install amp remove engine 12014 Ins Crank Bushing bearings and bushings 12015 Ins Cam Bushing 12016 12017 12018 amp 12109 Brg Installers OTHER APPLICATIONS 3226 FLYWHEEL PULLER KIT Used to remove flywheels and 12485 Puller w forcing screw bearing plates from engine 5108 Bolt 1 4 w washer 3 12505 Bolt 10 24 w washer 2 12504 Bolt 3 8 w washer 2 12506 Storage Bag FLYWHEEL STRAP WRENCH Used to hold flywheel for nut 10357 removal OFFSET WRENCH Used to remove amp install cylinder 11797 Wrench 1 2 barrel retaining nuts 4923 Wrench 9 16 FEELER GAGE Used to set oil pump drive gear 11767 backlash on twin cylinder engine TIMING GAGE Used to hold balance gears in timed 10355 Timing Gage position when assembling engine SCRAPER Used to scrape machined surfaces 11762 without damage HANDLE Used with bearing installers slide 4747 Handle hammer and val
79. and Run the engine for 5 10 minutes between idle and midrange Ad just the carburetor mixture settings as necessary Refer to Fuel System and Governor section Muffler Shield 2 Make sure the maximum engine speed does not d ENT exceed 3600 RPM 4000 RPM for model K91 only d Adjust the high speed stop as necessary Refer to the Fuel System and Governor section Figure 12 49 Installing Muffler INSTALL AIR CLEANER 1 install the base gasket base and air cleaner 12 19 ELT 2ifittrarevml d AL e AES LE LEIT jM tne ORI FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 This publication replaces ENS 575 o e EASI NHE RSNA I ESSASI n nis ES Hen c SH i SUPE pep Greener e ccv ast ote H Hu Ei CE epe De eee T CRLIDSU N H ES ASES EIEE EN TEESE S NENEN RER s BUSES i gs is eb ii YES EPELELI SEERE Erra onr Anor TT P M d IMAGO AE e ES ere oo DERI EEEE REREN g in a seers AEE SE ERIS re m ITI RT miren nner EUH Eutr c pH UE UE pu 2 G cand cs basen ERE a e us d NIHU CE e Du KOHLEREJGUDES ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 m HH 142441144442244 44444214 Huius EL AA LATIAN MARIUM pud uis ERE enm oo uininnI Tm zx pouem pum tre gate Xue 3 Seat EE ie tase ens OM E 1 puru 2s UU P TEST uu ATIE 2 x a Wu 33332 Hi ii EHE dt DE E E FORM NO HHRHUR E
80. and 14 Prevent rewind spring from escaping from cover by carefully lifting rotor about 1 2 inch and detach inside spring loop from rotor NOTE If spring should escape it can easily be replaced in cover by coiling in turns Starting Rope Replacement LE When installing a new rope Key 16 in rotor thread through rotor hole then wind rope onto rotor as explained in Reassembly Replace handle and washer if used and tie a double knot in the end of the rope Rewind Spring Replacement 1 Start with the inside loop remove spring care fully from cover by pulling out one loop at a time holding back the rest of the turns When replacing with new spring note the position of spring loop Spring holders furnished with replacement springs simplify the assembly procedure Place spring in proper position as shown with the outside loop engaged around the pin Then press the spring into cover cavity thus releas ing the spring holder A few drops of SAE 20 or 30 oil should then be applied to spring and light grease on cover shaft Reassembly 1 Replace washers Keys 9 and 10 friction shoe assembly washers Keys 9 and 10 spring Key 8 washer Key 7 and retaining ring Key 6 Starter rope is now completely wound on rotor in the direction shown in Figure 7 2 The starter will be damaged if not centered properly To insure the proper centering of the starter pull out the centering pin Key 19 about 1 8
81. and in the event of flooding excess fuel is blown out of the lifted exhaust valve and does not hamper starting e Engines with ACR start much faster in cold weather than those without ACR e Engines with ACR can be started with spark plugs that are worn or fouled Engines without ACR probably could not be started with those same plugs INSPECTION AND SERVICE The ACR mechanism is extremely rugged and vir tually troublefree If hard starting is experienced check the exhaust valve for lift as follows 1 Check exhaust valve to tappet clearance and adjust as necessary to specification 2 Remove cylinder head and turn the crankshaft clockwise by hand and observe the exhaust valve carefully When the piston is approximately 2 3 of the way up the cylinder during the compression stroke the exhaust valve should lift off the seat slightly If the exhaust valve does not lift the ACR spring may be unhooked or broken To service the spring remove the oil pan and rehook spring or replace it The camshaft does not have to be re moved The flyweights are not serviceable If they are stuck or worn excessively the camshaft must be replaced NOTE The tab on the flyweights is hardened and is not adjustable Do not attempt to bend the tab it will break and a new camshaft will be re quired 9 2 COMPRESSION TESTING Because of the ACR mechanism it is difficult to obtain an accurate compression reading To check the con
82. and turn coun 2 Make sure the oil drain plugs oil sentry pressure terclockwise as far as it will go The governor shaft switch and a new oil filter are installed can be adjusted for end clearance by moving needle bearing in block Set bearing to allow a 3 Fill the crankcase with the correct amount weight slight back and forth movement of shaft and type of oil Refer to the oil recommendations and procedures in the General Information and 3 Torque the palnut on governor arm to 15 in Ib Periodic Maintenance sections NOTE Make sure there is at least 1 16 clearance between the governor arm and the upper left cam gear cover fastener to prevent interference 4 Fill the fuel tank with the proper type of gasoline and open fuel shut off valve if equipped Refer to the fuel recommendations in the General Information section INSTALL MUFFLER 5 Adjustthe carburetor main fuel needle idle fuel needie or idle speed adjusting screw as necessary 1 If the engine is equipped with a flat muffler install Refer to the Fuel System and Governor section muffler and gasket using cap screws if equipped with a round muffler install muffler and threaded ex haust pipe between the muffler and engine using a pipe wrench Referto Figure 12 49 TESTING THE ENGINE It is recommended that the engine be operated on a test MA stand or bench prior to installation in the piece of Cap Screws MEM equipment 1 Set the engine up on a test st
83. apscrew to 20 over the nominal torque value listed below Loosen cap screws 3 Orient the notch on Style C piston or Fly to below the nominal value do not leave symbol Style D piston and match marks overtorqued Retorque bolts to the nominal on connecting rod towards the flywheel end of torque value crankshaft Gently push the piston connecting N i rod into bore do nopen deton OTE To prevent damage to connecting rod and engine do not overtorque loosen and retorque the hex nuts on Posi Lock connecting rods 4 Lubricate the crankshaft and connecting rod Torque nuts in increments directly to the speci journal surfaces with engine oil Install the con fied value necting rod cap make sure the match marks are aligned and the oil hole is towards the 6 Rotate the crankshaft until the piston is at top camshaft It is important that marks on con dead center in bore to protect the dipper on necting rod and cap line up and face flywheel the connecting rod If locking tabs are used end of engine Refer to Figure 12 37 bend tabs to lock cap screws Engine Model Connecting Rod New Service Rod Used Reinstalled Rod K91 All K161 All K181 Posi Lock K181 Capscrew K241 K301 K321 K341 Posi Lock K241 K301 K321 K341 Capscrew INSTALL OIL PAN Torque screws and oil drain plug as specified 1 Install the gasket oil pan and oil drain plug in General Information 12 12 Intake Valve 1 Rotate the
84. arburetor 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 1 Remove fuel line from fuel tank outlet fitting 2 Remove tank with bracket s REMOVE DIPSTICK 1 Remove the dipstick REMOVE CYLINDER HEAD BAFFLE AND SIDE AIR BAFFLES 1 Remove the cylinder head baffle 2 Remove the carburetor side air baffle 3 Remove the starter side air baffle REMOVE BREATHER ASSEMBLY 1 Remove palnut breather cover and gasket Gasket a amp me Gasket Breather Breather Cover Figure 10 2 Removing Breather Components 2 Remove the filter seal reed stop reed breather plate gasket and stud REMOVE SPARK PLUG AND CYLINDER HEAD 1 Remove the spark plug cylinder head and gasket REMOVE BLOWER HOUSING 1 Remove breaker point cover gasket breaker point lead breaker assembly and push rod REMOVE DRIVE CUP OR ROPE START PULLEY GRASS SCREEN AND FLYWHEEL NOTE Always use a flywheel strap wrench to hold the flywheel when loosening or tightening flywheel and fan retaining fasteners Do not use any type of bar or wedge between fins of cooling fan as the fins could become cracked or damaged Al ways use a puller to remove flywheel from crank shaft Do not strike the crankshaft or flywheel
85. arburetor and throttle linkage 28 Install muffler 29 Install air cleaner WOON ODN H WDA INSTALL REAR BEARING 1 Install the rear bearing into crankcase using the 4747 handle and appropriate bearing in Staller Refer to the Special Tools section Make sure the bearing is bottomed fully and is straight and true in bore Refer to Figure 12 1 Install the rear main bearing by pressing it into cylinder block If using a shielded type bearing install with shielded side facing toward inside of block Rear Bearing Figure 12 1 Installing Rear Bearing INSTALL GOVERNOR GEAR AND CROSS SHAFT 1 Slide cross shaft into place from inside of block 2 Place speed control disc on governor bushing nut and thread bushing nut into block On ear lier models the cross shaft has an extension riveted in place to line up with governor gear Torque bushing nut as follows K91 70 90 in Ib K161 K181 130 150 in Ib K241 K301 K321 K341 100 120 in Ib 3 Install the thrust washer governor gear cop per washer and stop pin Refer to Figures 12 2 and 12 3 12 1 Copper Washer Bushing Nut Cross Shaft Figure 12 2 Installing Cross Shaft And Stop Pin Figure 12 3 Installing Governor Gear 4 Rotate governor gear assembly to be sure stop pin does not contact weight section of governor gear INSTALL TAPPETS AND CAMSHAFT 1 Install the intake valve tappet and exhaust valve
86. ary mark on crankshaft should align with the secondary timing mark on lower balance gear Refer to Figure 12 16 The primary mark on crankshaft should align with timing mark on camshaft Refer to Fig ure 12 15 if the marks do not align the timing is incorrect and must be corrected 2A NEW STYLE BALANCE GEAR ASSEMBLY WITH A BALANCE GEAR TIMING TOOL Count and mark the teeth on the crankshaft gear and the lands notches between teeth on the camshaft gear as follows Crankshaft Locate the primary timing mark on crankshaft While looking at the PTO end of crankshaft start with the tooth directly below timing mark and count five 5 teeth in a counterclockwise direction Mark the fifth tooth Refer to Figure 12 18 harness between the bearing plate and crankcase before pressing the crankshaft all the way in a 28 1 5th Tooth From 2 Align the primary timing mark on the crank Timing Mark Pi shaft with the timing mark on the camshaft d gear Refer to Figure 12 15 Press the crank shaft all the way into the rear bearing Make sure the camshaft and crankshaft gears mesh and that the timing marks align while pressing Primary Timing Mark 3 Position the crankshaft so it is about 15 past BDC Install 3 8 spacer and one 010 shim spacer Align the secondary timing mark on the lower balance gear with the secondary tim ing mark on the crankshaft Install the lower balance gear on the stub shaft If properly Figure 12 18
87. ay out A smooth steady pull will start engine under normal conditions FAIRBANKS MORSE STARTERS Starters have die cast aluminum housings A fric tion shoe assembly under spring tension is used and engages in the drive cup when the starter 4 handle is pulled The drive cup is held in place on l l the engine with the flywheel nut A pin on the cup rope will not receive excessive wear from fric is engaged in crankshaft keyway to prevent slip tion against guide Proper procedure will pre page of the drive cup vent unnecessary wear Always pull starter handle straight out so that 5 If recoil starter should ever fail starter assem bly can be removed and engine cranked with a rope The starter drive cup will serve as a pul ley for emergency purposes Refer to Figure 7 1 3 MOUNTING FLANGE 5 MIDDLE FLANGE CENTERIN os 17 ROTOR 18 REWIND FRICTION d SPRING SHOE ASSEMBLY HOUSING 20 Figure 7 1 Fairbanks Morse Starter Exploded View 7 1 Disassembly If starting rope breaks or if starting spring fails the following procedure should be followed NOTE Handle rewind springs with extreme caution 1 To remove starter from engine remove four mounting bolts Refer to Figure 7 2 Hold washer Key 7 in position with thumb while removing retainer ring Key 6 witha screwdriver Remove washer Key 7 spring Key 8 washers Keys 9 and 10 then remove friction shoe assembly Keys 11 12 13
88. be replaced 8 5 Spark Plugs Engine misfire and starting difficulty are often caused by the spark plug being in poor condition or being improperly gapped The spark plug FROM ALTERNATOR should be removed after every 100 hours of op eration for a check of its condition At this time the gap should be reset or the spark plug re placed as necessary Refer to Figure 8 9 TO IGNITION SWITCH OR COIL ASSEMBLY 4 TRIGGER MODULE Figure 8 7 Trigger Module Lead Connections BUILD UP ON MOVABLE CONTACT COULD INDICATE UNDER CAPACITANCE MOVABLE CONTACT BUILD UP ON STATIONARY CONTACT COULD INDICATE OVER CAPACITANCE STATIONARY CONTACT Figure 8 8 Metal Transfer On Breaker Points 8 6 Spark Plug Wire Gauge Ground Ah Electrode Figure 8 9 Setting Spark Plug Gap Engine K91 K 181 ignition Type Battery Magneto Breakerless K241 K341 Battery Breakerless Standard resistor plug Short resistor plug Service the spark plug as follows 1 Clean the area around the base of the spark plug to keep dirt out of the engine upon re moval 2 Remove the spark plug and check its condi tion Replace it if it is badly worn or if re use is questionable Clean it if it is re useable NOTE Do not clean the spark plug in a machine that uses abrasive grit Some grit could remain in recesses and enter the engine causing extensive wear and damage 3
89. bushing over the shaft Using a vise and the screws installation tool from the kit press the bushing into the counterbore until it bottoms in the car buretor body Refer to Figure 6 11 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 11 Installing Throttle Shaft Bushing 4 Allow the Loctite to set for 5 to 10 minutes then remove the throttle shaft 5 Install the new throttle shaft and lever in carbu retor body Rotate the shaft and check that it does not bind NOTE If binding occurs locate the cause and correct Figure 6 10 Installing Choke Shaft Bushings before proceeding Use throttle shaft to align bushing 4 Install new choke shaft in bushings Rotate if necessary shaft and check that it does not bind E 6 Remove the shaft and allow the Loctite to NOTE If binding occurs locate and correct the set for an additional 30 minutes before pro cause before proceeding Use choke shaft to align ceeding bushings if necessary 7 Wipe away all excess Loctite from bushing and 5 Remove choke shaft and allow Loctite to set throttle shaft for an additional 30 minutes before proceed ing Install Detent Spring and Ball Choke Shaft and Choke Plate 6 Wipe away any excess Loctite from bushings and choke shaft 1 Install ne
90. carbu retor if the fuel inlet seat is damaged Tool KO1018 Pry Out Plug 3 Remove the idle fuel adjusting needle and Do Not Allow spring Remove the idle speed adjusting screw Tip To Strike and spring Carburetor Body Pierce Plug 4 Remove the main fuel jet 5 In order to clean the off idle ports and the With Tip Welch Plug bowl vent channel thoroughly the welch plugs covering these areas must be removed Use Figure 6 23 Removing Welch Plugs 6 15 A Pierce the welch plug with the tip of the tool reassembly refer to Figure 6 25 Also take note of the choke plate position in bore and CAUTION To prevent damage to the carburetor do the position of the choke lever not allow the tool to strike the carburetor body B Pry out the welch plug using the tool Choke Plate Throttle And Choke Shaft Removal Further disassembly to remove the throttle shaft and choke shaft is recommended only if these parts are to be cleaned or replaced Throttle Shaft Removal 1 Because the edges of throttle plate are bev F e Y 4 eled mark the throttle plate and carburetor s E Darbureior B od body with a marking pen to ensure correct reassembly refer to Figure 6 24 Also take note of the throttle plate position in bore and the position of the throttle lever Figure 6 25 Marking Choke Plate And Carburetor Body Marking Pen T 2 Carefully and slowly remove the screws secur ing the choke plate to choke shaf
91. chome Idle Main Fuel ter Readjust the speed as necessary RU adn n di Needle rew Adjust To Midpoint Figure 6 5 Optimum Low Idle Fuel Setting Disassembly Refer to Figure 6 7 1 Remove the bowl retaining screw retaining Figure 6 6 Kohler Built Adjustable Jet screw gasket and fuel bowl Carburetor 6 4 Cleaning WARNING Flammable Solvents A Carburetor 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 addition 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 these seals Inspection 1 Carefully inspect all components and replace those that a
92. cking of the insert Remove Valve Seal Insert To remove a valve seat insert refer to Figure 11 8 and proceed as follows 1 Install valve seat puller on forcing screw and lightly secure with washer and nut 2 Center the puller assembly on valve seat in sert 3 Hold forcing screw with a hex wrench to pre vent turning and slowly tighten nut See Figure 11 8a 3 16 Hex Wrench Valve Seat Insert Yt gt 9 16 Open end or Box Wrench t 5 ANN 722225 Sharp Lip DA N N 222 9 A DSSS L3 tre GIL Cylinder Block b TTC Slide a Hammer j L i TET Jl Lj Ej H a Adapter Valve Seat P d Insert Puller Hex Nut Washer Forcing Screw Figure 11 8 Pulling Valve Seat Insert Typical NOTE Make sure sharp lip on puller see insert engages in joint between bottom of valve seat in sert and cylinder block counterbore all the way around 4 Continue to tighten nut until puller is tight against valve seat insert 5 Assemble adapter to valve seat puller forcing screw and slide hammer to adapter See Fig ure 11 8b 6 Use slide hammer to remove valve seat insert Install Valve Seat Insert To install valve seat insert proceed as follows 1 Make sure valve seat insert bore is clean and free of nicks or burrs 2 Align valve seat insert in counterbore and us ing valve seat installer and driver
93. d element cover Tighten nut to 50 in Ib 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 Gasket Base Screws 3 Breather Hose Air Cleaner Base Element Element Cover Figure 5 2 K181 New Look Air Cleaner Assembly 5 2 NOTE Damaged worn or loose air cleaner com ponents could allow unfiltered 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 oil from the bowl 2 Thoroughly wash bowl and cover in clean sol 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 OIL LEVEL 5 Install base gasket and place fi
94. d clean combustion chamber Refer to Figure 3 6 3 4 Wooden Or Plastic Scraper Qe O 3A K91 200 in Ibs Q4 O2 5 Rees Cylinder Head E Figure 3 6 Cleaning Cylinder Head And K161 K181 Combustion Chamber YO 15 20 ft Ibs 1 Remove the cylinder head baffle and cylinder head 2 Clean away combustion deposits using a wooden or plastic scraper 3 Reinstall the cylinder head using a new gasket Torque the cylinder head fasteners in se quence to the values specified in Figure 3 7 CHECK VALVE TO TAPPET CLEARANCE K241 Every 500 operating hours remove breather valve K301 K321 cover and check valve to tappet clearance with a 25 30 ft Ibs flat feeler gauge Refer to Figure 3 8 The engine must be cold when checking this clearance Os O 1 Remove the air cleaner assembly carburetor and breather assembly Refer to appropriate Disassembly section 2 Position the crankshaft so the piston is at top of compression stroke cam has no effect on 7 38 tappets O 1 Q K341 25 30 ft Ibs Qe 3 Qs Q2 Includes K141 Figure 3 8 Measuring Valve To Tappet Figure 3 7 Cylinder Head Fastener Clearance Tightening Sequence 3 Measure valve to tappet clearance with a flat feeler gauge On Model K91 K141 K161 K181 f the clearance is too small remove the valves and grind the valve stems until the correct clear ance is obtained Make s
95. dition of the combustion cham ber and related mechanisms physical inspection and a crankcase vacuum test are recommended AUTOMATIC COMPRESSION RELEASE ACR CHANGES New ACR Tabs Engines with serial no 9006118 and after have hardened and ground steel ACR tabs on the cam shaft assemblies These new assemblies are manufactured with improved techniques which permanently set the ACR mechanism making ad justments to the mechanism unnecessary and im possible NOTE Do not attempt to bend these hardened steel ACR tabs These tabs will break if bent Procedure For Checking And Adjusting ACR On Engines Prior To Serial No 9006118 On engines manufactured before serial no 9006118 the ACR can still be checked and reset using the procedure described below ACR is set according to the amount of valve lift on the exhaust valve The correct amount of lift is established by the height of the lifting tab in rela tion to the camshaft If improper lift is suspected the setting can be checked and adjusted as fol lows 1 Check valve tappet clearances and adjust as necessary to specification 2 Remove cylinder head and turn the engine over by hand until you reach BDC of the intake stroke intake valve will be closing 3 Mount a dial indicator on the top of the ex haust valve and set at O 4 Slowly turn the flywheel clockwise and watch the dial indicator When the piston is about 2 3 of the way up the cylinder the exhaust
96. e Worn guides and faulty valve springs may cause this condition Also check for clogged air intake blocked fins and lean fuel mixture when this condition is noted Carbon Cut Excessive build up of deposits in the combustion chamber may result in valve damage because deposits can become hard enough to cut the valve Cleaning of the cylinder head at proper intervals could prevent such damage Stem Corrosion Moisture from the fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Gum Gum deposits usually result from using stale gasoline This condition is often noted in applica tions where fuel is not drained out of the tank dur ing the off season Gum is a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition 11 5 Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in a burnt valve face or seat loss of com pression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split bal gauge measure the inside diameter Then using an outside micrometer measure the diameter of the valve s
97. e sure reed valve is installed properly and that oil drain hole on breather plate is down Refer to Figures 12 45 and 12 46 NOTE All K181 Specifications have been changed to call for 2 pieces of breather filter 231419 in stead of 1 Testing has revealed the use of two filters prevents oil droplets from being expelled through the breather system All K181 engines are now being built with two filters and when serviced two should always be used FILTER GASKET N Nao BREATHER GASKET 4 K161 K181 Figure 12 45 K181 Breather Assembly 15 20 ft Ibs CLOSED BREATHER PLATE BREATHER AN ANSG SN TS BAFFLE iS N DIT 3 PLATE SEA GASKET VALVE COVER REED FILTER over GASKET K301 K321 25 30 ft Ibs STUD IN CRANKCASE Kioso 6 M Q5 Q 2 Figure 12 46 K241 Breather Assembly 2 Install the gasket breather cover and palnut INSTALL SIDE AIR BAFFLES AND CYLINDER HEAD BAFFLE 1 Install the starter side air baffle plain washer and hex cap sems screws Leave the screws loose K341 12 2 Install the carburetor side air baffle plain washer and hex cap sems screws Leave the screws loose 3 Install the cylinder head baffle plain washer and hex cap sems screws Leave the screws loose 4 Tighten the screws securely when all pieces are in position Figure 12 44 Cylinder Head Fastener Torque NOTE Shorter screws go into lower portion of Sequence blower hou
98. e top sur the bowl retaining screw Torque screw to face Refer to Figure 6 29 45 55 in Ib 6 18 7 Install the idle speed adjusting screw and spring 8 Install the idle fuel adjusting needle and spring Turn the adjusting needle in clockwise until it bottoms lightly CAUTION The tip of the idle fuel adjusting needle is tapered to critical dimensions Damage to the needle and the seat in carburetor body will result if the needle is forced 9 Turn the idle fuel needle out counterclock wise from lightly bottomed according to the instructions in the Adjustment section of this Bulletin HIGH ALTITUDE OPERATION FIXED JET When operating the engine at high altitudes the main fuel mixture tends to get overrich An over rich mixture can cause conditions such as black sooty exhaust smoke misfiring loss of speed and power poor fuel economy and poor or slow gov ernor response To compensate for this a special high altitude main fuel jet is available for each carburetor The high altitude main fuel jet is sold in a kit which in cludes the jet and necessary gaskets High Altitude Jet Installation Fixed Jet 1 Remove the fuel bowl retaining screw retain ing screw gasket fuel bowl and bowl gasket NOTE f necessary remove the air cleaner and carburetor from engine to make fuel bowl removal easier 2 Remove the float pin float and fuel inlet needle 3 Remove the existing main fuel jet 4 In
99. ears containing the new bearings The nee dles are no longer caged and will drop out If this should occur the bearing case should be greased and the needles reset There are 27 individual needles in each bearing Spacer w Balance Gear Retaining a Shim Spacer Figure 12 9 Installing Balance Gears 2 Check end play with a flat feeler gauge Refer to Figure 12 10 Recommended end play is 002 010 If end play is not within range install or remove 005 and 010 spacers as necessary Balance gear spacer kit Kohler Part 47 755 01 contains enough 3 8 005 010 and 020 spacers to obtain correct end play for both bal ance gears 12 3 Balance Gear Figure 12 10 Measuring Balance Gear End Play INSTALL CRANKSHAFT On Engines Without Balance Gears 1 Lubricate the crankshaft rear bearing surface Insert the crankshaft through the rear bearing NOTE If the crankshaft and bearing plate have not been separated position the fuel line and wiring harness between the bearing plate and crankcase before pressing the crankshaft all the way in 2 Align the primary timing mark on crankshaft with the timing mark on camshaft Refer to Figure 12 11 Press the crankshaft into rear bearing Make sure the camshaft and crank shaft gears mesh and that the timing marks remain aligned while pressing On Engines With Balance Gears K Series engines have two styles of balance gear assemblies
100. ecom mended level NOTE Do not overfill the battery Poor perform ance or early failure will result 2 Keep the cables terminals and external bat tery surfaces clean A buildup of corrosive acid or dirt on the surfaces can cause the bat tery to self discharge Wash the cables termi nals and external surfaces with a baking soda and water solution Rinse thoroughly with clean water NOTE Do not allow the baking soda solution to enter the battery cells The solution will chemically destroy the electrolyte SECTION 9 AUTOMATIC COMPRESSION RELEASE All K Series single cylinder engines except the K91 are equipped with Automatic Compression Release ACR The ACR mechanism lowers com pression at cranking speeds to make starting eas ier OPERATION The ACR mechanism consists of two flyweights and a spring attached to the gear on camshaft When the engine is rotating at low cranking speeds 600 RPM or lower the flyweights are held by the spring in the position shown in Figure 9 1 Exhaust Valve Open Camshatt N Tab 2 p Spring SS EN We gt NN Y K gt 3 Uu S Poo Flyweights Tappet 7 Tab Spring Fiyweights Figure 9 1 Automatic Compression Release ACR Starting Position In this position the tab on the larger flyweight pro trudes above the exhaust cam lobe This lifts the exhaust valve off its seat during the first part of the compression stroke The
101. ecting Rod Figure 10 6 Removing Piston From Connecting Rod REMOVE PISTON RINGS 1 Remove the top and center compression rings and the oil control ring spacer using a ring ex pander tool Refer to Figure 10 7 2 Remove the rails and expander spring s Center Compression Ring Top Compression Ring Ring Expander Tool Oil Control Ring Figure 10 7 Removing Piston Rings REMOVE CRANKSHAFT AND BEARING PLATE 1 Remove the hex cap sems screws securing the bearing plate to crankcase 2 Remove the bearing plate from the crankshaft using a puller Refer to Figure 10 8 NOTE The front bearing may remain either in the bearing plate or on the crankshaft when the bear ing plate is removed 3 Press the crankshaft out of the crankcase from the PTO side It may be necessary to press crankshaft out of cylinder block Bearing plate should be removed first if this is done NOTE If the repair does not require separating the bearing plate from crankshaft the crankshaft and bearing plate can be pressed out as an assembly REMOVE CAMSHAFT AND TAPPETS 1 Drive the camshaft pin and cup plug on bear ing side plate out of the crankcase from the PTO side 2 Remove the camshaft pin camshaft and shim s on bearing plate side of camshaft Refer to Figure 10 9 za P Figure 10 9 Removing Camshaft 3 Mark the tappets as being either intake or ex haust Remove the tappets from the crank case Refer
102. ed Main Fuel Jet E 2 Off Idle Throttle Plate Float Level Float Drop Port Adjusting Tab Limiting Tab Non Adjustable idle Air Bleed 1 Float Hinge N o e s Bowl Vent Nozzle i N S Air Bleed AirCleaner O O R yg aa Mounting Surface Idle Fuel Fuel Inlet Inlet Needle Figure 6 17 Major Components And Service Locations Typical Fixed Jet Carburetor 6 11 TROUBLESHOOTING e Make sure the carburetor is securely fastened l l to the engine using gaskets in good condition If engine troubles are experienced that appear to be fuel system related check the following areas ded i i e Make sure the air cleaner element is clean before adjusting or disassembling the carburetor and all air cleaner components are fastened e Make sure the fuel tank is filled with clean securely fresh gasoline e Make sure the ignition system governor sys tem exhaust system and throttle and choke controls are operating properly e Make sure the fuel tank cap vent is not blocked and that it is operating properly e Make sure fuel is reaching the carburetor This includes checking the fuel shut off valve fuel tank filter screen in line fuel filter fuel lines and fuel pump for restrictions or faulty compo nents as necessary If after checking the items listed above starting problems or other conditions similar to those listed in the following table exist it may be
103. electrical shock 4A WARNING Overspeed Is Alb Hazardous Do not tamper with the governor setting Overspeed is hazardous and could cause personal injury WARNING Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Fol low the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent A 1 2 ux amp vVsn s SB teet tere MOI T E PAS acida t x Carbon Monoxide can cause severe nausea fainting or death Do not operate engine in closed or confined area WARNING Lethai Exhaust Gases Engine exhaust gases contain poi sonous 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 WARNING Spring Under Tension Retractable starters contain a pow erful flat wire recoil spring that is under tension Do not remove the center screw from the starter until the spring tension is released Re moving the center screw before re leasing spring tension or improper starter disassembly 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
104. energy is pro vided by a battery The battery is maintained at full charge by an engine mounted motor generator or alternator The coil in a battery ignition system is connected as follows Refer to Figure 8 3 The positive terminal is connected to the posi tive terminal of the battery The negative terminal is connected to the breaker points The high tension center terminal is connected to the spark plug Battery Ignition System Timing The timing procedure for the battery ignition sys tem is the same as for the magneto system When using a timing light refer to the manufactur er s instructions NOTE The Model K341QS Specification 71276A engine is unique in that it is timed slightly differ ently than other K series engines These engines operate at lower speed so the timing is set at 16 degrees before top dead center to improve run ning smoothness Instead of having an S or SP at the timing mark on the flywheel these engines have a 1 above and a 6 below the mark When timing these engines the timing mark is centered as with other engines HIGH TENSION LEAD 3 N SPARK PLUG ER Ewa CONDENSER KID m it PRIMARY SECONDARY CONNECTION BREAKER POINTS Figure 8 3 Wiring Diagram Battery Ignition System 8 3 NEGATIVE TERMINAL TO CONDENSER amp POINTS HIGH TENSION MOUNTING BRACKET Figure 8 4 Typical Battery Ignition Coil Battery Ignition Service 10 16 H
105. engine speed decreases rich Note the position of the needle Adjust To Midpoint 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 See Figure 6 21 7 Recheck the low idle speed using a tachome ter Readjust the speed as necessary Figure 6 21 Optimum Low Idle Fuel Setting DISASSEMBLY Refer To Figures 6 17 and 6 22 Throttle shaft w seal Throttle plate a plate screws Breather ci Idle adjusting needle s Idle needle et spring Choke spring High speed Choke Ball N lt needle ide X Throttle adjusting Choke plate spring Throttle adjusting screw Carburetor Assembly Le Choke plate screws Main needle spring Jt N Choke shaft Bowl gasket is Fuel bowl C3 Gasket for bowl retainer screw Float amp Bowl retainer screw Figure 6 22 Walbro Fixed Adjustable Jet Carburetor Exploded View 1 Remove the bowl retaining screw retaining tool No KO1018 and the following procedure screw gasket and fuel bowl to remove the welch plugs Refer to Figure 6 23 2 Remove the bowl gasket float pin float and fuel inlet needle CAUTION To prevent damage to the carburetor do not attempt to remove the fuel inlet seat as itis not serviceable Replace the
106. er 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 base Inspect Air Cleaner Components Whenever the air cleaner cover is removed or serv icing 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 K181 New Look engines only make 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 Figure 3 2 Air Cleaner Components NOTE Damaged worn or loose air cleaner com ponents could allow unfiltered air into the engine Wire Gauge causing premature wear and failure Replace all damaged or worn components Spark Plug 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
107. er Tension Do not attempt to pull or pry the recoil spring from the housing Doing so can cause the sudden and potentially dangerous release of the spring from the housing Follow these instructions carefully to en sure personal safety and proper spring replacement Make sure adequate face protection is worn throughout the following procedure 1 Carefully note the position of the spring in the housing Also refer to Figure 7 17 The new spring must be installed in the proper position it is possible to install it backwards in the housing 2 Place the housing on a flat wooden surface with the recoil spring and center shaft down and away from you 3 Grasp the housing by the top so that your fin gers are protected Do not wrap your fingers around the edge of the housing 7 9 4 Lift the housing and rap it firmly against the wooden surface Repeat this procedure until the spring is released from the spring pocket in housing Refer to Figure 7 18 VETT VP RPPPPPP Housing Surface Figure 7 18 Removing Spring From Housing 5 Discard the old spring Reinstalled Do not attempt to rewind or reinstall a spring once it has been removed from the starter housing Severe personal injury could result from the sudden uncoil ing of the spring Always order and install a new spring which is held in a specially designed c ring spring retainer T CAUTION Old Spring Cannot Be 6 Thoroughly clean the s
108. er to replace bearings if required BALANCE GEAR BEARING AND BALANCE GEAR ASSEMBLY A new needle bearing for the Dynamic Balance System is now being used on 10 16 HP Kohler engines The new bearing part number 47030 01 has been in use beginning with serial number 9641311 It is not interchangeable with the old needle bearing part number 236506 11 11 11 16 NOMINAL PRESS DEPTH 735 STUB SHAFT ABOVE ra MAIN m To LE STUB SHAFT BOSS y Me eL IF SHAFT PROTRUDES ABOUT 11 16 ABOVE STUB SHAFT BOSS DO NOT USE 3 8 SPACER NV 1 1 16 NOMINAL PRESS DEPTH 1 110 STUB SHAFT 3 8 SPACER STUB SHAFT BOSS IF SHAFT PROTRUDES ABOUT 1 1 16 ABOVE STUB SHAFT BOSS USE 3 8 THICK SPACER NEXT TO BOSS Figure 11 15 Stub Shaft Press Depth Complete balance gear assemblies are inter changeable and old style gear assemblies have been superceded with a new gear assembly part number 47 042 01 Critical consideration is required when only the needle bearing is to be replaced The engine se rial number alone can correctly determine which needle bearing is involved on original equipment engines However should a bearing replacement be required after a complete balance gear has been replaced on an engine with a serial number prior to 9641311 the following methods will assist in identifying the correct bearing Method 1 I D of Balance Gear Bore 0825 236506 6821 6865 47 030 01 6869 M
109. ervice NOTE In the event of a false start engine starts but fails to keep running the engine must be al lowed to come to a complete stop before the starter is re engaged If the flywheel is still rotat ing when the starter is engaged the pinion and ring gear may be damaged NOTE Do not crank the engine for longer than 10 seconds A 60 second cool down period must be allowed between starting attempts Failure to fol low this procedure could result in starter burnout Service the permanent magnet starter as follows bracket and frame off of the drive end of the Refer to Figure 8 29 armature 1 Remove the stop nut and the remainder of the Bendix drive 5 Separate the end cap from the armature be ing careful to restrain the brushes in the end 2 Remove both through bolts cap 3 Remove the end bracket capscrew from the EP 6 Inspect the commutator If dirty clean it with a end cap E coarse lint free cloth If grooved dress it with 4 Remove mounting bracket and frame by rotat a commutator stone or turn it down on a lathe ing the end bracket and slipping the mounting and undercut the mica HIGH MOUNT TYPE PM STARTER PERMANENT THRU BOLT MAGNETS Pa ARMATURE END CAP A ae a LY sie ee NNN d lies Loi ge SS ge i mme eig M e DRIVE PINION SRRI NOTE MOUNTING WITHOUT DUST n f PLATE PART OF FRAME ON SOME PM STARTERS i
110. eshes with a ring gear on the flywheel The armature and ring gear remain engaged until the engine starts to run When the flywheel begins to turn faster than the starter the pinion is thrown from the ring gear and returns to the disengaged position A small anti drift spring on the armature 8 18 shaft holds the pinion in this position as the starter slows to a stop Permanent Magnet Bendix Drive Starter Opera tion of this type starter is the same as that of the wound field starter The major difference between the two is in the method of generating the mag netic field to turn the armature This starter uses strong permanent magnets in place of field coils Safety Interlocks In an effort to enhance safe operation of their equipment many manufacturers install safety in terlocks to prevent engine start before certain safety requirements are met These interlocks are usually incorporated in the starter circuit Unless all interlock switches are closed the starter will not function Before servicing a starter that is reported to have failed always check the safety interlock system first This is done by bypassing the interlock switches with a temporary jumper wire SAFETY INTERLOCK CIRCUIT ON VEHICLE O 7 O07 C oc f gC SEAT DRIVE P T O SPRING LOADED SWITCHES SOL ae KEY SWITCH JUMPER TEST ONLY se 1000 BATTERY SMALL TERMINAL lt x
111. et surface of the carburetor body exposed free end of float 690 720 3 Install the choke plate to choke shaft Make from bowl gasket surface Refer to Figure sure the plate is positioned properly in bore as 6 30 marked and noted during disassembly The numbers stamped on plate should face the air cleaner mounting surface and be upright Ap Bend Tab ply Loctite 609 to threads of 2 plate retain To Adjust ing screws Install the screws so they are g slightly loose 4 Operate the choke lever check for binding Parallel Parallel between the choke plate and carburetor bore Adjust plate as necessary then torque screws N S to 8 12 in Ib je Bowl Gasket Carburetor Reassembly T ui MAP Inverted Carburetor 1 If the welch plugs have been removed for cleaning new welch plugs must be installed Figure 6 30 Setting Float Level Use tool No KO1017 and the following proce dure to install the welch plugs Bend the float tab with a small screw driver to ad just A Position the carburetor body securely with the 5 Install a new bowl gasket and the fuel bowl welch plug cavities to the top Make sure the bowl gasket and bowl are cen tered and positioned properly to ensure a B Place a new welch plug into the cavity with the good seal raised portion up Use the end of the tool that is about the same size as plug and flatten the 6 Install a new bowl retaining screw gasket and plug Do not force the plug below th
112. ethod 2 O D of Old Bearing 6825 236506 6828 6870 47 030 01 6875 GOVERNOR GEAR Inspection Inspect the governor gear teeth Look for any evi dence of worn chipped or cracked teeth If one 11 12 or more of these problems is noted replace the governor gear CAMSHAFT AND CRANKSHAFT Inspection and Service Inspect the gear teeth on both the crankshaft and camshaft If the teeth are badly worn chipped or some are missing replacement of the damaged components will be necessary Also inspect the crankshaft bearings for scoring grooving etc Do not replace bearings unless they show signs of damage or are out of running clear ance specifications If crankshaft turns easily and noiselessly and there is not evidence of scoring grooving etc on the races or bearing surfaces the bearings can be reused Check crankshaft keyways If worn or chipped replacement of the crankshaft will be necessary Also inspect the crank pin for scoremarks or me talic pickup Slight score marks can be cleaned with crocus cloth soaked in oil If wear limits as stated in Section1 General Information are ex ceeded it will be necessary to either replace the crankshaft or regrind the crank pin to 010 under size If reground a 010 undersize connecting rod big end must then be used to achieve proper running clearance Measure the crank pin for size taper and out of round NOTE If the crank pin is reground visuall
113. follow the procedures in this section carefully A WARNING Sulfuric Acid in batteries can cause severe injury or death Charge only in well ventilation Keep sources of ignition away WARNING Dangerous Acid Explosive Gases Batteries contain sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Bat teries produce explosive hydrogen gas while being charged To pre vent a fire or explosion charge bat teries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batter ies out of the reach of children Re move all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark wil 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 always 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 significance of these numbers is shown below A cma KOHLER EEUU CIE KOHLER SMON 00 HP 00 H p SPEC NO 000000 E 0 B sera No 0000000 SPEC NO 000000 REFER TO OWNER S MANUAL REFER TO OWNER MANUAL FOR OPERATION MAINTENANCE FOR OPERAT
114. g Side Gi earance f e 5 006 m 06 006 PISTON PIN Oulside Diameter 591 8588 8752 8754 8752 8754 8752 8754 Guide Reamer Size NK 3125 3125 j 305 MA 3125 gfamet mw H 00 009 006 000 O0 008 U08 010 008 010 000 010 000 0109 Coid takansi 011 015 047 019 017 019 017 019 017019 017 019 017 019 Minimum Intake 2035 ane 318 318 318 318 Gers ash Bento 1768 ee 318 Mini o die d 2478 3103 3103 3103 3103 3103 E 3103 VALVES valve Siem ae E 258 a088 3088 3074 NE m E XI 3074 Nominal Angle Valve Seat 4 4 49 4 MM EE E ru Guide LD mas 005 005 00 p 006 Maximum CC l I oa Cero 1 a lwear Limito ers f 7 007 S007 008 008 000 D 8 Maximum limits combination of 1 0 and 0 0 measurements Q Ball bearing 1 3779 1 3784 Maximum Wear 1 3779 Ball bearing 1 7716 1 7721 Maximum Wear 1 7716 Includes K141 Figure 1 5 1800 RPM generator sets 005 007 amp Measure above the bottom of the piston skirt Top and center compression rings Pre Series il 1 3733 1 3738 Maximum Wear 1 3728 Ball bearing 002 023 Champion spark plugs or equivatent Measure just below oil ring groove and at rigrit angles to piston pin Engine Specifications And Tolerances 1 6 HORSEPOWER Max RPM Engine Model EXE K341 New 260 In Ibs Used 200 In Ibs
115. g of hous ing NOTE Do not allow the pulley spring to unwind Enlist the aid of a helper or use a c clamp to hold pulley in position 16 Insert the free end of rope through rope guide bushing Tie a temporary slip knot approxi mately 12 from the free end of the rope 17 Hold the pulley firmly with thumbs and allow the pulley to rotate slowly until the slip knot reaches the rope guide bushing of housing Refer to Figure 7 23 7 11 Figure 7 23 Winding Rope Onto Pulley 18 Slip the handle and rope retainer onto rope 19 Tie a single knot at the end of rope and install rope retainer into handle Refer to Figure 7 12 Untie the slip knot and pull the handle out until the rope is fully extended Slowly retract the rope into the starter If the spring has been properly tensioned the rope will fully retract until the handle hits the housing SECTION 8 ELECTRICAL SYSTEMS AND COMPONENTS IGNITION SYSTEMS Kohler K series engines are fitted with one of three types of ignition systems each available in several different versions Most parts in one system are not interchangeable with parts from another sys tem Care should be taken in selection of replace ment parts to ensure the right parts are used The three types of systems and their available versions are Magneto Ignition System 1 Magneto rotor type ignition only 2 Magneto flywheel type magnet ring ignition only 3 Magneto flyweel t
116. g system output less 20 amps Faulty regulator winding on stator replace stator Charge rate Is 4 amps or less Stator Is good Replace rectifler regulator Charging system continues to charge at high rate Regulator winding shorted replace stator No found Charge 2 Connect leads of flashlight type continuity 2 To tester from BAT NEG to one AC terminal Battery then reverse leads Repeat procedure on the other AC terminal 3 Remove red lead from REG terminal all other leads connected to appropriate ter minals If unit does not have ammeter connect ammeter between BAT REG terminal and battery Start engine and operate at full speed 1 Remove two red leads from rectlfler regu Battery lator connect these two leads together Continuously Start engine and operate at full speed Charges At High Rate ELECTRIC STARTING SYSTEMS There are three types of starters used in the K series of engines The three types are Motor Generator This starter also functions as a DC generator In the starting mode it turns the crankshaft through a V belt arrangement The V belt transmits turning force from a small pulley on the motor generator to a large pulley on the crankshaft Wound Field Bendix Drive Starter In the field wound starters electrical current flows through coils to build up a strong magnetic field to turn the armature When the armature Starts to rotate a drive pinion moves forward on the armature shaft and m
117. ge Is 14 7 volts or less the charging sys Battery voltage from B lead to ground using a DC tem Is OK The battery Is unable to hold charge Continuously voltmeter Service battery or replace as necessary riu If voltage Is more than 14 7 volts the rectlfler Ig ate regulator is faulty Replace rectifler regulator 8 14 Electric Start Engine 25 Amp Regulated Battery Charging System AC AC Regulator B Flywheel Alternator Cees 12 Volt Battery Spark Breaker Points Condenser Coil Figure 8 18 Wiring Diagram Electric Start Engines 25 Amp Regulated Battery Charging System 25 Amp Stator Figure 8 19 25 Amp Stator And Rectifier Regulator Troubleshooting Guide 25 Amp Battery Charging System NOTE Zero ohmmeters and voltmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3600 RPM no load Battery must be fully charged Insert an ammeter In B lead from rectifier 1 regulator With engine running at 3600 RPM and B lead connected measure the volt age from B at terminal on rectlfler regula tor to ground using a DC voltmeter If voltage Is 13 8 volts or more place a minimum load of 5 Amps on battery to re duce voltage Observe ammeter NOTE Turn on lights If 60 watts or more Or place a 2 5 100 ohm watt resistor across battery terminals Conclusion If charge rate Increases when load Is applied the
118. gnition coil in other systems The flywheel has a projection that triggers ignition Refer to Fig ure 8 6 In some applications a 22 ohm 1 2 watt resistor has been placed between the key switch and the ignition coil This has been added to prevent cur rent feedback through a dirty or wet switch This feedback if not held in check by a resistor can damage the trigger unit CAPACITOR mi Figure 8 5 Schematic Of Typical Breakerless Ignition System 8 4 BRACKET ___ RS eS TENSION T 1 im r0 TRIGGER amp SWITCH Figure 8 6 Typical Breakerless Ignition Coil Breakerless Ignition System Timing Because there are no breaker points in this sys tem there is no requirement for timing However there is a requirement for positioning the trigger module for proper relationship with the flywheel projection The gap between the projection and trigger module is normally set between 005 and 010 This setting is not critical but selecting a 005 gap promotes better cold weather starting Set the gap as follows 1 Remove the spark plug lead to prevent inad vertent starting 2 Rotate the flywheel so that the projection is aligned with the trigger module 3 Loosen the cap screws on the trigger module bracket and insert a 005 feeler gauge in the gap 4 Move the trigger module until it touches the feeler gauge making sure that the flat sur faces of module and projection are parallel 5 Tighten
119. hands feet hair and clothing and its vapors can explode if ig away from all moving parts to pre nited Store gasoline only in ap vent injury Never operate the en proved containers in well gine with covers shrouds or ventilated unoccupied buildings guards removed 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 igni tion Do not start the engine near spilled fuel Never use gasoline as a cleaning agent A WARNING 0 Gu a Hot Parts can cause severe burns Do not touch engine while operating or just after stopping 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 it is turned off Never operate the engine with heat shields or guards removed 1 1 Accidenta Starts can cause severe injury or death Disconnect and ground spark plug lead before servicing WARNING Accidental Starts Before servicing the engine or equipment always disconnect 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 Shockl Never touch electrical wires or components while the engine is running They can be sources of
120. he battery voltage drops below 9 while cranking the battery is in need of a charge or replacement Battery Charging WARNING Dangerous Acid Explosive A Gases Batteries contain sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Batteries produce explosive hydrogen gas while be ing charged Charge the battery only in a well ventilated area Keep cigarettes sparks open flame and other sources of ignition away from the battery at all times 8 24 To prevent accidental shorting and the resultant sparks remove all jewelry before servicing the battery When disconnecting battery cables always discon nect the negative cable first When connecting battery cables always connect the negative cable last Before disconnecting the negative cable make sure all switches are OFF if any switch is ON a spark will occur at the ground terminal This could result in an explosion if hydrogen gas or gasoline vapors are present Keep batteries and acid out of the reach of children Battery Maintenance Regular maintenance will ensure that the battery will accept and hold a charge A WARNING Ignition Coli Overheat Always turn the ignition switch OFF or disconnect the battery cables before charging the battery Fail ure to do this could result in overheating and explo sion of the ignition coil 1 Check the level of the electrolyte regularly Add distilled water to maintain it at its r
121. he 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 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 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 or 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 low idle speed for Basic En gines is 1200 rpm To ensure best results when setting the low idle fuel needle 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
122. he governed setting the governor spring tension and the force applied by the regulating pin will again be in equilibrium This maintains engine speed at a relatively constant level Governed speed may be at a fixed point as on constant speed applications or variable as deter mined by a throttle contro lever Adjustment A WARNING Overspeed Is Hazardous The maximum allowable speed for these engines is 3600 RPM no load Never tamper with the governor Setting to increase the maximum speed Severe personal injury and damage to the engine or equip ment can result if operated at speeds above maximum INITIAL ADJUSTMENT Make this initial adjustment whenever the governor arm is loosened or removed from cross shaft Make sure the throttle linkage is connected to gov ernor arm and throttle lever on carburetor to en sure proper setting Refer to Figure 6 44 le D Linkage Governor Arm E EN Figure 6 44 Initial Governor Adjustment 1 Pull the governor arm away from the carbure tor as far as it will go 2 Grasp the end of cross shaft with pliers and turn counterclockwise as far as it will go 3 Tighten the palnut on governor arm to 15 in Ib torque NOTE Make sure there is at least 1 16 clearance between governor arm and cross shaft bushing nut to prevent interference HIGH SPEED ADJUSTMENT The maximum allowable speed is 3600 RPM no load The actual high speed setting depends on the application
123. he root of the problem and ad vise the engine owner of your findings The starter bendix drive used by Kohler is de signed and manufactured to withstand forces far in excess of those required for normal operation when the recommended starter procedures are followed Missing or damaged teeth on the bendix drive gears are not being caused by a defect in material or workmanship Rather our testing and analysis of returned failed starter drives has shown that bendix drive damage is being caused by en gaging the starting motor while the flywheel is in motion For this reason warranty claims for a failed bendix drive with damaged or missing teeth will no longer be accepted Overcranking cranking the starter continuously for more than the recommended period and or not allowing a sufficient cool down period between Starting attempts Parasitic Load at cranking a load or force on the engine at cranking that opposes normal engine rotation Battery Service A battery is supplied by the equipment manufac turer The battery should be a 12 volt unit rated at 32 amp hours minimum Battery Test If the battery does not have enough charge to crank the engine recharge it NOTE Do not attempt to jump start the engine with another battery Starting with a battery larger than recommended can burn out the starter mo tor The battery is tested by connecting a DC voltme ter across the battery terminals and cranking the engine If t
124. heck engine speed with a tachometer Speed should be approxi mately 3600 RPM 3 If speed is not correct loosen the capscrew on the high speed stop bracket and adjust the bracket to achieve the required speed 4 Tighten the high speed stop bracket screw 6 31 Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes in the governor arm If set too sensitive speed surging will occur with any change in load If a considerable speed drop occurs with the application of a load sensitivity is set too low The governor spring is placed in the third hole from the end of the governor arm when the engine leaves the factory To increase gover nor control sensitivity move the spring to a hole closer to the cross shaft To decrease sensitivity move it to a hole farther from the cross shaft Sensitivity adjustment may not cure a hunting problem in all cases If hunting persists after sen sitivity is adjusted try one or more of the following steps 1s Set spark plug point gap to 020 and readjust the carburetor for peak performance See Carburetor Adjustment subsection of this section 6 32 C2 Stop the engine and check for free movement of the governor linkage from idle to full open throttle Remove excess paint from the gover nor spring and make sure that there is no in terference between governor components and other parts With the engine shut do
125. heck for defective stator or rectifier regulator Test C B 1 Indicates alternator system OK battery was fully charged B 2 Check for defective stator or rectifier regulator TEST C C 1 Defective stator replace with new assembly C 2 Defective rectifier regulator replace with new unit Possible Fault Remedy D 1 Rectifier regulator not functioning properly Replace with new unit D 2 Alternator system OK Battery unable to hold charge Check specific gravity of battery Replace If neces sary Turn lights on if 60 watts or more or simulate load by placing a 2 5 ohm 100 watt resistor across battery terminals Electric Start Engines 15 Amp Regulated Battery Charging System Flywheel Alternator Regulator Starter 12 Volt Battery Breaker Points Coil Condenser Figure 8 16 Wiring Diagram Electric Start Engines 15 Amp Regulated Battery Charging System Rectifier Regulator AC Leads 3 15 Amp Stator Figure 8 17 15 Amp Stator And Rectifier Regulator Troubleshooting Guide 15 Amp Battery Charging System NOTE Zero ohmmeters and voltmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3600 RPM no load Battery must be fully charged Problem Test Conclusion Insert an ammeter In B lead from rectifler 1 charge rate Increases when load Is applied regulator With engine running at 3600 R
126. ice Tool 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 availability Figure 2 1 KOHLERENC P C r aS 12 12347 1 epg 3 NS 3 N SS E R SS 4 S S SH SS N SS SN SOOO SS SS NNN Special Service Tool Kit nes A 2021 2022 2 1 VALVE SERVICE TOOLS TOOL NO amp NAME APPLICATION ILLUSTRATION VALVE SEAT PULLERS 11726 11913 FORCING SCREW 11915 ADAPTER 11918 VALVE SEAT INSTALLER 11811 11812 3222 SLIDE HAMMER 11799 Weight 12244 Slide Bolt 3268 VALVE GUIDE REMOVAL KIT 11838 Stud 3 1 2 12100 Stud 2 1 2 11800 Adapter 0917 Nut 12008 Nut 3224 VALVE GUIDE INSTALLER KIT 12325 Driver 11763 Driver 11770 Gage 11771 Gage REAMERS Valve Guide 11843 5 16 11844 1 4 3223 SEAL INSTALLER KIT 11782 Seal Installer 11783 Seal Installer 11784 Seal Installer 11785 Seal Installer 11786 Seal Installer 11787 Seal Installer 11790 Seal Installer 11791 Seal Installer 11792 Seal Installer 11793 Seal Installer 11795 Handle Removal of valve seats Use 11918 adapter 3222 slide hammer amp 11915 forcing screw Used with valve seat pullers 11726 amp 11913 Used to connect valve seat pullers to slide hammer Used to install intake and exhaust seats Use with 4747 handle Provides pulling force for valve seat and guide remov
127. in starter burnout NOTE If the engine being serviced is a Model K161 or K181 and has special shouldered cap screws and lock washers for mounting make sure these same parts are used for reinstalling the starter These special parts ensure alignment of the pinion and ring gear DUST SHIELD OPEN END TYPE DUST SHIELD CUP TYPE SHIELD D RETAINER Ca cw N PINION x As STOP LUBRICATE DA A FROM KIT N SPLINE SPRING 4 9 N S PINION A N STOP E DISCARD RETIGHTEN NUT TO ORIGINAL 120 INCH LBS _ OPEN END TYPE SHIELD INSTALLED l Figure 8 26 Bendix Drive installation CR KX SOLID STATE MODULE TYPICAL SIZE 1 x 1 RED LEAD TO ENGINE IGNITION CIRCUIT CONNECTOR TO SAFETY SWITCH CIRCUIT P BROWN LEADS NOTE Delta Systems Module Depicted this must have T designation to function properly with Kohler Engines Figure 8 27 Magneto Ignition Safety Interlock System 8 21 END CAP ASSEMBLY FRAME INCLUDES NEG BRUSH SS Aj oo POSITIVE BRUSH THRU BOLT SHOULDER CAPSCREW MOUNTING HIGH MOUNT STARTER WOUND FIELD COILS LOW MOUNT STARTER THRUST WASHER DRIVE PINION END PLAY SPACER S STOP NUT 180 150 IN LBS Figure 8 28 Wound Field Starter Exploded View Service the wound field starter as follows Refer to Figure 8 28 1 Remove the end cap assembly by taking out the two through bolts and carefully sli
128. in the com bustion chamber is usually the result of worn pis ton rings and or valve guides device is intended for battery charging and light ing Refer to the wiring diagrams and troubleshooting guides in this subsection to test and service these systems There are no adjustments in these sys tems Replace if faulty NOTE To prevent damage to the electrical system and components a Make sure the battery polarity is correct A negative ground system is used with K se ries engines b Disconnect the rectifier regulator leads and or wiring harness plug if electric arc welding is to be done on the equipment powered by the engine Disconnect any other electrical acces sories that share a common ground with the Figure 8 14 Chalky White Deposits engine Chalky White Deposits Chalky white deposits indi c Make sure the stator AC leads do not touch cate overheating This condition is usually accom Shorting them together could permanently panied by excessive gap erosion A clogged grass damage the stator screen clogged cooling fins and excessively lean carburetion are some causes of overheating d Do not operate the engine with the battery dis connected Alternator Operation NOTE If a battery has discharged to less than 4 There are five different models of alternators used volts there may not be sufficient power to acti in the K series of engines They are rated at 1 25 vate the rectifier regulator
129. ing of the spring 11 Remove the rope from pulley If necessary remove the starter pawl components from pul ley as instructed under To Replace Starter Pawls Inspection and Service 1 Carefully inspect rope starter pawls housing center screw and other components for wear or damage 2 Replace all worn or damaged components Use only genuine Kohler replacement parts specified in the Parts Manual All components shown in Figure 7 3 are available as service parts Do not use nonstandard parts 3 Do not attempt to rewind a spring that has come out of the keeper Order and install a new spring and keeper assembly 4 Clean away all old grease and dirt from starter components Generously lubricate the spring and center shaft of starter housing with any commercially available bearing grease Reassembly 1 Make sure spring is well lubricated with grease Position the spring and keeper assem bly to pulley side opposite pawls The out side spring tail must be positioned opposite rope pocket Refer to Figure 7 9 2 Install the pulley with spring and keeper as sembly into starter housing Refer to Figure 7 10 7 6 Figure 7 10 Installing Pulley And Spring Into Housing The pulley is in position when the center shaft is extending slightly above the face of the pulley Do not wind the pulley and recoil spring at this time 3 Lubricate the brake spring sparingly with grease Install the brake spring into
130. ions on its proper and safe use Never use gasoline as a cleaning 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 areas e Carburetor body and bore especially the areas where the throttle plate choke plate and shafts are seated e Idle fuel and off idle ports in carburetor bore main jet bowl vent and fuel inlet seat NOTE These areas can be cleaned using a piece of fine wire in addition to cleaners Be careful not to enlarge the ports or break the cleaning wire within ports Blow out all passages with com pressed air e Float and float hinge e Fuel Bowl e Throttle plate choke plate throttle shaft and choke shaft CAUTION Do not submerge the carburetor in cleaner or solvents when fiber rubber or foam seals or gaskets or the fuel inlet needle are installed The cleaner may damage these parts INSPECTION Carefully inspect all components and replace those that are worn or damaged e Inspect the carburetor body for cracks holes and other wear or damage e Inspect the float for cracks or holes Check the float hinge for wear and missing or dam aged float tabs e Inspect the fuel inlet needle for wear or grooves e Inspect the tip of the idle fuel adjusting needle for wear or grooves e Inspect the throttle and choke shaft and plate assemblies for wear or excessive play REPAIR Always use
131. ir cleaner cover cial equipment precleaner if so equipped paper element three base screws base and base gasket 1 Disconnect spark plug lead 2 Drain oil from crankcase REMOVE MUFFLER 3 Remove air cleaner 4 Remove muffler 1 If the engine is equipped with a flat muffler 5 Remove throttle linkage and carburetor remove muffler and gasket by unscrewing cap 6 Remove external governor components and screws lf equipped with a round muffler re throttle control move by turning the threaded exhaust pipe 7 Remove fuel pump between the muffler and engine with a pipe 8 Remove retractable starter wrench 10 1 REMOVE THROTTLE LINKAGE AND CARBURETOR A WARNING Explosive Fuel Gasoline may be present inthe 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 1 Close the fue shut off valve at fuel tank if so equipped or drain fuel from tank 2 Loosen the hose clamp and remove fuel line from the carburetor inlet 3 Remove two slotted hex cap sems screws the carburetor and gasket 4 Remove the throttle linkage from the carbure tor throttle lever REMOVE EXTERNAL GOVERNOR COMPO NENTS AND THROTTLE CONTROL 1 Note the position of the governor spring in governor arm 2 Loosen
132. is drawn into the combustion Test 1 Check for the following A Make sure the tank contains fuel B Make sure the fuel cap vent is open C Make sure the fuel shutoff valve is open 2 Check for fuel In the combustion chamber A Disconnect the spark plug lead B Close the choke on carburetor C Crank the engine several times D Remove the spark plug and check for fuel at tip 3 Check for fuel flow from tank to fuel pump A Remove fuel line from inlet fitting at fuel pump B Hold line below bottom of tank Open shutoff valve and observe flow 4 Check operation of fuel pump A Remove fuel line from inlet fitting at carburetor B Crank engine several times and observe flow 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 A WARNING Explosive Fuel 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 Conclusion If there is fuel at tip of spark plug fuel is reaching the com bustion chamber If there Is no fuel at tip of spark plug check for fuel from the fuel tank Test 3 If fuel does flow from line check for faulty fuel pump Test
133. le 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 throttle lever as fol lows Models K91 K181 1 2 Carb Carefully grind or file away the riveted portion of the throttle shaft Save the throttle shaft as it will be used to install the new throttle shaft bushing Discard the throttle lever Models K241 K341 1 Carb a 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 C Compare the old shaft with the new shafts in the kit Select the appropriate new shaft and discard the old shaft d Attach throttle lever to throttle shaft Make sure lever is installed correctly as noted in step a e Apply Loctite to threads of 1 72 56 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 drill bit of the following size in the drill press chuck Lower the bit no
134. lignment The primary timing mark on crankshaft should align with the timing mark on cam shaft Refer to Figure 12 15 If the marks do not align the timing is incorrect and must be corrected 1B OLD STYLE BALANCE GEAR ASSEMBLY WITHOUT A BALANCE GEAR TIMING TOOL 12 5 NOTE The lower balance gear should be installed after the crankshaft has been installed 1 Lubricate the crankshaft rear bearing surface Insert the PTO end of crankshaft through rear bearing Align the primary timing mark on crankshaft with the primary timing mark on upper balance gear Refer to Figure 12 17 Press the crankshaft into rear bearing until the crankgear just starts to mesh about 1 16 with the center ring of balance gear teeth Crankshaft Primary Timing Mark Balance Gear Primary Timing Mark m Q dll LAN ORA i SUD Qj Su AK f i A Balance Gear Secondary Timing Mark Crankshaft Secondary Timing Mark Figure 12 17 Timing Marks On Balance Gear And Crankshaft NOTE If the crankshaft and bearing plate have not been separated position the fuel line and wiring play of lower balance gear as instructed under INSTALL BALANCE GEARS Refer to Figures 12 9 and 12 10 Check the timing of the crankshaft camshaft and balance gears The primary mark on crankshaft should align with the primary timing mark on upper bal ance gear Refer to Figure 12 17 The prim
135. ling coarse stones in hone proceed as fol lows 1 Lower hone into bore and after centering ad just so that stones are in contact with the cyl inder wall Use of a commercial cutting cool ing agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing process Move hone up and down while resizing to prevent formation of cutting ridges Check size frequently NOTE Keep in mind the temperatures caused by honing may cause inaccurate measurements Make sure the block is cool when measuring 3 When bore is within 0025 of desired size remove coarse stones and replace with bur nishing stones Continue with burnishing stones until within 0005 of desired size and then use finish stones 220 280 grit and polish to final size A crosshatch should be observed if hon ing is done correctly The crosshatch should intersect at approximately 23 33 off the horizontal Too flat an angle could cause the rings to skip and wear excessively too high an angle will result in high oil consumption Refer to Figure 11 2 Figure 11 2 Cylinder Bore Crosshatch After 4 Honing After resizing check the bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements Refer to Figure 11 3 The measurements should be taken at three loca tions in the cylinder at the top middle and bottom Two measurements
136. lter on air horn 6 Add engine oil to filter and fill to the OIL LEVEL mark 7 Install filter 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 interchange able unless other modifications are made to the engine Figure 5 3 Optional Oil Bath Air Cleaner 5 3 SECTION 6 FUEL SYSTEM AND GOVERNOR FUEL SYSTEM GASOLINE The typical gasoline fuel system and related com ponents include the fuel tank with vented cap shutoff valve with screen in line fuel filter fuel pump some models carburetor and intercon necting fuel line 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 bowl and is moved into the carburetor body where it is mixed with air The fuel air mixture
137. m parts Inspect y valve springs and related hardware for excessive Dg D1 wear or distortion Valve spring free height should C be at approximately the dimension given in the chart below Check valves and valve seat area or inserts for evidence of deep pitting cracks or dis d tortion Check clearance of valve stems in guides See Figure 11 5 for valve details and specifica tions Style A Style A Measure piston diameter D1 perpendicular topiston pin just below the oil ring groove EMEN d Style D bh 4 Styles C and D Measure piston diameter D1 perpendicular to piston pin at 1 2 above the bottom of the skirt Figure 11 4 Measuring Piston Diameter DIMENSION SEE FIG 11 5 A SEAT ANGLE 89 89 B SEAT WIDTH 037 045 037 045 C INSERT O D 972 973 D GUIDE DEPTH NONE E GUIDE 1 D NONE F VALVE HEAD DIA 979 989 807 817 G VALVE FACE ANGLE 45 45 H VALVE STEM DIA 2480 2485 2460 2465 Model K91 Model K161 K181 intake Exhaust Intake Exhaust Intake Exhaust 037 045 312 313 1 3 8 1 1 8 3105 3110 Model K241 K301 K321 K341 89 89 89 89 037 045 037 045 037 045 1 2535 1 2545 1 2535 1 2545 1 312 1 497 312 313 312 313 312 313 1 370 1 380 1 120 1 130 45 45 45 3090 3095 3105 3110 3084 3091 1 370 1 380 on all K341 engines and any K321 with suffix D or later EXHAUST INTAKE SS y v j il i x
138. mponents are 6 5 available Always refer to the Parts Manual for the engine being serviced to ensure that the correct carburetor repair kits and replacement parts are ordered 42 56x7 32 or 4 3 48x7 32 Brass Screw 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 Throttle Shaft Lever Assembly 2 Styles For Models K91 K181 1 2 Carb Throttle Shaft 4 Styles For Models K241 K341 amp KT17 KT189 1 Carb Choke Shaft at Choke Detent Ball Spring 7 bi Choke Shaft Bushing Choke Pur uate 3 48x7 32 Brass Screws choke Shaft choke Lever Reused 2 56x7 32 or 3 48x7 32 Brass Screw 3 48x7 32 Brass Screws Nue Lever Reused rnm MN eu Bushing Throttle Plate Reused throttle Shaft Bushing Installation Tool Carburetor Body pattie Gasket Figure 6 8 Throttle And Choke Shaft Replacement Kits A WARNING Prevent Eye Injury Suitable eye protection safety glasses goggles or face hood should be worn for any procedure involv ing the use of compressed air punches hammers Chisels drills or grinding tools Disassemble Carburetor Refer to Disassembly at the beginning of this section 6 6 Remove Choke Plate and Choke Shaft Transfer Choke Lever 1 To ensure correct rea
139. mproperly 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 Kohler Engine Analysis Kit is recommended Refer side If there is no vacuum level in engine to the Special Tools section for more informa side is the same as in open side or a positive tion pressure level in open side is higher than in engine side check for the conditions in the Crankcase Vacuum Test following table To test crankcase vacuum with the manometer 4 Close the shutoff clamp before shutting off the M engine 1 Insert the stopper hose into the oil fill hole Leave the other vent of the manometer open Compression Test to the atmosphere Make sure the shutoff clamp is closed Because these engines are equipped with an auto matic compression release mechanism ACR it is 2 Start the engine and run at high speed 3200 difficult to obtain an accurate compression read to 3600 RPM ing 3 Open the clamp and note the water level in To check the condition of the combustion chamber the tube The level in the engine side should and related mechanisms physical inspection and a be 5 to 10 inches above the level in the open crankcase vacuum test are recommended NO CRANKCASE VACUUM PRESSURE IN CRANKCASE 1 Crankcase breather clogged or inoperative 1 Disassemble breather clean parts thoroughly reassemble
140. ndle in this position and tighten the can cause the sudden and potentially dangerous Screws securely J f the spring release of the spring To Replace Starter Pawls Dogs Always wear safety goggles when servicing retract Use pawl repair kit 41 757 02 This kit includes able starters full face protection is recommended two starter pawls two pawl springs two retaining To ensure personal safety and proper starter disas rings and installation instructions sembly the following procedures must be followed 1 Remove starter from engine carefully CENTER SCREW PAWL REPAIR Q WASHER AE 6 PAWL CAM STARTER P AK HANDLE Ze oe Ey WITH ROPE O A S 10 24x1 4 FLANGE LOCK SCREW SPRING amp KEEPER STARTER HOUSING Figure 7 3 Exploded View 7 3 A CAUTION Spring Under Tension Do not remove the center screw of the starter when replacing pawls Removal of the center screw can cause the sudden and potentially dangerous release of the recoil spring ft is not necessary to remove the center screw when making this repair 2 Carefully note position of the pawls pawl springs and retaining rings before disassem bly Components must be assembled cor rectly for proper operation Refer to Figure 7 4 3 Remove the retaining rings pawls and pawl springs from pawl pins on pulley 4 Clean pins and lubricate with any commercially available bearing grease 5 Install new pawl springs pawls and
141. necessary to adjust or service the carburetor Possible Cause Probable Remedy 6 12 Engine starts hard or runs roughly or stalls at idle speed Engine runs rich Indicated by black sooty exhaust smoke misfiring loss of speed and power governor hunting or excessive throttle opening Engine runs lean Indicated by misfiring loss of speed and power governor hunt ing Or excessive throttle opening Fuel leaks from carburetor Idle fuel mixture or idle speed are improperly adjusted Adjust the idle speed screw then adjust idle fuel needle Choke partially closed during operation Check the choke lever and linkage to ensure choke is opening after warm up Idle fuel mixture is improperly adjusted Adjust idle fuel needle c Float level set too high With fuel bowl removed and carburetor in verted set exposed surface of float parallel with the bowl gasket surface of carburetor body Dirt under fuel inlet needle Remove needle Clean needle and seat and blow with compressed air Bowl vent or air bleeds plugged Remove fuel bowl idle fuel adjust ing needle and welch plugs Clean vent ports and air bleeds Blow out all passages with compressed air Fuel bowl gasket leaks Remove fue bowl and replace gasket Leaky cracked or damaged float Submerge float to check for leaks Idle fuel mixture is improperly adjusted Adjust idle fuel needle Float level set too low
142. ng piston rings 1 If the cylinder block does not need reboring and if the old piston is within wear limits refer to Section 1 General Information and free of score or scuff marks the old piston may be reused 2 Remove old rings and clean up grooves Never reuse old rings 3 Before installing new rings on piston place top two rings each in turn into its running area in cylinder bore and check end gap see Figure 11 11 K91 K161 007 027 K181 K241 K301 K321 K341 007 017 010 020 010 030 On Model K181 using piston style C or D New 010 023 Used 010 032 Figure 11 11 Measuring Piston Ring End Gap 4 After installing the new compression top and middle rings on piston check piston to ring side clearance Maximum recommended side clearance is 006 If side clearance is greater than 006 a new piston must be used Refer to Figure 11 12 11 10 Figure 11 12 Measuring Piston Ring Side Clearance Oil Ring End Gaps Although 4 sizes of service ring sets are available Std 4 010 4 020 030 only two sizes of oil rings are supplied Std and 020 oversize When using 010 and 030 oversize ring sets the oil rings appear to have excessive end gap This is not detrimental and proper sealing will be achieved due to the additional scraper rings and expander NOTE Scraper and main ring end gaps should be staggered around the groove to prevent combus
143. nylon spring re tainer spacer are located under the pawl re tainer These parts are fragile and can be easily lost or damaged If necessary use a small screw driver to loosen the spring retainer from the post on pulley Replace the spring if it is broken stretched or shows other signs of damage 11 12 14 Remove the 1 1 8 DIA thrust washer brake return spring nylon spring retainer and pawls Rotate the pulley clockwise 2 full turns There should be no resistance to this rotation This will ensure the pulley is disengaged from the recoil spring Hold the pulley into the starter housing and invert starter so the pulley is away from your face and others in the area Rotate the pulley slightly from side to side and carefully separate the pulley from the starter housing Refer to Figure 7 15 15 Figure 7 15 Removing Pulley From Housing If the pulley and housing do not separate eas ily the spring could be engaged with pulley or there is still tension on the spring Return the pulley to the housing and repeat step 12 be fore separating the pulley and housing Only if it is necessary for the repair of starter remove the spring from the starter housing as instructed under To Replace Recoil Spring Do not remove the spring unless it is abso lutely necessary Inspection and Service 1 Carefully inspect the rope starter paw s housing center screw center shaft spring and other componen
144. o engine manifold to engage in notch in base of choke unit 3 Loosen clamp bolt choke lever push arm up ward to move choke plate toward closed posi tion After desired position is attained tighten clamp bolt then remove drill 4 After replacing air cleaner check for evidence of binding in linkage adjust as needed Be sure chokes are fully open when engine is at normal operating temperature THERMO ELECTRIC AUTOMATIC CHOKES Service Before working on or near the carburetor or choke area take these PRECAUTIONS 1 Do not operate engine without air cleaner as ing always remove spark plug lead to prevent injury may result engine from starting and to avoid personal in 2 When checking choke operation during crank jury Refer to Figure 6 32 SHUT DOWN ONE LEAD TO SOLENOID STARTER RELAY THE OTHER LEAD TO DECISION 2 S 1 2 TURN MAKER TENSION AL UA CHOKE PLATE FLAT WASHER Je R c SAL J Q AN CHOKE pr E37 A SHAFT L AUTOMATIC ZONE Z N LOCKWASHER BO UN TO A HEATER TERMINAL i I ADJUSTING _ SLOT 7 e sr Figure 6 32 Thermo Electric Automatic Choke Troubleshooting ohmmeter Resistance should be 3 ohms or more If resistance is less than 3 ohms replace the Before proceedin ith analysis of choke prob A cobi Vi i choke lems check resistance of heater terminal using an PROBLEM Choke will not fully open breaks or plate comes o
145. of crankcase a For Models K161 and K181 drive the cam shaft pin to a depth of 275 285 from the machined bearing plate gasket surface b For Models K241 K301 K321 and K341 drive the camshaft pin to a depth of 300 330 from the machined bearing plate gasket surface Refer to Figure 12 8 Camshatt Pin 300 330 PTO Side Bearing Plate Side Figure 12 8 Installing Camshaft Pin To install the old longer camshaft pin drive the camshaft pin into the crankcase until the PTO end of camshaft pin is flush with the mounting surface on PTO side of crankcase INSTALL BALANCE GEARS On Engines So Equipped NOTE The balance gears must be timed to the crankshaft whenever the crankshaft is installed Use a balance gear timing tool to simplify this pro cedure refer to the Special Tools section in this manual If the balance gears must be timed with out using the tool do not install the lower balance gear closest to the oil pan until after the crank shaft has been installed Refer to INSTALL CRANKSHAFT for specific timing procedures 1 Install the 3 8 spacer one 010 shim spacer balance gear one 020 shim spacer and retaining ring rounded edge towards bal ance gear Refer to Figure 12 9 A new style needle bearing is now being used on the K Series balance gear assembly NOTE Extreme care must be taken when handling the new needle bearings or when removing bal ance g
146. ometer Digital Thermometer Digital Engine Analyzer Slack Tube Manometer 8 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 1 2 x 1 8 Bushing 3 4 x 1 8 Bushing Tube With Fittings Carrying Case Plain Thermocouple wa n iM Waa a c A 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 included Using the instruments in the kit you will be able to B Measure temperatures of e spark plug base gasket cylinder head bolt e oil sump e air into flywheel and carburetor M Measure engine speed RPM BI Measure crankcase vacuum and exhaust system back pressure E Measure voltage M Measure charging system current Bl Measure electric starter current Amp draw The Engine Analyzer Kit can be ordered complete as shown or the instruments can be ordered indi vidually Contact your Kohler Distributor for price and availability 2 5 SECTION 3 PERIODIC MAINTENANCE REQUIRED MAINTENANCE These required maintenance procedures should be performed at the frequency stated in the table Required Maintenance Frequency Check Oil Level oo ce teen Rim he II RRHRRRERE aha Daily Clean CMS MO CEOs nc arae Ear Ue e aede dd quc RC 9 8X8 ES S RIE a4 e oxen dan Daily Clean
147. on Rotate the choke unit clockwise on the carbu retor viewed from the choke side with a slight pressure until it can no longer be ro tated While holding the choke unit in the above posi tion tighten the two mounting screws NOTE With engine not running and before any cranking the choke plate will be closed 5 to 10 at a temperature of about 75 F As the tempera 6 22 ture decreases the choke plate will close even more 5 Check choke function by removing the spark plug lead and cranking the engine The choke plate should close a minimum of 45 at tem peratures above 75 F The plate will close more at lower temperatures NOTE During cranking the choke will remain closed only 5 to 10 seconds as choke closing time is controlled by the Decision Maker Choke Shaft Spring Adjustment 1 To adjust the choke spring hold the plate in the wide open position Windup the spring 1 2 turn and then place the straight end of the spring through the hole in the shaft GAS FUEL SYSTEM The main components of the gas fuel system as used with Kohler K series engines are Liquified petroleum gas tank Primary regulator Secondary regulator Gas Carburetor In some applications the primary and secondary regulators are combined in one two stage unit The gas carburetor and secondary regulator or two stage regulator are normally furnished with the engine Other components are furnished by the fuel supplier There
148. ong bolts with the hexagon heads removed and screwdriver slots cut in the stem screw the two headless bolts into the cylinder block diagonally from each other Bolt thread sizes are 1 4 20 U N C for K91 K181 3 8 16 U N C for K241 K361 2 Lubricate the bearing surface of crankshaft and bearing Install the gasket two or three 005 shims as required and bearing plate over studs NOTE Crankshaft end play is determined by the thickness of the gasket and shims between crank ENGINE MODEL 1 32 1 32 OE 1 32 Full In 1 32 1 32 1 32 1 32 1 32 1 2 1 2 2 1 2 1 2 52 52 1 2 1 2 case and bearing plate Check the end play after the bearing plate is installed 3 Install two hex cap sems screws and hand tighten Remove the locating studs and install the remaining two hex cap sems screws and hand tighten 4 Tighten the screws evenly drawing bearing plate to crankcase Torque K91 K181 to 115 in Ib Torque K241 K341 to 35 ft Ib 5 Check crankshaft end play between the inner bearing race and shoulder of crankshaft using a flat feeler gauge Refer to Figure 12 32 Recommended total end play is K91 004 023 K161 K181 002 023 K241 K301 K321 K341 003 020 If measured end play is not within limits remove the bearing plate and remove or install shims as necessary NOTE Crankshaft end play
149. ope from the pulley Place the rope in the notch in the pulley This will keep the rope from interfering with the 7 10 starter housing leg reinforcements as the pul ley is rotated later during reassembly 4 Install the pulley onto the center shaft If the pulley does not fully seat it is resting on the inner center spring coil Rotate the pulley slightly from side to side while exerting slight downward pressure This should move the in ner spring coil out of the way and allow the pulley to drop into position The pulley is in position when the center shaft is flush with the face of the pulley Do not wind the pulley and recoil spring at this time 5 Install the starter pawls into the appropriate pockets in the pulley Refer to Figure 7 21 Nylon Spring LAS Retain vti SE ES J37 Return Spring FL Jw aoe 1 1 8 DIA Washer Figure 7 21 Installing Pawls Pawl Retainer And Related Components 6 Sparingly lubricate the underside of the 1 1 8 DIA washer with grease and install it over the center shaft Make sure the threads in center shaft remain clean dry and free of grease or oil 7 Sparingly lubricate the insides of the legs of the brake spider with grease Install the brake to the retainer 8 Install the small return ring to the pawl re tainer Make sure it is positioned properly 9 Position the pawl retainer and return spring next to the small post on pulley Install the
150. operly gapped a maverick spark can occur which can cause improper igni tion of unburned gases and can create a force causing the flywheel key to shear When repairing this type of failure replace the flywheel crankshaft key flywheel washer and nut or bolt CYLINDER HEAD Inspection Blocked cooling fins often cause localized hot spots which can result in a blown cylinder head gasket If the gasket fails high temperature gases can burn away portions of the aluminum alloy head A cylinder head in this condition must be replaced If the cylinder head appears in good condition use a block of wood or plastic scraper to scrape away carbon deposits Be careful not to nick or scratch the aluminum especially in gasket seating area The cylinder head should also be checked for flat ness Use a feeler gauge and a surface plate or a piece of plate glass to make this check Cylinder head flatness should not vary more than 003 if it does replace the cylinder head Refer to Figure 11 1 Apply Slight Downward Pressure Feeler Gauge Figure 11 1 Checking Cylinder Head Flatness NOTE Measure cylinder head flatness between each cap screw hole In cases where the head is warped or burned it will also be necessary to replace the head screws The high temperatures that warped or burned the head could have made the screws ductile which will cause them to stretch when tightened CYLINDER BLOCK Inspection and
151. or throttle controls cables Faulty spark plug Carburetor improperly adjusted Incorrect valve to tappet clearance 9 Low compression 10 Faulty ACR mechanism Engine Will Not Crank ONO c DY 1 Hydrostatic transmission is not in neutral PTO drive is engaged Battery is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty keyswitch or ignition switch Faulty electric starter starter solenoid Retractable starter not engaging in drive cup Seized internal engine components ONOnA WP Engine Runs But Misses 1 Dirt or water in fuel system 2 Spark plug lead loose 3 Loose wires or connections intermittently short ing ignition to ground 4 Carburetor improperly adjusted 5 Engine overheating 6 Incorrect valve to tappet clearance Engine Will Not Idle Idle speed adjusting screw improperly set Dirt or water in fuel system Idle fuel adjusting screw improperly set Fuel tank vent restricted Faulty spark plug Incorrect valve to tappet clearance Low compression NOOO fP WBN Engine Overheats 1 Grass screen cooling fins or shrouding clogged 2 Excessive engine load 3 Low crankcase oil level 4 High crankcase oil level 5 Carburetor improperly adjusted Engine Knocks 1 Low crankcase oil level 2 Excessive engine load Engine Loses Power Low crankcase oil level High crankcase oil level Restricted air cleaner element Di
152. pping the end cap off of the armature 2 Lift the spring holding the positive brush and remove the brush 3 Carefully remove the armature 4 Inspect both brushes positive on frame nega tive on end cap If brushes are worn unevenly or are shorter than 5 16 replace them 5 Remove the negative brush by drilling out the rivet holding it to the end cap Install the re placement brush and rivet 6 Remove the positive brush by peeling back insulating material on the field winding and un clipping or unsoldering Install the replacement brush and clip or solder in place 7 Use a coarse cloth to clean the commutator If the commutator is grooved or extremely dirty use a commutator stone or fine sandpaper NOTE Never use emery cloth to clean a commu tator 8 Carefully insert the armature 8 22 9 Lightly coat the end cap bushing and armature shaft with light engine oil 10 Hold the positive brush spring back and care fully place end cap in position on armature shaft Release spring after brushes are con tacting commutator 11 Insert two through bolts and torque to 40 to 55 in Ib 12 Inspect pinion and splined shaft If any damage is noted replace the Bendix drive 13 If the Bendix drive is in good condition wipe everything clean and apply a very thin coat of special silicone grease Kohler Part No 52 357 01 to the splined portion of the armature shaft Permanent Magnet Bendix Drive Starter S
153. r Locate the secondary timing mark on balance gear Starting with the Press the crankshaft all the way into the rear land next to the timing mark count seven 7 bearing Make sure the camshaft and crank lands in a clockwise direction Mark the sev shaft gears mesh and the marks align while enth land Refer to Figure 12 26 pressing Refer to Figure 12 28 12 8 Crankshaft Primary Timing Mark Timing Mark e Lower Balance Gear y Secondary Timing Mark E i Eara 4 Crankshaft Primary ill Timing Mark Figure 12 30 Crankshaft Gear Lower Balance Figure 12 28 Aligning Camshaft Gear And Gear mignmiant Crankshaft Gear 7 Check the timing of the crankshaft camshaft and balance gears The primary timing mark on crankshaft should align with the secondary timing mark on lower balance gear Refer to Figure 12 23 4 Install the 3 8 spacer and one 1 010 shim spacer to the stub shaft for the lower balance gear 5 Position the crankshaft so it is about 15 past bottom dead center BDC Align the secon dary timing mark on lower balance gear with the secondary timing mark on crankshaft Re fer to Figure 12 29 e The primary timing mark on crankshaft should align with the timing mark on cam shaft Refer to Figure 12 24 The primary timing mark on crankshaft should align with the primary timing mark on upper balance gear Refer to Figure 12 31 Crankshaft Secondary Timing Mark
154. r dirt Dirt in the throat is further indication that the air cleaner is not functioning properly Check the oil level 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 oil 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 oil 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 4 2 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 traces of the cleaner are removed before the engine is reassembled and placed in opera tion Even small amounts of these cleaners quickly break down the lubricating properties of engine oil BASIC ENGINE TES
155. r 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 filling 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 oiled foam precleaner which surrounds the paper element Refer to Fig ure 3 2 3 2 Precleaner If so equipped wash and reoil the precleaner every 25 operating hours more often under ex tremely dusty dirty conditions 1 Remove precleaner from paper element Wash the precleaner in warm water with detergent 2 Rinse precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow precleaner to air dry 3 Saturate precleaner 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 dirty conditions check the paper element Replace the element as necessary 1 Remove the precleaner if so equipped element cover and paper element 2 Replace 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 preclean
156. rade of oil as used in the engine SECTION 12 REASSEMBLY The following sequence is suggested for complete engine reassembly This procedure assumes that all components are new or have been recondi tioned and all component subassembly work has been completed This procedure may have to be varied slightly to accommodate options or special equipment NOTE Make sure the engine is assembled using all specified torque values tightening sequences and clearances Failure to observe specifications could cause severe engine wear or damage Always use new gaskets Install rear bearing Install governor gear and cross shaft Install tappets and camshaft Install balance gears Install crankshaft Install front bearing Install fuel line and wiring harness Install bearing plate Install oil seals 10 Install piston rings 11 Install piston to connecting rod 12 Install piston connecting rod 13 Install oil pan 14 Install valves 15 Install stator 16 Install flywheel grass screen and drive cup or rope start pulley 17 Install blower housing 18 Install cylinder head and spark plug 19 Install breather assembly 20 Install side air baffles and cylinder head baffle 21 Install dipstick 22 Install fuel tank 23 Install electric starter 24 Install retractable starter 25 Install fuel pump 26 Install external governor components and throttle controls 27 Install c
157. rburetor bore Loosen screws and adjust throttle plate as necessary then torque screws to 8 12 in Ib Choke Shaft Installation 1 Install the detent spring and ball into the car buretor body 6 17 CAUTION If the detent ball does not drop through the tapped air cleaner base screw hole by its Tool KO1017 own weight do not force it Forcing the ball could permanently lodge it in the hole Install the ball through the choke shaft bore instead 2 Compress the detent ball and spring Insert the choke lever shaft assembly into carburetor body with the cutout portion of shaft facing the air cleaner mounting surface refer to Figure 6 28 Make sure the choke lever is on the New Welch Plug correct side of carburetor body Carburetor Body Figure 6 29 Installing Welch Plugs Cutout Portion Compress Ball C After welch plugs are installed seal the ex Of Choke Shatt And Spring posed surface with glyptal or an equivalent h CS sealant Allow the sealant to dry NOTE If a commercial sealant is not available fingernail polish can be used 2 Install the main fuel jet 3 Install fuel inlet needle into inlet seat Install float and slide float pin through float hinge and float hinge towers on carburetor body 4 Set Float Level Invert the carburetor so the float tab rests on the fuel inlet needle The exposed surface of float should be parallel Figure 6 28 Installing Choke Lever Shaft with the bowl gask
158. re worn or damaged 2 Inspect the carburetor body for cracks holes and other wear or damage 3 Inspect the float for dents or holes Check the float hinge for wear and missing or damaged float tabs 4 nspect the inlet needle and seat for wear or grooves 5 Inspect the tips of the main and idle fuel ad justing needles for wear or grooves Inspect the throttle and choke shafts and plate assemblies for wear or excessive play Main Fuel Pus Needle H Idle Speed Screw Spring x idle Fuel MIS oe Needle Fuel Inlet Seat ae Gasket 8 Fuel Inlet a Seat f Fuel Inlet Needle aot Fuel Bowl Bowl Retaining Screw Bowl Retaining Screw Gasket Figure 6 7 Kohler 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 K321 and K341 both relief holes in the choke plate have been enlarged to 11 32 while on the K241 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 staling carburetors Several repair kits which in clude the gaskets and other co
159. refer to Special Tools section press seat in until bottomed 3 Use a standard valve seat cutter see Figure 11 9 and cut seat to dimensions shown in Figure 11 5 Valve Seat Cutter Typical Figure 11 9 Standard Valve Seat Cutter Reground or new valves must be lapped in to pro vide proper fit Use a hand valve grinder with suc tion cup for final lapping Lightly coat valve face with fine grade of grinding compound then ro tate valve on seat with grinder Continue grinding until smooth surface is obtained on seat and on valve face Thoroughly clean cylinder block in soap and hot water to remove all traces of grinding compound After drying cylinder block apply a light coating of SAE 10 oil to prevent rusting 11 PISTON AND RINGS Identification Three different styles of pistons are currently being used in Kohler K Series engines Style A pistons can be used in all K Series en gines The style A piston can be identified by its full skirt and its lack of an installation direction identifier on its crown a new piston can be in stalled facing either direction NAA WOO MQ ws WOO SSS N S ES No Installation NS Style A Piston The Style C piston is used on the K341 engines only It can be identified by its partial skirt and raised criss cross design in the recessed area around the piston pin bore In addition it has an installation direction identifier a notch
160. retaining rings When properly installed the pawl springs will hold the pawls against the pawl cam NOTE Make sure the snap rings are securely seated in grooves of pawl pins Failure to seat the snap ring can cause pawls to dislodge during op eration 6 Pull rope to make sure pawls operate properly 7 Install starter to engine as instructed under To Install Starter To Replace Rope The rope can be replaced without complete starter disassembly Figure 7 4 Starter Pawls 1 Remove the starter from engine 2 Pull the rope out approximately 12 and tie a temporary slip knot in it to keep it from re tracting into starter Refer to Figure 7 5 7 4 3 Remove the rope retainer from inside handle Untie the knot and remove the retainer and handle 4 Hold the pulley firmly with thumb and untie the slip knot Allow the pulley to rotate slowly as the spring tension is released Refer to Figure 7 6 5 When all spring tension on the starter pulley is released remove old rope from pulley Tie a single knot in one end of new rope Rotate the pulley counterclockwise when viewed from pawl side of pulley until the spring is tight Approx 6 full turns of pulley 8 Rotate the pulley clockwise until the rope pocket is aligned with the rope guide bushing of housing NOTE Do not allow pulley spring to unwind Enlist the aid of a helper if necessary or use a c clamp to hold pulley in position Figure 7 6
161. rimary Timing Marks Timing Tool 4 Teeth Vice Grips Or Clamp Figure 12 13 Installing Balance Gear TimingTool 2 Lubricate the crankshaft rear bearing surface Insert the PTO end of crankshaft through rear bearing Straddle the primary and secondary timing marks on crankshaft over the rear bear ing oil drain refer to Figure 12 14 Press the crankshaft into rear bearing until the crankgear is just above the camshaft gear but not in mesh with it Rear Bearing Oil Drain Figure 12 14 Aligning Crankshaft And Balance Gears NOTE If the crankshaft and bearing plate have not been separated position the fuel line and wiring harness between the bearing plate and crankcase before pressing the crankshaft all the way in 3 Remove the balance gear timing tool and align the primary timing mark on the crank shaft with the timing mark on the camshaft gear Refer to Figure 12 15 Press the crank shaft all the way into the rear bearing Make sure the camshaft and crankshaft gears mesh and that the timing marks align while press ing Crankshaft Timing Mark Camshaft Timing Mark Figure 12 15 Aligning Crankshaft And Camshaft Timing Marks 4 Check the timing of the crankshaft camshaft and balance gears 9 The primary timing mark on crankshaft should align with the secondary timing mark on lower balance gear Refer to Figure 12 16 Figure 12 16 Checking Crankshaft And Balance Gear A
162. rings Intake Valve Spring Retainer Exhaust Valve 1 777 Figure 12 40 installing Valves K91 K161 And K181 On Models K241 K301 K321 and K341 install the valve spring upper retainers valve springs close coils to top intake valve spring lower retainer exhaust valve rotator or retainer and valves Refer to Figure 12 41 dio od Valve Spring a iie PARLER s Valve Springs Ex Exhaust Valv 5 Rotator l i 2A P NEN AA Valve Tappet fo z Intake Valve laws Screws t Spring Lower Retainer E Ne F Figure 12 41 Installing Valves K241 K301 K321 And K341 NOTE Some models use a valve rotator on both valves 5 Compress springs using a valve spring com pressor and install keepers Refer to Figure 12 42 Valve Spring Compressor Figure 12 42 Installing Valve Keepers INSTALL STATOR 1 On flywheel magneto ignition systems the magneto coil core assembly is secured in sta tionary position on the bearing plate On the magneto alternator systems the coil is part of the stator assembly which is also secured to the bearing plate Permanent magnets are af fixed to the inside rim of the flywheel except in rotor type magneto systems On these the magnet or rotor has a keyway and is press fitted on crankshaft The magnet rotor is marked engine side for proper assembly 2 After installing magneto components run all leads out through hole provided in 11 o clock position
163. rks will be present on the flywheel T for top dead center and S or SP for the firing point 20 deg before top dead cen ter There are two ways to time a magneto ignition System static and timing light The timing light 8 2 method is the more accurate of the two A stor age battery is needed for use with most timing lights Static Timing Method Perform static timing as follows 1 2 7 8 Remove the breaker point cover Remove the spark plug lead to prevent unin tentional starting of the engine Rotate the engine slowly by hand in the direc tion of normal operation Rotation should be clockwise when viewed from the flywheel end The breaker points should just begin to open when the S or SP mark T mark on Model K91 appears in the center of the timing sight hole Continue rotating the engine until the breaker points are fully opened Measure the breaker point gap with a feeler gauge The gap should be 020 If the gap is not 020 loosen the gap adjust ment screw and adjust the gap Tighten the gap adjustment screw Replace the breaker point cover Timing Light Timing Method Several different types of timing lights are available Follow the manufacturer s directions for use Perform timing with a timing light as follows 1 2 Remove the lead from the spark plug Wrap one end of a short piece of fine bare wire around the spark plug terminal and re place the lead The free end of the
164. rod breaker assembly and breaker point lead 4 Set breaker point gap at 020 full open 5 Install gasket and breaker point cover 12 16 INSTALL CYLINDER HEAD AND SPARK PLUG 1 Install the gasket and cylinder head Always use a new gasket when head has been re moved for service work 2 Torque the hex cap screws and hex nuts in increments in the sequence and torques shown in Figure 12 44 NOTE The importance of torquing cylinder head bolts to specified values and following the recom mended sequences cannot be overemphasized Blown head gaskets and cylinder head distortion may result from improper torquing Following is the recommended torquing procedure 1 Lubricate the cylinder head bolts with oil be fore installation 2 Initially torque each bolt to 10 ft Ibs following the recommended torque sequence 3 Sequentially tighten each bolt in 10 ft Ib in crements until the specified torque values are reached NOTE After reaching the final torque value run the engine for 15 minutes stop and allow to cool Then sequentially retorque the head bolts to the specified torque value 4 Make sure the spark plug is properly gapped 5 Install the spark plug and torque it to 18 22 ft Ib INSTALL BREATHER ASSEMBLY 1 Install the stud gasket breather plate reed reed stop seal and filter The accompanying illustrations show the correct order of assem bly for two types of breather assemblies Mak
165. rt or water in fuel system Excessive engine load Engine overheating Faulty spark plug Carburetor improperly adjusted ON ON WD 4 1 9 Low compression Engine Uses Excessive Amount of Oil Incorrect oil viscosity or type 2 Clogged or improperly assembled breather system 3 Worn or broken piston rings 4 Worn cylinder bore 5 Worn valve stems and or guides EXTERNAL ENGINE INSPECTION Before cleaning or disassembling the engine check its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause once it is disassembled 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 fuel and oil leaks and dam aged components Excessive oil leakage can indicate a clogged or improperly assembled breather worn or damaged seals and gaskets or loose or improperly torqued fasteners 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 fo
166. s 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 needles out counterclockwise in creases the supply of fuel to the carburetor This gives 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 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 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 T
167. s using the Research method it should be 90 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 1096 ethyl alcohol 9096 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not ap proved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 1596 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved OIL REFILL QUANTITIES U S STANDARD QUARTS K141 K161 K181 K241 K301 K321 K341 K241A K301A K321A K341A After refilling 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 HORSEPOWER Maximum RPM Enine Model
168. screws 4 Operate the throttle lever and check that the throttle plate does not bind in the bore Loosen screws and adjust plate if necessary then tighten screws securely Reassemble Carburetor Refer to the following Reassembly portion of this section Reassembly 1 4 Install the fuel inlet seat gasket and fuel inlet seat into carburetor body Torque seat to 35 45 in Ib Install the fuel inlet needle into inlet seat In stall float and slide float pin through float hinge and float hinge towers on carburetor body Set float level Invert carburetor so the float tab rests on the fuel inlet needle There should be 11 64 1 32 clearance between the machined surface of body and the free end of float Bend the float tab with a small screw driver to adjust Refer to Figure 6 13 Bend Tab To Adjust Inverted Carburetor Figure 6 13 Setting Float Level Set float drop Turn the carburetor over to its normal operating position and allow float to drop to its lowest level The float drop should be limited to 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 Bend Tab To Adjust Figure 6 14 Setting Float Drop 6 9 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
169. should be taken perpendicular to each other at each of the three locations Figure 11 3 Measuring Cylinder Bore Thoroughly clean cylinder wall with soap and hot water Use a scrub brush to remove all traces of boring honing process Dry thor oughly and apply a light coat of SAE 10 oil to prevent rust Measuring Piston to Bore Clearance 2 Use an inside micrometer telescoping gauge or bore gauge and measure the cylinder bore Before installing the piston into the cylinder bore it Take the measurement approximately 2 1 2 is necessary that the clearance be accurately below the top of the bore and perpendicular to checked This step is often overlooked and if the the piston pin clearances are not within specifications generally engine failure will result 3 Piston to bore clearance is the difference be tween the bore and the piston diameter step NOTE Do not use a feeler gauge to measure pis 2 minus step 1 For style A pistons only Md dias hl eR RU Adda clearance should be 0035 006 for K91 007 010 for K161 K341 For piston styles C The following procedures should be used to accu and D clearance should be 0034 0051 for rately measure the piston to bore clearance K181 0045 0062 for K301 0050 0067 for K321 and 0030 0050 for K341 1 Use a micrometer and measure the diameter of the piston as shown in Figure 11 4 VALVES Inspection and Service Carefully inspect valve mechanis
170. sing 12 17 INSTALL DIPSTICK 1 Install dipstick INSTALL FUEL TANK A WARNING Explosive Fuel 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 1 Install fuel tank with brackets 2 Install fuel line on fuel tank outlet fitting INSTALL ELECTRIC STARTER 1 Install electric starter 2 Install hex cap sems screws which mount elec tric starter to engine 3 Install Keyswitch panel 4 Connect lead to electrical starter 5 Connect electrical connector s INSTALL RETRACTABLE STARTER 1 Install the retractable starter and hex cap screws Leave the screws slightly loose 2 Pull the starter handle out 8 10 until the pawls engage in the drive cup Hold the handle in this position and tighten screws securely INSTALL FUEL PUMP 1 Install the gasket fuel pump plain washers and fillister head screws Refer to Figure 12 47 Fuel Pump Camshaft Fuel Pump Lever Figure 12 47 Mechanical Fuel Pump 12 18 NOTE Make sure the fuel pump lever is positioned above the camshaft Damage to the fuel pump and subsequent severe engine damage could re sult if the lever is positioned below the camshaft Refer to Figure 12 48 Fuel Pump j Fuel Pump
171. ssembly 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 3 File off any burrs which may have been left on the choke shaft when the screws were re moved Place carburetor on workbench with choke side down Remove choke shaft the detent ball and spring will fall 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 Attach 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 56 x 7 32 brass screw Secure lever to shaft Models K241 K341 Apply Loctite to threads of 1 43 48 x 7 32 brass screw Secure lever to shaft Remove Throttle Plate and Throttle Shaft Transfer Throttle Lever 1 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 slowly remove the screws secur ing the throttle plate to throttle shaft Remove and save the thrott
172. stall the new high altitude main fuel jet and torque to 12 16 in Ib 5 Reinstall the fuel inlet needie float and float pin 6 Install the new bowl gasket from kit and the fuel bowl Make sure the bowl gasket and bowl are centered and positioned properly to ensure a good seal 7 Install the new bowl retaining screw gasket from kit and the bowl retaining screw Torque screw to 45 55 in Ib 8 Reinstall the carburetor and air cleaner to en gine as necessary using the new gaskets from kit IDLE ADJUSTMENT PROCEDURE FOR K341AQS ENGINES WITH ANTI DIESELING SOLENOID The idle speed of some vibro mounted K341AQS engines has been increased to allow smoother op eration at low idle and an anti dieseling solenoid has been added to prevent dieseling during shut down at the higher idle speed If called upon to adjust the idle on any K341AQS engine with this solenoid use the following procedure Refer to Figure 6 31 STEP 1 IDLE FUEL MIXTURE ADJUSTMENT With engine stopped turn the idle fuel adjusting screw all the way in clockwise until it bottoms lightly then back out 1 2 turn STEP 2 IDLE SPEED ADJUSTMENT Start engine and check idle speed with a hand tachometer Idle no load speed should be 2100 RPM To set the idle speed loosen the jam nut on the anti dieseling solenoid and turn the solenoid in or out until 2100 RPM idle speed is attained retighten jam nut to lock solenoid in position 6 19 SOLENOID A
173. t Remove the choke plate Choke Plate 3 File off any burrs which may have been left on the choke shaft when the screws were re moved Do this before removing the choke shaft from carburetor body 4 Rotate the choke shaft until the cutout portion of shaft is facing the air cleaner mounting sur face refer to Figure 6 26 Place the carbure tor body on work bench with choke side down Remove the choke lever shaft assembly from carburetor body the detent ball and spring will Figure 6 24 Marking Throttle Plate And drop out Carburetor Body 2 Carefully and slowly remove the screws secur ing the throttle plate to throttle shaft Remove the throttle plate Air Cleaner Choke Lever Mounting Surface 3 File off any burrs which may have been left on Shaft Assembly the throttle shaft when the screws were re moved Do this before removing the throttle shaft from carburetor body 4 Remove the throttle lever shaft assembly with foam dust seal from carburetor body Choke Shaft Removal 1 Because the edges of choke plate are bev eled mark the choke plate and carburetor body with a marking pen to ensure correct Figure 6 26 Removing Choke Lever Shaft Cutout Portion Of Choke Shaft 6 16 CLEANING A WARNING Flammable Solvents Carburetor 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 instruct
174. t in it to keep it from re tracting into starter Refer to Figure 7 12 3 Remove the rope retainer from inside handle Untie the Knot and remove the retainer and handle Rope ut d 9 Figure 7 12 Removing Handle 4 Rotate the pulley counterclockwise until the notch in pulley is next to the rope guide bush ing 5 Hold the pulley firmly to keep it from turning Untie the slip knot and pull the rope through the bushing 6 Place the rope into the notch in pulley This will keep the rope from interfering with the starter housing leg reinforcements as the pul ley is rotated step 7 7 Hold the housing and pulley with both hands Release pressure on the pulley and allow it to rotate slowly as the spring tension is released Be sure to keep the rope in the notch Refer to Figure 7 13 7 8 8 10 Housing Leg Reinforcements Keep Rope _ Allow Pulley In Notch To Rotate Slowly Figure 7 13 Releasing Spring Tension Make sure the spring tension is fully released The pulley should rotate easily in either direc tion When all spring tension on the pulley is re leased remove the center screw 3 4 DIA washer and 1 2 DIA washer Carefully lift the pawl retainer from pulley Re fer to Figure 7 14 Nylon Spring Retainer db Return Spring i 1 1 8 DIA Washer Figure 7 14 Removing Pawl Retainer Pawls And Related Components NOTE A small return spring and
175. t rotating through both choke shaft bores then tighten vise This ensures accurate alignment of the carburetor body with the drill press chuck Models K91 K181 1 2 Carb 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 Drilling 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 piloted 5 16 reamer 5 Blow out all metal chips using compressed air Thoroughly clean the carburetor body in carbu retor cleaner 6 7 Install Choke Shaft Bushings 2 Install a throttle shaft without throttle lever in carburetor body to use as a pilot 1 Install screws in the tapped holes that enter the choke shaft bores until the screws bottom Models K91 K181 1 2 Carb Use the old lightly Refer to Figure 6 10 throttle shaft removed previously Models K141 K341 1 Carb Use one of the 2 Coat the outside surface of the kit supplied ii remaining new throttle shafts from the kit choke shaft bushings with Loctite from the kit Carefully press the bushings into the carbure 3 Coat the outside surface of the throttle shaft tor body using a smooth jawed vise Stop bushing with Loctite from the kit Slip the pressing when bushings bottom against
176. tappet into crankcase Intake valve tap pet towards bearing plate side exhaust valve tappet towards PTO side of crankcase Refer to Figure 12 4 Figure 12 4 Installing Tappets 12 2 NOTE On K161 and K181 ACR engines install the shorter tappet in the exhaust bore guide Intake and exhaust tappets are interchangeable on other models 2 Install the camshaft one 005 shim spacer and the camshaft pin from bearing plate side Do not drive the camshaft pin into its final position at this time Refer to Figure 12 5 PTO Side Figure 12 5 Installing Camshaft NOTE On pre ACR models with the automatic spark advance camshaft spread actuators and insert cam Align the timing marks on cam and gear as shown in Figure 12 6 Figure 12 6 Timing Marks Pre ACR Camshaft 3 Measure the camshaft end play between the spacer and crankcase boss using a flat feeler gauge Refer to Figure 12 7 Recommended camshaft end play is 005 020 for model K91 and 005 010 for all other K Series models Add or subtract 005 and or 010 shim spacers as necessary to obtain the proper end play 4 K Series engines now use a new camshaft pin the new camshaft pins are shorter than the old pins originally used in K Series engines Flat Feeler Gauge Figure 12 7 Measuring Camshaft End Play To install the new shorter camshaft pin drive the camshaft pin from the bearing plate side of crankshaft into the PTO side
177. tarter housing removing all old grease and dirt 7 Carefully remove the masking tape surround ing the new spring c ring 8 Position the spring c ring to the housing so the spring hook is over the post in the housing Make sure the spring is coiled in the correct direction Refer to Figures 7 17 and 7 19 9 Obtain Seal Installer 11791 and Handie 11795 Refer to Special Tools Section Hook the spring hook over the post in housing Make sure the spring c ring is centered over the spring pocket in housing Drive the spring out of the c ring and into the spring pocket using the seal installer and handle Refer to Figure 7 20 Spring dra Spring Hook Spring Pocket Figure 7 19 Positioning New Spring C Ring 10 Make sure all of the spring coils are bottomed against ribs in spring pocket Use the seal in staller and handle to bottom the coils as nec essary 11 Lubricate the spring moderately with wheel bearing grease before reassembling the start er Figure 7 20 Installing Spring Using Seal Installer And Handle Reassembly 1 Install the recoil spring into the starter housing as instructed under To Replace Recoil Spring 2 Sparingly lubricate the center shaft of starter with wheel bearing grease 3 Make sure the rope is in good condition If necessary replace the rope as instructed un der To Replace Rope Ready the pulley and rope for assembly by unwinding all of the r
178. te 24 Remove camshaft and tappets 25 Remove balance gears Clean all parts thoroughly as the engine is disas sembled Only clean parts can be accurately in spected 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 traces of the cleaner are removed before the en gine is reassembled and placed in operation even small amounts of these cleaners quickly break down the lubricating properties of engine oil Check all parts for evidence of 26 Remove governor gear and cross shaft 27 Remove oil seals Excessive sludge and varnish 28 Remove bearings e Scoring of the cylinder wall e Piston damage DISCONNECT SPARK PLUG LEAD e Evidence of external oil leaks DRAIN OIL FROM CRANKCASE e Evidence of overheating REMOVE AIR CLEANER Any of the listed problems could be the result of 1 Disconnect the spark plug lead and position it improper engine servicing or maintenance The away from the spark plug terminal owner should be made aware of the benefits of 1 0 proper servicing and maintenance 2 Unscrew the oil drain plug s and drain the crankcase oil into a suitable container for dis The following sequence is suggested for complete posal engine disassembly This procedure may have to be varied slightly to accommodate options or spe 3 Remove the wing nut a
179. tem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clear ance On models K91 K161 and K181 the clear ance should not exceed 005 for intake and 007 for exhaust valves On models K241 K301 K321 and K341 the clearance should not exceed 006 for intake and 008 for exhaust valves If the clearance exceeds these specifications deter mine whether the valve stem or the guide is re sponsible for the excessive clearance NOTE The exhaust valves on these engines have a slightly tapered valve stem to help prevent stick ing Because of the taper the valve stem must be measured in two places to determine if the valve stem is worn If the valve stem diameter is within specifications replace the valve guide See Figure 11 5 Remove Valve Guide The valve guides are a tight press fit in the cylin der block A valve guide removal tool is recom mended to remove the guides refer to Special Tools section To remove valve guide refer to Figure 11 6 and proceed as follows Slide Adapter Hammer Cylinder SP frt tr tg i H i s Stud 5 16 x 2 1 2 Figure 11 6 Pulling Valve Guide 1 Install 5 16 18 NC nut on coarse threaded end of 2 1 2 long stud K161 and K181 or 3 1 2 long stud K241 K301 K321 and K341 11 6 2 Insert other end of stud through valve guide bore and install 5 16 24 NF nut Tighten both nuts securely NOTE Val
180. the cap screws and replace the spark plug lead The trigger module has two clip on type terminals Make sure that the leads are connected as shown in Figure 8 7 TRIGGER MODULE BREAKERLESS The trigger module used on breakerless ignition systems is a solid state device which includes diodes resistor sensing coil and magnet plus an electronic switch called an SCR The terminal marked A must be connected to the alternator while terminal I must be connected to the ignition switch or ignition coil Operating with these leads reversed will cause damage to the solid state de vices If a faulty trigger module is suspected dis connect and remove the trigger from the engine and perform the following tests with a flashlight tester Reset air gap when reinstalling trigger Diode Test Turn tester switch ON and connect one lead to the I terminal and the other to the A terminal then reverse these leads light should come on with leads one way but not the other way If light stays on or off both ways this indicates diodes are faulty replace trigger module SCR Test Turn tester on then connect one lead to the I terminal and the other to the trigger mounting bracket NOTE If light comes on reverse the leads as the light must be off initially for this test Lightly tap magnet with a metal object when this is done tester light should come on and stay on until leads are disconnected If light does not come on this indicates
181. the recess in center shaft of starter housing Refer to Fig ure 7 3 Make sure the threads in center shaft remain clean dry and free of grease or oil 4 Apply a small amount of Loctite 271 to the threads to center screw Install the center screw with washer and cam to the center shaft Torque screw to 65 75 in Ib 5 f necessary install the pawl springs pawls and retaining rings to pins on starter pulley Refer to To Replace Starter Pawls 6 Tension the spring and install the rope and handle as instructed in steps 5 through 12 un der To Replace Rope 7 Install the starter to engine CAST HOUSING MODELS Center Screw Washer Spring Retainer Return Spring Pulley Sheave Pawl Retainer Recoil Spring Pawls 3 1 1 8 DIA Rope Retainer Screws 4 Handle Rope Figure 7 11 Exploded View 7 7 1 Remove the starter from engine A CAUTION Spring Under Tension Do not remove the center screw of the starter until the tension of recoil spring has been released Re moving the center screw before releasing spring tension or improper starter disassembly can cause the sudden and potentially dangerous release of the recoil spring Follow these instructions carefully to ensure personal safety and proper starter disassem bly Make sure adequate face protection is worn by all persons in the area 2 Pull the rope out approximately 12 and tie a temporary slip Kno
182. tion of the flywheel and crankshaft before installation to make sure they are in good condition and free of cracks The old crankshaft design has an externally threaded end and uses a square key plain washer and marsden nut to align and secure the flywheel The new crankshaft design has an internally threaded end and uses a woodruff key washer and or bushing hex cap screw or hex nut Position key properly in keyway as shown in Figure 12 43 and carefully guide key slot in flywheel hub over the key while installing to avoid pushing the key inward Figure 12 43 Installing A Square Flywheel Key Models K91 K161 And K181 Rope Start Models A Install rope pulley plain washer and hex nut lubricate threads with oil Hold flywheel with strap wrench and torque hex nut to 40 50 ft Ib for K91 and 85 90 ft Ib for K161 and K181 If a hex head sems screw is used torque screw to 250 in Ib Retractable Start Models B Install the grass screen Install the drive cup plain washer and hex nut lubricate threads with oil Hold the flywheel with strap wrench and torque hex nut to 40 50 ft Ib for K81 and 85 90 ft Ib for K161 and K 181 If a hex head sems screw is used torque screw to 250 in Ib Electric Start Models A B Install the plain washer and hex nut lubricate threads with oil Hold the flywhee with strap wrench and torque hex nut to 40 50 ft Ib for K91 and 85 90 ft Ib for K
183. trifugal force causes the fly weights or flyball to move outward with an in 6 26 crease in speed and inward with a decrease As the flyweights move outward they force the regu lating pin of the assembly to move outward The regulating pin contacts the tab on the cross shaft causing the shaft to rotate with changing speed One end of the cross shaft protrudes through the side of the crankcase Through external linkage attached to the cross shaft the rotating action is transmitted to the throttle on the carburetor When the engine is not running the governor spring holds the throttle in the open position When a normal load is applied to an operating en gine the speed tends to decrease The resulting rotation of the cross shaft acts against the gover nor spring opening the throttle wider This action admits more fuel restoring engine speed As speed again reaches the governed setting the shaft rotates to close the throttle valve enough to maintain governed speed Governed speed may be at a fixed point as on constant speed applications or variable as deter mined by a throttle control setting Initial Adjustment K91 K141 K161 K181 Governors are adjusted at the factory Further ad justment should not be necessary unless the gov ernor arm or linkage work loose or become dis connected The need for governor adjustment may be indicated by engine speed surges or hunting with changes in load or by a considerable drop in
184. ts for wear or damage Replace all worn or damaged components Use only genuine Kohler replacement parts specified in the Parts Manual All components shown in Figure 7 11 are available as service parts Do not use nonstandard parts Carefully clean all old grease and dirt from starter components Lubricate the spring cen ter shaft and certain other components as specified in these instructions with any com mercially available bearing grease To Replace Rope The starter must be completely disassembled to replace the rope T 2 Remove the starter from engine Disassemble starter as instructed in steps 2 through 14 under Disassembly Remove the 4 Phillips head screws securing the pulley and sheave Separate the pulley and sheave and remove the old rope Refer to Fig ure 7 16 Figure 7 16 Replacing Rope 4 Position the new rope in the notch in the pulley and around the rope lock post NOTE Use only a genuine Kohler replacement rope which is designed for this starter Using rope of the incorrect diameter and or type will not lock properly in the pulley 5 Install the sheave to the pulley and install the 4 Philips head screws Use care not to strip or cross thread the threads in pulley 6 Inspect the pulley to make sure the sheave is securely joined to the pulley Pull firmly on the rope to make sure it is securely retained in the pulley To Replace Recoil Spring A CAUTION Spring Und
185. ure 8 2 Typical Flywheel Magneto Ignition Coil And Stator The stator windings are connected to the magneto ignition coil Current flow in the ignition coil reaches its highest peak at the instant the mag netic flux reverses direction This is the point at which the system is timed to provide a spark at the spark plug The ignition coil has a low tension primary winding and a high tension secondary winding The secon dary winding has approximately 100 turns of wire for every 1 turn in the primary This relationship causes the voltage induced in the secondary wind ing to be about 100 times higher than in the pri mary If the magneto produces 250 volts in the primary winding the secondary winding voltage will be 25 000 volts When ignition is required the breaker points open to break the primary circuit The resultant sudden collapse of the field around the primary winding causes sufficient energy to be produced in the secondary winding to bridge the spark plug gap The collapsing field also induces energy in the pri mary winding but the condenser shunts this en ergy to ground preventing it from bridging the breaker point gap Figure 8 2 shows a typical sta tor and coil assembly Magneto Ignition Timing Engines are equipped with a timing sight hole either in the bearing plate or in the blower hous ing If a snap button covers the hole pry it out with a screwdriver or similar tool so that the timing marks may be seen Two ma
186. ure valve stems are ground perfectly flat and smooth Intake Valve Exhaust Valve 005 009 011 015 006 008 K241 K301 008 010 017 019 K321 K341 Figure 3 9 Valve Clearances If clearance is too large replace the valves and recheck clearance NOTE Large clearances can also be reduced by grinding the valves and or valve seats Refer to the Inspection And Repair Reconditioning section for valve specifications On Models K241 K301 K321 K341 Adjust the clearance by turning the adjusting screw on tap pets Refer to Figure 3 9 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 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 Drain the fuel tank and fuel system or run engine until fuel tank and fuel system are empty Remove the spark plug Add one tablespoon of engine oil into the spark plug hole Install plug by do not connect plug lead Crank the engine two or three revolutions Remove the spark plug Cover the spark plug
187. ut Choke won t close when cranking Choke shaft CAUSES 1 Choke spring not properly ad justed 2 Choke shaft fails to move freely 3 Faulty choke adjustment 1 Incorrect ignition timing 2 Too much compression 1 Faulty lead wires or terminals 2 Air cleaner gasket interference with choke shaft lever 4 5 KW only 3 Open circuit in solenoid wiring 4 Faulty Decision Maker or ground in Decision Maker 5 Choke lever lacks sufficient travel or smooth movement SOLUTIONS d Remove spring retainer and with choke wide open windup spring 1 2 turn Install new shaft assembly re pair kit Adjust choke Time engine as specified and install new shaft assembly re pair kit Adjust ACR to specification and install new shaft assembly repair kit Change lead wires or replace choke Reposition flat of gasket to provide clearance for choke shaft lever Check continuity with ohmme ter between the two solenoid terminals on the choke unit Replace choke if open circuit Replace lead to Decision Maker with a jumper wire to ground If choke functions properly replace Decision Maker Manually move the choke lever until the choke plate is fully closed Replace the choke unit if it does not move freely Choke Replacement And Adjustment 1 Position the choke unit on the two mounting screws so that it is slightly loose Hold the choke plate in the wide open positi
188. valve should open for ACR Exhaust valve opening as indicated on the dial indicator should be 031 042 If the exhaust valve does not open to the specified amount adjust the ACR according to STEP 5 NOTE Caution must be exercised in the bending down carefully to within the 031 042 range of the tab as it is hardened and may crack or If the valve lift was below 031 remove the break if bent back and forth more than 3 or 4 camshaft cover on the side of the engine ex times posing the cam gear and bend the ACR tab 5 f the valve lift was above 042 hold a wooden carefully upward until the valve lift is within the dowel or peg on the top of the valve and tap it specified range 9 3 SECTION 10 DISASSEMBLY A 9 Remove electric starter WARNING Accidental Starts 10 Remove fuel tank Before servicing the engine or equipment always 11 Remove dipstick remove the spark plug lead to prevent the engine 12 Remove cylinder head baffle and side air from starting accidentally Ground the lead to pre baffles vent sparks that could cause fires 13 Remove breather assembly 14 Remove spark plug and cylinder head 15 Remove blower housing 16 Remove drive cup or rope start pulley grass screen and flywheel 17 Remove stator 18 Remove valves 19 Remove oil pan 20 Remove connecting rod and piston 21 Remove piston from connecting rod 22 Remove piston rings 23 Remove crankshaft and bearing pla
189. ve guide must be held firmly by the stud assembly so that all slide hammer force will act on the guide 3 Assemble the valve guide removal adapter to the stud and then the slide hammer to the adapter 4 Use the slide hammer to pull the guide out Install Valve Guide To install valve guide proceed as follows 1 Make sure valve guide bore is clean and free of nicks or burrs 2 Using valve guide driver refer to Special Tools section align and then press guide in until valve guide driver bottoms on valve guide counterbore 3 Valve guides are often slightly compressed during insertion Use a piloted reamer and then a finishing reamer to resize the guide bore to 3125 for K161 K181 K241 K301 K321 and K341 Refer to Figure 11 7 5 16 Reamer Figure 11 7 Reaming Valve Guide Valve Seat Inserts The intake valve seat is usually machined into the cylinder block however certain applications may specify a hard alloy insert If the seat becomes badly pitted cracked or distorted the insert must be replaced The insert is a tight press fit in the cylinder block A valve seat removal tool is recommended for this job refer to Special Tools section Since insert removal causes loss of metal in the insert bore area use only Kohler service replacement inserts which are slightly larger to provide proper retention in the cylinder block Make sure new insert is properly started and pressed into bore to prevent co
190. ve seat installers TOOL BOARD AND HOOK SET Used to store and identify tools 12033 SEE FRONT PAGE 2 3 KIT NO 3211 A TOOL USAGE CHART MODEL K SERIES PART NO amp NAME VALVE TOOLS 11726 Valve Seat Puller 11913 Valve Seat Puller 11771 Valve Guide Depth Gage 11843 Valve Guide Reamer 5 16 11844 Valve Guide Reamer 1 4 12017 installer Bearing PTO 11782 Installer Seal PTO 11783 Installer Seal Flywheel 11784 Installer Seal PTO 11793 Installer Seal Flywheel 12126 Seal Sleeve USE AS REQUIRED 12127 Seal Sleeve USE AS REQUIRED 12128 Seal Sleeve USE AS REQUIRED 10357 Flywheel Strap Wrench 1 2 11797 Offset Wrench 1 4923 Offset Wrench 9 16 11767 Feeler Gauge Crank Oil Pump 10355 Timing Tool Balance Gear 11762 Scraper 4747 Drive Handle 3226 Flywheel Puller Kit NOTE K141 requires same tools as K161 Digital Tachometer Digital Engine Analyzer Thermocouples Digital Voltmeter Digital Thermometer Slack Tube Manometer Carrying Case 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 Qty Description Digital Voltmeter Digital Tach
191. vented fill 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 filter Visually inspect the filter periodically Re place when dirty with a genuine Kohler filter Refer to Figure 3 5 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 52 357 01 must be used on all Kohler electric starter drives The use of other lubricants can cause the drive to stick or bind 5 Apply a small amount of Loctite No 271 to stop nut threads Assemble drive parts in re verse order of removal Torque stop nut to 160 in Ib 6 Reinstall starter to crankcase Refer to appro priate Reassembly section CLEAN CYLINDER HEAD AND COMBUS TION CHAMBER Every 500 operating hours 250 hours when leaded gasoline is used remove cylinder head an
192. voltmeter With engine stopped measure the resistance of stator from lighting lead to ground using an ohmmeter Conclusion If voltage Is more than 12 5 volts charging system Is OK If voltage Is 12 5 volts or less the stator or diode are probably faulty Test the stator and diode Test 2 3 and 4 1 25 amp If voltage Is 11 5 volts or more sta tor winding Is OK 3 amp If voltage Is 28 volts or more stator winding Is OK If voltage Is less than specified test stator using an ohmmeter Tests 3 and 4 If resistance Is low In both directions the diode Is shorted Replace the diode If resistance Is high In both directions the diode or stator winding Is open Use Test 4 If resistance Is 0 7 1 3 ohms stator winding Is OK If resistance Is 0 ohms stator winding Is shorted Replace stator If resistance Is Infinity ohms stator winding or lead is open Replace stator 1 Make sure lights are not burned out 1 Replace burned out lights If voltage Is 15 volts or more stator Is OK Check for loose connections or shorts In wiring harness If voltage Is less than 15 volts test stator us Ing an ohmmeter Test 3 If resistance Is approx 0 4 ohms stator Is OK If resistance Is 0 ohms stator Is shorted Re place stator If resistance Is Infinity onms stator or lighting lead Is open Replace stator Electric Start Engines 1 25 Amp Or 3 Amp Unregulated Battery Charging System
193. w detent spring and ball in carburetor body in the side opposite the choke lever Install Throttle Shaft Bushing 2 Compress detent ball and spring and insert 1 Make sure the dust seal counterbore in the choke shaft through bushings Make sure the carburetor body is thoroughly clean and free of choke lever is on the correct side of the car chips and burrs buretor body Refer to Figure 6 12 6 8 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 83 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 Ej E1 3 Ej E1 Ej E E Ei E z 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 plate to throttle shaft Make sure marks are aligned and plate is positioned properly in the bore Apply Loctite to threads 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 seated against pivot in carburetor body Rotate the throttle shaft until the throttle plate fully closes the bore around its perime ter then tighten
194. w idle speed for Basic En mensions Damage to the needles and the seats gines is 1200 rpm To ensure best results when in carburetor body will result if the needles are setting the low idle fuel needle the low idle speed forced must not exceed 1500 rpm 6 13 PRELIMINARY SETTINGS K SERIES MODELS KOHLER ADJUSTABLE JET WALBRO FIXED JET WALBRO ADJUSTABLE JET K91 K141 K161 K181 K241 K301 K321 K341 KT17 KT19 K582 Low idle 1 1 2 turns 1 1 2 turns 1 1 2 turns 1 1 4 turns 2 1 2 turns 2 1 2 turns 2 1 2 turns 2 1 2 turns 1 turn 1 turn 1 1 4 turns High Idle 2 turns 3 turns 3 turns 2 turns 2 turns 2 turns 3 1 4 turns 3 1 2 turns 2 1 2 turns 2 1 2 turns 3 turns Includes New Look Models Low idle NOT APPL NOT APPL NOT APPL 2 1 2 turns 1 1 4 turns 1 1 4 turns 1 1 2 turns 1 turn 1 1 4 turns 1 1 4 turns NOT APPL Low Idle 2 B DETERMD NOT APPL 2 B DETERMD 2 1 2 turns 1 3 4 turns 1 3 4 turns 2 B DETERMD 2 B DETERMD 1 1 4 turns 1 1 4 turns 2 B DETERMD High Idle 2 B DETERMD NOT APPL 2 B DETERMD 3 4 turn 1 1 8 turns 1 1 8 turns 2 B DETERMD 2 B DETERMD 1 1 4 turns 1 turn 2 B DETERMD Figure 6 20 Preliminary Low Idle And High Idle Fuel Needle Settings 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
195. wn the throttle will be in the wide open position Adjust the governor linkage so that there is approximately 1 32 of space between the throttle lever and carbure tor body Use a tachometer to set the idle speed to 1680 RPM with the throttle lever against the idle speed screw If hunting still occurs move the governor spring to the last hole in the governor arm If this improves governing but permits too great a speed reduction when going from no load to full load move the spring up one position in the arm SECTION 7 RETRACTABLE STARTERS Retractable starters are lubricated during manufac Operation ture and should require no further lubrication until disassembly for cord or rewind spring replacement 1 Be sure starter screen is kept clean when op or for other repair erating engine or serious engine damage can result from lack of cooling air Frequently check mounting screws to make sure starter is securely tightened on blower housing of 2 After engine has started do not allow starter engine If screws are loose starter realignment rope to snap back into starter housing Con bh be necessary Also mane a Mad s alr i tinue to hold handle and allow starter rope to inta e screen is maintained in clean condition at a rewind slowly times NOTE Releasing handle when starter rope is ex MODEL K91 tended will shorten life of starter 3 Do not use starter in a rough manner such as jerking or pulling starter rope all the w
196. xcess oil gasket and hose 4 Reinstall the precleaner over the paper ele ment bu OPTION Figure 5 1 Air Cleaner Assembly Exploded View 5 1 Paper Element Every 100 operating hours more often under ex tremely dusty or dirty conditions check the paper element Replace the element as follows 1 Remove the precleaner if so equipped ele ment cover nut element cover and paper ele ment 2 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 Optional Precleaner Air Cleaner Cover Element Cover Nut Wing Nut Inspect Air Cleaner Components Whenever the air cleaner cover is removed or when servicing the paper element 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 2 Element 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 an
197. y check to ensure that the fillet blends smoothly with the crank pin surface Refer to Figure 11 16 threads different mounting hardware is required High Point From The internally threaded crankshafts are sold in kits Fillet Intersections which include the hardware The mounting hard 4 ware can also be purchased separately The Fillet Must NOTE Blend S thi With The Bearing 1 Use a 13 32 I D x 1 1 4 O D x 1 8 TH plain Journal Surface Minimum washer Part No 52114 01 when installing drive cups with a 1 1 4 Dia spotface ma chined recessed area around mounting hole This Fillet Area These drive cups are primarily used on Inter Must Be national Harvester applications but may be Completely Smooth found on other applications Therefore use the drive cup to identify which washer should be Figure 11 16 Crankpin Fillets used When replacing a crankshaft with external threads 2 Required for drive cups with 5 8 mounting on the flywheel end with one that has internal hole O 0 ROT MA e OIL DRAIN amp CHECK Pup WOODRUFF KEY THRUST BEARING REDUCTION GEAR GASKET S USE FOR PROPER END PLAY SHAFT END GEAR HUB DIMENSION COPPER WASHER K91 740 750 EXPANSION p ad PLUG K141 1 105 1 115 K161 1 105 1 115 K181 1 105 1 115 K241 1 074 1 084 SA HOUSING K301 1 074 1 084 REAR OIL SEAL Figure 11 17 Gear Reduction Unit Exploded View OPTIONA
198. ype with 3 Amp lighting coils 4 Magneto flywheel type with 10 Amp alternator Battery Ignition Systems 1 Battery ignition with motor generator 2 Battery ignition with 10 Amp alternator PERMANENT an MAGNET ON FLYWHEEL Ny FLUX DIRECTION y COIL ASSEMBLY 3 Battery ignition with 15 Amp alternator 4 Battery ignition with 30 Amp alternator Breakerless Ignition System 1 Breakerless ignition with 10 Amp alternator 2 Breakerless ignition with 15 Amp alternator Magneto Ignition System Operation In all magneto ignition systems high strength per manent magnets provide the energy for ignition In rotor type systems the magnet is pressed onto the crankshaft and is rotated inside a coil core assembly stator mounted on the bearing plate in the other systems a permanent magnet ring on the inside of the flywheel revolves around the sta tor Movement of the magnets past the stator in duces electric current flow in the stator coil and in alternator and lighting coils if provided The magnets are mounted with alternate North and South poles so that the direction of magnetic flux constantly changes producing an alternating cur rent AC in the stator coil windings Refer to Fig ure 8 1 fT APO re uae f PEXNE L2 a i FLUX DIRECTION t Figure 8 1 Magneto Cycle Showing Flux Reversal 8 1 MAGNETO IGNITION COIL Jj TENSION LEAD d om CONDENSER i Nc BREAKER POINTS Fig

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