Kohler K91 K141 K161 K181 K241 K301 K321 K341 Single Cylinder Engine Workshop Service & Repair Manual

OWNER’s MAN UAL MODELS K91 I (4 hP) Kl6l,&Kl81 (7 hP) (8 hP) operating & maintenance instructions CONGRATULATIONS-You have selected a fine four-cycle engine. Kohler designs long-life strength and on-the-job durability into each engine...making a Kohler engine dependable...dependability you can count on. n Parts subject to the most wear and tear (like cylinders, crankshafts, and camshafts) are made from precision-formulated castiron...and because the cast iron cylinders can be rebored, these engines can last even longer. n Kohler engines are easy to service, all routine service parts--points, condenser, spark plug, air filter, carburetor--are easily and quickly accessible. 0 Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Service support is just a phone call away. Call l-800-544-2444 (U.S. & Canada) for Sales & Service Assistance. To keep your engine in top operating condition, follow the simple maintenance procedures given in this manual.

Safety Information For Your Safety! These precautions should be followed at all times. Failure to.follow these precautions could result in injury to yourself and others. A WARNING db Explosive Fuel can cause fires and severe burns. Stop engine before filling fuel tank. Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not stat? the engine near spilled fuel. Never use gasoline as a cleaning agent. ( A WARNING Carbon Monoxide can cause severe nausea, fainting or death. Do not operate engine in closed or confined area. Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. California Proposition 65 Warning Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. A WARNING r- # u -v Rotating Parts can cause severe injury. Stay away while engine is in operation. Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury Never operate the engine with covers, shrouds, or guards removed. A CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. dh WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead before servicing. Accidental Starts! Before servicing the engine or equipment, always disconnect the sparkplug lead to prevent the engine from starting accidentally Ground the lead to prevent sparks that could cause fires. Make sure the equipment is in neutral. A WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Hot Parts! Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running-or immediately after it is turned off. Never operate the engine with heat shields or guards removed. dh WARNING +P Explosive Gas can cause fires and severe acid burns. Charge battery only in a well ventilated area. Keep sources of ianition awav. Explosive Gas! Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition a way from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF: If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. 2

FUEL RECOMMENDATIONS e, WARNING: Explosive Fuel1 Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well-ventilated, unoccupied buildings, away from sparks or flames. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuef; wipe up spills immediately. Never use gasoline as a cleaning agent. General Recommendations Purchase gasoline in small quantities and store in clean, approved containers. A container with a capacity of 2 gallons or less with a pouring spout is recommended. Such a container is easier to handle and helps eliminate spillage during refueling. Do not use gasoline left over from the previous season, to minimize gum deposits in your fuel system and to insure easy starting. Do not add oil to the gzisoline. Do not overfill the fuel tank. Leave room for the fuel to expand. Fuel Type For best results, use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum. Unleaded gasoline is recommended as it leaves less combustion chamber deposits. Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated. Be aware however, that the cylinder head will require more frequent service. See “Required Maintenance” on page 7. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved. OIL RECOMMENDATIONS Using the proper type and weight crankcase oil is extremely important as is checking oil daily and changing oil and filter regularly. (See ‘Required Maintenance” on page 7.) Failure to use the correct oil or using dirty oil causes premature engine wear and failure. Before starting engine, fill the crankcase with the proper type and quantity of oil. Oil Type Use high-quality detergent oil of API (American Petroleum Institute) service class SG or SH. Select the viscosity based on the air temperature at the time of operation as shown in the table. Recommended SAE Viscosity Wades TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHAW6E Straight 30-welght oil Is preferred. SAE lOW-30 oil is not recommended above 32” F. Using this oil substantially increases oil consumption and combustion chamber deposits. (See Changing Oil” and “Required Maintenance” on pages 4 and 7.) NOTE: Using other than service class SG or SH 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. 3

The top position of the symbol shows service class such as API SERVICE CLASS SG. The symbol may show additional categories such as SG/CC, CD. The center portion shows the viscosity grade such as SAE 30 in the example. If the bottom portion shows “Energy Conserving”, it means that oil is intended to improve fuel economy in passenger car engines. Checking Oil The importance of checking and changing crankcase oil cannot be overemphasized. Check oil BEFORE EACH USE when the engine is cool and the oil has drained back into the sump. Add oil, if low, to bring level up to, but not over, the ‘Fwmark on the dipstick. Oil should always be checked while engine is off and on a level surface. With threaded plug-type dipstick, remove and wipe oil off--reinsert, but do not turn plug in. To check oil level, shoulder plug on top of hole. After checking, again turn plug all the way into crankcase. With extended oil fill tube and dipstick, push dipstick all the way down in tube then take reading. F ’ t I -lM ........... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... Operating .;;;:::..:.:. ................... . ......... .......... ......... Range .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... 1 ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... .......... ......... ........... r , L NOTE: To prevent extensive engine wear or damage, always maintain the proper oil.level in the crankcase. Never operate the engine with the oil level below the “L” mark or over the “F” mark on the dipstick. Changing Oil For a new engine, change oil after the first 5 hours of operation and then every 25 hours of operation thereafter. Drain oil while engine is still warm from operation--it flows freely and carries away more impurities. (See Engine Identification illustration for location of drain PWJ Remove the oil drain plug and oil fill cap. Tilt the engine slightly towards the oil drain to obtain better drainage. After draining, reinstall drain plug. Make sure it is tightened securely. Fill with proper viscosity oil to “F” mark on dipstick. Always check level on dipstick before adding more oil. Make sure the engine is level when filling and checking oil. 4

OPERATING INSTRUCTIONS ALSO READ THE OPERATING INSTRUCTIONS OF THE EQUIPMENT THIS ENGINE POWERS PRE-START CHECKLIST cl cl El El El Check oil level. Add oil if low. Check fuel level. Add fuel if low. Check cooling air intake areas and external surfaces of engine. Make sure they are clean and unobstructed. Check that the air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened. Check that any clutches or transmissions are disengaged or placed in neutral. This is especially important on equipment with hydrostatic drive. The shift lever must be exactly in neutral to prevent resistance which could keep the engine from starting. a WARNING: Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. STARTING Move the throttle control lever to mid point of travel. Move choke lever into full choke position and gradually return to Off position after engine starts and warms up. For Rope Start Engines--Place the starting rope knot in the slot in starting pulley. Wrap the rope around the pulley. Pull the starter handle with a smooth, steady motion. For A Retractable Start Engine - SLOWLY pull the starter handle until just past compression - STOP! Return starter handle, pull firmly with a smooth, steady motion to start. Pull the handle straight out to avoid excessive rope wear from the starter rope guide. Extend the starting rope periodically and check its condition. If the rope is frayed, have it replaced immediately by your Kohler Engine Service Dealer. a WARNING: Accidental Starts! Before extending and checking the retractable starter rope, remove the spark plug lead to prevent the engine from starting accidentally. Ground the lead to prevent sparks that could cause fires. Make sure the equipment is in neutral. For An switch. starts. NOTE: NOTE: Electric Start Engine -- Activate the starter Release the switch as soon as the engine Do not crank the engine continuously for more than 10 seconds at a time. If the engine does not start, allow a 60second cool-down period between starting attempts. Failure to follow these guidelines can burn out the starter motor. If the engine develops sufficient speed to disengage the starter but does not keep running (a “false start”), the engine rotation must be allowed to come to a complete stop before attempting to restart the engine. If the starter is engaged while the flywheel is rotating, the starter pinion and flywheel ring gear may clash, resulting in damage to the starter. If starter does not turn the engine over, shut off starter immediately. Do not make further attempts to start the engine until the condition is corrected. Do not jump start using another battery (refer to “BATTERY”.) See your Kohler Engine Service Dealer for trouble analysis.

BAlTERY ’ A 12 volt battery is normally used. Refer to the operating instructions of the equipment this engine powers for specific information. If the battery charge is not sufficient to turn over the engine, recharge the battery (see page 13). OPERATING Optional spark arrestor mufflers are available from your Kohler Engine Service Dealer. Check your local laws and statutes regarding engine spark arrestor muffler requirements. Angle of Operation These engines can be operated at angles up to 35” in any direction (intermittent operation when crankcase is filled to “FM mark on dipstick). NOTE: Do not exceed these angles of operation as engine damage may result from lack of lubrication. Refer to the operating instructions of the equipment this engine powers. It may have more stringent guidelines as to angle of operation due to equipment design. L NOTE: If debris builds up on air intake screen other intake areas, STOP the engine immediately and clean. Obstructed air areas cause engine damage due to overheating. A WARNING: Hot Parts! Engine components can get extremely hot from intake operation. To prevent severe burns, do not touch these areas while the engine is running - or immediately after it is turned off. Never operate the engine with heat shields or guards removed. and Engine Speed NOTE: Do not tamper with the governor setting to increase the maximum speed. Overspeed is hazardous and will void the warranty. A WARNING: Rope Starting Pulley Is Not a Drive Pulley! Do not use optional backup ropestarting pulley as a drive pulley. Using starting pulley as a drive could loosen the flywheel fastener, resulting in bodily harm. STOPPING Disengage all possible load from the engine. Place the throttle control in the idle position. Allow the engine to run at idle for 30-60 seconds. Turn ignition switch OFF. On engines so equipped, press and hold STOP button until engine comes to a complete stop. 6

MAINTENANCE INSTRUCTIONS A WARNING: Accidental Starts! Before servicing the engine or equipment, always disconnect the spark plug lead to prevent the engine from starting accidentally. Ground the spark plug lead to prevent sparks that could cause fires. Make sure the equipment is in neutral. These service procedures should also be performed as part of any seasonal tune-up. Maintenance Rewired Frecwencv .. CleanAirlntakeScreen’ .................................................................................. DAILY CheckOil Level ........................................................................................ MILY ReplenishFuelSupply ................................................................................... DAILY Service Precleaner ..................................................................................... 25Hm. ChangeOil .......................................................................................... 25Hf& Check Reduction Gear Unit .............................................................................. 50Hlls, Clean Cooling Fins and External Surfaces .................................................................... 50 Hrrr. Replace Air Cleaner Element’ ............................................................................. 100 Hrs. Check Spark Plug Condition and Gap ...................................................................... 100 Herr. Have Breaker Points Checked2 ........................................................................... .500 Hrs. HavelgnitionTimingChecked2............................................................................~H . Have Valve and Tappet Clearance Checked2 ................................................................ ,500 Hra. HaveCylinderHeadsServiced2 .......................................................................... 5OOHrs? Have Starter Motor Drive Serviced2 ........................................................................ ,500 Hrs. ‘Perform these maintenance procedures more frequentlyunder extremely dusty, dirty conditions. 2Have a Kohler Engine Service Dealer perform this service. ‘250 hours when leaded gasoline is used. ENGINE IDENTIFICATION ntak ?en / Retractable Oil Pan Starter e e Oil Drain 7

Precleaner Wing Nut Air Filter Plate SPARK PLUGS Every 100 hours of operation remove the spark plug, check condition and reset the gap, or replace with a new plug as necessary. 3 . Check gap (0.025”) using a wire feeler gauge. Adjust the gap as necessary by carefully bending the ground electrode. Install the plug and torque to 18-22 ft. lb. 1. Before removing the spark plug, clean the area around the base of the plug to keep dirt and debris out of the engine. 2 . Remove the plug and check its condition. Replace the plug if worn or reuse is questionable. NOTE: Do not clean the spark plug in a machine using abrasive grit. Some grit could remain in the spark plug and enter the engine causing extensive wear and damage. Wire /

CARBU.RETOR TRdUBLESHOOTlNG AND ADJUSTMENTS Carburetor adjustments should be made on/y after engine has warmed up. Kohler K91, K161 and K181 engines are equipped with one of two basic types of carburetors - Kohler or Walbro - fixed main jet or adjustable main jet. The carburetor is designed to deliver the correct fuel- to-air mixture to the engine under all operating conditions. The main fuel and idle fuel needles on adjustable jet carburetors are set at the factory and normally do not require further adjustment. On fixed jet carburetors, the low idle fuel needle is also set at the factory and normally does not need further adjustment. The main fuel jet is calibrated and installed at the factory and is not adjustable*. *NOTE: Engines operating at attitudes above approximately 1830 m (6000 ft) may require a special “high altitude” main jet. TROUBLESHOOTING If engine troubles are experienced that appear to be caused by the carburetor, check the following areas before adjusting the carburetor. Make sure the fuel tank is filled with clean, fresh gasoline. Make sure the fuel tank cap vent is not blocked and that it is operating properly. Make sure fuel is reaching the carburetor. This includes checking the fuel shut-off valve, fuel tank filter screen, in-line fuel filter, fuel lines, and fuel pump for restrictions or faulty components as necessary. Make sure the air cleaner base and carburetor is securely fastened to the engine using gaskets in good condition. Make sure the air cleaner element is clean and all air cleaner components are fastened securely. after checking the items listed above, starting or engine operation problems exist, it may be necessary to adjust or service the carburetor. NOTE: Carburetor adjustments should be made only after the engine has warmed up. Kohler Carburetor Adjustment 1 . With the engine stopped, turn the fuel adjusting needles In (clockwise) until they bottom lightly. NOTE: The tips of the fuel adjusting needles are tapered to critical dimensions. Damage to the needles and seats in carburetor body will result if the needles are forced. 2 . 3 . 4. Preliminary Settings: Turn the. adjusting needles out (counterclockwise) from lightly bottomed as follows: 1 KOHLER ADJ. 1 LOW IDLE 1 MAIN FUEL I K91 1 l-1/2 TURNS 1 2TURNS I K161 1 l-l/2 TURNS 1 3TURNS K181 l-1/4 TURNS 2 TURNS . Start the engine and run at half-throttle for 5 to IO minutes to warm-up. The engine must be warm before making final settings (steps 4-6). Main Fuel Needle Setting: This adjustment is required for adjustable main jet carburetors only. If the carburetor is a fixed main jet type refer to Walbro adjustment. Place the throttle into the Vast” position. If possible, place the engine under load. Turn the main fuel adjusting needle out (counterclockwise) from the preliminary setting until the engine speed decreases (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. 10

Kohler K91 K141 K161 K181 K241 K301 K321 K341 Single Cylinder Engine Workshop Service & Repair Manual

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