Kohler K9J, KJ4J, KJ6J, KJBJ, K24J Service Manual

Single

Cylinder

Engine

K9J,

SERVICE

KJ4J, KJ6J,

MANUAL

K24J, K30J, K32J,

KJBJ,

K34J

CONTENTS

SECTION

1.

General Information

2.

Special Tools

3.

Periodic Maintenance

4.

Troubleshooting

5.

Air Cleaner And Air Intake System

6.

Fuel System And Governor

7.

Retractable Starters

......................................................

................................................

...............................................

....................................................

................................................

..................................

..........................................

.

II

.

II

.

SECTION

8.

Electrical Systems And Components

9.

Automatic Compression Release

10.

Disassembly

11.

Inspection and Repair

12.

Reassembly

.......................................................

..............................................

........................................................

.................................

.....................................

.

II

.

Ill

.

GENERAL INFORMATION

SAFETY INFORMATION

For Your Safety!

These safety precautions should

in serious injury to yourself

A

WARNING

and

SECTION 1

be

followed at all times. Failure to follow these safety precautions

others.

A

WARNING

A

WARNING

could

result

~

Explosive Fuel can cause burns.

Stop fuel

WARNING: Explosive Fuel!

Gasoline is extremely flammable and

its vapors can explode

nited. Store gasoline only in approved containers, in wellventilated, away from sparks fill the fuel tank while the engine is hot

or could with

hot tion. Do spilled fuel. Never use gasoline as a cleaning agent.

fires

and severe

engine before filling

tank.

if

ig-

unoccupied

running, since spilled fuel

ignite

if

it

comes in contact

parts

or

sparks from igni-

not

start the engine near

buildings,

or

flames. Do

not

~

Rotating Parts can cause severe injury.

Stay

away

while

engine

is

operation.

WARNING: Rotating Parts!

Keep hands, feet, hair, away from vent injury. Never operate the engine with covers, shrouds,

guards removed.

all moving parts to pre-

in

and

clothing

or

¥Af

Hot Parts

can cause severe burns. Do

not touch engine

operating or just after stopping.

WARNING: Hot Parts!

Engine components can tremely vent severe burns,

these areas while the engine is runningturned off. Never operate the engine with heat shields removed.

hot

from operq.tion.

or

immediately after

while

do

or

guards

not

get

To

touch

it

ex-

pre-

is

1.1

A

WARNING

A

WARNING

A

WARNING

~~~

Accidental Starts can cause severe injury or

death.

Disconnect plug

WARNING: Accidental Starts!

Before

equipment, always disconnect the spark gine from starting accidentally. Ground the lead to prevent sparks that

could

the equipment is in neutral.

A CAUTION: Electrical

.a

Never touch electrical wires components while the engine is running. They can electrical shock.

A WARNING: Overspeed Is

.a

Do

not

setting. Overspeed is hazardous

could

and

A WARNING: Flammable

.a

Carburetor cleaners are extremely flammable. Keep sparks, flames, of

ignition away from the area. Follow the cleaner manufacturer's warnings

proper gasoline as

and

ground

lead before servicing.

seNicing

plug

lead to prevent the en-

cause fires. Make sure

tamper with the governor

cause personal injury.

and

instructions

and

safe use. Never use

spark

-

the engine

Shock!

be

sources

Hazardous!

Solvents!

and

other sources

or

solvents

on

its

a cleaning agent.

of

Carbon Monoxide

can cause severe nausea,

or

fainting Do

closed

WARNING: Lethal Exhaust Gases!

Engine exhaust gases contain

sonous carbon monoxide. Carbon monoxide is odorless, colorless, and

can cause death

Avoid inhaling exhaust fumes, never run the engine in a closed building

death.

not

operate engine or

confined

or

confined area.

area.

in

if

inhaled.

poi-

and

A WARNING: Spring Under

.a

Retractable starters contain a powerful, flat wire recoil spring that is under tension. Do

center screw from the starter until the spring tension is released. Removing the center screw before releasing spring tension, starter disassembly, can cause the sudden

release

Always wear safety goggles when seNicing retractable face protection is recommended.

To proper reassembly, follow the procedures in this section carefully.

and

potentially dangerous

of

the spring.

ensure personal safety

starter disassembly and

Tension!

not

remove the

or

starters-

improper

full

and

~

Sulfuric Acid in batteries can cause severe injury or death.

Charge

only

in

well

Keep

sources of ignition

WARNING: Dangerous Acid,

Batteries contain sulfuric acid. prevent with skin, eyes, teries gas while vent a fire teries only in well-ventilated areas. Keep sparks, open flames, other sources

the battery at all times. Keep batteries move all jewelry when batteries.

Before disconnecting the negative (-) switches are will minal which sion vapors are present.

acid

produce

being

or

out

of

the reach

ground cable, make sure all

occur

at the ground cable ter-

if

hydrogen gas

ventilation.

away.

Explosive Gases!

To

burns, avoid contact

and

clothing. Bat-

explosive hydrogen

charged.

explosion, charge bat-

of

ignition away from

OFF.

If

could

cause an explo-

of

children.

seNicing

ON,

a spark

or

gasoline

To

and

pre-

Re-

1.2

ENGINE IDENTIFICATION NUMBERS

When ordering parts, involving an engine, always give the fication and serial

or

number

in any

of

the engine.

communications

model,

speci-

The engine identification

numbers

appear

on a

decal (or decals) affixed to the engine blower housing. Refer to Figure 1-1 . The significance of these numbers

is shown below:

A'iKOHLERI~[Jjll§lTilrJCcil

MODELNO

__........,..sPEC

B--

I~SERIAlNO

REFER

FOR

INSTRUCTIONS AND

PRECAUTIONS

NO

TO

OWNERS

OPERATION

00

HP

0000

0 0 0 0 0 0

0000000

MANUAl

MAINTENANU

SAFFTY

MODEL

NO

0 0 0 0

;;,:;

~~~w~'~

,0M~N~?,

FOR

OPERATION

INSTRUCTIONS AND

PRECAUTIONS

~~~~~~~:~;~~~~~~~

MAINHNANCE

SAFETY

._....,..__

'JS,~

c

SERIAL

NO

IIIIIIIIIIIIIIIIIIIIIIIIIII~WIIIIII111

000000000

1

A

B

c

Identification Decal

A. MODEL NO.

K 32 1 PT

K-Serles

Engine

Approximate

Displacement

(Cu.

ln.)

Single

Cylinder

Figure

1-1.

Version

A - Special Oil Pan C - Clutch Model G -

Generator

P - Pump Model

Q - Quiet Model

R - Reduction

S - Electric

T - Retractable

ST - Electric

Retractable

EP

- Electric Plant

Location

of

Identification

Code

Application

Gear

Start

And

Start

Engine

Decal.

B.

SPEC NO.

C.

SERIAL NO.

E - 1 7 2 4 5 2

u

A

Letter

1965

A

1966

B

c 1967

D 1968 E 1969

Engine

~

26, 27,

Model

31 28 29 30 46 47 60 71

9076430

LJ

First Two Digits I If Seven

Digit Number

10-19 1969 20-29 1970 30-39 40-49 50-59 60-69 70-72 1975 73-79 80-89 1977 90-94 95-99 1979

1971 1972 1973 1974

1976 1978

Remaining digits are a

Code

M.2.d..!tl

K91 K161 K141 K181 K241

K301 K321 K341

60

1248

l

Variation Basic

1 0 0 2 6 6 9 2

L__j

First Three Digits I If Eight Digit Number

100-109 1980

110-119 120-129 130-139 140-149 150-159

factory

1981 1982 1983 1984 1985

code.

of

Engine

1 5 0 1 8 9 7 5 9 1

LJ

First

Two Digits I

Digit Number

15 16 1986 17 18 19 20 21 22 23 24 25

1985 1987

1988 1989 1990 1991 1992 1993 1994 1995

If

Ten

Figure

1-2.

Engine

Identification

Decals.

1.3

OIL

RECOMMENDATIONS

Using

the

proper crankcase ly

important,

regularly.

oil

dirty

Oil

Use troleum the viscosity

time

causes

Type

high-quality

Institute)

of

operation

and in

Failure

type

the

as is

premature

detergent

Service

based

as shown in

and weight

gear

checking

to

use the

on

the

of

oil in

the

reduction unit is

oil daily and changing oil

correct

engine

oil

of

Class

air

temperature

the

wear

API

SF

table.

oil

(American

or

extreme-

or

using

and failure.

SG.

Select

at

the

engine

Pe-

NOTE: Using

or

extending oil recommended which is

A

logo

or

symbol

service

class and SAE

other

not

than

covered

on oil

Service

change

could

cause

by

containers

viscosity

Class

SF

intervals

the

grade.

longer

engine

engine warranty.

identifies

or

SG

than

damage

the

API

oil

Recommended

Straight and 1 OW-40

(0°C).

consumption

30-weight

are

Using

these

and

Shoulder of flange

SAE

Viscosity

oil is

preferred.

not

recommended

oils substantially

combustion

SAE 1 OW-30

above

chamber

Grades

32 °F

increases

deposits.

oil

Check

Check Check

drain should be up

level the drain plug.

NOTE: Do not

Oil

Level

oil lever gear

reduction uniot oil level by

plug on

is low,

cover,

plug hole, and

add

below the

dipstick.

remove

BEFORE

the

lower

to

the

oil until it

operate

the

"L"

EACH USE.

part

bottom

the

vented

reaches

replace

the

mark

removing

of

the

cover.

of

the

plug hole.

plug at

the

drain plug and vented

engine

or

over

with

the

Oil

the

bottom

the

oil level

"F"

top

of the

mark

Bayonet

the level If

oil

of

on

Remove from block Place Read level

Figure

1.4

on

shoulder

1-3.

Dipsticks And

Oil

Fill Tubes.

Push down on tube

level

Read

Change

For a new engine, hours operation

For an overhauled engine shortblock Service Class operation. Change the oil period. Refill with Service Class specified in ing hours

Oil

of

operation.

thereafter.

or

the

thereafter.

change

Change oil

miniblock, use straight

SF

or

SG

table. Change oil

oil

aft~r

or

one rebuilt with a new

oil

for

after

FUEL RECOMMENDATIONS

the first 5

every

the first 5 hours

25 hours

30-weight

this initial

SF

or

SG

every

run-in

oil as

25

operat-

of

Do

not use gasoline left over

gum

son, to minimize and to insure easy starting.

Do

not add oil to the gasoline.

Do

not overfill the fuel tank. Leave

fuel to expand.

deposits

from

the previous sea-

in

your fuel system

room

tor

the

Fuel Type

For best results, use only clean, fresh, unleaded gasoline with a higher. should be 90

In

pump

sticker

countries using the Research

octane

minimum.

octane

rating

of

87

method,

or

it

£ WARNING: Explosive Fuel!

Gasoline may system. Gasoline is extremely flammable and it can explode other sources connect and ground the spark the possibility

General Recommendations

Purchase gasoline

clean, approved containers. A container with a ca-

pacity of 2 gallons recommended.

and

helps eliminate spoilage during refueling.

be

present in the carburetor and fuel

if

ignited. Keep sparks, open flames, and

of

ignition away from the engine. Dis-

plug

lead to prevent

of

sparks from the ignition system.

in

small quantities and store

or

less with a pouring spout

Such a container

is

easier to handle

in

is

Unleaded gasoline less combustion line

may

be used available and exhaust emissions are not regulated. Be

aware however, that the cylinder head will re-

quire

more

frequent

is

recommended,

chamber

in

deposits. Leaded gaso-

areas where unleaded is not

service.

as it leaves

Gasoline/ Alcohol blends

Gasohol (up gasoline by volume) is approved as a fuel engines. proved.

to

10% ethyl alcohol, 90% unleaded

for

Kohler

Other gasoline/alcohol blends are not ap-

Gasoline/Ether blends

Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a volume) are approved as a Other

gasoline/ether

maximum

blends are not approved.

fuel

of

15%

for

Kohler engines.

MTBE

by

OIL REFILL QUANTITIES (U.S. STANDARD QUARTS)

K91

1/2

Quart 1 Quart

*

A-type

level,

K141, K161,

(After

oil pan

then

capacity

add oil as necessary

K181

refilling, always

varies

K241, K301, K321,

2 Quarts

check

from 1 to

to

1-3/4

bring up

Figure

K341 K241

oil level --DO

quarts.

to

full level.

On

1-4.

A,

K301

1 Quart*

NOT

OVERFILL)

these add 1 quart

A,

of

K321

oil,

A,

K341

check

A

1.5

HORSEPOWER

GENERAL

BALANCE

GEAR

CAMSHAFT

CONNECTING

ROD

CRANKSHAFT

CYLINDER

BORE

CYLINDER

IGNITION

cv-•

=z--,:;;.

0

./

--""

PISTON

®:..:~.~~

PISTON

~

®-}raJJ

"""'!:

PISTON

VALVES

(Maximum

En

ine

Model

Displacement Max. Operating

Shalt

0.0.

Sleeve

Small

PTO

Flywheel

M

End

A R

I Max. Taper (Sleeve)

N

Running

S Clearance

-(Sieevef

c

:f---M-a_x

~~-~M=ax~.~O~u~l~of~R~o~u~nd-~.........:_~oo=0~5-+~.o~o=o5~-t-~.o~oo~5=--~.........:.~oo~o=5.........:+~.o~o=o5~-t-~.0~00~5:_~.........:~.o~oo=5.........:~

ff--~~~~~~~.........:~:_-t-~~-t--~=---j--~~--jL_~~-~~~-t-~~--~

N

Max.

HD.

Spark

Plug

T~e

Gap

Nominal Point

Service Replacement Sizes

Thrust Face

o.D.(J)

Ring

End

Max. Ring Side Clearance

Service Replacement Sizes

Thrust Face

0.0.®

Ring hNr.:e;:;;w"Bo;:;re;;o":--tt-----+------t---·0_1_0i_.0_23_t-----+-·-01..,0.,..i.0:--2_0-t-·0_1_0i_.0_20_+-_.0_10,...i.-:-02_0--l

End

Max.

Outside Diameter .5623/.5625

Guide Reamer

c!appet

··r~~f~ce

MiTmum

(Zero Lash)

Minimum

Valve Stem

0.0.

Nominal Guide

w~::l~~Wmlf---Ex-h-

RPM)

Bore x Stroke

Cu.

.~axlmum

W&arlimil

End

Play

1.0.

Installed

End

Play

End

1.0.

(New)

&

Maximum

0.0.

wear

~~~-

~~~~e~el

Ma~~r:,um

f----'l~<L-...f--.....:::_--jf--.........:=--+-=--t-.....:::_--jf--.........:=--+-=--t--==-----1

wear

New

Ste1~v~a'l~~ring

New

__

~w~e~ar_L_im-il-~~.~93~5~0~~~1.~18~5~0~+--1~.1-8-50~-r-1~.4-99-0~~-1.-49_9_0_+--1-.4-9-90--r-1-.4-9-90-~

Max.

Taper

End

Play .004/.023 .002/.023 .002/.023 .003/.020 .003/.020 .003/.020 .003/.020

Oul

ol

Round

Max.

Taper

Oul

of

Flatness

Type®

BaHery

Magneto Gaseous

f--="cc:ew=---11--"2~.3~71:...:/2:...:.3~6~9

::::mr~,

New

Used

Gap

f--o..;;M;;cc";;'=;m=:'"""n--ll--.........:_=---+---=_=----t.::c=2=.9.::c31=+-~_=---+==3:.:.3...:6.:.:7=-t.::c=3::..4::.92=-=+=-"3.::_74:..:.4:....:.:.

~~~~:C~".'':.t&~

Gap

Use~::""

Ring

Side Clearance _ _

Size

f--~'"=ak=e--~~·0:.:05:...:/.=00~9--j.........:·=00~6~/.0:.:0:::8-+~·0:.:0::.6/~.0=08:_~~-U=08~/.::.01...:0--j~·::.00~8~/.0~1::.0-+~·0:.:0::.8/~.0~10:_~·=00:.:8/~.0~1=0®~

Exhaus•

f----'"'_ak_e

E•haust

Intake

r------+---~r----~-------t-----r-------t-----t------i

Exhaust

Angle

Valve

1.0.

Intake

2.375x2.000

RPM New

New

limit

Fuel:

Gap

M

New

ln.

li

I.D.

Bore Bore

'·

8.86

4000

.005/.020

.001/.0025

.003 .0007/.0008 .5630/.5633

.9841/.9844

.9841

11

ro

.9360/.9355

.001

2.3755/2.3745 2.9380/2.9370 2.9380/2.9370

2.378 .003 .003 .003 .003 .003

.003

RCJ-8

.025 .025 .018 .020

-+=2~.9.::c29:..:.7..::/2.:.:.9.::c28:..:1+='2.-"92:.:9.:c7/.::c2

2.366 2.925

.0035/.006 .007/.010

.007/.017 .007/.017

.027 .027 .006 .006

- -

_ _

.250

.0111.o15

__

~--~-2"'o3~5---+-~·.::c27~1=8---t--~·2:..:.7:...:18~-tc--~·3:..:.1~8--+---=·3_18~-t--~·c:.31~8---+--~·3~1=8--~

.1768 .2482 .2478 .2458

Seat 45' 45' 45' 45' 45' 45' 45'

.. -..

.005

---+--~.o=o"'7---+----":o~o7~~---:...:oo~7---+---:o~o...:8

2.938x2.500

16.94

.005/.010 .001/.002

.0025 .0006/.0011 .6255/.6258

1.1811/1.1814

1.1811

1.186011.1855

2.941 2.941

RCJ-8 RCJ-8

.62471.6249

.3125 .3125 .3125 .3125 .3125 .3125

.o17I.019 .o17I.019

.3103

.3088

2.938x2.750

3600

.005/.010 .001/.002

.0006/.0011 .6255/.6258

1.1811/1.1814

1.1811

_ _ _ _ _ _

1.186011.1855

.001 .001 .001 .001 .001 .001

.003 .003 .003

.025 .025 .035 .025 .025 .025 .025 .018 .020 .020 .020 .020 .020 .020

.007/.010 .007/.017

2.9329/2.9336

.0034/.0051

.62471.6249

005 005 006

3.251x2.875

18.64 3600

.4998/.5001

.002/.010

.005/.010

.0025

.003 .002 .002 .002

.018

2.925

.027 .030 .006

.032 .006

.2482 .3103 .3088

.001/.002

.0003/.0008 .8596/.8599

1.5745/1.5749

1.5745

1.5000/1.4995

3.251513.2505

·..:c92:.:8c..1

+'3:...:.2:.:4..:c32:...:/3:...:.2:.:4:...:13+"'3.-=-36~8-=/3.:.:.3..:c65

3.238 3.363 .007/.010 .007/.010 .007/.010 .010/.020 .010/.020 .010/.020

.8591/.8593

.o111.o19

3.375x3.250

23.85 3600

.4996

.0025

3.254

RH-10

.018 .018

.006

.318 .318 .318

.3103 .3103 .3103 .3103 .3074

.4998/.5001

.002/.010

.005/.010 .001/.002

.0003/.0008 .8757/.8760

1.5745/1.5749

1.5745

1.500011.4995 1.500011.4995 1.500011.4995

3.375513.3745

.003

- 3.3700/3.3693 3.4945/3.4938 3.7465/3.7455

- .0045/.0062

_ _

3.378 3.503

RH-10

.003

-

.003-

.8752/.8754 .8752/.8754 .8752/.8754

.o17I.019 .o17I.019

.3074

__

-r--~:o...:oa--~--_...::o"'o8~-t---:=oo~8--~

3.500x3.250

29.07 3600

.4996

.0025

.003

.035

.010 -.020 -.030

.030 .006

.010-

.030 .030 .006

006

31.27 3600

.4998/.5001

.4996

.002/.010

.005/.010 .001/.002

.0025 .0003/.0008 .8757/.8760

1.5745/1.5749

1.5745

3.5005/3.4995 3.7505/3.7495

.003

RH-10 RH-10

.035 .025 .018

-=-3.'-'49:.:4..::1/-=-3.~49:.:2c:.5

4

.020-

.0050/.0067

+'3:..:..

3.491

.030 .006

.030

.006 .006

.3074 .3074

006 006

3.

750x3.250

35.90 3600

.4998/.5001

.4996

.002/.010

.005/.010 .001/.002

.0025 .0003/.0008 .8757/.8760

1.5745/1.5749

1.5745

3.753 .003 .002 .003

.035 .025 .018

7:...:42:.:5...:/3:...:.

74.:..c1:.:0®

4

3.738®

.007/.010®

.010/.020

.030 .006

4

.0030/.0050

.030

.o111.o19

.318

CD

Maximum limits combination of

0.0.

measurements

®Ball

bearing 1.3779/1.3784, Maximum Wear 1.3779

(])Ball

bearing 1.7716/1.7721, Maximum Wear 1.7716

•

Includes

K141

1.0.

and

Figure

1.6

® Pre Series ®

BaH

bearing .002/.023

® Champion spark plugs or equivalent

(J)

Measure just below oil ring groove and at right angles

1-5.

Engine

II

1.3733/1.3738, Maximum Wear 1.3728

to

piston pin

Specifications

And

Tolerances.

® 1800 RPM generator sets .005/.007 ® Measure W' above the bottom

of the piston skirt.

~

Top

and center compression rings.

HORSEPOWER

CONNECTING

RODSCD

SPARK

CYLINDER

HEADCD

FLYWHEEL RETAINING

GOVERNOR

GRASS

SCREEN

OIL

PAN

MANIFOLD

CAMSHAFT

NON

METALLIC

MOUNTING

(Max.

RPM)

Engine

Model

Posi-lock®

Capscrew@

PLUGS

NUT

SCREW

BUSHING

Metal

Plastic

Aluminum

Cast

Iron

Sheet

Metal®

SCREW/NUT

NUT

FUEL

PUMP

SCREWS

~

-

140

ln.lbs.

18·22 ft. lbs.

ps

((J1

~

K91 200 ln. lbs.

~4

2 a

0

40·50 ft. lbs.

250 in. lbs.

70-90 in. lbs.

-

250 in. lbs.

-

~

9}

X,

1

New 140 ln. lba.

-

Used 100 ln. lbs.

200 ln. lbs.

18·22

fl.

lbs.

p,

0'

~)

K161,

K181

~

15-20

fl.lbs.

3 0

\,_25

(QJ2

85-90 fl.

lbs.®

-

130·150 in. lbs.

70-140

in. lbs.

-

Grade

5-250

Grade 8--350 in. lbs.

in. lbs.

-

37·45 in. lbs.

K321

(ll6

K301

New 260 ln. lbs.

Used 200 ln. lbs.

2851n. lbs.

18-22 ft. lbs.

([jl I

50·60

fl.

lbs.

22-27

ft.

100-120 in. lbs.

70·140

in. lbs.

20·30 in. lbs.

IXI%1~

~IQJ

8

(QJ 4 (QJ

.

IQJ

01

I K241, 9

rQJ

K301,

25-30 ft. lbs.

6

3

l_SdJs

(ji2

-

35

fl.lbs.

200 in. lbs.

-

37·45 in. lbs.

K321

(7

(Q!a

(QJ

I

(QJ

I 9 25-30 ft. lbs.

·~~·,,}

25

(QJ2

lbs.

~

1

1o(Ql,

(ji6

K341

IQJ9

USE STANDARD TORQUE SETTINGS WHEN

SPECIFIC VALUES ARE NOT SPECIFIED.

CD

Lubricate with engine

®

DO

NOT overtorque

NEW-

Component directly from stock.

USED-

Component that was

Cast Iron or Steel

Grade 2

Size

0

----=-=

20 32 32

150 260

300

35ft. 45ft. 50 70ft.

75ft. 100ft. 110ft. 140ft. 150ft. 200ft.

in. lb. in. lb. 1n. in. ln. ln. ln. in. lb. in. lb.

ft.

8-3~

10-24 10-32 1/4-20 70

1/4-28 85 5/16-18 5/16-24 165 3/8-t6 3/8-24 7/t6-14 7/16-20

1/2-13

1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16

Conversions

oil

-loosen

-and in

Grade s•

Q

i--=-

--

lb.

115

lb.

140

lb. lb.

250 270

lb.

lb. lb. lb. lb.

105ft. 125ft.

lb.

t65

lb.

180ft.

lb.

230ft.

lb.

245ft.

lb.

325ft.

lb.

in. lbs. x .083 =ft. lbs.

ft. lbs. x ft.lbs.

ft.

lbs. x 1.3558 ~ N m

retorque the hex nuts on Pos1-Lock connecting rods.

a running engine.

25

ln.

lb.

40

ln.

lb.

40

ln.

lb.

ln.

lb

ln.

lb

1n.

lb.

1n.

lb

35ft.

lb.

40ft.

lb

55ft

lb.

75ft.

lb.

80ft.

lb. lb. lb.

ft.

lb. lb. lb. lb. lb.

12

~in.

x

.1383~kgm

Grade 8

@

165

ln.

200

ln.

350

ln.

30ft. 50

ft. 60ft. 80ft.

105ft. 115ft. 165ft.

~75ft.

230ft. 260ft. 330ft. 350ft. 470ft.

lbs.

lb. lb.

lb. lb. lb. lb. lb. lb. lb. lb.

lb.

lb. lb. lb. lb. lb.

OIL

DRAIN

at

150 180

20 ft. lbs. 25 ft. lbs.

20·25

PLUGS

Assembly)

Tightening

in. lb. in.

lb.

ft. lbs.

Torque

Aluminum

100 120

13 ft.lbs. 16

20·25

Pans

in.

lb.

in.

lb.

ft.

lbs.

ft.

lbs.

(Oil

~

1/4" 3/8" 1/2" 3/4"

X-708-1@

® Overtorque 20%, loosen below torque value and retorque to

®Torque

twice with minimum of one minute interval

<ID

3/8~16

thread with hex head nut and fibre gasket

® Pnor

to

Ser.

#23209832 45-55 ~-lbs.

Cast Iron Pans

f1nal

torque value

•

Includes

K141

Figure

1-6.

Torque

Values &

Sequences

For Fasteners.

1.7

SECTION 2

SPECIAL TOOLS

SPECIAL SERVICE TOOL KIT

These quality tools are designed form

specific procedures. By using tools designed you can service engines easier, faster and safer! In

addition, you·

customer

and

time.

down The Special Service Tool Kit No.

ordered tools can be Kohler Engine Distributor

disassembly, repair and reassembly

II

increase

satisfaction by decreasing engine

complete

as shown

ordered

your

individually. Contact

for

NO.

3211-A

to

help you per-

for

the

job,

service capabilities

3211-A

in

Figure 2-1

price and availability.

can be

or

the

your

Figure

2-1.

Special Service Tool Kit

2.1

VALVE

SERVICE

TOOLS

TOOL NO. &

VALVE SEAT PULLERS Removal

11726 11913

FORCING SCREW Used 11915

ADAPTER

11918

VALVE SEAT INSTALLER

11811 seats. Use 11812

SLIDE

3222

11799

Weight

12244

Slide

3268 VALVE GUIDE REMOVAL KIT

11838

Stud 3 1/2"

12100

Stud 2 1/2"

11800

Adapter

0917

Nut

12008

Nut

NAME

HAMMER

Bolt

adapter, 3222

forcing

pullers

Used

to

Used

Provides and

Used slide

screw

with

11726 & 11913

to

connect

slide

hammer

to

install

guide

to

pull

hammer

APPLICATION

of

valve seats, Use 11918

slide

hammer

valve seat

intake

with

pulling

removal. Use 4747

valve

and

exhaust

4747

handle

force for valve seat

guides

with

& 11915

pullers

handle.

3222

ILLUSTRATION

~

Ct==tP

©

~

(

llB~ii

:~~~

3224 VALVE GUIDE INSTALLER KIT

12325 Driver 11763 Driver 11770Gage 11771 Gage

REAMERS (Valve Guide)

11843 5/16" 11844 1/4"

SEAL

3223 SEAL INSTALLER KIT Used

11782 Seal 11783 Seal 11784 Seal 11785 Seal 11786 Seal 11787 Seal 11790 Seal

11791 Seal 11792 Seal 11793 Seal 11795

Installer Installer Installer Installer

Installer Installer Installer Installer Installer Installer

Handle

Used proper 11770 & 11771

To ream valve

AND

damage 11795

to

install

valve

depth.

Use 11763

depth

guides

BEARING

to

install

seals

and

to

proper

handle

with

installers

guides

gages

to

driver

with

INSTALLERS

without

depth.

Use

~

cw

c(

(])

v

X:1~

2.2

SEAL

AND

BEARING

INSTALLERS

TOOL NO. & NAME

3242 SEAL PROTECTOR SLEEVE KIT

12021

12020 12022 12127 1.50 12128 1.44

3241

12014 Ins. (Crank 12015 Ins. (Cam Bushing) 12016, 12017, 12018 & 12109

.75"

1.25 12126 1.12

BEARING INSTALLING KIT

Brg.

Installers

1.00

Bushing)

Used on seals

Used bearings

OTHER

3226 FLYWHEEL PULLER KIT

12485 Puller

5108 12505 12504 12506 Storage Bag

FLYWHEEL STRAP WRENCH Used 10357

Bolt BoltBolt-

w/forcing

- 1/4"

w/washer

10-24

3/8"

w/washer

screw

(3)

w/washer

(2)

Used bearing

removal

APPLICATION

crankshaft

to

prevent

to

install

and

bushings

when

damage

& remove

installing

engine

APPLICATIONS

to

remove

plates

to

hold

flywheels

from

engine

flywheel for nut

and

ILLUSTRATION

a

@

<(((

((

r

~~

~

~~

J J

)

~

OFFSET

11797 Wrench 1/2"

4923

FEELER GAGE

11767

TIMING GAGE

10355

SCRAPER

11762

HANDLE

4747

TOOL BOARD AND HOOK SET

12033

WRENCH

Wrench

Timing

Handle

9/16"

Gage

Used

to

remove &

barrel

retaining

to

Used backlash

Used position

Used without

Used hammer, and valve seat

Used

set

on

to

hold

when

to

scrape

damage

with

to

store and

bearing

install

nuts

oil

pump

twin

cylinder

balance

assembling

machined

installers,

identify

drive gear

gears in

cylinder

engine

timed

engine

surfaces

slide

installers

tools

n

~-

~

I

~

SEE FRONT PAGE

:=J

o)

2.3

KIT

3222 3268 Valve

NO.

VALVE TOOLS

11726 Valve Seat 11913 Valve Seat 11915

Forcing

11918

Adapter 11811 Valve Seat 11812 Valve Seat

Slide

12325 Valve 11763 Valve 11770 Valve 11771 Valve 11843 Valve 11844 Valve

3211

PART NO & NAME

Screw

Hammer

Guide

Guide Guide Guide Guide Guide Guide

1

KT19

-A

Puller Puller

Installer Installer

Removal Kit

Driver Driver (depth) Depth

Gage

Depth

Gage

Reamer

engines

5/16"

1/4"

prior

to

TOOL

......

co

0)

...... ......

~

•

• •

•

• •

•

• • •

• • • •

•

Series

II

USAGE

MODEL("

...... ...... ......

..,.

co

~

• •

•

• •

......

N

0

M M

C?

~ ~

•

• •

•

• •

•

K"

• • • • •

•

• •

(Spec

No.

CHART

SERIES)

.....

......

..,:..

~

0)

......

..,:..

~

......

..,.

~

• • • •

•

• •

•

• •

•

• • •

•

• •

(1)

•

49199

and

N N

M

co

LO

U?

~

•

• •

•

lower).

BEARING

12014

Installer-

12015

Installer-

12016

Installer-

12017

Installer12018

Installer-

12019

Installer11782

Installer

11783

Installer-

11784

Installer 11785

Installer

11786

Installer-

11787

Installer

11790

Installer-

11791

Installer

11792

Installer-

11793

Installer-

11795

Handle-

12020 Seal Sleeve 12021 Seal Sleeve 12022 Seal Sleeve

12126 Seal Sleeve 12127 Seal Sleeve 12128 Seal Sleeve

- Seal (PTO)

Crank

Cam

Bushing Bearing Bearing Bearing

Bearing

Seal

(Flywheel)

Seal

(Flywheel)

Seal

(Flywheel)

Seal

(Flywheel)

Seal

(Flywheel)

Installer

AND

Bushing

(PTO)

Seal

SEAL

INSTALLERS

•

• • • •

• • •

• •

•

USE AS REQUIRED USE AS REQUIRED USE AS REQUIRED USE AS REQUIRED USE AS REQUIRED USE AS REQUIRED

•

• •

•

• •

•

10357

Flywheel

11797

Offset

4923

Offset

11767

Feeler

10355

Timing

11762

Scraper 4747 Drive 3226

Flywheel

NOTE: K141

2.4

Strap

Wrench

Gauge-Crank(OII

Tool

Handle

Puller

requires

MISCELLANEOUS

Wrench

'/2'

9/16"

(Balance

Kit

same

1/2"

• •

Pump)

Gear)

•

• •

tools as K161.

• • • • •

•

TOOLS

•

• •

•

• •

•

• •

•

• •

•

• •

•

• •

•

Digital

Engine

Thermocouples

Tachometer

Analyzer

Digital

Slack

Thermometer

Tube

Manometer

Digital

Voltmeter

Figure

2-2.

The Kohler Engine Analysis Kit contains a selection of

instruments

critical

items You will find from

basic

cated

application

The kit includes

Qty.

1 1 1 Digital 1 1 1

3

which will enable you

that relate

many

crankcase

uses

vacuum

to for

engine

these

checks

tests.

the

following:

Description

Digital Digital

Voltmeter Tachometer Thermometer

Digital Engine Analyzer Slack Tube

Manometer

8 Ft. Lead With Plug

mm

14

Spark Plug

to

measure

performance.

instruments

to

sophisti-

-

Thermocouple

2 Head Bolt

1 Oil 1 1 1 1 1 1

Sump

/4"

318" x 1

1/2" X 1/8" 3/4" X 1/8" Tube With Fittings

1 Carrying

3

Plain

Thermocouple

x 1

/8"

Bushing

/8"

Bushing Bushing Bushing

Case

Thermocouple

Engine

Analysis

The

Kit

voltmeter,

gine analyzer circuitry the

and digital readouts. Guidelines

instruments

feature

the instruments

• Measure

temperatures

• spark plug base

• oil

sump.

• air into flywheel and

• Measure engine

• Measure

system

crankcase

back

• Measure voltage.

• Measure charging

• Measure

electric

The Engine Analyzer Kit can as shown,

vidually.

or

the

Contact

and availability.

tachometer,

state

and

for

testing

in

the kit you will

gasket/cylinder

carburetor.

speed

vacuum

pressure.

system

starter

instruments

your

Kohler Distributor

Carrying

thermometer

of

the

art

are

be

of

-

(RPM) .

and exhaust

current.

current

be

ordered

can

be

Case

and

en-

electronic

for

using

included. Using

able to:

head bolt.

(Amp}

draw.

complete

ordered

for

indi-

price

2.5

SECTION 3

PERIODIC MAINTENANCE

REQUIRED

These required maintenance procedures should be

MAINTENANCE

Required Maintenance

Check Clean Clean/Replace Fuel Filter

Clean Foam Precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hours*

Change Check Optional Reduction

Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hours

Clean Cooling Fins and

External Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hours*

Clean Paper Air

Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 00 Hours*

Check Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 00 Hours

Check

Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Hours

Clean Cylinder Head and Combustion Service Starter

Motor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annually

• Perform these maintenance procedures

Oil

Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily

Grass Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily*

..........................................

Oil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hours

Valve-

extremely dusty and dirty conditions.

To-

Tappet

Chamber*

..............................................

performed

more

frequently when engine is operated under

at the

frequency

stated

As Required

or

in

the table:

Frequency

500

Hours**

500 Hours

*

• 250 Hours when leaded gasoline is used.

~

WARNING: Accidental Starts!

Before remove the spark starting accidentally. Ground the lead to prevent sparks that

CHECK

The proper oil phasized. Check oil

seNicing

OIL

importance

the engine

plug

to prevent the engine from

could

cause fires.

LEVEL

of checking and maintaining the

level in crankcase cannot be

BEFORE

or

equipment, always

EACH

USE

overem-

as follows:

1. Make sure the engine is stopped, level, and is cool so the oil has had sump.

2.

Clean the area around oil fill fore removing etc.,

out of the engine.

3. Remove sert dipstick and push it tube. Remove dipstick and

4.

On

engines with threaded

shoulder plug on

oil fill

to

keep dirt, grass clippings,

cap/dipstick;

top

time

to

drain into the

cap/dipstick

wipe oil off. Rein-

all the way down into

of

check

type

hole

the level.

plug dipstick,

to

observe level.

be-

3.1

The oil level should "F"

mark

on

the

dipstick. Refer

be

up to, but not over, the

to

Figure

3-1.

Precleaner

If

so

equipped, every tremely

25 operating hours

dusty,

wash and reoil

(more

dirty

conditions).

the

precleaner

often

under

ex-

Figure

5. Add the Always adding

CAUTION:

CHANGE

For a new engine, hours

of thereafter.

hours those rebuilt with a use straight for

the first 5 hours

after

this initial

hours

thereafter.

warm

from

carry

away

proper

check

more

oil.

Never

operate below stick.

"L"

OIL

operation. Change oil

For an overhauled engine

30-weight

run-in

Drain oil while the engine is still operation. The oil will flow freely and more

impurities. Change oil as follows:

t

Operating Range

__l_

L

3-1.

Oil Level Range.

type

of

oil if the level is low.

the level with dipstick

the engine with the oil level

mark

or

over

"F"

change

new

of

oil

after

the first 5

every

shortblock Service Class operation. Change the oil

period. Change oil

or

SF

before

mark

on

dip-

25 operating

or

miniblock,

or

SG

oil

every

25

1 . Remove

the

2.

Rinse detergent water (do not wring). dry.

3. Saturate Squeeze out excess oil.

4. Reinstall

precleaner

are eliminated. Squeeze out excess

precleaner

from

paper

in warm

thoroughly until all

water

Allow

precleaner

in

clean, fresh engine oil.

over

paper

element.

with

element.

detergent.

traces

to

Paper Element

Every 100 tremely element. Replace the element as necessary.

1.

Remove the precleaner (if so equipped), element cover, and paper element.

2.

Replace a dirty, bent, a genuine Kohler element. Handle new elements faces are bent

NOTE:

Reinstall the paper element.

3.

4.

Install the precleaner (cleaned and oiled) over the

hours

dusty

carefully; do not use of the sealing sur-

Do

not wash the paper element

pressed air as this will

paper

of operation

or

dirty conditions),

or

damaged.

element.

(more

damaged

damage

often under ex-

check

the paper

element with

or

element.

use

Wash

of

air

com-

1. Remove engine

better

2.

Reinstall ened securely.

Fill with new oil

3. mark on dipstick the engine is oil.

SERVICE

K-Series paper

also

are which surrounds the ure

3-2.

the

oil drain plug and dipstick. Tilt the

slightly towards the drain hole to obtain

drainage.

the

drain plug. Make sure it is tight-

of

the

on

the

AIR

engines are

air

cleaner

equipped

proper

dipstick. Always

before

adding

level when filling and checking

CLEANER

equipped

element.

with an oiled

paper

Some

element.

type

check

more

with a

specifications

foam

3.2

to the

oil. Make sure

high-density

precleaner

Refer

"F"

the level

to

Fig-

5.

Install the air cleaner en wing nut. Make sure element is sealed tightly against air cleaner base.

cover

and wing nut. Tight-

Inspect Air Cleaner Components

Whenever the air cleaner icing the element components:

Air

Cleaner Base - Make sure it

carburetor Element

New Look is not bent nut

is cleaner base and 50 in. lb. torque.

Breather

cleaner base and breather

and is not

Cover

~ngines

or

secured tightly to seal

Tube

or

and

only,

damaged.

element

- Make sure it

cover

precleaner,

bent

or

Element

make

Check

element

cover. Tighten nut to

cover.

is

removed,

check

is

damaged.

Cover

sure

that element cover

is

sealed tightly

the following

secured tightly to

Nut -On

element

between air

or

serv-

K181

cover

in

air

"'--

PRECLEANER

(OPTION)

Figure

NOTE: ponents could allow unfiltered air into the engine causing damaged

Damaged, worn,

premature

or

wear and failure. Replace all

worn components.

or

loose air cleaner

3-2.

Air Cleaner Components.

com-

CLEAN AIR INTAKE/COOLING AREAS

To ensure screen, cooling fins, and other external surfaces of engine are kept clean at operating hours dusty, dirty conditions), remove the blower housing and fins and external surfaces as necessary. Make sure the cooling shrouds are reinstalled. Refer to

the

"Disassembly"

cooling shroud removal and installation proce-

dures.

NOTE: screen, dirty ing shrouds removed due to overheating.

proper

other

Operating the engine with a blocked grass

cooling, make sure the grass

all times. Every 50

(more

cooling shrouds. Clean the cooling

or

plugged cooling fins,

often under extremely

and "Reassembly" sections

and/or

will cause engine damage

cool-

CHECK SPARK PLUG

for

Ground Electrode

Figure

1 . Before removing spark plug, clean the area

around the base of plug to keep dirt and debris out of engine.

3-3.

Servicing Spark Plug.

Every 1 00 operating hours, remove the spark plug,

check

new plug as necessary. Refer

its condition, and reset gap

to

or

replace with

Figure

3-3.

2. Remove the plug and place the plug if worn able.

check

or

its condition.

if reuse is question-

Re-

3.3

NOTE: Do not clean the spark plug using abrasive grit. spark plug and wear and

3.

Check gap by

enter

damage.

gap

using a wire feeler gauge. Adjust

carefully bending the ground electrode.

Some

grit could remain

the engine causing extensive

in

a machine

in

4. Reinstall

plug

spark

to

18/22 ft. lb.

plug into cylinder head. Torque

SERVICE OPTIONAL REDUCTION GEAR UNIT

On

engines check hours. Refer

equipped

the oil level

to

Figure

with a reduction

in

unit

every

3-4.

gear

50 operating

unit,

Figure

3-5.

In-line

Fuel Filter.

SERVICE STARTER MOTOR DRIVE

Every 500 operating hours occurs of

1. Remove

2. Remove dust

first) , clean and lubricate the drive splines

the Bendix-drive

starter

propriate

spacer, spring, dust pinion.

electric

from

"Disassembly"

cover,

or

annually (whichever

starter

crankcase. (Refer

stop nut, stop gear cover

motor.

section.)

spacer, and drive

to

ap-

Drain Plug (Oil Level

Figure

1 . Remove the plug on the lower part of

cover. to the

2.

To add oil,

of

top used

3.

Reinstall and tighten the plugs securely.

3-4.

Reduction Gear Unit.

With engine level, the oil should be up

bottom

the unit. Use the

in

of

the plug hole.

remove

the engine crankcase.

the vented fill plug at the

same

type of oil as

Check)

gear

unit

CHECK FUEL FILTER

Some filter. Visually

to

engines are equipped with

inspect the filter periodically. Re-

place when dirty with a genuine Kohler filter. Refer

Figure

3-5.

an

in-line

fuel

3.

Clean the drive shaft splines with solvent. Dry solvent thoroughly.

4.

Apply a small drive

lubricant (Part No.

NOTE: Kohler

357 01) must be used on all Kohler drives. The use drive to stick

5.

Apply a small stop nut threads. Assemble drive parts

verse

6. Reinstall

order

160 in. lb.

priate

"Reassembly"

amount

starter

of

other

or

bind.

amount

of

removal. Torque stop nut

starter

to

of

Kohler

52

drive lubricant (Part No.

lubricants can cause the

of

Loctite®

crankcase. (Refer

section.)

electric

357 01)

electric

No.

to

splines.

271

in

to

starter

52

starter

to

re-

to

appro-

CLEAN CYLINDER HEAD AND COMBUSTION CHAMBER

Every 500 operating hours (250 hours when leaded gasoline is used) , combustion

remove

chamber.

cylinder head and clean

Refer to Figure

3-6.

3.4

~1

Figure

1 . Remove the cylinder head baffle and cylinder

head.

2. Clean away wooden

3. Reinstall the cylinder head using a new gasket. Torque the cylinder head fasteners quence

CHECK

Every 500 operating hours, cover flat feeler gauge. Refer to Figure must

1 . Remove the air cleaner assembly, carburetor,

and "Disassembly"

2.

Position the crankshaft so the piston of

tappets).

3-6.

Cleaning Cylinder Head And Combustion Chamber.

combustion

or

plastic scraper.

to

the values specified

VALVE-

and

check

be cold when checking this clearance.

breather

compression

TO-

valve-to-tappet

assembly. (Refer

section.)

stroke

deposits using a

TAPPET

remove

(cam

has no

in

se-

in

Figure

CLEARANCE

breather/valve

clearance with a

3-8.

The engine

to

appropriate

is

effect

3-7.

at top

on

K161, K181 • 15-20

0)2

7©8Q)14(Q)

Q)

©

3

Q5

K241,

K301, K321

25-30

ft. lbs.

9

©

ft. lbs.

~6

Figure

3-8.

Measuring ValveClearance.

To-

Tappet

Q)

3

g5

* Includes

Figure

3-7.

K341 25-30

ft. lbs.

g2

K141

Cylinder Head Fastener Tightening Sequence.

3. Measure

valve-to-tappet

clearance with a flat feeler gauge. On

Model

clearance is too small,

grind the valve

K91, K141, K161,

remove the valves and

stems

until the

K181

correct

-If

the

clearance is obtained. Make sure valve stems are ground perfectly flat and smooth.

Model Intake Valve Exhaust Valve

K91 K161,K181 K241, K321,

If

K301 K341

clearance is too large, replace the valves and

Figure

.005" I .009" .006" I .008" .008" I .01

3-9.

0"

Valve Clearances

.011

"/.015" .017"/.019" .017"/.019"

recheck clearance.

NOTE: grinding the valves the for

On

Large clearances can also be reduced by

and/or

valve seats. Refer to

"Inspection And Repair/Reconditioning" section

valve specifications.

Models

K241, K301, K321,

K341

- Adjust the clearance by turning the adjusting screw on tappets. Refer to Figure

3-9.

STORAGE

If the engine will be out mately two months storage procedure.

1 . Change the oil when engine is still warm from

operation. Refer to "Change

2. Change the oil equipped. Refill with the engine crankcase fer

to "Service Optional Reduction Gear Unit. "

Run

engine

for

clean oil throughout engine.

3. Drain the

fuel tank and fuel system (or run engine until fuel tank and fuel system are empty).

4. Remove the spark plug. Add one tablespoon of engine oil into the spark plug hole. Install

by do not connect plug lead. Crank the

plug, engine two

or

5. Remove the spark plug. Cover the spark plug

with

hole

thumb piston is at the top of its stroke (pressure against thumb is greatest). do not connect plug lead.

of

service

or

more,

use the following

Oil."

in

reduction

gear

same

for

season of operation. Re-

a few minutes

to

three revolutions.

and turn engine

Reinstall plug, but

for

approxi-

unit, if so

oil as used

distribute

over

until the

in

Figure

3-10.

Clearance Through

Adjusting

K341.

Valve-

Models

To-

Tappet

K241

6. Clean the exterior surfaces of engine. Spread a light film of oil over any exposed metal surfaces of engine to prevent rust.

7. Store the engine

in

a clean, dry place.

3.6

SECTION 4

TROUBLESHOOTING

When trouble occurs, be sure to causes which, at first, be considered. For example, a starting problem

could be caused Some

listed below. Use this as a guide to locate trouble

causing factors.

Engine Cranks But

1 . Empty fuel tank.

2. Fuel shutoff valve closed.

3. Clogged fuel line.

4. Spark plug lead disconnected.

5. Keyswitch

6. Faulty spark

7. Faulty ignition.

8. Dirt

Engine

1 . Restricted

2. Dirt

3. Faulty choke

4. Loose wires

5. Carburetor improperly adjusted.

6. Faulty cylinder head gasket.

7. Faulty fuel pump.

Engine

1 . Hydrostatic transmission not

2. Loose wires

3. Dirt

4.

5. Faulty choke

6. Faulty spark plug.

7. Carburetor improperly adjusted.

8.

9. Low compression.

10. Faulty

Engine Will Not Crank

1 . Hydrostatic transmission is not

common

or

water

Starts

or

water

ground.

Starts Hard

drive is engaged.

or

water

Clogged

Incorrect

ACR

drive is engaged.

by

causes

or

kill switch

plug.

in

But

Does Not Keep Running

fuel tank vent.

in or

or

in

or

restricted fuel lines.

or

valve-to-tappet

mechanism.

GUIDE

check

may

seem too obvious to

an

empty of

Will Not Start

fuel system.

throttle controls/cables.

connections shorting ignition to

connections.

fuel system.

throttle controls/cables.

fuel tank.

engine troubles are

in

"off"

in

clearance.

the simple

position.

neutrai/PTO

in

neutrai/PTO

2. Battery is discharged.

3. Safety interlock switch is or

4. Loose

5. Faulty keyswitch

6. Faulty electric starter/starter solenoid.

7. Retractable starter not engaging

8. Seized internal engine components.

Engine Runs

1 . Dirt

2. Spark plug lead loose.

3. Loose wires ing ignition to ground.

4. Carburetor improperly adjusted.

5. Engine overheating.

6.

Incorrect

Engine Will Not Idle

1 . Idle speed adjusting screw improperly set.

2. Dirt

3. Idle fuel adjusting screw improperly set. Fuel tank vent restricted.

4.

5. Faulty spark

6. Incorrect

7. Low compression.

Engine Overheats

1 . Grass screen, cooling fins

clogged.

2. Excessive engine

3. Low crankcase oil level.

4. High crankcase oil level.

5. Carburetor improperly adjusted.

Engine Knocks

1 . Low crankcase

2. Excessive engine load.

Engine Loses Power

1 . Low crankcase oil level.

2. High crankcase oil level.

3. Restricted air cleaner element.

4. Dirt

5. Excessive engine load.

6. Engine overheating.

7. Faulty spark

8. Carburetor improperly adjusted.

faulty wires

But

or

water

valve-to-tappet

or

water

valve-to-tappet

or

water

plug.

or

Misses

in

fuel system.

or

connections intermittently short-

in

fuel system.

plug.

load.

oil level.

in

fuel system.

"engaged"

or

connections.

ignition switch.

in

clearance.

or

shrouding

.

drive cup.

II

4.1

9. Low compression.

Engine Uses Excessive Amount of Oil

1. Incorrect oil viscosity or

2. Clogged

system.

3. Worn

4. Worn cylinder bore.

5. Worn valve

improperly assembled breather

or

broken piston rings.

stems

or

and/or

type.

guides.

EXTERNAL ENGINE INSPECTION

0 Before cleaning

check

This inspection can give clues to what might

be found inside the engine (and the cause)

once

its external appearance and condition.

it is disassembled.

or

disassembling the engine,

CLEANING THE ENGINE

After inspecting the external condition of the engine, clean it thoroughly before disassembling. Also clean individual components as the engine is disassembled. inspected and gauged

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

sure all traces of the cleaner are removed before the engine is reassembled and placed tion. Even small amounts of these cleaners quickly break down the lubricating properties of engine oil.

BASIC ENGINE

Only clean parts can be accurately

for

wear

or

damage.

instructions carefully. Make

in

opera-

TESTS

for

0 Check

crankcase, cooling fins, grass screen and other external surfaces. Dirt or debris areas are causes of overheating.

0 Check

aged components. Excessive oil leakage can indicate a clogged breather, worn or

loose

0 Check the air cleaner cover, element cover

and air cleaner base

of improper fit

0 Check the air cleaner element. Look for holes,

tears, cracked

other damage that could allow dirt to enter the

engine. Also note if the element is clogged

restricted. These conditions could indicate that

the air cleaner has been underserviced.

0 Check the carburetor throat for dirt. Dirt

throat is further indication that the air cleaner is not functioning properly.

0 Check the oil level. Note if the oil level

within the operating range it is low

0 Check the condition

into a container - it should flow freely. Check for

metal chips and other foreign particles.

NOTE: away from the workbench.

time

Sludge is a natural small accumu_lation formation could indicate that the oil has not been changed as weight

settings

It

for

of

buildup of dirt and debris on the

in

these

for

obvious fuel and oil leaks and

or

improperly assembled

or

damaged seals and gaskets

or

improperly torqued fasteners.

for

damage

or

seal.

or

damaged sealing surfaces or

on

or

overfilled.

of

the oil. Drain the oil

is good practice to drain oil at a location

Be

sure to allow ample

complete

oil has been used,

or

weak ignition, to name a few.

drainage.

by-product

is

normal. Excessive sludge

recommended,

of combustion; a

an

over-rich

or

the dipstick,

incorrect type or

dam-

indications

in

is

or

carburetor

or

the

Fuel System Test

To

determine if fuel is getting disconnect the fuel line at inlet to carburetor - if fuel does not flow out of line, to tank cap, blocked filter screen, faulty fuel pump, etc. fuel is getting as far as the carburetor, remove the spark plug, crank engine and inside combustion chamber. here, check

for

clogged lines, wrong (unvented) filler

for

faulty carburetor.

to

the carburetor,

check

If

system back

check

no fuel is present

for

If

fuel

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. 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 the ignition system further. If points are pitted, don't bad shape. Dirty points may be cleaned. A bad condenser will cause premature failure of points.

if

Check the breaker push rod ing

or can be tested on commercial manufacturer's instructions. Check ignition coil coil tester for continuity.

or

a weak spark is produced,

attempt

sticking - replace as needed. Condenser

to service them - replace points

for

evidence of bind-

tester

per tester

If

check

a

in

on

Crankcase Vacuum

A partial vacuum should exist

when the engine is operating at normal temperatures. Pressure

by a clogged or improperly assembled breather)

can cause oil to be forced out at oil seals, gaskets

or

other available spots.

Crankcase vacuum is best measured with a slack tube manometer. The

in

the crankcase (usually caused

manometer

in

the crankcase

included

in

the

4.2

Kohler Engine Analysis Kit is

to

the

"Special

tion.

Tools"

section

Crankcase Vacuum Test

recommended.

for

more

informa-

Refer

side.

If

there

side is the

pressure engine side) following table.

same

(level

check

is no

vacuum

as in open side)

in

open side is higher than

for

(level

the conditions

in

engine

or

a positive

in

the

To

test

crankcase

1. Insert the Leave the to

the

atmosphere.

clamp

2.

Start the engine and run at high speed (3200 to 3600

3.

Open the the be 5

1.

Crankcase

2.

Seals

improperly

3.

Piston inspecting

is closed.

RPM)

tube.

to

1 0 inches above the level

and/or

blowby

vacuum

stopper

other

vent

.

clamp The level

and note the water level

Possible Cause

breather

gaskets leaking. Loose

torqued

or

leaky valves.

components.)

with the

hose into the oil fill hole.

of

the

manometer

Make sure the shutoff

in

the engine side should

NO

CRANKCASE VACUUM/PRESSURE

clogged

fasteners.

or

manometer:

in

inoperative.

or

(Confirm

open

in

the open

by

4. Close the shutoff engine.

clamp

before

Compression Test

Because these engines are matic

compression release difficult ing.

To

and related crankcase

1.

Disassemble breather, clean parts reassemble, and recheck pressure.

2.

Replace all Make sure fasteners are

appropriate

necessary.

3.

Recondition

and valve guides.

to

check

obtain an

the condition

mechanisms,

vacuum

IN

CRANKCASE

worn

torque

piston, rings,

accurate

test

Solution

or

damaged

values and sequences when

equipped mechanism

of

the

physical inspection and a

are

recommended.

tightened

cylinder

shutting

with an auto-

compression

combustion

thoroughly,

seals and gaskets.

securely. Use

bore, valves,

off

(ACR), it is

read-

chamber

the

II

4.

Restricted exhaust.

MEASURE

BETWEEN

DIFFERENCE COLUMNS

Figure

4.

Replace restricted

4-1.

muffler/exhaust

system.

Figure

4-2.

"U"

Tube

Manometer

4.3

SECTION 5

AIR CLEANER AND AIR INTAKE SYSTEM

K series engines are equipped with a paper air

fications are also equipped with

precleaner that surrounds the paper element. Re-

fer

cleaner

to Figure

5-1.

element.

Engines of

high-density

an

oiled foam

some

speci-

AIR CLEANER DISASSEMBLY

1 . Remove the wing nut and air cleaner cover.

2.

Remove the precleaner (if so per

element

3. Remove the base screws, air cleaner base, gasket and hose.

and seal.

equipped),

pa-

AIR CLEANER SERVICE

Precleaner

If

so equipped, wash and every 25 operating hours tremely

1 . Wash the precleaner

2. Rinse the precleaner thoroughly

3. Saturate the precleaner with

4. Reinstall the precleaner

dusty

or

dirty conditions).

gent.

detergent

of cess water (do not wring). dry.

gine

oil. Squeeze out excess oil.

ment.

are eliminated. Squeeze out ex-

re-oil

the precleaner

(more

in

often under ex-

warm water and

Allow precleaner to

clean, fresh en-

over

the

deter-

until all traces

paper

ele-

II

Figure

5-1.

Air

Cleaner

"'------

Assembly

PRECLEANER

- Exploded View.

(OPTION)

5.1

Paper Element

Inspect Air Cleaner Components

Every 1 00 operating hours tremely element. Replace

1 . Remove the precleaner (if so equipped), ele-

2.

NOTE: compressed

3. Reinstall the

4.

5.

dusty

or

dirty conditions)

the

ment

cover

ment.

Replace a dirty, bent new genuine Kohler elements carefully; bent

or

Do not wash the paper element or use

Install the precleaner (cleaned and oiled) over the paper element.

Install the air cleaner Tighten wing nut. Make sure element tightly against air cleaner base.

nut, element cover and paper ele-

damaged.

air as this will damage the element.

paper

(more

element

or

element.

do

not use if surfaces are

element.

cover

often under ex-

check

as follows:

damaged

Handle new

and wing nut.

element with a

the

is

paper

sealed

Whenever the air cleaner when servicing the paper element check

1 .

2.

3. Breather

NOTE: tain specifications, the element the breather tube, making it impossible crankcase vacuum. the end of the breather tube that protrudes through the air cleaner base at approximately a 45 degree angle.

the following components:

Air

Cleaner Base - Make sure it is secured tightly to carburetor and is not bent aged.

Element K181 ment that element seal element between air cleaner base and element cover. Tighten nut torque. Refer to Figure

in

the air cleaner base and breather cover.

Cover and

New Look engines only, make sure ele-

cover

is not bent

cover

Tube

- Make sure it is sealed tightly

On

Model

K181

cover

is removed,

or

precleaner,

or

Element

nut is secured tightly

Cover

or

damaged. Check

to

Nut -On

50 in. lb.

5-2.

New Look engines of

cover

may

to

To

prevent this problem, cut

or

dam-

to

cer-

contact

maintain

Air

Cleaner

Cover

~

Figure

5.2

5-2.

K181

New Look,

Air

Cleaner

Assembly.

Air

Cleaner

Base

Breather Hose

NOTE:

ponents causing damaged

OPTIONAL OIL BATH

If clean and tion to Figure

1 . Remove the

2.

NOTE: Do ment. The filtering material could be damaged.

3. Lightly

4. Inspect base and

Damaged, worn

could

premature

the engine has an oil bath type air cleaner,

or

more

bowl and drain the oil

Thoroughly wash bowl and vent.

low it

damaged.

allow unfiltered air into the engine

or

worn

service

frequently if conditions warrant. Refer

5-3.

cover,

Swish the

to

dry.

not

use

re-oil

the

or

loose air cleaner

wear and failure. Replace all

components.

AIR

CLEANER

it

after

every

lift the element out

element

compressed

element

cover

25

hours

of

from

the bowl.

cover

in

clean sol-

in

the solvent and al-

air to dry the ele-

with engine oil.

gaskets. Replace if

of

com-

opera-

the

5. Install base gasket and place filter on air horn.

6.

Add engine oil mark.

7.

Install filter Secure with wing nut finger tight only.

COOLING

Effective cooling on an unobstructed flow fins. Air is drawn into the cooling shroud

located on the flywheel. The blower housing, cool-

ing shroud, air screen covering the flywheel and cooling fins on the cylinder and cylinder head be kept clean and unobstructed at all

Never operate the engine with the blower housing or

cooling shroud-removed. These devices direct

air flow NOTE:

some

and able unless other modifications are engine.

AIR

over

Some

use metal. The two are

to

filter and fill

element,

cover

to

the

OIL

LEVEL

gasket and cover.

INTAKE SYSTEM

of

an air cooled engine depends

of

air

over

the cooling

by

fins

times.

the cooling fins.

engines use a plastic grass screen

not

interchange-

made

to

the

must

II

OIL LEVEL

Figure

5-3.

Optional Oil Bath Air Cleaner.

5.3

SECTION 6

FUEL

SYSTEM AND GOVERNOR

FUEL SYSTEM - GASOLINE

The typical gasoline fuel ponents include the fuel tank with vented cap, shutoff valve with screen, pump

(some

models),

necting fuel line.

system

in-line

carburetor

and related

fuel filter, fuel

and intercon-

Operation

The fuel screen and shutoff valve, lines by the fuel Fuel enters the into the The

from

carburetor

fuel-air

the tank

pump

carburetor

is

moved

in-line

through the

filter and fuel

(if so equipped)

float bowl and

body

where it is mixed with air.

or

gravity.

is

moved

mixture is drawn into the combustion

com-

chamber

where it is

compressed,

then ignited by

the spark plug.

Troubleshooting

Use the following reaching the combustion

~

WARNING: Explosive Fuel!

Gasoline may be present in the carburetor and fuel system. Gasoline is extremely flammable and explode

if

ignited. Keep sparks, open flames, and other sources connect and ground the spark the possibility

procedure

to

check

that fuel is

chamber.

of

ignition away from the engine. Dis-

plug

lead to prevent

of

sparks from the ignition system.

it

can

II

Test

Check

1 .

A.

B.

C. Make sure the fuel

Check

2.

A.

B.

C. D.

3.

Check

A.

B.

4.

Check

A.

B.

for

the

following: Make sure Make sure

Disconnect the spark plug lead. Close the choke on Crank Remove the spark plug and check

Remove fuel line

Hold line below valve and observe flow.

Remove fuel line Crank engine several times and observe flow.

the

tank contains fuel.

the

fuel

for

fuel

In

the

the engine several

for

fuel

flow

from

bottom

operation

of

fuel

from

cap

vent

is

shutoff

valve

combustion

carburetor.

times.

tank

inlet fitting

of

tank. Open

pump

inlet fitting

open.

to

is

fuel

open.

chamber.

for

fuel

pump.

at

fuel pump.

shutoff

at

carburetor.

at

tip.

If

there

2.

bust ion If

there

fuel tank.

3.

If fuel

does

(Test

4).

If fuel

does

vent,

shutoff

If

the fuel tank

the tank, modify

1/32"

to

If fuel

4.

does

line

Is

unobstructed,

placed. If fuel

does

faulty. Refer

Is fuel

at

chamber.

Is

no

fuel

(Test

flow

not

valve

cap

1 I 1 6"

off

not

flow

to

Conclusi~n

tip

of

spark plug, fuel

at

tip

of

3).

from

flow

screen,

the

flow

from

the

spark plug, check

line, check

from

line, check

and fuel lines.

vent does not allow air

vent

for

proper

bottom.

from

fuel

fuel line, the

"Carburetor"

Refer

line, check

pump

Is

is

reaching

for

faulty fuel pump.

for

clogged fuel tank

to

operation by cutting

to

faulty and

carburetor

portion

escape

Figure 6-1 .

for

clogged fuel line. If

must

probably

of

this section.

fuel

be

the

from

re-

com-

the

from

Is

6.1

Cut Off

1/32"-1/16"

Operation

The mechanical fuel that rides on the engine camshaft. The transmits a pumping action to the flexible diaphragm inside the tion draws fuel in through the downward stroke of the diaphragm. upward stroke, the

outlet

check

valve. Refer

pump

is operated by a lever

lever

pump

body. The pumping

the

inlet

check

fuel is forced out through the

to

Figure

valve on

On

6-2.

ac-

the

Figure

6-1.

("New

Fuel

Look"

Tank

Only)

Cap.

FUEL TANK

Engine-mounted are

constructed vented cap. The venting properties of the cap should be cause pressure buildup result is

loosened.

the tank, stopping the engine.

Fuel

Some valve with a wire mesh screen. a shutoff valve, a straight outlet fitting is used. The wire the tank valve permits work on the fuel system without the need

checked

in

fuel spraying

Shutoff

engines are equipped with a fuel shutoff

mesh

from

for

draining the tank.

fuel tanks on K series engines

of

steel. They are fitted with a

regularly. A clogged vent can

in

the tank, which could

from

the filler when the cap

It

can also cause a partial vacuum

Valve

On

engines without

prevents relatively large particles

reaching the carburetor. The shutoff

FUEL FILTER

Some engines covered by this manual equipped with a

When

the

interior of the filter appears

it should

be

see-through

replaced.

in

line fuel filter.

may

to

be dirty,

be

FUEL PUMP

All K series engines except the

for

sions pump. gines, a pad on the crankcase.

Older fuel els have a better

mizing the

mounting a mechanically operated fuel

If

no fuel

cover

pumps

insulates the fuel

pump

is placed over the

body

made

chance

is mounted on these en-

have a metal body. Later

of plastic. The plastic body

of

vapor

from

K91

have provi-

pump

mounting

mod-

the hot engine, mini-

lock.

in

Figure

6-2.

Mechanical

Fuel

Pump.

Removal

1 . Disconnect the fuel lines

outlet fittings

2. Remove the fillister head washers, fuel

3.

If

required, remove the fittings

body.

of

the

pump

from

the inlet and

pump.

sems

and gasket.

screws, flat

from

the pump

Repair

Plastic bodied fuel must be replaced when faulty. Replacement pumps are available pump, mounting gasket and

pumps

are not serviceable and

in

kits which include the

plain washers.

Installation

1 . Fittings - Apply a small amount

Aviation Perm A Gasket (or equivalent gasoline resistant thread sealant)

in

to

pump

the

Figure

same

tings into

fittings

rection is reached.

Install new gasket, fuel

2. lock washers and Refer

six

fillister head

6-3.

to

full

turns;

direction until desired di-

pump,

of

Permatex®

fittings. Turn fit-

continue turning

flat washers,

sems

screws.

6.2

Plain Washer (2)

~

-----

~~

,:IJ..

Fillister Head Sems

L

Screws

Figure

NOTE: tioned above the pump sult if the lever

Make sure that the flat washers are installed next to the mounting flange the lock washers.

If

bodied

is discarded and the new thin gasket

3. Torque screws to

4. Connect fuel lines

Make sure that the fuel

and severe

a metal bodied

pump,

make

(2)

6-3.

Installing Fuel Pump.

camshaft.

damage

is

positioned below the camshaft.

to

pump

was replaced by a plastic

sure that the old thick gasket

37 - 45

to

inlet and outlet fittings.

\Fuel

pump

Damage to the fuel

to the engine could re-

prevent

in.llb.

CARBURETOR -GASOLINE

Pump

Mounting

lever

damage

is

used.

Flange

is

posi-

from

tor. This gives a the adjusting needles out (counterclockwise) increases the supply gives a dles midway between the lean and rich positions will usually give the best results. Adjust the carburetor as

1 . With the engine stopped, turn the low idle fuel

NOTE:

adjusting needles are tapered Damage to the needles and the seats body will result if the needles are

2.

3. Start the engine and run at half throttle

4. High Idle Fuel Needle Setting: This adjustment

Place the throttle into the ble, place the engine under load.

Turn the high idle fuel adjusting needle out (counterclockwise) engine speed of the needle.

richer

follows:

adjusting needle lightly.

The tip

Preliminary Settings: Turn the adjusting needles out (counterclockwise) according to the table shown

to ten minutes to warm up. The engine must be warm before making final settings (Steps 4,

5,

6,

and

is

required only

jet

carburetors.

jet

main

leaner

fuel-to-air

of

the low idle fuel and high idle fuel

7).

type,

from

decreases

fuel-to-air

of

fuel

to

mixture. Setting the nee-

in

(clockwise) until it

from

for

adjustable high idle (main)

If

the

carburetor

go

to

step 5.

"fast"

the preliminary setting until the

(rich}. Note the position

mixture. Turning

the carburetor. This

to

critical dimensions.

in

forced.

lightly

bottomed

in

Figure

is

a fixed

position.

bottoms

carburetor

6-4.

for

five

If

possi-

II

•

£ WARNING: Explosive Fuel!

Gasoline may

system. Gasoline is extremely flammable

explode other sources connect the possibility

Adjustment

The

carburetor fuel/air mixture conditions. Carburetors are set at the normally exhibits conditions like those found

that

follows, it carburetor.

In

general, turning the adjusting needles in (clock-

decreases

wise)

be

present in the carburetor

if

ignited. Keep sparks, open flames, and

of

ignition away from the engine. Dis-

and

ground the spark

of

sparks from the ignition system.

is designed to deliver the to

the engine under all operating

do

not need adjustment.

may

be necessary to adjust the

the supply of fuel to the carbure-

plug

and

fuel

and

it

can

lead to prevent

correct

factory

If

the engine

in

the table

and

Now turn the adjusting needle

may

engine speed as the needle of the needle.

Set the adjusting needle midway between the rich and lean settings. See Figure

5. Low Idle Speed Setting: Place the throttle control into the low idle speed to by turning the low idle speed adjusting screw

in

or out. Check the speed using a

ter.

NOTE: application. Refer to the

instructions The gines setting the low idle fuel needle, the low idle speed must not exceed

The actual low idle speed

for

recommended

is

1200 rpm. To ensure best results when

increase, then it will

is

turned

"idle"

specific low idle speed settings.

1500

in

or

1200

low idle speed

rpm.

in

(clockwise). The

decrease

(lean). Note the position

6-5.

"slow"

equipment

position. Set the

rpm*

( +

or

depends

manufacturer's

for

- 75 rpm)

tachome-

on the

Basic En-

6.3

PRELIMINARY SETTINGS - K-SERIES MODELS

KOHLER Low

K91 K141 K161* K181* K241 K301 K321 K341

6. Low Idle Fuel Needle Setting: Place the throttle into the

Turn the terclockwise) engine speed decreases (rich). Note the position of the

Now turn the adjusting needle in (clockwise). The engine speed as the of the

Set

the adjusting needle

lean settings. See Figure

and

"idle"

low idle fuel adjusting needle

from

needle.

may

needle is turned in (lean). Note the position

needle.

1-1/2 1-1/2 1-1/2 1-1/4turns 2-1/2 2-1/2 2-1/2 2-1/2

• Includes Figure

or

6-4.

"slow"

the preliminary setting until the

increase, then it will decrease

midway

ADJUST

Idle High Idle Low Idle

turns turns 3 turns turns

turns 2 turns turns 2 turns turns turns

"New

Preliminary

position.

between the rich

6-5.

Look"

ABLE

2 turns

3 turns 2 turns

3-1/4 3-1/2

Models

Low

out

(coun-

JET

turns turns

Idle And High Idle Fuel Needle

WALBRO

2. Remove the

3. Remove the

4. Further disassembly

FIXED

NOT NOT NOT 2-1/2 1-1/4 1-1/4turns 1-1/2 1 turn

baffle

ket. Remove the ing speed adjusting

choke shafts is parts are and Choke Shaft Replacement" later section.

JET

APPL. APPL. APPL.

turns turns

turns

gasket and bowl gasket.

needles and springs. Remove the idle

to

NOTE: Refer tion TP2377B Carburetor Reference Manual for additional information.

Settings.

float pin, float, fuel inlet needle,

fuel inlet seat and inlet seat gas-

idle fuel and main fuel adjust-

screw

recommended

be replaced. Refer

and spring.

to

publica-

remove the throttle and

only if these

to

"Throttle

in

this

7. Recheck the low idle speed using a ter. Readjust the speed as necessary.

Adjust Midpoint

Figure

6-5.

To

Optimum

Low

Idle Fuel

tachome-

Lean

Setting.

Disassembly

(Refer 1 . Remove the bowl retaining screw, retaining

to

screw

Figure

gasket and fuel bowl.

6-7)

Idle Speed

Screw

Figure

6-6.

Kohler-Built Carburetor.

Main Fuel

~Needle

Adjustable

Jet

6.4

Cleaning

WARNING:

All parts should be carefully cleaned using a carburetor cleaner (such as

gum

deposits are

eas:

Carburetor where throttle plate, choke plate and shafts are seated.

Float

and

Fuel bowl. Idle

fuel

ports

fuel

seat.

NOTE: of fine wire to enlarge the ports within the ports.

Flammable

Carburetor cleaners and solvents are extremely flammable. Keep sparks,

flames

away from the area. Follow the cleaner manufacturer's warnings and instructions on its proper and

use.

Never use gasoline as a clean-

ing agent.

body

and

float

hinge.

and

"off-idle"

in

main

fuel

These areas can be cleaned using a piece

in

addition

Solvents!

and

other sources

acetone).

removed

adjusting

or

from

the following ar-

bore;

especially the areas

ports

in

carburetor

needle

to

cleaners.

break the cleaning wire

of

ignition

Be

sure all

and

main

Be

careful not

safe

bore,

Main Fuel

VNeedle

Idle

Speed

Screw

/Spring

iJ

\

J~/

~pring

/

@

Carburetor Body

,-~~~~

Idle

Fuel

Needle /

~~:!

~~~

Gasket e

Fuel/~

Inlet Seat

j

Fuellnlet Needle \

Float~

Fuel

____

Bowl

~-==-~--------

~

~~Gasket

~

~~Hinge

~

r-~---~~

~

1

~~:~

..

Baffle

II

Float

p;,

Blow out

NOTE: Do not solvent when fiber The cleaner

all passages with

submerge

may

or

damage

compressed

carburetor

rubber seals are installed.

these seals.

air.

in

cleaner or

Inspection

1 . Carefully inspect all

those that are worn

2. Inspect the

and

other

Inspect the float

3. float hinge float tabs.

Inspect the inlet needle and seat

4. grooves.

5.

Inspect the tips

justing needles

Inspect the throttle and choke shafts and plate assemblies

carburetor

wear

for

components

or

damaged.

body

or

damage.

for

dents

wear and missing

of

the main and idle fuel ad-

for

wear

or

wear

or

excessive play.

and replace

for

cracks, holes

or

holes. Check the

or

for

grooves.

damaged

wear

or

Bowl

Retaining-~

Screw

Figure

6-7.

Kohler-Built Carburetor

~--Bowl

Screw

Adjustable

- Exploded View.

Retaining

Gasket

Jet

Choke Plate Modification

The choke action has been changed on production carburetors to

On

ing. K321 plate have been enlarged K241 the other is are mensions.

NOTE: sary precautions the engine.

production carburetors now used on the

and

and K301, one relief hole is now

smaller than this, enlarge

When redrilling the holes, take the neces-

reduce

K341

, both relief holes

3/16" . If

the chances of

to

11

/32"

you find that the relief holes

them

to

prevent chips

over

in

the choke

while on the

11/32"

to these di-

from

chok-

and

entering

Repair

Always use new gaskets when servicing and reinstalling carburetors. Several repair kits, which in-

other

clude the gaskets and

components,

are

6.5

available. Always refer engine being serviced to ensure that the carburetor ordered.

repair kits and replacement parts are

to

the Parts Manual

for

the

correct

Throttle

And

Choke Shaft

Replacement

To Replace Throttle And Choke Shafts

Two kits are available that allow replacement of the carburetor carburetors. Refer

throttle and choke shafts of Kohler

to

Figure

6-8.

Choke

Choke Plate (Reused) \

Detent

Choke

Ball-Spring__.'"'

Shaft

?~(Q

#3-48x7/32"

Brass Screws £

I

#2-56x7/32" #3-48x7

Brass

/32"

Screw

l:J/,Y

.,.~

or

'choke

~

"'Choke

Choke

Bushing

Shall

Lever

(Reused)

#2-56x7/32"

B<ass

Throttle For

KT17-KT19,

Shaft

~

, _ (Reused)

Shaft

Models

Bushing

K241-K341 &

1"

\ Brass Screws _ Lever

or

#3-48x7/32"

Sc,.w

~

-4

Styles y

~

ca,b.

~

#3-48x7/32"

~,

~

'S~~\J

"""'-

,

'"\]

/~--"

Throttle

2 Styles For K91-K181,

/

+ -

'Th,ottle

Throttle

Shaft/Lever

Models

1/2"

Carb.

Throttle

_j

Shaft Bushing

Plate (Reused)

\Throttle

Installation

Assembly-

1

Shaft

Tool

Bushing

Figure

6-8.

A WARNING: Prevent Eye Injury!

Suitable eye protection (safety glasses, goggles, face hood) should be worn for any procedure involving the use chisels, drills,

Disassemble Carburetor

Refer section.

6.6

of

compressed

or

grinding tools.

to

"Disassembly"

air,

punches, hammers,

at the beginning

Throttle

of

this

And

Choke Shaft Replacement Kits.

Remove Choke Plate and Choke Shaft;

or

Transfer Choke Lever

1. To ensure plate and carburetor body with a marking pen.

Also take note and choke lever position.

2. Carefully and slowly ing choke plate to choke shaft. Remove and save the choke plate as it will be reused.

correct

reassembly,

of

choke plate position

remove

the screws secur-

mark

choke

in

bore

3. File

4. Note the position

5.

6.

Models

#2-56 x 7/32"

Models K241 - K341

#3-48 x 7/32"

off

any burrs which

choke

the

moved. choke detent

spect shaft.

Carefully grind of

the shaft. Remove and save the choke

lever; discard the old Attach the

from correctly choke

K9

shaft when the screws were re-

Place

carburetor

side down. Remove

ball and spring will fall out.

to

the

cut

out portion

or

choke

the kit. Make sure the lever

as noted

shaft as follows:

1 - K181

,-

Apply Loctite to threads

brass screw. Secure lever

,-

brass screw. Secure lever

may

have been left on

on workbench with

choke

of

the

choke

file away the riveted portion

choke

lever to the new choke shaft

in

step 4. Secure lever to

Apply Loctite

shaft; the

lever with re-

of

the

shaft.

is

to

threads of 1

choke

installed

to

of

1

shaft.

Remove Throttle Plate and Throttle Shaft; Transfer

1 . To ensure

plate Also take the

Throttle Lever

correct

and

carburetor note

bore

and the throttle lever position.

reassembly,

body

with a marking pen.

of

the throttle plate position

mark

throttle

in

c.

Compare the kit. Select the appropriate new shaft and discard the

d. Attach

sure step a.

Apply Loctite

e.

brass is

2-49/64"

Drill

Choke Shaft Bores Using A

the old shaft with the new shafts

old shaft.

throttle lever to throttle shaft. Make

lever is installed

to

screw

(use

long.

correctly

threads

of

1

#3-48 x 7/32"

Secure

lever

as noted

#2-56 x 7/32"

screw

to

shaft.

Press

1. Mount the Keep the vise jaws

2.

Install a drill bit

press chuck. Lower the bit (not rotating)

through both vise. This ensures carburetor

Models

ameter

Models K241 - K341

ameter Refer to Figure

K91

drill bit.

carburetor

choke

body

- K181

6-9.

body

in

a drill press vise.

slightly loose.

of

the following size

shaft bores; then tighten

accurate

with the drill press

(1

12"

(1"

Garb.);

alignment of the

Garb.);

Use a 7132" di-

Use a 1

chuck.

Drill

in

the drill

/4"

in

if shaft

di-

II

Carefully and slowly

2. ing the throttle plate and save the

File

3.

NOTE: Failure shaft body

4. Remove throttle shaft

5. Remove and transfer the

Models

Carefully grind

the

be used Discard the

Models K241 - K341

a. Note the position

b.

off

throttle shaft when screws were

the

may

cause

when shaft is

Remove and discard the from

the throttle shaft.

lows:

K91

throttle shaft. Save the throttle shaft as it will

to

spect

to

shaft. Carefully grind

of

the shaft. Remove the throttle lever.

throttle plate

any burrs that

to

remove

permanent

- K181 (112" Garb.),-

or

install the new throttle shaft bushing.

throttle lever.

the

cutout

remove

to

may

burrs

removed.

from

file away the riveted portion of

(1"

Garb.),-

of

the throttle lever with re-

portion of the throttle

or

file away the riveted portion

the screws

throttle shaft. Remove

for

reuse.

have been left on

from

the throttle

damage

foam

throttle lever as fol-

to

carburetor

rubber dust seal

secur-

removed.

carburetor

body.

Figure

3.

4. Ream the

5.

6-9.

Aligning/Drilling Carburetor Body.

Install a 19/64" drill bit

press

to

a low speed suitable

Drill slowly

5/16".

reamer.

Blow out all metal chips using Thoroughly clean the retor

to

ensure a

choke

For best results use a piloted 5/16"

cleaner.

shaft bores

in

the

chuck.

for

good

finish. to

compressed

carburetor

Set drill

aluminum.

a final size of

air.

body

in

carbu-

6.7

Install Choke Shaft Bushings

1 . Install screws

the choke shaft bores until the screws bottom

lightly. Refer to Figure

2. Coat the outside surface of the kit-supplied choke shaft bushings with Loctite from the kit. Carefully press the bushings into the carburetor

body pressing when bushings bottom against screws.

Models

bushing is pressed below the surface of the large choke shaft boss until the bushing screw.

K91 -K181

in

using a

the tapped holes that enter

6-10.

smooth-jawed

vise. Stop

(112" Carb.); Make sure the

bottoms

against

2. Install a throttle shaft (without throttle lever) carburetor body

Models

throttle shaft removed previously.

Models

remaining new throttle shafts from the kit.

3. Coat the outside surface of the throttle shaft

K91 -K181

K141 -K341

bushing with Loctite from the kit. Slip the bushing over the shaft. Using a vise and the installation tool into the counterbore until it buretor body. Refer to Figure 6-11 .

to

use as a pilot:

(112" Carb.); Use the old

(1"

Carb.); Use one of the

from

the kit, press the bushing

bottoms

in

the car-

in

Allow Loctite to

3. then

remove

Figure

4. Install new choke shaft

NOTE: cause before proceeding. Use choke shaft to align bushings if necessary.

5. Remove choke shaft and

6. Wipe away any excess Loctite from bushings

6-10.

shaft and

If binding occurs, locate and

for

an additional 30 minutes before proceed-

ing.

and choke shaft.

"set"

for

5 to 1 0 minutes,

screws.

Installing Choke Shaft Bushings.

in

bushings. Rotate

check

that it does not bind.

correct

allow Loctite to

the

"set"

Install Throttle Shaft Bushing

1 . Make sure the dust seal counterbore

carburetor body is thoroughly clean and free of

chips and burrs.

in

the

Figure

4. Allow the Loctite to

5.

NOTE: before proceeding. Use throttle shaft to align bushing

if necessary.

6. Remove the shaft and allow the Loctite to

7.

Install Detent Spring and

6-11.

Installing Throttle Shaft Bushing.

"set"

for

5 to 1 0 minutes,

then remove the throttle shaft. Install the new throttle shaft and lever

retor body. Rotate the shaft and does not bind.

If

binding occurs, locate the cause and correct

"set"

for

an

additional 30 minutes before pro-

ceeding. Wipe away all excess Loctite from bushing and

throttle shaft.

·

Ball,

in

check

Choke

carbu-

that it

Shaft and Choke Plate

1 . Install new detent spring and ball

body

in

the side opposite the choke lever.

2. Compress detent ball and spring and insert choke shaft through bushings. Make sure the choke

buretor body. Refer to Figure

lever is on the

correct

in

carburetor

side of the car-

6-12.

6.8

3. Attach choke plate marks are erly

in

#3-48 x 7/32"

that they are slightly loose.

aligned and plate is positioned prop-

the bore. Apply Loctite to threads of 2

brass screws. Install screws so

to

choke shaft. Make sure

Reassembly

1 . Install the fuel inlet seat gasket and fuel inlet

seat into carburetor body. Torque seat to

35/45

in.

lb.

4. Operate the choke lever. Check that there is no binding between choke plate and carburetor bore. Loosen screws and adjust plate as necessary; then tighten screws.

Figure

6-12.

Installing Choke Shaft.

2. Install the fuel inlet needle into inlet seat. Install float and float hinge towers on carburetor body.

3. Set tab rests on the fuel inlet needle. There should be 11/64" machined surface

float. Bend the float tab with a small screw-

driver to adjust. Refer

Bend To

and slide float pin through float hinge

float

level: Invert carburetor so the float

(+-

Tab

Adjust

Figure

1/32")

Inverted

6-13.

clearance between the

of

body

and the free end of

to

Figure

Carburetor

Setting

6-13.

Float Level.

Install Throttle Shaft and Throttle Plate

1 . Install throttle shaft

of

portion

2. Attach sure properly of

2

screws

3. Apply finger pressure to throttle shaft to keep

it firmly seated against pivot

body. Rotate the

plate fully closes the bore around its perimeter; then tighten screws.

4. Operate throttle plate does not bind Loosen screws and adjust plate if necessary;

then tighten screws securely.

the shaft facing out.

throttle plate

marks

are aligned and plate is positioned

in

the bore. Apply Loctite to threads

#3-48 x 7/32"

so

that they are slightly loose.

the

throttle lever and

in

carburetor with cutout

to

throttle shaft. Make

brass screws. Install

in

carburetor

throttle shaft until the throttle

check

in

the bore.

that the

Reassemble Carburetor

Refer

to

the following "Reassembly" portion of this

section.

4. Set

float

drop:

Turn the carburetor over to its

normal operating position and allow float

drop to its lowest level. The float be limited surface of body and the end screwdriver

to

1-1/32"

of

float. Bend the float tab with a small

to

adjust. Refer

between the machined

bottom

to

Figure

-t

1-1/32"

t

Figure

6-14.

Setting

Float Drop.

drop

of

the free

Bend To

to

should

6-14.

Tab

Adjust

6.9

5.

Check Invert the carburetor so the float tab rests

the fuel inlet needle. Insert a .

gauge between float and float hinge towers.

the feeler gauge cannot be inserted,

is interference between the float and towers, file the towers to obtain the proper clearance. Refer to Figure

float-to-float

6-15.

hinge

tower

01

clearance:

0"

feeler

or

there

on

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. lb.

WALBRO FIXED/ADJUSTABLE CARBURETOR

If

This section covers the idle adjustment, disassembly, cleaning, inspection, repair, and reassembly of the main

Walbro-built,

jet

carburetors.

Idle Speed Adjusting

Screw

side

draft,

fixed/adjustable

Idle Fuel

Float

If

File

Inverted

9.

Carburetor

Figure

Install the idle speed adjusting screw and spring. justing needles and springs. Turn the adjusting needles clockwise until they bottom

6-15.

Install the idle fuel and main fuel ad-

Checking

0.010" Feeler Gauge

(Both

·r·l

Float

Hinge

(On

Carburetor

Float Clearance.

Towers

lightly.

Body)

Figure

~

Before servicing the carburetor, engine, ment, always remove the spark the engine from staning accidentally. Ground the leads to prevent sparks that

~

Gasoline may system. Gasoline is extremely flammable vapors can explode flame, area to prevent the possibility

6-16.

WARNING: Accidental Starts!

WARNING: Explosive Fuel!

and

other sources

Fixed Main

be

present in the carburetor and fuel

if

ignited. Keep sparks, open

of

Jet

plug

could

cause fires.

ignition away from the

of

fires

Carburetor.

or

equip-

leads to prevent

and

its

or

explosions.

NOTE: to critical dimensions. Damage to needles and seats will result if needles are forced.

10. Reinstall the carburetor to the engine using a

11

The ends

new gasket.

. Adjust the carburetor as outlined under the

"Adjustment"

6.10

of

adjusting needles are tapered

portion of this section.

~

WARNING: Prevent Eye Injury!

Suitable eye protection (safety glasses, goggles, face shield) should be worn for any procedure involving the use mers, chisels, drills,

of

compressed

or

grinding tools.

air,

punches, ham-

or

Choke Ball

And

I

Detent

Spring

Date

Code*

Idle

Speed

Screw

And

Idle

Fuel

Needle

Welch

Choke Shaft

Adjusting

Spring

'NOTE: lever) Side the

bottom

Adjusting

And

Spring

Plugs

Lever/

Assembly

These

of

(fuel

will

be

mount1ng

bowl)

on

flange

s1de

e1ther

of

the

top

(throttle

as

shown,

mounting

or

flange

---c_ Fuel

on

Throttle Shaft

Bowl

Screw

Lever/

Assembly

Retaining

And

Gasket

Mounting

Idle Bleed

Flange

Air

"Off-Idle" Port

Throttle

Plate

Fuel

Bowl

Gasket

Fixed Fuel

Main

Jet

I

I I

I

Drop

Tab

I

Float Limiting (Non-Adjustable)

II

Nozzle Air

Bleed

Figure

6-17.

Major

Components

Air

Cleaner

Mounting

And

Bowl

Surface

Service

Vent

Idle Inlet

Locations -Typical

Fuel

Fixed

Jet

Carburetor.

Fuel

Inlet

Needle

6.11

TROUBLESHOOTING

If engine troubles are experienced that appear to be fuel system related, before adjusting

•

Make sure the fuel tank is filled with clean,

fresh gasoline.

• Make sure the fuel tank blocked and that it is operating properly.

• Make sure fuel is reaching the carburetor. This includes checking the fuel

tank filter screen, in-line fuel filter, fuel lines, and fuel nents as necessary.

or

pump

check

disassembling the carburetor.

for

restrictions

the following areas

cap

vent is not

shut-off

or

faulty

valve, fuel

compo-

• Make sure the carburetor to the engine using gaskets

• Make sure the air cleaner element is clean and all air cleaner components are fastened securely.

• Make sure the ignition system, governor system,

exhaust system, and throttle and choke

controls are operating properly.

If, after checking the items listed above, starting problems in

the following table exist, it

adjust

or

other conditions similar to those listed

or

service the carburetor.

is.

securely fastened

in

good condition.

may

be necessary to

Condition

1. Engine starts hard,

runs roughly idle

speed.

2. Engine runs rich. (Indicated

sooty exhaust smoke, misfiring, loss speed and power, governor hunting, excessive throttle opening.)

Engine runs lean.

3. (Indicated

loss

of power, governor hunting,

or

throttle opening.)

or

stalls at

by

black,

of

by

misfiring,

speed and

excessive

or

Possible Cause/Probable Remedy

1. Idle fuel mixture

idle speed screw, then adjust idle fuel needle.

2a. Choke

linkage

b. 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

surface of carburetor body.

d. Dirt under fuel inlet needle. Remove needle. Clean needle and seat

and blow with compressed air. Bowl vent

e.

ing

out all passages with compressed air.

Fuel bowl gasket leaks. Remove fuel bowl and replace gasket.

f. g. Leaky, cracked,

leaks.

3a. Idle fuel mixture is improperly adjusted. Adjust idle fuel needle.

b. Float level set too low. With fuel bowl removed and carburetor in-

verted, set exposed surface surface of carburetor body.

Idle holes plugged; dirt

c.

idle fuel adjusting needle, main fuel jet, and welch plugs. Clean all

passages and blow out with compressed air.

partially closed during operation. Check the choke lever and

to

or

needle, and welch plugs. Clean vent, ports, and air bleeds. Blow

or

idle speed are improperly adjusted. Adjust the

ensure choke is opening after

of

float parallel with the bowl gasket

air bleeds plugged. Remove fuel bowl, idle fuel adjust-

or

damaged float. Submerge float

of

float parallel with the bowl gasket

in

fuel delivery channels. Remove fuel bowl,

warm-up.

to

check

for

Fuel leaks

4. carburetor.

6.12

from

4a. Float level set too high. See Remedy 2c.

b. Dirt under fuel inlet needle. See Remedy 2d. c.

d. Float is cracked e. Bowl retaining screw gasket damaged. Replace gasket. f. Bowl retaining screw is not tightened. Torque screw

Bowl vent plugged. Remove fuel bowl and clean bowl vent. Blow out with compressed air.

or

damaged. Replace float.

to

specifications.

In

general, turning the adjusting needles wise) decreases the supply of fuel to the carburetor. This gives a

the

adjustfng needles creases the supply of fuel gives a richer

needles tions will usually give the best results.

midway

leaner

fuel-to-air

between the lean and rich posi-

fuel-to-air

out

(counterclockwise) in-

to

the carburetor. This

mixture. Setting the

In

(clock-

mixture. Turning

Figure

Adjust To

6-18.

Midpoint

Fixed Main

Idle Adjusting

Jet

Carburetor.

Lean

Fuel

Needle

Adjust the carburetor as

1. With the engine stopped, turn the low idle fuel

adjusting needle

lightly.

2.

Preliminary

dles out (counterclockwise) tomed

6-20.

3. Start the engine and run at half throttle to ten minutes to warm up. The engine must be warm before making final settings (Steps 4, 5, 6, and

4. High Idle Fuel Needle

is required only for adjustable high idle (main)

jet

carburetors.

jet

type, go to step 5.

Place the throttle into the ble, place the engine under load.

Turn the high idle fuel adjusting needle terclockwise)

engine speed decreases (rich). Note the position of the needle.

Settings: Turn the adjusting nee-

according to the table shown

7).

from

follows:

in

(clockwise) until it bottoms

from

lightly bot-

in

Figure

for

five

Setting:

If

the carburetor is a fixed main

"fast"

the preliminary setting until the

This adjustment

position. If possi-

out

(coun-

II

Figure

6-19.

carburetor

Adjustment.

CARBURETOR ADJUSTMENT

NOTE: fuel mensions. Damage to the in forced.

The tip of the low idle fuel and high idle

adjusting needles are tapered to critical di-

needles and the seats

carburetor body will result if the needles are

in

Now turn the adjusting needle

engine speed as the needle is turned

of the Set

and

5.

*NOTE: The actual low idle speed depends on the application. Refer to the equipment instructions for specific low idle speed settings. The recommended low idle speed gines is 1200 rpm. To ensure best results when setting the low idle fuel needle, the low idle speed must not exceed 1500 rpm.

needle.

the adjusting needle

lean settings. See Figure

Low control into the the low idle speed to 1200 rpm) by turning the low idle speed adjusting screw in chometer.

may

Idle Speed

or

out.

increase, then it will decrease

in

(lean) . Note the position

midway

Setting:

"idle"

or

Check the speed using a ta-

(clockwise). The

between the rich

6-21.

Place the throttle

"slow"

position. Set

rpm*

( +

manufacturer's

for

Basic En-

or

- 75

6.13

PRELIMINARY SETTINGS

K-SERIES MODELS

KOHLER ADJUSTABLE Low

Idle High Idle

K91 K141 K161* K181* K241 K301 K321 K341 KT17 1 turn KT19

K582

*Includes

6.

Low throttle into the

Turn the terclockwise) engine speed decreases (rich). Note the position of the

needle.

1-1/2

turns 2 turns 1-1/2 1-1/2 1-1/4 2-1/2 2-1/2 2-1/2 2-1/2

1 turn 1-1/4

"New

Idle

Fuel Needle

low idle fuel adjusting needle

turns 3 turns

turns 2 turns

turns

turns 2 turns

turns

turns 3 turns

Look"

Figure

from

Models

6-20.

Setting:

"idle"

the preliminary setting until the

or

"slow"

JET

2 turns

3-1/4

turns

3-1/2

turns

2-1/2

turns

2-1/2

turns

Preliminary

Place the

position.

out

Low

(coun-

WALBRO

FIXED JET

Low

Idle

NOT

APPL.

NOT

APPL. 2 8

NOT

APPL.

2-1/2

turns

1-1/4

turns 1-1/4turns 1-1/2

turns 1 turn

1-1/4turns

1-1/4

turns

NOT

APPL.

Idle And High Idle Fuel Needle

WALBRO

Low 2 8

NOT

2-1/2 1-3/4

1-3/4 2 8 2 8

1-1/4

1-1/4 2 8

Adjust Midpoint

To

Idle

DETERMD

APPL.

DETERMD

turns turns

turns DETERMD DETERMD

turns turns 1 turn

DETERMD

ADJUSTABLE JET

High

Idle

2 8

DETERMD

NOT

APPL.

2 8

DETERMD

314

turn

1-1/8

turns

1-1/8

turns

2 8

DETERMD

2 8

DETERMD

1-1/4

turns

2 8

DETERMD

Settings.

Lean

Now turn the adjusting needle in (clockwise). The

may

engine speed as the of the

Set and

7. Recheck

needle is turned in (lean). Note the position

needle.

the

adjusting needle midway between the rich

lean settings. See Figure

the

ter. Readjust the speed as necessary.

increase, then it will decrease

6-21.

low idle speed using a

tachome-

Figure

Rich

6-21.

----

Optimum

Low

Idle Fuel

Setting.

6.14

DISASSEMBLY

Refer

To

Figures

6-17

and

6-22.

Carburetor

Assembly

Breather

Choke ball

Choke plate -

Choke plate

Throttle

shaft~~

fitting

/:;,

~~@

Choke

spring

,'\.

-"

~

j:,~

screws

~~

II

Figure

1 . Remove the bowl retaining screw, retaining

screw gasket, and fuel bowl.

2. Remove fuel inlet needle.

CAUTION: To prevent damage to the carburetor, do

3. Remove the idle fuel adjusting needle and spring. Remove the idle speed adjusting screw and spring.

4. Remove the main fuel jet.

5.

In bowl vent channel thoroughly, the welch plugs covering these areas must be removed. Use

the

bowl gasket, float pin, float, and

not

attempt as it is not serviceable. Replace the carburetor

if the fuel inlet seat is damaged.

order

to

clean the

6-22.

to remove the fuel inlet seat

"off-idle"

Walbro

Fixed/Adjustable

ports and the

©>-Gasket

~--Bowl

Jet

Carburetor

tool No. to remove the welch plugs. Refer to Figure

- Exploded

K01 018 and the following procedure

for

retainer

View

bowl

screw

retainer

6-23.

Tool

#K01018

\ry

Do

Not

Allow

Tip

To

Strike

Carburetor

~

-~.._

Figure

Body

-___

6-23.

Pierce Plug WithTip

j.J:"li.-.:::::::::::=----W-e-1-c-h-P-Iu_g

Removing

Welch

)

Plugs.

Out

__

screw

Plug

_

6.15

A. Pierce the welch plug with the tip of the tool. CAUTION:

B.

Pry out the welch plug using the tool.

To prevent damage to the carburetor, do not allow the tool to strike the carburetor body.

Throttle And Choke Shaft Removal

Further disassembly to remove the throttle shaft and choke shaft is parts are to be cleaned

recommended

or

replaced.

only if these

Throttle Shaft Removal

reassembly (refer to Figure note of the choke plate position the position of the choke lever.

6-25).

Also take

in

bore, and

1 . Because the edges

eled,

mark

the throttle plate and carburetor body with a marking pen to ensure reassembly (refer note of the throttle plate position the position

Figure

of

6-24.

of

throttle plate are bev-

to

Figure

the throttle lever.

Marking

Carburetor

Throttle

Body.

correct

6-24).

Also take

in

bore, and

, Carburetor

Body

-""---

Plate And

Carburetor

Figure

2.

Carefully and slowly remove the screws securing the choke plate to choke shaft. Remove

the choke

3. File off any burrs which the choke shaft when the screws were removed. shaft from carburetor body.

4. Rotate the choke shaft of shaft is facing the air cleaner mounting surface (refer to Figure tor Remove the choke lever/shaft assembly from carburetor body; the detent ball and spring will drop out.

6-25.

Marking

Carburetor

plate.

Do

this

before

body on work bench with choke side down.

Choke Plate

Body.

may

have been left on

removing the choke

until the cutout portion

6-26).

Place the carbure-

And

Body

Carefully and slowly remove the screws secur-

2. ing the throttle plate to throttle shaft. Remove the

throttle plate.

3. File

4. Remove the

off

any burrs which may have been left on the throttle shaft when the screws were removed. shaft

foam dust

Do

this

before

from

carburetor body.

throttle lever/shaft assembly with

seal from carburetor body.

removing the throttle

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

6.16

correct

Choke Shaft

Figure

Lever/

Assembly

6-26.

Removing

Choke Lever/Shaft.

CLEANING

£ WARNING: Flammable Solvents!

Carburetor cleaners and solvents are extremely

and

flammable. Keep sparks, flames of

ignition away from the area. Follow the cleaner

manufacturer's warnings

proper

cleaning agent.

All parts should be carefully cleaned using a car-

buretor gum deposits are removed from the following areas:

•

• Idle

NOTE: of fine wire in addition to within ports. pressed air.

• Float and

• Fuel Bowl.

•

CAUTION: Do not submerge the carburetor

and

safe use. Never use gasoline as a

cleaner (such as acetone).

Carburetor

areas where the and shafts are seated.

fuel

bore,

These areas can be cleaned using a piece

enlarge the ports,

Throttle and

choke

body

and

main

jet,

Blow out all passages with

float

plate,

shaft.

or

solvents when fiber, rubber,

seals

or are installed. The cleaner may damage these parts.

and

instructions on its

and

bore; especially the

throttle plate, choke plate,

"off-idle"

bowl

or

hinge.

choke

gaskets,

ports

vent, and

to

cleaners.

break the cleaning wire

plate,

or

INSPECTION

other sources

Be

sure all

in

carburetor

fuel

inlet

seat.

Be

careful not

com-

throttle

the fuel inlet needle

shaft,

in

cleaner

or

foam

REPAIR

Always use new gaskets when servicing and reinstalling carburetors. Repair kits are available which include new gaskets and other components. These kits are described

Components such as the throttle and choke shaft assemblies, throttle plate, choke plate, idle fuel needle, rately.

Refer the correct carburetor repair kits. and parts are ordered.

main jet, and others, are available sepa-

to

the appropriate Parts Manual

below.

to

ensure

replacement

REASSEMBLY

Throttle

1 . Install the foam dust seal on throttle shaft. In-

sert the throttle lever/shaft assembly into carburetor body with the cutout portion facing the carburetor mounting

2. Install the throttle plate to throttle shaft. Make

sure the plate is positioned properly marked and noted during disassembly (the numbers stamped on carburetor mounting

#609 to threads

Install screws so they are slightly loose.

3. Apply finger pressure to keep it firmly seated against pivot retor body. Rotate the throttle plate fully closes the bore around its entire perimeter; then tighten screws. Refer to Figure

Apply Tightening

Shaft

6-27.

Pressure When

Installation

of

Screws

of

shaft

flange.

in

bore as •

plate should face the

flange). Apply Loctite®

2 plate retaining screws.

to

the throttle lever/shaft

in

carbu-

throttle shaft until the

Throttle Shaft Assembly

-

Lever/

./

II

Carefully inspect all components and replace those

or

that are worn

• Inspect and other wear

• Inspect the float the

float hinge

aged float tabs.

• Inspect the fuel inlet needle for wear or grooves.

• Inspect

for

wear

• Inspect the throttle and choke shaft and plate assemblies

damaged.

the

carburetor body for cracks, holes,

or

damage.

for

cracks or holes. Check

for

wear, and missing

the

tip

of

the idle fuel adjusting needle

or

grooves.

for

wear or excessive play.

or

dam-

. \

Figure

Operate the throttle lever; check

4. between the Loosen screws and adjust necessary; then torque screws

Choke

1 . Install the detent spring and ball into the car-

buretor body.

6-27.

Shaft

Installing

throttle plate and carburetor bore.

Throttle

Lever/Shaft.

throttle plate as

to

for

8112

binding

in. lb.

Installation

6.17

CAUTION:

If

the

detent tapped own weight, do not ball could permanently lodge it in the hole.

ball does not drop through the

air cleaner base screw hole by its

force

it. Forcing the

Tooi#KO~

Install bore instead.

Compress

2. the

choke

body

with the

air

cleaner

6-28).

correct

Figure

3. Install the

sure the marked numbers cleaner mounting surface and be upright.) ply Loctite® #609 ing screws. slightly loose.

4.

Operate the between the Adjust to

plate as necessary; then

8/12

the ball through the choke shaft

the

detent

lever/shaft

cutout

mounting surface (refer

Make sure the choke lever is on the

side

of

6-28.

Installing

choke

plate is positioned properly

and noted during disassembly. (The

stamped

Install the screws so they are

choke

in.

lb.

ball and spring. Insert

assembly into

portion

carburetor

plate

to

on plate should

to

threads

lever;

plate and

of

body.

Choke

choke

of

check

shaft facing the

Compress

And

Lever/Shaft.

shaft. Make

2 plate retain-

for

carburetor

torque

carburetor

to

Figure

Ball

Spring

in

bore as

face

the air

binding

bore.

screws

Ap-

Carburetor

Figure

C. After welch plugs are installed, seal the ex-

posed surface with

sealant) . Allow the sealant

NOTE: fingernail polish

If a commercial

2. Install the main fuel

Body

~

6-29.

Installing

glyptal (or an equivalent

sealant is not available,

can be used.

~New

Welch

jet.

to

Welch

dry.

Plug

Plugs.

3. Install fuel inlet needle into inlet seat. Install

float

and slide float pin through float hinge and

float. hinge towers on

4.

Set Float Level: Invert the float tab rests on the fuel inlet needle. The exposed surface with the bowl gasket body (exposed, from

bowl gasket

carburetor

of

float should be parallel

surface

free

end

of

surface).

body.

carburetor

of

the

float . 690"

Refer to Figure

so the

carburetor

I.

720"

6-30.

Bend

Tab

To

Adjust

I

)

,Jf

Carburetor Reassembly

1 .

If

the welch plugs have been cleaning, new welch plugs Use tool No. K01 017 and the following dure

to

install the welch plugs.

A. Position the

welch plug cavities

B.

Place a new welch plug into the cavity with the raised portion up. Use the end of the

about

is plug. Do face.

Refer

carburetor

the

same

not

force

to

the

size as plug and

the plug below the top sur-

Figure

6-29.

6.18

removed

must

body

securely with the

top.

for

be installed.

proce-

tool that

flatten

the

Figure

Bend the just.

6-30.

Setting

float tab with a small

Float Level.

screw

driver

to

5. Install a new bowl gasket and the fuel bowl.

Make sure the bowl gasket and bowl are tered

and positioned properly

good

seal.

6. Install a new bowl retaining

bowl retaining screw. Torque screw

the

45/55

in.

lb.

to

screw

ensure a

gasket and

cen-

to

ad-

7. Install the idle speed adjusting screw and spring.

4. Install the new high altitude main fuel torque

to

12/16

in.

lb.

jet

and

Install the idle fuel adjusting needle and spring.

8. Turn the adjusting bottoms

CAUTION: The tip

9. Turn the idle fuel needle out (counterclockwise) instructions Bulletin.

lightly.

tapered

needle and the seat

the will result if the needle is

from

lightly

in

needle

of

the idle fuel adjusting needle

to

critical dimensions. Damage to

bottomed

the

"Adjustment"

in

(clockwise) until it

in

carburetor

forced.

according to the

section

body

of

HIGH ALTITUDE OPERATION (FIXED JET)

When operating the engine at high altitudes the

fuel mixture tends

main rich mixture can cause conditions such as black, sooty

exhaust power, ernor response.

To-compensate

main fuel high

cludes the

High

1 . Remove the fuel bowl retaining screw, retain-

NOTE: carburetor easier.

2. Remove the

3. Remove the existing main fuel

poor

altitude main fuel

Altitude Jet Installation (Fixed Jet)

ing

screw

If

needle.

smoke,

fuel

economy,

for

jet

is available

jet

and

gasket, fuel bowl, and bowl gasket.

necessary,

from

engine to

float pin, float, and fuel inlet

to

get

overrich.

misfiring, loss

and

poor

this, a special high altitude

for

each carburetor. The

jet

is

sold

in

necessary

remove

gaskets.

the air cleaner and

make

fuel bowl removal

An

of

speed and

or

slow

a kit which in-

jet.

over-

gov-

this

5. Reinstall the fuel inlet needle, float, and float pin.

6.

is

Install the new bowl fuel bowl. Make sure the bowl gasket and bowl are

centered

a

good

7. Install the new bowl retaining

from

kit and the bowl retaining screw. Torque

screw

8. Reinstall the

gine as kit.

to

and positioned

seal.

45/55 in. lb.

carburetor

necessary

gasket

using the new gaskets

from

properly

screw

and air

IDLE ADJUSTMENT PROCEDURE FOR K341

AQS ENGINES WITH ANTI-DIESELING

SOLENOID

The idle speed engines has been increased

eration at low idle and an anti-dieseling solenoid has been added down at the higher adjust the idle on solenoid, use the following Figure 6-31 .

STEP

1 engine stopped, turn the all the way then

back

STEP

2 -

check

and Idle, no load, speed should be 2100

idle speed, loosen the

the dieseling solenoid and turn the solenoid in until

21

00

jam

nut to lock solenoid

of

some

vi

bra-mounted

to

allow

to

prevent dieseling during shut-

idle

speed.

any·

K341

IDLE

FUEL

MIXTURE

in

(clockwise) until it

out

1/2

turn.

IDLE

SPEED

idle speed with a hand

RPM

idle speed is attained - retighten

ADJUSTMENT: Start engine

in

If

called upon AQS engine with this procedure.

ADJUSTMENT: With

idle fuel adjusting screw

bottoms

jam

nut on the

position.

kit and the

to

ensure

gasket

cleaner

tachometer.

RPM.

to

K341

AQS

smoother

Refer

to

lightly

To set

anti-

or

en-

from

op-

to

out

G

6.19

SOLENOID,

(45

435

ANTI-DIESELING

01)

BRACKET,

(45

126

SOLENOID---------

05)

~

~THROTTLE

LINKAGE

*~:

turned throttle

Automatic Chokes Thermostatic Type

The automatic tatic unit. At be set start when cranked, adjust choke determine Once this has been established, adjustment can be

Adjustment

1 . Loosen adjustment lock screw on choke body.

2. Moving adjustment bracket downward

3. After adjustment is made, tighten adjustment

in

made

This changed.

crease ment

lock

choke

room

temperature, choke lever will

a vertical position.

if

choke

to

remedy

allows the position of adjustment to be

the

amount

will result

screw.

Make

sure

counterclockwise

bracket--this

is a heat sensitive

If

engine should fail to

setting

in

is

too

lean

situation.

of choking. Upward

less choking.

idle

speed

until

allows the

Figure

lever by hand to

6-31.

thermos-

or

too

will in-

Anti-Dieseling

rich.

move-

,

sare~

on

aarburetor

it

no

longer

throttle

Solenoid.

made on cold engine. If starting in extreme cold, choke should be gine is started. A needed

Adjustment

1 . Move choke arm until hole

2.

3. Loosen

4. After replacing air cleaner,

in

up with

Insert #43 drill (.089) and push all the way down base of choke unit.

ward to tion. After desired position is attained, tighten clamp

of binding sure chokes are fully open when engine is at normal operating

plate

milder temperatures.

slot

to

engine manifold to engage

clamp

move

bolt then

in

has been

contacts

in

full closed position before en-

lesser

in

bearings.

bolt

choke

remove

linkage, adjust as needed.

the

to

close

degree

choke

plate toward closed posi-

temperature.

fully.

of

choking is

in

brass shaft lines

lever, push arm up-

drill.

check

THERMO-ELECTRIC AUTOMATIC

in

notch

for

evidence

Be

CHOKES

in

Electric-

Remove air cleaner position of

Thermostatic Type

from

carburetor to observe

choke

plate. Choke adjustment must be

6.20

Service

Before working on area take these

PRECAUTIONS:

or

near the

carburetor

or

choke

1 . Do not

injury

2. When

ONE STARTER

THE

LEAD DECISION MAKER

operate

may

result.

checking

LEAD

TO

RELAY

OTHER

TO

engine without air cleaner as

choke

operation, during crank-

ing, always engine

jury. Refer

from

remove

starting and

to

Figure

CHOKE SPRING l/2 TENSION

spark plug lead

to

avoid personal in-

6-32.

TURN

to

prevent

Figure

6-32.

Thermo-Electric

AUTOMATIC CHOKE

UNIT~

I

I I

\

Automatic

\

'

Choke.

CHOKE

/

-

/

ADJUSTING

SLOT

.......

'

.....

---

PLATE

-

.......

'

II

'

\

I

/

Troubleshooting

Before proceeding with analysis lems,

check

resistance

of

heater terminal using

of

choke

prob-

an

ohmmeter. If

resistance is less than 3

choke.

Resistance should be 3

ohms,

ohms

or

replace the

more.

6.21

PROBLEM

CAUSES

SOLUTIONS

Choke open.

Choke breaks

comes

Choke when

will

not

shaft

or

plate

out.

won't

close

cranking.

fully 1.

2.

3. Faulty

1.

2.

1. Faulty lead wires

2. Air

3. Open

4.

5.

Choke justed.

Choke freely. 2. Install

spring

shaft

choke

not

properly

fails

to

move

adjustment.

ad-

1.

Remove with spring 1

pair

3. Adjust

1 .

Incorrect Too

with KW

Faulty Decision Maker ground

Choke travel

ignition timing.

much

compression.

cleaner

choke

only).

gasket

shaft

circuit

or

in

solenoid wiring.

in Decision Maker.

lever

lacks sufficient

smooth

or

terminals.

interference

lever

movement.

(4.5

or

Time

install pair kit.

2. Adjust and install repair

1 .

Change choke.*

2. Reposition flat provide shaft

3.

Check ter

between

terminals

Replace

4. Replace lead

Maker ground. properly, Maker.

spring

choke

/2

new

kit.

choke.*

engine

new

ACR

kit.

lead wires

clearance

lever.

continuity

on

choke

with a

If

choke

replace

retainer

wide

open

turn.

shaft

assembly

as

specified

shaft

assembly

to

specification

new

shaft

of

gasket

with

the

two

the

choke

if

open

to

Decision

jumper

functions

Decision

windup

assembly

or

replace

for

choke

ohmme-

solenoid

unit.

circuit.

wire

and

re-

and

re-

to

*Choke Replacement

1 . Position

screws

2. Hold

3. Rotate retor

slight tated.

4. While holding tion, tighten

NOTE: With cranking, at a temperature

the

so

that

the

choke

the

choke

(viewed

pressure

engine

the

choke

the

unit on

it is slightly loose.

plate in

unit

from

the

until it

the

choke

two

not

running and

plate will be

of

about

And

Adjustment

the

wide open position.

clockwise

choke

can

no

unit in the

mounting

75 o

F.

two

mounting

on

the

side) with a

longer

closed

As

be

above

screws.

before

5°

the

tempera-

carbu-

ro-

posi-

any

to

1

oo

Manually

5. lever until fully choke freely.*

ture

decreases

more.

5.

Check plug lead and cranking

plate should peratures more

NOTE: During cranking, closed time

choke

at

only 5

is

controlled

above

lower

to

move

the

choke

closed.

the

close a minimum

10

Replace

unit if it

choke

function

temperatures.

by

does

plate will

by

the

75°

F.

the

seconds,

the

Decision

The plate will

choke

removing

as

choke

plate is

the

not

move

close

engine.

of

will remain

choke

Maker.

Choke Shaft Spring Adjustment

1. To adjust the turn and then spring

wide

through

the

choke

open

position. Windup

place

the

spring, hold

the

straight

hole in

the

end

shaft.

the

The

45°

closing

spring

even

spark

choke

at

tem-

close

plate in

of

the

1/2

6.22

GAS

FUEL

The main

used with

Liquified Primary Secondary regulator

SYSTEM

components

Kohler K series engines are:

petroleum

regulator

of the gas fuel

gas tank

system

as

Gas Carburetor

In

some

applications, the primary and regulators The gas two stage

the engine. the

fuel supplier.

There are equipment system servicing these the

equipment

Depending on the air of gasses tank can be as high as 180 Figure

are

combined

carburetor

regulator) are normally furnished with

Other

some

manufacturer

for

operation with gas. Information on

in

6-33.

components

isolated instances

systems

manufacturer.

the tank, pressure at the outlet of the

in

and

secondary

supplies the entire fuel

must

temperature

one

two-stage

are furnished by

be obtained

to

200 psi. Refer to

secondary

unit.

regulator (or

in

which the

from

and the mixture

Secondary Regulator

The

secondary

compact

are regulator

carburetor

the when the

it

fails, authorized gas

tempt

Secondary regulators used on Kohler engines require regulators have an idle adjustment. This adjustment ning. Refer

must

to

repair

only one adjustment. Ensign Models F

should be

regulators used on Kohler engines

single diaphragm types. This type

accurately

demand

be replaced

regulates the flow

and shuts the gas

for

gas ceases.

or

reconditioned by an

equipment

repair shop. Do

off

automatically

If

the regulator

a faulty regulator.

to

Figure

performed

while the engine is run-

6-34.

of

gas to

not

or

at-

F1

4. Turn the air flow stops.

NOTE: A soap bubble for

complete

still flowing, turn the

180

160

140

120

l

00

::::;-

80

(/)

0..

w

60

0:::

::::J

~

40

w

0:::

0..

20

0

lock

shutoff.

.....

-40

off

(Approximate

/

""

-20

TEMPERATURE

Figure

6-33.

LP

Gas Vapor Pressure Curve.

IDLE

ADJUSTMENT~

adjusting

test

If

bubbles indicate that air

screw

VAPOR

screw

is a

good

in one

more

PRESSURE

in slowly until

way to

Values)

PROPANE

II

I

'I'

ILso-so-

I

Mixtwz

,

v

.....

/~

~

v

~

0 +20 +40 +60 +80

/

v

......

BUJA~E

I""'

1

(°FAHRENHEIT)

~~

'-----

check

full turn.

j_

1/

J

!--

V-

J

t_

V"

"'

is

II

Garretson Model S, lockoff ing Figures

NOTE: The regulator should be to vertical as possible, and adjusted in

1 . Connect

2. Turn air supply on.

3.

or

fuel control adjustment. Use the follow-

procedure

6-35

and

which it will be

regulator inlet compressed nect

to

a gas supply.

If

the regulator being adjusted is a Model

open the lock

flowing through the regulator.

starts

SD

and

KN

to

make

this adjustment. Refer to

6-36.

mounted

air, not over 1 0 psi.

off

on the engine. to

adjusting

a source

regulators have a

mounted

screw

as close

in

the position

of

clean

Do

not

con-

KN,

until air just

FUEL

j_

INLET~

Figure

6-34.

Model F and

Regulators.

..,

F1

Secondary

VENT

(OR

BALANCE

LINE)

~FUEL

OUTLET

6.23

6. Check that air flow stops when the released.

7.

If

air flow does not

~~

I~

I

___

_

adjustment screw ment more

primer

stop

completely, loosen the

lock nut and turn the adjustscrew in until air flow stops, then one full turn.

is

LOCK-OFF

ADJUSTMENT~

Figure

NOTE: The to

adjust fuel flow while the engine is idling. Never

adjust at any speed above

5.

If SD, depress the This

6-35.

Models S and Regulators.

lock

off

adjusting screw

the regulator being adjusted is a Model S

primer

will allow air

to

flow through the regulator.

idle.

button

SO

Secondary

may

for

be used

an

instant.

or

8. Repeat steps 5 through 7 every time.

9. Tighten adjustment

screw

until air flow stops

lock

nut.

Primary Regulator

The primary regulator provides initial control of the fuel under pressure as it ply tank. The inlet pressure should tor

6 ounces lator does not function properly, replace it it serviced by an authorized gas

Never attempt to service

Upon demand for fuel, pressure drops on the outlet side of the regulator diaphragm. The gas inlet valve through the As the need valve Refer

Pressure may be adjusted by removing the bonnet

cap and turning the spring tension adjustment with a the pressure; turning it.

never exceed 250 psi. The primary regula-

is

adjusted

then begins

opens further, allowing

to

large screwdriver. Turning clockwise increases

for

outlet pressure

per

square inch

to

regulator to the secondary regulator.

for

more

Figure

6-37.

comes

from

the fuel sup-

for

primary regulators

of

approximately

(11"

W.C.).

equipment

If

the regu-

or

shop.

have

a faulty primary regulator.

open, allowing fuel

fuel increases, the fuel inlet

more

counterclockwise decreases

to

pass

fuel to pass.

LOCK-OFF

ADJUSTMENT

DIAPHRAGM

6.24

SPRING

FUEL

INLET

Figure

6-36.

Model

KN

Secondary Regulator.

VENT

________

I

~REGULATOR

COVER

I I

I

DIAPHRAGM

Figure

6-37.

Typical

Two Stage Regulator

The two stage regulator used on Kohler engines is a

double diaphragm type regulator designed use with and secondary regulation tor let is fails to operate properly, replace it iced

attempt to service

Vaporized fuel is admitted to the regulator at fuel tank pressure (up dary pressure on the internal side phragm builds up until the pressure overcomes the spring action on the opposite side phragm. This primary diaphragm spring has suffi-

air-cooled

fuel inlet is connected to the fuel tank. Its out-

connected

by

an authorized gas equipment shop. Never

engines. It combines primary

in

one unit. The regula-

to

the carburetor.

If

the regulator

or

have it serv-

a faulty regulator.

to

250 psi). Because the secon-

valve is closed (engine not running), the

of

the primary dia-

of

the dia-

for

Primary

cient tension sure on the internal side of the diaphragm to counteract the opening When the pressure reaches this level, the valve is • closed, preventing further pressure rise.

The secondary diaphragm acts against the secondary valve spring. Its action results from vacuum caused acting on the diaphragm, the diaphragm is moved nearer secondary valve until equilibrium is reached. As more increases, causing the secondary valve to open further. When fuel is flowing, pressure on the primary diaphragm is lowered spring to open the primary bring the pressure back to 1 0 psi. Refer to Figure

Regulator.

to

require approximately 1 0 psi pres-

force

by

the carburetor. As

to

the

center

fuel is needed, vacuum

of

the regulator, opening the

slightly, permitting the

valve

due

to

the spring. II

the

vacuum begins

from

the carburetor

in

an

attempt

to

6-38.

6.25

________

I

I I

I

I I

j

SECONDARY ADJUSTMENT

PRESSURE

CHAMBER

(PRIMARY -10

PSI)

CHAMBER

SECONDARY

DIAPHRAGM

Figure

Adjust the two stage regulator as follows.

1 . Turn the

wise as 3 turns.

Connect a source

2. at least 25 psi press

3.

Connect fuel outlet and press and hold the ton. The mately pressure rises slowly, the primary valve is leaking and the regulator pressure remains constant,

4. Remove pressure gauge and a film

secondary Slowly turn the

5. left until the bubble expands, then

one persists, replace the regulator.

secondary

far

as it will go. Then turn it clockwise

primer

of

complete

button 3

a 0

to

pressure

2 psi and hold steady at this reading.

soap

valve is leaking.

adjustment

of

clean

to

the regulator inlet and

times.

15 psi pressure gauge

gauge should read approxi-

solution.

secondary

turn

If

to

stop the leak.

counterclock-

compressed

primer

must

be

replaced.

proceed.

cover

a bubble

adjustment to the

forms,

to

6-38.

air of

de-

to

the

but-

If

outlet with

the

the right

If

leaking

Two

Stage Regulator.

crease the flyweights lating pin regulating pin causing the shaft to rotate with changing speed. One end side attached transmitted

When the engine is not running, the spring holds the throttle in the open position.

If

When a normal load is applied to an operating engine, the speed tends rotation of the nor spring, opening the throttle wider. This action admits speed again reaches the shaft rotates to close the throttle valve enough to maintain governed speed.

Governed speed constant speed applications mined by a throttle control setting.

Initial

in

speed and inward with a

move

outward,

of

the assembly

contacts

of

the

cross

of

the crankcase. Through external linkage

to the

more

cross

to

the throttle on the carburetor.

cross

fuel, restoring engine speed. As

may

Adjustment-

to

the tab on the

shaft

protrudes

shaft, the rotating action is

to

decrease.

shaft

acts

governed

be at a fixed point as on

or

K91,

decrease.

they

force

move

outward. The

governor

The resulting

against the

setting, the

variable as

K141,

cross

through the

K161,

As

the regu-

shaft,

gover-

deter-

K181

GOVERNOR

Engine

(with the exception gal flyweight mechanical type. The flyball. The nism are contained within the crankcase. The ernor

speed

gear

governors

governor

is driven by a gear on the camshaft.

in the K series

of

the K91) are

gear

and flyweight

Operation

In

operation, centrifugal

weights (or flyball)

6.26

to

force

move

causes the fly-

outward with

of

the centrifu-

K91

utilizes a

mecha-

an

engines

gov-

in-

Governors are adjusted at the factory. Further adjustment ernor connected. be indicated by engine with changes engine speed when a normal load is applied. The internal all K series engines. The external different on the sure to follow the adjustment model

should not be necessary unless the

arm

or

linkage work loose

The need

in

governor

engine being serviced.

for

speed

load

or

by

mechanism

K241

through

governor

or

become

adjustment

surges

a considerable drop

is basically similar

mechanism

K341

models.

procedure

or

for

gov-

dis-

may

hunting

in

for

is

Be

the

GOVERNOR

SPRING

SPEED

CONTROL

THROTTLE

BRACKET

BUSHING

DISC

NUT

CROSS

Figure

Make initial adjustment as follows.

1. Loosen, but the governor

2. Grasp the end and turn counterclockwise as far as possible. The tab on the cross shaft will touch the rod on the governor

Pull the governor

3. tor governor

as

6-39.

far

Governor Components.

do

not

remove,

arm

to

the

of

the

cross

gear

assembly.

arm

away from the carbure-

as it will go, then tighten nut holding

arm

to cross shaft.

the nut that holds

governor cross shaft.

shaft with pliers

SHAFT

NUT

Figure

6-40.

Initial Adjustment.

Throttle Wire Installation

In

those applications where a throttle is

nected to the engine,

6-41

to Figure 1 . Bend the end

Figure

2. Place throttle control throttle wire the throttle bracket.

3. Install throttle cable clamp and bolt it throttle bracket.

4. Remove drive pin from speed control disc and operate the throttle control, rotating the disc from idle to

.

6-41

.

full speed.

connect

of

the throttle wire as shown

in

speed control disc hole nearest

it as follows. Refer

in

open position. Insert

to

be con-

to

in

the

II

Speed Adjustment

~

WARNING: Overspeed Is Hazardous!

The

maximum allowable

4000

RPM. 3600 RPM maximum. Never tamper with the governor

setting to increase engine

limits. Severe personal injury

engine ated at speeds above these maximums.

Models K161

or

equipment

can

speed

for

Model

and

K181 are restricted to

speed

and

result

above these

damage to the

if

the engine is oper-

K91

is

6.27

Figure

6-41.

Installing

Throttle.

After making an initial adjustment throttle wire, set speed adjustment as follows. Re-

fer

to

Figure

1 . Start the engine and allow a few minutes

warmup.

2. Open the throttle to full speed and gine speed with a tachometer. Speed should be 3600-RPM

3. If speed is not as required, slightly loosen the bushing nut at the speed control disc.

4. Move the increase engine speed crease speed.

5. When nut.

NOTE: Do not use excessive force bushing nut. Excessive or

stripping of threads.

6-42.

approximately 4000

for

Model

throttle bracket counterclockwise to

proper

speed is set, tighten the bushing

K161

force

RPM

or

connecting a

for

check

for

Model

or

K181.

clockwise

in

tightening the

could cause binding

to

K91

de-

en-

and

Governor "New Look"

Throttle

Governor

Arm

-----,.....-/

Governor Spring

Throttle/ Control

Linka~e

~

Carburetor Throttle

~--Governor

K181

Lever

Gear

Assembly

High Speed Stop

/

DECREASE

SPEED

(

Figure

6.28

6-42.

Speed

Adjustment.

Figure

6-43.

Centrifugal

Mechanical

Flyweight

Governor.

Operation

Centrifugal gear assembly causes the flyweights ward as speed increases and inward as speed creases. As the flyweights force the 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 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 the

"fast"

force

acting on the rotating governor

to

move

out-

de-

move

outward they

regulating pin of the assembly to move

of

the crankcase. Through

in

position, the tension

of

the governor

spring holds gine is operating (governor

the

ing) , against the cross shaft tends valve. The applied by the regulating pin are during operation, holding the engine speed constant.

When a load is applied and the engine speed (and governor speed) decreases, the governor spring tension throttle plate wider. This admits stores engine speed. (This action takes place very rapidly, As the speed reaches the governed setting, the governor the regulating pin maintains engine speed at a relatively constant level.

Governed speed constant speed applications, mined by a throttle control lever.

the

throttle valve open. When the en-

gear

assembly is rotat-

force

applied by the regulating pin

to

close the throttle

governor

moves

so

a reduction in speed is hardly noticed.)

spring tension and the

the

governor

will again

may

be at a fixed point as on

arm to open the

be

or

in

"equilibrium"

more

fuel and re-

force

applied by

in equilibrium. This

variable as

force

deter-

Adjustment

1 .

Pull

the

governor

tor

as far as it will

2. Grasp the end turn counterclockwise as far as it

3. Tighten the pal nut on

in. lb. torque.

NOTE: between governor arm and to

Make sure there is at least 1116" clearance

prevent interference.

arm

away

from

the carbure-

go.

of

cross shaft with pliers and

will

governor

cross

arm

to

shaft bushing nut

go.

15

HIGH SPEED ADJUSTMENT

The maximum allowable load. The actual high speed setting depends on the application. Refer turer's tings. Check the operating speed with a ter; do not exceed the speed stop:

1 . Loosen the

instructions

screw. Refer

lock

to

speed

to

the

for

specific high

maximum.

nut on high speed adjusting

Figures

is 3600

equipment

speed

To adjust high

6-45.

RPM,

manufac-

set-

tachome-

no

II

~

WARNING: Overspeed Is Hazardous!

The

maximum allowable

RPM,

no

3600 setting to increase the maximum speed. Severe

personal injury

ment can result maximum.

load. Never tamper with the governor

and

if

operated at speeds above

speed

damage to the engine

for these engines is

or

equip-

INITIAL ADJUSTMENT

Make this initial adjustment whenever the governor arm is loosened Make sure the throttle linkage ernor arm and throttle lever on carburetor to ensure proper setting. Refer

or

removed

to

from

Figure

cross shaft.

is

connected

6-44.

to

gov-

Figure

2. Turn the adjusting speed is reached. Tighten

3. Recheck the speed with the just if necessary.

6-45.

High Speed Adjusting Screw.

screw

in

or

out until desired

the

lock nut.

tachometer;

read-

SENSITIVITY ADJUSTMENT

Governor sensitivity is adjusted by repositioning the governor spring set too sensitive, speed surging will

change when normal load is applied, the be set

in

for

load.

greater

in

the holes

If

a big

sensitivity.

drop

in

governor

in

speed

governor

occur

occurs

arm.

with a

should

If

Figure

6-44.

Initial Governor Adjustment.

The standard spring position is in the from

the

cross

shaft. The position can vary, pending on the engine application. Therefore, make a note of (or mark) the spring position fore removing it Figure

6-46.

from

the

governor

third hole

arm.

Refer

de-

be-

to

6.29

To

increase spring tension by moving the spring towards the cross

shaft.

To

decrease trol,

decrease

away

from

sensitivity,

spring tension by moving the spring

the

cross

increase the

and

shaft.

allow

governor

broader

con-

Figure

6-46.

Governor

Sensitivity

Adjustment.

6.30

Figure

6-47.

Initial

Adjustment.

HIGH

SPEED

\

STOP

II

Figure

Initial Adjustment - K241, K301, K341

Initial adjustment the to

same

Figure

as

6-4

for

these

for

models

7

for

parts description.

models

K91

is essentially

through K181. Refer

Throttle Wire Installation

Install a throttle follows. Refer

1 . Mount

clamp

6-48.

ure

2. Move the throttle control and place the hole in

3. Use a long nose pliers the end

for

variable speed applications as

to

Figure

the

throttle control

on

the

of

the throttle wire around the pin.

6-48.

or

throttle cable

blower housing as shown in Fig-

to

the open position

end

of

the throttle wire through

pin on speed control bracket.

or

similar tool

6-48.

K321,

to

Variable Speed Governor.

Speed Adjustment

£ WARNING: Overspeed Is Hazardous!

The

maximum allowable through with the governor setting to increase the maximum

speed. Severe personal injury engine speeds above the established maximum.

Adjust the governed speed follows. Refer

1 . Start the engine and allow a short warmup

2.

3.

loop

4. Tighten the high speed

K341

or

equipment can result

riod. Open the throttle fully and

with a mately

If

speed is not on the high speed stop bracket

speed

is 3600

tachometer.

3600

to

RPM,

to

Figure

Speed should be approxi-

RPM.

correct,

achieve the required speed.

for Models

no

load. Never tamper

and

if

operated at

of

these

6-48.

check

loosen the

bracket

stop

bracket screw.

K241

damage to the

models

engine speed

and adjust the

as

capscrew

pe-

6.31

Sensitivity Adjustment

Governor sensitivity is adjusted by repositioning the governor spring If set

too

sensitive, speed surging will any change occurs set third

the engine

nor

closer move

Sensitivity adjustment problem sitivity is adjusted, try one steps.

1. Set spark

with the application

too

low. The

hole

control sensitivity,

to

the

it

to

in

the

carburetor

"Carburetor

section.)

in

the holes

in

load.

If

governor

from

the end of the governor arm when

leaves the factory. To increase gover-

cross

shaft. To decrease sensitivity,

a hole farther

may

all cases.

plug point gap

If

for

peak performance. (See

Adjustment"

in

the governor arm.

occur

a considerable speed

of

a load, sensitivity is

spring is placed

move

the spring

from

the cross shaft.

not cure a hunting

hunting persists after sen-

or

more

of the following

to

.020"

and readjust

subsection

to

of

with drop

in

a hole

this

the

2. Stop the engine and of the governor linkage throttle. Remove excess paint nor spring and make sure that there is no interference other parts.

3. With the engine shut down the in

the wide open position. Adjust the governor linkage so that there is approximately 1 space between the tor

body.

4. Use a 1680

idle speed screw.

If hunting still occurs, the

last hole governing but permits when going spring up one position

between

tachometer

RPM

with the throttle lever against the

in

the governor arm.

from

no load

check

governor

throttle lever and carbure-

to

move

too

in

for

free

from

idle

to

from

components

throttle will be

set the idle speed

the governor spring to

If

this improves

great

a speed reduction

to

full load,

the arm.

move

movement

full open

the gover-

and

/32"

of

to

the

6.32

SECTION

7

RETRACTABLE

Retractable ture and should disassembly or

for

Frequently starter engine. may

be necessary. Also

intake

times.

MODEL

FAIRBANKS-MORSE STARTERS

Starters have die tion shoe and engages

handle is pulled. The drive

the engine with

is

engaged

page

of

other

check

is

securely

If

screws

screen

K91

assembly

in

the drive

starters

for

repair.

in

are lubricated during require cord

is maintained

the drive cup when the starter

the

crankshaft keyway

no

further

or

rewind spring

mounting screws

tightened on blower housing

are

loose,

make

in

cast

aluminum housings. A fric-

under

flywheel nut. A pin on the

cup.

spring tension

cup

lubrication until

to

starter

realignment

sure that the air

clean condition at all

is

held

to

prevent slip-

manufac-

replacement

make sure

of

is

used

in

place on

cup

STARTERS

Operation

1 .

Be

sure

starter erating engine result

from

2.

After

engine has started,

rope

to

snap

tinue

to

hold handle and allow

rewind slowly.

NOTE: Releasing handle tended

3. Do not use

4.

will shorten life

jerking A normal conditions.

Always pull rope tion against guide. Proper vent unnecessary wear.

or

smooth,

will not

or

lack

back

starter

pulling

steady

starter

receive

screen

serious engine

of

cooling air.

into

when

of

in

starter

pull will start engine under

handle straight out so that

excessive wear

is

kept clean when op-

damage

do

not allow

starter

starter.

a rough

rope

housing. Con-

starter

procedure

rope

manner,

all the way out.

can

starter

rope

is

ex-

such as

from

will pre-

to

fric-

Refer

to

Figure

7-1

.

CENTER!

NG

5.

If

recoil

starter bly can rope. The ley

/'

19

be

for

emergency

should

removed

starter

ever

fail,

starter

and engine cranked with a

drive

cup

will serve as a pul-

purposes.

assem-

Figure

7-1.

Fairbanks-Morse Starter - Exploded View.

7.1

Disassembly

If

starting rope breaks

following NOTE:

1. To

2. Hold washer (Key

3. Remove washer (Key

4.

NOTE: replaced

procedure

Handle rewind springs with extreme caution.

remove

mounting bolts. Refer

while removing retainer ring (Key screwdriver.

washers (Keys 9 and 1 shoe

Prevent rewind spring cover and detach inside spring loop

If

spring should

starter

assembly

by carefully lifting rotor about 1 /2 inch

in

cover

or

if starting spring fails, the

should be followed.

from

engine,

to

Figure

7)

in

position with

7),

spring (Key

0)

(Keys 11, 12, 13, and 14).

from

escape,

by coiling

in

remove

7-2.

thumb

6)

with a

then

remove

escaping

from

it can easily be

turns.

from

rotor.

Starting Rope Replacement

1 . When installing a new rope (Key 16)

rotor

thread through rotor,.as handle and washer, if used, and tie a double

knot

in

the end

explained

hole, then wind rope onto

in

"Reassembly."

of

the rope.

in

Rewind Spring Replacement

1 . Start with the inside loop,

fully

from

cover

time,

holding back the rest of the turns. When

replacing with new spring, note the position of

spring loop.

by pulling out one loop at a

remove

spring care-

four

8), friction

rotor,

Replace

2.

Spring holders furnished with replacement springs simplify the assembly procedure. spring outside loop engaged around the pin. Then

press the spring into ing the spring holder. A few

or

light grease on

in

proper

30 oil should then be applied to spring and

position as shown, with the

cover

cavity thus releas-

cover

drops

shaft.

of

SAE

Reassembly

1 . Replace washers (Keys 9 and 1

shoe assembly, washers (Keys 9 and 1 spring (Key ring (Key

2.

Starter rope is now in

the direction shown

3. The starter will be properly. To insure the starter, pull out the centering pin (Key 19) about 1 screws, make sure the centering pin engages

the centerhole

position. Hold the place the and tighten securely.

Reinstalling Starter

1. To align the starter, place it on the blower housing tering pin engaged crankshaft. reach the crankshaft, use a pair pull the pin out to the

8),

washer (Key 7), and retaining

6)

.

completely

in

damaged

proper

/8".

Place the

in

lock

washers and nuts on the screws

in

the desired position, with the cen-

(If the centering pin is

starter

the crankshaft and press into

starter

On

Engine:

in

the

correct

0)

, friction

0) ,

wound on rotor

Figure

with one hand and

7-2.

if not centered

centering

on the

center

hole

too

of

pliers and

length.)

four

of

the

short to

Place

20

of

the

A

7.2

Figure

B

7-2.

Fairbanks-Morse Starter Disassembly.

2. Press the four ers.

Hold the

3. sition and

STAMPED

~

CAUTION: Spring Under Tension!

Retractable starters contain a powerful flat wire recoil

spring that is under tension. Do center leased. Removing the center ing can cause the sudden release

screw

spring tension,

of

starter

screws

starter

securely

HOUSING

from the starter until the tension is re-

the spring.

into position and install the

with

lock

washers and flat wash-

assembly

tighten the four screws.

in

this

centered

MODELS

not

remove the

screw

before releas-

or

improper starter disassembly,

and

potentially dangerous

po-

To Remove

1 . Remove the five

assembly

To Install

1 . Install

mounting screws. Leave

2. Pull the handle out approximately until the pawls

the handle screws securely.

To Replace

Starter

to

Starter

starter

in

Starter

screws

blower housing.

to

blower housing using the five

engage

this position and tighten

securing the

screws

in the drive

Pawls (Dogs)

starter

slightly loose.

8"

to

10"

cup.

Hold

the

Always wear safety goggles when servicing retractable starters - full face protection is recommended. To

ensure personal safety sembly, the following procedures must carefully.

and

proper

starter disas-

be

followed

Use pawl repair two

starter

rings, and installation instructions.

1. Remove

STARTER

ASSY.

kit#

41

757 02. This kit includes

pawls, two pawl springs, two retaining

starter

from

engine.

Figure

7-3.

Exploded View.

7.3

~

CAUTION:

Do not remove the center screw replacing pawls. Removal

Spring

Under

of

Tension!

of

the starter when

the center screw can cause the sudden and potentially dangerous release of

the recoil spring. It is

not

necessary to remove

the center screw when making this repair.

3. Remove the rope retainer Untie the knot and handle.

4. Hold the pulley firmly with slip knot. Allow the pulley the spring tension 7-6.

remove

is

released. Refer to Figure

from

inside handle.

the retainer and

thumb

to

and untie the

rotate

slowly

as

2. Carefully note position of the pawls, pawl springs, and retaining rings before disassembly. (Components rectly

for

proper

must

be assembled

operation.) Refer to Figure

cor-

7-4.

3. Remove the retaining rings, pawls, and pawl springs

4. Clean pins and lubricate with any available bearing grease.

5.

Install new pawl springs, pawls, and retaining rings. When properly springs will hold the pawls against the pawl cam.

NOTE: Make sure the snap rings are securely seated snap ring can eration.

6.

Pull rope Install

7. "To

in

grooves

starter

Install

from

pawl pins on pulley.

installed, the pawl

of

pawl pins. Failure to seat the

cause

to

Starter."

pawls to dislodge during op-

make

sure pawls operate properly.

to engine as instructed under

commercially

5. When all spring tension on the starter pulley released,

6.

Tie a single knot

7. Rotate the viewed spring is tight. (Approx. 6

8. Rotate the pulley clockwise until the rope pocket of housing.

NOTE: the aid of a helper if necessary, hold pulley

Do

remove

pulley counterclockwise (when

from

is aligned with the rope guide bushing

not allow pulley/spring to unwind. Enlist

in

position.

old rope

in

one end

pawl side of pulley) until the

from

pulley.

of

new rope.

full turns of pulley).

or

use a

c-clamp

is

to

To Replace Rope

The rope can be replaced without

disassembly.

Figure

1. Remove the Pull the rope out approximately

2. temporary tracting into starter. Refer to Figure

7-4.

starter

(slip) knot

Starter

from

engine.

in

it to keep it

Pawls.

complete

12"

and tie a

from

7-5.

starter

re-

Figure

9. Insert the new rope into the rope pulley and through rope guide bushing ing. Refer to Figure

7-6.

7-5.

Removing

Releasing

7-7.

Handle.

Spring

Tension.

pocket

in

of

hous-

7.4

Rope Guide

Figure

0. Tie a slip knot approximately

1

end of rope. allow pulley knot

reaches

ing.

11.

Slip

the

single knot at

Tie a

rope retainer into handle. Refer

12. Untie

the

out until the rope is fully extended. Slowly re-

tract

the

been

properly

tract

until

7-7.

Installing

Hold pulley firmly with

to

rotate

the rope guide bushing

handle and

slip knot

rope

into the starter.

tensioned, the rope will fully re-

the

handle hits the housing.

rope the

in

slowly

rope

Rope. 12"

until the

retainer onto rope.

end

of

rope and install

and pull the handle

If

from

to

Figure

the spring has

Bushing

the free

thumb

and

temporary

in

hous-

7-5.

5. When all spring tension on has been released, pulley.

6. Remove and brake spring.

7. Rotate the will ensure the pulley spring.

Hold

8. starter and away

9. Rotate the carefully housing. Refer

If the pulley and housing ily, the spring could be ley,

turn the

before

7

10. Note the position sembly

(The spring and rectly positioned on pulley tion.) Remove from

the

center

pulley clockwise 2 full turns. This

the

pulley into

so

the from

pulley slightly

separate

or

there

is still tension on the spring. Re-

pulley

separating the pulley and housing.

on the pulley. Also

the

pulley as a

remove

screw, washer, pawl

is

disengaged

starter

pulley is away

others

to

the

in

the pulley

Figure

engaged

the housing and

of

the spring and

keeper

assembly

spring and

package.

the

starter

the

housing and invert

from

the

area.

from

side

from

rope

your

to

the

pulley

from

side and

starter

7-8.

do

not separate eas-

with the pul-

repeat

keeper

refer

to

Figure

must

for

proper

keeper

operaassembly

the

cam,

the

face,

step

as-

7-9.

be

cor-

Disassembly

1. Remove

~

Do

not the tension moving the center screw before releasing spring tension, the sudden recoil spring. Follow these instructions carefully to ensure personal safety and bly.

Make sure adequate face protection is worn

all persons in the area.

2. Pull

temporary tracting into starter. Refer

3. Remove the rope retainer

and untie the knot dle.

starter

from

engine.

CAUTION: Spring Under Tension!

remove the center screw

of

recoil spring has been released.

or

improper starter disassembly can cause

and

potentially dangerous release

the

rope

out

approximately

(slip) knot

to

of

proper

in

it

to

from

remove

the starter until

starter disassem-

12"

keep it

Figure

inside handle

retainer and han-

Re-

of

the

by

and tie a

from

re-

7-5.

Figure

7-8.

Removing

Pulley

From

Housing.

4. Hold the pulley firmly with

slip knot. Allow pulley spring tension is

released. Refer

to

thumb

rotate

and untie the

slowly

to

as the

Figure

7-6.

Figure

7-9.

Position On Pulley.

Of

Spring

And

Keeper

7.5

~

CAUTION: Spring Under Tension!

Do not remove the spring from the keeper. Severe

personal injury

of

the spring.

11

. Remove the rope from pulley.

remove the starter ley as instructed under

Pawls."

could

result from sudden uncoiling

If

pawl components from pul-

"To

Replace Starter

necessary,

Inspection and Service

1. Carefully inspect rope, starter pawls, housing, center or

screw, and other components

damage.

for

wear

Figure

7-10.

Installing Pulley And Spring Into Housing.

2. Replace all worn

Use only genuine Kohler replacement parts specified shown parts. Do

3.

Do

come new spring and keeper assembly.

4.

Clean away all old grease and dirt from starter components. Generously lubricate the spring and commercially available bearing grease.

in

not

attempt

out

center

in Figure

not

of

or

damaged components.

the Parts Manual. All components

7-3

are available as service

use nonstandard parts.

to rewind a spring that has

the keeper. Order and install a

shaft of starter housing with any

Reassembly

1 . Make sure spring is well lubricated with

grease. Position the spring and keeper assembly to pulley (side opposite pawls). The outside spring tail must be positioned opposite rope pocket. Refer to Figure

2. Install the pulley with spring and keeper assembly

into starter housing. Refer to Figure

7-10.

7-9.

The pulley is extending slightly above the face

not wind the time.

in

position when the

pulley and recoil spring at this

center

of

shaft is

the pulley. Do

3. Lubricate the brake spring sparingly with

grease. Install the brake spring into the recess in

center shaft of starter housing. Refer to Fig-

ure

7-3.

(Make sure the threads shaft remain clean, dry, and free of grease oil.}

4. Apply a small amount of Loctite #271 to the threads to screw with washer and shaft. Torque screw

5.

If

necessary, install the pawl springs, pawls, and retaining rings to pins on starter pulley. Refer to

6. Tension the spring and install the rope and handle as instructed der

"To

7.

Install the starter to engine.

center

"To

Replace

screw. Install the center

cam

to

65175 in. lb.

Replace Starter Pawls."

in

steps 5 through 12 un-

Rope."

to the

in

center

or

7.6

CAST HOUSING MODELS

Rope

Retainer-

-

Sheave

Recoil

I

Spring

r

!10

I'

I

~

Rope

Figure

7-

Exploded

11

·

View.

7.7

1. Remove the

starter

from

engine.

£ CAUTION: Spring Under Tension!

Do

not

remove the center

the tension

moving the center

tension, the sudden

of

recoil spring has been released.

screw

or

improper starter disassembly can cause

and

potentially dangerous release recoil spring. Follow these instructions carefully to ensure personal safety bly.

Make sure adequate face protection is worn by

all persons in the area.

2. Pull

3. Remove

the

rope

out temporary tracting into starter. Refer

Untie the knot and handle.

(slip) knot

the

rope

screw

of

the starter until

Re-

before releasing spring

of

the

and

proper

approximately 12" and tie a

in

retainer

remove

starter disassem-

it

to

keep it

to

Figure

from

inside handle.

the retainer and

from

7-12.

re-

Figure

7-13.

Releasing

Spring

8. Make sure the spring tension

(The

pulley should rotate easily

tion.)

9. When all spring tension on leased, washer, and 1

10.

Carefully fer

remove

/2"

lift the pawl retainer

to

Figure

7-14.

the

center

DIA. washer.

the screw,

Tension.

is

fully released.

in

either direc-

pulley is re-

3/4"

from

pulley. Re-

DIA.

Rope

Retainer /

/

Handle

Slip Knot

Figure

4. Rotate the notch ing.

Hold the pulley firmly

5. Untie

the

bushing.

Place

6. will keep the starter ley

is

7. Hold

the Release pressure on the rotate Be sure

to

Figure

7-12.

pulley

in

pulley is next

slip knot and pull the rope through

the

rope

into the notch

rope

housing leg

rotated (step

housing and pulley with both hands.

slowly

as the spring tension is released.

to

keep

7-13.

Knot

.•

Removing

counterclockwise

to

from

reinforcements

7).

the rope

Handle.

the

rope

keep it

in

interfering with the

pulley and allow it

in

the notch. Refer

until the

guide bush-

from

turning.

pulley. This

as the pul-

to

Nylon Spring Retainer

Pawls

1-1/8"

DIA.

Washer

Figure

NOTE: A small return spring and nylon spring retainer (spacer) tainer. These parts lost

or driver on

pulley. Replace the spring if it is broken,

stretched,

11. Remove the

return spring,

12. Rotate

should will ensure the pulley recoil spring.

13. Hold the pulley into the

invert face

14. Rotate the pulley slightly

carefully housing. Refer

7-14.

Removing

And

located are

fragile and can be easily

damaged.

to

loosen the spring retainer

or

the

be

starter

and others

If necessary, use a small screw-

shows

separate the pulley

other

signs

1-1/8"

pulley clockwise 2 full turns. There

no resistance

so the pulley is away

DIA. thrust washer, brake,

nylon spring retainer, and pawls.

is

in

the area.

to

Figure

Pawl Retainer, Pawls,

Components.

under the pawl re-

from

the post

of

damage.

to

this rotation. This

disengaged

starter

from

housing and

from

side

to

side and

the

starter

the

your

7-15.

7.8

Figure

15.

7-15.

If

the pulley and housing do not separate eas-

the spring could be engaged with pulley,

ily,

there

pulley

fore separating the pulley and housing. Only if it is necessary

remove instructed Do

not

lutely

Removing

is still tension on the spring. Return the

to

the housing and repeat step

the spring

under

remove

necessary.

the

Pulley

for

from

the

"To

Replace Recoil

spring

From

the repair of starter,

starter

unless

Inspection and Service

1.

Carefully housing, and other

2.

Replace all worn Use specified shown parts. Do not use nonstandard parts.

Carefully clean all old grease and dirt

3. starter ter specified mercially available bearing grease.

inspect the rope, starter pawls,

center

only genuine Kohler replacement parts

in

Figure 7-11 are available as service

components.

shaft, and certain other

in

screw,

components

or

the Parts Manual. All

these instructions with any

center

for

damaged

Lubricate the spring, cen-

shaft, spring

wear

or

components.

components

Housing.

12

be-

housing as

Spring."

it

is abso-

damage.

components

from

as

com-

or

Figure

4.

Position the new rope and around the rope

NOTE: Use only a genuine Kohler replacement rope which is designed of the properly

5. Install the sheave to the pulley and install the 4

6.

incorrect

in

Phillips head screws. Use care not to strip cross-thread

Inspect the pulley to securely joined to the pulley.

to

rope pulley.

7-16.

diameter

the pulley.

the threads

make

sure it

Replacing

in

lock

for

this starter. Using rope

and/or

make

is

securely retained

Rope.

the notch

post.

in

pulley.

sure the sheave

in

type will not lock

Pull

firmly on the

the pulley

in

or

is

the

To Replace Recoil Spring

~

CAUTION: Spring Under Tension!

Do not attempt

the housing. Doing so can cause the sudden and potentially dangerous release housing. Follow these instructions carefully to sure personal safety and Make sure adequate face protection is worn throughout the following procedure.

to

pull

or

pry the recoil spring from

of

the spring from the

proper

spring replacement.

en-

To Replace Rope

The

starter

replace the rope.

1. Remove the starter

2.

Disassemble

through 14

3. Remove the 4 Phillips head screws securing the sheave and ure

must

be

completely

from

engine.

starter

under

pulley and sheave. Separate the pulley and

remove

7-16.

as instructed

"Disassembly."

the old rope. Refer to Fig-

disassembled to

in

steps 2

1 . Carefully note the position of the spring

housing. spring

- it is housing.

2.

Place the housing on a flat wooden surface with the and away

3. Grasp the housing by the gers are around the

Also refer

must

be installed

possible to install it backwards

recoil spring and

from

protected.

edge

to

you.

Do

of

the housing.

Figure

in

the

center

top

not wrap

7-17.

proper

shaft down

so that your fin-

your

The new

in

the

position

the

fingers

7.9

4. Lift the housing and rap it firmly against the wooden surface. Repeat this the spring is in

housing. Refer to Figure

released

from

procedure

the spring

7-18.

until

pocket

Hook the spring hook Make sure the spring the seal installer and

pocket

c-ring

spring/c-ring

in

housing. Drive the spring out of

and into the spring

handle. Refer

over

the post

is

centered

pocket

to

in

housing.

using the

Figure

over the

7-20.

Figure

5. Discard the old spring.

A CAUTION:

.a

Do

not has been removed from the starter housing. personal injury ing

of

spring which is

7-17.

Position

7-18.

Removing

Old

attempt to rewind

Of

Spring

Reinstalled!

or

reinstall a spring once it

From

Cannot

In

Housing.

Be

Severe

could

result from the sudden uncoil-

the spring. Always order and install a new

held

in a specially designed

"c-ring"

spring retainer.

6.

Thoroughly clean the all old grease and dirt.

Carefully

7.

ing the new

8. Position the

spring hook is Make sure the spring is coiled direction. Refer

remove

spring/c-ring.

spring/c-ring

over

starter

the masking tape surround-

the post

to

Figures

housing removing

to

the housing so the

in

the housing.

in

the

correct

7-17

and

7-19.

9. Obtain Seal Installer # 11791 and Handle

#11795.

(Refer

to"

Special Tools" Section.)

Figure

10. Make sure all

11

. Lubricate the spring

7-19.

against ribs staller and handle to essary.

bearing grease er.

Figure

7-20.

Positioning

of

the spring coils are

in

spring

before

Installing Installer

New

Spring/C-Ring.

pocket.

bottom

moderately

reassembling the start-

Spring

And

Use the seal in-

the coils, as nec-

with wheel

Using Seal

Handle.

Reassembly

1 . Install the recoil spring into the

"To

as instructed under

Spring."

2.

Sparingly lubricate the with wheel bearing grease.

3. Make sure the rope necessary, replace the rope as instructed under

"To

Replace

Ready the pulley and rope unwinding Place the rope will keep the rope

all

Rope."

of

the rope

in

the notch

Replace Recoil

center

is

in

good

from

interfering with the

starter

shaft

of

condition.

for

assembly by

the pulley.

in

the pulley. This

bottomed

housing

starter

If

7.10

starter

ley

Install

4.

If the pulley the inner slightly

housing leg

is

rotated later during reassembly.

the

pulley onto the

does

center

from

side

reinforcements

not fully seat, it

spring coil. Rotate the pulley

to

side while exerting slight downward pressure. This should ner spring coil pulley

The

is

wind

to

pulley

flush with the

the

5. Install the

pockets

in

drop

into position.

is

in

pulley

starter

the

pulley. Refer

out

of

the way and allow the

position when the

face

of

and

recoil

pawls into the appropriate

as the pul-

center

shaft.

is

move

center

the pulley. Do

spring

to

at

Figure

resting on

the in-

shaft

not

this

time.

7-21.

11

. As a test, rotate the pawl retainer slightly

from

clockwise. Pressure

In

should be felt. should return leased.

tainer

unhooked,

steps

12.

Sparingly

3/4"

DIA. washer

If

no spring pressure

does

or

8,

9,

lubricate the 1

addition, the pawl retainer

to

its original position when re-

not return,

improperly

and 1 0

in tainer. Make sure the threads remain clean, dry, and

13. Apply a threads of screw

small

to

center

amount

screw. Install the

shaft. Torque

the return spring

is

the

spring

assembled.

to

correct

/2"

DIA. washer and

the

center

free

of

of Loctite #271

felt or the re-

is

the

problem.

of pawl re-

in

center

grease

screw

in. lb.

damaged,

Repeat

shaft

or

oil.

to

the

center

to

55170

Figure

6.

Sparingly DIA. washer with

center

7-21.

Installing

And

lubricate

grease

shaft. Make sure the threads shaft remain clean, dry, and oil.

Sparingly

7. the brake to

the retainer.

8.

Install the small return ring

lubricate the insides spider

with grease. Install the brake

tainer. Make sure it

the

9. Position next

to

free

loop of

Install

10. Invert center

damage sure the pawls

pawl retainer and return spring

the small

the

nylon spring retainer

the

pawl retainer

hub

post

the

return spring

of

pulley. Take

or unhook the return spring. Make

are

positioned

pawl retainer.

d '

/iWt,

1-1/8"

Pawls, Pawl Retainer,

Components.

underside of the

and install it

in

free

of

grease

of

the

to

the pawl re-

is

positioned properly.

on pulley. Install the

over

the post.

over

the post.

over

the pawls and

great

care

in

the slots of

DIA.

1-1/8"

over

center

"legs"

not

to

the

or

of

14. Rotate the viewed spring pulley.) Make sure the held ence

fer

to

Keep

Rope

In

Notch

Figure

pulley

from

is

tight. (Approximately 4 full turns of

counterclockwise

the pawl side

of

pulley) until the

fully extended rope

in

the

notch

in

pulley

with the housing leg

Figure

7-22.

Tensioning

to

prevent

reinforcements.

Spring.

(when

interfer-

15. Rotate the pulley clockwise until the notch aligned with

the

rope

guide bushing of hous-

ing.

NOTE: Do not allow the pulley/spring Enlist the aid of a helper, hold pulley

Insert

16. bushing. Tie a

mately

17.

Hold the pulley firmly with the pulley reaches the Refer

in

the

12"

to

position.

free

from

to

rotate

rope

Figure

end temporary

7-23.

or

use a

of

rope

(slip) knot approxi-

the

free

end

thumbs

slowly

until the slip knot

guide bushing of housing.

to

unwind.

c-clamp

through rope guide

of

the rope.

and allow

is

Re-

is

to

7.11

18. 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

7-12.

19. Untie the slip knot and pull the handle out until

the rope is fully extended. Slowly retract the

rope into the starter. properly tensioned, the rope

If the spring has been

will fully retract

until the handle hits the housing.

Figure

7-23.

Winding

Rope

Onto

Pulley.

7.12

SECTION 8

ELECTRICAL

SYSTEMS AND COMPONENTS

IGNITION SYSTEMS

Kohler K series engines are fitted with one of

types

of ignition different not tem. ment three are:

Magneto

1.

2.

3.

4.

Battery Ignition Systems

1 . Battery ignition with

2. Battery ignition with 1 0

versions. Most parts

interchangeable

Care should be taken in selection

parts types

Ignition System

Magneto Magneto

only) Magneto Magneto

systems,

to

ensure

of

systems

rotor flywheel

flyweel flywheel

with parts

the

and

type;

ignition only

type

motor

each available

in

one

from

right parts are used. The

their

available versions

(magnet

with 3

Amp

with 10

generator

Amp

alternator

in

system

another

of

replace-

ring; ignition

lighting coils

alternator

three

several

are

sys-

3. Battery ignition with 15

4. Battery ignition with 30

Breakerless Ignition System

1 . Breakerless ignition with 1 0

2. Breakerless ignition with 15

Amp Amp

alternator alternator

Amp

alternator

Amp

alternator

Magneto Ignition System Operation

In

all

magneto manent rotor the assembly In the tor. duces in magnets South constantly rent (AC) in ure

magnets

type

crankshaft

the

other

inside of

Movement

electric

alternator and lighting coils if

poles so that

8-1.

ignition

systems,

and is rotated inside a

(stator)

systems, a permanent

the

of

current

are

mounted

changes,

the

systems,

provide

mounted

flywheel revolves around

the

stator

the

magnet

magnets

flow

in

with alternate North and

the

direction

producing

coil windings. Refer

high-strength

energy

is

pressed

on

the

bearing plate.

magnet

past

the

stator

provided).

of

magnetic

an alternating

for

ignition.

coil-core

stator coil (and

per-

onto

ring on

the

sta-

The

flux

cur-

to

Fig-

In

in-

Figure

8-1.

Magneto

Cycle Showing Flux Reversal.

8.1

MAGNETO

IGNITION

COIL

~----HIGH

TENSION

LEAD

Figure

The

stator

windings ignition coil. reaches its highest netic

flux

which

spark

the The ignition coil has a

and a high tension dary

winding has approximately 1 00 turns

for

every causes the voltage induced ing

to mary. primary be 25,000 volts.

When ignition is to

break collapse causes sufficient secondary The collapsing field also induces energy mary

winding, but the

ergy

to breaker tor

and coil

Current

reverses

the

.system is

plug.

1 turn

be

about

If

the

magneto

winding, the

the

primary

of

the field around the

winding

ground,

point gap. Figure

assembly.

are

flow

peak

direction. This is the point at

timed

secondary

in

the primary. This relationship

100

times

produces

secondary

required,

circuit. The resultant sudden

energy

to

bridge the spark plug gap.

preventing it

8-2.

Typical Flywheel Magneto Ignition Coil And Stator.

connected

in

the ignition coil

at the instant the

to

low tension

in

higher than

the

to

be

condenser

8-2

to

provide a spark at

primary

winding. The

the

secondary

250 volts winding voltage will

breaker

primary

produced

shunts this en-

from

bridging the

shows a typical sta-

the

in

points open

Magneto Ignition Timing

Engines are either ing.

If with a marks the flywheel; T for

the firing point (20

ter). There are

system,

equipped

in

the bearing plate

a snap button

screwdriver

may

be

seen.

for

two

ways

static and timing light. The timing light

with a timing sight hole

or

in

the blower hous-

covers

or

similar tool so that the timing

Two

top

to

the hole, pry it out

marks

dead

deg.

time a magneto

will be present on

center,

before

and S

top

magneto

mag-

winding

secon-

of

the pri-

in

the

winding

in

the

in

the pri-

or

dead

ignition

wire

wind-

SP

cen-

w---TO

CONDENSER

~

~TO

method age lights.

Static Timing Method - Perform static timing as

follows.

1 . Remove the

2. Remove the spark plug lead

3. Rotate the engine

4. The

5. Measure the

6.

7. Tighten

8. Replace the

Timing Light Timing Method - Several different

types of timing lights are available. manufacturer's with a timing light as follows.

1 . Remove the lead

2. Wrap one end

is

the

more

accurate

battery

tentional starting

tion of normal operation. Rotation should be

clockwise when viewed

when the K91) appears hole. Continue rotating the engine until the breaker

gauge. The If

ment

wire around the spark plug terminal and re-

place the lead. The protrude lead.

is needed

breaker

the gap is not

screw

points should

S ,or

in

points are fully

breaker

gap

and adjust the gap.

the

gap

breaker

directions

from

beneath the

for

of

the

slowly

SP

mark

the

should

.020",

adjustment

from

of

a short

of the two. A stor-

use with

point

cover.

engine.

by

from

just

(T

mark

center

opened.

point

gap

be

.020".

loosen the gap adjust-

point

cover.

for

use. Perform timing

the spark plug.

piece

free

end

rubber

BREAKER

POINTS

most

timing

to

prevent

hand

the flywheel end.

begin

on Model

of the timing sight

with a

screw.

Follow the

of

the wire must

unin-

in

the

direc-

to

open

feeler

fine bare

boot

on the

8.2

NOTE:

an

light

lead, simply

prong and

metal

3. Connect one timing

4. Connect one timing light lead

5. Connect the third timing

The preceding

alligator clip

in

use has a sharp prong on the spark plug

penetrate

make

to

connect

contact

step

is

for

timing lights using

to the spark plug.

the

rubber boot with the

with the spark plug lead

connector.

light lead

wrapped around the spark

grounded)

terminal of the battery.

to

the wire

plug terminal.

to

the hot (un-

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 is centered in

center

the

mark

sight hole

on

the

or

bearing plate

is

SP

in

line with

or

mark

blower

housing. If timing is not as specified, carefully remove the

8. breaker point cover and

slightly loosen the justing screw, shift the breaker point timing mark is

properly positioned, and tighten the

gap

plate until the

screw.

9.

Shut off

the

engine and replace the breaker

point cover.

If

the

ad-

Battery Ignition System Operation

The battery ignition system operates in a manner

similar to the magneto system. The major difference

is that,

in

the battery system, energy is provided by a battery. The battery is maintained at full charge by an engine mounted or

alternator.

The coil as

in

a battery ignition system is connected

follows. Refer to Figure

8-3.

The positive ( +) terminal is connected tive

terminal of the battery.

(-)

The negative

terminal is

motor-generator

connected

to

the posi-

to

the

breaker points. The high tension (center)

terminal is connected

the spark plug.

Battery Ignition System Timing

The timing procedure

tem

is the

same

When using a timing

er's

instructions.

NOTE:

The Model engine is unique in that it is ently than other K series engines. These engines operate at

lower speed, degrees before ning smoothness.

the timing

mark have a 1 above and a 6 timing these engines, the timing

as with other engines.

for

the battery ignition sys-

as

for

the

magneto

light,

refer

K341

QS

Specification 71276A

timed

so

the timing is set at

top

dead

center

Instead of having an S

system.

to

the manufactur-

slightly differ-

to

improve run-

or

SP

on the flywheel, these engines

below

the

mark. When

mark

is centered

16

to

at

~

f:::.l===o::it

1

f----iSECONDARY

PRIMARY

CIRCUIT

t

BATTERY

~

" I !GNITIOII

-

__.,

t

GROUND~

Figure

COIL

8-3.

-----+-

Wiring

PRIMARY

lit~~~~~~-

Diagram -

Battery

SECONDARY COIJNECTI

=

Ignition

HIGH

TENSION

LEAD---~

-

OIJ

System.

8.3

-_/TERMINAL

NEGATIVE TO

CONDENSER

&

POINTS

Breakerless Ignition System Operation

The breakerless ignition

same

general principle as the

not

use

does

condenser

tion containing solid state same

function as the

ure

8-5.

breaker

to

system

points and conventional igni-

time

the spark. A electronics breaker

operates on the

magneto

performs

points. Refer

system

trigger

module

the

to

but

Fig-

MOUNTING

BRACKET

Figure

Battery Ignition Service - 1 0 -

8-4.

Typical

Battery

Ignition

16

Coil.

HP

Single Cylinder Models

Ignition models ignition coil, spark plug, replacing an ignition coil always use the genuine Kohler and gap setting is also important. The specified plug is a Champion H10/RH10, gapped at recommendations ignition misfire

problems

are

replacement.

.035"

and

poor

often the result of using an

or

Use

of

(.9mm).

will result

or

cutting-out

Failure

performance

plug gap setting. When

the

correct

or

equivalent,

to

in

erratic high speed

under load.

on these

incorrect

spark plug

follow these

The breakerless components:

• Ignition winding on alternator

• Trigger

• Ignition coil assembly

•

Flywheel-mounted

The ignition winding is separate windings on the alternator stator. the

magneto three diodes, a resistor, a sensing net and an SCR, a sort ignition pulse as the ignition has a projection that triggers ignition. Refer to Figure

In has been ignition rent feedback, if not

damage

coil assembly includes a

transformer

8-6.

some

applications a

placed between the key switch and the

coil. This has been added

feedback

the trigger unit.

system

module

winding. The

that serves the

coil

through a dirty

held in

in

consists

trigger

of

other

22

check

of

four major

stator

from

the

other

It

functions like

trigger

electronic switch. The

systems.

ohm,

module

coil and

capacitor

same

purpose

The flywheel

1/2

watt resistor

to

prevent

or

wet switch. This

by

a resistor, can

contains

mag-

and a

cur-

AC

WINDING

(ON

STATOR)

Figure

8.4

DIODE

8-5.

DIODE

l

Schematic

2

Of

Typical

Breakerless

Ignition

CAPACITOR

System.

BRACKET-~--~

(PART

OF

COIL)

vices. If a faulty trigger module is suspected, disconnect and and perform the following tests with a flashlight tester. Reset air gap when reinstalling trigger.

remove

the trigger from the engine

Diode Test

Figure

8-6.

Typical

-----TO

Breakerless

TRIGGER

&

SWITCH

Ignition

Coil.

Breakerless Ignition System Timing

Because there are no breaker points tem,

there is no requirement there is a requirement module projection. The gap between the projection and trigger

.010". .005"

Set the

1 . Remove the spark plug lead to prevent inad-

2. Rotate the

3. Loosen the

4. Move the trigger module until it touches the

5. Tighten the cap screws and replace the spark

The trigger module has two Make sure that the leads are connected as shown in

TRIGGER

The trigger module used on breakerless ignition systems is a solid state device which includes diodes, resistor, sensing coil and magnet plus electronic switch called an marked A must be connected to the alternator while terminal I must be connected to the ignition switch reversed will cause damage to the solid state de-

for

proper

module is normally set between . 005 and This setting is not critical, but selecting a

gap promotes

gap

as follows.

vertent starting.

flywheel so that the projection is

aligned with the trigger module.

cap bracket and insert a . gap.

feeler gauge, making sure that the flat surfaces of

plug lead.

Figure

module and projection are parallel.

8-7.

MODULE

or

ignition coil. Operating with these leads

for

relationship with the flywheel

better

screws on the trigger module

(BREAKERLESS)

for

positioning the trigger

cold weather starting.

005"

feeler gauge

clip-on

SCR.

in

this sys-

timing. However,

in

the

type terminals.

an

The terminal

Turn tester switch

the I terminal and the

reverse these leads one way but not the other way. If light stays

or

off both ways, this indicates diodes are

on

faulty--replace

SCR

Test

Turn tester on then connect one lead to the I terminal and the other to the trigger mounting

bracket.

NOTE: light must be

Lightly tap magnet with a metal is done, tester until leads are disconnected. If light does not come erly placed.

IGNITION

If light

on, this indicates

in

which case trigger module should be re-

COILS

Breakerless

Use an assembly. (A) --Remove high tension lead from terminal on coil. Insert one terminal and the other to the coil mounting bracket. A resistance of about 11,500 indicated here. the coil mounting bracket and the other ignition switch wire. Continuity should not be indicated here. Replace ignition coil assembly if wrong results are obtained

ohmmeter

ON

and connect one lead

other

to

the A terminal then

leads--light

trigger module.

comes off

initially

light should

should

on, reverse the leads as the

for

come

SCR

come

this test.

object--when

on and stay on

is not switching prop-

Type Ignition Coil

to test breakerless type coil

ohmmeter

ohms

(B) --Connect one

from

either of these tests.

on with

lead

should be

tester

to

this

in

coil

lead to

the

Magneto and Battery System Breaker

Points

Engine operation is greatly affected point condition and adjustment of the gap. points are burned current will pass. The engine all

or

may miss at high speed. Size point gap affects the amount of are open and closed. If the gap is set too wide,

will open too early and close

they nite period in

the ignition coil.

long

or

produced by the coil. Figure

much capacitance buildup on either contact indicates that the condenser is not properly matched to the rest of the

system and

of

too short a period, a weak spark will be

8-8

shows the

or

badly oxidized, little

may

time is required

If

the points are closed for too

effects

in

the condenser. Severe metal

should be replaced.

of

by

not operate at

of

the breaker

time

the points

too

late. A defi-

for

the field

too

little and too

breaker

If

or

no

to

build

8.5

Spark Plugs

Engine misfire and starting difficulty are often caused or

being

by

the spark plug being in

improperly

gapped. The spark plug

poor

condition

should eration for a the gap placed as necessary. Refer

be removed after every 1 00 hours of

check

should be reset

of its condition. At this time

or

TO

IGNITION SWITCH COIL

ASSEMBLY

the spark plug re-

to

Figure

8-9.

OR

op-

"BUILD-UP"

MOVABLE

COULD

INDICATE

UNDER

CAPACITANCE

ON

CONTACT

Figure

1-------TRIGGER

8-7.

Trigger Module Lead Connections.

MOVABLE

CONTACT

STATIONARY CONTACT

MODULE

COULD OVER

INDICATE

CAPACITANCE

Figure

8.6

8-8.

Metal Transfer On Breaker Points.

Service the spark plug as follows.

Spa•kPiug~

I[

Ground~

Electrode

Figure

8-9.

Setting Spark Plug Gap.

t

1 . Clean the area around the base

plug to keep dirt out moval.

2.

Remove the spark plug and check its condition. Replace it if it is badly worn is

questionable. Clean it if it is re-useable.

NOTE: that uses abrasive grit. recesses and enter the engine, causing extensive wear and damage.

3. Check the gap with a wire type feeler gauge.

4.

Do not clean the spark plug in a machine

Set the gap as shown carefully bending the side electrode.

Install the spark plug and torque to 18

lb.

of

the engine upon re-

Some grit could remain

in

the following table by

of

the spark

or

if

re-use

to

20

Spark Plug Specifications

Inspect the spark plug as soon as it

from the engine. The deposits on tip are a good

indicator of the general condition valves and carburetor. Normal and faulty spark plugs are shown

in

Figures

8-10

is

removed

of

piston rings,

through

8-14.

in

ft.

Engine

K91-K181 Battery

K241-K341 Battery

K241-K341

* Standard resistor plug

* *

Short resistor plug

NOTE:

On

gas fueled engines, gap is .018" on all models

Ignition Type

Magneto Breakerless

Breakerless

Magneto

Plug Part No.

270321-S 41

132 06*

41

132 02* *

235040-S 235041-S* 41

132 02* *

235040-S 235041-S*

Gap

.025" .025" .025"

.035" .035" .035"

.025" .025"

8.7

Figure

8-12.

Worn.

Figure

Normal: A plug taken

under deposits. plug

normal conditions will have light tan

If the

center

in

this condition

8-10.

Normal.

from

an engine operating

or

electrode is not worn, a

may

be gapped and

re-used.

gray

Worn:

On

a worn plug, the be rounded and the gap will more spark

beyond the

plug.

Figure

correct

8-13.

gap. Replace a worn

Wet Fouled.

center

be

eroded

electrode will

.010"

or

Figure

8-11.

Carbon Fouled.

Carbon Fouled: Soft, sooty, black deposits indi-

incomplete combustion. This

cate caused by overrich

tion

or

poor

compression.

carburetor

is

settings, weak igni-

8.8

usually

Wet Fouled: Wetness is caused by excess fuel

oil

in

the combustion

chamber.

Excess fuel could be caused by operating the engine without fully opening the choke after warmup. bustion ton rings

chamber

and/or

is

usually the result of worn pis-

valve guides.

Oil

in

the

com-

or

device is intended

ing. Refer to the wiring diagrams and troubleshooting

guides systems. There are no adjustments in these systems. Replace if faulty.

in

this subsection

for

battery charging and light-

to

test and service these

Figure

Chalky cate overheating. This condition is usually panied screen, clogged cooling fins and excessively lean carburetion

White

by

8-14.

Chalky

Deposits: Chalky white deposits indi-

excessive gap erosion. A clogged grass

are

some

White

causes of overheating.

Deposits.

accom-

Alternator Operation

There are five different models of alternators used in

the K series of engines. They are rated at 1.25, 3, 1 0, 15 and 30 amperes. The 1 . is intended

for

battery charging only. The 3 amp

25

amp

system

NOTE: and components:

a. Make sure the battery polarity is

b. Disconnect the

c. Make sure the stator (AC) leads do not touch.

d.

NOTE: volts, there vate the rectifier-regulator. If the battery fails to accept a battery charger and reinstall.

To prevent damage

negative ries engines.

wiring harness plug if electric (arc) welding is to be done on the equipment powered by the engine. Disconnect any other electrical sories that share a engine.

Shorting them together could permanently damage the stator.

Do connected.

(-)

ground system is used with K se-

rectifier-regulator

not operate the engine with the battery dis-

If

a battery has discharged to less than 4

may

not be sufficient power to acti-

a charge from the alternator, charge it on

to

the electrical system

common

correct.

leads and/or

ground with the

A

acces-

II

8.9

Troubleshooting Guide

1.25 Amp

Optional

Or 3 Amp Unregulated Charging System

70

Watt Lighting

NOTE:

Zero

ohmmeters

and voltmeters on each scale to ensure accurate readings. Voltage test should be

made with engine running at

Problem

With engine running

1.

voltage across voltmeter.

Disconnect the charging lead

2. With engine running

voltage DC

from

voltmeter.

No

Charge

To

Battery

With charging lead disconnected

3. and engine stopped, measure resistance charging lead Note

reading.

Reverse the leads and measure resistance again.

3000

RPM

Test

at

battery

at

charging lead

to

ground using an

-no

load. Battery must be fully charged.

3000 RPM, measure

terminals using a DC

from

battery.

3000 RPM, measure

to

ground using a

from

battery

ohmmeter.

from

If voltage

1. system

If

voltage diode diode

2a. 1 .

25

tor

2b. 3 amp.

winding If

voltage

using an

If resistance

3. Is

shorted. Replace the diode.

If resistance

diode

Is

are

(Test

amp.

winding

If Is

ohmmeter

or

voltage Is

stator

Conclusion

Is

more

than

OK.

Is

12.5 volts

probably faulty.

2, 3, and

If voltage

Is

OK.

less than specified

Is

low

Is

high

winding

12.5

or

4).

Is

11

Is

28

volts

(Tests 3 and

In

both

In

both

Is

volts, charging

less,

the

stator

Test

the

. 5 volts

or

more, test

4).

directions, the diode

directions, the

open. (Use

stator

more

stator

Test

or

sta-

and

4).

No

Lights

In

one direction, the resistance should be Infinity ohms (open reversed, some resistance should be measured (about midscale on

Cut

4.

1 .

2.

3.

the sleevlng on the charging lead

pose the diode connections. OK. Measure the resistance

diode

to

ground using an

Make sure lights are not burned out.

Disconnect the lighting lead

harness. Check With engine running

voltage AC

With engine stopped, measure the resistance of ohmmeter.

from

voltmeter.

stator

from

circuit).

at

lighting lead

3000 RPM, measure

With the leads

Rx1

range).

to

ex-

from

the

stator

side

ohmmeter.

from

the wiring 2. If voltage

to

ground using an If voltage

to

ground using

of

an

If resistance

4.

If resistance shorted. Replace

If resistance

lead

Is

Replace burned out lights.

1 .

harness.

lng an

If resistance

3. OK.

If

resistance

place

Is

open. Replace

Is

15

for

loose connections

Is

less than

ohmmeter

Is

stator.

0. 7 I 1 . 3 ohms,

0 ohms,

Infinity ohms,

volts

approx.

0 ohms,

stator.

or

15

(Test

stator

more,

volts,

3).

0.4

stator

winding

stator

or

shorts

test

ohms,

Is

winding

Is

winding

Is

OK.

In

wiring

stator

us-

stator

Is

shorted. Re-

Is

or

8.10

If resistance lead

Is

open. Replace

Is

Infinity ohms,

stator.

stator

or

lighting

Electric

1.25 Amp Optional

Start

Engines

Or 3 Amp Unregulated Battery Charging System

70

Watt Lighting

Breaker

Points

Condenser

Figure

Spark

Plug

8-15.

Coil

12

V.

Wiring

Battery

Diagram -

Battery

(Blue)

Electric

Charging

Diode

r------,

: I

I

L

______

Start Engines 1.

System/70

Watt

::.

Lights

25

Amp

Lighting.

(Black)

(Yellow)

I

J

or 3 Amp

Flywheel

Stator

Optional

Lighting

Unregulated

70 Watt

Stator

8.11

TROUBLE ANALYSIS - 10 AMP ALTERNATOR SYSTEM

TEST WITH ENGINE RUNNING AT 3600 RPM - NO LOAD

CONDITION: No Charge

TEST A --Disconnect

1---

TEST B

~

TEST C --Unplug leads

battery.

cable and ground. Check DC voltage:

A-1 --If above

A-2 --If less than A-3 --If

---

--With terminal on with place minimum load to

B-1

B-2 --If charge

--- ------------

VOM (multimeter) across

AC

C-1 --If less than C-2 --If

Connect DC

0 volts.

---

B+

cable

DC

Voltmeter.

reduce voltage.

--

If charge

voltage:

more

To

Battery

B+

cable

to

positive terminal

Voltmeter

14

volts.

14

volts (but above 0

--- --- ---

reconnected,

rectifier-regulator)

If 13.8 volts

of

5 amps • on

rate

Increases. B-1 --Indicates

rate

does

at

rectifier-regulator,

20

volts.

than 20 volts.

CONDITION: Battery Continuously

Charges At High Rate

TEST D --Check

*Turn

lights

B+

to

ground with DC

D-1

--If

over 14.7 volts.

D-2 --If under 14. 7 volts.

on

If

60

watts

or

more

between

check

not

AC

Voltmeter:

---

B+

(at

to

ground

or

higher, battery

Increase.

---

connect

leads, check

or simulate load

of

B+

volts).

--

-1---

by

A-1

--Alternator reading. Repair

A-2 --Check

A-3 --Check

--- ---

B-2 --Check

--- --- ---

--

C-1 C-2 --Defective

D-1 --Rectifier - regulator

D-2 --Alternator

placing a 2.5

for

(TEST

C).

for

(Test

C).

ohm

alternator

for

C).

100

fully charged.

(TEST

Defective

with new unit.

Check specific gravity sary.

Possible Fault/Remedy

system

defective

stator, rectifier-regulator,

OK--ammeter

or

replace

---

replace with new assembly.

ammeter.

rectifier-regulator

stator

or

rectifier

--- ---

system

stator

OK,

or

rectifier

--- ---

replace with new unit.

battery

may

Possible Fault/Remedy

not

functioning properly. Replace

system

OK.

watt

resistor across

Battery

of

battery.

unable

Replace If

battery

be giving false

- regulator

---

- regulator

---

to

terminals.

-

was

----1

hold charge.

neces-

8.12

Electric 15

Amp Regulated Battery Charging System

Start

Flywheel Alternator

Engines

fJC

Regulator

R

Starter

12

Volt

Battery

+

0

Ammeter

Breaker

Points

Coil

Condenser

Figure

8-16.

Wiring

Rectifier-Regulator

Diagram -Electric

Start

Engines/15

Amp

Regulated

Battery

Charging

System.

II

Figure

8-17.

15 Arr.p

Stator

And

Rectifier-Regulator.

8.13

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

Problem Test

No

Charge

To

Battery

1. Insert an regulator. With engine running and age regulator)

If voltage

minimum load

duce voltage. Observe

*NOTE: Turn on lights, If Or across

Remove

2. With engine running AC voltmeter.

3a. With engine stopped, measure the resls-

tance ter.

With engine stopped, measure the resls-

3b.

tance using an

ammeter

B+

lead

from

B+

Is

place a 2. 5 ohm, 1

battery

connector

voltage across

across

from

ohmmeter.

3600

RPM

In

B+

connected,

(at

to

ground using a DC

13.8 volts of 5 Amps•

terminals.

stator

each

measure the volt-

terminal on

or

ammeter.

00

from

at

3600 RPM, measure

stator

leads using

stator

lead

- no load. Battery must be fully charged.

Conclusion

lead

from

rectifier-

at

3600

rectifier-

voltmeter.

more,

place a

on

battery

60

watts

watt

rectifier-regulator.

leads using an AC

to

or

resistor

an

ohmme-

ground

to

more.

1. If charge

RPM

re-

2. If voltage

3a.

3b. If resistance

rate

the charging

fully charged. If

charge

applied,

(tests

2 and

Rectifier-regulator tier-regulator.

If voltage faulty and should be replaced. Test ther

using an

If resistance If resistance

Replace

stator

Is

If resistance

stator

leads are shorted

stator.

Increases when load

system

rate

does

test

Is

28

Is

less than

stator.

OK (not shorted

not

stator

and

3).

volts

or

Is

ohmmeter

Is

0. 1

/0.2

Is

Infinity ohms,

Is

Infinity ohms (no continuity), the

(or

continuity)

Is

OK and

Increase when load

rectifier

more,

faulty. Replace the

28

volts, (test

ohms, the

stator

to

ground).

Is

to

ground. Replace

applied,

battery

-regulator

stator

Is

stator

Is

stator

3).

stator

Is

open.

measured, the

was

Is

OK.

recti-

probably

fur-

Is

OK.

Battery

Continuously

Charges

At

High Rate

With engine running

1. voltage voltmeter.

from

B+

at

3600 RPM, measure

lead

to

ground using a

DC

1 .

If voltage

tern

Is

OK. The

Service

If voltage

regulator

Is

14.7 volts

battery

or

Is

more

Is

faulty. Replace

or

less the charging sys-

Is

unable

to

replace as necessary.

than 14.7 volts, the

rectifier-regulator.

hold charge.

rectifier-

8.14

Electric 25

Amp Regulated Battery Charging System

Start

Flywheel

Alternator

Engine

fC,

Regulator

Starter

Ammeter

Coil

+

Condenser

12

Volt

Battery

Breaker

Points

Figure

8-18.

Wiring

Diagram -

Rectifier-Regulator

Electric

Start

Engines/25

Amp

Regulated

Battery

Charging

System.

\

25

Amp

Stator

II

Figure

8-19.

25

Amp

Stator

And

Rectifier-Regulator.

8.15

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

Problem Test

No

Charge

To

Battery

1 . Insert an

regulator. With engine running

and age

tor) If voltage

minimum load duce voltage. Observe

*NOTE: Or across

2. Remove With engine running AC voltmeter.

With engine stopped, measure the

3a.

resistance across ohmmeter.

3b. With engine stopped, measure the resls- 3b. If resistance

tance an

ammeter

B+

lead

from

to

place a 2. 5 1

voltage across

ohmmeter.

connected,

B+

(at

ground using a DC voltmeter.

Is

13.8 volts of

Turn on lights, If

battery

connector

from

00

terminals.

each

RPM

- no load. Battery must be fully charged.

In

B+

lead

from

rectifier-

at

measure the volt- fully charged.

terminal

5 Amps • on

stator

on

or

more,

ammeter.

ohm,

watt

from

rectifier-regulator.

at

3600 RPM, measure

stator

leads using an AC

stator

leads using an

lead

3600

rectifier-regula-

place a

battery

60

watts

or

resistor

to

ground using

to

more.

1. If charge

RPM

re-

2.

3a. If resistance

Conclusion

rate

the charging

If

charge

applied,

(tests

2 and

If

voltage

Rectifier-regulator

tier-regulator. If

voltage ably faulty and should be replaced. further

OK. If resistance

Replace

stator

Is

If resistance stator

leads are

stator.

Increases when load

system

rate

does

test

Is

28

Is

less than

using an

stator.

OK (not shorted

not

stator

and

3).

volts

or

Is

ohmmeter

Is

0. 064/0.096 ohms, the

Is

Infinity ohms,

Is

Infinity ohms (no continuity) the

(or

continuity)

shorted

Is

OK and

Increase when load

more,

faulty. Replace the

28

battery

rectifier-regulator

stator

volts,

stator

(test

3).

stator

to

ground).

Is

measured, the

to

ground. Replace

Is

applied,

Is

OK.

Is

Test

stator

Is

open.

was

Is

recti-

prob-

stator

Is

Battery

Continuously

Charges

At

1. With engine running at 3600 RPM, measure 1 . voltage voltmeter.

from

B+

lead

to

ground using a DC

If voltage system charge. Service sary.

High Rate If voltage

regulator

Is

14.7 volts

Is

OK. The

battery

Is

more

Is

faulty. Replace

or

less the charging

battery

than 14.7 volts, the

Is

unable

or

replace as neces-

rectifier-regulator.

to

hold

rectifier-

8.16

Electric 30

Amp Regulated Battery Charging System

Start

Engine

Figure

.--------Red----------,

8-20.

Wiring

Black

Diagram -

-------,

------;.:;::;:t-+,:-=-,

Regulator

u····

Swltch-------r~~-----r--"""""EL-_~

(Key Start)

Electric

Start

Engines/30

Coil

Amp

Regulated

12

Battery

+

Condenser

Battery

Volt

Breaker Points

Charging

System.

Figure

8-21.

30

Amp

Black

Stator

Red

And

Rectifier-Regulator.

Full

Wave

Rectifier

8.17

Troubleshooting Guide 30

Amp Regulated Battery Charging System

Output tests should

Problem

Remove 4 Input Set

1a.

1b.

1c.

No

Charge

To

Battery

Continuously

Charges

High

Rate

2.

3.

1.

At

be

made

ohmmeter

Connect check

Measure lead

to

Replace found.

Connect tester from then

reverse

the

other

Remove other

leads

mlnals). If

connect terminal operate

Remove lator,

connect

Start

engine

with engine running at 3600

Test leads

from rectifier-regulator.

on

Rx1

scale

and

zero

scale.

ohmmeter

resistance.

ohmmeter

resistance.

the

ground.

stator

leads

BAT

AC

red

lead

connected

unit ammeter and

at

full

two

red and

across

resistance

If

of

leads.

terminal.

does

battery. Start

speed.

these

from

specified

flashlight

NEG

to

Repeat

from

REG to

not

have

between + BAT

leads

from

two

operate

red

leads

black

leads

each

values

are

type

continuity

one

AC

terminal,

procedure

terminal

appropriate ter-

ammeter,

engine

rectlfler-regu-

leads

together.

at

full

speed.

and

stator

not

(all

REG and

RPM -no

and

on

1c.

2.

3.

1 .

1a.

1

b.

load. Battery

Resistance

(no

continuity).

Lamp

off

reversed. Diodes

In

Replace the

Charging Faulty

stator.

Charge Replace

Charging rate.

rectifier-regulator

same

regulator

rate

rectifier-regulator.

Regulator

Conclusion

should

In

one

direction.

regulator

In

both

system

winding

Is 4 amps

system

winding

must

be

2.0

ohms.

be

0.

1

ohms.

be

Infinity

are

good.

directions.

output

less

on

or

continues

shorted,

be

on

If

lamp

20

stator,

less.

to

fully

ohms

when

amps.

Stator

charge

replace

charged.

leads

are

Indication

replace

Is

good.

at

high

stator.

Is

ELECTRIC

There are series

Motor-Generator DC

generator.

crankshaft through a

belt transmits turning

motor-generator

the crankshaft.

Wound-Field wound starters, electrical current flows through coils

to armature. When the armature starts drive pinion

meshes

and armature and ring engine starts turn

faster

from

the ring

position. A

STARTING SYSTEMS

three

types

of

starters used in the K

of

engines. The three types are:

- This

In

the starting

Bendix

build up a strong

moves

with a ring

gear

to

run. When the flywheel begins

than the starter, the pinion is thrown

gear

small

anti-drift

starter

V belt arrangement. The V

force

to a large pulley on the

Drive

forward on the armature shaft

gear

remain engaged until the

and returns

also functions as a

mode,

from

Starter -In

magnetic

on the flywheel. The

spring on the armature

it turns the

a small pulley on

field to turn the

to

the disengaged

the

field-

rotate, a

8.18

to

shaft holds the pinion in this position as the slows

to

a stop.

Permanent

tion

of wound-field the two is in the netic

field to turn the

strong

Safety

In

an effort

equipment,

terlocks

safety requirements

usually all interlock switches are closed, the not function.

Before servicing a failed, always first. This is switches with a

Magnet

this

type

starter. The

permanent

Bendix

starter

method

magnets

Interlocks

to

enhance safe operation

many

manufacturers

to

prevent engine start

are

incorporated

check

done

in the

starter

the safety

by bypassing the interlock

temporary

Drive

is the

same

major

of

generating the

armature.

in place

met.

These interlocks are

starter

that is

jumper

Starter

difference

This

install safety in-

before

circuit. Unless

reported

interlock

wire.

- Opera-

as that

starter

of

field coils.

of

their

certain

starter

system

starter

of

the

between

mag-

uses

will

to have

SEAT

SAFETY INTERLOCK CIRCUIT

ON

VEHICLE

JUMPER (TEST

BATTERY

Figure

~

WARNING: Never return an engine to the owner with the safety interlock system removed bypassed.

Great bodily harm result.

Interlocks ignition system are bypassed simply jumper

connected

wire as shown

or

equipment damage

to

an engine with a battery

in

Figure

8-22.

could

by

placing a

Battery

or

ONLY)

Ignition

Interlock

Brush Replacement

(Refer

.--------------.

to

Brush

Figure

Springs

SOLENOID

Bypass.

8-23.)

Stud Terminal With Positive(+)

Brushes

Negative (-) Brushes

II

:

~

WARNING: Make sure all safety conditions have been observed before starting an engine with the interlocks bypassed.

The safety interlock system on manual start neto ignition engines is placed in the ignition system.

The series connected interlock switches are connected nected to the ignition system. The module serves

two functions. all interlocks have closed and, after the engine has started, it prevents the ignition from grounding

as the individual interlocks are opened operation (transmission placed gaged,

to

a solid state module that is con-

It grounds the ignition system until

etc.).

Refer to Figure

8-23.

in

Drive,

in

normal

PTO

mag-

en-

Brush

Holder

Figure 1 . Remove the brush springs

2. Remove the

3. Remove hex nut, split lock washer, plain wash-

Remove the stud terminal with positive ( brushes, and plastic brush holder

8-23.

Commutator

brush holder.

self-tapping

(-)

brushes.

er, and fiber washer

End Cap

screws and negative

from

With

from

the pockets

the stud terminal.

from

end cap.

Brushes.

in

+)

8.19

4. Reinstall nal with positive (+) brushes into end cap. Secure with the fiber washer, plain washer, split

CAUTION: To prevent electric arcing, make sure

the

brush holder and new stud

lock

washer, and hex nut.

the stud terminal and braided brush leads

do

not touch the end cap.

termi-

Commutator End

Cap

5. Install the new negative

cure

with

the

self-tapping

Install

the

6.

pockets fered sides springs.

NOTE: brushes easily be Figure

Use a brush holder tool

8-24.

brush springs and brushes into the

in brush holder. Make sure the

of

brushes are away

in

the pockets. A brush holder tool can

made

from

thin sheet metal. Refer to

(-)

brushes and se-

screws.

from

to

keep the

cham-

the

Figure

3. Install the brush holder tool

4. Install the

5. Make sure the

6.

8-25.

Starter

brushes in the cap. Refer

and starter frame. Firmly hold the drive end cap and frame. Remove the brush holder

frame the thru bolts.

Install the drive pinion, dust anti-drifting spring, stop nut, and dust cover. Refer Service."

to

commutator

are aligned. Refer

pockets

Figure

match

Assembly

of

8-24.

end cap to armature

end cap

marks on end cap and

Match

to

keep the

commutator

to

the starter tool.

to

Figure

cover

gear

spacer, stop

to

"Starter

8-25.

spacer,

Marks.

end

Install

Drive

Figure

Brush Over

8-24.

Brush

Holder

Brushes

Holder

Tool

And

Tool.

Commutator Service

Clean the cloth. Do not use is badly worn replace the armature.

commutator

emery

or

grooved, turn down on a lathe, or

with a coarse, lint free

cloth.

If

the

commutator

Reassembly

1. Insert

2.

the

armature into the starter frame.

Make sure the magnets are closer

of

shaft end the armature inside the frame.

Install the thrust washer and drive end cap. Make sure the frame

armature. The magnets will hold

match

are aligned. Refer to Figure

marks on end cap and

Installed End Cap

to

the drive

8-25.

NOTE: with special shouldered cap screws and lock washers

used

parts ensure alignment of the pinion and ring gear.

Wound-Field Bendix Drive

NOTE: but fails

lowed starter is ing when the starter is engaged, the pinion and ring

NOTE: seconds. A allowed between starting attempts. Failure low this procedure could result

NOTE: K161 screws and lock washers these starter. These special parts ensure alignment of the pinion and ring gear.

If

the, engine being serviced is equipped

for

mounting, make sure these

for

reinstalling the starter. These special

Starter

In

the event of a false start (engine starts

to

keep running) the engine must be al-

to

come

to a complete

re-engaged.

gear

may

be

Do not crank the engine

60-second

If

the engine being serviced is a Model

or

K181

and has special shouldered cap

same

parts are used

If

damaged.

cool-down

stop before the

the flywheel is still rotat-

for

period must be

in

starter burnout.

for

mounting, make sure

for

reinstalling the

same

parts are

Service

longer than 1 0

to

fol-

8.20

DUST

SHIELD~

(OPEN

END

TYPE)

DUST

(CUP

SHIEL7

TYPE)

------

SHIELD

RETAINER~

!

/

DRIVE

'

_/

PINION

'

I

Figure

8-26.

Bendix Drive Installation.

::::::

STOP~

(DISCARD

ORIGINAL)

r-----RED

~

_/r-et)

~

(b

I

.-:·.

;(._.<

J1~t(.

··~

/ '

(j

~

RETIGHTEN 120

LEAD

IGNITION

~

.r&,

///

>TMTn~

~+~~ON

(FROM

KIT)

NUT

INCH

TO CIRCUIT

TO

LBS.

ENGINE

NOTE:

Delta

Systems

Module

function properly with

Figure

Depicted--this

Kohler

8-27.

Engines.

Magneto

BROWN

LEADS

Ignition

must

Safety

have

.. T ..

Interlock

CONNECTOR SAFETY CIRCUIT

\

designation to

System.

TO

SWITCH

8.21

FRAME

WOUND

FIELD

COILS

SHOULDER/

CAPS

CREW

(MOUNTING)

~~

Figure

~·--------ARMATURE

8-28.

Wound-Field Starter - Exploded View.

~

@@

[END

SPACER(S)

~LOW

----THRUST

PLAY

MOUNT

STARTER

WASHER

DRIVE PINION

STOP

NUT

(130-150 IN.

LBS.)

Service the Figure

1 . Remove

the two through end

2. Lift the spring remove

3.

Carefully Inspect both brushes (positive on frame; nega-

4. tive on end or

5. Remove the negative brush by rivet placement brush and rivet.

6. Remove insulating material on the field winding and un-

clipping

brush and clip

7.

Use a the use a

wound-field

8-28.

the

end cap assembly by taking out

bolts and carefully slipping the

cap

off

of the armature.

holding the positive brush and

the brush.

remove

are shorter than

holding it

the

or

unsoldering. Install the replacement

coarse

commutator

the armature.

cap).

to

the end cap. Install the re-

positive brush by peeling back

or

cloth

is grooved

starter as follows. Refer to

If brushes are worn unevenly

5/16",

solder

to

stone or fine sandpaper.

replace them.

in

place.

clean the

or

drilling out the

commutator.

extremely dirty,

9. Lightly coat the end cap bushing and armature shaft with

10. Hold fully place end cap in position on armature shaft. tacting

11

. Insert two through bolts and

in.

lb.

12. Inspect pinion and splined shaft. is

noted, replace the Bendix drive.

13.

If

the Bendix drive is in everything special silicone grease (Kohler Part No. 52 357

01) shaft.

light engine oil.

the positive brush spring

Release spring after brushes are con-

commutator.

torque

good

condition, wipe

clean and apply a very thin coat of

to

the splined portion of the armature

Permanent Magnet Bendix Drive Starter Service

NOTE: but lowed

If

starter is ing when the starter is engaged, the pinion and ring

In

the event of a false start (engine starts

fails

to

keep running) the engine must be al-

to

come

gear

to a complete

re-engaged.

may

be

damaged.

stop

If

the flywheel is still rotat-

back

and

to

If

any damage

before the

care-

40

to

55

NOTE: tator.

8.

Never use

Carefully insert

8.22

emery

the

cloth to clean a

armature.

commu-

NOTE: seconds. A allowed between starting low

Do not crank the engine

60-second

this procedure could result

for

cool-down

attempts.

in

longer than 1 0

period must be

Failure

starter burnout.

to

fol-

Service the permanent magnet starter as follows. Refer

to

Figure

8-29.

bracket and frame off armature.

of

the drive end

of

the

1 . Remove

Bendix drive.

2. Remove both through

3. Remove the end bracket capscrew from the end cap.

4. Remove mounting bracket and frame by rotating the end bracket and

the

stop nut and the remainder

bolts.

slipping the mounting

of

the

PERMANENT MAGNETS

5. Separate the end cap from the armature, being careful cap.

6.

Inspect the commutator. If dirty, clean it with a coarse, a

commutator

and undercut the mica.

/THRU

lint-free

BOLT

to

restrain the brushes

cloth. If grooved, dress it with

stone

or

turn it down on a lathe

HIGH

MOUNT

PM

STARTER

in

the end

TYPE

/

BRUSH DETAIL

Figure

8-29.

Permanent Magnet Starter - Exploded View.

Failure Analysis - Bendix Drive Starters

Starter failures from overcranking * or cranking with an

abnormal parasitic load* * on the engine, will

one

or

display

1 . The armature wire insulation

pear discolored and cases, you from the burnt wire coating or see it oozing from the starter housing.

2.

One

or may burnt ing or be

a number of the following signs:

or

may

be swollen.

may

be able to detect

a number

have wires

in

two. Wires

partially fused together.

of

the armature windings

or

wire connections that have

may

have insulation miss-

coating will ap-

In

many

an

odor

ally,

in

many instances the starter brushes will

be welded or stuck

Some load at cranking are:

2.

3. Malfunctioning or inoperative direct

4. Engaged accessory

of

the frequent causes

Improper viscosity engine crankcase oil.

1 .

Incorrect fluid unit - remember, even position, a direct coupled hydrostatic pump place

a parasitic load on the engine at crank-

ing.

clutch

assembly.

in

the brush holders.

of

abnormal parasitic

in

a direct coupled hydrostatic

in

the idle or neutral

or

drive clutch assembly.

MOUNTING

will

coupled

3. The starter brushes galling and brush material transfer. Addition-

will show heavy surface

Starter against

failures from overcranking

an

abnormal parasitic load are not covered

or

cranking

8.23

by

Kohler engine Warranty. We would recommend that you identify the root of the problem and advise the engine owner

The starter bendix drive used by signed and manufactured to withstand forces far excess when the followed . Missing drive gears are not being caused material analysis of returned failed starter drives has shown that bendix drive damage is being caused by engaging the starting motion. For this reason, warranty claims

failed bendix drive with damaged will no longer be

*Overcranking - cranking the starter continuously

for allowing a sufficient cool down period between starting attempts.

more

of

those required

recommended

or

workmanship. Rather, our testing and

than the

of

your findings.

Kohler is

for

normal operation

starter procedures are

or

damaged teeth on the bendix

by a defect

motor

accepted.

recommended

while the flywheel is

or

missing teeth

period

and/or

de-

for

in

a

not

in

To

prevent accidental shorting and the resultant sparks, remove all jewelry before servicing the battery.

When

disconnecting battery cables, always disconnect the negative (-) cable first. battery cables, always connect the negative cable

When

connecting

last.

Before disconnecting the sure all switches are spark will result in an explosion vapors are present.

Keep batteries and

occur

at the ground terminal. This could

negative(-)

OFF.

If

if

hydrogen gas

acid

out

any switch

of

the reach

cable, make

is

ON,

a

or

gasoline

of

children.

**Parasitic Load at cranking - a load the engine at cranking that opposes normal engine rotation.

or

force on

Battery Service

A battery is supplied by the equipment manufacturer. The battery should be a at

32

amp

hours minimum.

Battery Test - If the battery does not have enough

charge to crank the engine, recharge it. NOTE:

with another battery. Starting with a battery than tor.

The battery is tested

ter

engine. If the battery voltage drops below 9 while cranking, the battery is replacement.

Battery Charging -

Do not

recommended

across the battery terminals and cranking the

attempt

to

can burn out the starter

by

connecting a

in

12

volt unit, rated

jump-start

need of a charge

the engine

DC

larger

mo-

voltme-

or

A WARNING: Dangerous Acid, Explosive

.a

Batteries contain sulfuric acid. burns, avoid contact with skin,

Gases!

To

prevent acid

eyes and clothing.

Battery Maintenance - Regular maintenance will

ensure that the battery will charge.

~

WARNING: Ignition Coli Overheat!

Always turn the ignition switch the battery cables before charging the battery. Fail-

could

ure to do this sion

of

the ignition coil.

1 . Check the level of the electrolyte regularly.

Add distilled water to maintain it at its mended level.

NOTE: ance

2. Keep the cables, terminals and external bat-

NOTE: enter the battery cells. The solution will chemically

destroy the electrolyte.

Do

not overfill the battery. Poor

or

early failure will result.

tery surfaces clean. A buildup acid

or

dirt on the surfaces can cause the battery to self-discharge. Wash the nals and external surfaces with a baking soda and water solution. Rinse thoroughly with clean water .

Do

not allow the baking soda solution to

result in overheating and explo-

accept

OFF

and hold a

or

disconnect

perform-

of

corrosive

cables, termi-

recom-

Batteries produce explosive hydrogen ing charged. Charge the battery only in ventilated area. Keep cigarettes, sparks, open flame and other at all times.

sources

of

ignition away from the battery

8.24

gas

a

while be-

well-

SECTION 9

AUTOMATIC COMPRESSION RELEASE

All

K-Series K91, are Release (ACR). The pression at cranking speeds to make starting easier.

OPERATION

The ACR and a spring attached to the gear on camshaft. When the engine speeds (600 by the spring

single cylinder engines, except the

equipped

mechanism

Exhaust

Valve (Open)'-.,__

with

Automatic

ACR

mechanism lowers

consists

is

rotating at low cranking

RPM

or

lower) the flyweights are held

in

the position shown

Compression

of

two flyweights

in

Figure 9-1 .

com-

results 2:

After the engine speed increases to about

RPM, position shown tab on the the exhaust tab has no engine operates at power.

in

an effective compression ratio

1 during cranking.

centrifugal

force

in

Figure

larger flyweight

cam

lobe. When

effect

on the exhaust valve and the

moves

full compression and full

the flyweights to the

9-2.

In

this position the

drops

into the recess

in

the recess, the

of

about

600

in

Camshaft

Tab

"'O

Flyweights

Spring

F=~

~~=T7-5'r====i

t~----'

Spring

L~

Flyweights

Spring

Figure

9-2.

Automatic Compression Release

(ACR) - Running Position.

Tab

Figure

In

this position, the tab on the larger flyweight protrudes above the exhaust exhaust the compression stroke. The reduced compression

9-1.

Automatic Compression Release

(ACR) - Starting Position.

cam

valve off its seat during the first part

lobe. This lifts the

of

is

When the engine flyweights to the position shown

ready

for

the next start.

stopped, the spring returns the

BENEFITS

Because cranking speeds, obtained.

of

the reduced compression pressures at

several important benefits are

in

Figure

9-2,

9.1

• Manual starting (rope start is much easier. Without

full compression would be virtually impossible.

• Electric start models can use a starter and battery

size that are practical

which these engines are used.

•

ACR

eliminates the need vance mechanism. A spark retard/advance mechanism would be required on engines without

ACR

to

prevent " kickback" that occurs when starting. manual starting safer.

• The choke control setting is less critical, and the event of starting.

• Engines with weather than those without

• Engines with plugs that are worn ACR same

ACR

eliminates this

of

flooding, excess fuel is blown out

the lifted exhaust valve and does not hamper

ACR

start much faster

ACR

can be started with spark

or

probably could not be started with those

plugs.

or

retractable start)

ACR,

manual starting at

for

the applications

for

a spark retard/ad-

"kickback"

ACR.

fouled. Engines without

in

making

cold

in

INSPECTION AND SERVICE

The

ACR

mechanism is extremely rugged and vir-

tually troublefree. If hard starting is experienced,

check 1 . Check exhaust valve to tappet clearance and

2. Remove cylinder head and turn the crankshaft

When the piston is approximately 2/3 of the way up the cylinder during the compression stroke, the exhaust

If

may spring, remove the oil pan and rehook spring or replace it. The camshaft does not have to be removed.

The flyweights are not serviceable. stuck replaced.

NOTE: The tab on the flyweights is hardened and is not adjustable. Do not attempt to bend the tab

- it quired.

the exhaust valve

adjust as necessary

by

clockwise valve carefully.

valve should lift off the seat slightly.

the exhaust valve does not lift, the

be unhooked

or

worn excessively, the camshaft must be

will break and a new camshaft will be re-

hand and observe the exhaust

for

lift as follows:

to

specification.

or

broken. To service the

If

ACR

they are

spring

in

COMPRESSION TESTING

Because obtain

To ber, and related mechanisms, physical inspection and a crankcase vacuum test are recommended.

an

check

of

the

ACR

mechanism, it is difficult to

accurate compression reading. the condition

of

the combustion cham-

AUTOMATIC COMPRESSION RELEASE

(ACR) CHANGES

New

ACR

Tabs

Engines with serial no. 9006118 and after have hardened and ground steel shaft assemblies. These new assemblies are manufactured with improved techniques, which permanently set the

justments to the mechanism unnecessary and im-

possible. NOTE:

steel

Do

not attempt

ACR

tabs. These tabs will break if bent.

ACR

tabs on the

mechanism, making ad-

to

bend these hardened

cam-

Procedure For Checking And

ACR

On

Adjusting

Engines Prior To Serial

No. 9006118

On

engines manufactured before serial no.

9006118 the

using the procedure described below. ACR

is set according to the amount the exhaust valve. The established tion to the camshaft. the setting can be checked and adjusted as follows:

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 stroke (intake valve will be closing) .

3. Mount a dial indicator on the top of the ex-

haust valve and set at 0.

4. Slowly turn the flywheel clockwise and watch

the of the way up the should open as indicated on the dial indicator should be .031 - .042.

If

the exhaust valve does not open to the specified

amount, adjust the

ACR

can still be checked and reset

of

valve lift on

correct

by

the height of the lifting tab

If

improper lift is suspected,

dial indicator. When the piston is about 2/3

cylinder, the exhaust valve

for

ACR.

ACR

according to

amount of lift is

in

rela-

BDC

of the intake

Exhaust valve opening

STEP

5.

9.2

NOTE: of the tab as it is hardened and may break if bent back and forth times.

5.

Caution must be exercised

If

the valve lift was above .042, hold a wooden

dowel

or

peg on the top of the valve and tap it

more

in

the bending

crack

than 3

or

down

carefully

If

the valve lift was below .

4

camshaft posing the carefully upward until the valve lift is within the specified range.

cover

cam

to

within the .031 - .042 range.

031

, remove the on the side gear

and bend the

of

the engine ex-

ACR

tab

9.3

SECTION 10

DISASSEMBLY

~

WARNING: Accidental Starts!

Before servicing the engine remove the spark from starting accidentally. Ground the lead to prevent sparks that

Clean all parts thoroughly as the engine

sembled. Only clean parts can be accurately inspected are

quickly parts. When such a cleaner is used, follow the manufacturer's traces of the cleaner are gine is reassembled and placed small amounts down the lubricating properties

Check

• Excessive sludge and varnish

• Scoring of the cylinder wall

•

• Evidence

• Evidence of overheating.

Any of the listed improper owner should be proper

The following engine disassembly. This be varied slightly cial

1 . Disconnect spark plug lead.

2.

3. Remove air cleaner.

4. Remove

5. Remove throttle linkage and carburetor.

6.

7.

8. Remove retractable starter.

and gauged

many

commercially

remove

all parts

Piston

engine servicing

servicing and maintenance.

equipment.

Drain oil

Remove external throttle control. Remove fuel

plug

could

grease, oil, and

instructions carefully. Make sure all

of

these cleaners quickly break

for

evidence of:

damage

of

external oil leaks

problems

made

sequence

to

accommodate

from

crankcase.

muffler.

pump.

or

equipment, always

lead to prevent the engine

cause fires.

is

disas-

for

wear

or

damage.

available cleaners that

grime

removed

could be the result of

or

aware of the benefits of

is suggested

procedure

governor

before the en-

in

operation-even

of

engine oil.

maintenance. The

options

components

There

from engine

for

complete

may

have to

or

and

spe-

9. Remove

10. Remove fuel tank.

11. Remove dipstick.

12. Remove cylinder head baffle and side air baffles.

13. Remove breather assembly.

14. Remove spark plug and cylinder head.

15. Remove blower housing.

16. Remove drive screen and flywheel.

7.

Remove stator.

1

18. Remove valves.

19. Remove oil pan.

20. Remove connecting rod and piston.

21

. Remove piston

22. Remove piston rings.

23. Remove crankshaft and bearing plate.

24. Remove

25. Remove balance gears.

26. Remove governor gear and

27. Remove oil seals.

28. Remove bearings.

electric

camshaft

starter.

cup

or

from

connecting rod.

and tappets.

rope start pulley, grass

cross

shaft.

DISCONNECT SPARK PLUG LEAD DRAIN OIL FROM CRANKCASE REMOVE

1 . Disconnect the spark plug lead and position it

away

2.

Unscrew the oil drain plug (s) and drain the

crankcase oil into a suitable container

posal.

3. Remove the wing nut, air cleaner precleaner (if so three base screws, base, and base gasket.

AIR

CLEANER

from

the spark plug terminal.

equipped),

paper

for

cover,

element,

dis-

REMOVE MUFFLER

1 .

If

the engine is equipped with a flat muffler, remove screws. move between the wrench.

muffler If

by turning the threaded exhaust pipe

and gasket by unscrewing cap

equipped with a round

muffler

and engine with a pipe

muffler

re-

10.1

REMOVE THROTTLE LINKAGE AND CARBURETOR

.A

WARNING: Explosive Fuel!

Gasoline may system. Gasoline is extremely flammable and explode other sources connect and ground the spark the possibility

be

present in the carburetor and fuel

if

ignited. Keep sparks, open flames, and

of

ignition away from the engine. Dis-

plug

lead to prevent

of

sparks from the ignition system.

it

can

2. Disconnect the fuel line outlet fitting. Refer

to

from

Figure 1

the fuel

0-1

.

pump

1 . Close the fuel

equipped}

2. Loosen

from

the

shut-off

or

drain fuel

hose

clamp

carburetor

valve at fuel tank (if so

from

tank.

and remove fuel line

inlet.

3. Remove two slotted hex cap sems screws, the

carburetor, and gasket.

4. Remove

tor

the

throttle linkage

throttle lever.

from

the carbure-

REMOVE EXTERNAL GOVERNOR COMPONENTS

1 . Note

AND THROTTLE CONTROL

the

governor

position

arm.

of

the

governor

spring in

2. Loosen pal nut. Remove governor arm and

spacer

NOTE: Loosening pal nut will disrupt ment. sembly.

3.

Remove the arm.

4.

Remove spacer,

from

cross

shaft.

or

removing governor arm

governor

Readjustment will be required upon reas-

the

bracket

arm

to

cross

shaft adjust-

governor

hex cap screw, plain washer,

spring

and throttle lever.

from

the governor

REMOVE FUEL PUMP

~

WARNING: Explosive Fuel!

Gasoline may be present in the carburetor and fuel

it

system. Gasoline is extremely flammable and

explode other sources connect the possibility

if

ignited. Keep sparks, open flames, and

of

ignition away from the engine. Dis-

and

ground the spark

of

sparks from the ignition system.

plug

lead to prevent

can

Figure 1

3. Remove the fillister head

washers, fuel

0-1.

Removing Fuel Pump.

sems

pump,

and gasket.

screws, plain

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

electric starter

sems

to

engine.

screws which mount

5. Remove electric starter.

REMOVE FUEL TANK

~

WARNING: Explosive Fuel!

Gasoline may be present in the carburetor and fuel

it

system. Gasoline is extremely flammable and explode other sources connect and ground the spark the possibility

1 . Remove

2. Remove tank with

if

ignited. Keep sparks, open flames, and

of

ignition away from the engine. Dis-

plug

lead to prevent

of

sparks from the ignition system.

fuel line

from

fuel tank outlet fitting.

bracket(s}.

can

REMOVE DIPSTICK

1.

Remove the dipstick.

1 . Disconnect

inlet fitting.

10.2

the

fuel line

from

the fuel

pump

REMOVE CYLINDER HEAD BAFFLE AND SIDE

1 . Remove the cylinder head baffle.

AIR

BAFFLES

2.

Remove the

carburetor

side air baffle.

Rope

Start

Models

3. Remove the

starter

side air baffle.

REMOVE BREATHER ASSEMBLY

1. Remove palnut, breather

Gasket........_

Breather Plate

Filter

Cover

........

,

cover,

and gasket.

1 . Remove the grass screen retainer and wire

mesh grass screen

2. Hold the flywheel with a strap wrench and loosen the hex cap

screw, plain washer, rope pulley, and spacer. Remove the nylon grass screen from the fan.

Retractable

1 . Hold the flywheel with a strap wrench and

loosen hex cap screw securing flywheel crankshaft. Remove the hex washer, and drive cup.

2. Remove the grass screen

Electric

1 . Remove the grass screen

2. Hold the loosen hex cap screw wheel to crankshaft. Remove the hex cap screw

On All

Models

Start

or

Models

flywheel with a strap wrench and

hex nut. Remove plain washer.

from

rope pulley.

cap

screw. Remove the hex

Models

cap

screw, plain

from

the drive cup.

from

the fan.

or

hex nut securing fly-

to

Figure

2.

10-2.

Remove the filter, seal, reed stop, reed, breather plate, gasket, and stud.

Removing

Breather

Components.

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 the flywheel when loosening and fan retaining fasteners.

or

of bar the fins could ways use a shaft. these parts could

wedge between fins

become

puller

to

remove

Do

not strike the crankshaft

become

or

tightening flywheel

Do

not use any type

of

cooling fan, as

cracked

or

damaged. Al-

flywheel from crank-

or

cracked

or

to

hold

flywheel, as

damaged.

1 . Flywheel is

crankshaft. Use for

removing flywheel. Bumping end of crankshaft with be avoided as this can Refer

Figure

NOTE: able!

10-3.

Ignition

to

Figure 1

mounted

hammer

Removing

magnet

on tapered portion of

of

a puller is

to

loosen flywheel should

recommended

damage

0-3.

Flywheel

is

not removable

With

crankshaft.

A Puller. or

service-

Do

not

attempt

flywheel. Loosening

to

remove

or

removing

ignition

magnet

from

mounting

10.3

Kohler K9J, KJ4J, KJ6J, KJBJ, K24J Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual