Kohler SNOWPRO WH208 User manual

Service Manual
Horizontal CranksHaft
WH208
SNOW PRO

2
Figure 1. Explanation of Engine Identication
Numbers.
Electrical Shock!
Use only a 3-wire extension cord and
Ground Fault Circuit Interrupter (GFCI)
outlet. Plug into the engine rst then the
wall outlet. After starting, remove cord
from wall outlet rst, then remove from
the electric starter.
WARNING
Electrical Shock can cause severe
injury or death.
Use only a 3 wire extension cord with
a Ground Fault Circuit Interrupter
(GFCI) outlet.
Engine Identication Numbers
When ordering parts, or in any communication
involving an engine, always give the Model,
Specication, and Serial Numbers, including leer
suxes if there are any.
The engine identication numbers appear on a
decal, or decals, axed to the engine shrouding. An
explanation of these numbers is shown in Figure 1.
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
daily and changing oil regularly. Failure to use the
correct oil, or using dirty oil, causes premature engine
wear and failure.
5W-30
RECOMMENDED SAE VISCOSITY GRADES
°F -20 0 20 32 40 6050 80 100
°C -30 -20 -10 0 10 20 30 40
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
10W-30
Kohler 10W-30
SAE 30
Figure 2. Oil Viscosity Grades Table.
Maintenance Schedule
These required maintenance procedures should be
performed at the frequency stated in the table below.
They should also be included as part of any seasonal
tune-up.
Frequency Maintenance Required
Daily or
Before Starting
Engine
Check oil level.
Fill fuel tank.
Check air intake and cooling
areas; clean as necessary.
Yearly Change oil.
Every 100
Hours
Clean cooling areas.
Replace spark plug, and set gap.
Replace fuel lter (if equipped).
This Manual Provides the Needed Information to Service the WH208 Engine. Please See
the CH270 Service Manual For Information Not Covered Here.
NOTE: This engine is intended for winter use.
A. Model No. W H 2 0 8
B. Spec. No.
Winter Engine
C. Serial No.
WH208-0001
Factory Code
3924895008
Numerical Designation
Horizontal Crankshaft
Model No.
Variation No. of
Basic Spec.
Year Manufactured Code
Code Year
39 2009
40 2010

3
Figure 3. Typical Engine Dimensions-WH208 With Optional Electric Starter.

4
Perform the following steps to remove the
engine cover, electric starter, fuel tank,
and the engine control assembly.
Remove Control Knobs
Choke
1. Pull the choke control knob out. Pry the linkage
out from underneath the knob and lift the knob
o the linkage and remove from the engine cover.
See Figure 4.
Choke
Control
Knob
Linkage
Figure 4. Remove Choke Knob.
Throttle
1. Pull the control lever knob o the control lever.
See Figure 5.
Control Lever
Knob
Stop/Run Key
Figure 5. Remove Key and Control Lever Knob.
Stop/Run Key
1. Pull out the stop/run key. See Figure 5.
Remove Retractable Starter Cover
1. Remove the Torx screws securing the retractable
starter cover, and remove the cover. See Figure 6.
Torx Screws
Figure 6. Remove Cover Torx Screws.
Remove Air Box Cover
1. Remove the hex ange nuts from the air box
cover and remove the cover. See Figure 7.
Hex Flange Nuts
Figure 7. Remove Cover.
Remove Engine Cover
1. Remove the hex ange shoulder screws retaining
the engine cover to the blower housing. See
Figure 8.
Shoulder Screws
Figure 8. Remove Shoulder Screws.

5
2. Remove the Torx screws securing the engine
cover. See Figure 9.
Torx Screws
Figure 9. Remove Torx Screws.
3. Do not fully remove the cover from the engine.
The primer hose and the key switch wires are still
aached at this time.
Disconnect Primer Assembly Hose
1. Pull the hose o the back of the primer assembly.
See Figure 10.
Primer Hose
Stop/Run
Key Switch
Wires
Figure 10. Remove Hose and Wires.
Disconnect Key Switch Wires
1. Remove the stop/run key switch wires from the
back of the engine cover. See Figure 10.
2. The engine cover can now be set aside.
Remove Air Box
1. Remove one hex ange screw and two hex
nuts securing the air box to the carburetor, and
remove the air box from the studs. See Figures 11
and 12.
Hex Flange
Screws
Figure 11. Remove Air Box Screw.
Hex Nuts
Figure 12. Remove Air Box Hex Nuts.
Remove Electric Starter (If Equipped)
1. Remove the hex ange screws securing the
electric starter to the crankcase, and remove the
electric starter. See Figure 13.
Hex Flange
Screws
Figure 13. Remove Electric Starter.

6
Remove Fuel Tank
1. Remove the hex ange screws securing the
engine extension cover, and remove the engine
extension cover. See Figure 14.
Hex Flange
Screws
Figure 14. Remove Cover Hex Flange Screws.
2. Remove the hex ange screw securing the
dipstick tube. Remove the tube. See Figure 15.
Dipstick Tube
Dipstick Tube Hex
Flange Screw
Fuel Tank
Hex Flange
Screws
Figure 15. Remove Dipstick Tube.
3. Remove the hex ange screws securing the fuel
tank to the control assembly. See Figures 15 and
16.
Fuel Tank
Hex Flange
Screws
Figure 16. Remove Fuel Tank Hex Flange Screws.
4. Remove the fuel line from carburetor, and
remove the tank from the bracket. See Figure 17.
Fuel Line
Figure 17. Remove Fuel Line from Carburetor.
Remove Mufer
1. Remove the hex ange screws securing the
muer to the head. See Figure 18.
Hex Flange
Screws
Figure 18. Remove Hex Flange Screws.

7
2. Remove the hex nut, and remove the muer. See
Figure 19.
Hex Flange Nut
Figure 19. Remove Hex Flange Nut.
3. Remove the exhaust gasket from the outlet.
Remove Engine Control Assembly
1. Disconnect the governor spring from the control
lever spring arm. See Figure 20.
Hex Flange
Screws
Control Assembly
Governor Spring
Figure 20. Remove Hex Flange Screws.
2. Remove the hex ange screws, and remove the
control assembly. See Figures 20 and 21.
Hex Flange
Screws
Figure 21. Remove Hex Flange Screws.
NOTE: Reverse the previous steps to reassemble the
engine, referring to the torque specications
on Page 11.
NOTE: If further disassembly of the engine is
needed, reference the CH270 service manual
for more information.
Engine Control Lever Assembly
1. Assemble the control lever assembly as follows:
at washer, nylon washer, control lever, spring
washer, control lever washer, with the locking
hex ange nut torqued such that it requires
6 ±1 lb. (2.72 ±0.45 kg) to move the control lever
at location A. See Figure 22.
NOTE: The spring washer shape should cup towards
the control lever washer.
Flat Washer
Nylon Washer
Control Lever
Spring Washer
Hex Flange Lock Nut
Control
Lever
Washer
Location A
Figure 22. Engine Control Lever.
NOTE: A spring scale or hanging weight are the
preferred method to apply the required load
force. If these are not available, adjust the nut
so it has adequate resistance to keep the lever
in place.

8
2. With the applied load force at location A, begin
to slowly loosen the lock nut until the lever
can barely rotate to the full downward (stop)
position.
Adjusting Governor Lever
To adjust the governor lever, the air box has to be
installed and tightened on the carburetor studs to hold
the carburetor in its normal position.
1. Loosen the governor lever hex ange nut. Push
and hold the governor lever in the direction
indicated in Figure 23. Continue holding in this
direction throughout this procedure. Turn the
governor shaft clockwise until it stops. Tighten
the hex ange nut on the governor lever clamp
bolt to lock the lever on the shaft. Torque the nut
to 10 N·m (89 in. lb.).
Push Lever
Governor Lever
Hex Flange Nut
Governor Shaft
Figure 23. Governor Lever Adjustment.
Fuel Filter
Replace the in-nipple fuel lter every 100 hours of
operation, with a genuine Kohler lter. Remove the air
box cover, retractable starter cover, and engine cover
to access the fuel line. See Figure 24.
Fuel Tank Nipple
In-Nipple Fuel Filter
Fuel Line
Figure 24. In-Nipple Fuel Filter.
1. Remove the fuel line to access the fuel lter. The
fuel lter may remain in the fuel line when the
fuel line is removed. Pull the fuel lter out of the
fuel tank nipple or the fuel line and discard.
2. Insert a new fuel lter into the fuel tank nipple
and push the fuel line onto the fuel tank nipple.
Check Spark Plug
Every 100 hours of operation, remove the spark plug,
check condition, and reset the gap or replace with
a new plug as necessary. The original spark plug is
a Champion® XC12YC. Equivalent alternate brand
plugs can also be used. Refer to the CH270 service
manual for instructions to service the spark plug.
Electronic Ignition System and Stator
Stator
18 Watt
Terminal
Ignition Module
Ground
Ground
Ground
Stop/Run Key Control Lever Switch
Spark
Plug
Figure 25. Wiring Diagram.
Check Oil Level
The importance of checking and maintaining
the proper oil level in the crankcase cannot be
overemphasized. Check oil BEFORE EACH USE as
follows:
1. Make sure the engine is stopped, level, and is
cool so the oil has had time to drain into the
sump.
2. Clean the area around and beneath the dipstick
before removing it. This will help keep snow, ice,
and other foreign maer out of the engine. See
Figure 26.

9
Oil Fill Cap/
Dipstick
Oil Fill
Tube
Figure 26. Oil Fill Cap/Dipstick and Oil Fill Tube.
3. Unscrew and remove the oil ll cap/dipstick;
wipe o oil. Reinsert the dipstick into the oil ll
tube and screw in.
4. Unscrew and remove the oil ll cap/dipstick and
check that oil level is correct. The correct oil level
is between the Fand Lmarks on the dipstick. See
Figure 27.
Oil Fill
Cap
Dipstick Operating
Range
Figure 27. Correct Oil Level.
5. If the level is low, add oil of the proper type (refer
to Oil Recommendations) and to the correct
level. Always check the level before adding more
oil.
NOTE: To prevent extensive engine wear or damage,
always maintain the proper oil level in the
crankcase. Never operate the engine with the
oil level above or below the correct operating
range.
6. Reinstall the oil ll cap/dipstick and tighten
securely. See Figure 26.
Change Oil
For a new engine, change oil after the rst 5 hours of
operation. Thereafter, change oil yearly.
For an overhauled engine, use Kohler 5W-30 service
class, SJ or higher oil for the rst 5 hours of operation.
Change the oil after this initial run-in period. Rell
with service class SJ or higher oil as specied in the
Oil Viscosity Grades Table (Figure 2).
Change the oil while the engine is still warm. The
oil will ow freely and carry away more impurities.
Make sure the engine is level when lling, checking,
or changing the oil.
Change the oil as follows:
1. To keep snow, ice, etc., out of the engine, clean
the area around the oil ll cap/dipstick before
removing it. See Figure 26.
2. Remove the oil drain plug and the oil ll cap/
dipstick. Allow ample time for complete
drainage. See Figures 26 and 28.
Oil Drain Plug
Figure 28. Oil Drain Plug Location.
3. Reinstall the oil drain plug and tighten to
9-13.5 N·m (80-120 in. lb.). See Figure 28.
4. Fill the crankcase, with new oil of the proper
type. Refer to Oil Recommendations. Always
check the level before adding more oil.

10
5. Reinstall the oil ll cap/dipstick and tighten
securely. See Figure 26.
NOTE: To help protect the environment dispose of
used oil in accordance with local ordinances.
Retractable Starter
To service the retractable starter, refer to the CH270
service manual. The retractable starter is similar to
the CH270 in operation, though there are some visual
dierences. See Figure 29. To remove the retractable
starter, removal of the air box cover, retractable starter
cover, and engine cover is required.
Center Screw
Drive Pawls
Pawl Springs
Rope
Starter
Handle
Drive
Plate
Friction
Spring
Pulley
Recoil
Spring
Starter
Housing
Figure 29. Retractable Starter - Exploded View.
Adjusting High Speed Stop Screw
1. Using a T25 drive, turn the screw to adjust high
speed. See Figure 30 for the location of the high
speed stop screw. Do not exceed 3750 RPM.
High Speed
Stop Screw
Figure 30. High Speed Stop Screw Location.
Breather Hose
The breather hose is inserted into the valve cover and
positioned down along the valve cover. It does not
connect to the air box. See Figure 31.
Breather Hose
Figure 31. Breather Hose Orientation.

11
General Specications¹
Gross Power (@ 3600 RPM, exceeds SAE J1940 HP Standards) ..................................5.2 kW (7 HP)
Net Power (@ 3600 RPM, exceeds SAE J1940 HP Standards) ......................................4.5 kW (6 HP)
Net Peak Torque (@ 2500 RPM) ........................................................................................11.8 N·m (8.7 ft. lb.)
Compression Ratio .............................................................................................................8.2:1
Weight (Approximate) .......................................................................................................17.2 kg (38.0 lb.)
Fuel Tank Capacity ............................................................................................................3.2 L (3.4 U.S. qt.)
Air Box
Air Box Nut Torque ...........................................................................................................8 N·m (71 in. lb.)
Air Box Screw Torque ........................................................................................................8 N·m (71 in. lb.)
Air Box Cover Nut Torque ...............................................................................................4 N·m (35 in. lb.)
Dipstick Tube
Dipstick Tube Screw Torque ............................................................................................8 N·m (71 in. lb.)
Electric Starter
Electric Starter Screw Torque ...........................................................................................24.4 N·m (216 in. lb.)
Engine Control Assembly
Engine Control Assembly Screw Torque ........................................................................24 N·m (213 in. lb.)
Engine Cover
Engine Cover Shoulder Screw Torque ............................................................................2.5 N·m (23 in. lb.)
Engine Extension Cover Screw Torque ...........................................................................8 N·m (71 in. lb.)
Fuel Tank
Fuel Tank Screw Torque ....................................................................................................8 N·m (71 in. lb.)
Governor Lever
Governor Lever Nut Torque .............................................................................................10 N·m (89 in. lb.)
Mufer
Muer to Engine Control Assembly Nut Torque ........................................................24 N·m (213 in. lb.)
Oil Drain Plug
Oil Drain Plug .....................................................................................................................9-13.5 N·m (80-120 in. lb.)
Retractable Starter
Retractable Starter Cover Screw Torque..........................................................................5.4 N·m (48 in. lb.)
Retractable Starter Center Screw Torque.........................................................................5.4 N·m (48 in. lb.)
Spark Plug
Spark Plug Type (Champion® or Equivalent) ...............................................................XC12YC
Spark Plug Torque .............................................................................................................24 N·m (18 ft. lb.)
¹Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior
to assembly.

FORM NO.: 17 690 02 Rev. --
ISSUED: 1/11
REVISED:
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL 1-800-544-2444
KohlerEngines.com
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
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