Kohler K9J User manual

Single Cylinder Engine
SERVICE MANUAL
K9J, KJ4J, KJ6J, KJBJ,
K24J, K30J, K32J, K34J

CONTENTS
SECTION 1. General Information ................................................ .
SECTION 2. Special Tools ...................................................... .
SECTION 3. Periodic Maintenance ............................................... .
SECTION 4. Troubleshooting .................................................... .
SECTION 5. Air Cleaner And Air Intake System .................................. .
SECTION 6. Fuel System And Governor .......................................... .
SECTION 7. Retractable Starters ................................................ .
SECTION 8. Electrical Systems And Components ................................. .
SECTION 9. Automatic Compression Release ..................................... .
SECTION 10. Disassembly ....................................................... .
SECTION 11. Inspection and Repair .............................................. .
SECTION 12. Reassembly ........................................................ .
II
II
II
II
Ill
Ill

SECTION 1
GENERAL INFORMATION
SAFETY INFORMATION
For Your Safety!
These safetyprecautions should be followed at all times. Failure to follow these safetyprecautions could result
in serious injury to yourself
and others.
A WARNING
~
Explosive Fuel
can cause fires and severe
burns.
Stop engine before filling
fuel tank.
WARNING: Explosive Fuel!
Gasoline is extremelyflammable
and its vapors can explode if ig-
nited. Store gasoline onlyin ap-
provedcontainers, in well-
ventilated, unoccupied buildings,
away from sparks or flames. Do not
fill the fuel tank while the engine is
hot or running, since spilledfuel
could ignite if it comes in contact
with
hot parts or sparks from igni-
tion. Do not start the engine near
spilled fuel. Never use gasoline as
a cleaning agent.
A WARNING
~
Rotating Parts
can cause severe injury.
Stay away while engine is in
operation.
WARNING: Rotating Parts!
Keep hands, feet, hair, and clothing
away from all movingparts to pre-
vent injury. Never operate the en-
gine with covers, shrouds, or
guards removed.
A WARNING
¥Af
Hot Parts
can cause severe burns.
Do not touch engine while
operating or just after stopping.
WARNING: Hot Parts!
Engine components can get ex-
tremely hot from operq.tion. To pre-
vent severe burns, do not touch
these areas while the engine is run-
ning- or immediately after it is
turned off. Never operate the engine
with heatshields or guards
removed.
1.1

A WARNING
~~~
Accidental Starts
can cause severe injury
or death.
Disconnect
and ground spark
plug lead before servicing.
-
WARNING: Accidental Starts!
Before seNicing the engine or
equipment, always disconnect the
spark
plug lead to prevent the en-
gine from starting accidentally.
Ground the lead to preventsparks
that could cause fires. Make sure
the equipmentis in neutral.
A CAUTION: Electrical
.a Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
A WARNING: Overspeed Is
.a Hazardous!
Do not tamper with the governor
setting. Overspeed is hazardous
and
could cause personal injury.
A WARNING: Flammable
.a Solvents!
Carburetor cleaners and solvents
are extremely flammable. Keep
sparks, flames, and other sources
of ignition away from the area. Fol-
low the cleanermanufacturer's
warnings and instructions on its
proper and safe use. Never use
gasoline as a cleaning agent.
1.2
A WARNING
Carbon Monoxide
can cause severe nausea,
fainting
or death.
Do not operate engine in
closed or confined area.
WARNING: Lethal Exhaust Gases!
Engine exhaust gases contain poi-
sonous carbon monoxide. Carbon
monoxide is odorless, colorless,
and can cause death if inhaled.
Avoidinhaling exhaust fumes, and
neverrun the engine in a closed
building
or confined area.
A WARNING: Spring Under
.a Tension!
Retractable starters contain apow-
erful, flat wire recoil spring that is
under tension. Do not remove the
centerscrew from the starter until
the spring tension is released. Re-
moving the centerscrew before re-
leasing spring tension, or improper
starter disassembly, can cause the
sudden and potentially dangerous
release of the spring.
Always wear safety goggles when
seNicing retractable starters- full
face protection is recommended.
To ensure personal safety and
proper starter disassembly and
reassembly, follow the procedures
in this section carefully.
A WARNING
~
Sulfuric Acid in batteries
can cause severe injury
or death.
Charge
only in well ventilation.
Keep sources of ignition away.
WARNING: Dangerous Acid,
Explosive Gases!
Batteries contain sulfuric acid. To
prevent acid burns, avoidcontact
with skin, eyes,
and clothing. Bat-
teries produce explosive hydrogen
gas while
being charged. To pre-
vent a fire or explosion, charge bat-
teries onlyin well-ventilated areas.
Keep sparks, open flames, and
othersources of ignition away from
the battery at all times. Keep batter-
ies out of the reach of children. Re-
move alljewelry when seNicing
batteries.
Before disconnecting the negative
(-) ground cable, make sure all
switches are OFF. If ON, a spark
will occur atthe ground cable ter-
minal which could cause an explo-
sion if hydrogen gas or gasoline
vapors are present.

ENGINE IDENTIFICATION NUMBERS
When ordering parts, or in any communications
involving an engine, always give the model, speci-
fication and serial
number of the engine.
A'iKOHLERI~[Jjll§lTilrJCcil
00 HP
MODELNO 0000
__........,..sPEC NO 0 0 0 0 0 0
B-- I~SERIAlNO 0000000
c
REFER TO OWNERS MANUAl
FOR OPERATION MAINTENANU
INSTRUCTIONS AND SAFFTY
PRECAUTIONS
A. MODEL NO.
K-Serles Engine
B. SPEC NO.
A
MODEL NO 0 0 0 0
;;,:; ~~~w~'~ ,
0
M~N~?, ._....,..__ B
FOR OPERATION MAINHNANCE
INSTRUCTIONS AND SAFETY
PRECAUTIONS
~~~~~~~:~;~~~~~~~ 'JS,~
SERIAL NO
IIIIIIIIIIIIIIIIIIIIIIIIIII~WIIIIII111
1
000000000
K 32 1 PT
Approximate
Displacement
(Cu. ln.)
c
Engine Model Code
The engine identification numbers appear on a de-
cal (or decals) affixed to the engine blower hous-
ing. Refer to Figure 1-1 . The significance of these
numbers is shown below:
Identification
Decal
Single
Cylinder
Figure 1-1. Location of Engine
Identification Decal.
Version Code
A - Special Oil Pan
C - Clutch Model
G - Generator Application
P - Pump Model
Q - Quiet Model
R - Reduction Gear
S - Electric Start
T - Retractable Start
ST -Electric Start And
Retractable Start
EP -Electric Plant
~ M.2.d..!tl
60 1248
C. SERIAL NO.
E - 1 7 2 4 5 2
u
A Letter
A 1965
B 1966
c 1967
D 1968
E 1969
26, 27,
31 K91
28 K161
29 K141
30 K181
46 K241
47 K301
60 K321
71 K341
9076430
LJ
First Two Digits I If
Seven Digit Number
10-19 1969
20-29 1970
30-39
1971
40-49 1972
50-59 1973
60-69 1974
70-72 1975
73-79 1976
80-89 1977
90-94 1978
95-99 1979
l
Variation of
Basic Engine
1 0 0 2 6 6 9 2
L__j
First Three Digits I If
Eight Digit Number
100-109 1980
110-119
1981
120-129 1982
130-139 1983
140-149 1984
150-159 1985
Remaining digits are a factory code.
Figure 1-2. Engine Identification Decals.
1 5 0 1 8 9 7 5 9 1
LJ
First Two Digits I If Ten
Digit Number
15 1985
16 1986
17 1987
18 1988
19 1989
20 1990
21 1991
22 1992
23 1993
24 1994
25 1995
1.3

OIL RECOMMENDATIONS
Using the proper type and weight of oil in the engine
crankcase and in the gear reduction unit is extreme-
ly important, as is checking oil daily and changing oil
regularly. Failure
to use the correct oil or using
dirty oil
causes premature engine wear and failure.
Oil Type
Use high-quality detergent oil of API (American Pe-
troleum Institute) Service Class SF or SG. Select
the viscosity based on the air temperature at the
time of operation as shown in the table.
Recommended SAE Viscosity Grades
Straight 30-weight oil is preferred. SAE 1OW-30
and 1OW-40 are not recommended above 32 °F
(0°C). Using these oils substantially increases oil
consumption and combustion chamber deposits.
Shoulder of flange
Remove from block
Place
on shoulder
Read level
NOTE: Using other than Service Class SF or SG oil
or extending oil change intervals longer than
recommended could cause engine damage
which is not covered by the engine warranty.
A logo
or symbol on oil containers identifies the API
service class and SAE viscosity grade.
Check Oil Level
Check oil lever BEFORE EACH USE.
Check gear reduction uniot oil level by removing the
drain plug on
the lower part of the cover. Oil level
should be up to the bottom of the plug hole. If oil
level is low,
remove the vented plug at the top of
the cover, add oil until it reaches the bottom of the
drain plug hole, and
replace drain plug and vented
plug.
NOTE: Do not operate the engine with the oil level
below
the "L" mark or over the "F" mark on
the dipstick.
Bayonet
Push down on tube
Read level
Figure 1-3. Dipsticks And Oil Fill Tubes.
1.4

Change Oil
For a new engine, change oil aft~r the first 5
hours
of operation. Change oil every 25 hours of
operation thereafter.
For an overhauled engine or one rebuilt with a new
shortblock or miniblock, use straight 30-weight
Service Class SF or SG oil for the first 5 hours of
operation. Change the oil after this initial run-in
period. Refill with Service Class SF or SG oil as
specified in
the table. Change oil every 25 operat-
ing hours thereafter.
FUEL RECOMMENDATIONS
£ WARNING: Explosive Fuel!
Gasoline may be presentin the carburetor andfuel
system. Gasoline is extremely flammable andit can
explode
if ignited. Keep sparks, open flames, and
othersources
of ignition away from the engine. Dis-
connect andground the spark
plug lead to prevent
the possibility
of sparks from the ignition system.
General Recommendations
Purchase gasoline in small quantities and store in
clean, approved containers. A container with a ca-
pacity of 2 gallons
or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spoilage during refueling.
Do not use gasoline left over from the previous sea-
son, to minimize
gum deposits in your fuel system
and to insure easy starting.
Do not add oil to the gasoline.
Do not overfill the fuel tank. Leave room tor the
fuel to expand.
Fuel Type
For best results, use only clean, fresh, unleaded
gasoline with a
pump sticker octane rating of 87 or
higher. In countries using the Research method, it
should be 90
octane minimum.
Unleaded gasoline is recommended, as it leaves
less combustion chamber deposits. Leaded gaso-
line may be used in areas where unleaded is not
available and exhaust emissions are not regulated.
Be aware however, that the cylinder head will re-
quire
more frequent service.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel
for Kohler
engines. Other gasoline/alcohol blends are not ap-
proved.
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a
maximum of 15% MTBE by
volume) are approved as a fuel
for Kohler engines.
Other gasoline/ether blends are not approved.
OIL REFILL QUANTITIES (U.S. STANDARD QUARTS)
K91 K141, K161, K181 K241, K301, K321, K341 K241 A, K301 A, K321 A, K341 A
1/2 Quart 1 Quart 2 Quarts 1 Quart*
(After refilling, always check oil level -- DO NOT OVERFILL)
* A-type oil pan capacity varies from 1 to 1-3/4 quarts. On these add 1 quart of oil, check
level, then add oil as necessary to bring up to full level.
Figure 1-4.
1.5

1.6
HORSEPOWER (Maximum RPM)
En ine Model
GENERAL
BALANCE
GEAR
CAMSHAFT
CONNECTING
ROD
Bore x Stroke
Displacement
Cu. ln.
Max. Operating RPM
Shalt
0.0.
New
.~axlmum
W&arlimil
End Play
Sleeve
1.0. Installed
End Play
Small
End 1.0. (New)
PTO & New
Flywheel Maximum
M End 0.0. wear li 11
A R ~~~- ~~~~e~el
I Max. Taper (Sleeve)
2.375x2.000
8.86
4000
.005/.020
.001/.0025
.003
.0007/.0008
.5630/.5633
.9841/.9844
.9841
2.938x2.500
16.94
3600
.005/.010
.001/.002
.0025
.0006/.0011
.6255/.6258
1.1811/1.1814
1.1811
2.938x2.750
18.64
3600
.005/.010
.001/.002
.0025
.0006/.0011
.6255/.6258
1.1811/1.1814
1.1811
3.251x2.875
23.85
3600
.4998/.5001
.4996
.002/.010
.005/.010
.001/.002
.0025
.0003/.0008
.8596/.8599
1.5745/1.5749
1.5745
3.375x3.250
29.07
3600
.4998/.5001
.4996
.002/.010
.005/.010
.001/.002
.0025
.0003/.0008
.8757/.8760
1.5745/1.5749
1.5745
3.500x3.250
31.27
3600
.4998/.5001
.4996
.002/.010
.005/.010
.001/.002
.0025
.0003/.0008
.8757/.8760
1.5745/1.5749
1.5745
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
N Running Ma~~r:,um _ _ _ _ _ _
S Clearance f----'l~<L-...f--.....:::_--jf--.........:=--+-=--t-.....:::_--jf--.........:=--+-=--t--==-----1
CRANKSHAFT -(Sieevef wear limit ro
CYLINDER
BORE
CYLINDER HD.
IGNITION
cv-• =z--,:;;.
0
./ --""
PISTON
®:..:~.~~
PISTON
New Ste
1
~v~a'l~~ring I.D.
c New .9360/.9355 1.186011.1855 1.186011.1855 1.5000/1.4995 1.500011.4995 1.500011.4995 1.500011.4995
:f---M-a_x __ ~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-~
~~-~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. Taper .001 .001 .001 .001 .001 .001 .001
End Play .004/.023 .002/.023 .002/.023 .003/.020 .003/.020 .003/.020 .003/.020
Max. Oul ol Round
Max. Taper
Max.
Oul of Flatness
Spark
Plug
T~e
Gap
Type®
BaHery
Magneto
Gaseous
Fuel:
Nominal Point Gap
Service Replacement Sizes
2.3755/2.3745 2.9380/2.9370 2.9380/2.9370 3.251513.2505 3.375513.3745 3.5005/3.4995 3.7505/3.7495
2.378 2.941 2.941 3.254 3.378 3.503 3.753
.003 .003 .003 .003 .003 .003 .003
.003 .003 .003 .002 .002 .002 .002
.003 .003 .003 .003 .003
.003 .003
RCJ-8 RCJ-8 RCJ-8
RH-10
RH-10 RH-10 RH-10
.025 .025 .025 .035 .035 .035 .035
.025 .025 .025 .025 .025 .025 .025
.018
.018 .018 .018 .018 .018 .018
.020 .020 .020 .020 .020 .020 .020
.003
- .010 - .020 - .030
Thrust Face f--="cc:ew=---11--"2~.3~71:...:/2:...:.3~6~9 -+=2~.9.::c29:..:.7..::/2.:.:.9.::c28:..:1+='2.-"92:.:9.:c7/.::c2 ·..:c92:.:8c..1 +'3:...:.2:.:4..:c32:...:/3:...:.2:.:4:...:13+"'3.-=-36~8-=/3.:.:.3..:c65
4
-=-3.'-'49:.:4..::1/-=-3.~49:.:2c:.5 +'3:..:.. 7:...:42:.:5...:/3:...:. 74.:..c1:.:0®
4
o.D.(J) ::::mr~,
Ring
End Gap
New Bore
Used Bore
M '·
Max. Ring Side Clearance
2.366 2.925
.0035/.006 .007/.010
.007/.017 .007/.017
.027 .027
.006 .006
2.925 3.238 3.363 3.491
.007/.010 .007/.010 .007/.010 .007/.010
.007/.017 .010/.020 .010/.020 .010/.020
.027 .030 .030 .030
.006 .006
.006 .006
Service Replacement Sizes .003- .010- .020- .030
3.738®
.007/.010®
.010/.020
.030
.006
Thrust Face New - - 2.9329/2.9336 -3.3700/3.3693 3.4945/3.4938 3.7465/3.7455
0.0.® f--o..;;M;;cc";;'=;m=:'"""n--ll--.........:_=---+---=_=----t.::c=2=.9.::c31=+-~_=---+==3:.:.3...:6.:.:7=-t.::c=3::..4::.92=-=+=-"3.::_74:..:.4:....:.:.
4
~~~~:C~".'':.t&~ - - .0034/.0051 -.0045/.0062 .0050/.0067 .0030/.0050
~ 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
®-}raJJ """'!: End Gap Use~::"" _ _ .032 _ .030 .030 .030
Max. Ring Side Clearance _ _ .006 _ .006 .006 .006
PISTON PIN
Outside Diameter .5623/.5625 .62471.6249 .62471.6249 .8591/.8593 .8752/.8754 .8752/.8754 .8752/.8754
Guide Reamer Size
.250 .3125 .3125 .3125 .3125 .3125 .3125
c!appet 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®~
··r~~f~ce Exhaus• .0111.o15 .o17I.019 .o17I.019 .o111.o19 .o17I.019 .o17I.019 .o111.o19
MiTmum f----'"'_ak_e __ ~--~-2"'o3~5---+-~·.::c27~1=8---t--~·2:..:.7:...:18~-tc--~·3:..:.1~8--+---=·3_18~-t--~·c:.31~8---+--~·3~1=8--~
(Zero Lash) E•haust .1768 .2482 .2482 .318 .318 .318 .318
VALVES
Minimum Intake .2478 .3103 .3103 .3103 .3103 .3103 .3103
Valve Stem r------+---~r----~-------t-----r-------t-----t------i
0.0. Exhaust .2458 .3088 .3088 .3074 .3074 .3074 .3074
Nominal Angle Valve Seat 45' 45' 45' 45' 45' 45' 45'
Guide 1.0.
Intake .005 005 005 006 006 006 006
w~::l~~Wmlf---Ex-h- .. - .. ---+--~.o=o"'7---+----":o~o7~~---:...:oo~7---+---:o~o...:8 __ -r--~:o...:oa--~--_...::o"'o8~-t---:=oo~8--~
CD Maximum limits combination of 1.0. and
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
® Pre Series II 1.3733/1.3738, Maximum Wear 1.3728
® BaH bearing .002/.023
® Champion spark plugs or equivalent
(J) Measure just below oil ring groove and
at right angles to piston pin
® 1800 RPM generator sets .005/.007
® Measure W' above the bottom
of the piston skirt.
~ Top and center compression rings.
Figure 1-5. Engine Specifications And Tolerances.

HORSEPOWER (Max. RPM)
~
Engine Model
CONNECTING
Posi-lock®
-
RODSCD
Capscrew@
140 ln.lbs.
SPARK PLUGS
18·22 ft. lbs.
CYLINDER
ps ((J1
K91
~
HEADCD
200 ln. lbs. 9}
~4
02 a
FLYWHEEL
NUT 40·50 ft. lbs.
RETAINING
SCREW
250 in. lbs.
GOVERNOR BUSHING
70-90 in. lbs.
GRASS
Metal
-
SCREEN
Plastic
-
Aluminum
-
OIL
Cast Iron
250 in. lbs.
PAN
Sheet Metal®
-
MANIFOLD SCREW/NUT
-
CAMSHAFT NUT
-
NON METALLIC FUEL PUMP
MOUNTING SCREWS
-
USE STANDARD TORQUE SETTINGS WHEN
SPECIFIC VALUES ARE NOT SPECIFIED.
Cast Iron or Steel
Size Grade 2 Grade s• Grade 8
0 Q @
8-3~
----=-= --
i--=-
20 in. lb.
25 ln. lb.
10-24
32 in. lb. 40 ln. lb.
10-32 32
1n. lb.
40 ln. lb.
1/4-20 70 in. lb.
115 ln. lb 165 ln. lb.
1/4-28 85 ln. lb.
140 ln. lb
200 ln. lb.
5/16-18 150
ln. lb. 250 1n. lb.
350 ln. lb.
5/16-24 165 ln. lb.
270 1n. lb
30ft. lb.
3/8-t6
260 in. lb. 35ft. lb.
50 ft. lb.
3/8-24 300
in. lb. 40ft. lb
60ft. lb.
7/t6-14
35ft. lb.
55ft lb. 80ft. lb.
7/16-20 45ft. lb.
75ft. lb. 105ft. lb.
1/2-13 50 ft. lb.
80ft. lb.
115ft. lb.
1/2-20
70ft. lb. 105ft. lb.
165ft. lb.
9/16-12
75ft. lb.
125ft. lb.
~75ft. lb.
9/16-18 100ft. lb.
t65 ft. lb.
230ft. lb.
5/8-11 110ft. lb.
180ft. lb.
260ft. lb.
5/8-18
140ft. lb.
230ft. lb. 330ft. lb.
3/4-10
150ft. lb.
245ft. lb. 350ft. lb.
3/4-16
200ft. lb.
325ft. lb. 470ft. lb.
in. lbs. x .083 =ft. lbs.
Conversions ft. lbs. x 12 ~in. lbs.
ft.lbs. x .1383~kgm
ft. lbs. x 1.3558 ~ N m
CD Lubricate with engine oil
~
1
X,
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
6
85-90 fl. lbs.®
-
130·150 in. lbs.
70-140 in. lbs.
-
-
Grade 5-250 in. lbs.
Grade 8--350 in. lbs.
-
-
-
37·45 in. lbs.
® DO NOT overtorque -loosen -and retorque the hex nuts on Pos1-Lock connecting rods.
NEW- Component directly from stock.
USED- Component that was in a running engine.
• Includes K141
IXI%1~
K301 K321 K341
New 260 ln. lbs.
Used 200 ln. lbs.
2851n. lbs.
18-22 ft. lbs.
~IQJ 8 (QJ 4 (QJ
(7 (Q!a (QJ
1
~
. IQJ 01
I K241, 9 I
(QJ 1o(Ql,
rQJ K301, K321 ([jl I
·~~·,,}
3 25-30 ft. lbs. I 9 25-30 ft. lbs.
IQJ9
l_SdJs
(ji2
~
1/4"
3/8"
1/2"
3/4"
X-708-1@
(ll6
25 (QJ2 (ji6
50·60 fl. lbs.
22-27 ft. lbs.
100-120 in. lbs.
70·140 in. lbs.
20·30 in. lbs.
-
35 fl.lbs.
200 in. lbs.
-
-
37·45 in. lbs.
OIL DRAIN PLUGS
(Oil at Assembly)
Tightening Torque
Cast Iron Pans
150 in. lb.
180 in. lb.
20 ft. lbs.
25 ft. lbs.
20·25 ft. lbs.
Aluminum Pans
100 in. lb.
120 in. lb.
13 ft.lbs.
16 ft. lbs.
20·25
ft. lbs.
® Overtorque 20%, loosen below torque value and retorque to f1nal torque value
®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.
Figure 1-6. Torque Values & Sequences For Fasteners.
1.7

SECTION 2
SPECIAL TOOLS
SPECIAL SERVICE TOOL KIT NO. 3211-A
These quality tools are designed to help you per-
form specific disassembly, repair and reassembly
procedures. By using tools designed
for the job,
you can service engines easier, faster and safer!
In addition, you· II increase your service capabilities
and
customer satisfaction by decreasing engine
down
time.
The Special Service Tool Kit No. 3211-A can be
ordered complete as shown in Figure 2-1 or the
tools can be
ordered individually. Contact your
Kohler Engine Distributor for price and availability.
Figure
2-1. Special Service Tool Kit
2.1

VALVE SERVICE TOOLS
TOOL NO. & NAME
APPLICATION ILLUSTRATION
VALVE SEAT PULLERS Removal of valve seats, Use 11918
~
11726 adapter, 3222
slide hammer & 11915
11913
forcing screw
FORCING SCREW Used with valve seat
Ct==tP
11915
pullers 11726 & 11913
ADAPTER Used
to connect valve seat pullers
©
11918
to slide hammer
VALVE SEAT INSTALLER Used
to install intake and exhaust
~
11811 seats. Use with 4747 handle
11812
3222 SLIDE
HAMMER
Provides pulling force for valve seat
~
11799 Weight
and guide removal. Use 4747 handle.
12244 Slide Bolt
3268 VALVE GUIDE REMOVAL KIT Used
to pull valve guides with 3222
~
11838 Stud 3 1/2"
slide hammer
12100 Stud 2 1/2"
11800 Adapter
~
0917 Nut
12008 Nut
( llB~ii
:~~~
3224 VALVE GUIDE INSTALLER KIT Used
to install valve guides to
~
12325 Driver
proper depth. Use 11763 driver with
11763 Driver 11770 & 11771
depth gages
cw
~
11770Gage
11771 Gage
REAMERS (Valve Guide) To ream valve
guides
11843 5/16" c(
X:1~
11844 1/4"
SEAL AND BEARING INSTALLERS
3223 SEAL INSTALLER KIT Used to install seals without
11782 Seal Installer damage and to proper depth. Use
(])
11783 Seal Installer
11795 handle with installers
11784 Seal Installer
11785 Seal Installer
11786 Seal Installer
11787 Seal Installer
11790 Seal Installer
v
11791 Seal Installer
11792 Seal Installer
11793 Seal Installer
11795 Handle
2.2

SEAL AND BEARING INSTALLERS
TOOL NO. & NAME APPLICATION ILLUSTRATION
3242 SEAL PROTECTOR SLEEVE KIT Used on
crankshaft when installing
)
12020 .75" 12021 1.00 seals
to prevent damage
a
12022 1.25 12126 1.12
12127 1.50 12128 1.44
3241 BEARING INSTALLING KIT Used
to install & remove engine
@
~
12014 Ins. (Crank Bushing) bearings and bushings
12015 Ins. (Cam Bushing)
12016, 12017, 12018 & 12109
Brg.
Installers
OTHER APPLICATIONS
3226 FLYWHEEL PULLER KIT Used
to remove flywheels and
~~
12485 Puller w/forcing screw
bearing plates from engine
5108 Bolt -1/4" w/washer (3)
~
<((( (( J J
12505 Bolt- 10-24 w/washer (2)
r
12504 Bolt- 3/8" w/washer (2)
12506 Storage Bag
FLYWHEEL STRAP WRENCH Used to hold flywheel for nut
~~
10357 removal
OFFSET WRENCH Used
to remove & install cylinder
n
11797 Wrench 1/2" barrel
retaining nuts
4923 Wrench 9/16"
FEELER GAGE Used
to set oil pump drive gear
11767
backlash on twin cylinder engine
~-
o)
TIMING GAGE Used
to hold balance gears in timed
~
10355 Timing Gage
position when assembling engine
:=J
SCRAPER Used
to scrape machined surfaces
I
11762 without damage
HANDLE Used
with bearing installers, slide
~
4747 Handle
hammer, and valve seat installers
TOOL BOARD AND HOOK SET Used
to store and identify tools
12033 SEE FRONT PAGE
2.3

KIT NO. 3211 -A
TOOL USAGE CHART
PART NO & NAME
MODEL(" K" SERIES)
......
...... ...... ......
......
......
.....
0)
N N
......
co
co
..,.
0 N
..,.
...... ......
M
co
0)
...... ......
~ C?
M M
..,:.. ..,:..
U?
LO
VALVE TOOLS
~ ~ ~ ~ ~ ~ ~
~
~
~ ~
11726 Valve Seat Puller
• • • • • • • • • •
11913 Valve Seat Puller
• • • • •
11915 Forcing Screw
• • • • • • • • • •
11918 Adapter
• • • • • • • • • •
11811 Valve Seat Installer
• • • • • • • • • •
11812 Valve Seat Installer
•
3222 Slide Hammer
• • • • • • • • • •
3268 Valve Guide Removal Kit • • • • • • • • • •
12325 Valve Guide Driver • • • • • • • •
11763 Valve Guide Driver (depth) • •
11770 Valve Guide Depth Gage
• (1)
11771 Valve Guide Depth Gage
•
11843 Valve Guide Reamer 5/16"
• • • • • • • • • •
11844 Valve Guide Reamer 1/4"
•
1 KT19 engines prior to Series II (Spec No. 49199 and lower).
BEARING AND SEAL INSTALLERS
12014 Installer- Crank Bushing
• •
12015 Installer- Cam Bushing
• •
12016 Installer- Bearing
•
12017 Installer- Bearing (PTO) • •
12018 Installer- Bearing
• •
12019 Installer- Bearing
• • • •
11782 Installer -Seal (PTO) • •
11783 Installer- Seal (Flywheel)
• •
11784 Installer -Seal (PTO) • • • •
11785 Installer -Seal (PTO) • •
11786 Installer- Seal (Flywheel)
•
11787 Installer -Seal (PTO) •
11790 Installer- Seal (Flywheel)
• •
11791 Installer -Seal (PTO) • •
11792 Installer- Seal (Flywheel)
• • • •
11793 Installer- Seal (Flywheel)
• •
11795 Handle- Installer Seal • • • • • • • • • • •
12020 Seal Sleeve USE AS REQUIRED
12021 Seal Sleeve USE AS REQUIRED
12022 Seal Sleeve USE AS REQUIRED
12126 Seal Sleeve USE AS REQUIRED
12127 Seal Sleeve USE AS REQUIRED
12128 Seal Sleeve USE AS REQUIRED
MISCELLANEOUS TOOLS
10357 Flywheel Strap Wrench 1/2"
• • • • • • • • • • •
11797 Offset Wrench '/2'
• •
4923 Offset Wrench 9/16"
• •
11767 Feeler Gauge-Crank(OII Pump)
• •
10355 Timing Tool (Balance Gear) • • • •
11762 Scraper
• • • • • • • • • • •
4747 Drive Handle
• • • • • • • • • • •
3226 Flywheel Puller Kit • • • • • • • • • • •
NOTE: K141 requires same tools as K161.
2.4

Digital Tachometer
Digital Thermometer
Slack Tube Manometer
Digital Engine Analyzer
Thermocouples
Carrying Case
Digital Voltmeter
Figure 2-2. Engine Analysis Kit
The Kohler Engine Analysis Kit contains a selection
of instruments which will enable you to measure
critical items that relate to engine performance.
You will find many uses for these instruments -
from basic crankcase vacuum checks to sophisti-
cated application tests.
The kit includes the following:
Qty.
Description
1 Digital
Voltmeter
1 Digital
Tachometer
1 Digital Thermometer
1 Digital Engine Analyzer
1 Slack Tube
Manometer
1 8 Ft. Lead With Plug
3 14
mm Spark Plug
Thermocouple
2 Head Bolt Thermocouple
1 Oil Sump Thermocouple
1 1 /4" x 1 /8" Bushing
1 318" x 1
/8" Bushing
1
1/2" X 1/8"
Bushing
1
3/4" X 1/8"
Bushing
1 Tube With Fittings
1 Carrying Case
3 Plain
Thermocouple
The voltmeter, tachometer, thermometer and en-
gine analyzer feature state of the art electronic
circuitry and digital readouts. Guidelines for using
the instruments and for testing are included. Using
the instruments
in the kit you will be able to:
• Measure temperatures of -
• spark plug base gasket/cylinder head bolt.
• oil sump.
• air into flywheel and carburetor.
• Measure engine speed (RPM) .
• Measure crankcase vacuum and exhaust
system back pressure.
• Measure voltage.
• Measure charging system current.
• Measure electric starter current (Amp} draw.
The Engine Analyzer Kit can
be ordered complete
as shown, or the instruments can be ordered indi-
vidually. Contact your Kohler Distributor for price
and availability.
2.5

SECTION 3
PERIODIC MAINTENANCE
REQUIRED MAINTENANCE
These required maintenance procedures should be performed at the frequency stated in the table:
Required Maintenance Frequency
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Clean Grass Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily*
Clean/Replace Fuel Filter
.......................................... As Required
Clean Foam Precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hours*
Change
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hours
Check Optional Reduction
Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hours
Clean Cooling Fins and
External Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hours*
Clean Paper Air
Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Hours*
Check Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Hours
Check Valve- To- Tappet
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Hours
Clean Cylinder Head and
Combustion
Chamber* .............................................. 500 Hours**
Service Starter
Motor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annually
or 500 Hours
• Perform these maintenance procedures more frequently when engine is operated under
extremely dusty and dirty conditions.
*• 250 Hours when leaded gasoline is used.
~ WARNING: Accidental Starts!
Before
seNicing the engine or equipment, always
remove the spark
plug to prevent the engine from
starting accidentally. Groundthe lead to prevent
sparks that
could cause fires.
1. Make sure the engine is stopped, level, and is
cool so the oil has had time to drain into the
sump.
CHECK OIL LEVEL
The importance of checking and maintaining the
proper oil level in crankcase cannot be
overem-
phasized. Check oil BEFORE EACH USE as follows:
2. Clean the area around oil fill cap/dipstick be-
fore removing to keep dirt, grass clippings,
etc., out of the engine.
3. Remove oil fill
cap/dipstick; wipe oil off. Rein-
sert dipstick and push it all the way down into
tube. Remove dipstick and
check the level.
4. On engines with threaded type plug dipstick,
shoulder plug on top of hole to observe level.
3.1

The oil level should be up to, but not over, the
"F" mark on the dipstick. Refer to Figure 3-1.
t
Operating
Range
__l_
L
Figure 3-1. Oil Level Range.
5. Add the
proper type of oil if the level is low.
Always check the level with dipstick before
adding more oil.
CAUTION: Never
operate the engine with the oil level
below "L" mark or over "F" mark on dip-
stick.
CHANGE OIL
For a new engine, change oil after the first 5
hours
of operation. Change oil every 25 operating
hours
thereafter. For an overhauled engine or
those rebuilt with a new shortblock or miniblock,
use straight
30-weight Service Class SF or SG oil
for the first 5 hours of operation. Change the oil
after this initial run-in period. Change oil every 25
hours thereafter. Drain oil while the engine is still
warm from operation. The oil will flow freely and
carry away more impurities. Change oil as follows:
1. Remove the oil drain plug and dipstick. Tilt the
engine slightly towards the drain hole to obtain
better drainage.
2. Reinstall
the drain plug. Make sure it is tight-
ened securely.
3. Fill with new oil
of the proper type to the "F"
mark on the dipstick. Always check the level
on dipstick before adding more oil. Make sure
the engine is level when filling and checking
oil.
SERVICE AIR CLEANER
K-Series engines are equipped with a high-density
paper air cleaner element. Some specifications
are also
equipped with an oiled foam precleaner
which surrounds the
paper element. Refer to Fig-
ure
3-2.
3.2
Precleaner
If so equipped, wash and reoil the precleaner
every 25 operating hours (more often under ex-
tremely dusty, dirty conditions).
1. Remove
precleaner from paper element. Wash
the
precleaner in warm water with detergent.
2. Rinse precleaner thoroughly until all traces of
detergent are eliminated. Squeeze out excess
water (do not wring). Allow
precleaner to air
dry.
3. Saturate
precleaner in clean, fresh engine oil.
Squeeze out excess oil.
4. Reinstall precleaner over paper element.
Paper Element
Every 100 hours of operation (more often under ex-
tremely dusty or dirty conditions), check the paper
element. Replace the element as necessary.
1. Remove the precleaner (if so equipped), element
cover, and paper element.
2. Replace a dirty, bent, or damaged element with
a genuine Kohler element. Handle new ele-
ments carefully; do not use of the sealing sur-
faces are bent
or damaged.
NOTE: Do not wash the paper element or use com-
pressed air as this will damage element.
3. Reinstall the paper element.
4. Install the precleaner (cleaned and oiled) over
the
paper element.
5. Install the air cleaner
cover and wing nut. Tight-
en wing nut. Make sure element is sealed tight-
ly against air cleaner base.
Inspect Air Cleaner Components
Whenever the air cleaner cover is removed, or serv-
icing the element
or precleaner, check the following
components:
Air Cleaner Base -Make sure it is secured tightly to
carburetor and is not bent or damaged.
Element Cover and Element Cover Nut - On K181
New Look ~ngines only, make sure element cover
is not bent or damaged. Check that element cover
nut
is secured tightly to seal element between air
cleaner base and
element cover. Tighten nut to
50 in. lb. torque.
Breather Tube -Make sure it is sealed tightly in air
cleaner base and breather
cover.

"'-- PRECLEANER (OPTION)
Figure 3-2. Air Cleaner Components.
NOTE: Damaged, worn, or loose air cleaner com-
ponents could allow unfiltered air into the engine
causing
premature wear and failure. Replace all
damaged or worn components.
CLEAN AIR INTAKE/COOLING AREAS
To ensure proper cooling, make sure the grass
screen, cooling fins, and other external surfaces
of engine are kept clean at all times. Every 50
operating hours (more often under extremely
dusty, dirty conditions), remove the blower hous-
ing and
other cooling shrouds. Clean the cooling
fins and external surfaces as necessary. Make
sure the cooling shrouds are reinstalled. Refer to
the
"Disassembly" and "Reassembly" sections for
cooling shroud removal and installation proce-
dures.
NOTE: Operating the engine with a blocked grass
screen, dirty
or plugged cooling fins, and/or cool-
ing shrouds removed will cause engine damage
due to overheating.
CHECK SPARK PLUG
Every 100 operating hours, remove the spark plug,
check its condition, and reset gap or replace with
new plug as necessary. Refer
to Figure 3-3.
Ground Electrode
Figure 3-3. Servicing Spark Plug.
1. Before removing spark plug, clean the area
around the base of plug to keep dirt and de-
bris out of engine.
2. Remove the plug and
check its condition. Re-
place the plug if worn or if reuse is question-
able.
3.3

NOTE: Do not clean the spark plug in a machine
using abrasive grit.
Some grit could remain in
spark plug and enter the engine causing extensive
wear and
damage.
3. Check gap using a wire feeler gauge. Adjust
gap by carefully bending the ground electrode.
4. Reinstall spark plug into cylinder head. Torque
plug to 18/22 ft. lb.
SERVICE OPTIONAL REDUCTION GEAR
UNIT
On engines equipped with a reduction gear unit,
check the oil level in unit every 50 operating
hours. Refer
to Figure 3-4.
Drain Plug
(Oil Level Check)
Figure 3-4. Reduction Gear Unit.
1. Remove the plug on the lower part of gear unit
cover. With engine level, the oil should be up
to the
bottom of the plug hole.
2. To add oil, remove the vented fill plug at the
top
of the unit. Use the same type of oil as
used
in the engine crankcase.
3. Reinstall and tighten the plugs securely.
CHECK FUEL FILTER
Some engines are equipped with an in-line fuel
filter. Visually inspect the filter periodically. Re-
place when dirty with a genuine Kohler filter. Refer
to Figure 3-5.
3.4
Figure 3-5. In-line Fuel Filter.
SERVICE STARTER MOTOR DRIVE
Every 500 operating hours or annually (whichever
occurs first) , clean and lubricate the drive splines
of the Bendix-drive electric starter motor.
1. Remove starter from crankcase. (Refer to ap-
propriate "Disassembly" section.)
2. Remove dust cover, stop nut, stop gear
spacer, spring, dust
cover spacer, and drive
pinion.
3. Clean the drive shaft splines with solvent. Dry
solvent thoroughly.
4. Apply a small amount of Kohler electric starter
drive lubricant (Part No.
52 357 01) to splines.
NOTE: Kohler
starter drive lubricant (Part No. 52
357 01) must be used on all Kohler electric starter
drives. The use of other lubricants can cause the
drive to stick
or bind.
5. Apply a small
amount of Loctite® No. 271 to
stop nut threads. Assemble drive parts in re-
verse order of removal. Torque stop nut to
160 in. lb.
6. Reinstall starter to crankcase. (Refer to appro-
priate "Reassembly" section.)
CLEAN CYLINDER HEAD AND COMBUS-
TION CHAMBER
Every 500 operating hours (250 hours when leaded
gasoline is used) , remove cylinder head and clean
combustion chamber. Refer to Figure 3-6.

Figure 3-6. Cleaning Cylinder Head And
Combustion Chamber.
1. Remove the cylinder head baffle and cylinder
head.
2. Clean away
combustion deposits using a
wooden
or plastic scraper.
3. Reinstall the cylinder head using a new gasket.
Torque the cylinder head fasteners
in se-
quence to the values specified in Figure 3-7.
CHECK VALVE- TO- TAPPET CLEARANCE
Every 500 operating hours, remove breather/valve
cover and check valve-to-tappet clearance with a
flat feeler gauge. Refer to Figure
3-8. The engine
must be cold when checking this clearance.
1. Remove the air cleaner assembly, carburetor,
and
breather assembly. (Refer to appropriate
"Disassembly" section.)
2. Position the crankshaft so the piston is at top
of compression stroke (cam has no effect on
tappets).
Figure 3-8. Measuring Valve- To- Tappet
Clearance.
~1
K161, K181 •
15-20 ft. lbs.
0)2
7©8Q)14(Q)
Q) K241,
©
3
K301, K321
25-30 ft. lbs.
9
©
Q5
~6
K341
Q) 25-30 ft. lbs.
3
g5 g2
* Includes K141
Figure 3-7. Cylinder Head Fastener
Tightening Sequence.

3. Measure valve-to-tappet clearance with a flat
feeler gauge.
On Model K91, K141, K161, K181 -If the
clearance is too small, remove the valves and
grind the valve stems until the correct clear-
ance is obtained. Make sure valve stems are
ground perfectly flat and smooth.
Model Intake Valve Exhaust Valve
K91 .005" I .009" .011 "/.015"
K161,K181 .006" I .008" .017"/.019"
K241, K301 .008" I .01 0" .017"/.019"
K321, K341
Figure 3-9. Valve Clearances
If clearance is too large, replace the valves and
recheck clearance.
NOTE: Large clearances can also be reduced by
grinding the valves and/or valve seats. Refer to
the "Inspection And Repair/Reconditioning" section
for valve specifications.
On Models K241, K301, K321, K341 -Adjust the
clearance by turning the adjusting screw on tap-
pets. Refer to Figure 3-9.
3.6
Figure 3-10. Adjusting Valve- To- Tappet
Clearance - Models K241
Through K341.
STORAGE
If the engine will be out of service for approxi-
mately two months or more, use the following
storage procedure.
1. Change the oil when engine is still warm from
operation. Refer to "Change Oil."
2. Change the oil in reduction gear unit, if so
equipped. Refill with the same oil as used in
engine crankcase for season of operation. Re-
fer to "Service Optional Reduction Gear Unit. "
Run engine for a few minutes to distribute
clean oil throughout engine.
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
plug, by do not connect plug lead. Crank the
engine two
or three revolutions.
5. Remove the spark plug. Cover the spark plug
hole with
thumb and turn engine over until the
piston is at the top of its stroke (pressure
against thumb is greatest). Reinstall plug, but
do not connect plug lead.
6. Clean the exterior surfaces of engine. Spread
a light film of oil over any exposed metal sur-
faces of engine to prevent rust.
7. Store the engine in a clean, dry place.