Kohler Magnum 8 HP User manual

1
Congratulations  You have selected a fine four-cycle, single cylinder, air-cooled engine. Kohler designs long
life strength and on-the-job durability into each enginemaking a Kohler engine dependabledependability you
can count on. Here are some reasons hy:
 Kohler engines are easy to service. All routine service areas (like the dipstick and oil fill, air cleaner, spark
plug, and carburetor) are easily and quickly accessible.
 Parts subject to the most ear and tear (like the cylinder, crankshaft, and camshaft) are made from
precision formulated cast iron. Because the cast iron cylinder can be rebored, these engines can last even
longer.
 Dependable, maintenance-free electronic ignition system ensures fast, easy starts time after time.
 Every Kohler engine is backed by a orld ide net ork of over 10,000 distributors and dealers. Service
support is just a phone call a ay. Call 1-800-544-2444 (U.S. & Canada) for Sales & Service assistance.
To keep your engine in top operating condition, follo the maintenance procedures in this manual.
MAGNUM 8,12,16 HP
HORIZONTAL CRANKSHAFT
OWNER'S MANUAL

2
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
Rotating Parts!
Keep hands, feet, hair, and clothing
away from all moving parts to
prevent injury. Never operate the
engine with covers, shrouds, or
guards removed.
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
WARNING
Hot Parts!
Engine components can get
extremely hot from operation. To
prevent severe burns, do not touch
these areas while the engine is
running, or immediately after it is
turned off. Never operate the engine
with heat shields or guards
removed.
CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
Explosive Fuel can cause fires and
severe burns.
Stop engine before filling fuel tank.
Explosive Fuel!
asoline is extremely flammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or flames. Do not
fill the fuel tank while the engine is
hot or running, since spilled fuel
could ignite if it comes in contact
with hot parts or sparks from
ignition. Do not start the engine near
spilled fuel. Never use gasoline as a
cleaning agent.
WARNINGWARNING
California
Proposition 65 Warning
Engine exhaust from this product
contains chemicals known to the
State of California to cause cancer,
birth defects, or other reproductive
harm.
Safety Precautions
To insure safe operations please read the follo ing statements and understand their meaning.
Also refer to your equipment o ner's manual for other important safety information. This manual
contains safety precautions hich are explained belo . Please read carefully.
WARNIN
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death,
or substantial property damage if the arning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or
property damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.
For Your Safety!
These precautions should be followed at all times. Failure to follow these precautions could result
in injury to yourself and others.

3
Safety Precautions (Cont.)
Accidental Starts can cause severe
injury or death.
Disconnect and ground spark plug
lead before servicing.
WARNING
arbon Monoxide can cause
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
WARNING
Lethal Exhaust ases!
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled. Avoid inhaling exhaust
fumes, and never run the engine in
a closed building or confined area.
WARNING
Explosive Gas can cause fires and
severe acid burns.
Charge battery only in a well
ventilated area. Keep sources of
ignition away.
Accidental Starts!
Disabling engine. Accidental starting
can cause severe injury or death.
Before working on the engine or
equipment, disable the engine as
follows: 1) Disconnect the spark
plug lead(s). 2) Disconnect negative
(-) battery cable from battery.
Explosive as!
Batteries produce explosive
hydrogen gas while being charged.
To prevent a fire or explosion,
charge batteries only in well
ventilated areas. Keep sparks, open
flames, and other sources of ignition
away from the battery at all times.
Keep batteries out of the reach of
children. Remove all jewelry when
servicing batteries.
Before disconnecting the negative
(-) ground cable, make sure all
switches are OFF. If ON, a spark will
occur at the ground cable terminal
which could cause an explosion if
hydrogen gas or gasoline vapors
are present.
Figure 1. Typical Model M8 Engine.
Identification Plate
(Under Air Cleaner Cover)
Blower Housing
Fuel Tank
Throttle
Control Retractable
Starter
Air Intake
Screen
Dipstick &
Oil Fill
Cooling
Fins Spark
Plug Muffler
Air
Cleaner
Oil Drain
Oil Sump
Electric Starter
Fuel Filter
Choke
Control

4
Refer to Maintenance Instructions beginning on
page 7 for detailed oil check and oil change
procedures.
Fuel Recommendations
WARNIN : Explosive Fuel!
asoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Do not fill the fuel tank
while the engine is hot or running, since spilled fuel
could ignite if it comes in contact with hot parts or
sparks from ignition. Do not start the engine near spilled
fuel. Never use gasoline as a cleaning agent.
General Recommendations
Purchase gasoline in small quantities and store in
clean, approved containers. A container ith a capacity
of 2 gallons or less, ith a pouring spout, is
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
Do not use gasoline left over from the previous season,
to minimize gum deposits in your fuel system and to
insure easy starting.
Do not add oil to the gasoline.
Do not overfill the fuel tank. Leave room for the fuel to
expand.
Fuel Type
For best results use only clean, fresh, unleaded
gasoline ith a pump sticker octane rating of 87 or
higher. In countries using the Research method, it
should be 90 octane minimum.
Unleaded gasoline is recommended as it leaves less
combustion chamber deposits. Leaded gasoline may be
used in areas here unleaded is not available and
exhaust emissions are not regulated. Be a are
ho ever, that the cylinder head ill require more
frequent service.
asoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends are not
approved.
asoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
Oil Recommendations
Using the proper type and eight 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 ear and
failure.
Before each start, make sure the crankcase is filled
ith the proper type and quantity of oil.
Oil Type
Use high quality detergent oil of API (American
Petroleum Institute) service class S , SH, SJ or
higher. Select the viscosity based on the air
temperature at the time of operation as sho n in the
follo ing table.
Figure 2. Viscosity rades Table.
Straight 30-weight oil is preferred. SAE 10W-30 oil is
not recommended above 32°F. Using this oil
substantially increases oil consumption and combustion
chamber deposits.
NOTE: Using other than service class SG, SH, SJ or
higher oil or extending oil change intervals
longer than recommended can cause engine
damage hich is not covered by the engine
arranty.
A logo or symbol on oil containers identifies the API
service class and SAE viscosity grade. See Figure 3.
*Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, up to 40°F.
**Synthetic oils provide better starting in extreme cold
(belo -10°F).
Figure 3. Oil Container Logo.

5
Operating Instructions
Also read the operating instructions of the equipment
this engine powers.
Pre-Start Checklist
Check oil level. Add oil if lo . Do not overfill.
Check fuel level. Add fuel if lo .
Check cooling air intake areas and external
surfaces of engine. Make sure they are clean and
unobstructed.
Check that the air cleaner components and all
shrouds, equipment covers, and guards are in
place and securely fastened.
Check that any clutches or transmissions are
disengaged or placed in neutral. This is especially
important on equipment ith hydrostatic drive. The
shift lever must be exactly in neutral to prevent
resistance hich could keep the engine from
starting.
WARNIN : Lethal Exhaust ases!
Engine exhaust gases contain poisonous carbon
monoxide. Carbon monoxide is odorless, colorless, and
can cause death if inhaled. Avoid inhaling exhaust
fumes, and never run the engine in a closed building or
confined area.
Cold Weather Starting ints
1. Be sure to use the proper oil for the temperature
expected. See Figure 2 on page 4.
2. Declutch all possible external loads.
3. A arm battery has much more starting capacity
than a cold battery.
4. Use fresh inter grade fuel. NOTE: Winter grade
gasoline has higher volatility to improve starting.
Do not use gasoline left over from summer.
Engine Identification Numbers
When ordering parts, or in any communication involving
an engine, al ays give the Model, Specification, and
Serial Numbers of the engine.
The engine identification numbers appear on a decal
affixed to the engine shrouding. Include letter suffixes, if
there are any.
Record your engine identification numbers on the
identification label belo (Figure 4) for future reference.
Figure 4. Engine Identification Label.
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the
number of operating hours for hich the engine has
been sho n to meet Federal and CARB emission
requirements. The follo ing table provides the Engine
Compliance Period (in hours) associated ith the
category descriptor found on the certification label.
Emission Compliance Period (Hours)
*Small Off-Road Engines
IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA 2004 AND
CALIFORNIA 2006 AND LATER EMISSION
CONTROL REGULATIONS FOR SI SORE*
FAMILY
DISPL. (CC)
MODEL NO.
SPEC. NO.
SERIAL NO.
EMISSION COMPLIANCE PERIOD:
EPA: CARB:
KOHLER CO. KOHLER, WISCONSIN USA
THIS ENGINE IS CERTIFIED TO OPERATE
ON:
REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE SPECS AND AD USTMENTS.
FOR SALES/SERVICE IN US/CANADA, CALL:
1-800-544-2444
www.kohlerengines.com
N11236
EPA
CARB
Category C
250 hours
Moderate
125 hours
Category B
500 hours
Category A
1000 hours
Intermediate
250 hours
Extended
500 hours
Refer to certification label for engine displacement.
Exhaust Emission Control System for models M8, M12,
and M16 is EM.

6
If the starter does not turn the engine over, shut
off starter immediately. Do not make further
attempts to start the engine until the condition is
corrected. Do not jump start using another battery
(refer to Battery belo ). See your Kohler Engine
Service Dealer for trouble analysis.
3. For a Cold Engine  Gradually return the choke
control to the off position after the engine starts
and arms ups. The engine/equipment may be
operated during the arm-up period, but it may be
necessary to leave the choke partially on until the
engine arms up.
4. For a Warm, Certified Engine  Return the
choke to the off position as soon as the engine
starts.
Stopping
1. Remove the load by disengaging all PTO
attachments.
2. Place the throttle control in the idle position. Allo
the engine to run at idle for 30-60 seconds.
3. Move the throttle control to the stop position.
On engines equipped ith a key s itch, turn
s itch to stop or off position.
Battery
A 12 volt battery is normally used. Refer to the
operating instructions of the equipment this engine
po ers for specific battery requirements.
If the battery charge is not sufficient to crank the
engine, recharge the battery (see page 10).
Operating
Optional spark arrestor mufflers are available from your
Kohler Engine Service Dealer. Check your local la s
and statutes regarding engine spark arrestor muffler
requirements.
Angle of Operation
This engine ill operate continuously at angles up to
30°. Check oil level to assure crankcase oil level is at
the F mark.
Refer to the operating instructions of the equipment
this engine po ers. Because of equipment design or
application, there may be more stringent restrictions
regarding the angle of operation.
NOTE: Do not operate this engine continuously at
angles exceeding 30° in any direction. Engine
damage could result from insufficient
lubrication.
Starting
1. For a Cold Engine  Place the throttle control
midway bet een the slow and fast
positions. Place the choke control into the on
position.
For a Warm Engine (normal operating
temperatures)  Place the throttle control
midway bet een the slow and fast
positions. For non-certified engines, place the
choke into the off position. For certified
engines, place the choke in the on position.
2. Start the engine as follo s:
For Rope Start Engines  Place the starting rope
knot in the slot in starting pulley. Wrap the rope
around the pulley. Pull the starter handle ith a
smooth, steady motion.
For a Retractable Start Engine  SLOWLY pull
the starter handle until just past compression 
STOP! Return starter handle, pull firmly ith a
smooth, steady motion to start. Pull the handle
straight out to avoid excessive rope ear from the
starter rope guide.
Extend the starting rope periodically and check its
condition. If the rope is frayed, have it replaced
immediately by your Kohler Engine Service
Dealer.
WARNIN : Accidental Starts!
Before extending and checking the retractable starter
rope, remove the spark plug lead to prevent the engine
from starting accidentally. round the lead to prevent
sparks that could cause fires. Make sure the
equipment is in neutral.
For an Electric Start Engine  Activate the
starter s itch. Release the s itch as soon as the
engine starts.
NOTE: Do not crank the engine continuously for
more than 10 seconds at a time. If the
engine does not start, allo a 60 second
cool do n period bet een starting
attempts. Failure to follo these
guidelines can burn out the starter motor.
NOTE: If the engine develops sufficient speed to
disengage the starter but does not keep
running (a false start), engine rotation
must be allo ed to come to a complete
stop before attempting to restart the
engine. If the starter is engaged hile the
fly heel is rotating, the starter pinion and
fly heel ring gear may clash, resulting in
damage to the starter.

7
Maintenance Instructions
Maintenance, repair, or replacement of the emission control devices and systems, which are being done at
the customers expense, may be performed by any non-road engine repair establishment or individual.
Warranty repairs must be performed by an authorized Kohler service outlet.
WARNIN : Accidental Starts!
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or
equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery
cable from battery.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table. They should
also be included as part of any seasonal tune-up.
Cooling
NOTE: If debris builds up on the grass screen or
other cooling air intake areas, stop the engine
immediately and clean. Operating the engine
ith blocked or dirty air intake and cooling
areas can cause extensive damage due to
overheating.
WARNIN : Hot Parts!
Engine components can get extremely hot from
operation. To prevent severe burns, do not touch these
areas while the engine is running, or immediately after
it is turned off. Never operate the engine with heat
shields or guards removed.
Engine Speed
NOTE: Do not tamper ith the governor setting to
increase the maximum engine speed.
Overspeed is hazardous and ill void the
engine arranty.
WARNIN : Rope Starting Pulley is Not
a Drive Pulley!
Do not use rope starting pulley as a drive pulley. Using
starting pulley as a drive could loosen flywheel
fastener, resulting in bodily harm.
1Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
2Have a Kohler Engine Service Dealer perform this service.
3Or annually, whichever occurs first.
4250 hours when leaded gasoline is used.
 Have bendix starter drive serviced2,3.
 Have optional Oil Sentry s itch checked2.
 Have valve and tappet clearance checked2.
 Have cylinder head serviced2,4.
Maintenance Required
Daily or Before
Starting Engine
Frequency
 Fill fuel tank.
 Check oil level.
 Check air cleaner for dirty1, loose, or damaged parts.
 Check air intake and cooling areas, clean as necessary1.
 Change oil1.
 Service precleaner element1.
 Check gear reduction unit.
 Remove cooling shrouds and clean cooling areas1.
Every 50 Hours
 Replace air cleaner element1.
Every 100 Hours
Every 25 Hours
Annually or
Every 500 Hours
 Check spark plug condition and gap.
Every 200 Hours

8
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 follo s:
1. Make sure the engine is stopped, level, and is
cool so the oil has had time to drain into the sump.
2. To keep dirt, grass clippings, etc., out of the
engine, clean the area around the oil fill cap/
dipstick before removing it.
3. Remove the oil fill cap/dipstick and push it all the
ay do n into tube. Remove dipstick and check
the level.
4. If the level is lo , add oil of the proper type, up to
the F mark on the dipstick. (Refer to Oil Type
on page 4.) Al ays check the level ith the
dipstick before adding more oil.
NOTE: To prevent extensive engine ear or
damage, al ays maintain the proper oil
level in the crankcase. Never operate the
engine ith the oil level belo the L
mark or over the F mark on the dipstick.
Change Oil
For a new engine, change oil after the first 5 hours of
operation. Thereafter, change oil after every 25 hours
of operation.
Change the oil hile the engine is still arm. The oil
ill flo freely and carry a ay more impurities. Make
sure the engine is level hen filling, checking, or
changing the oil.
Change the oil as follo s:
1. To keep dirt, grass clippings, etc., out of the
engine, clean the area around the drain plug and
dipstick before removing it.
2. Remove the oil drain plug and dipstick. Tilt the
engine slightly to ards the oil drain to obtain
better drainage. Be sure to allo ample time for
complete drainage.
3. Reinstall the drain plug. Make sure it is tightened
securely.
4. Fill the crankcase, ith ne oil of the proper type,
to the F mark on the dipstick. Refer to Oil Type
on page 4. Al ays check the level ith the dipstick
before adding more oil.
5. Reinstall the oil fill cap or plug and tighten
securely.
NOTE: To prevent extensive engine ear or
damage, al ays maintain the proper oil
level in the crankcase. Never operate the
engine ith the oil level belo the L
mark or over the F mark on the dipstick.
Service Precleaner and Air Cleaner lement
This engine is equipped ith a replaceable, high
density paper air cleaner element. Most engines are
also equipped ith an oiled, foam precleaner hich
surrounds the paper element. See Figure 6.
Figure 6. Air Cleaner Housing Components.
Operating
Range
F Mark
Figure 5. Oil Level Dipstick.
Oil Sentry
Some engines are equipped ith an optional Oil
Sentry oil level s itch. If the oil level drops belo an
acceptable level, the Oil Sentry ill either shut off the
engine or activate a arning signal, depending on the
application.
NOTE: Make sure the oil level is checked BEFORE
EACH USE and is maintained up to the F
mark on the dipstick. This includes engines
equipped ith Oil Sentry.
Optional
Precleaner
Paper Element
Element Cover
Element Cover Nut
Air Cleaner
Base

9
NOTE: Operating the engine ith damaged or
loose components could allo unfiltered
air into the engine causing premature
ear and failure.
4. Reinstall the paper element, element cover and
ing nut. Tighten the cover nut securely to be sure
the element is sealed tightly against the element
cover and base plate.
5. If so equipped, install the precleaner ( ashed and
oiled) over paper element.
6. Install air cleaner cover and ing nut. Tighten ing
nut until it is snug against cover. Do not
overtighten.
7. When air cleaner element replacement is
necessary al ays use genuine Kohler parts.
Clean Air Intake/Cooling Areas
To ensure proper cooling, make sure the grass screen,
cooling fins, and other external surfaces of the engine
are kept clean at all times.
Every 50 hours of operation (more often under
extremely dusty, dirty conditions), remove the blo er
housing and other cooling shrouds. Clean the cooling
fins and external surfaces as necessary. Make sure the
cooling shrouds are reinstalled.
NOTE: Operating the engine ith a blocked grass
screen, dirty or plugged cooling fins, and/or
cooling shrouds removed, ill cause engine
damage due to overheating.
Check Spark Plug
Every 200 hours of operation, remove the spark plug,
check its condition, and reset the gap or replace ith a
ne plug as necessary.
1. Before removing the spark plug, clean the area
around the base of the plug to keep dirt and debris
out of the engine.
2. Remove the plug and check its condition.
Replace the plug if orn or reuse is questionable.
NOTE: Do not clean the spark plug in a machine
using abrasive grit. Some grit could
remain in the spark plug and enter the
engine causing extensive ear and
damage.
Check the air cleaner daily or before starting the
engine. Check for a buildup of dirt and debris around
the air cleaner system. Keep this area clean. Also
check for loose or damaged components. Replace all
bent or damaged air cleaner components.
NOTE: Operating the engine ith loose or damaged
air cleaner components could allo unfiltered
air into the engine causing premature ear
and failure.
Service Precleaner
Wash and reoil the precleaner every 25 hours of
operation, (more often under extremely dusty or dirty
conditions).
1. Remove the ing nut and air cleaner cover.
2. Remove the precleaner from the paper element. It
is not necessary to remove element cover or
paper element.
3. Wash the precleaner in arm ater ith
detergent. Rinse the precleaner thoroughly until all
traces of detergent are eliminated. Squeeze out
excess ater (do not ring). Allo the precleaner
to air dry.
4. Saturate the precleaner ith ne engine oil.
Squeeze out all excess oil.
5. Reinstall the precleaner over the paper element.
6. When precleaner replacement is necessary
al ays use genuine Kohler parts.
Service Paper Element
Every 100 hours of operation (more often under
extremely dusty or dirty conditions), replace the paper
element.
1. Remove the precleaner (if so equipped) element
cover and paper element.
2. Do not ash the paper element or use
pressurized air, as this ill damage the element.
Replace a dirty, bent, or damaged element ith a
genuine Kohler element. Handle ne elements
carefully; do not use if the sealing surfaces are
bent or damaged.
3. When servicing the air cleaner, check the air
cleaner base. Make sure it is secured and not
bent or damaged. Also check the element cover,
seals and breather tube for damage or improper
fit. Replace all damaged air cleaner components.

10
3. Check gap (0.025") using a ire feeler gauge.
Adjust the gap as necessary by carefully bending
the ground electrode. See Figure 7.
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 18-22 ft. lb.
round
Electrode
Wire auge
Spark Plug
0.025" ap
Reduction Gear Units
On engines equipped ith a reduction gear unit,
remove the oil plug on lo er part of cover every
50 hours of operation to check oil level. With the
engine level, the oil level of the unit should be up to the
bottom of the oil plug hole. To add oil, remove the
vented plug at the top of the unit. Use the same eight
and grade of oil as used in the engine crankcase.
Carburetor Troubleshooting
and Adjustments
Kohler M8 - M16 engines are equipped ith one of
three types of carburetors; Kohler adjustable main jet,
Walbro adjustable main jet, or Walbro fixed main jet.
Emissions certified engines ill have fixed jet
carburetors. Walbro carburetors have the brand name
embossed in the side of the body casting, near the top.
The carburetor is designed to deliver the correct
fuel-to-air mixture to the engine under all operating
conditions. The main fuel and idle fuel needles on
adjustable jet carburetors are set at the factory and
normally do not require further adjustment. On fixed jet
carburetors, the lo idle fuel needle is also set at the
factory and normally does not need further adjustment.
The main fuel jet is calibrated and installed at the
factory and is not adjustable.
Troubleshooting
If engine troubles are experienced that appear to be
fuel system related, check the follo ing areas before
adjusting the carburetor.
 Make sure the fuel tank is filled ith clean, fresh
gasoline.
 Make sure the fuel tank cap vent is not blocked
and that it is operating properly.
 If the fuel tank is equipped ith a shut-off valve,
make sure it is open.
 If the engine is equipped ith an in-line fuel filter,
make sure it is clean and unobstructed. Replace
the filter if necessary.
 Make sure fuel is reaching the carburetor. This
includes checking the fuel lines and fuel pump for
restrictions or faulty components, replace as
necessary.
 Make sure the air cleaner element is clean and all
air cleaner element components are fastened
securely.
If, after checking the items listed above, the engine is
hard to start, runs roughly, or stalls at lo idle speed, it
may be necessary to adjust or service the carburetor.
Figure 7. Servicing Spark Plug.
Battery Charging
WARNIN : Explosive as!
Batteries produce explosive hydrogen gas while being
charged. To prevent a fire or explosion, charge
batteries only in well ventilated areas. Keep sparks,
open flames, and other sources of ignition away from
the battery at all times. Keep batteries out of the reach
of children. Remove all jewelry when servicing
batteries.
Before disconnecting the negative (-) ground cable,
make sure all switches are OFF. If ON, a spark will
occur at the ground cable terminal which could cause
an explosion if hydrogen gas or gasoline vapors are
present.
On engines equipped with an alternator charging
system, disconnect plug from rectifier-regulator prior to
charging battery.
Fuel Filter
Some engines are equipped ith an in-line fuel filter.
Periodically inspect the filter and replace hen dirty.
Use a genuine Kohler filter.

11
Kohler Carburetor Adjustment
1. With the engine stopped, turn the fuel adjusting
needles in (clock ise) until they bottom lightly.
NOTE: The tip of the idle fuel and main fuel
adjusting needles are tapered to critical
dimensions. Damage to the needles and
the seats in carburetor body ill result if
the needles are forced.
2. Preliminary Settings: Turn the adjusting needles
out (counterclock ise) from lightly bottomed as
follo s:
Kohler Adjustable Jet
5. Low Idle Fuel Needle Setting: Place the throttle
into the idle or slow position.
Use the same procedure used for the main fuel
needle and set the adjusting needle midway
bet een the rich and lean settings.
6. Low Idle Speed Setting: Place the throttle control
into the idle or slow position. Set the lo idle
speed to 1200 RPM* (± 75 RPM) by turning the
lo idle speed adjusting scre in or out. Check
the speed using a tachometer.
*NOTE: The actual lo idle speed depends on the
application  refer to equipment
manufacturer's recommendations. The
recommended lo idle speed for basic
engines is 1200 RPM. To ensure best
results hen setting the lo idle fuel
needle, the lo idle speed must not
exceed 1500 RPM.
Walbro Carburetor Adjustment
In general, turning the adjusting needles in (clock ise)
decreases the supply of fuel to the carburetor. This
gives a leaner fuel-to-air mixture. Turning the adjusting
needles out (counterclock ise) increases the supply of
fuel to the carburetor.
Carburetors on certified engines have a fixed (non-
adjustable) main jet. In steps 1 and 2, perform only
hat pertains to the idle fuel needle. Skip step 4.
3. Start the engine and run at half throttle for 5 to 10
minutes to arm up. The engine must be arm
before making final settings (steps 4-6).
4. Main Fuel Needle Setting: This adjustment is
required for adjustable main jet carburetors only. If
the carburetor is a fixed main jet type, refer to
Walbro adjustment.
Place the throttle into the fast position. If
possible, place the engine under load.
Turn the main fuel adjusting needle out
(counterclock ise) from the preliminary setting
until the engine speed decreases (rich). Note the
position of the needle.
No turn the adjusting needle in (clock ise). The
engine speed may increase, then it ill decrease
as the needle is turned in (lean). Note the position
of the needle.
Set the adjusting needle midway bet een the rich
and lean settings. See Figure 8.
Figure 9.
1. With the engine stopped, turn the adjusting
needle(s) in (clock ise) until it bottoms lightly.
NOTE: The tips of the fuel adjusting needles are
tapered to critical dimensions. Damage to
the needles and the seats in carburetor
body ill result if the needles are forced.
Low Idle High Idle
M8 1-1/4 turns 2 turns
M12 2-1/2 turns 2 turns
M16 2-1/2 turns 3-1/2 turns
Lean
Rich
Adjust to
Midpoint
Figure 8.
Low Idle Speed
Adjusting Screw
Low Idle Fuel
Adjusting Needle
High Idle Fuel
Adjusting Needle
(Adj. Jet Carbs. Only)

12
2. Preliminary Settings: Turn the adjusting
needle(s) out (counterclock ise) from lightly
bottomed as follo s or to the rich side of
adjustment.
Walbro Fixed Jet
5. Low Idle Fuel Needle Setting: Place the throttle
into the idle or slow position.
Turn the adjusting needle in (clock ise). The
engine speed may increase, then it ill decrease
as the needle is turned in (lean). Note the position
of the needle.
Back the needle out approximately 1/8 to 1/4 turn.
See Figure 11 for best lo idle fuel performance.
Figure 11. Optimum Low Idle Fuel Setting.
6. Low Idle Speed Setting: Place the throttle control
into the idle or slow position. Set the lo idle
speed to 1200 RPM* (± 75 RPM) by turning the
lo idle speed adjusting scre in or out. Check
the speed using a tachometer.
*NOTE: The actual lo idle speed depends on the
application. Refer to the equipment
manufacturer's instructions for specific
lo idle speed settings. To ensure best
results hen setting the lo idle fuel
needle, the lo idle speed must not
exceed 1500 RPM.
3. Start the engine and run at half throttle for five to
ten minutes to arm up. The engine must be
arm before making final settings.
4. Main Fuel Needle Setting: This adjustment is
required only for adjustable main jet carburetors. If
the carburetor is a fixed main jet type, disregard
this setting.
Place the throttle into the fast position.
Turn the adjusting needle in (clock ise). The
engine speed may increase, then it ill decrease
as the needle is turned in (lean). Note the position
of the needle. Back the needle out approximately
1/4 turn. See Figure 10 for best main fuel
performance.
Walbro Adjustable Jet
Low Idle
M8 2-1/2 turns
M12 1-1/4 turns
M16 1 turn
Low Idle Main Idle
M8 2-1/2 turns 3/4 turn
M12 1-3/4 turns 1-1/8 turns
M16 2 turns 7/8 turn
Back Out Approx. 1/4 Turn
Lean
Figure 10. Optimum Main Fuel Setting.
Back Out Approx.
1/8 to 1/4 Turn
Lean Lean

13
Troubleshooting
When troubles occur, be sure to check the simple causes hich, at first, may seem to obvious to be considered.
For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles
are listed in the follo ing table.
Do not attempt to service or replace major engine components, or any items that require special timing or
adjustment procedures. Have your Kohler Engine Service Dealer do this ork.
Storage
If the engine ill be out of service for t o months or
more, use the follo ing storage procedure:
1. Clean the exterior surfaces of the engine.
2. Change the oil and filter hile the engine is still
arm from operation. See Change Oil on
page 8.
3. Change oil in reduction gear unit, if so equipped.
Refill ith the same oil as used in engine
crankcase for season of operation. See page 10.
4. The fuel system must be completely emptied, or
the gasoline must be treated ith a stabilizer to
prevent deterioration. If you choose to use a
stabilizer, follo the manufacturers
recommendations, and add the correct amount for
the capacity of the fuel system. Fill the fuel tank
ith clean, fresh gasoline. Run the engine for 2-3
minutes to get stabilized fuel into the carburetor.
To empty the system, run the engine until the fuel
tank and system are empty.
5. Remove the spark plug. Add one tablespoon of
engine oil into the spark plug hole. Install the plug,
but do not connect the plug lead. Crank the engine
t o or three revolutions.
6. Remove the spark plug. Cover the spark plug hole
ith your thumb, and turn the engine over until the
piston is at the top of its stroke. (Pressure against
thumb is greatest.) Reinstall the plug, but do not
connect the plug lead.
7. Store the engine in a clean, dry place.
Parts Ordering
The engine Specification, Model, and Serial Numbers
are required hen ordering replacement parts from
your Kohler Engine Service Dealer. These numbers are
found on the identification plate hich is affixed to the
engine shrouding. Include letter suffixes if there are
any. See Engine Identification Numbers on page 5.
Always insist on genuine Kohler parts. All genuine
Kohler parts meet strict standards for fit, reliability, and
performance.
Possible ause No Improper Dirt In Dirty Incorrect Engine Dirty Air Faulty
Problem Fuel Fuel Fuel Line Grass Screen Oil Level Overloaded leaner Spark Plug
Will Not Start      
Hard Starting     
Stops Suddenly  
Lacks Power    
Operates Erratically   
Knocks or Pings   
Skips or Misfires  
Backfires 
Overheats    
High Fuel onsumption 

14
Major Repair
Major repair information is available in Kohler Engine
Service Manuals. Ho ever, major repair generally
requires the attention of a trained mechanic and the
use of special tools and equipment. Your Kohler
Engine Service Dealer has the facilities, training, and
genuine Kohler replacement parts necessary to
perform this service. For Sales & Service assistance
call 1-800-544-2444 (U.S. & Canada) or contact your
Kohler Engine Dealer or Service Distributor, they're in
the Yello Pages under Engines-Gasoline.
Specifications
Model: .......................................................................... M ...................................... M12 ..................................... M16
Bore: ........................................... in. (mm) .................. 2.94 (74.61) ....................... 3.3 ( 5.73) ........................ 3.75 (95.25)
Stroke: ......................................... in. (mm) .................. 2.75 (69. 5) ....................... 3.25 ( 2.55) ........................ 3.25 ( 2.55)
Displacement: ............................. in3 (cm3) .................. 1 .64 (305.4) ..................... 29.07 (476.5) ...................... 35.9 (5 .2)
Power (@3600 RPM): ................. HP (kW) .................. (6.0) ................................ 12 (9.0) ............................... 16 (11.9)
Compression Ratio: ..................................................... 6. :1 ................................... 6.6:1 .................................... 7.3:1
Weight: ...........................................lb. (kg).................. 71 (32.2) ............................ 129 (5 .5) ........................... 129 (5 .5)
Oil Capacity: ............................ U.S. qt. (L) .................. 1 (0.95) .............................. 2 (1.90) ............................... 2.25 (2.13)
Spark Plug Type: ......Champion® or Equiv. .................. RCJ- ................................. RH-10 ................................. RH-10
Fuel Tank Capacity: .............. U.S. gal. (L) .................. 1.25 (4.75) ......................... 1.5 (5.6 ) ............................ 1.5 (5.6 )
Exhaust Emission Control System for models M8, M12, and M16 is EM.
LIMITED 2 YEAR MAGNUM ENGINE WARRANTY
We warrant to the original consumer that each new MAGNUM engine sold by us will be free from manufacturing defects in materials or
workmanship in normal service for a period of two (2) years from date of purchase, provided it is operated and maintained in accordance
with Kohler Co.s instructions and manuals.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044,
or at a service facility designated by us, of such part or parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers,
which are warranted for two (2) years.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide
reasonable and necessary maintenance.
The following items are not covered by this warranty:
Engine accessories, such as fuel tanks, clutches, transmissions, power drive assemblies, and batteries, unless supplied or installed by
Kohler Co. These are subject to the warranties, if any, of their manufacturers.
WE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but
not limited to labor costs or transportation charges in connection with the replacement or repair of defective parts.
ANY IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is
anyone authorized to make any in our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. For the facility nearest you, consult your Yellow Pages or write
Kohler Co., Attn: Engine Warranty Service Dept., Kohler, Wisconsin, 53044.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
Model Designation
Model M8S for example: M designates Magnum
engine, and 8 designates horsepo er. The letter suffix
designates a specific version as follo s:
Suffix Designates
EP Generator Set
P Pump Application
(Threaded Crankshaft)
R Gear Reduction
S Electric Start
T Retractable Start
G Generator Application
(Tapered Crankshaft)
ST Electric ith Retractable Start

15
KO LER CO.
FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS
LIMITED WARRANTY
SMALL OFF-ROAD ENGINES
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the
Federal and California Emission Control Systems Warranty on your small off-road equipment engine. For California, engines produced in
1995 and later must be designed, built and equipped to meet the states stringent anti-smog standards. In other states, 1997 and later
model year engines must be designed, built and equipped, to meet the U.S. EPA regulations for small non-road engines. The engine must
be free from defects in materials and workmanship which cause it to fail to conform with U.S. EPA standards for the first two years of
engine use from the date of sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the
period of time listed above, provided there has been no abuse, neglect or improper maintenance.
The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic
converter. Also included are the hoses, belts and connectors and other emission related assemblies.
Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed
at an authorized dealer), parts and labor.
MANUFACTURERS WARRANTY COVERAGE
Engines produced in 1995 or later are warranted for two years in California. In other states, 1997 and later model year engines are
warranted for two years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of
charge.
OWNERS WARRANTY RESPONSIBILITIES
(a) The engine owner is responsible for the performance of the required maintenance listed in the owners manual. Kohler Co.
recommends that you retain all receipts covering maintenance on the engine, But Kohler Co. cannot deny warranty solely for the
lack of receipts or for your failure to assure that all scheduled maintenance was performed.
(b) Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
(c) For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists. Call
1-800-544-2444, or access our website at: www.kohlerengines.com, for the names of the nearest service centers. The warranty
repairs should be completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an
Engine Service representative.
COVERAGE
Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the
time of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the
engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period
of two years.
Engines produced in 1995 or later are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers
to warrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial
purchaser. If any emission related part on the engine is defective, the part will be replaced by Kohler Co. at no cost to the owner. Kohler
Co. is liable for damages to other engine components caused by the failure of a warranted part still under warranty.
Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an
authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.
Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may
require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are:
Oxygen sensor (if equipped) Ignition module(s) with high tension lead
Intake manifold (if equipped) Gaseous fuel regulator (if equipped)
Exhaust manifold (if equipped) Electronic control unit (if equipped)
Catalytic muffler (if equipped) Carburetor or fuel injection system
Fuel metering valve (if equipped) Fuel lines (if equipped)
Spark advance module (if equipped) Air filter, fuel filter, and spark plugs (only
Crankcase breather to first scheduled replacement point)
Continued on next page

16
LIMITATIONS
This Emission Control Systems Warranty shall not cover any of the following:
(a) repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements
not conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not
recommended or approved in writing by Kohler Co.,
(b) replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled
replacement point,
(c) consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.,
(d) diagnosis and inspection fees that do not result in eligible warranty service being performed, and
(e) any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.
MAINTENANCE AND REPAIR REQUIREMENTS
The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records
covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period,
the maintenance records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the
engine has not been properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair
maintenance or failure to keep maintenance records.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or
individual; however, warranty repa rs must be performed by a Kohler author zed serv ce center. Any replacement part or service that
is equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty
obligations of the engine manufacturer.
LITHO IN U.S.A.
FORM NO.: TP-2200-F
ISSUED: 7/85
REVISED: 12/01
MAILED:
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL
1-800-544-2444