Kohler Magnum 8 HP User manual

0 WNER 's MANUAL
HOREONUL CRANKSHAFT
Congratulations-You have selected a finefour-cycle, singlecylinder,air-cooledengine. Kohlerdesigns long
life strength and on-the-jobdurability intoeach engine...makinga Kohlerenginedependable...dependabilityyou
can count on. Here are some reasonswhy:
Kohler engines are easyto service. All routineserviceareas (likethe dipstickand oil fill, air cleaner, spark
plug, and carburetor)are easily and quickly accessible.
Partssubject to the mostwear and tear (likethe cylinder, crankshaft,and camshaft) are madefrom
precisionformulated cast iron. Becausethe cast ironcylinder can be rebored,these enginescan last even
Ionger .
Dependable,maintenance-freeelectronic ignitionsystemensuresfast, easy startstime after time.
Every Kohlerengine is backedby a worldwide networkof over 10,000distributorsand dealers. Service
support isjust a phonecall away. Call 1-800-544-2444 (U.S. & Canada)for Sales & Serviceassistance.
To keepyour engine in top operatingcondition,follow the maintenanceproceduresin this manual.

Safety Precautions
To insure safe operations please read the following statements and understandtheir meaning.
Also refer to your equipment owner's manualfor other important safety information.This manual
contains safety precautionswhich are explainedbelow. Please readcarefully.
a WARNING
Warning is usedto indicatethe presenceof a hazardthat can cause severe personalinjury, death,
or substantialproperty damage if the warning is ignored.
a CAUTION
Caution is usedto indicatethe presenceof a hazard that will or can cause minor personalinjury or
property damage if the caution is ignored.
NOTE
Note is usedto notify peopleof installation,operation, or maintenanceinformationthat is important
but not hazard-related.
For YourSafety!
Theseprecautionsshouldbe followedat all times. Failure to follow theseprecautionscould result
in injuy
to yourself and others.
I a WARNING
Explosive Fuel can cause fires and
severe burns.
Stop engine before filling fuel tank.
Explosive Fuel!
Gasolineis extremely flammable
and its vaporscan explodeif
ignited. Storegasoline only in
approvedcontainers,in well
ventilated,unoccupiedbuildings,
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
withhotparts or sparks from
ignition.Do not start the engine near
spilled fuel. Never use gasolineas a
cleaningagent.
I a WARNING
Rotating Parts can cause severe
injury.
Stay away while engine is in
I operation.
RotatingParts!
Keephands, feet, hair,andclothing
away from all movingparts to
prevent injuty Never operatethe
engine withcovers, shrouds, or
guards removed.
CAUTION
24
*
ElectricalShock can cause injury.
Do not touch wires while engine is
running.
I a WARNING
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
I
Hot Parts!
Engine components can get
extremelyhot from operation.
To
prevent severeburns, do not touch
theseareas while the engineis
running,or immediately after it is
turned off. Never operate the engine
withheat shields or guards
removed.
California
Proposition
65 Warning
Engine exhaustfrom this product
containschemicalsknown to the
State of Californiato cause cancer,
birthdefects,or other reproductive
harm.
ElectricalShock!
Never touch electrical wires or
components while the engineis
running. Theycan be sources of
electricalshock.
2

Safefy Precautions (Conf.)
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
I a WARNING I
severe acid burns.
Charge battey only in a well
ventilated area. Keep sources
of
ianition awav.
I a WARNING I I a WARNING I
Explosive Gas can cause fires and
injury or death.
I
Disconnect and ground spark plug
lead before Servicing.
AccidentalStarts!
Disablingengine.Accidentalstarting
can cause severe injuty or death.
Before workingon the engine or
equipment, disablethe engine as
follows:
1) Disconnectthe spark
plug lead(s).
2) Disconnectnegative
(-) battery cable from battety.
Lethal Exhaust Gases!
Engine exhaustgases contain
poisonous carbon monoxide.
Carbonmonoxide is odorless,
colorless,and can causedeath if
inhaled.Avoid inhaling exhaust
fumes,andnever run the enginein
a closedbuilding or confinedarea.
Explosive Gas!
Batteriesproduce explosive
hydrogen gas whilebeing charged.
To prevent a fire or explosion,
chargebatteries only in well
ventilatedareas. Keepsparks, open
flames, and other sources of ignition
away from the battery
at all times.
Keepbatteries out of the reachof
children.Remove alljewelty when
servicingbatteries.
Beforedisconnectingthe negative
(-) groundcable, make sure all
switchesare
OFF: If ON, a spark will
occur at the groundcable terminal
whichcould causean explosionif
hydrogen gas or gasoline vapors
arepresent.
Blower Housing
\ Fuel Tank
Identification Plate
(UnderAir Cleaner Cover)
Throttle
Control
\
Retractable
Starter
FC
rke
I
Oil Drain
Oil
Sump
7gure 1. TypicalModel M8 Engine,
3

Oil Recommendations
Usingthe proper type and weight of oil in the crankcase
is extremely important.
So is checking oil daily and
changing oil regularly. Failureto use the correct oil, or
using dirty oil, causes prematureengine wear and
failure.
Beforeeach start, make sure the crankcase is filled
with the propertype and quantityof oil.
Oil Type
Use high quality detergentoil of API (American
Petroleum Institute)service class
SC; SH, SJ or
higher.
Select the viscosity based on the air
temperature at the time of operation as shown in the
followingtable.
RECOMMENDED SAE VISCOSITY GRADES I
I
I I
I I I
I I I I
OF -bO 0 do d2 do 60 80 100
I I 1
%LO -ho -10 10 20 30 40
Q
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
*Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, upto
40°F.
**Syntheticoils provide better starting inextremecold
rigwe 2, ViscosityGrades Table,
(below -1 0°F).
Straight30-weight oil is preferred. SAE 1 OW-30 oil is
not recommendedabove
32°F. Usingthis oil
substantiallyincreasesoil consumptionand combustion
chamber deposits.
NOTE: Usingother than service class SG,
SH, SJ or
higher oilor extending oil change intervals
longer than recommendedcan cause engine
damage which is not coveredbythe engine
warranty.
A logo or symbol on oil containers identifiesthe API
service class and SAE viscosity grade. See Figure
3.
Refer to “MaintenanceInstructions” beginning on
page
7 for detailed oil checkand oil change
procedures,
Fuel Recommendations
a WARNING: ExplosiveFuel!
Gasolineis extremely flammableand its vaporscan
explodeif ignited. Storegasolineonly in approved
containers,in well ventilated,unoccupiedbuildings,
away from sparks or flames. Do not fill the fuel tank
while the engineis hot or running,since spilled fuel
could ignite if it comes in contact withhotparts or
sparks from ignition. Do not start the enginenear spilled
fuel. Never usegasoline as a cleaningagent.
General Recornmendations
Purchase gasoline in small quantitiesand store in
clean, approvedcontainers.A containerwith
a capacity
of
2 gallons or less, with a pouringspout, is
recommended.Such a container is easier to handle
and helpseliminatespillage during refueling.
Do not use gasoline left over from the previous season,
to minimizegum depositsinyour fuel system and to
insureeasy starting.
Do not add oilto the gasoline.
Do not overfill the fuel tank. Leave roomfor the fuel to
expand.
Fuel Type
For best resultsuse only clean, fresh, unleaded
gasoline with a pump sticker octane ratingof 87 or
higher. In countries using the Research method, it
should be
90 octane minimum.
Unleadedgasoline is recommendedas it leaves less
combustionchamber deposits. Leadedgasoline may be
used in areas where unleadedis not available and
exhaust emissionsare not regulated.Be aware
however,that the cylinder headwill requiremore
frequent service.
Gasoline/Alcoholblends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline byvolume) is approvedas a fuel for Kohler
engines. Other gasoline/alcohol blends are not
approved.
Gasoline/Etherblends
MethylTertiary Butyl Ether (MTBE)and unleaded
gasoline blends (up to a maximumof
15% MTBE by
volume) are approved as a fuel for Kohlerengines.
Other gasoline/ether blends are not approved.
I I
Figure 3. Oil ContainerLogo,
4

Engine Identification Numbers
When ordering parts, or in any communicationinvolving
an engine, always give the
Model, Specification,and
Serial Numbers
of the engine.
The engine identificationnumbersappear on a decal
affixedto the engine shrouding. Includeletter suffixes, if
there are any.
Recordyour engine identificationnumbers on the
identification label below (Figure
4) for future reference.
-- IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA 2004 AND
CALIFORNIA 2006 AND LATER EMISSION
CONTROL REGULATIONSFOR SI SORE*
FAMILY
DISPL,(CC)
MODEL NO,
SPEC. NO,
ON11236
SERIALNO,
EMISSION COMPLIANCE PERIOD:
EPA: CARB:
THIS ENGINE IS CERTIFIEDTO OPERATE
ON:
REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE SPECS AND ADJUSTMENTS.
FOR SALES/SERVICE IN US/CANADA, CALL:
www. kohlerenaines.com
1-800-544-2444
KOHLER co. KOHLER, WECONSIN USA
*Small Off-RoadEngines
igure
4, Engine ldentification Label,
The EmissionCompliance Period referredto on the
EmissionControl or Air Indexlabel indicatesthe
numberof operatinghoursfor which the engine has
been shown to meet Federaland CARB emission
requirements. The followingtable providesthe Engine
Compliance Period(in hours) associatedwith the
category descriptorfound on the certification label.
Emission CompliancePeriod (Hours)
Refer to certification labelfor engine displacement.
Operating Instructions
Also read the operatinginstructionsof the equipment
this enginepowers.
Pre-Start Checklist
Check oil level.Add oil if low. Do not overfill.
Check fuel level.Add fuel if low.
Check cooling air intake areas and external
surfacesof engine. Make sure they are clean and
unobstructed.
Check that the air cleaner components and all
shrouds, equipmentcovers, and guards are in
place and securelyfastened.
Check that any clutches or transmissions are
disengagedor placed in neutral.This is especially
important on equipmentwith hydrostaticdrive. The
shift lever must be exactly in neutralto prevent
resistancewhich could keep the engine from
starting.
a WARNING: Lethal Exhaust Gases!
Engine exhaustgases containpoisonous carbon
monoxide.Carbonmonoxideis odorless,colorless,and
can cause deathif inhaled.Avoid inhaling exhaust
fumes, andnever run the enginein a closedbuilding or
confinedarea.
Cold WeatherStarting Hints
1. Be sure to usethe proper oil for the temperature
expected. See Figure
2 on page 4.
2. Declutchall possible external loads.
3. A warm battery has much more starting capacity
than a cold battery.
4. Use fresh winter grade fuel. NOTE:Winter grade
gasoline has highervolatility to improvestarting.
Do not use gasoline left over from summer.
Exhaust Emission Control Systemfor models M8, MI
2,
and MI6is EM.
5

Starting
1.
2.
For a ColdEngine - Place the throttle control
midway betweenthe “slow” and “fast”
positions. Place the choke control into the “on”
position.
For a Warm Engine (normal operating
temperatures)
- Place the throttle control
midway betweenthe “slow” and “fast”
positions. For non-certifiedengines, placethe
choke into the
“off position. For certified
engines, placethe choke in the
“on” position.
Start the engine as follows:
For Rope Start Engines - Placethe starting rope
knot in the slot in starting pulley.Wrap the rope
aroundthe pulley. Pullthe starter handlewith a
smooth, steady motion.
For a Retractable Start Engine - SLOWLYpull
the starter handle untiljust past compression
-
STOP! Returnstarter handle, pull firmly with a
smooth, steady motionto start. Pullthe handle
straight out to avoid excessive rope wear from the
starter rope guide.
Extendthe starting rope periodicallyand check its
condition. If the rope isfrayed, have it replaced
immediatelybyyour Kohler EngineService
Dealer.
a WARNING: AccidentalStarts!
Before extendingand checking the retractablestarter
rope, remove the sparkplug lead to prevent the engine
from startingaccidentally. Groundthe lead to prevent
sparks that could cause fires.Make sure the
equipment
is in neutral.
For an Electric Start Engine -Activate the
starter switch. Releasethe switch as soon as the
engine starts.
NOTE:
NOTE:
Do not crank the engine continuouslyfor
morethan
10 secondsat a time. If the
enginedoes not start, allow a 60 second
cool down period between starting
attempts. Failureto follow these
guidelinescan burn out the starter motor.
If the engine developssufficientspeed to
disengagethe starter but does not keep
running (afalse start),engine rotation
must be allowedto come to a complete
stop before attemptingto restart the
engine.
If the starter is engagedwhile the
flywheel is rotating,the starter pinionand
flywheel ring gear may clash, resultingin
damaae to the starter.
3.
4.
If the starter does notturn the engine over, shut
off starter immediately. Do not make further
attemptsto start the engine untilthe condition is
corrected. Do notjump start usinganother battery
(refer to “Battety” below). See your Kohler Engine
Service Dealerfor trouble analysis.
For a ColdEngine - Graduallyreturnthe choke
controlto the
“off” positionafter the engine starts
and warms ups. The engine/equipment may be
operatedduring the warm-up period, but it may be
necessaryto leave the choke partiallyon untilthe
enginewarms up.
For a Warm, CertifiedEngine - Returnthe
choke to the
“off positionas soon as the engine
starts.
Stopping
1. Removethe load by disengagingall PTO
attachments.
2. Placethe throttle control in the idle position.Allow
the engineto run at idlefor 30-60 seconds.
3. Movethe throttle controlto the “stop”position.
On enginesequippedwith a key switch, turn
switch to
“stop” or “off” position.
Battery
A 12 volt battery is normally used. Refer to the
operating instructionsof the equipmentthis engine
powersfor specific battery requirements.
If the battery charge is not sufficient to crank the
engine, rechargethe battery (see page
10).
Operating
Optionalspark arrestor mufflersare available from your
Kohler EngineService Dealer.Checkyour local laws
and statutes regardingengine spark arrestor muffler
requirements.
Angle of Operation
This enginewill operatecontinuouslyat angles upto
30”. Check oil levelto assure crankcase oil level is at
the
“F mark.
Refer to the operating instructionsof the equipment
this engine powers. Becauseof equipment design or
application,there may be more stringent restrictions
regardingthe angle of operation.
NOTE: Do not operatethis engine continuouslyat
angles exceeding30” in any direction. Engine
damage could result from insufficient
lubrication.
6

Cooling
NOTE: If debris builds up on the grass screen or
other coolingair intake areas, stop the engine
immediatelyandclean. Operatingthe engine
with blockedor dirty air intakeand cooling
areas can cause extensive damagedue to
overheating.
a WARNING: Hot Parts!
Engine components can get extremelyhot from
operation. To prevent severe burns, do not touch these
areas whilethe engine is running,or immediately after
it is turned off. Never operatethe engine withheat
shields or guards removed.
Frequency
Daily or Before
StartingEngine
Engine Speed
NOTE: Do nottamperwith the governorsettingto
increasethe maximumengine speed.
Overspeedis hazardousandwill void the
enginewarranty.
a WARNING: Rope StartingPulley is Not
a Drive Pulley!
Do not use rope startingpulley as a drivepulley. Using
startingpulley as a drivecould loosen flywheel
fastener,resultingin bodilyharm.
Maintenance Required
Fillfuel tank.
Check oil level.
0 Check air cleaner for dirty’, loose, or damaged parts.
0 Check air intakeandcoolingareas, clean as necessary’.
Maintenance Instructions
Maintenance,repai5 or replacement of the emissioncontroldevicesand systems, whichare being done at
the customersexpense, may be performed by any non-road engine repair establishmentor individual,
Warrantyrepairsmust be performed by an authorized Kohler service outlet,
a WARNING: AccidentalStarts!
DisabHng engine.Accidenta/staHingcan cause severe injury or death. Before workingon the engine or
equipment,disablethe engineas follows: I) Disconnectthe spark plug lead@). 2) Disconnectnegative (-) battery
cable from battey.
Every 700 Hours
Every200 Hours
Replaceair cleaner element’.
0 Check spark plugconditionand gap.
Changeoil’.
Service precleanerelement’.
I Every25Hours I
Annually or
Every 500 Hours
Check gear reductionunit.
I
Every 50 Hours I Removecoolingshrouds and clean coolingareas’.
0 Havebendixstarter drive ~erviced~,~.
0 HaveoptionalOil SentryTMswitch checked2.
0 Havevalve and tappet clearance checked2.
Havecylinder head ~erviced~,~.
‘Performthesemaintenanceproceduresmore frequentlyunder extremelydusty,dirty conditions.
2Havea Kohler Engine ServiceDealerperform this service.
30rannually, whichever occurs first.
4250 hours when leadedgasolineis used.
7

Check Oil Level
The importanceof checking and maintainingthe proper
oil level in the crankcase cannot be overemphasized.
Check oil BEFORE EACH USE as follows:
1. Makesure the engine is stopped, level, and is
cool so the oil has had time to drain intothe sump.
2. To keep dirt, grass clippings,etc., out of the
engine, clean the area aroundthe oil fill cap/
dipstick before removing it.
3. Removethe oil fill cap/dipstick and push it all the
way down intotube. Remove dipstick and check
the level.
4. If the level is low, add oil of the propertype, upto
the “F mark on the dipstick. (Refer to “OilType”
on page 4.) Always check the levelwith the
dipstick before adding more oil.
NOTE: To preventextensiveengine wear or
damage, always maintainthe proper oil
level in the crankcase. Never operate the
enginewith the oil level belowthe “L”
mark or over the “F’ mark on the dipstick.
“F” Mark
I
Figure 5. OilLevel Dipstick,
Oil SentryTM
Some engines are equippedwith an optional Oil
Sentry’” oil levelswitch. If the oil level drops belowan
acceptablelevel, the Oil Sentry’” will either shut off the
engineor activate a warning signal, dependingon the
application.
NOTE: Make sure the oil level is checked BEFORE
EACH USE
and is maintainedup to the “F
mark on the dipstick. This includesengines
equippedwith Oil Sentry’”.
Change Oil
For a new engine, change oil after the first 5 hours of
operation. Thereafter,change oil after every 25 hours
of operation.
Changethe oil while the engine is still warm. The oil
will flow freely and carry away more impurities. Make
sure the engine is level when filling, checking, or
changingthe oil.
Changethe oil as follows:
1. To keep dirt, grass clippings, etc., out of the
engine,cleanthe area around the drain plug and
dipstick before removing it.
2. Removethe oil drain plug and dipstick. Tilt the
engineslightlytowardsthe oil drain to obtain
better drainage. Be sure to allow ample time for
complete drainage.
3. Reinstallthe drain plug. Makesure it istightened
securely.
4. Fillthe crankcase,with new oil of the propertype,
to the “F’ mark on the dipstick. Refer to “Oil Type”
on page 4. Always check the levelwith the dipstick
before adding more oil.
5. Reinstallthe oil fill cap or plug and tighten
securely.
NOTE: To preventextensiveengine wear or
damage, always maintainthe proper oil
level in the crankcase. Never operate the
enginewith the oil level belowthe “L”
mark or over the “F’ mark on the dipstick.
Service Precleaner and Air Cleaner Element
This engine is equippedwith a replaceable,high
density paper air cleaner element. Most engines are
also equippedwith an oiled, foam precleanerwhich
surrounds the paper element. See Figure 6.
I
Figure 6, Air Cleaner Housing Components,
8

Checkthe 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 damagedcomponents. Replace all
bent or damaged air cleaner components.
NOTE: Operatingthe enginewith looseor damaged
air cleaner componentscould allow unfiltered
air into the engine causing prematurewear
and failure.
Service Precleaner
Wash and reoilthe precleanerevery 25 hours of
operation, (moreoften under extremelydusty or dirty
conditions).
1. Removethe wing nut and air cleanercover.
2. Removethe precleanerfrom the paper element. It
is not necessaryto remove elementcover or
paper element.
3. Wash the precleaner in warm water with
detergent. Rinsethe precleanerthoroughly untilall
traces of detergentare eliminated.Squeezeout
excess water (do not wring).Allow the precleaner
to air dry.
4. Saturatethe precleanerwith new engine oil.
Squeeze out all excess oil.
5. Reinstallthe precleanerover the paper element.
6. When precleaner replacementis necessary
always use genuine Kohler parts.
Service Paper Element
Every 700 hours of operation (more often under
extremelydusty or dirty conditions), replacethe paper
element.
1. Removethe precleaner (if so equipped) element
cover and paper element.
2. Do not wash the paper elementor use
pressurized air,
as this will damage the element.
Replacea dirty, bent, or damaged element with a
genuine Kohler element. Handle new elements
carefully; do not use if the sealing surfaces are
bent or damaged.
3. When servicingthe air cleaner, check the air
cleaner base. Make sure it is secured and not
bent or damaged. Also check the element cover,
seals and breathertube for damage or improper
fit. Replaceall damaged air cleaner components.
NOTE: Operatingthe enginewith damaged or
loose componentscould allow unfiltered
air intothe engine causing premature
wear andfailure.
4. Reinstallthe paper element,element cover and
wing nut.Tighten the cover nut securelyto be sure
the element is sealedtightly against the element
cover and base plate.
5. If so equipped, installthe precleaner (washedand
oiled) over paper element.
6. Installair cleaner cover andwing nut.Tightenwing
nut until it is snug againstcover.
Do not
overtighten.
7. When air cleaner element replacementis
necessaryalways use genuine Kohler parts.
CleanAir Intake/CoolingAreas
To ensure proper cooling, make sure the grass screen,
coolingfins, and other external surfacesof the engine
are kept clean
at all times.
Every 50 hours of operation (more often under
extremelydusty, dirty conditions), removethe blower
housingand other cooling shrouds. Cleanthe cooling
fins and external surfaces as necessary. Make sure the
cooling shrouds are reinstalled.
NOTE: Operatingthe enginewith a blocked grass
screen, dirty or pluggedcooling fins, and/or
cooling shrouds removed, will cause engine
damage due to overheating.
CheckSpark Plug
Every 200 hours of operation, remove the spark plug,
check its condition,and reset the gap or replacewith a
new plugas necessary.
1. Before removingthe spark plug, clean the area
aroundthe base of the plugto keep dirt and debris
out of the engine.
2. Removethe plug and check its condition.
Replacethe plug if worn or reuse is questionable.
NOTE:
Do not cleanthe spark plug in a machine
usingabrasive grit. Some grit could
remain in the spark plug and enter the
engine causing extensivewear and
damage.
9

3. Check gap (0.025") using a wire feeler gauge.
Adjust the gap as necessaryby carefully bending
the groundelectrode.See Figure
7.
4. Reinstallthe spark plug intothe cylinder head.
Torque the sparkplugto
78-22 ft. Ib.
-/" u
Ground
Electrode
0.025"
Figure 7, ServicingSparkPlug,
Battery Charging
a WARNING: Explosive Gas!
Batteriesproduce explosivehydrogen gas while being
charged.
To prevent a fire or explosion,charge
batteries only in well ventilatedareas. Keep sparks,
open flames,and other sources of ignitionaway from
the batteryat all times.Keep batteriesout of the reach
of children. Removealljewelry whenservicing
batteries.
Beforedisconnectingthe negative
(-) groundcable,
make sure all switches are
OFF: If ON, a spark will
occur at the ground cable terminal whichcouldcause
an explosionif hydrogen gas or gasoline vaporsare
present.
On enginesequipped withan alternatorcharging
system, disconnectplug from rectifier-regulatorprior to
chargingbattery.
Fuel Filter
Someenginesare equippedwith an in-linefuel filter.
Periodicallyinspectthe filter and replacewhen dirty.
Use a genuine Kohlerfilter.
Reduction Gear Units
On engines equippedwith a reductiongear unit,
removethe oil plugon lower partof cover every
50 hours of operationto check oil level. With the
engine level,the oil levelof the unitshould be up to the
bottom of the oil plughole.To add oil, removethe
vented plugat the top of the unit. Usethe same weight
and grade of oil as used inthe engine crankcase.
Carburetor Troubleshooting
andAdjustments
Kohler M8 - M16enginesare equippedwith one of
three types of carburetors; Kohler adjustable mainjet,
Walbro adjustable mainjet, or Walbro fixed mainjet.
Emissionscertifiedengineswill havefixedjet
carburetors.Walbro carburetors havethe brand name
embossedin the side of the bodycasting, near the top.
The carburetor is designedto deliverthe correct
fuel-to-air mixtureto the engine under all operating
conditions.The mainfuel and idlefuel needleson
adjustablejet carburetorsare set at the factory and
normallydo not requirefurther adjustment.On fixedjet
carburetors,the low idlefuel needleis also set at the
factory and normallydoes not needfurther adjustment.
The mainfueljet iscalibratedand installedat the
factory and is not adjustable.
Troubleshooting
If enginetroubles are experiencedthat appear to be
fuel system related, checkthe following areas before
adjustingthe carburetor.
Make sure the fuel tank is filledwith clean,fresh
gasoline.
Make sure the fuel tank cap vent is not blocked
andthat it isoperating properly.
If thefuel tank is equippedwith a shut-offvalve,
makesure it isopen.
If the engine isequippedwith an in-linefuel filter,
makesure it is clean and unobstructed. Replace
the filter if necessary.
Makesurefuel is reachingthe carburetor.This
includeschecking the fuel lines and fuel pump for
restrictionsor faulty components, replace as
necessary.
Makesurethe air cleaner element is clean and all
air cleaner element componentsare fastened
securely.
If,after checking the items listedabove, the engine is
hardto start, runs roughly,or stallsat low idlespeed, it
may be necessaryto adjust or service the carburetor.
10

Kohler CarburetorAdjustment
1. With the engine stopped,turn the fuel adjusting
needles
in (clockwise)untilthey bottom lightly.
NOTE: The tip of the idle fuel and mainfuel
adjusting needlesare tapered to critical
dimensions.Damageto the needlesand
the seats incarburetor body will result if
the needlesare forced.
2.
Preliminary Settings: Turn the adjusting needles
out (counterclockwise)from lightly bottomedas
follows:
KohlerAdjustable Jet
Low Idle High Idle
1-1/4 turns 2 turns
2-1/2 turns 2 turns
2-1/2 turns 3-1/2 turns
3. Startthe engine and run at half throttle for 5 to 10
minutesto warm up. The engine must be warm
before makingfinal settings (steps 4-6).
4.
Main Fuel Needle Setting: This adjustment is
requiredfor adjustable mainjet carburetorsonly. If
the carburetoris a fixed mainjet type, referto
Walbro adjustment.
Placethe throttle intothe “fast”position. If
possible,placethe engine under load.
Turn the mainfuel adjusting needle
out
(counterclockwise)from the preliminarysetting
untilthe engine speed decreases (rich). Notethe
positionof the needle.
Nowturn the adjusting needle
in (clockwise).The
engine speed may increase,then itwill decrease
as the needleis turned in (lean). Note the position
of the needle.
Setthe adjusting needle
midway betweenthe rich
and leansettings.See Figure
8.
Lean
5. Low Idle Fuel Needle Setting: Placethe throttle
intothe
“idle” or “slow” position.
Usethe same procedure used for the main fuel
needleand set the adjusting needle
midway
betweenthe richand lean settings.
6. Low Idle Speed Setting: Placethe throttlecontrol
intothe
“id1e”or “s1ow”position. Set the low idle
speedto
7200 RPM”(+ 75 RPM) byturningthe
low idle speed adjusting screw
in or out. Check
the speed usinga tachometer.
*NOTE: The actual low idle speed dependsonthe
application
- referto equipment
manufacturer’srecommendations.The
recommendedlow idle speedfor basic
engines is 1200RPM.To ensure best
resultswhen settingthe low idlefuel
needle,the low idle speed must not
exceed 1500 RPM.
Walbro Carburetor Adjustment
In general, turningthe adjusting needles in (clockwise)
decreasesthe supply of fuel to the carburetor.This
gives a leanerfuel-to-air mixture.Turningthe adjusting
needles
out (counterclockwise)increasesthe supply of
fuel to the carburetor.
Carburetorson certifiedengines have a fixed (non-
adjustable)mainjet. In steps 1 and 2, performonly
what pertainsto the idlefuel needle.Skip step4.
Low Idle Fuel
4 Adjusting Needle
Low Idle Speed
Hi‘gh Idle Fuel
Adjusting Needle
(Adj, Jet Carbs, Only)
I
Figure 9,
1. With the engine stopped,turn the adjusting
needle(s)
in (clockwise)until it bottoms lightly.
NOTE: The tips of the fuel adjusting needlesare
taperedto criticaldimensions. Damageto
the needlesand the seats in carburetor
bodywill result if the needlesare forced.
Tgure 8,
11

2. PreliminarySettings: Turn the adjusting
needle(s)
out (counterclockwise)from lightly
bottomedas follows or to the rich side of
adjustment.
Walbro FixedJet
LowIdle
2-1/2 turns
1-1/4 turns
If 1turn
WalbroAdjustableJet
LowIdle MainIdle
2-1/2 turns 3/4 turn
f 1-3/4 turns 1-1/87/8 turnturns
2 turns
3. Startthe engine and run at half throttle for five to
ten minutesto warm up. The engine must be
warm before makingfinal settings.
4. MainFuelNeedle Setting:
Thisadjustmentis
required only for adjustablemainjet carburetors. If
the carburetoris a fixedmainjet type, disregard
this setting.
Placethe throttle intothe “fast” position.
Turn the adjusting needle
in (clockwise).The
engine speed may increase,then itwill decrease
as the needle isturned in (lean). Notethe position
of the needle. Backthe needleout approximately
1/4turn. See Figure 10for best mainfuel
performance.
BackOutApprox,
1/4 Turn
Lean
igure
10, OptimumMainFuelSetting,
5. LowIdleFuelNeedle Setting: Placethe throttle
intothe “id1e”or “s1ow”position.
Turn the adjusting needle
in (clockwise).The
enginespeed may increase,then itwill decrease
as the needle isturned in (lean). Note the position
of the needle.
Backthe needleout approximately 1/8to 1/4turn.
See Figure 11 for best low idlefuel performance.
BackOutApprox,
1/8 to 1/4 Turn
Lean Lean
Figure
11. OptimumLowIdleFuelSetting.
6. LowIdleSpeedSetting: Placethe throttlecontrol
intothe “id1e”or “s1ow”position. Setthe lowidle
speedto 1200RPM*
(* 75 RPM) byturningthe
low idlespeed adjusting screw in or out. Check
the speed usinga tachometer.
*NOTE: The actual low idle speed depends on the
application. Referto the equipment
manufacturer’sinstructionsfor specific
low idle speed settings. To ensure best
resultswhen settingthe low idlefuel
needle,the low idle speed mustnot
exceed 1500 RPM.
12

Troubleshooting
When troubles occur, be sure to check the simple causes which, at first, may seem to obviousto be considered.
For example, a starting problemcould be caused by an empty fuel tank. Some commoncauses of engine troubles
are listedinthe following table.
Do not attemptto service or replace major engine components, or any itemsthat requirespecialtiming or
adjustment procedures.Haveyour Kohler Engine Service Dealerdo this work.
Possible Cause No Improper Dirt In Dirty Incorrect Engine DirtyAir Faulty
Problem Fuel Fuel Fuel Line Grass Screen Oil Level Overloaded Cleaner Spark Plug
Will Not Start
Hard Starting
StopsSuddenly
Lacks Power
Operates Erratically
Knocks or Pings
Skips or Misfires
Backfires
Overheats
Hiah Fuel Consumntion
Storage
If the engine will be out of service for two monthsor
more, use the following storage procedure:
1. Clean the exteriorsurfacesof the engine.
2. Change the oil and filter while the engine is still
warm from operation. See “Change Oil” on
page
8.
3. Change oil in reductiongear unit, if so equipped.
Refillwith 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 betreated with a stabilizer to
prevent deterioration.If you chooseto use a
stabilizer, follow the manufacturers
recommendations,and add the correct amount for
the capacity of the fuel system. Fillthe fuel tank
with clean, fresh gasoline. Runthe enginefor 2-3
minutesto get stabilizedfuel intothe carburetor.
To empty the system, run the engine untilthe fuel
tank and systemare empty.
5. Removethe spark plug. Add one tablespoonof
engineoil intothe spark plug hole. Installthe plug,
but do notconnectthe plug lead. Crank the engine
two or three revolutions.
6. Removethe spark plug. Coverthe spark plug hole
with your thumb, andturn the engine over untilthe
piston is at the top of its stroke. (Pressure against
thumb is greatest.) Reinstall the plug, but do not
connectthe plug lead.
7. Storethe engine in a clean, dry place.
Parts Ordering
The engine Specification,Model,and Serial Numbers
are requiredwhen ordering replacementparts from
your Kohler Engine Service Dealer.These numbersare
found on the identificationplate which is affixed to the
engine shrouding. Includeletter suffixes if there are
any. See “Engine IdentificationNumbers” on page
5.
Always insist ongenuineKohler parts. All genuine
Kohler parts meet strict standards for fit, reliability,and
performance.
13

Major Repair Model Designation
Major repair information is available in Kohler Engine
Service Manuals. However, major repair generally
requiresthe attentionof a trained mechanic and the
use of special tools and equipment. Your Kohler
Engine Service Dealer hasthe facilities, training, and
Suffix Designates
genuine Kohler replacement parts necessaryto EP GeneratorSet
performthis service. For Sales
& Serviceassistance
call 1-800-544-2444
(U.S. & Canada)or contactyour
Kohler Engine Dealeror Service Distributor,they’re in
theYellow Pages under Engines-Gasoline.
S Electric Start
Model M8S for example: M designates Magnum
engine, and 8 designates horsepower.The letter suffix
designatesa specific version as follows:
P PumpApplication
R Gear Reduction
T RetractableStart
G GeneratorApplication
(TaperedCrankshaft)
ST Electric with Retractable Start
(Threaded Crankshaft)
Specifications
Model: ............................................................................ M8 ....................................... M12 ...................................... M16
Bore: ............................................ in. (mm) .................. 2.94 (74.61) ........................ 3.38 (85.73) ......................... 3.75 (95.25)
Stroke:
.......................................... in. (mm) .................. 2.75 (69.85) ........................ 3.25 (82.55) ......................... 3.25 (82.55)
Displacement:
.............................. in3(cm3) .................. 18.64 (305.4) ...................... 29.07 (476.5) ....................... 35.9 (588.2)
Power (Q3600 RPM):
................. HP (kW) .................. 8 (6.0) ................................. 12 (9.0) ................................ 16 (11.9)
Compression Ratio:
....................................................... 6.8:l .................................... 6.6:l ..................................... 7.3:l
Weight:
........................................... Ib. (kg) .................. 71 (32.2) ............................. 129 (58.5) ............................ 129 (58.5)
Oil Capacity:
............................ U.S. qt. (L) .................. 1 (0.95) ............................... 2 (1.90) ................................ 2.25 (2.13)
Spark Plug Type:
..... Champion@or Equiv. .................. RCJ-8 .................................. RH-10 .................................. RH-10
Fuel Tank Capacity:
............... U.S. gal. (L) .................. 1.25 (4.75) .......................... 1.5 (5.68) ............................. 1.5 (5.68)
Exhaust EmissionControl System for models M8, M12, and M16 is EM.
LIMITED 2 YEAR MAGNUMENGINE WARRANTY
We warrant to the original consumer that each new MAGNUM engine sold by us will be free from manufacturingdefects 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.3 instructionsand manuals.
Our obligation underthis warranty is expressly limited, at our option, to the replacementor 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, includingfaulty 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 CONSEQUENTIALDAMAGES OF ANY KIND, including but
not limited to labor costs or transportation charges in connection with the replacementor repair of defective parts.
ANY IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE EXPRESSLY LIMITEDTO 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 limitationson 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 vayfrom 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: EngineWarranty Service Dept., Kohler, Wisconsin, 53044.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
14

KOHLER CO,
FEDERALAND CALIFORNIA EMISSION CONTROL SYSTEMS
LIMITED WARRANTY
SMALL OFF-ROADENGINES
The US. EnvironmentalProtectionAgency (EPA), the CaliforniaAir Resources Board (CARB), and Kohler Co. are pleased to explain the
Federaland 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, 1997and later
model year engines must be designed, built and equipped, to meet the
US. EPA regulationsfor small non-road engines. The engine must
be free from defects in materials and workmanship which cause it to fail to conform with
US. EPA standardsfor 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, providedthere 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, includingdiagnosis (if the diagnostic work is performed
at an authorized dealer), parts and labor.
MANUFACTURER’S WARRANTYCOVERAGE
Engines produced in 1995 or later are warranted for two years in California. In other states, 1997 and later modelyear engines are
warrantedfor
two years. If any emission related part on the engine is defective,the part will be repairedor replaced by Kohler Co. free of
charge.
OWNER’S WARRANTY RESPONSIBILITIES
(a) The engine owner is responsiblefor the performanceof the required maintenancelisted in the owner’s manual. Kohler Co.
recommendsthat you retain all receipts covering maintenanceon the engine, But Kohler Co. cannot deny warranty solely for the
lack of receiptsor for your failure to assure that all scheduled maintenance was performed.
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.
For warranty repairs,the engine must be presentedto 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 reasonableamount of time, not to exceed
30 days.
(b)
(c)
If you have any questions regardingwarranty rights and responsibilities,you should contact Kohler Co. at 1-920-457-4441and ask for an
Engine Service representative.
COVERAGE
Kohler Co. warrants to the ultimate purchaser and each subsequent purchaserthat 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 workmanshipwhich cause the engine to fail to conform with applicable regulationsfor a period
of two years.
Engines produced in 1995 or later are warranted for
two years in California. For 1997 and later modelyears, 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 bythe initial
purchaser. If any emission related part on the engine is defective,the part will be replacedby Kohler Co. at no cost to the owner. Kohler
Co. is liable for damages to other engine componentscaused by the failure of a warranted part still under warranty.
Kohler Co. shall remedywarranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an
authorized dealer or warranty station shall befree of charge to the owner if such work determinesthat a warranted part is defective.
Listed below are the parts covered by the Federaland California Emission Control Systems Warranty. Some parts listed below may
requirescheduled maintenanceand are warranted up to the first scheduled replacementpoint for that part. The warrantedparts are:
Oxygen sensor (if equipped)
Intake manifold (if equipped)
Exhaust manifold (if equipped)
Catalytic muffler (if equipped)
Fuel meteringvalve (if equipped)
Spark advance module (if equipped)
Crankcase breather
Ignition module(s) with high tension lead
Gaseous fuel regulator (if equipped)
Electroniccontrol unit (if equipped)
Carburetor or fuel injection system
Fuel lines (if equipped)
Air filter, fuel filter, and spark plugs (only
to first scheduled replacementpoint) Continuedon next page
15

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
recommendedor approved in writing by Kohler Co.,
replacementof parts and other services and adjustments necessary for required maintenanceat and after the first scheduled
replacement point,
consequential damages such as
loss of time, inconvenience, loss of use of the engine or equipment, etc.,
diagnosis and inspectionfees that do not result in eligible warranty service being performed, and
any add-on or modified part, or malfunctionof authorized parts due to the use of add-on or modified parts,
(b)
(c)
(d)
(e)
MAINTENANCEAND REPAIR REQUIREMENTS
The owner is responsiblefor the proper use and maintenanceof the engine. Kohler Co. recommends that all receipts and records
covering the performanceof regular maintenance be retained in case questions arise. If the engine is resold during the warranty period,
the maintenance records should be transferredto each subsequent owner. Kohler Co. resetves the right to deny warranty coverage if the
engine has not been properly maintained; however, Kohler Co. may not deny warranty repairssolely because of the lack of repair
maintenance or failure to keep maintenance records.
Normal maintenance, replacementor repair of emission control devices and systems may be performed by any repair establishment or
individual;however,
warrantyrepairs must be performed by a Kohler authorized service center. Any replacementpart or setvice that
is equivalent in performanceand durability may be used in non-warrantymaintenanceor repairs,and shall not reduce the warranty
obligations of the engine manufacturer.
FOR SALES AND SERVICE INFORMATION
IN
US. AND CANADA, CALL
1-800-544-2444
60- Iy, RUN'"
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
FORM NO.: TP-2200-F
REVISED: 12/01
I MAILED: I
LITHO IN U.S.A.