Kohler K161 Users Manual Owner's S K91, K161, & K181
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K181 to the manual e7ee4659-a5f6-4cef-8306-9b93d3f32cea
2015-01-21
: Kohler Kohler-K161-Users-Manual-219849 kohler-k161-users-manual-219849 kohler pdf
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Page Count: 16
OWNER’s MAN UAL
MODELS
K91 I
(4 hP)
Kl6l,&Kl81
(7 hP) (8 hP)
operating & maintenance
instructions
CONGRATULATIONS-You have selected a fine four-cycle engine. Kohler designs long-life
strength and on-the-job durability into each engine...making a Kohler engine
dependable...dependability you can count on.
n Parts subject to the most wear and tear (like cylinders, crankshafts, and camshafts) are
made from precision-formulated castiron...and because the cast iron cylinders can be
rebored, these engines can last even longer.
n Kohler engines are easy to service, all routine service parts--points, condenser, spark plug,
air filter, carburetor--are easily and quickly accessible.
0 Every Kohler engine is backed by a worldwide network of over 10,000 distributors and
dealers. Service support is just a phone call away. Call l-800-544-2444 (U.S. & Canada)
for Sales & Service Assistance.
To keep your engine in top operating condition, follow the simple maintenance procedures
given in this manual.
Safety Information
For Your Safety!
These precautions should be followed at all times. Failure to.follow these precautions could result
in injury to yourself and others.
A WARNING
db
Explosive Fuel can cause fires and
severe burns.
Stop engine before filling fuel tank.
Explosive Fuel!
Gasoline 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 stat? the engine
near spilled fuel. Never use
gasoline as a cleaning agent.
( A WARNING
Carbon Monoxide can cause
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
Lethal Exhaust Gases!
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.
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.
A WARNING
r-
#
u
-v
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.
A CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
dh WARNING
Accidental Starts can cause
severe injury or death.
Disconnect and ground spark plug
lead before servicing.
Accidental Starts!
Before servicing the engine or
equipment, always disconnect the
sparkplug lead to prevent the
engine from starting accidentally
Ground the lead to prevent sparks
that could cause fires. Make sure
the equipment is in neutral.
A WARNING
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
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.
dh WARNING
+P
Explosive Gas can cause fires and
severe acid burns.
Charge battery only in a well
ventilated area. Keep sources of
ianition awav.
Explosive Gas!
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 a way 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.
2
FUEL RECOMMENDATIONS
e, WARNING: Explosive Fuel1
Gasoline 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 fuef; wipe up spills immediately. Never use
gasoline as a cleaning agent.
General Recommendations
Purchase gasoline in small quantities and store in
clean, approved containers. A container with a
capacity of 2 gallons or less with 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 gzisoline.
Do not overfill the fuel tank. Leave room for 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 gasoline may
be used in areas where unleaded is not available and
exhaust emissions are not regulated. Be aware
however, that the cylinder head will require more
frequent service. See “Required Maintenance” on
page 7.
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
approved.
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 RECOMMENDATIONS
Using the proper type and weight crankcase oil is
extremely important as is checking oil daily and
changing oil and filter regularly. (See ‘Required
Maintenance” on page 7.) Failure to use the correct oil
or using dirty oil causes premature engine wear and
failure.
Before starting engine, fill the crankcase with the
proper type and quantity of oil.
Oil Type
Use high-quality detergent oil of API (American
Petroleum Institute) service class SG or SH. Select the
viscosity based on the air temperature at the time of
operation as shown in the table.
Recommended SAE Viscosity Wades
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHAW6E
Straight 30-welght oil Is preferred. SAE lOW-30 oil
is not recommended above 32” F. Using this oil
substantially increases oil consumption and
combustion chamber deposits.
(See Changing Oil” and “Required Maintenance” on
pages 4 and 7.)
NOTE: Using other than service class SG or SH 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.
3
The top position of the symbol shows service class
such as API SERVICE CLASS SG. The symbol may
show additional categories such as SG/CC, CD. The
center portion shows the viscosity grade such as SAE
30 in the example. If the bottom portion shows
“Energy Conserving”, it means that oil is intended to
improve fuel economy in passenger car engines.
Checking Oil
The importance of checking and changing crankcase
oil cannot be overemphasized.
Check oil BEFORE EACH USE when the engine is cool
and the oil has drained back into the sump. Add oil, if
low, to bring level up to, but not over, the ‘Fw mark on
the dipstick.
Oil should always be checked while engine is off and
on a level surface.
With threaded plug-type dipstick, remove and wipe oil
off--reinsert, but do not turn plug in. To check oil level,
shoulder plug on top of hole. After checking, again
turn plug all the way into crankcase.
With extended oil fill tube and dipstick, push dipstick
all the way down in tube then take reading.
F
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Operating .;;;:::..:.:.
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L
NOTE: To prevent extensive engine wear or damage,
always maintain the proper oil.level in the
crankcase. Never operate the engine with the
oil level below the “L” mark or over the “F” mark
on the dipstick.
Changing Oil
For a new engine, change oil after the first 5 hours of
operation and then every 25 hours of operation
thereafter.
Drain oil while engine is still warm from operation--it
flows freely and carries away more impurities. (See
Engine Identification illustration for location of drain
PWJ
Remove the oil drain plug and oil fill cap. Tilt the
engine slightly towards the oil drain to obtain better
drainage.
After draining, reinstall drain plug. Make sure it is
tightened securely. Fill with proper viscosity oil to “F”
mark on dipstick. Always check level on dipstick
before adding more oil.
Make sure the engine is level when filling and checking
oil.
4
OPERATING INSTRUCTIONS
ALSO READ THE OPERATING INSTRUCTIONS OF THE EQUIPMENT
THIS ENGINE POWERS
PRE-START CHECKLIST
cl
cl
El
El
El
Check oil level. Add oil if low.
Check fuel level. Add fuel if low.
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 with hydrostatic drive. The
shift lever must be exactly in neutral to prevent
resistance which could keep the engine from
starting.
a
WARNING: Lethal Exhaust Gases!
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.
STARTING
Move the throttle control lever to mid point of travel.
Move choke lever into full choke position and gradually
return to Off position after engine starts and warms up.
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 with a smooth, steady
motion.
For A Retractable Start Engine - SLOWLY pull the
starter handle until just past compression - STOP!
Return starter handle, pull firmly with a smooth, steady
motion to start. Pull the handle straight out to avoid
excessive rope wear 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.
a WARNING: Accidental Starts!
Before extending and checking the retractable starter
rope, remove the spark plug lead to prevent the engine
from starting accidentally. Ground the lead to prevent
sparks that could cause fires. Make sure the
equipment is in neutral.
For An
switch.
starts.
NOTE:
NOTE:
Electric Start Engine -- Activate the starter
Release the switch as soon as the engine
Do not crank the engine continuously for more
than 10 seconds at a time. If the engine does
not start, allow a 60second cool-down period
between starting attempts. Failure to follow
these guidelines can burn out the starter
motor.
If the engine develops sufficient speed to
disengage the starter but does not keep
running (a “false start”), the engine rotation
must be allowed to come to a complete stop
before attempting to restart the engine. If the
starter is engaged while the flywheel is
rotating, the starter pinion and flywheel ring
gear may clash, resulting in damage to the
starter.
If 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”.) See
your Kohler Engine Service Dealer for trouble analysis.
BAlTERY ’
A 12 volt battery is normally used. Refer to the
operating instructions of the equipment this engine
powers for specific information.
If the battery charge is not sufficient to turn over the
engine, recharge the battery (see page 13).
OPERATING
Optional spark arrestor mufflers are available from your
Kohler Engine Service Dealer. Check your local laws
and statutes regarding engine spark arrestor muffler
requirements.
Angle of Operation
These engines can be operated at angles up to 35” in
any direction (intermittent operation when crankcase is
filled to “FM mark on dipstick).
NOTE: Do not exceed these angles of operation as
engine damage may result from lack of
lubrication.
Refer to the operating instructions of the equipment
this engine powers. It may have more stringent
guidelines as to angle of operation due to equipment
design.
L
NOTE: If debris builds up on air intake screen
other intake areas, STOP the engine
immediately and clean. Obstructed air
areas cause engine damage due to
overheating.
A WARNING: Hot Parts!
Engine components can get extremely hot from
intake
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.
and
Engine Speed
NOTE: Do not tamper with the governor setting to
increase the maximum speed. Overspeed is
hazardous and will void the warranty.
A WARNING: Rope Starting Pulley Is Not
a Drive Pulley!
Do not use optional backup ropestarting pulley as a
drive pulley. Using starting pulley as a drive could
loosen the flywheel fastener, resulting in bodily harm.
STOPPING
Disengage all possible load from the engine.
Place the throttle control in the idle position. Allow the
engine to run at idle for 30-60 seconds.
Turn ignition switch OFF. On engines so equipped,
press and hold STOP button until engine comes to a
complete stop.
6
MAINTENANCE INSTRUCTIONS
A WARNING: Accidental Starts!
Before servicing the engine or equipment, always disconnect the spark plug lead to prevent the engine from
starting accidentally. Ground the spark plug lead to prevent sparks that could cause fires. Make sure the
equipment is in neutral.
These service procedures should also be performed as part of any seasonal tune-up.
Maintenance Rewired Frecwencv
..
CleanAirlntakeScreen’ .................................................................................. DAILY
CheckOil Level ........................................................................................ MILY
ReplenishFuelSupply ................................................................................... DAILY
Service Precleaner ..................................................................................... 25Hm.
ChangeOil .......................................................................................... 25Hf&
Check Reduction Gear Unit .............................................................................. 50Hlls,
Clean Cooling Fins and External Surfaces .................................................................... 50 H rrr.
Replace Air Cleaner Element’ ............................................................................. 100 Hrs.
Check Spark Plug Condition and Gap ...................................................................... 100 Herr.
Have Breaker Points Checked2 ........................................................................... .500 Hrs.
HavelgnitionTimingChecked2............................................................................~H .
Have Valve and Tappet Clearance Checked2 ................................................................ ,500 Hra.
HaveCylinderHeadsServiced2 .......................................................................... 5OOHrs?
Have Starter Motor Drive Serviced2 ........................................................................ ,500 Hrs.
‘Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
2Have a Kohler Engine Service Dealer perform this service.
‘250 hours when leaded gasoline is used.
ENGINE IDENTIFICATION
ntak
?en
/ Retractable
Oil Pan Starter
e
e
Oil Drain
7
Precleaner
Wing
Nut
Air Filter Plate
SPARK PLUGS
Every 100 hours of operation remove the spark plug,
check condition and reset the gap, or replace with a
new plug as necessary.
3 . Check gap (0.025”) using a wire feeler gauge.
Adjust the gap as necessary by carefully
bending the ground electrode. Install the plug
and torque to 18-22 ft. lb.
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 worn 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 wear
and damage.
Wire
/
CARBU.RETOR TRdUBLESHOOTlNG AND ADJUSTMENTS
Carburetor adjustments should be made on/y after engine has warmed up.
Kohler K91, K161 and K181 engines are equipped
with one of two basic types of carburetors - Kohler or
Walbro - fixed main jet or adjustable main jet.
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 low 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*.
*NOTE: Engines operating at attitudes above
approximately 1830 m (6000 ft) may require
a special “high altitude” main jet.
TROUBLESHOOTING
If engine troubles are experienced that appear to be
caused by the carburetor, check the following areas
before adjusting the carburetor.
Make sure the fuel tank is filled with clean, fresh
gasoline.
Make sure the fuel tank cap vent is not blocked
and that it is operating properly.
Make sure fuel is reaching the carburetor. This
includes checking the fuel shut-off valve, fuel tank
filter screen, in-line fuel filter, fuel lines, and fuel
pump for restrictions or faulty components as
necessary.
Make sure the air cleaner base and carburetor is
securely fastened to the engine using gaskets in
good condition.
Make sure the air cleaner element is clean and all
air cleaner components are fastened securely.
after checking the items listed above, starting or
engine operation problems exist, it may be
necessary to adjust or service the carburetor.
NOTE: Carburetor adjustments should be made
only after the engine has warmed up.
Kohler Carburetor Adjustment
1
. With the engine stopped, turn the fuel adjusting
needles In (clockwise) until they bottom lightly.
NOTE: The tips of the fuel adjusting needles are
tapered to critical dimensions. Damage to
the needles and seats in carburetor body will
result if the needles are forced.
2 .
3 .
4.
Preliminary Settings: Turn the. adjusting
needles out (counterclockwise) from lightly
bottomed as follows:
1 KOHLER ADJ. 1 LOW IDLE 1 MAIN FUEL
I K91 1 l-1/2 TURNS 1 2TURNS
I K161 1 l-l/2 TURNS 1 3TURNS
K181 l-1/4 TURNS 2 TURNS .
Start the engine and run at half-throttle for 5 to
IO minutes to warm-up. The engine must be
warm before making final settings (steps 4-6).
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 Vast” position. If
possible, place the engine under load.
Turn the main fuel adjusting needle out
(counterclockwise) from the preliminary setting
until the engine speed decreases (rich). Note
the position of the needle.
Now turn the adjusting needle in (clockwise).
The engine speed may increase, then it will
decrease as the needle is turned in (lean).
Note the position of the needle.
Set the adjusting needle midway between the
rich and lean settings.
10
5 . Low Idle Fuel Needle Setting: Place the throttle
into the Tdlem or %low’ position.
Turn the low idle fuel adjusting needle out
(counterclockwise) from the preliminary setting
until the engine speed decreases (rich). Note the
position of the needle.
Now turn the adjusting needle In (clockwise). The
engine speed may increase, then it will decrease
as the needle is turned in (lean). Note the
position of the needle.
Set the adjusting needle midway between the rich
and lean settings.
Adjust To
Midpo lint
Rich
Lean
6 . Low Idle Speed Settlng: Place the throttle
control into the idle or slow position. Set the idle
speed to 1200” RPM (* 75 RPM) by turning the
idle speed adjusting screw in or out. Check the
speed using a tachometer.
NOTE: *The actual idle speed depends on
the application. Refer to the
equipment manufacturer’s
instructions for specific low idle
speed settings. The recommended
low idle speed for the Basic Engines
is 1200 RPM. To ensure best results
when setting the low idle fuel
needle, the low idle speed must not
exceed 1500 RPM.
Walbro Carburetor Adjustment
3 .Idle SDeed Screw
\ Main Fuel Needle
In general, turning the adjusting needles In
(clockwise) decreases the supply of fuel to the
carburetor. This gives a leaner fuel-to-air mixture.
Turning the adjusting needles out (counterclockwise)
increases the supply of fuel to the carburetor.
1. With the engine stopped, turn the adjusting
needle(s) In (clockwise) 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
will result if the needles are forced.
2. Preliminary Settlngs: Turn the adjusting
needle(s) out (counterclockwise) from lightly
bottomed as follows or to the rich side of
adjustment.
1 WALBRO FIXED JET 1 LOW IDLE I
I K91 NOT APPL.
I K161 I NOT APPL.
I K181 I 2-l/2 TURNS I
1 WALBRO ADJ 1 LOW IDLE 1 MAIN FUEL 1
I K91 1 l-3/4 TURNS 1 3/4 TURNS 1
I K161 1 2-l/4 TURNS 1 l-1/8 TURNi 1
I K181 1 2-I/2 TURNS 1 3/4 TURNS 1
11
3
.
4 .
5 .
Start the engine and run at hatf throttle for five to
ten minutes to warm up. The engine must be
warm before making final settings.
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 Vast” position.
Turn the adjusting needle In (clockwise). The
engine speed may increase, then it will decrease
as the needle is turned in (lean). Note the
position of the needle. Back the needle out
approximately l/8 to i/4 turn. See figure below
for best main fuel performance.
6 .
Back out
Appx. 118
to 114
Lean turn. Lean
r I
\ \ I
I
11
@
I
8
Optimum Main Fuel Setting.
Low Idle Fuel Needle Setting: Place the throttle
into the “idle” or %loW position.
Turn the adjusting needle in (clockwise). The
engine speed may increase, then it will decrease
as the needle is turned in (lean). Note the
position of the needle.
L
\ \
Back out
Appx. 118
to 114
Lean turn. Lean
CI
I
I
I
\I
@
I
{
I
I
I
v
---
c3
Optimum Low Idle Fuel Settlng.
Low Idle Speed Setting: Place the throttle
control into the “idle” or %lown position. Set the
low idle speed to 1200 RPM* (+ or - 75 RPM) by
turning the low idle speed adjusting screw In or
out. Check the speed using a tachometer.
*NOTE: The actual low idle speed depends on the
application. Refer to the equipment
manufacturer’s instructions for specific low
idle speed settings. To ensure best results
when setting the low idle fuel needle, the
low idle speed must not exceed 1500 RPM.
FUEL FILTER
Some engines are equipped with an in-line fuel filter.
Visually inspect the filter periodically and replace
when dirty with a genuine Kohler filter.
Back the needle out approximately i/8 to l/4 turn.
See figure below for best low idle fuel
performance.
12
Dirt Dirty Inconed Engine Dirty F=m
No Im
TROUBLESHOOTING P= In Air oil over- Fitter spark
Fuel ueI FueILineScreen IAM Loaded Element mug
When a problem occurs, do not
overlook the simple causes. For
example, starting problems could be
caused by an empty fuel tank. The
table lists some common causes of
troubles.
Do not attempt to service or replace
major items or any items that call for
special timing or adjustment
procedures (governor, valves, etc.).
Have this work done by your Kohler
Engine Service Dealer.
Will not start X X X X X X
Hard starting X X X X X X
Stops suddenly X X X X X X
Lacks power X X X X X X X
Operates
erratically
Knock& or pings
Skips or misfires
Backfires
X X X X X X
X X X X
X X X X X
X X X X X
Overheats
High fuel
consumption
X X X X X X
X X X X
BAlTERY CHARGING REDUCTION GEAR UNITS
A WARNING: Explosive Gas!
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 jewe/ty when servicing
batteries.
On engines equipped with a reduction gear unit,
remove the oil plug on lower part of cover every 50
hours 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 weight and grade
of oil as used in the engine crankcase.
Before disconnecting the negative (-) ground cab/e,
make sure all switches are OFF. If ON, a spark will
occur at the ground cab/e terminal which could
cause an explosion if hydrogen gas or gasoline
vapors are present.
13
MODEL DESIGNATION
The Model number designates the cubic inch
displacement and the number of cylinders--Model
K181S; for example: designates 18 cubic inch
displacement, 1 designates single cylinder. The
letter suffii designates a specific version as follows:
SUffbC Designation
EP
P
R
S
T
Generator Set
Pump Model
Gear Reduction
Electric Start
Retractable Start
ENGINE IDENTIFICATION
NUMBERS
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification, and Serial Numbers of the engine.
The engine identification numbers appear on decal
(or decals) affixed to the engine shrouding. See
figure below. Include letter suffiies, if there are any.
MODEL NO.
SPEC. NO.
SERIAL NO.
REFER TO OWNER’S MANUAL
FOR OPERATlON/MAlNTENANCE
INSTRUCTIONS AND SAFETY
PRECAUTIONS.
KOHLER COMPANY
KOHLER WISCONSIN USA
Record your engine identification numbers on the
identification plate illustration for future reference.
PARTS ORDERING
The engine Specification, Model, and Serial numbers
are required when ordering replacement parts from
your Kohler Engine Service Dealer. These numbers
are found on the identification plate which is affixed
to the engine shrouding. Include letter suffixes if
there are any. See “Engine Identification Numbers”
above.
A/ways insist on genuine Kohler pans. All genuine
Kohler parts meet strict standards for fit, reliability,
and performance.
STORAGE
If the engine is to be out of service for approximately
two months or more, use the following storage
procedure:
1 .
2 .
3 .
Clean exterior surfaces of the engine.
Change oil when engine is still warm from
operation. See Changing Oil” on page 4.
Drain reduction gear unit, if so equipped, and
refill with same oil as used in engine for season
of operation.
4 . The fuel system must be completely emptied, or
the gasoline must be treated with a stabilizer to
prevent deterioration. If you choose to use a
stabilizer, follow the manufacturers
recommendations, and add the correct amount
for the capacity of the fuel system. Fill the fuel
tank with 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
tank and system are empty.
5 . Remove the spark plug. Add one tablespoon of
engine oil into each spark plug hole. Install
plugs but do not connect plug leads. Crank the
engine two or three revolutions.
6 . Remove plug, cover hole with thumb and turn
engine over until piston is at top of stroke-
determined when pressure against thumb is
greatest.
7 . Store the engine in a clean dry place.
MAJOR REPAIR
Major repair information is provided in the Kohler
Single Cylinder Service Manual, available from your
Kohler Engine Service Dealer. However, 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 replacement parts
necessary to properly perform the service. For sales
and service assistance call l-800-544-2444 (U.S. and
Canada) or contact your Kohler Engine Dealer or
Service Distributor. They’re in the Yellow Pages
under ENGINES, GASOLINE.
14
SPECIFICATIONS
K91
Power Rating at4000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...? . . . . . . . . . . . . . . . . . . . . . ..4hp
Displacement . .
Bore . . . . . . . .
Stroke . . . . . . .
Approx. Weight
Oil Capacity . . .
Spark Plug Gap
Spark Plug Size
Spark Plug Type
,..,..............,,.,,.................................... 8.9 in3 (145 cm3)
. . . . . . . . . . . . . . . . ..l.............................~ . . . . . . . . 2.375 in (60.33 mm)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*....... 2.000 in (50.80 mm)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 lb (19.5 kg)
. . . . . . . . . . . . . ..L.............................................. 1.5 U.S. pints
(0.7 L)
. . . . . . . . . . . . . . . . . ..I............................................. 0.025 in*
(0.65 mm)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...*.. 14 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RJ8C
or equivalent
Breaker Point Gap (Nominal) . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in
(0.50 mm)
K161
Power Rating at3600RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7hp
Displacement . .
Bore . . . . . . . .
Stroke . . . . . . .
Approx. Weight
Oil Capacity . . .
Spark Plug Gap
Spark Plug Size . ...* . . . . . . . . . . . . . . . ...* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm
Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RJ8C
or equivalent
(5.2 kW)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9 in3 (277 cm3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.938 in (74.62 mm)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.500 in (63.50 mm)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 lb (29.5 kg)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 U.S. pints
(1.2 L)
. . . . . . . . . . . . . . . . . . . . . ..*..............*.......................... 0.025 in*
(0.65 mm)
Breaker Point Gap (Nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in
(0.50 mm)
Power Ratina at3600RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8hp
v (6 kW)
Displacement . .
Bore . . . . . . . .
Stroke . . . . . . .
Approx. Weight
Oil Capacity . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6 in3 (305 cm3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.938 in (74.62 mm)
. . ...* . ...* . . . . . . ..I . . . . . . . . . . . . ..I . . . . . . . . . . . . . . . . . . . . . . 2.750 in (69.85 mm)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 lb (29.5 kg)
. . . . . . . . . . . . . . . . ..I..... . . ..a 0. I. . . . . . . . . . ..I............... . . 2.5 U.S. pints
(1.2 L)
Spark Plug Gap . . . . . . . . . . . . . . . . . ..I I... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 in*
(0.65 mm)
Spark Plug Size . . . . . . . . . . . . . . . . ..I................................................ 14 mm
Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RJ8C
or equivalent
K181
Breaker Point Gap (Nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in
(0.50 mm)
*Gaseous fueled engines-gap .Oi 8 in (0.45 mm).
15
LIMITED 1 YEAR ENGINE WARRANTY
We warrant to the original consumer that each new engine sold by us will be free from manufacturing defects in materials or
workmanship in normal service for a period of one (1) year from date of purchase, provided it is operated and maintained in
accordance with Kohler Co.% 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:
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 insta
Kohler Co. These are subject to the warranties, if any, of their manufacturers.
Jled by
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 WRIT-TEN WARRANTY.
anyone authorized to make any in our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion
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
TO OBTAIN WARRANTY SERVICE:
We make no other express warranty, nor is
or limitation of incidental or consequential
from state to state.
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 5304
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL
I-800-544-2444
1 FORM NO.: ENS-593-F I
1 ISSUED: 3/84 I
1 REVISED: 7/97 I
1 MAILED: I
LITHO IN U.S.A.
