1\

.'
KOHLER' ENGINE
OWNER'S MANUAL
MODELS: K91, K141 , K161, K1'81
HOHlZONTAL CHANKHArT NUlN8
OPERATING INSTRUCTIONS
MAINTENANCE SCHEDULE
MINTENANCE PROCEDURE
PARTS IDENTIFICATION
PARTS ORDERING
OPERATING INSTRUCTIONS
CHECK OIL LEVEL
DRY TYPE
PRE-START INSTRUCTIONS
LUBRICATING OIL
I
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DO NOT I
EXCEED
I
"F" MRK
'
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SAE 30
+
30 F,
SAE 10W-30
0 F
SAE 5W-20
+
USE API
SERVICE
MS OIL
AIR CLEANER
USE
GENUINE
KOHLER
ELEMENT
OIL BATH TYPE
(MKE SURE CO'PONEtTS ARE SECURE)
FUEL
USE CLEAN, FRESH, __ __
REGULAR GRADE GAS
aLI NE -- DO NOT
MIX OIL WITH FUEL
"- FILL TO LEVEL MARK
WITH SAME OIL AS ENGINE
STARTING PROCEOURE
FUEL ON CLOSE CHOKE CRANK ENGINE (HAND)
CHECK POLARITY
TURN FUEL
VALVE TO
ON POS ITION
GRADUALLY RETURN
CHOKE TO OPEN
POSITION AFTER
ENGINE STARTS
PULL IN
DI RECTION
SHOWN - USE
STEADY MOTION
CRANK ENGINE (ELECTRIC START
NEGATIVE (-) GROUND
SYSTEM USED
1. PULL IGNITION
KNOB OUT*
2. DEPRESS AND HOLD
START BUTTON UNTIL
ENGINE STARTS
*OR MOVE TOGGLE
SWITCH TO "ON" POSITION
On engines with 10 AMP Magneto-Alternator, always disconnect leads hom Rectifier-Regulator
before doing any welding on equipment in common ground with engine .
To prevent overheating of starting motor, limit cranking time (continuous) to 60 seconds then allow
2 minute period before recranking (limit Motor-Generator to 30 seconds cranking).
STOPPING PROCEDURE
STOP BUTTON
DEPRESS AND
HOLD BUTTON
UNTI L ENG I NE
COMPLETELY STOPPED
SAFETY PRECAUTIONS
STOP SWITCH
PUSH KNOB IN
OR MOVE SWITCH
TO "OFF" POSITION
Do nol add fuel while engine is running. Stop engine and, if possible, allow cooling period to
prevent spilled fuel from igniting on contact with hot engine parts.
Always disconnect spark plug cable to prevent unintentional starting before making any
adjustments on equipment powered by engine.
Make sure all safety guards on engine and driven equipment are in proper position and
secure.
Make sure hands, feet, and clothing are at a safe distance from any movable parts prior to
starting.
Do not tamper with governor settings. The governor establishes safe operating limits.
These limits must not be exceeded.
2
:,
SERVICE PROCEDURE
PERFORM SERVICE AT INTERVALS INDICATED ()
EACH
DAY
CHECK OIL LEVEL (maintain in safe operating range) --- - X
CLEAN AIR INTAKE SCREEN (plus other external surfaces) - X
REPLENISH FUEL SUPPLY (Use clean, fresh fuel) -------- - X
CHANGE OIL (Use API Service MS of proper weight) ----- ------
SERVICE FUEL FILTER (remove and clean sediment bowl) - -----
SERVICE AIR CLEANER (per i nstructi ons
-
Page 3) ------ -----
CHECK AIR CLEANER ELEMENT (dry type only) ------------ ------
SERVICE SPARK PLUG
(gap .025" for gasoline) ---------- -----
SERVICE BREAKER POINTS (gap .020" ) ------------------- -----
EVERY
25 HOURS
---- X
---- X
---- X
----------
---------
----------
EVERY EVERY EVERY
50 HOURS 100 HOURS 500 HOURS
--- X
-------- ---- X
--------- ---------- ---- X
NOTE: Intervals stated ar for good, clean operating conditions
--
perform services more frequently if
dusty or dirty condltions prevail.
PREVENTATIVE MAINTENANCE In addition to the routine services listed above, there are other
important preventative maintenance steps that should be taken to keep engine in top condition. Usually,
the tools and instruments required for these additional steps are not available to the engine owner. For
this reason, the engine should be returned periodically to an authorized Sevice Center for complete
servicing and tune-up. The benefits of such service will not only be noted immediately in improved
performance but, most important, in continued satisfactory operation during a long, trouble free,
service life.
LUBRICATING OIL
Oil Level: Check daily to make sure level is between L and F marks--level must not exceed "F" mark.
Oil Change: Change oil after first 5 hours of operation on new engineuthereafter change at 25 hour
intervals or more often in severe conditions.
Oil Type: Use only detergent type oils with API Service MS classification. See Temperature-Viscosity
Guide (on cover) for proper weight. Special ois are not required for new engines, however, place
engine under load immediately as this promotes final seating of the rings.
AIR CLEANER
Dry Type: Every 50 hours, service by tapping element lightly against flat surface to remove loose
dirt--do not clean in any liquid or with compressed air. Replace element after 100 hours--this can be
extended up to 200 hours if good clean operating conditions prevail. Use only genuine Kohler parts
when replacing element.
Oil Bath Type: Service at least every 25 hours. To service, swish element in solvent--do not dry
with air hose. Lightly re-oil element after ceaning. Drain and clean bowl then add new oil (same
weight and grade as engine) to OIL LEVEL mark. After reinstalling serviced parts, place copper
washer on cover then secure wing nut "finger tight".
COOLING SYSTEM
Keep air intake screen and cooling fins clean at all times. Do not operate engine with blower hous
ing or cooling shrouds removed as this will also cause overheating due to improper air circulation.
IGNITION SYSTEM
Spark Plug: Every 100 hours remove plug and check condition. Good operating conditions are indicated
if plug has light coating of gray or tan deposit. A dead white, blistered coating could indicate overheat
ing. A black (carbon) coating may indicate an
"
overrich'fuel mixture caused by clogged air cleaner or
improper carburetor adjustment. Do not sandblast, wire brush, scrape or otherwise service plug in
poor condition--best results are obtained with new plug. Set spark gap to .025" (or. 018" for gas fuels,
.020" on radio shielded plugs). Tighten plug to 324 in. lbs. torque when installing.
Breaker Points: Every 500 hours breaker points should be inspected and serviced. If oxidized, dirty
or oily, cean with coarse cloth--do not use emery cloth or sandpaper. Slightly pitted points can be
dressed with point file--replace badly pitted or burned points. The gap must be adjusted after points
are serviced or replaced since this setting establishes ignition timing. To adjust, turn engine over by
hand until points are at maximum opening--check with feeler gauge. If gap is not .. 020", loosen adjust
ing screw then shift movable plate until . 020" gap is obtained. After retightening screw, check to make
sure proper gap is present when points are full open.
3
TROUBLE SHOOTING
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Lack of power and black sooty exhaust smoke usually indicates that fuel mixture is too rich. An
"overrich" mixture may also be caused by a clogged air cleaner--check this before readjusting car
buretor. Fuel mixture may be too lean if engine "skips" or backfires at high speed.
Main Fuel Adjustment: For preliminary setting. turn MAIN FUEL screw in clockwise direction until it
bottoms lightly (do not force) then back out 2 turns. With engine thoroughly warmed up and running at
full throttle and full load; turn MAIN FUEL screw in until engine slows down (lean setting) then turn
screw out until engine regains speed and then starts to slow down (overrich setting), Turn screw back
in until it is positioned halfway between lean ald overrich settings--when properly adjusted engine will
accelerate smoothly and operate with steady governor action.
Idle Adjustment: Rough idle is usually caused by the idle speed being set too low. Turn IDLE SPEED
screw in (clockwise direction) to increase speed. Ii engine still idles poorly after speed is increased,
stop engine and turn IDLE FUEL screw all the way in (clockwise) until it bottoms lightly (do not force
screw), then back out 1-1/4 turns. Restart engine and check idle--turn needle in or out (1/4 turn at a
time) until smoothest idle is achieved.
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INSTALLING THROTTLE WIRE
GOVERNOR ADJUSTMENT
CONTROL
DISC ,
THROTTLE
\
WIRE
BUSHING NUT
Arrow indicates ditection to
move bracket to decrease speed.
GOVERNOR COMPONENTS
GOVERNOR
-
ARM
The governor functions to maintain engine speed under changing load conditions and also acts as
a speed limiting device. The position of the throttle bracket determines speed range of the engine
(ar row indicates direction to decrease speed). The hole in the control disc into which the throttle
cable is inserted is also important as this establishes degree of governor control. I is a good idea to
permanently mark the exact position of the throttle bracket (scribe mark on crankcase) and also the
control disc hole in case linkage becomes disconnected or bushing or arm retaining nuts work loose.
If this is done, the governor can be quickly reset to original position.
Initial Adjustment: This is made (with engine stopped) as follows: Loosen (do not remove) governor
arm retaining nut, grasp end of cross shaft in pliers and turn in counterclockwise direction until shaft
stops internally. Hold cross shaft in this position, then pull governor arm all the way away from car
buretor (with updraft type carburetor, lift arm as far as it will go) and retighten arm nut to complete
initial adjustment.
Cable Installation: If throttle cable becomes disconnected, use following procedure: Bend end of throttle
Wlre exacty as shown in inset--if carelessly hooked or looped, wire will bind on control disc and cause
poor governor- action. Move throttle control handle to open position then insert wire into control disc
hole nearest to throttle bracket.
Speed Adjustment: After readjusting governor, restart engine then move throttle to open position and
check top speed with hand tachometer. Maximum permissible speed for K91 is 4000 RPM while for
most other models it is 3600 RPM. To decrease speed, loosen bushing nut and move throttle bracket
in cockwise direction. Retighten bushing nut after adjustment (Do not overtighten--this could cause
binding of the cross shaft).
STORAGE INSTRUCTIONS Use the following procedure to preserve engine before placing in storage.
Drain oil from crankcase (while hot) then flush with clean light oil. Refili crankcase after flushing.
Drain fuel from tank, sediment bowl and carburetor. Clean exterior of engine then spread light film
of oil over surfaces subject to corrosion (unpainted metal surfaces). Pour tablespoon of oil into spark
plug hole, turn engine over several times by hand then reinstall plug. Cover engine and store in dry
place.
5
COMPOSITE EXPLODED VIEW
PARTS IDENTIFICATION
13

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'16
(, '1'
1
4
15A
12
\'68
56V
,
V
/
5
2
@
/
5
3
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125
12
4

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/
126
6
PARTS ORDERING INSTRUCTIONS
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' SPECIFICATION
\: NUMBER ___.
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10. iii)
1 1
2 1
3A 1
36 T
4A 1
46 T
5 1
6 1
7 1
8 1
9 1
10 1
llA 1
116 1
12 T
13 1
14 1
15A 2
156 2
16 'I
17 1
18 1
19 2
20 2
21 1
22 4
23 2
24 I
25 I
26 1
27 I
28 A R
A R
29A 1
29B I
30 I
31 4
32 1
33 1
34
35A
358
36A
368
37
38 1
39 1
40
:::i;:i :
u:-tst
s. iit)
AIR INTAKE GROUP
Gasket
Cleaner assembly (K9l, K16l, K181)
B.se, cleaner (K141)
Base, cleaner (Kg], K161, Kl81)
Element, cleaner (K14l)
Elelnt, cleaner (K91, K161, K18l)
air cleaner (K91, K16l, K1Bl)
wing
BAFFLES AND SHROUD GROUP
Baffle, head
Baffle, cylinder
Housing, blower
Baffle, side ai r (K141 K181)
BREA THE AND VENT GROUP
41
42
43
44
45
46
47
4a
49
50
51
52 6
Cover, va1 ve 7
Cover, valve , K161, Kla]) 53 6
7 Sea 1, by ea they
FiT ter 54 1
Reed, breather (K91)
Gasket, cover (K91)
Gasket, cover (K141, K161, K18J)
Plate, breather (K91)
Breather - assembly (KI41, K161, KlaT)
Studj valve cover
CAMSHAFT AND VALVES GROUP
Retainer, spring
55 1
56A 1
56B 1
57 1
Spring, valve 58
Tappet, intake va lve 59
Keeper, valve (K14I, K161, K181) 60
Pin, valve lock (K9l)
Va lve intake
ValVe, exhaust _. J
Tappet, exhaust va 1 ,' ' 61
Pin, camshaft
62
Spacer, camshaft 005 (KI41, K161, K181) 63
Spacer, camshaft , OTO (K141, K161, K1Sl) 64
Camshaft - assembly (K9!) 65
Camshaft - assembly (KI41, K161, K18!) 66
Retainer, flyba11 (K9!) 67
Ball, steel 7/16 (K9!)
Bushing, thrust (K9!)
Ring, snap (K9])
6B
CARBURETOR GROUP 69
70
Ga5ket carburetor 71
Carburetor - assembly (K91, K161, KIa!) 72
Carburetor - assembly (KI41) 73
Elbow (K91, K161, K1S!) 74
Elbow (K141) 75
Connector (KIST)
Sleeve (KI8l)
Nut (KI8!)
CRANKCASE GROUP
Seal, front oil
76
77
78
79
BOA
80B
A,R. - As Required
PARTS LIST
::tti;ti.
Plate, bearing
Bearing, ban
Gasket, bearing plate
Button, plug
Slock, cylinder assembly
Guide, valve (K141, K16l, KI8!)*
Insert. exhaust valve
Plug, expansion (K14l, K161, Klal)
Seal rear oil
Shaft, governor (K141, K16l, K18T)
CRANKSHAFT GROUP
Crankshaft
CYLINDER HEAD GRO<P
Screw, H.C ( K9l)
Screw, H.C. (K14l, K16l, K18])
Washer (K91)
Washer (K14l, K161, K18l)
Head, cyl i nder
Gasket, cyl inder head
Strap, lifting (KI41, K151)
Strap, 1 ifting (K1Bl)
01 PST! CK GROUP
Dipstick - assemly
EXfUST GROUP
Stud, muffler
Muffl er
Gasket, mffler
FLYWHEEL GROUP
Rope
Key
Retainer, screen
Screen, grass
Pulley
flywheel
Washer, tens ion
FUEL PUMP GROUP
Cover, pump "ad (K141, K16l)
Gasket, fuel pump (KI4l, K161, Klal)
Pump, fuel - assembly (K181)
Elbow, hose (K1BT)
Line, fuel (K1Bl)
Connector (Kla1)
Sleeve (K1B1)
Nut (K1Bl)
FUEL TANK AND FITTINGS GROUP
Nipple (K9l, K16l)
Filter, fuel (K9l, K161)
Line; fuel
Elbow (K9l, Kl6!)
Tank, fuel (K91, K16l)
Tank, fuel (K14l, KlaT)
.. Valve gUldes not used on K91 models
1
|t:-:t
lD. iii)
Bl 1
82A 2
82S'< 2
83 1
84 1
85 1
86 I
87 1
a 2
89 1
90 1
91 I
92 1
93 1
94 1
95 1
96 I
97
98
99
100A
100B
101
102
T03
104
105
106
107
108
109
110
111
112A
112B
113A
1138
114
115A
115B
116
117
118
119
120
121
122
123
124
125
126
127
128
::tti;ti.:
Cap, tank
Strap, tank (K9l, K16l)
Strap, tank (K141, K1SI)
Bracket, tank - L H (K9T)
Bracket, tank - R.H. (K91)
Bracket, tank (K161)
Bracket, tank - lower (K141,
Bracket, tank upper (Kl4l,
Webbing (K9l, K161)
Tank, fuel - assembly (KI41, Klal)
Extension, lower (KI41)
Extension, upper (KI41)
Sleeve, fuel Hne (K14l, Kl81)
Valve, fuel (K141, K1Sl)
GOVERNOR GROUP
Linkage, governor
Pin, governor stop (KI41, K161, K18l)
Lever, governor
Spy i ng, governor
Bushi ng governor
Disc, regulating
Shaft, governor (K9])
Shaft, gov. cross - assem. (K14l,K161,KI81)
Bearing, needle (KI4l, K16l, K18!)
Bracket, speed control
Ring, snap (K9l)
Gear, governor (K141, K161, K1Sl)
IGNITION GROUP
Rodl breaker
Bracket - assembly
Points breaker
Gasket, cover
Cover, bteaker assembly
Plug, spar k
Cable, hi-tension
Clip, cable (K9!)
Clip, cable (KI4l, K161, Kla1)
Stator assembly (K9!)
Stator - assembly (KI41, K161, K181)
Condenser
Coil, mgneto (K91)
Coil - assembly (KI41, K16l, K181)
Rotor (K141, K161, K18!)
Lead, breaker
Sleeve, cable (K141, K161, K18l)
OJ L PAN GROUP
Plug, pipe
Gasket, pan
Base; oi 1 pan
PISTON AND ROD GROUP
Ring set
Piston - assembly
Pin, piston
Retainer! piston pin
Rod, connecting .. assembly
Lock, connecting rod
Screw, connecting rod
ENGINE SPECIFICATIONS
ENGINE MODEL
SPECIFICATION K91 K141 K161 K181
BORE X STROKE 2-3/8 x 2" 2-7/8 X 2-1/2" 2-7/8 x 2-1/2" 2-15/16 x 2-3/4"
PISTON DISPLACEMENT (CUBIC INCHES) 8.86 16.22 16.22 18.6
OIL CAPACITY (COMPLETELY DRY SUMP) 1-1/2 pi nts 2-1/2 pints 2-1/2 pints 2-1/2 pints
FUEL TANK CAPAC ITY -- GALLONS 2/3 ga 1. 3/4 gal. 1-1/4 gal. 1 gal.
SPARK PLUG SIZE 14 T 14 T 14 T 14 mm
SPARK PLUG GAP (STANDARD PLUG) .025" .025" .025" .025"
SPARK PLUG GAP (SHIELDED PLUG) .020" .020" .020" .020"
SPARK PLUG -- TIGHTENING TORQUE VALUE 324 in. Ibs. 324 in. Ibs. 324 in. lbs. 324 in. lbs.
BREAKER POINT GAP .018 - .022" .018 - .020" .018 - .022" .018 - .022"
INTAKE VALVE -- TAPPET, COLD CLEARANCE .005 - .009" .006 - .008" .006 - .008" .006 - .008"
EXHAUST VALVE -- TAPPET, COLD CLEARANCE .011 - .015" .015 - .017" .015 - .017" .015 - .017"
HORSEPOWER @ 1800 RPM 1.8 3.7 3.8 4.6
HORSEPOWER @ 2000 RPM 2.1
- - -
HORSEPOWER @ 2400 RPM
-
5.0 5.1 6.1
HORSEPOWER @ 2800 RPM 3.0
- - -
HORSEPOWER @ 3000 RPM
-
5.9 6.3 7.3
HORSEPOWER @ 3400 RPM 3.6
- -
HORSEPOWER @ 3600 RPM
-
6.25 7.0 8.0
HORSEPOWER @ 4000 RPM 4.0
- - -
MAXIMUM PERMISSIBLE SPEED 4000 RPM 3600 RPM 3600 RPM 3600 RPM
WARRANTY
We warrant each new engine sold by us to be free from manufacturing defects in normal ser
vice for a period of one (1) year commencing \,vith delivery of the engine to the original user.
OUR OBLIGATION UNDER THIS WARRANTY IS EXPRESSLY LIMITED TO THE REPLACE
MENT OR REPAIR AT KOHLER CO., KOHLER, WISCONSIN, OR AT A POINT DESIGNATED
BY US, OF SUCH PART OR PARTS AS SHALL ApPEAR TO US TO HAVE BEEN DEFECTIVE,
WE SHALL NOT BE LIABLE FOR CONSEQUENTIAL LABOR COSTS OR TRANSPOR TA TION
CHARGES IN CONNECTION WITH THE REPLACEMENT OR REPAIR OF DEFECTIVE PARTS.
THIS WARRANTY DOES NOT APPLY TO AN ENGINE UPON WHICH REPAIRS OR ALTERA
TIONS HAVE BEEN MADE BY OTHERS EXCEPT WITH OUR PRIOR WRITTEN APPROVAL.
WE MAKE NO WARRANTY WITH RESPECT TO TRADE ACCESSORIES. THEY ARE SUB
JECT TO THE WARRANTIES OF THEIR MANUFACTURERS.
WE SHALL NOT BE LIABLE FOR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILI
TIES NOR FOR THE FITNESS OF ANY ENGINE FOR,ANY PARTICULAR PURPOSE.
WE MAKE NO OTHR EXPRESS, IMPLIED OR STATUTORY WARRANTY, NOR IS ANYONE
AUTHORIZED TO MAKE ANY IN OUR BEHALF.
KOHLER CO., KOHLER, WISCONSIN
ENS-593 25 M 1-68 U Class III Printed in U.S.A.