OWNER’s MAN UAL MODELS K91 I (4hP) Kl6l,&Kl81 (7hP) (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 A WARNING A WARNING # db r-u -v Explosive Fuel can cause fires and Rotating Parts can cause severe Hot Parts can cause severe burns. severe burns. injury. Do not touch engine while operating Stop engine before filling fuel tank. Stay away while engine is in or just after stopping. operation. Explosive Fuel! Rotating Parts! Hot Parts! Gasoline is extremely flammable Keep hands, feet, hair, and clothing Engine components can get and its vapors can explode if away from all moving parts to extremely hot from operation. To ignited. Store gasoline only in prevent injury Never operate the prevent severe burns, do not touch approved containers, in well engine with covers, shrouds, or these areas while the engine is ventilated, unoccupied buildings, guards removed. running-or immediately after it is away from sparks or flames. Do not turned off. Never operate the fill the fuel tank while the engine is engine with heat shields or guards hot or running, since spilled fuel A CAUTION removed. could ignite if it comes in contact with hot parts or sparks from ignition. Do not stat? the engine dh WARNING near spilled fuel. Never use gasoline as a cleaning agent. Electrical Shock can cause injury. Do not touch wires while engine is +P ( A WARNING running. Explosive Gas can cause fires and severe acid burns. Electrical Shock! Charge battery only in a well ventilated area. Keep sources of Never touch electrical wires or ianition awav. components while the engine is Carbon Monoxide can cause running. They can be sources of Explosive Gas! severe nausea, fainting or death. electrical shock. Batteries produce explosive hydrogen gas while being charged. Do not operate engine in closed or To prevent a fire or explosion, confined area. dh WARNING charge batteries only in well Lethal Exhaust Gases! ventilated areas. Keep sparks, open Engine exhaust gases contain flames, and other sources of poisonous carbon monoxide. ignition a way from the battery at all Carbon monoxide is odorless, times. Keep batteries out of the reach of children. Remove all colorless, and can cause death if Accidental Starts can cause inhaled. Avoid inhaling exhaust severe injury or death. jewelry when servicing batteries. fumes, and never run the engine in a closed building or confined area. Disconnect and ground spark plug Before disconnecting the negative lead before servicing. (-) ground cable, make sure all California Accidental Starts! switches are OFF: If ON, a spark Proposition 65 Warning Before servicing the engine or will occur at the ground cable terminal which could cause an Engine exhaust from this product equipment, always disconnect the sparkplug lead to prevent the explosion if hydrogen gas or contains chemicals known to the gasoline vapors are present. State of California to cause engine from starting accidentally cancer, birth defects, or other Ground the lead to prevent sparks reproductive harm. that could cause fires. Make sure the equipment is in neutral. 2 FUEL RECOMMENDATIONS OIL RECOMMENDATIONS e, WARNING: Explosive Fuel1 Using the proper type and weight crankcase oil is Gasoline is extremely flammable and its vapors can extremely important as is checking oil daily and explode if ignited. Store gasoline only in approved changing oil and filter regularly. (See ‘Required containers, in well-ventilated, unoccupied buildings, Maintenance” on page 7.) Failure to use the correct oil away from sparks or flames. Do not fill the fuel tank or using dirty oil causes premature engine wear and while the engine is hot or running, since spilled fuel failure. could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near Before starting engine, fill the crankcase with the spilled fuef; wipe up spills immediately. Never use proper type and quantity of oil. gasoline as a cleaning agent. Oil Type General Recommendations Use high-quality detergent oil of API (American Purchase gasoline in small quantities and store in Petroleum Institute) service class SG or SH. Select the clean, approved containers. A container with a viscosity based on the air temperature at the time of capacity of 2 gallons or less with a pouring spout is operation as shown in the table. recommended. Such a container is easier to handle and helps eliminate spillage during refueling. Do not Recommended SAE Viscosity Wades 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 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHAW6E higher. In countries using the Research method, it should be 90 octane minimum. Unleaded gasoline is recommended as it leaves less Straight 30-welght oil Is preferred. SAE lOW-30 oil combustion chamber deposits. Leaded gasoline may is not recommended above 32” F. Using this oil be used in areas where unleaded is not available and substantially increases oil consumption and exhaust emissions are not regulated. Be aware combustion chamber deposits. however, that the cylinder head will require more frequent service. See “Required Maintenance” on (See Changing Oil” and “Required Maintenance” on page 7. pages 4 and 7.) Gasoline/Alcohol blends NOTE: Using other than service class SG or SH oil or Gasohol (up to 10% ethyl alcohol, 90% unleaded extending oil change intervals longer than gasoline by volume) is approved as a fuel for Kohler recommended could cause engine damage engines. Other gasoline/alcohol blends are not which is not covered by the engine warranty. approved. A logo or symbol on oil containers identifies the API Gasoline/Ether blends service class and SAE viscosity grade. 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. 3 F I..................... .........-lM ................... ’ t ................... Operating ...........;;;:::..:.:.............................. Range ................... ................... 1 r.............................. , L The top position of the symbol shows service class such as API SERVICE CLASS SG. The symbol may NOTE: To prevent extensive engine wear or damage, show additional categories such as SG/CC, CD. The always maintain the proper oil.level in the center portion shows the viscosity grade such as SAE crankcase. Never operate the engine with the 30 in the example. If the bottom portion shows oil level below the “L” mark or over the “F” mark “Energy Conserving”, it means that oil is intended to on the dipstick. improve fuel economy in passenger car engines. Changing Oil Checking Oil For a new engine, change oil after the first 5 hours of The importance of checking and changing crankcase operation and then every 25 hours of operation oil cannot be overemphasized. thereafter. Check oil BEFORE EACH USE when the engine is cool Drain oil while engine is still warm from operation--it and the oil has drained back into the sump. Add oil, if flows freely and carries away more impurities. (See low, to bring level up to, but not over, the ‘Fw mark on Engine Identification illustration for location of drain the dipstick. PWJ Oil should always be checked while engine is off and Remove the oil drain plug and oil fill cap. Tilt the on a level surface. engine slightly towards the oil drain to obtain better drainage. With threaded plug-type dipstick, remove and wipe oil off--reinsert, but do not turn plug in. To check oil level, After draining, reinstall drain plug. Make sure it is shoulder plug on top of hole. After checking, again tightened securely. Fill with proper viscosity oil to “F” turn plug all the way into crankcase. mark on dipstick. Always check level on dipstick before adding more oil. With extended oil fill tube and dipstick, push dipstick all the way down in tube then take reading. 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 For A Retractable Start Engine - SLOWLY pull the PRE-START CHECKLIST starter handle until just past compression - STOP! Return starter handle, pull firmly with a smooth, steady cl Check oil level. Add oil if low. motion to start. Pull the handle straight out to avoid excessive rope wear from the starter rope guide. cl Check fuel level. Add fuel if low. Extend the starting rope periodically and check its El Check cooling air intake areas and external surfaces condition.