Kohler 4 and 5 kW Generator Set

1. Make a scribe mark on the black plastic cover where the choke casting mark meets it.
2. Loosen the two choke adjusting screws and rotate choke cover counterclockwise toward leaner setting.
3. When distance between scribe mark and casting mark is 5/16 in. (8 mm) tighten the two adjusting screws.

⚠ If not previously adjusted, leave as factory set.

1. Loosen the two choke adjusting screws and rotate choke cover clockwise (opposite arrow on choke).
2. When the scribe mark on the black plastic cover and the choke casting mark line up, tighten the two adjusting screws.

⚠ Damage to needles and seats will result if the needles are forced.

1. Stop engine and turn main fuel and idle fuel adjusting needles in until they bottom lightly.
2. Back out main fuel needle 2 1/4 turns and idle fuel needle 1 1/2 turns.
3. Start engine and run at half-load for 5-10 minutes to warm up.
4. At 3/4 to full load, turn main fuel needle in until engine does not operate smoothly; note position.
5. Turn the main fuel needle out 1/4 turn.
6. Set idle fuel needle using the same procedure.

1. Turn MAIN FUEL valve clockwise until it bottoms lightly (do not force), then back out 1 turn.
2. With engine warm at rated rpm under full load, turn MAIN FUEL valve in until engine slows (lean).
3. Turn valve out until engine regains full speed (about 1/8 turn).

1. Stop the engine.
2. Turn IDLE FUEL screw all the way in (clockwise) then back out 1/4 turn.
3. Adjust for proper no load operation.

⚠ Piston must be at top dead center (TDC) of the compression stroke to measure clearance.

Tools: flat feeler gauge

1. Rotate the flywheel and look into the valve boxes; measure clearance for the cylinder in which no movement was observed using a flat feeler gauge.
2. Rotate the flywheel 360° and measure the valve-to-tappet clearance for the remaining cylinder.
3. If clearance is too small or too large, remove generator set and take to an authorized Kohler service dealer.

⚠ Do not let cleaning solutions enter battery cells.

Tools: wire brush

1. Keep battery clean by wiping with a damp cloth; keep all electrical connections dry and tight.
2. If corrosion is present, disconnect cables and remove corrosion with a wire brush.
3. Clean battery and cables with a solution of baking soda and water; do not let solution enter battery cells.
4. Flush battery and cables with clean water and wipe dry.
5. Reconnect cables and coat terminals with petroleum jelly or other non-conductive grease.

⚠ Avoid scratching aluminum surfaces of the cylinder head.

Tools: torque wrench, scraper (wood or plastic)

1. After each 500 hours remove the cylinder heads from the engine.
2. Remove carbon deposits from combustion chamber with a sharp piece of wood or plastic.
3. Use new cylinder head gaskets when reinstalling.
4. Tighten head bolts in the proper sequence to 15-20 ft. lbs. (20-27 Nm).

⚠ Do not use synthetic oils during the first five hours of operation.

Tools: oil filter wrench, container

1. Drain oil while warm by opening petcock located beneath the dipstick assembly.
2. Remove filter by rotating counterclockwise with an oil filter wrench.
3. Coat rubber seal of new filter with fresh oil and install replacement filter.
4. Close petcock and add new oil of proper weight and grade.
5. Restart and check area around filter for evidence of leakage; tighten filter if needed.

⚠ Do not sandblast, wire brush, scrape, or otherwise service a plug in poor condition.

1. Every 100 hours remove both spark plugs and check condition.
2. Reset gap or replace plug if needed.
3. Set gap at 0.025 in. (0.64 mm) on gasoline sets and 0.018 in. (0.46 mm) on LP gas sets.
4. Tighten plug to 10-15 ft. lbs. (13.6-20 Nm) when installing.

Tools: container

1. Change the oil and filter while engine is warm; run engine a few minutes to distribute clean oil.
2. Gasoline: drain carburetor bowl or run unit until empty (gas stabilizer may be used). LP: shut off fuel supply and run until set stops.
3. Gasoline only: remove fuel line at pump outlet to drain fuel line to carburetor, then reconnect.
4. Remove spark plugs, pour about 1 tablespoon of engine oil into each plug hole, install plugs (do not connect leads), crank two or three revolutions.
5. Clean exterior surface and spread a light film of oil over unpainted metallic surfaces.

⚠ Failure to follow these guidelines may result in burn out of the starter motor.

1. Move START-STOP switch to START and hold until engine runs, then release.
2. Do not crank continuously for more than 10 seconds at a time.
3. Allow a 60 second cool-down between cranking attempts.
4. If unit fails to start after three attempts contact an authorized service dealer.
5. To stop, move switch to STOP.