Kohler CS4 Generator Set

⚠ Carburetor adjustments only after engine warmed up.

Tools: tachometer

1. Start engine and run at half throttle 5 to 10 minutes to warm up.
2. Place throttle into idle or slow position.
3. Turn low idle fuel adjusting needle within adjustment range for best low speed performance.
4. Set low idle speed to 2000 RPM (± 150 RPM) with tachometer.
5. Turn low idle speed adjusting screw in or out to set speed.

1. Close fuel shut-off valve.
2. Remove air cleaner outer cover; access governor shaft and lever joint.
3. Loosen governor lever mounting bolt.
4. Move governor lever clockwise until it stops.
5. Rotate governor shaft clockwise until it stops.
6. Hold both in position and tighten governor lever bolt.
7. Torque bolt to 8 N·m (CS4, CS6) or 10 N·m (CS8.5-12).

Tools: tachometer

1. Start engine and allow warm up.
2. Place throttle control lever into fast or high idle position.
3. Check engine speed with tachometer.
4. To increase speed, turn high idle speed adjusting screw out (counterclockwise) with light pressure.
5. To decrease speed, turn screw in (clockwise) until desired speed attained.

Tools: tachometer

1. With engine warm, move throttle lever clockwise until it stops.
2. Check idle speed with tachometer.
3. Turn adjustment screw in (clockwise) to increase idle speed.
4. Turn adjustment screw out (counterclockwise) to decrease idle speed.

1. Single cylinder: measure from the PTO end to the face of the block.
2. Twin cylinder: measure from the PTO end to the machined mounting surface of the closure plate.

1. Check the crankpin diameter of the unknown crankshaft.
2. Locate the matching dimension in the crankpin diameter column of the identification chart.
3. Compare main bearing and oil seal journal diameters to confirm the model series.
4. If diameters are shared by several models, check the Other Identifying Differences column.
5. Refer to the Common Features illustration at the start of each model section.

⚠ To prevent engine wear, never operate below low oil level.

1. Clean area around oil fill/check plug.
2. Remove oil drain plug and oil fill/check plug; allow complete drainage.
3. Reinstall drain plug; tighten to 17.6 N·m (13 ft. lb.).
4. Fill crankcase with proper oil to point of overflowing filler neck.
5. Reinstall oil fill/check plug and tighten securely.

1. Ensure engine is stopped, level, and cool.
2. Clean area around oil fill cap.
3. Unthread and remove oil fill cap.
4. Oil level should be at point of overflowing filler neck.
5. Add oil if low to bring level to overflowing.

⚠ Do not operate engine without air cleaner element.

1. Remove two screws and outer air cleaner cover/housing.
2. Remove foam element from housing.
3. Wash foam element in warm water with detergent; rinse.
4. Squeeze out excess water; do not wring; air dry.
5. Lightly oil element with new engine oil; squeeze to distribute.
6. Check case and cover; reinstall cover with two screws.

1. Loosen cover knob or unhook latches; remove cover/housing.
2. Remove precleaner from paper element.
3. Do not wash paper element or use pressurized air.
4. Replace dirty, bent, or damaged element with genuine Kohler element.
5. Check air cleaner base and cover for damage or improper seal.
6. Reinstall serviced precleaner over element.
7. Secure element/precleaner with wing nut; reinstall cover.

⚠ Do not wring precleaner.

1. Remove air cleaner cover knob or unsnap latches; remove cover.
2. Remove precleaner from filter element.
3. Wash precleaner in warm water with detergent; rinse thoroughly.
4. Squeeze out excess water; do not wring; air dry.
5. Saturate precleaner with new engine oil; squeeze out excess.
6. Install precleaner over paper element.
7. Reinstall air cleaner cover; secure with knob or latches.

Tools: retaining ring removal tools

1. Remove starter from engine.
2. Push back spring holder to expose retaining ring; remove ring.
3. Remove spring holder, spring, and drive pinion assembly.
4. Use solvent to clean splines of dirt or old lubricant.
5. Inspect splines and drive components for wear or damage.
6. Apply small amount of molybdenum disulfide lubricant to splines.
7. Install drive pinion, spring, and spring holder onto armature shaft.
8. Install new retaining ring into groove of armature shaft.