Kohler K241 Generator Set

⚠ Do not force tapered adjusting needles; damage to needles and seats will result.

Tools: tachometer

1. With engine stopped, turn low idle fuel needle in until it bottoms lightly.
2. Turn adjusting needles out from bottom according to preliminary settings table.
3. Start engine and run at half throttle 5 to 10 minutes to warm up.
4. Set high idle fuel needle midway between rich and lean for adjustable main jet.
5. Place throttle in idle position; set low idle speed to 1200 rpm.
6. Set low idle fuel needle midway between rich and lean.
7. Recheck low idle speed with tachometer.

⚠ Explosive fuel - keep sparks and open flames away; damage to needles and seats will result if forced

Tools: Tachometer

1. With engine stopped, turn low idle fuel adjusting needle in (clockwise) until it bottoms lightly.
2. Make preliminary settings by turning adjusting needles out per the model table.
3. Start engine and run at half throttle five to ten minutes to warm up.
4. Set high idle fuel needle midway between rich and lean settings.
5. Set low idle speed to 1200 rpm (+/- 75 rpm) with the idle speed adjusting screw.
6. Set low idle fuel needle midway between rich and lean; recheck speed with tachometer.

Tools: Flat feeler gauge

1. Remove air cleaner assembly, carburetor and breather assembly.
2. Position crankshaft so piston is at top of compression stroke.
3. Measure valve-to-tappet clearance with a flat feeler gauge (engine must be cold).
4. On K91, K141, K161, K181 grind valve stems if clearance is too small, or replace valves if too large.
5. On K241, K301, K321, K341 adjust clearance by turning the adjusting screw on tappets.

⚠ Tab is hardened - do not bend back and forth more than 3 or 4 times

⚠ Do not attempt to bend hardened steel ACR tabs on engines serial no. 9006118 and after

Tools: Dial indicator, Wooden dowel or peg

1. Check valve tappet clearances and adjust as necessary to specification.
2. Remove cylinder head and turn the engine over by hand until BDC of the intake stroke.
3. Mount a dial indicator on the top of the exhaust valve and set at 0.
4. Slowly turn the flywheel clockwise; exhaust valve should open when piston is about 2/3 of the way up the cylinder.
5. If valve lift was above .042, tap valve down to within range; if below .031, remove camshaft cover and bend ACR tab upward.

⚠ Overspeed is hazardous - never tamper with governor setting to increase engine speed above maximum

Tools: Pliers, Torque wrench

1. Loosen, but do not remove, the nut holding the governor arm to the governor cross shaft.
2. Grasp the end of the cross shaft with pliers and turn counterclockwise as far as possible.
3. Pull the governor arm away from the carburetor as far as it will go.
4. Tighten the nut holding the governor arm to the cross shaft.
5. For K181 New Look, torque the palnut to 15 in. lb. and keep at least 1/16 in. clearance to bushing nut.

⚠ Do not use excessive force in tightening the bushing nut

Tools: Tachometer

1. Start the engine and allow a few minutes for warmup.
2. Open throttle to full speed and check engine speed with a tachometer.
3. If speed is not as required, slightly loosen the bushing nut at the speed control disc.
4. Move the throttle bracket counterclockwise to increase speed, or clockwise to decrease speed.
5. When proper speed is set, tighten the bushing nut.

Tools: small screwdriver

1. Invert carburetor so float tab rests on fuel inlet needle.
2. There should be 1/64 in. (±1/32 in.) clearance between machined surface and free end of float.
3. Bend float tab with small screwdriver to adjust.
4. Turn carburetor to normal operating position for float drop.
5. Float drop should be limited to 1-1/32 in. between machined surface and bottom of free end of float.
6. Bend float tab to adjust.

Tools: Small screwdriver, Feeler gauge, Torque wrench

1. Install fuel inlet seat gasket and seat; torque seat to 35/45 in. lb.
2. Install fuel inlet needle into inlet seat; install float and slide float pin through float hinge towers.
3. Invert carburetor so float tab rests on inlet needle; there should be 11/64 in. (+/- 1/32 in.) clearance between machined surface of body and free end of float.
4. Bend the float tab with a small screwdriver to adjust level.
5. Set float drop by allowing float to drop to its lowest level; drop limited to 1-1/32 in.
6. Check float-to-float hinge tower clearance with a .010 in. feeler gauge.

⚠ Remove spark plug lead to prevent unintentional starting.

Tools: feeler gauge

1. Remove breaker point cover.
2. Remove spark plug lead to prevent unintentional starting.
3. Rotate engine slowly clockwise by hand.
4. Breaker points should just begin to open when S or SP mark appears in timing sight hole.
5. Continue rotating until breaker points are fully opened.
6. Measure breaker point gap with feeler gauge; gap should be .020 in.
7. Loosen gap adjustment screw and adjust gap if needed.
8. Tighten gap adjustment screw and replace cover.

⚠ Do not attempt to bend hardened steel ACR tabs; they will break.

Tools: dial indicator, feeler gauge

1. Check valve-to-tappet clearances and adjust to specification.
2. Remove cylinder head and turn engine over by hand to BDC of intake stroke.
3. Mount dial indicator on top of exhaust valve and set at 0.
4. Slowly turn flywheel clockwise and watch dial indicator.
5. When piston is about 2/3 of way up cylinder, exhaust valve should open .031-.042 in.
6. If valve lift is not within range, adjust ACR tab.

Tools: Slack tube manometer, Kohler Engine Analysis Kit

1. Insert the stopper hose into the oil fill hole with the manometer's other vent open; make sure the shutoff clamp is closed.
2. Start the engine and run at high speed (3200 to 3600 RPM).
3. Open the clamp and note the water level in the tube.
4. Close the shutoff clamp before shutting off the engine.

⚠ Dangerous acid and explosive gases

⚠ Turn ignition switch OFF or disconnect battery cables before charging to prevent ignition coil overheating and explosion

⚠ Do not allow baking soda solution to enter the battery cells

1. Charge the battery only in a well-ventilated area away from sparks and flames.
2. When disconnecting battery cables, always disconnect the negative (-) cable first.
3. When connecting battery cables, always connect the negative cable last.
4. Check electrolyte level regularly; add distilled water to maintain it.
5. Clean cables, terminals and external surfaces with a baking soda and water solution, then rinse.