Kohler Kt19 Generator Set

1. Loosen the cover retaining screws.
2. Shift the cover in clockwise direction for richer setting or counterclockwise direction for leaner setting.
3. Tighten the cover retainer screws.

Tools: Feeler gauge, Screwdriver

1. Loosen point gap adjustment screw.
2. Readjust gap to .020" fully open.
3. Gap may vary .017"-.023" to achieve smoothest running.
4. Securely tighten adjusting screw after timing.

⚠ 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.

Tools: Pliers, Wrench

1. With pliers, turn governor cross shaft clockwise as far as it will go.
2. Pull governor arm back away from carburetor as far as it will go.
3. Tighten governor clamp nut.

⚠ 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.

⚠ Never tamper with governor settings to increase maximum speed of the engine.

Tools: Hand tachometer, Screwdriver

1. Check operating speed with a hand tachometer; do not exceed 3600 RPM no load.
2. If adjustment needed, loosen the governor speed adjusting screw.
3. Pivot the high speed stop tab until desired speed setting is reached.
4. Tighten the screw.

⚠ 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: ohmmeter or continuity tester, feeler gauge

1. Make sure ignition switch is off. Completely disconnect spark plug leads from plugs.
2. Remove breaker point cover, connect an ohmmeter or continuity tester from breaker point terminal to ground.
3. Rotate the engine by hand in direction of normal rotation (clockwise viewed from flywheel end).
4. When points are just breaking, the S mark on the flywheel should be directly opposite the roll pin in the #1 cylinder barrel.
5. If S is above or below roll pin, adjust point gap in or out until S mark is directly opposite the roll pin.
6. If no ohmmeter, measure gap with feeler gauge; gap should be .020 inch fully open.

Tools: timing light

1. Remove high tension lead at spark plug; wrap one end of a short piece of fine wire around spark plug terminal and reconnect lead.
2. Connect one timing light lead to the wire wrapped around the spark plug terminal.
3. Connect second timing light lead to hot (ungrounded) side of battery; connect third lead to ground.
4. Start engine, run at 1200-1800 RPM, aim timing light into sight hole; light should flash just as S mark is opposite the roll pin.
5. If timing is off, remove breaker point cover; loosen gap adjusting screw and shift breaker plate until S mark is exactly centered, then retighten.
6. Check timing before replacing breaker point cover.

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.