Engine Service Manual

Fuel System
34 32 690 03 Rev. IKohlerEngines.com
For Keihin Carburetors Only
To install choke repair kit go to step 10, otherwise go
to step 21.
10. Remove and discard plastic cap from top of choke
lever/shaft assembly.
11. Note position of spring legs and choke plate for
correct reassembly later.
12. Remove two screws attaching choke plate to choke
shaft. Pull shaft out of carburetor body and discard
removed parts.
13. Use a screw extractor (easy out) and remove
original choke shaft bushing with old choke lever
from carburetor housing. Save bushing to use as a
driver for installing new bushing. Discard old lever.
14. Clean I.D. of both choke shaft bores as required.
15. Insert new bushing through new choke lever from
outside, and start bushing in outer shaft bore.
Position choke lever so that protruding boss on
carburetor housing is between two stops formed in
choke lever.
16. Turn old bushing upside down and use it as a driver
to carefully press or tap new bushing into carburetor
body until it bottoms. Check that choke lever pivots
freely without restriction or binding.
17. Install new return spring onto new choke shaft, so
upper leg of spring is between two formed stops on
end of choke shaft.
18. Slide choke shaft and spring, into carburetor. Pivot
(preload) shaft and set inner leg of spring, against
formed stop within choke lever, as originally
assembled. Opposing leg of spring must still be
between formed stops of choke shaft.
19. Place a drop of Loctite® on threads of each new
screw. Install new choke plate to fl at side of choke
shaft and start two screws. Larger cutout must be on
right. Close choke and check plate alignment within
carburetor throat, then tighten screws securely. Do
not overtighten.
20. Check for proper operation and free movement of
parts. Install new cap.
21. Clean carburetor body, jets, vent ports, seats, etc.,
using a good commercially available carburetor
solvent. Use clean, dry compressed air to blow out
internal channels and ports. Inspect and thoroughly
check carburetor for cracks, wear, or damage.
Inspect fuel inlet needle seat for wear or damage.
Check spring loaded choke plate to make sure it
moves freely on shaft.
22. Clean carburetor fl oat bowl as required.
23. Install main nozzle and main jet into tower of
carburetor body.
24. Install slow jet and new plug into end of slow jet
tube.
25. Attach inlet needle to metal tang of fl oat with wire
clip. Formed 90° lip of metal tang should point up,
with needle valve hanging down.
26. Install new fl oat and new inlet needle down into seat
and carburetor body. Insert new pivot pin through
fl oat hinge and secure with new retaining screw.
27. Hold carburetor body so fl oat assembly hangs
vertically and rests lightly against fuel inlet needle.
Inlet needle should be fully seated but center pin of
needle (on retainer clip end) should not be
depressed. Check fl oat height adjustment.
28. Correct fl oat height adjustment is 12.0 mm
(0.472 in.) measured from fl oat bottom to body of
carburetor. Adjust fl oat height by carefully bending
metal tang of fl oat.
29. When proper fl oat height is obtained, carefully install
new O-ring for fuel bowl.
30. Install fuel bowl onto carburetor. Secure with four
original screws. Torque screws to 2.5 ± .3 N·m
(23 ± 2.6 in. lb.).
31. Install new cover gasket and top cover on
carburetor. Secure with two large-head screws and
attach ground lead (if equipped with a fuel solenoid),
to original screw location. Torque top cover screws
to 2.5 ± .3 N·m (23 ± 2.6 in. lb.).
32. Place new spring onto idle speed adjusting screw
and install into carburetor. Thread in until 3 or 4
threads are exposed, as an initial adjustment.
33. Reinstall carburetor using appropriate new
carburetor and air cleaner base gaskets.
34. Reconnect spark plug lead(s) and negative (–)
battery cable. Start engine and perform Idle Speed
(RPM) Adjustment.
For Walbro Carburetors Only
10. Clean carburetor body, jets, vent ports, seats, etc.,
using a good commercially available carburetor
solvent. Use clean, dry compressed air to blow out
internal channels and ports. Inspect and thoroughly
check carburetor for cracks, wear, or damage.
Inspect fuel inlet needle seat for wear or damage.
Check spring loaded choke plate to make sure it
moves freely on shaft.
11. Clean carburetor fl oat bowl as required.
12. Install main nozzle and main jet into tower of
carburetor body.
13. Install new solenoid gasket on solenoid.
Reassemble fuel bowl and solenoid.
14. Reinstall carburetor using appropriate new
carburetor and air cleaner base gaskets.
15. Reconnect spark plug lead(s) and negative (–)
battery cable. Start engine and perform Idle Speed
(RPM) Adjustment.
High Altitude Operation
If this engine is operated at an altitude of 4000 ft.
(1219 meters) or above, a high altitude carburetor
kit is required. To obtain high altitude carburetor kit
information or to fi nd a Kohler authorized dealer, visit
KohlerEngines.com or call 1-800-544-2444 (U.S. and
Canada).
This engine should be operated in its original
confi guration below 4000 ft. (1219 meters).
Operating this engine with the wrong engine
confi guration at a given altitude may increase its
emissions, decrease fuel effi ciency and performance,
and result in damage to the engine.