LH640, LH685, LH690

Owner's Manual

IMPORTANT: Read all safety precautions and instructions carefully before

operating equipment. Refer to operating instruction of
equipment that this engine powers.
Ensure engine is stopped and level before performing any
maintenance or service.
Warranty coverage as outlined in the warranty card and on
KohlerEngines.com. Please review carefully as it provides you
specific rights and obligations.

Record engine information to reference when ordering parts or obtaining warranty coverage.

Engine Model
Specification
Serial Number
Purchase Date

66 590 05 Rev. -- KohlerEngines.com

 Safety Precautions
WARNING: A hazard that could result in death, serious injury, or substantial property damage.

CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING WARNING WARNING

Explosive Fuel Carbon Accidental
can cause fires Monoxide can Starts can cause
and severe cause severe severe injury or
burns. nausea, fainting death.
Do not fill fuel or death.
Disconnect and
tank while Avoid inhaling ground spark
engine is hot or exhaust fumes. plug lead(s)
running. before servicing.
Engine exhaust gases
Gasoline is extremely contain poisonous carbon Before working on engine or
flammable and its vapors monoxide. Carbon equipment, disable engine
can explode if ignited. monoxide is odorless, as follows: 1) Disconnect
Store gasoline only in colorless, and can cause spark plug lead(s). 2)
approved containers, in death if inhaled. Disconnect negative ()
well ventilated, unoccupied battery cable from battery.
buildings, away from sparks
or flames. Spilled fuel
could ignite if it comes in
contact with hot parts or
sparks from ignition. Never
use gasoline as a cleaning
agent. WARNING
Hot liquid can
cause severe
WARNING burns.
WARNING
Rotating Parts Do not loosen
radiator cap Hot Parts can
can cause cause severe
severe injury. while engine
is operating or burns.
Stay away while warm to touch. Do not touch
engine is in engine while
operation. Liquid coolant can get operating or just
extremely hot from after stopping.
Keep hands, feet, hair, operation. Turning radiator
and clothing away from all cap when engine is hot can Never operate engine with
moving parts to prevent allow steam and scalding heat shields or guards
injury. Never operate engine liquid to blow out and removed.
with covers, shrouds, or burn you severely. Shut
guards removed. off machine. Only remove
radiator cap when cool
enough to touch with bare
hands. Slowly loosen cap to
first stop to relieve pressure
before removing completely.

CAUTION California Proposition 65 Warning

Electrical Shock Engine exhaust from this product contains chemicals known
can cause injury. to State of California to cause cancer, birth defects, or other
reproductive harm.
Do not touch
wires while
engine is
running.

2 KohlerEngines.com 66 590 05 Rev. --

 O
P

Q
R N
M

K
L

B
J
C

H
F I

G
D
E

Heavy-Duty Air
A B Oil Fill C Spark Plug D Oil Filter
Cleaner
Radiator Drain Overflow
E Oil Drain Plug F Radiator G H
Plug Reservoir
I Dipstick J Reservoir Cap K Radiator Cap L Intake Screen
Dust Ejector
M Element N End Cap O P Retaining Clip
Valve
Air Cleaner
Q Inner Element R Housing

Pre-Start Checklist
1. Check oil level. Add oil if low. Do not overfill.
2. Check fuel level. Add fuel if low. Check fuel system components and lines for leaks.
3. Check coolant level. Add coolant if low. Check coolant hoses and connections for leaks.
4. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly
after storage).
5. Check that air cleaner components and all shrouds, equipment covers, and guards are in place
and securely fastened.
6. Check spark arrestor (if equipped).
66 590 05 Rev. -- KohlerEngines.com 3
 Starting Cold Weather Starting Hints
1. Use proper oil for temperature expected.
WARNING 2. Disengage all possible external loads.
Carbon Monoxide can cause 3. Use fresh winter grade fuel. Winter grade
severe nausea, fainting or death. fuel has higher volatility to improve starting.
Avoid inhaling exhaust fumes. Stopping
Engine exhaust gases contain poisonous 1. If possible, remove load by disengaging all
carbon monoxide. Carbon monoxide is PTO driven attachments.
odorless, colorless, and can cause death if
inhaled. 2. Position throttle control between half and full
throttle; stop engine.

Angle of Operation
WARNING
Refer to operating instructions of equipment
Rotating Parts can cause severe this engine powers. Do not operate this engine
injury. exceeding maximum angle of operation; see
Stay away while engine is in specification table. Engine damage could result
operation. from insufficient lubrication.
Keep hands, feet, hair, and clothing away Engine Speed
from all moving parts to prevent injury. Never
operate engine with covers, shrouds, or NOTE: Do not tamper with governor setting to
guards removed. increase maximum engine speed.
Overspeed is hazardous and will void
NOTE: Do not crank engine continuously for warranty.
more than 10 seconds. Allow a 60
second cool down period between
starting attempts. Failure to follow Cold Weather Operation
these guidelines can burn out starter Anti-icing kits can be installed to improve cold
motor. weather operation and are available through
NOTE: Upon start-up, a metallic ticking may your local Kohler authorized dealer.
occur. Run engine for 5 minutes. If
noise continues, run engine at mid High Altitude Operation
throttle for 20 minutes. If noise persists, This engine may require a high altitude
take engine to your local Kohler carburetor kit to ensure correct engine
authorized dealer. operation at altitudes above 4000 ft.
1. Place throttle control midway between slow (1219 meters). To obtain high altitude kit
and fast positions. Place choke control into information or to find a Kohler authorized dealer
ON position. visit KohlerEngines.com or call 1-800-544-2444
(U.S. and Canada).
2. Turn key switch to START position. Release
switch as soon as engine starts. If starter This engine should be operated in its original
does not turn engine over, shut off key switch configuration below 4000 ft. (1219 meters) as
immediately. Do not make further attempts to damage may occur if high altitude carburetor kit
start engine until condition is corrected. Do is installed and operated below 4000 ft. (1219
not jump start. See your Kohler authorized meters).
dealer for trouble analysis.
3. Cold engine: Gradually return choke control
to OFF position after engine starts and
warms up. Engine/equipment may be
operated during warm-up period, but it may
be necessary to leave choke partially on until
engine warms up.
Warm engine: return choke to OFF position
as soon as engine starts.

4 KohlerEngines.com 66 590 05 Rev. --

 Maintenance Instructions

WARNING
Before working on engine or equipment, disable
Accidental Starts can cause engine as follows: 1) Disconnect spark plug
severe injury or death. lead(s). 2) Disconnect negative () battery cable
Disconnect and ground spark from battery.
plug lead(s) before servicing.
Normal maintenance, replacement or repair of emission control devices and systems may be
performed by any repair establishment or individual; however, warranty repairs must be performed
by a Kohler authorized dealer found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada).

Maintenance Schedule
Every 200 Hours1
Change oil and oil filter.
Every 200 Hours
Replace fuel filter.
Every 250 Hours1
Replace air cleaner element and check inner element.
Every 500 Hours1
Replace air cleaner inner element.
Every 500 Hours
Replace spark plugs and set gap.
Every 1000 Hours
Change engine coolant.
1
Perform these procedures more frequently under severe, dusty, dirty conditions.

3. Remove dipstick; check oil level. Level

Oil Recommendations should be at top of indicator on dipstick.
We recommend use of Kohler oils for best 4. If oil is low on indicator, add oil up to top of
performance. Other high-quality detergent indicator mark.
oils (including synthetic) of API (American
Petroleum Institute) service class SJ or higher 5. Reinstall and secure dipstick.
are acceptable. Select viscosity based on air
temperature at time of operation as shown in Change Oil and Filter
table below.
Change oil while engine is warm.

10W-30
1. Clean area around oil fill cap/dipstick, drain
plug/oil drain valve. Remove drain plug and
oil fill cap/dipstick. Allow oil to drain
SAE 30
completely.
5W-30
2. Clean area around oil filter. Place a container
F -20 0 20 32 40 50 60 80 100
under filter to catch any oil and remove filter.
C -30 -20 -10 0 10 20 30 40
Wipe off mounting surface. Reinstall drain
plug. Torque to 10 ft. lb. (13.6 Nm).
3. Place new filter in shallow pan with open end
Check Oil Level up. Fill with new oil until oil reaches bottom of
threads. Allow 2 minutes for oil to be
NOTE: To prevent extensive engine wear or absorbed by filter material.
damage, never run engine with oil level
below or above operating range 4. Apply a thin film of clean oil to rubber gasket
indicator on dipstick. on new filter.
Ensure engine is cool. Clean oil fill/dipstick 5. Refer to instructions on oil filter for proper
areas of any debris. installation.
1. Remove dipstick; wipe oil off. 6. Fill crankcase with new oil. Level should be
at top of indicator on dipstick.
2. Reinsert dipstick into tube; press completely
down.

66 590 05 Rev. -- KohlerEngines.com 5

7. Reinstall oil fill cap/dipstick and tighten
securely. Spark Plugs

8. Start engine; check for oil leaks. Stop engine;

correct leaks. Recheck oil level. CAUTION
9. Dispose of used oil and filter in accordance Electrical Shock can cause injury.
with local ordinances.
Do not touch wires while engine
Oil Sentry (if equipped) is running.
This switch is designed to prevent engine Clean out spark plug recess. Remove plug and
from starting in a low oil or no oil condition. Oil replace.
Sentry may not shut down a running engine 1. Check gap using wire feeler gauge. Adjust
before damage occurs. In some applications gap, see specification table for adjustment.
this switch may activate a warning signal. Read
your equipment manuals for more information. 2. Install plug into cylinder head.
3. Torque plug to 20 ft. lb. (27 Nm).
Fuel Recommendations
Air Cleaner
WARNING NOTE: Operating engine with loose or
damaged air cleaner components
Explosive Fuel can cause fires could cause premature wear and
and severe burns. failure. Replace all bent or damaged
components.
Do not fill fuel tank while engine is
hot or running. NOTE: Paper element cannot be blown out
with compressed air.
Gasoline is extremely flammable and
its vapors can explode if ignited. Store 1. Unhook retaining clips and remove end
gasoline only in approved containers, in cap(s).
well ventilated, unoccupied buildings, away 2. Check and clean inlet screen (if equipped).
from sparks or flames. Spilled fuel could
ignite if it comes in contact with hot parts or 3. Pull air cleaner element out of housing and
sparks from ignition. Never use gasoline as a replace. Check condition of inner element;
cleaning agent. replace when dirty.
NOTE: E15, E20 and E85 are NOT approved 4. Check all parts for wear, cracks, or damage,
and should NOT be used; effects of and that ejector area is clean.
old, stale or contaminated fuel are not 5. Install new element(s).
warrantable.
6. Reinstall end cap(s) with dust ejector valve/
Fuel must meet these requirements: screen down; secure with retaining clips.
Clean, fresh, unleaded gasoline.
Breather Tube
Octane rating of 87 (R+M)/2 or higher.
Ensure both ends of breather tube are properly
Research Octane Number (RON) 90 octane connected.
minimum.
Gasoline up to 10% ethyl alcohol, 90%
unleaded is acceptable.
Methyl Tertiary Butyl Ether (MTBE) and
unleaded gasoline blend (max 15% MTBE by
volume) are approved.
Do not add oil to gasoline.
Do not overfill fuel tank.
Do not use gasoline older than 30 days.

Fuel Line
Low permeation fuel line must be installed on
carbureted Kohler Co. engines to maintain EPA
and CARB regulatory compliance.

6 KohlerEngines.com 66 590 05 Rev. --

 Air Cooling Loosen/remove radiator drain plug and allow
coolant to drain.
2. If equipped, remove coolant drain plugs
WARNING located on each side of engine block. Drain
coolant into a suitable container. After
Hot Parts can cause severe coolant has drained completely, apply pipe
burns. sealant with Teflon (Loctite PST 592 or
equivalent), to threads and reinstall plugs.
Do not touch engine while Torque plugs to 325 in. lb. (36.7 Nm).
operating or just after stopping.
3. Remove overflow hose from reservoir.
Never operate engine with heat shields or Unhook inboard retainer and slide reservoir
guards removed. out of supports. Pour out contents and wash
NOTE: Operating engine with a restricted air or clean as required. Dispose of all old
intake screen or radiator, damaged/ coolant in accordance with local ordinances.
broken fan assembly, or missing fan 4. Reinstall reservoir cap. Do not kink/pinch
shroud will cause engine damage due hose.
to over heating.
5. Flush cooling system.
Proper cooling is essential. To prevent over
heating, clean screens, cooling fins, and other Flush Cooling System
external surfaces of engine. Avoid spraying
water at wiring harness or any electrical 1. Fill cooling system with clean water and a
components. See Maintenance Schedule. cooling system cleaner recommended for
aluminum engines. Follow directions on
Cooling System container.
2. Reinstall and tighten radiator cap.
3. Start and run engine for five minutes, or until
WARNING it reaches operating temperature. Stop
Hot liquid can cause severe engine and allow it to cool.
burns. 4. Drain cooling system.
Do not loosen radiator cap while 5. Fill cooling system.
engine is operating or warm to
touch.
Fill Cooling System
Liquid coolant can get extremely hot from 1. Check condition of cooling system hoses,
operation. Turning radiator cap when engine clamps, and associated components.
is hot can allow steam and scalding liquid Replace as required.
to blow out and burn you severely. Shut off
machine. Only remove radiator cap when 2. Fill with 2.1 U.S. qt. (2.0 L) equal parts of
cool enough to touch with bare hands. Slowly ethylene glycol (anti-freeze) and water only.
loosen cap to first stop to relieve pressure Distilled or deionized water is recommended,
before removing completely. especially in areas where water contains a
high mineral content. Propylene glycol based
NOTE: Do not operate engine without fan and anti-freeze is not recommended.
cooling system functioning properly, or
engine damage will occur. 3. Fill radiator with coolant mixture. Allow
coolant to drain into lower areas. Fill overflow
This engine is liquid-cooled, circulating a reservoir to a level between FULL and ADD
mixture of ethylene glycol and water for marks. Reinstall radiator and reservoir caps.
dependable operation. Maintaining correct
coolant level and cleaning any debris 4. Start and run engine for five minutes. Stop
accumulation from inlet screen and radiator engine and allow to cool.
surfaces are critical to ensuring long life, 5. Recheck coolant level in reservoir. Coolant
proper system performance, and preventing level should be between FULL and ADD
overheating. A drive belt is designed and marks. Add coolant to reservoir if required.
constructed for this application. Do not use a
substitute belt. If belt is cracked, damaged,
or adequate tension does not exist, have Repairs/Service Parts
necessary servicing performed by a Kohler We recommend that you use a Kohler
authorized dealer. authorized dealer for all maintenance,
service, and replacement parts for engine.
Drain Cooling System To find a Kohler authorized dealer visit
KohlerEngines.com or call 1-800-544-2444
1. Ensure engine is cool. When radiator is cool (U.S. and Canada).
to touch, slowly loosen radiator cap to first
stop and allow any pressure to bleed off.
Then loosen it fully and remove it.

66 590 05 Rev. -- KohlerEngines.com 7

 Storage
If engine will be out of service for 2 months or more follow procedure below.
1. Coolant (anti-freeze) mixture should be in good condition and tested to guard against freezing in
cold temperatures. Recommended 50/50 mixture will normally provide protection down to
temperatures of -34F (-37C). If storage temperatures will fall below this, cooling system should
be drained completely. A note should then be attached to equipment and/or engine as a reminder
to refill cooling system before starting.
2. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get
stabilized fuel into fuel system (failures due to untreated fuel are not warrantable).
3. Change oil while engine is still warm from operation. Remove spark plug(s) and pour about 1 oz.
of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil.
4. Disconnect negative (-) battery cable.
5. Store engine in a clean, dry place.

Troubleshooting
Do not attempt to service or replace major engine components, or any items that require special
timing or adjustment procedures. This work should be performed by a Kohler authorized dealer.
Possible Cause
Dirt In Dirty Faulty
Problem No Improper Fuel Debris Incorrect Engine Dirty Air Spark
Fuel Fuel Line Screen Oil Level Overloaded Cleaner Plug
Will Not Start
Hard Starting
Stops Suddenly
Lacks Power
Operates Erratically
Knocks or Pings
Skips or Misfires
Backfires
Overheats
High Fuel
Consumption

Engine Specifications

Oil Capacity Spark Plug Maximum Angle

Model Bore Stroke Displacement of Operation
(Refill) Gap (@ full oil level)*

3.03 in. 38.1 cu. in.

LH640 (77 mm) 2.6 in. (624 cc) 1.7-1.9 U.S. qt. 0.03 in. 20
3.15 in. (67 mm) 41.1 cu. in. (1.6-1.8 L) (0.76 mm)
LH685/LH690 (80 mm) (674 cc)
*Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.
Additional specification information can be found in service manual at KohlerEngines.com.
Exhaust Emission Control System for models LH640, LH685, and LH690 is EM for U.S. EPA,
California, and Europe.
Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940
& J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com

2011 by Kohler Co. All rights reserved.

KohlerEngines.com 66 590 05 Rev. --