Kohler Courage SH265 User manual

1
18 690 01 Rev. A KohlerEngines.com
SH265
Service Manual
2 Safety
3 Maintenance
5 Specications
12 Tools and Aids
15 Troubleshooting
19 Air Cleaner/Intake
20 Fuel System
24 Governor System
25 Lubrication System
26 Electrical System
30 Starter System
34 Disassembly/Inspection and Service
43 Reassembly
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.

2
Safety
KohlerEngines.com 18 690 01 Rev. A
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
Explosive Fuel can cause
res and severe burns.
Do not ll fuel tank while
engine is hot or running.
Gasoline is extremely ammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or ames.
Spilled fuel could ignite if it comes
in contact with hot parts or sparks
from ignition. Never use gasoline
as a cleaning agent.
WARNING
Rotating Parts can cause
severe injury.
Stay away while engine
is in operation.
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never
operate engine with covers,
shrouds, or guards removed.
WARNING
Carbon Monoxide can
cause severe nausea,
fainting or death.
Avoid inhaling exhaust
fumes.
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.
WARNING
Accidental Starts can
cause severe injury or
death.
Disconnect and ground
spark plug lead(s) before
servicing.
Before working on engine or
equipment, disable engine as
follows: 1) Disconnect spark plug
lead(s). 2) Disconnect negative (–)
battery cable from battery.
WARNING
Hot Parts can cause
severe burns.
Do not touch engine
while operating or just
after stopping.
Never operate engine with heat
shields or guards removed.
WARNING
Cleaning Solvents can
cause severe injury or
death.
Use only in well
ventilated areas away
from ignition sources.
Carburetor cleaners and solvents
are extremely ammable. Follow
cleaner manufacturer’s warnings
and instructions on its proper and
safe use. Never use gasoline as a
cleaning agent.
CAUTION
Electrical Shock can
cause injury.
Do not touch wires while
engine is running.
CAUTION
Damaging Crankshaft
and Flywheel can cause
personal injury.
Using improper procedures can
lead to broken fragments. Broken
fragments could be thrown from
engine. Always observe and use
precautions and procedures when
installing ywheel.
WARNING
Uncoiling Spring can
cause severe injury.
Wear safety goggles or
face protection when
servicing retractable
starter.
Retractable starters contain a
powerful, recoil spring that is
under tension. Always wear safety
goggles when servicing retractable
starters and carefully follow
instructions in Retractable Starter
for relieving spring tension.

3
Maintenance
18 690 01 Rev. A KohlerEngines.com
MAINTENANCE INSTRUCTIONS
WARNING
Before working on engine or equipment, disable engine as
follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Accidental Starts can cause severe injury or
death.
Disconnect and ground spark 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.
MAINTENANCE SCHEDULE
After rst 5 Hours
● Change oil. Lubrication System
Every 50 Hours or Annually
● Service/replace dual-element precleaner. Air Cleaner/Intake
Every 100 Hours or Annually¹
● Clean low-prole air cleaner element. Air Cleaner/Intake
● Replace dual-element air cleaner element. Air Cleaner/Intake
● Change oil. Lubrication System
● Clean cooling areas. Air Cleaner/Intake
● Clean spark arrestor (if equipped).
● Replace spark plug and set gap. Electrical System
● Replace fuel lter (if equipped).
Every 100 Hours2
● Check and adjust valve clearance when engine is cold. Reassembly
● Have combustion chamber decarbonized.
Every 200 Hours²
● Replace fuel line. Fuel System
Every 300 Hours
● Replace low-prole air cleaner element. Air Cleaner/Intake
1 Perform these procedures more frequently under severe, dusty, dirty conditions.
2 Have a Kohler authorized dealer perform this service.
REPAIRS/SERVICE PARTS
Kohler genuine service parts can be purchased from Kohler authorized dealers. To nd a local Kohler authorized
dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

4
Maintenance
KohlerEngines.com 18 690 01 Rev. A
OIL RECOMMENDATIONS
We recommend use of Kohler oils for best performance.
Other high-quality detergent oils (including synthetic)
of API (American Petroleum Institute) service class SJ
or higher are acceptable. Select viscosity based on
air temperature at time of operation as shown in table
below.
FUEL RECOMMENDATIONS
WARNING
Explosive Fuel can cause res and severe
burns.
Do not ll fuel tank while engine is hot or
running.
Gasoline is extremely ammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or ames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
NOTE: E15, E20 and E85 are NOT approved and
should NOT be used; effects of old, stale or
contaminated fuel are not warrantable.
Fuel must meet these requirements:
● Clean, fresh, unleaded gasoline.
● Octane rating of 87 (R+M)/2 or higher.
● Research Octane Number (RON) 90 octane 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 overll fuel tank.
● Do not use gasoline older than 30 days.
STORAGE
If engine will be out of service for 2 months or more
follow procedure below.
1. 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).
2. 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.
3. Disconnect negative (-) battery cable.
4. Store engine in a clean, dry place.

5
Specications
18 690 01 Rev. A KohlerEngines.com
369.40
[14.543]
113.44
[4.466]
273.97
[10.786]
88.00
[3.465]
339.90
[13.382]
106.00
[4.173]
30.00
[1.181]
METRIC FLANGE: 4X M8 X 1.25-6H THRU
SAE A FLANGE: 4X 5/16-24 UNF-2B THRU
METRIC FLANGE: 4X M8 X 1.25-6H 15.00 [0.591]
SAE A FLANGE: 4X 5/16-24 UNF-2B 15.00 [0.591]
162.00
[6.378]
342.20
[13.473]
65.05
[2.561]
32.53
[1.281]
66.00 [2.598]
32.53 [1.281]
65.05 [2.561]
318.66
[12.545]
STRAIGHT PTO
181.60
[7.150]
SPARK
PLUG
OIL FILL
DRAIN PLUG
37.98 [1.495]
37.50 [1.476]
78.00
[3.071]
2X Ø 10.00 [0.394]
2X 10.00 X 15.50
SLOT [0.394 X 0.610]
110.00 [4.331]
AIR CLEANER
COVER
REMOVAL
12.50
[0.492]
GAS CAP
REMOVAL
Engine Dimensions
Dimensions in millimeters.
Inch equivalents shown in [ ].

6
Specications
KohlerEngines.com 18 690 01 Rev. A
ENGINE IDENTIFICATION NUMBERS
Kohler engine identication numbers (model, specication and serial) should be referenced for efcient repair,
ordering correct parts, and engine replacement.
Model .....................SH265
Courage Engine
Horizontal Shaft
Numerical Designation
Specication . . . . . . . . . . . . . . . SH265-0001
Serial .....................3923500328
Year Manufactured Code Factory Code
Code Year
39 2009
40 2010
41 2011
GENERAL SPECIFICATIONS3,6 SH265
Bore 68 mm (2.7 in.)
Stroke 54 mm (2.1 in.)
Displacement 196 cc (12.0 cu. in.)
Oil Capacity (rell) 0.6 L (0.63 U.S. qt.)
Maximum Angle of Operation (@ full oil level)425°
TORQUE SPECIFICATIONS3,5 SH265
Air Cleaner
Mounting Screw (into intake manifold) 8 N·m (70.8 in. lb.)
Blower Housing and Sheet Metal
M6 Shoulder Screw 10 N·m (88.5 in. lb.)
M6 Nut 8 N·m (70.8 in. lb.)
Carburetor
Stud 10 N·m (88.5 in. lb.)
Primary Nut 8 N·m (70.8 in. lb.)
Secondary Nut 10 N·m (88.5 in. lb.)
Intake Cover Nut 4 N·m (35.4 in. lb.)
Connecting Rod
Cap Fastener (torque in increments) 12 N·m (106 in. lb.)
Crankcase
Oil Drain Plug 18 N·m (13 ft. lb.)
Closure Plate Screw 24 N·m (212 in. lb.)
Cylinder Head
Fastener (torque in 2 increments) rst to 12 N·m (106 in. lb.)
nally to 24 N·m (212 in. lb.)
3 Values are in Metric units. Values in parentheses are English equivalents.
4 Exceeding maximum angle of operation may cause engine damage from insufcient lubrication.
5 Lubricate threads with engine oil prior to assembly.
6 Any and all horsepower (hp) references by Kohler are Certied Power Ratings and per SAE J1940 & J1995 hp
standards. Details on Certied Power Ratings can be found at KohlerEngines.com.

7
Specications
18 690 01 Rev. A KohlerEngines.com
TORQUE SPECIFICATIONS3,5 SH265
Flywheel
Retaining Nut 74 N·m (655 in. lb.)
Fuel Tank
Mounting Nut 24 N·m (212 in. lb.)
Mounting Screw 24 N·m (212 in. lb.)
Inlet Fitting 1.5 N·m (13.3 in. lb.)
Governor
Arm Nut 10 N·m (88.5 in. lb.)
Throttle Control Lever Nut 4.5-6 N·m (40-53 in. lb.)
Ignition
Spark Plug 27 N·m (20 ft. lb.)
Module Fastener 8 N·m (70.8 in. lb.)
Module Screw 10 N·m (88.5 in. lb.)
Oil Sentry™ Module Screw 8 N·m (70.8 in. lb.)
Mufer
M8 Exhaust Screw 24 N·m (212 in. lb.)
M6 Mufer Shield Screw 8 N·m (70.8 in. lb.)
M4 Mufer Shield Screw 2 N·m (17.7 in. lb.)
M5 Spark Arrestor Screw 3.5 N·m (31 in. lb.)
Retractable Starter
Cover Screw 5.4 N·m (47.8 in. lb.)
Screw 10 N·m (88.5 in. lb.)
Rocker Arm
Stud 13.6 N·m (120 in. lb.)
Pivot Jam Nut 10 N·m (88.5 in. lb.)
Valve Cover
Fastener 8 N·m (70.8 in. lb.)
3 Values are in Metric units. Values in parentheses are English equivalents.
5 Lubricate threads with engine oil prior to assembly.

8
Specications
KohlerEngines.com 18 690 01 Rev. A
CLEARANCE SPECIFICATIONS3SH265
Camshaft
End Play 0.025/0.602 mm (0.0010/0.0237 in.)
Running Clearance 0.016/0.052 mm (0.0006/0.0020 in.)
Bore I.D.
New
Max. Wear Limit
14.000/14.018 mm (0.5512/0.5519 in.)
14.048 mm (0.5531 in.)
Connecting Rod
Crankpin End I.D. @ 21°C (70°F)
New
Max. Wear Limit
30.021/30.026 mm (1.1819/1.1821 in.)
30.08 mm (1.184 in.)
Connecting Rod-to-Crankpin Running Clearance
New
Max. Wear Limit
0.041/0.051 mm (0.002/0.002 in.)
0.12 mm (0.005 in.)
Connecting Rod-to-Crankpin Side Clearance
New
Max. Wear Limit
0.58/0.60 mm (0.023/0.024 in.)
1.10 mm (0.043 in.)
Connecting Rod-to-Piston Pin Running Clearance 0.01/0.027 mm (0.0004/0.0011 in.)
Piston Pin End I.D. @ 21°C (70°F)
New
Max. Wear Limit
18.010/18.015 mm (0.709/0.709 in.)
18.08 mm (0.712 in.)
Crankcase
Governor Cross Shaft Bore I.D.
New
Max. Wear Limit
6.000/6.018 mm (0.2362/0.2369 in.)
6.037 mm (0.2377 in.)
Crankshaft
End Play (free) 0.025/0.703 mm (0.0010/0.028 in.)
Ball Bearing 0.003/0.25 mm (0.0001/0.0010 in.)
Bore (in crankcase)
New, without Main Bearing 51.961/51.991 mm (2.0457/2.0469 in.)
Bore (in closure plate)
New, without Main Bearing 51.961/51.991 mm (2.0457/2.0469 in.)
Flywheel End Main Bearing Journal O.D.
O.D.-New
O.D.-Max. Wear Limit
Max. Taper
Max. Out-of-Round
24.975/24.989 mm (0.9833/0.9838 in.)
24.95 mm (0.9823 in.)
0.025 mm (0.0010 in.)
0.025 mm (0.0010 in.)
Closure Plate End Main Bearing Journal O.D.
O.D.-New
O.D.-Max. Wear Limit
Max. Taper
Max. Out-of-Round
24.975/24.989 mm (0.9833/0.9838 in.)
24.95 mm (0.9823 in.)
0.025 mm (0.0010 in.)
0.025 mm (0.0010 in.)
Connecting Rod Journal O.D.
O.D.-New
O.D.-Max. Wear Limit
Max. Taper
Max. Out-of-Round
Width
29.975/29.985 mm (1.1801/1.1805 in.)
29.920 mm (1.1779 in.)
0.025 mm (0.0010 in.)
0.025 mm (0.0010 in.)
25.02/25.08 mm (0.9850/0.9874 in.)
Runout (either end) 0.025 mm (0.0010 in.)
Main Bearing I.D. (Crankcase/Closure Plate)
New (installed) 24.994/25.000 mm (0.9840/0.9842 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.
5 Lubricate threads with engine oil prior to assembly.

9
Specications
18 690 01 Rev. A KohlerEngines.com
CLEARANCE SPECIFICATIONS3SH265
Cylinder Bore
Bore I.D.
New
Max. Wear Limit
Max. Out-of-Round
Max. Taper
70.027/70.035 mm (2.757/2.757 in.)
70.200 mm (2.764 in.)
12.7 microns (0.0005 in.)
12.7 microns (0.0005 in.)
Cylinder Head
Max. Out-of-Flatness 0.1 mm (0.0039 in.)
Governor
Governor Cross Shaft-to-Crankcase Running Clearance 0.013/0.075 mm (0.0005/0.0029 in.)
Governor Cross Shaft O.D.
New
Max. Wear Limit
5.95/5.98 mm (0.2342/0.2354 in.)
5.85 mm (0.2303 in.)
Governor Gear Shaft-to-Governor Gear Running Clearance 0.09/0.19 mm (0.0035/0.0074 in.)
Governor Gear Shaft O.D.
New
Max. Wear Limit
6.028/6.043 mm (0.2373/0.2379 in.)
6.018 mm (0.2369 in.)
Ignition
Spark Plug Gap 0.76 mm (0.030 in.)
Module Air Gap 0.254 mm (0.0100 in.)
Piston, Piston Rings, and Piston Pin
Piston-to-Piston Pin Running Clearance 0.009/0.016 mm (0.0003/0.0006 in.)
Piston Pin Bore I.D.
New
Max. Wear Limit
18.004/18.005 mm (0.7088/0.7089 in.)
18.05 mm (0.7106 in.)
Piston Pin O.D.
New
Max. Wear Limit
17.992/17.995 mm (0.7083/0.7084 in.)
17.95 mm (0.7067 in.)
Top and Center Compression Ring Side Clearance
New Bore
Used Bore (max.)
0.04 mm (0.002 in.)
0.15 mm (0.006 in.)
Top and Center Compression Ring End Gap
New Bore
Used Bore (max.)
0.325 mm/0.4 (0.013/0.016 in.)
1.00 mm (0.039 in.)
Top and Center Compression Ring Width
New Bore
Used Bore (max.)
1.5/1.51 mm (0.059/0.059 in.)
1.37 mm (0.054 in.)
Oil Control Ring-to-Groove Side Clearance 0.06/0.18 mm (0.0023/0.0071 in.)
Piston Thrust Face O.D.7
New
Max. Wear Limit
67.975/67.985 mm (2.6762/2.6766 in.)
67.85 mm (2.6712 in.)
Piston Thrust Face-to-Cylinder Bore Running Clearance
New 0.057/0.075 mm (0.0022/0.0029 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.
7 Measure 15 mm (0.5905 in.) above bottom of piston skirt at right angles to piston pin.

10
Specications
KohlerEngines.com 18 690 01 Rev. A
CLEARANCE SPECIFICATIONS3SH265
Valves and Valve Lifters
Intake Valve Stem-to-Valve Guide Running Clearance 0.020/0.044 mm (0.008/0.0017 in.)
Exhaust Valve Stem-to-Valve Guide Running Clearance 0.030/0.054 mm (0.0011/0.0021 in.)
Intake Valve Stem O.D.
New
Max. Wear Limit
5.480 mm (0.2157 in.)
5.32 mm (0.2094 in.)
Exhaust Valve Stem O.D.
New
Max. Wear Limit
5.47 mm (0.2153 in.)
5.305 mm (0.2088 in.)
Intake Valve Stem to Guide
New
Max. Wear Limit
0.024/0.039 mm (0.001/0.002 in.)
0.10 mm (0.0004 in.)
Exhaust Valve Stem to Guide
New
Max. Wear Limit
0.098/0.112 mm (0.0038/0.0044 in.)
0.12 mm (0.0005 in.)
Valve Guide Reamer Size
Standard Intake
Standard Exhaust
5.506 mm (0.2168 in.)
5.506 mm (0.2168 in.)
Valve Seat Width 0.800/2.00 mm (0.0315/0.787 in.)
Nominal Valve Face Angle 30°, 45°, 60°
3 Values are in Metric units. Values in parentheses are English equivalents.

11
Specications
18 690 01 Rev. A KohlerEngines.com
GENERAL TORQUE VALUES
Metric Fastener Torque Recommendations for Standard Applications
Property Class Noncritical
Fasteners
Into Aluminum
Size 4.8 5.8 8.8 10.9 12.9
Tightening Torque: N·m (in. lb.) ± 10%
M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)
Tightening Torque: N·m (ft. lb.) ± 10%
M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
Torque Conversions
N·m = in. lb. x 0.113 in. lb. = N·m x 8.85
N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737
English Fastener Torque Recommendations for Standard Applications
Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners
Into Aluminum
Size Grade 2 Grade 5 Grade 8
Tightening Torque: N·m (in. lb.) ± 20%
8-32 2.3 (20) 2.8 (25) — 2.3 (20)
10-24 3.6 (32) 4.5 (40) — 3.6 (32)
10-32 3.6 (32) 4.5 (40) — —
1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)
1/4-28 9.6 (85) 15.8 (140) 22.6 (200) —
5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)
5/16-24 18.7 (165) 30.5 (270) — —
3/8-16 29.4 (260) — — —
3/8-24 33.9 (300) — — —
Tightening Torque: N·m (ft. lb.) ± 20%
5/16-24 — — 40.7 (30) —
3/8-16 — 47.5 (35) 67.8 (50) —
3/8-24 — 54.2 (40) 81.4 (60) —
7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —
7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —
1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —
1/2-20 94.9 (70) 142.4 (105) 223.7 (165) —
9/16-12 101.7 (75) 169.5 (125) 237.3 (175) —
9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —
5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —
3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Tools and Aids
12 18 690 01 Rev. AKohlerEngines.com
Certain quality tools are designed to help you perform specic disassembly, repair, and reassembly procedures. By
using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service
capabilities and customer satisfaction by decreasing engine downtime.
Here is a list of tools and their source.
SEPARATE TOOL SUPPLIERS
Kohler Tools
Contact your local Kohler source of
supply.
SE Tools
415 Howard St.
Lapeer, MI 48446
Phone [phone]
Toll Free 800-664-2981
Fax [phone]
Design Technology Inc.
768 Burr Oak Drive
Westmont, IL 60559
Phone [phone]
Fax [phone]
TOOLS
Description Source/Part No.
Alcohol Content Tester
For testing alcohol content (%) in reformulated/oxygenated fuels.
Kohler 25 455 11-S
Camshaft Endplay Plate
For checking camshaft endplay.
SE Tools KLR-82405
Camshaft Seal Protector (Aegis)
For protecting seal during camshaft installation.
SE Tools KLR-82417
Cylinder Leakdown Tester
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Individual component available:
Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)
Kohler 25 761 05-S
Design Technology Inc.
DTI-731-03
Dealer Tool Kit (Domestic)
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester
Cylinder Leakdown Tester
Oil Pressure Test Kit
Rectier-Regulator Tester (120 V AC/60Hz)
Kohler 25 761 39-S
Kohler 25 455 01-S
Kohler 25 761 05-S
Kohler 25 761 06-S
Kohler 25 761 20-S
Dealer Tool Kit (International)
Complete kit of Kohler required tools.
Components of 25 761 42-S
Ignition System Tester
Cylinder Leakdown Tester
Oil Pressure Test Kit
Rectier-Regulator Tester (240 V AC/50Hz)
Kohler 25 761 42-S
Kohler 25 455 01-S
Kohler 25 761 05-S
Kohler 25 761 06-S
Kohler 25 761 41-S
Digital Vacuum/Pressure Tester
For checking crankcase vacuum.
Individual component available:
Rubber Adapter Plug
Design Technology Inc.
DTI-721-01
Design Technology Inc.
DTI-721-10
Electronic Fuel Injection (EFI) Diagnostic Software
For Laptop or Desktop PC.
Kohler 25 761 23-S
EFI Service Kit
For troubleshooting and setting up an EFI engine.
Components of 24 761 01-S
Fuel Pressure Tester
Noid Light
90° Adapter
In-line "T" Fitting
Code Plug, Red Wire
Code Plug, Blue Wire
Shrader Valve Adapter Hose
Kohler 24 761 01-S
Design Technology Inc.
DTI-019
DTI-021
DTI-023
DTI-035
DTI-027
DTI-029
DTI-037
Flywheel Holding Tool (CS)
For holding ywheel of CS series engines.
SE Tools KLR-82407
Flywheel Puller
For properly removing ywheel from engine.
SE Tools KLR-82408
Flywheel Strap Wrench
For holding ywheel during removal.
SE Tools KLR-82409

Tools and Aids
1318 690 01 Rev. A KohlerEngines.com
TOOLS
Description Source/Part No.
Hydraulic Valve Lifter Tool
For removing and installing hydraulic lifters.
Kohler 25 761 38-S
Ignition System Tester
For testing output on all systems, including CD.
Kohler 25 455 01-S
Inductive Tachometer (Digital)
For checking operating speed (RPM) of an engine.
Design Technology Inc.
DTI-110
Offset Wrench (K and M Series)
For removing and reinstalling cylinder barrel retaining nuts.
Kohler 52 455 04-S
Oil Pressure Test Kit
For testing/verifying oil pressure on pressure lubricated engines.
Kohler 25 761 06-S
Radiator Tester
For pressure testing radiator and cap on Aegis liquid-cooled engines.
Kohler 25 455 10-S
Rectier-Regulator Tester (120 volt current)
Rectier-Regulator Tester (240 volt current)
For testing rectier-regulators.
Components of 25 761 20-S and 25 761 41-S
CS-PRO Regulator Test Harness
Special Regulator Test Harness with Diode
Kohler 25 761 20-S
Kohler 25 761 41-S
Design Technology Inc.
DTI-031
DTI-033
Spark Advance Module (SAM) Tester
For testing SAM (ASAM and DSAM) on engines with SMART-SPARK™.
Kohler 25 761 40-S
Starter Servicing Kit (All Starters)
For removing and reinstalling drive retaining rings and brushes.
Individual component available:
Starter Brush Holding Tool (Solenoid Shift)
SE Tools KLR-82411
SE Tools KLR-82416
Triad/OHC Timing Tool Set
For holding cam gears and crankshaft in timed position while installing timing belt.
Kohler 28 761 01-S
Valve Guide Reamer (K and M Series)
For properly sizing valve guides after installation.
Design Technology Inc.
DTI-K828
Valve Guide Reamer O.S. (Command Series)
For reaming worn valve guides to accept replacement oversize valves. Can be used
in low-speed drill press or with handle below for hand reaming.
Kohler 25 455 12-S
Reamer Handle
For hand reaming using Kohler 25 455 12-S reamer.
Design Technology Inc.
DTI-K830
Valve Guide Service Kit (Courage, Aegis, Command, OHC)
For servicing worn valve guides.
SE Tools KLR-82415
AIDS
Description Source/Part No.
Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S
Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S
Dielectric Grease Loctite® 51360
Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S
Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S
RTV Silicone Sealant
Loctite® 5900® Heavy Body in 4 oz. aerosol dispenser.
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved
for use. Loctite® Nos. 5900® or 5910® are recommended for best sealing
characteristics.
Kohler 25 597 07-S
Loctite® 5910®
Loctite® Ultra Black 598™
Loctite® Ultra Blue 587™
Loctite® Ultra Copper 5920™
Spline Drive Lubricant Kohler 25 357 12-S

Tools and Aids
14 18 690 01 Rev. AKohlerEngines.com
FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL
A ywheel holding tool can be made out of an old junk
ywheel ring gear and used in place of a strap wrench.
1. Using an abrasive cut-off wheel, cut out a six tooth
segment of ring gear as shown.
2. Grind off any burrs or sharp edges.
3. Invert segment and place it between ignition bosses
on crankcase so tool teeth engage ywheel ring
gear teeth. Bosses will lock tool and ywheel in
position for loosening, tightening, or removing with a
puller.
A spanner wrench to lift rocker arms or turn crankshaft
may be made out of an old junk connecting rod.
1. Find a used connecting rod from a 10 HP or larger
engine. Remove and discard rod cap.
2. Remove studs of a Posi-Lock rod or grind off
aligning steps of a Command rod, so joint surface is
at.
3. Find a 1 in. long capscrew with correct thread size to
match threads in connecting rod.
4. Use a at washer with correct I.D. to slip on
capscrew and approximately 1 in. O.D. Assemble
capscrew and washer to joint surface of rod.

1518 690 01 Rev. A KohlerEngines.com
Troubleshooting
Engine Cranks But Will Not Start
● Battery connected backwards.
● Blown fuse.
● Carburetor solenoid malfunction.
● Choke not closing.
● Clogged fuel line or fuel lter.
● Diode in wiring harness failed in open circuit mode.
● DSAI or DSAM malfunction.
● Empty fuel tank.
● Faulty electronic control unit.
● Faulty ignition coil(s).
● Faulty spark plug(s).
● Fuel pump malfunction-vacuum hose clogged or
leaking.
● Fuel shut-off valve closed.
● Ignition module(s) faulty or improperly gapped.
● Insufcient voltage to electronic control unit.
● Interlock switch is engaged or faulty.
● Key switch or kill switch in OFF position.
● Low oil level.
● Quality of fuel (dirt, water, stale, mixture).
● SMART-SPARKTM malfunction.
● Spark plug lead(s) disconnected.
Engine Starts But Does Not Keep Running
● Faulty carburetor.
● Faulty cylinder head gasket.
● Faulty or misadjusted choke or throttle controls.
● Fuel pump malfunction-vacuum hose clogged or
leaking.
● Intake system leak.
● Loose wires or connections that intermittently ground
ignition kill circuit.
● Quality of fuel (dirt, water, stale, mixture).
● Restricted fuel tank cap vent.
Engine Starts Hard
● Clogged fuel line or fuel lter.
● Engine overheated.
● Faulty ACR mechanism.
● Faulty or misadjusted choke or throttle controls.
● Faulty spark plug(s).
● Flywheel key sheared.
● Fuel pump malfunction-vacuum hose clogged or
leaking.
● Interlock switch is engaged or faulty.
● Loose wires or connections that intermittently ground
ignition kill circuit.
● Low compression.
● Quality of fuel (dirt, water, stale, mixture).
● Weak spark.
TROUBLESHOOTING GUIDE
When troubles occur, be sure to check simple causes which, at rst, may seem too obvious to be considered. For
example, a starting problem could be caused by an empty fuel tank.
Some general common causes of engine troubles are listed below and vary by engine specication. Use these to
locate causing factors.
Engine Will Not Crank
● Battery is discharged.
● Faulty electric starter or solenoid.
● Faulty key switch or ignition switch.
● Interlock switch is engaged or faulty.
● Loose wires or connections that intermittently ground
ignition kill circuit.
● Pawls not engaging in drive cup.
● Seized internal engine components.
Engine Runs But Misses
● Carburetor adjusted incorrectly.
● Engine overheated.
● Faulty spark plug(s).
● Ignition module(s) faulty or improperly gapped.
● Incorrect crankshaft position sensor air gap.
● Interlock switch is engaged or faulty.
● Loose wires or connections that intermittently ground
ignition kill circuit.
● Quality of fuel (dirt, water, stale, mixture).
● Spark plug lead(s) disconnected.
● Spark plug lead boot loose on plug.
● Spark plug lead loose.
Engine Will Not Idle
● Engine overheated.
● Faulty spark plug(s).
● Idle fuel adjusting needle(s) improperly set.
● Idle speed adjusting screw improperly set.
● Inadequate fuel supply.
● Low compression.
● Quality of fuel (dirt, water, stale, mixture).
● Restricted fuel tank cap vent.
Engine Overheats
● Cooling fan broken.
● Excessive engine load.
● Fan belt failed/off.
● Faulty carburetor.
● High crankcase oil level.
● Lean fuel mixture.
● Low cooling system uid level.
● Low crankcase oil level.
● Radiator, and/or cooling system components clogged,
restricted, or leaking.
● Water pump belt failed/broken.
● Water pump malfunction.
Engine Knocks
● Excessive engine load.
● Hydraulic lifter malfunction.
● Incorrect oil viscosity/type.
● Internal wear or damage.
● Low crankcase oil level.
● Quality of fuel (dirt, water, stale, mixture).

Troubleshooting
16 18 690 01 Rev. AKohlerEngines.com
Engine Loses Power
● Dirty air cleaner element.
● Engine overheated.
● Excessive engine load.
● Restricted exhaust.
● Faulty spark plug(s).
● High crankcase oil level.
● Incorrect governor setting.
● Low battery.
● Low compression.
● Low crankcase oil level.
● Quality of fuel (dirt, water, stale, mixture).
Engine Uses Excessive Amount of Oil
● Loose or improperly torqued fasteners.
● Blown head gasket/overheated.
● Breather reed broken.
● Clogged, broken, or inoperative crankcase breather.
● Crankcase overlled.
● Incorrect oil viscosity/type.
● Worn cylinder bore.
● Worn or broken piston rings.
● Worn valve stems/valve guides.
Oil Leaks from Oil Seals, Gaskets
● Breather reed broken.
● Clogged, broken, or inoperative crankcase breather.
● Loose or improperly torqued fasteners.
● Piston blow by, or leaky valves.
● Restricted exhaust.
EXTERNAL ENGINE INSPECTION
NOTE: It is good practice to drain oil at a location away
from workbench. Be sure to allow ample time for
complete drainage.
Before cleaning or disassembling engine, make a
thorough inspection of its external appearance and
condition. This inspection can give clues to what
might be found inside engines (and cause) when it is
disassembled.
● Check for buildup of dirt and debris on crankcase,
cooling ns, grass screen, and other external surfaces.
Dirt or debris on these areas can cause overheating.
● Check for obvious fuel and oil leaks, and damaged
components. Excessive oil leakage can indicate a
clogged or inoperative breather, worn or damaged
seals or gaskets, or loose fasteners.
● Check air cleaner cover and base for damage or
indications of improper t and seal.
● Check air cleaner element. Look for holes, tears,
cracked or damaged sealing surfaces, or other
damage that could allow unltered air into engine. A
dirty or clogged element could indicate insufcient or
improper maintenance.
● Check carburetor throat for dirt. Dirt in throat is further
indication that air cleaner was not functioning properly.
● Check if oil level is within operating range on dipstick.
If it is above, sniff for gasoline odor.
● Check condition of oil. Drain oil into a container; it
should ow freely. Check for metal chips and other
foreign particles.
Sludge is a natural by-product of combustion; a small
accumulation is normal. Excessive sludge formation
could indicate over rich fuel settings, weak ignition,
overextended oil change interval or wrong weight or
type of oil was used.
CLEANING ENGINE
WARNING
Cleaning Solvents can cause severe injury or
death.
Use only in well ventilated areas away from
ignition sources.
Carburetor cleaners and solvents are extremely
ammable. Follow cleaner manufacturer’s warnings
and instructions on its proper and safe use. Never use
gasoline as a cleaning agent.
After inspecting external condition of engine, clean
engine thoroughly before disassembly. Clean individual
components as engine is disassembled. Only clean
parts can be accurately inspected and gauged for wear
or damage. There are many commercially available
cleaners that will quickly remove grease, oil, and grime
from engine parts. When such a cleaner is used, follow
manufacturer’s instructions and safety precautions
carefully.
Make sure all traces of cleaner are removed before
engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down
lubricating properties of engine oil.

1718 690 01 Rev. A KohlerEngines.com
Troubleshooting
Condition Conclusion
Crankcase breather clogged or inoperative. NOTE: If breather is integral part of valve cover and
cannot be serviced separately, replace valve
cover and recheck pressure.
Disassemble breather, clean parts thoroughly, check
sealing surfaces for atness, reassemble, and recheck
pressure.
Seals and/or gaskets leaking. Loose or improperly torque
fasteners.
Replace all worn or damaged seals and gaskets. Make
sure all fasteners are tightened securely. Use appropriate
torque valves and sequences when necessary.
Piston blow by or leaky valves (conrm by inspecting
components).
Recondition piston, rings, cylinder bore, valves and
valves guides.
Restricted exhaust. Check exhaust screen/spark arrestor (if equipped). Clean
or replace as needed. Repair or replace any other
damaged/restricted mufer or exhaust system parts.
CRANKCASE VACUUM TEST
WARNING
Carbon Monoxide can cause severe nausea,
fainting or death.
Avoid inhaling exhaust fumes.
Engine exhaust gases contain poisonous carbon
monoxide. Carbon monoxide is odorless, colorless,
and can cause death if inhaled.
To test crankcase vacuum with manometer:
1. Insert rubber stopper into oil ll hole. Be sure pinch
clamp is installed on hose and use tapered adapters
to connect hose between stopper and one
manometer tube. Leave other tube open to
atmosphere. Check that water level in manometer is
at 0 line. Make sure pinch clamp is closed.
2. Start engine and run no-load high speed.
3. Open clamp and note water level in tube.
Level in engine side should be a minimum of 10.2
cm (4 in.) above level in open side.
If level in engine side is less than specied (low/no
vacuum), or level in engine side is lower than level in
open side (pressure), check for conditions in table
below.
4. Close pinch clamp before stopping engine.
To test crankcase vacuum with vacuum/pressure gauge:
1. Remove dipstick or oil ll plug/cap.
2. Install adapter into oil ll//dipstick tube opening,
upside down over end of a small diameter dipstick
tube, or directly into engine if a tube is not used.
Insert barbed gauge tting into hole in stopper.
3. Run engine and observe gauge reading.
Analog tester–needle movement to left of 0 is a
vacuum, and movement to right indicates a pressure.
Digital tester–depress test button on top of tester.
Crankcase vacuum should be a minimum of 10.2 cm
(4 in.) of water. If reading is below specication, or if
pressure is present, check table below for possible
causes and conclusions.
WARNING
Rotating Parts can cause severe injury.
Stay away while engine is in operation.
Keep hands, feet, hair, and clothing away from all
moving parts to prevent injury. Never operate engine
with covers, shrouds, or guards removed.
A partial vacuum should be present in crankcase when engine is operating. Pressure in crankcase (normally caused
by a clogged or improperly assembled breather) can cause oil to be forced out at oil seals, gaskets, or other available
spots.
Crankcase vacuum is best measured with either a water manometer or a vacuum gauge. Complete instructions are
provided in kits.

Troubleshooting
18 18 690 01 Rev. AKohlerEngines.com
COMPRESSION TEST
For Command Twins:
A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s)
before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160
psi and should not vary more than 15% between cylinders.
All other models:
These engines are equipped with an automatic compression release (ACR) mechanism. It is difcult to obtain an
accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described
below.
CYLINDER LEAKDOWN TEST
A cylinder leakdown test can be a valuable alternative to a compression test. By pressurizing combustion chamber
from an external air source you can determine if valves or rings are leaking, and how badly.
Cylinder leakdown tester is a relatively simple, inexpensive leakdown tester for small engines. This tester includes a
quick-connect for attaching adapter hose and a holding tool.
1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air lter from engine.
3. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke. Hold
engine in this position while testing. Holding tool supplied with tester can be used if PTO end of crankshaft is
accessible. Lock holding tool onto crankshaft. Install a 3/8 in. breaker bar into hole/slot of holding tool, so it is
perpendicular to both holding tool and crankshaft PTO.
If ywheel end is more accessible, use a breaker bar and socket on ywheel nut/screw to hold it in position. An
assistant may be needed to hold breaker bar during testing. If engine is mounted in a piece of equipment, it may
be possible to hold it by clamping or wedging a driven component. Just be certain that engine cannot rotate off of
TDC in either direction.
4. Install adapter into spark plug hole, but do not attach it to tester at this time.
5. Turn regulator knob completely counterclockwise.
6. Connect an air source of at least 50 psi to tester.
7. Turn regulator knob clockwise (increase direction) until gauge needle is in yellow set area at low end of scale.
8. Connect tester quick-connect to adapter hose. While rmly holding engine at TDC, gradually open tester valve.
Note gauge reading and listen for escaping air at combustion air intake, exhaust outlet, and crankcase breather.
Condition Conclusion
Air escaping from crankcase breather. Ring or cylinder worn.
Air escaping from exhaust system. Defective exhaust valve/improper seating.
Air escaping from intake. Defective intake valve/improper seating.
Gauge reading in low (green) zone. Piston rings and cylinder in good condition.
Gauge reading in moderate (yellow) zone. Engine is still usable, but there is some wear present.
Customer should start planning for overhaul or
replacement.
Gauge reading in high (red) zone. Rings and/or cylinder have considerable wear. Engine
should be reconditioned or replaced.

19
Air Cleaner/Intake
18 690 01 Rev. A KohlerEngines.com
AIR CLEANER
These systems are CARB/EPA certied and components
should not be altered or modied in any way.
Dual-Element Air Cleaner Components
A
B
D
C
E
A
AWing Nut BAir Cleaner Cover
CPrecleaner DPaper Element
EAir Cleaner Base
Low-Prole Air Cleaner Components
I
H
G
F
FAir Cleaner Base GFoam Element
HAir Cleaner Cover IScrew
NOTE: Operating engine with loose or damaged air
cleaner components could cause premature
wear and failure. Replace all bent or damaged
components.
NOTE: Paper element cannot be blown out with
compressed air.
Dual-Element
Remove wing nut and air cleaner cover.
Precleaner
1. Remove precleaner from paper element.
2. Replace or wash precleaner in warm water with
detergent. Rinse and allow to air dry.
3. Reinstall precleaner over paper element.
Paper Element
1. Remove wing nut (if equipped) and paper element
with precleaner.
2. Separate precleaner from element; service
precleaner and replace element.
3. Reinstall precleaner over paper element; secure with
wing nut (if equipped).
Reinstall air cleaner cover and secure with wing nut.
Low-Prole
1. Remove screw and air cleaner cover.
2. Remove foam element from base.
3. Wash foam element in warm water with detergent.
Rinse and allow to air dry.
4. Lightly oil foam element with new engine oil;
squeeze out excess oil.
5. Reinstall foam element into base.
6. Reinstall cover and secure with screw.
BREATHER TUBE
Make sure both ends of breather tube are properly
connected.
AIR COOLING
WARNING
Hot Parts can cause severe burns.
Do not touch engine while operating or just
after stopping.
Never operate engine with heat shields or guards
removed.
Proper cooling is essential. To prevent over heating,
clean screens, cooling ns, and other external surfaces
of engine. Avoid spraying water at wiring harness or any
electrical components. Refer to Maintenance Schedule.

20
Fuel System
KohlerEngines.com 18 690 01 Rev. A
Typical carbureted fuel system and related components
include:
● Fuel tank.
● Fuel lines.
● In-line fuel lter.
● Fuel tank lter.
● Carburetor.
● Fuel strainer screen in carburetor.
Fuel tank outlet is located above carburetor inlet,
allowing gravity to feed fuel through in-line lter and fuel
line to carburetor.
Fuel then enters carburetor through a fuel shut-off valve
and a ne screen/sediment bowl, and then to carburetor
oat bowl. Fuel is drawn into carburetor body and is
mixed with air. This fuel-air mixture is then burned in
engine combustion chamber.
FUEL RECOMMENDATIONS
Refer to Maintenance.
FUEL LINE
Low permeation fuel line must be installed on carbureted
Kohler Co. engines to maintain EPA and CARB
regulatory compliance.
FUEL FILTER
Fuel Tank Filter
A serviceable fuel tank lter is located under fuel tank
cap, in ller neck.
Daily or as required clean lter of any accumulation as
follows:
1. Remove fuel tank cap and lter.
2. Clean lter with solvent, replace if damaged.
3. Wipe lter and insert it.
4. Tighten fuel tank cap securely.
Fuel Shut-Off
WARNING
Explosive Fuel can cause res and severe
burns.
Do not ll fuel tank while engine is hot or
running.
Gasoline is extremely ammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or ames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
Engines are equipped with a fuel shut-off located at
carburetor. It controls fuel ow from tank to carburetor.
1. Stop engine.
2. Turn fuel shut-off lever to OFF position.
3. Remove fuel shut-off cup.
4. Clean fuel shut-off cup with solvent and wipe dry.
5. Inspect for worn or damaged O-ring; replace as
necessary.
6. Place O-ring on fuel shut-off cup. Install fuel shut-off
cup and O-ring; rotate until nger tight. Turn with a
wrench 1/2 to 3/4 full turn.
7. Turn fuel shut-off lever to ON position and check for
leaks. If fuel shut-off cup leaks, repeat steps 5 and 6.
8. Tighten fuel tank cap securely.
FUEL SYSTEM TESTS
When engine starts hard or turns over but will not start, fuel system might be causing problems. Test fuel system by
performing following test.
1. Check for fuel in combustion chamber.
a. Disconnect and ground spark plug lead.
b. Close choke on carburetor.
c. Crank engine several times.
d. Remove spark plug and check for fuel at tip.
2. Check for fuel ow from tank to carburetor.
a. Remove fuel line from inlet tting of carburetor.
b. Use an approved fuel container to catch fuel, and
hold line below bottom of tank to observe fuel
ow.
3. Check operation of fuel shut-off valve.
a. Remove fuel sediment bowl under inlet tting of
carburetor.
b. Turn fuel shut-off valve ON and OFF and observe
operation.
Condition Conclusion
Fuel at tip of spark plug. Fuel is reaching combustion chamber.
No fuel at tip of spark plug. Check fuel ow from fuel tank (step 2).
Fuel ows from fuel line. Check operation of fuel shut-off valve (step 3).
No fuel ow from fuel line. Check fuel tank vent, in-line lter threaded into tank, and
fuel line. Correct any observed problem and reconnect
line.
Fuel ows from valve. Check for dirt and water in sediment bowl and screen.
Clean bowl and screen as needed. Check for faulty
carburetor, refer to Carburetor.
No fuel ows from valve. Check for a restriction in fuel shut-off valve or inlet elbow.