Kohler Courage XT-6 User manual

SERVICE MANUAL
VERTICAL CRANKSHAFT
COURAGE XT-6, XT-7

Contents
Section 1. Safety and General Information.............................................................................
Section 2. Tools and Aids.........................................................................................................
Section 3. Troubleshooting ......................................................................................................
Section 4. Air Cleaner and Air Intake System.........................................................................
Section 5. Fuel System and Governor.....................................................................................
Section 6. Lubrication System.................................................................................................
Section 7. Electrical System and Components ......................................................................
Section 8. Disassembly.............................................................................................................
Section 9. Inspection and Reconditioning..............................................................................
Section 10. Reassembly............................................................................................................
1
2
3
4
5
6
7
8
9
10

1.1
Section 1
Safety and General Information
1
Section 1
Safety and General Information
Safety Precautions
To ensure safe operation please read the following statements and understand their meaning. Also
refer to your equipment manufacturer's manual for other important safety information. This manual
contains safety precautions which are explained below. Please read carefully.
WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death,
or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or
property damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.
For Your Safety!
These precautions should be followed at all times. Failure to follow these precautions could result in injury to
yourself and others.
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
WARNING
Rotating Parts!
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never operate
the engine with covers, shrouds, or
guards removed.
Hot Parts can cause severe burns.
Do not touch engine while operating
ȱȱĞȱǯ
WARNING
Hot Parts!
Engine components can get extremely
hot from operation. To prevent severe
burns, do not touch these areas while
the engine is running, or immediately
Ğȱȱȱȱěǯȱȱȱ
the engine with heat shields or guards
removed.
Accidental Starts can cause
severe injury or death.
Disconnect and ground spark plug
leads before servicing.
WARNING
Accidental Starts!
Disabling engine. Accidental
starting can cause severe injury or
death. Before working on the engine
or equipment, disable the engine by
disconnecting the spark plug lead.

1.2
Section 1
Safety and General Information
Carbon Monoxide can cause
severe nausea, fainting or death.
Avoid inhaling exhaust fumes, and
never run the engine in a closed
ȱȱęȱǯ
WARNING
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
CAUTION
Lethal Exhaust Gases!
Engine exhaust gases contain
poisonous carbon monoxide. Carbon
monoxide is odorless, colorless, and can
cause death if inhaled. Avoid inhaling
exhaust fumes, and never run the
ȱȱȱȱȱȱęȱ
area.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
([SORVLYH)XHOFDQFDXVH¿UHVDQG
severe burns.
ȱȱęȱȱȱȱȱȱ
engine is hot or running.
WARNING
Explosive Fuel!
ȱȱ¡¢ȱĚȱȱ
its vapors can explode if ignited. Store
gasoline only in approved containers,
in well ventilated, unoccupied
ǰȱ¢ȱȱȱȱĚǯȱ
ȱȱęȱȱȱȱȱȱ
engine is hot or running, since spilled
fuel could ignite if it comes in contact
with hot parts or sparks from ignition.
Do not start the engine near spilled
fuel. Never use gasoline as a cleaning
agent.
Cleaning Solvents can cause
severe injury or death.
Use only in well ventilated areas
away from ignition sources.
WARNING
Flammable Solvents!
Carburetor cleaners and solvents are
¡¢ȱĚǯȱȱǰȱ
Ěǰȱȱȱȱȱȱ
away from the area. Follow the
cleaner manufacturer’s warnings and
instructions on its proper and safe use.
Never use gasoline as a cleaning agent.

1.3
Section 1
Safety and General Information
1
(QJLQH,GHQWL¿FDWLRQ1XPEHUV
When ordering parts, or in any communication
involving an engine, always give the Model,
ęǰȱȱȱ of the engine.
ȱęȱȱȱȱȱȱ
Ĝ¡ȱȱȱȱǯȱȱȱŗȬŗǯȱȱ
¡ȱȱȱȱȱȱȱȱŗȬŘǯ
A. Model No.
Courage Vertical Shaft Engine
Numerical Designation
)LUVWVSHFL¿FDWLRQ
written in this
model series
B. Spec. No.
Engine Model
Model
XT-6
XT-7
C. Serial No.
Year Manufactured Code
Code Year
37 2007
38 2008
Factory Code
3723500328
XT173-0001
XT 7
)LJXUH,GHQWL¿FDWLRQ/DEHO
)LJXUH([SODQDWLRQRI,GHQWL¿FDWLRQ1XPEHUV
,GHQWL¿FDWLRQ/DEHO

1.4
Section 1
Safety and General Information
Oil Recommendations
Using the proper type and weight of oil in the engine
is extremely important, as is daily checking of oil level
ȱȱȱ¢ǯȱȱȱȱȱȱ
oil, or using dirty oil, will cause premature engine
wear and failure.
Oil Type
Use high quality detergent oil of ȱǻȱ
ȱǼȱȱȱȱȱ. Select
the viscosity based on the air temperature at the time
ȱȱȱȱȱȱŗȬřǯ
10W-30
RECOMMENDED SAE VISCOSITY GRADES
10W-30, SAE 30
°F -20 0 20 32 40 60 80 100
°C -30 -20 -10 0 10 20 30 40
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
Figure 1-3. Viscosity Grades Table.
NOTE: Using other than service class SJ or higher oil
or extending oil change intervals longer than
recommended can cause engine damage.
ȱȱȱ¢ȱȱȱȱęȱȱȱ
ȱȱȱȱ¢ȱǯȱȱȱŗȬŚǯȱ
10W-30
A
P
I
S
E
R
V
I
C
E
S
J
Figure 1-4. Oil Container Logo.
Refer to Section 6, Lubrication System, for detailed oil
check and oil change procedures.
Fuel Recommendations
WARNING: Explosive Fuel!
ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ
if ignited. Store gasoline only in approved containers, in
well ventilated, unoccupied buildings, away from sparks or
Ěǯȱȱȱęȱȱȱȱȱȱȱȱȱȱ
running, since spilled fuel could ignite if it comes in contact
with hot parts or sparks from ignition. Do not start the
engine near spilled fuel. Never use gasoline as a cleaning
agent.
General Recommendations
Purchase gasoline in small quantities and store
in clean, approved containers. A container with a
¢ȱȱŘȱȱȱȱȱȱȱȱȱ
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
To ensure easy starting and minimize gum deposits in
ȱȱ¢ǰȱȱȱȱȱĞȱȱȱȱ
previous season. Do not add oil to the gasoline. Do not
ęȱȱȱDzȱȱȱȱ¡ǯ
Fuel Type
ȱȱǰȱȱ¢ȱǰȱǰȱȱ
gasoline with a pump sticker octane rating of 86 or
ǯȱȱȱȱȱȱǰȱȱ
should be 90 octane minimum.
Unleaded gasoline is recommended, as it leaves less
combustion chamber deposits. Leaded gasoline may
be used in areas where unleaded is not available
and exhaust emissions are not regulated. Be aware
however, using unleaded gasoline will require more
frequent cylinder head servicing.
Gasoline/Alcohol Blends
ȱǻȱȱŗŖƖȱ¢ȱǰȱşŖƖȱȱ
gasoline by volume) is approved as a fuel for Kohler
ǯȱȱȦȱȱȱŘŖȱ
and E85 are not to be used and are not approved. Any
failures resulting from use of these fuels will not be
warranted.
Gasoline/Ether Blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
ȱȱǻȱȱ¡ȱȱŗśƖȱȱ¢ȱ
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.

1.5
Section 1
Safety and General Information
1
Periodic Maintenance
WARNING: Accidental Starts!
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment,
disable the engine by disconnecting the spark plug lead.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table. They should
also be included as part of any seasonal tune-up.
Frequency Maintenance Required
¢ȱȱȱȱ

ȱȱǯ
Check oil level.
ȱȱȱȱȱDzȱȱȱ¢ǯŵ
Yearly or Every 25 Hours ȱȱȱȱȱǻȱǼǯŵ
ȱȱȱȱȱ¢ǰȱȱȱȱǯŵ
Yearly or Every 50 Hours ȱȱęǰȱȱǯ
Change oil.
¢ȱȱ¢ȱŗŖŖȱ Replace spark plug and set gap.
ȱȱȱǯŵ
¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
Storage
ȱȱȱȱȱȱȱȱȱȱȱȱ
more, use the following storage procedure:
ȱ ŗǯȱ ȱȱ¡ȱȱȱȱǯ
ȱ Řǯȱ ȱȱȱȱȱȱȱȱȱ
ȱǯȱȱȱǰȱȱ
Section 6, Lubrication System.
ȱ řǯȱ ȱȱȱȱȱȱȱȱȱȱ
completely emptied, or the gasoline must be
treated with a stabilizer to prevent deterioration.
ȱ¢ȱȱȱȱȱ£ǰȱȱȱ
ȇȱǯȱȱȱȱ
tank with clean, fresh gasoline, and run the
ȱȱŘȬřȱȱȱȱ£ȱȱȱ
the carburetor.
ȱ Śǯȱ Remove the spark plug. Add one tablespoon of
engine oil into the spark plug hole. Reinstall the
plug, but do not connect the plug lead. Crank the
engine two or three revolutions.
5. Remove the spark plug. Cover the spark plug
hole with your thumb and turn the engine over
until the piston is at the top of its stroke (pressure
against the thumb is greatest). Reinstall the spark
plug, but do not connect the plug lead.
6. Store the engine in a clean, dry place. Never store
the machine or fuel container where there is an
ȱĚǰȱǰȱȱȱȱȱȱȱȱ
water heater or on other appliances.

1.6
Section 1
Safety and General Information
Dimensions in millimeters. Inch equivalents shown in parentheses.
(IF EQUIPPED)
(IF EQUIPPED)
Figure 1-5. Typical Engine Dimensions.

1.7
Section 1
Safety and General Information
1
*HQHUDO6SHFL¿FDWLRQVï
ȱȱǻȓȱřŜŖŖȱǼ
XT-6.................................................................................................................ŘǯŜȱȱǻřǯśȱǼ
XT-7.................................................................................................................řǯŚȱȱǻŚǯśȱǼ
ȱȱȱǻȓȱŘŜŖŖȱǼ
XT-6.................................................................................................................ŞȱȉȱǻśǯşȱĞǯȱǯǼ
XT-7.................................................................................................................şǯśȱȉȱǻŝȱĞǯȱǯǼ
Bore
XT-6..................................................................................................................ŜśȱȱǻŘǯśŜȱǯǼ
XT-7..................................................................................................................ŝŖȱȱǻŘǯŝśȱǯǼȱ
Stroke
XT-6..................................................................................................................ŚśȱȱǻŗǯŞȱǯǼ
XT-7..................................................................................................................ŚśȱȱǻŗǯŞȱǯǼ
Displacement
XT-6..................................................................................................................ŗŚşȱȱǻşǯŗȱǯȱǯǼ
XT-7..................................................................................................................ŗŝřȱȱǻŗŖǯŜȱǯȱǯǼ
Compression Ratio
XT-6..................................................................................................................ŞǯřDZŗ
XT-7..................................................................................................................ŞǯśDZŗ
Dry Weight
XT-6..................................................................................................................ŗŖǯŞȱȱǻŘŚȱǯǼ
XT-7..................................................................................................................ŗřǯŗȱȱǻŘşȱǯǼ
ȱ¢ȱǻęǼ
XT-6.................................................................................................................ŖǯŜŖȱȱǻŘŖȱ£ǯǼ
XT-7.................................................................................................................ŖǯŜŖȬŖǯŜśȱȱǻŘŖȬŘŘȱ£ǯǼ
ȱȱȱȬȱ¡ȱǻȱȱȱǼȱȱ................ŘśǚȱĴ
Air Cleaner Base
ȱȱȱȱ ......................................................................ŞȱȉȱǻŝŗȱǯȱǯǼ
ȱȱȱȱȱȱ...............................................ŞȱȉȱǻŝŗȱǯȱǯǼ
Blower Housing
ȱȱȱ........................................................................... ŗŖȱȉȱǻŞŞȱǯȱǯǼ
Brake
ȱȱȱ .................................................................... şǯśȱȉȱǻŞŚȱǯȱǯǼ
Breather Cover
ȱȱȱ ..................................................................... ŗŖȱȉȱǻŞŞȱǯȱǯǼ
Camshaft
End Play..................................................................................................................ŖǯŘȬŖǯŞȱȱǻŖǯŖŖŝŞȬŖǯŖřŗŚȱǯǼ
Running Side Clearance.......................................................................................ŖǯŗśȬŖǯśŗȱȱǻŖǯŖŖśşȬŖǯŖŘȱǯǼ
Carburetor
ȱȱȱ .................................................................... 9.0 N·m (80 in. lb.)

1.8
Section 1
Safety and General Information
Connecting Rod
ȱȱȱŶ .................................................................. ŗŘǯśȱȉȱǻŗŗŖȱǯȱǯǼ
Connecting Rod-to-Crankpin Running Clearance
New............................................................................................................... ŖǯŖŘśȬŖǯŖŚśȱȱǻŖǯŖŖŖşȬŖǯŖŖŗŝȱǯǼ
Connecting Rod-to-Crankpin Side Clearance................................................ ŖǯŗřȬŖǯřŝȱȱǻŖǯŖŖśŗȬŖǯŖŗŚśȱǯǼ
Connecting Rod-to-Piston Pin Running Clearance....................................... ŖǯŖŖŞȬŖǯŖŘśȱȱǻŖǯŖŖŖřȬŖǯŖŖŖşȱǯǼ
ȱȱȱǯǯ
New............................................................................................................... ŗŞǯŖŖŜȬŗŞǯŖŗŝȱȱǻŖǯŝŖŞŞȬŖǯŝŖşřȱǯǼ
ȱȱĞȱȱǯǯȱ
New............................................................................................................... ŜǯŖŖŖȬŜǯŖŗŞȱȱǻŖǯŘřŜŘȬŖǯŘřŜşȱǯǼȱ
ȱȱȱȱȱ ............................................. 8 N·m (70 in. lb.)
Crankshaft
End Play (free).................................................................................................... ŖǯŘŘśȬŗǯŗŚśȱȱǻŖǯŖŖŞŞȬŖǯŖŚśŖŝȱǯǼ
Ğȱȱȱȱǯǯ
New.............................................................................................................. ŘŚǯşşŚȬŘśǯŖŖŖȱȱǻŖǯşŞŚŖȬŖǯşŞŚŘȱǯǼȱ
Ğȱȱȱȱȱǯǯ
New.............................................................................................................. ŘśǯŚŖŖȬŘśǯŚŘŗȱȱǻŖǯşşşşȬŗǯŖŖŖŞȱǯǼȱ
¢ȱȱȱȱȱǯǯ
O.D. – Max. Wear Limit ............................................................................ ŘŚǯşŝśȬŘŚǯşŞşȱȱǻŖǯşŞřŘȬŖǯşŞřŞȱǯǼȱ
Max. Taper .................................................................................................. ŖǯŖŘśȱȱǻŖǯŖŖŖşȱǯǼ
Max. Out of Round.................................................................................... ŖǯŖŘśȱȱǻŖǯŖŖŖşȱǯǼ
PTO End Main Bearing Journal O.D.
New ............................................................................................................. ŘśǯřŝŖȬŘśǯřŞśȱȱǻŖǯşşŞŞȬŖǯşşşŚȱǯǼ
Max. Taper .................................................................................................. ŖǯŖŘśȱȱǻŖǯŖŖŖşȱǯǼ
Max. Out of Round.................................................................................... ŖǯŖŘśȱȱǻŖǯŖŖŖşȱǯǼ
Ğȱȱȱȱȱȱȱ
New.............................................................................................................. ŖǯŖŗśȬŖǯŖśŗȱȱǻŖǯŖŖŖśȬŖǯŖŖŘȱǯǼ
Crankcase
ȱȱĞȱȱǯǯȱ
New............................................................................................................... ŜǯŖŖŖȬŜǯŖŗŞȱȱǻŖǯŘřŜŘȬŖǯŘřŜşȱǯǼ
Ğȱȱȱȱȱȱ
New.............................................................................................................. ŖǯŖŖśȬŖǯŖŘśȱȱǻŖǯŖŖŖŘȬŖǯŖŖŖşȱǯǼ
Connecting Rod Journal O.D.
New.............................................................................................................. ŘşǯşŞśȬŘşǯşşśȱȱǻŗǯŗŞŖśȬŗǯŗŞŖşȱǯǼ
Max. Taper .................................................................................................. ŖǯŖŗŖȱȱǻŖǯŖŖŖŚȱǯǼ
Max. Out of Round.................................................................................... ŖǯŖŗŖȱȱǻŖǯŖŖŖŚȱǯǼ

1.9
Section 1
Safety and General Information
1
Cylinder Bore
¢ȱȱǯǯ
New.............................................................................................................. ŝŖǯŖŖŖȬŝŖǯŖŗśȱȱǻŘǯŝśśŞȬŘǯŝśŜŚȱǯǼ
Max. Taper .................................................................................................. ŗŘǯŝȱȱǻŖǯŖŖŖśȱǯǼ
Max. Out of Round.................................................................................... ŗŘǯŝȱȱǻŖǯŖŖŖśȱǯǼ
Cylinder Head
¢ȱȱȱŶ .................................................................... ŘŝǯŞ ȉȱǻŘŚŜȱǯȱǯǼȱ
¡ǯȱȬȬ ........................................................................................ ŖǯŖŞȱȱǻŖǯŖŖřŗȱǯǼ
ȱȱȱȱŶ ........................................................................ şǯśȱȉȱǻŞŚȱǯȱǯǼ
ȱȱȱŶ ................................................................................ ŗřǯŜȱȉȱǻŗŘŖȱǯȱǯǼ
Dipstick Tube Fastener
ȱȱȱȱ....................................................................... ŞȱȉȱǻŝŗȱǯȱǯǼ
Engine Cover
ȱȱȱȱȱȱ............................................. ŘǯŞȱȉȱǻŘśȱǯȱǯǼ
ȱȱȱȱȱȱȱ ............................... ŘǯřȱȉȱǻŘŖȱǯȱǯǼ
Fan/Flywheel
¢ȱȱ........................................................................................ śŗǯśȱȉȱǻŚśŜȱǯȱǯǼ
Fuel Tank
Tank Bracket to Crankcase Stud Torque........................................................ ŞȱȉȱǻŝŗȱǯȱǯǼ
ȱȱȱȱȱ........................................................... ŚǯśȱȉȱǻŚŖȱǯȱǯǼ
Governor
ȱȱĞȬȬȱȱ............................ ŖǯŖŘŖȬŖǯŖśŞȱȱǻŖǯŖŖŖŝȬŖǯŖŖŘŘȱǯǼ
ȱȱȱ.................................................................... şǯśȱȉȱǻŞŚȱǯȱǯǼ
ȱȱȱ...................................................................... şǯśȱȉȱǻŞŚȱǯȱǯǼ
ȱȱĞȱǯǯ
New.............................................................................................................. śǯşŜȬśǯşŞȱȱǻŖǯŘřŚŜȬŖǯŘřśŚȱǯǼ
ȱȱĞȬȬȱȱȱ ..................... ŖǯŖşȬŖǯŗşȱȱǻŖǯŖŖřśȬŖǯŖŖŝŚȱǯǼ
ȱȱĞȱǯǯ
New ............................................................................................................. ŜǯŖŗȬŜǯŖřȱȱǻŖǯŘřŜŜȬŖǯŘřŝŚȱǯǼ
Ignition
Spark Plug Type (Champion®or equivalent)................................................ ŗŘȱǻ®)
Spark Plug Gap ................................................................................................. ŖǯŝŜŘȱȱǻŖǯŖřŖȱǯǼ
Spark Plug Torque ............................................................................................ ŘŚǯśȱȉȱǻŘŗŝȱǯȱǯǼ
ȱȱȱ ................................................................................. ŖǯŘśŚȱȱǻŖǯŖŗŖȱǯǼ
ȱȱȱ ................................................................... ŗŖȱȉȱǻŞŞȱǯȱǯǼȱ

1.10
Section 1
Safety and General Information
0XIÀHU
Exhaust Stud Torque ........................................................................................ 9.0 N·m (80 in. lb.)
¡ȱȱȱȱ........................................................................ ȱşǯśȱȉȱǻŞŚȱǯȱǯǼ
Oil
ȱȱȱŶ...................................................................................... ȱŗŘǯřȱȉȱǻŗŖşȱǯȱǯǼ
Oil Drain Plug Torque³...................................................................................... ŗřǯśȱȉȱǻŗŘŖȱǯȱǯǼ
Piston, Piston Rings, and Piston Pin
ȱȱȱǯǯ
New.............................................................................................................. ŗŞǯŖŖŖȬŗŞǯŖŖŞȱȱǻŖǯŝŖŞŜȬŖǯŝŖŞşȱǯǼ
Piston Pin O.D.
New.............................................................................................................. ŗŝǯşşŖȬŗŝǯşşŜȱȱǻŖǯŝŖŞŘȬŖǯŝŖŞśȱǯǼ
Top Compression Ring-to-Groove Side Clearance ...................................... ŖǯŖŘȬŖǯŖŜȱȱǻŖǯŖŖŖŝȬŖǯŖŖŘřȱǯǼ
Middle Compression Ring-to-Groove Side Clearance................................ ŖǯŖŘȬŖǯŖŜȱȱǻŖǯŖŖŖŝȬŖǯŖŖŘřȱǯǼ
Top and Middle Compression Ring End Gap
New Bore..................................................................................................... ŖǯŖŘśȬŖǯŖŚŖȱȱǻŖǯŖŖŖşȬŖǯŖŖŗśȱǯǼ
ȱȱȱǯǯ
New............................................................................................................ ŜşǯşŜȬŜşǯşŞȱȱǻŘǯŝśŚřȬŘǯŝśśŗȱǯǼ
ȱȱȬȬ¢ȱȱȱ
New.............................................................................................................. ŖǯŖŘŖȬŖǯŖśśȱȱǻŖǯŖŖŖŝȬŖǯŖŖŘŗȱǯǼ
Recoil
ȱȱȱ .................................................................. ŞȱȉȱǻŝŗȱǯȱǯǼ
Speed Control
ȱȱȱ¢ȱȱ ......................................ŞȱȉȱǻŝŗȱǯȱǯǼȱ
Valve Cover
ȱȱȱ........................................................................... ŞȱȉȱǻŝŗȱǯȱǯǼ
Valves and Valve Lifters
ȱȱŚ............................................................................................. ŖǯŖŝŜŘȬŖǯŗŘŝȱȱǻŖǯŖŖřȬǯŖŖśȱǯǼ
Exhaust Valve LashŚ.......................................................................................... ŖǯŖŝŜŘȬŖǯŗŘŝȱȱǻŖǯŖŖřȬǯŖŖśȱǯǼ
ȱȱȱĞȱǻȱȱǼ............................................... śǯŘŖŖȱȱǻŖǯŘŖŚŝȱǯǼ
¡ȱȱȱĞȱǻȱȱǼ............................................ śǯŘŚŝȱȱǻŖǯŘŖŜśȱǯǼ
Nominal Valve Seat Angle............................................................................... ŘśǚǰȱŚśǚǰȱŜŖǚȱǻřȱǼ

1.11
Section 1
Safety and General Information
1
Valves and Valve Lifters (continued)
ȱȱȬȬȱȱȱ ............................... ŖǯŖŘŖȬŖǯŖŚŝȱȱǻŖǯŖŖŖŝȬŖǯŖŖŗŞȱǯǼ
Exhaust Valve Stem-to-Valve Guide Running Clearance............................ ŖǯŖśśȬŖǯŖŞŘȱȱǻŖǯŖŖŘŗȬŖǯŖŖřŘȱǯǼ
ȱȱȱǯǯ
New.............................................................................................................. śǯśŖŖȬśǯśŗŘȱȱǻŖǯŘŗŜśȬŖǯŘŗŝŖȱǯǼ
ȱȱȱȱ
New.............................................................................................................. śǯŚŜśȬśǯŚŞŖȱȱǻŖǯŘŗśŗȬŖǯŘŗśŝȱǯǼ
¡ȱȱȱǯǯ
New.............................................................................................................. śǯśŖŖȬśǯśŗŘȱȱǻŖǯŘŗŜśȬŖǯŘŗŝŖȱǯǼ
Exhaust Valve Stem Diameter
New.............................................................................................................. śǯŚřŖȬśǯŚŚśȱȱǻŖǯŘŗřŝȬŖǯŘŗŚřȱǯǼ
ŗValues are in metric units. English equivalents are shown in parentheses. Do not lubricate threads unless otherwise
indicated.
Ŷ¢ȱȱȱȱȱȱ¢ǯȱȱȱDZȱŗŖȬřŖȱȱǰȱȱ¢ȱȱ
ǻǛȱŚśŖřŖŚǼǰȱȱȬŗŖȱǻǛȱŖřŖŗřŗŖŚǼǰȱȱȬŚŖ®.
³Apply thread sealant around three full threads before assembly. No excess sealant allowed on inside or outside of joint.
ȱȱȬȱȱȱȱȱȱȱȱȱǯȱȱȱȱȬȱȱŗśŖǰȱ
ȬȱȱŗŗśǰȱȬȱȱŗŘŖǰȱȬȱȱŗŘŜǯ
Śȱȱȱ¢ȱŘŖŖȱDzȱȱȱǯ

1.12
Section 1
Safety and General Information
General Torque Values
Metric Fastener Torque Recommendations for Standard Applications
Size
M4ȱ ŗǯŘȱǻŗŗǼȱ ŗǯŝȱǻŗśǼȱ ŘǯşȱǻŘŜǼȱ ŚǯŗȱǻřŜǼȱ śǯŖȱǻŚŚǼȱ ŘǯŖȱǻŗŞǼ
M5ȱ ŘǯśȱǻŘŘǼȱ řǯŘȱǻŘŞǼȱ śǯŞȱǻśŗǼȱ ŞǯŗȱǻŝŘǼȱ şǯŝȱǻŞŜǼȱ ŚǯŖȱǻřśǼ
M6ȱ ŚǯřȱǻřŞǼȱ śǯŝȱǻśŖǼȱ şǯşȱǻŞŞǼȱ ŗŚǯŖȱǻŗŘŚǼȱ ŗŜǯśȱǻŗŚŜǼȱ ŜǯŞȱǻŜŖǼ
M8ȱ ŗŖǯśȱǻşřǼȱ ŗřǯŜȱǻŗŘŖǼȱ ŘŚǯŚȱǻŘŗŜǼȱ řřǯşȱǻřŖŖǼȱ ŚŖǯŝȱǻřŜŖǼȱ ŗŝǯŖȱǻŗśŖǼ
Tightening Torque: N·m (ft. lb.) + or - 10%
Property Class
Size
M10 ŘŗǯŝȱǻŗŜǼȱ ŘŝǯŗȱǻŘŖǼȱ ŚŝǯśȱǻřśǼȱ ŜŜǯŚȱǻŚşǼȱ ŞŗǯŚȱǻŜŖǼȱ řřǯşȱǻŘśǼ
M12 řŜǯŜȱǻŘŝǼȱ ŚŝǯśȱǻřśǼȱ ŞŘǯŝȱǻŜŗǼȱ ŗŗŜǯŜȱǻŞŜǼȱ ŗřşǯŝȱǻŗŖřǼȱ ŜŗǯŖȱǻŚśǼ
M14 śŞǯřȱǻŚřǼȱ ŝŜǯŚȱǻśśǼȱ ŗřŗǯśȱǻşŝǼȱ ŗŞŚǯŚȱǻŗřŜǼȱ ŘŗşǯŝȱǻŗŜŘǼȱ şŚǯşȱǻŝŖǼ
Noncritical
Fasteners
Into Aluminum
Noncritical
Fasteners
Into Aluminum
Tightening Torque: N·m (in. lb.) + or - 10%
Property Class
4.8 5.8 8.8 10.9 12.9
4.8 5.8 8.8 10.9 12.9
ȉȱƽȱǯȱǯȱ¡ȱŖǯŗŗř
ȉȱƽȱĞǯȱǯȱ¡ȱŗǯřśŜ
in. lb. = N·m x 8.85
Ğǯȱǯȱƽȱȉȱ¡ȱŖǯŝřŝ
Torque
Conversions
Oil Drain Plug Tightening Torque: N·m (English Equiv.)
Size
1/8" NPT
1/4"
3/8"
1/2"
3/4"
X-708-1
Into Cast Iron
–
ŗŝǯŖȱǻŗśŖȱǯȱǯǼ
ŘŖǯřȱǻŗŞŖȱǯȱǯǼ
ŘŝǯŗȱǻŘŖȱĞǯȱǯǼ
řřǯşȱǻŘśȱĞǯȱǯǼ
ŘŝǯŗȦřřǯşȱǻŘŖȦŘśȱĞǯȱǯǼ
Into Aluminum
ŚǯśȱǻŚŖȱǯȱǯǼ
ŗŗǯřȱǻŗŖŖȱǯȱǯǼ
ŗřǯŜȱǻŗŘŖȱǯȱǯǼ
ŗŝǯŜȱǻŗřȱĞǯȱǯǼ
ŘŗǯŝȱǻŗŜȱĞǯȱǯǼ
ŘŝǯŗȦřřǯşȱǻŘŖȦŘśȱĞǯȱǯǼ

2.1
Section 2
Tools & Aids
2
Section 2
Tools & Aids
ȱ¢ȱȱȱȱȱȱȱęȱ¢ǰȱǰȱȱ¢ȱǯȱ¢ȱ
ȱȱȱȱȱǰȱȱȱȱȱȱǰȱǰȱȱǯȱȱǰȱȱ
ȱȱȱȱȱȱȱ¢ȱȱȱǯ
Here is the list of tools and their sources:
Separate Tool Suppliers:
Kohler Tools
Contact your local Kohler
ȱȱ¢ǯȱ
SE Tools
Śŗśȱȱǯ
ǰȱȱȱŚŞŚŚŜ
DZȱŞŗŖȬŜŜŚȬŘşŞŗȱȱ
ȱDZȱŞŖŖȬŜŜŚȬŘşŞŗȱ
¡DZȱŞŗŖȬŜŜŚȬŞŗŞŗ
ȱ¢ȱǯ
ŝŜŞȱȱȱ
ǰȱȱȱŜŖśśş
DZȱŜřŖȬşŘŖȬŗřŖŖ
Tools
Description Source/Part No.
Cylinder Leakdown Tester
ȱȱȱȱȱȱ¢ǰȱǰȱǰȱȱȱȱǯ ȱŘśȱŝŜŗȱŖśȬ
Flywheel Strap Wrench
ȱȱĚ¢ȱȱǯ ȱȱȬŞŘŚŖş
Ignition System Tester
ȱȱȱȱȱ¢ǰȱ¡ȱǯ
ȱȱȱȱȱȱǻǼȱȱ¢ǯ
ȱŘśȱŚśśȱŖŗȬ
ȱŘŚȱŚśśȱŖŘȬ
Tachometer (Digital Inductive)
For checking operating speed (RPM) of an engine. Design Technology Inc.
DTI-110
Vacuum/Pressure Tester
Alternative to a water manometer. Kohler 25 761 22-S
Aids
Description Source/Part No.
ĞȱȱǻȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬ
Dielectric GreaseȱǻȦȱŜŜŗǼ ȱŘśȱřśŝȱŗŗȬ
RTV Silicone Sealant
ȬȱȱŗśŖ
Ȭȱȱŗŗś
ȬȱȱŗŘŖ
ȬȱȱŗŘŜǯ

2.2
Section 2
Tools & Aids

3.1
Section 3
Troubleshooting
3
Section 3
Troubleshooting
Troubleshooting Guide
When troubles occur, be sure to check the simple
ǰȱȱȱęȱ¢ȱȱȱȱȱȱ
considered. For example, a starting problem could
ȱȱ¢ȱȱ¢ȱȱǯ
ȱȱ¢ȱȱȱȱȱȱ
below. Use these to help locate the possible cause(s).
Engine Cranks But Will Not Start
ȱ ŗǯȱ ¢ȱȱǯ
ȱ Řǯȱ ȱǰȱȱȱȱȱȱ¢ǯ
ȱ řǯȱ ȱȱǯ
4. Spark plug lead disconnected.
ȱ śǯȱ ȱȱȱěȱǯ
ȱ Ŝǯȱ ¢ȱȱǯ
ȱ ŝǯȱ ¢ȱȱǯ
ȱ Şǯȱ ȱȱȱǻȱǼǯ
ȱ şǯȱ ȱȱȱǻȱǼǯ
Engine Starts But Does Not Keep Running
ȱ ŗǯȱ ȱȱȱȱǯ
ȱ Řǯȱ ȱǰȱȱȱȱȱȱ¢ǯ
ȱ řǯȱ ¢ȱȱ¢ȱȱȱȱĴȱ
ǰȱǻȱǼǯ
4. Loose wires or connections short ignition
module's kill terminal to ground.
ȱ śǯȱ ¢ȱ¢ȱȱǯ
ȱ Ŝǯȱ ¢ȱǯ
ȱ ŝǯȱ ȱ¢ȱǯ
Engine Starts Hard
ȱ ŗǯȱ ȱǰȱȱȱȱȱȱ¢ǯ
ȱ Řǯȱ ȱȱǯ
ȱ řǯȱ ȱȱ¢ȱȱȱǯ
ȱ Śǯȱ ¢ȱȱ¢ȱȱȱȱĴȱ
ȱǻȱǼǯ
ȱ śǯȱ ¢ȱȱǯ
6. Low compression.
7. Weak spark.
ȱ Şǯȱ ȱDzȱȱȱǯ
ȱ şǯȱ ¢ȱ¢ȱǯ
ȱŗŖǯȱ ȱ¢ȱǯ
Engine Will Not Crank
ȱ ŗǯȱ ȱȱ¢ȱȱȱǯ
ȱ Řǯȱ ¢ȱ¢ȱȱȱȱǯ
3. Seized internal engine components.
Engine Runs But Misses
ŗǯȱ ȱȱȱȱȱ¢ǯ
Řǯȱ ȱȱ¢ȱȱǯ
ȱřǯȱ ȱ¢ȱȱǯ
4. Spark plug lead boot loose on plug.
ȱ śǯȱ ȱȱȱȱĴ¢ȱȱ
the ignition module's kill terminal to ground.
ȱ Ŝǯȱ ȱǯ
ȱ ŝǯȱ ¢ȱȱȱȱ¢ȱǯ
ȱ Şǯȱ ȱȱ¢ǯ
Engine Will Not Idle
ȱ ŗǯȱ ȱȱȱȱȱ¢ǯ
ȱ Řǯȱ ȱȱȦȱȱȱǯ
ȱ řǯȱ ¢ȱȱǯ
ȱ Śǯȱ ȱ¢ȱǯ
ȱ śǯȱ ȱȱȱȱ¢ȱǯ
ȱ Ŝǯȱ ȱȱȱȱ¢ȱǯ
7. Low compression.
ȱ Şǯȱ ȱȱȱȱǯ
ȱ şǯȱ ȱDzȱȱ¢Ȧȱȱ
problem.
Engine Overheats
ȱ ŗǯȱ ȱǰȱȱǰȱȱęǰȱȱȱ
shroud clogged.
ȱ Řǯȱ ¡ȱȱǯ
ȱ řǯȱ ȱȱȱǯ
ȱ Śǯȱ ȱȱȱǯ
ȱ śǯȱ ¢ȱǯ
ȱ Ŝǯȱ ȱȱ¡ǯ

3.2
Section 3
Troubleshooting
Engine Knocks
ȱ ŗǯȱ ¡ȱȱǯ
ȱ Řǯȱ ȱȱȱǯ
ȱ řǯȱ ȱȱȱȱ¢ǯ
4. Internal wear or damage.
ȱ śǯȱ ¢ȱȱǯ
ȱ Ŝǯȱ ȱȱȱǯ
Engine Loses Power
ȱ ŗǯȱ ȱȱȱǯ
ȱ Řǯȱ ȱȱȱǯ
ȱ řǯȱ ¢ȱȱȱǯ
ȱ Śǯȱ ȱȱȱȱȱ¢ǯ
ȱ śǯȱ ¡ȱȱǯ
ȱ Ŝǯȱ ȱǯ
ȱ ŝǯȱ ¢ȱȱǯ
8. Low compression.
9. Exhaust restriction.
ŗŖǯȱ ȱȱĴǯ
Engine Uses Excessive Amount of Oil
ȱ ŗǯȱ ȱȱ¢ȱȱ¢ǯ
ȱ Řǯȱ ǰȱȱȱȱǯ
3. Worn or broken piston rings.
ȱ Śǯȱ ȱ¢ȱǯ
ȱ śǯȱ ȱȱȱȱȱǯ
ȱ Ŝǯȱ ȱęǯ
ȱ ŝǯȱ ȱȱDzȱǯ
Oil Leaks from Oil Seals, Gaskets
ȱ ŗǯȱ ǰȱȱȱȱǯ
2. Worn or broken piston rings.
ȱ řǯȱ ȱ¢ǰȱȱ¢ȱǯ
4. Restricted exhaust.
External Engine Inspection
ȱȱȱȱȱǰȱȱȱ
ȱȱȱȱ¡ȱȱȱ
ǯȱȱȱȱȱȱȱȱ
ȱȱȱȱȱȱǻȱȱǼȱ
when it is disassembled.
ȱ Ȋȱ ȱȱȱȱȱȱȱȱȱ
ǰȱȱęǰȱȱǰȱȱȱ
¡ȱǯȱȱȱȱȱȱȱ
ȱȱǯ
ȱ Ȋȱ ȱȱȱȱȱȱȱ
ǯȱ¡ȱȱȱȱȱ
ȱȱȱȱǰȱȱȱ
ȱȱȱǰȱȱȱǯ
ȱ Ȋȱ ȱȱȱȱȱȱȱȱǰȱ
ȱȱȱȱęȱȱǯ
ȱ Ȋȱ ȱȱȱȱǯȱȱȱǰȱ
ǰȱȱȱȱȱǰȱ
ȱȱȱȱȱȱęȱ
ȱȱȱǯȱȱȱȱȱȱȱ
¢ȱȱǯȱȱȱȱȱ
maintenance.
ȱ Ȋȱ ȱȱȱȱȱǯȱȱȱȱ
ȱȱȱȱȱȱȱȱ
ȱȱȱ¢ǯ
ȱ Ȋȱ ȱȱȱȱȱȱȱȱȱ
ȱȱȱǯȱȱȱȱǰȱěȱȱ
gasoline odor.
ȱ Ȋȱ ȱȱȱȱȱǯȱȱȱȱȱ
ȱDzȱȱȱĚȱ¢ǯȱȱȱȱ
ȱȱȱȱǯ
ȱȱȱȱ¢Ȭȱȱǰȱȱ
ȱȱȱȱȱǯȱ¡ȱ
ȱȱȱȱȱDZȱ
ȱȱ¢ȱȱȱȱȱȱǰȱȱȱȱ
ȱȱȱȱȱǰȱȱȬ
ȱȱ¡ǰȱȱȱȱǰȱȱȱȱȱ
possible causes.
NOTEDZȱ ȱȱȱȱȱȱȱȱȱȱ
¢ȱȱȱǯȱȱȱȱȱ
ȱȱȱȱǯ
Cleaning Engine
Ğȱȱȱ¡ȱȱȱȱǰȱ
ȱȱȱ¢ȱȱȱǯȱ
ȱȱȱȱȱȱȱȱ
ǯȱ¢ȱȱȱȱȱ¢ȱ
ȱȱȱȱȱȱǯȱȱ
ȱ¢ȱ¢ȱȱȱȱȱ
¢ȱȱǰȱǰȱȱȱȱȱ
parts. When such a cleaner is used, follow the
manufacturer’s instructions and safety precautions
carefully.
ȱȱȱȱȱȱȱȱȱȱ
the engine is reassembled and placed into operation.
ȱȱȱȱȱȱȱ¢ȱ
ȱȱȱȱȱȱȱǯ