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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
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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“žœȱŠĞŽ›ȱœ˜™™’—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
ŠĞŽ›ȱ’ȱ’œȱž›—Žȱ˜ěǯȱŽŸŽ›ȱ˜™Ž›ŠŽȱ
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
‹ž’•’—ȱ˜›ȱŒ˜—ę—ŽȱŠ›ŽŠǯ
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
Ž—’—Žȱ’—ȱŠȱŒ•˜œŽȱ‹ž’•’—ȱ˜›ȱŒ˜—ę—Žȱ
area.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
([SORVLYH)XHOFDQFDXVH¿UHVDQG
severe burns.
˜ȱ—˜ȱę••ȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱ
engine is hot or running.
WARNING
Explosive Fuel!
	Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱĚŠ––Š‹•ŽȱŠ—ȱ
its vapors can explode if ignited. Store
gasoline only in approved containers,
in well ventilated, unoccupied
‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱĚŠ–Žœǯȱ
˜ȱ—˜ȱę••ȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱ
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
Ž¡›Ž–Ž•¢ȱĚŠ––Š‹•Žǯȱ
ŽŽ™ȱœ™Š›”œǰȱ
ĚŠ–ŽœǰȱŠ—ȱ˜‘Ž›ȱœ˜ž›ŒŽœȱ˜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¿FDWLRQ1XPEHUV
When ordering parts, or in any communication
involving an engine, always give the Model,
™ŽŒ’ęŒŠ’˜—ǰȱŠ—ȱŽ›’Š•ȱž–‹Ž› of the engine.
—’—Žȱ’Ž—’ęŒŠ’˜—ȱ—ž–‹Ž›œȱŠ™™ŽŠ›ȱ˜—ȱŠȱŽŒŠ•ȱ
ŠĜ¡Žȱ˜ȱ‘ŽȱŽ—’—Žȱœ‘›˜ž’—ǯȱŽŽȱ’ž›ŽȱŗȬŗǯȱ—ȱ
Ž¡™•Š—Š’˜—ȱ˜ȱ‘ŽœŽȱ—ž–‹Ž›œȱ’œȱœ‘˜ —ȱ’—ȱ’ž›ŽȱŗȬŘǯ
A. Model No.
Courage Vertical Shaft Engine
Numerical Designation
)LUVWVSHFL¿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([SODQDWLRQRI,GHQWL¿FDWLRQ1XPEHUV
,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
Š—ȱŒ‘Š—’—ȱ˜’•ȱ›Žž•Š›•¢ǯȱŠ’•ž›Žȱ˜ȱžœŽȱ‘ŽȱŒ˜››ŽŒȱ
oil, or using dirty oil, will cause premature engine
wear and failure.
Oil Type
Use high quality detergent oil of ȱǻ–Ž›’ŒŠ—ȱ
Ž›˜•Žž–ȱ—œ’žŽǼȱœŽ›Ÿ’ŒŽȱŒ•Šœœȱ
ȱ˜›ȱ‘’‘Ž›. Select
the viscosity based on the air temperature at the time
˜ȱ˜™Ž›Š’˜—ȱŠœȱœ‘˜ —ȱ’—ȱ’ž›ŽȱŗȬřǯ
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˜›ȱœ¢–‹˜•ȱ˜—ȱ˜’•ȱŒ˜—Š’—Ž›œȱ’Ž—’ęŽœȱ‘Žȱȱ
œŽ›Ÿ’ŒŽȱŒ•ŠœœȱŠ—ȱȱŸ’œŒ˜œ’¢ȱ›ŠŽǯȱŽŽȱ’ž›ŽȱŗȬŚǯȱ
10W-30
A
P
I
SERVIC
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!
	Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱĚŠ––Š‹•ŽȱŠ—ȱ’œȱŸŠ™˜›œȱŒŠ—ȱŽ¡™•˜Žȱ
if ignited. Store gasoline only in approved containers, in
well ventilated, unoccupied buildings, away from sparks or
ĚŠ–Žœǯȱ˜ȱ—˜ȱę••ȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱ‘˜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
ŒŠ™ŠŒ’¢ȱ˜ȱŘȱŠ••˜—œȱ˜›ȱ•Žœœȱ ’‘ȱŠȱ™˜ž›’—ȱœ™˜žȱ’œȱ
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
To ensure easy starting and minimize gum deposits in
‘ŽȱžŽ•ȱœ¢œŽ–ǰȱ˜ȱ—˜ȱžœŽȱŠœ˜•’—Žȱ•ŽĞȱ˜ŸŽ›ȱ›˜–ȱ‘Žȱ
previous season. Do not add oil to the gasoline. Do not
˜ŸŽ›ę••ȱ‘ŽȱžŽ•ȱŠ—”Dzȱ•ŽŠŸŽȱ›˜˜–ȱ˜›ȱŽ¡™Š—œ’˜—ǯ
Fuel Type
˜›ȱ‹Žœȱ›Žœž•œǰȱžœŽȱ˜—•¢ȱŒ•ŽŠ—ǰȱ›Žœ‘ǰȱž—•ŽŠŽȱ
gasoline with a pump sticker octane rating of 86 or
‘’‘Ž›ǯȱ—ȱŒ˜ž—›’Žœȱžœ’—ȱ‘Žȱ›ŽœŽŠ›Œ‘ȱ–Ž‘˜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
	Šœ˜‘˜•ȱǻž™ȱ˜ȱŗŖƖȱŽ‘¢•ȱŠ•Œ˜‘˜•ǰȱşŖƖȱž—•ŽŠŽȱ
gasoline by volume) is approved as a fuel for Kohler
Ž—’—Žœǯȱ‘Ž›ȱŠœ˜•’—ŽȦŠ•Œ˜‘˜•ȱ‹•Ž—œȱ’—Œ•ž’—ȱŘŖȱ
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
Šœ˜•’—Žȱ‹•Ž—œȱǻž™ȱ˜ȱ–Š¡’–ž–ȱ˜ȱŗśƖȱȱ‹¢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
Š’•¢ȱ˜›ȱŽ˜›ŽȱŠ›’—ȱ
—’—Ž
’••ȱžŽ•ȱŠ—”ǯ
Check oil level.
‘ŽŒ”ȱŠ’›ȱ’—Š”ŽȱŠ—ȱŒ˜˜•’—ȱŠ›ŽŠœDzȱŒ•ŽŠ—ȱŠœȱ—ŽŒŽœœŠ›¢ǯŵ
Yearly or Every 25 Hours
Ž›Ÿ’ŒŽȱ˜›ȱ›Ž™•ŠŒŽȱ™›ŽŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ȱǻ’ȱŽšž’™™ŽǼǯŵ
‘ŽŒ”ȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ȱ˜›ȱ’›¢ǰȱ•˜˜œŽȱ˜›ȱŠ–ŠŽȱ™Š›œǯŵ
Yearly or Every 50 Hours
Ž™•ŠŒŽȱžŽ•ȱę•Ž›ǰȱ’ȱŽšž’™™Žǯ
Change oil.
ŽŠ›•¢ȱ˜›ȱŸŽ›¢ȱŗŖŖȱ‘˜ž›œ
Replace spark plug and set gap.
Ž™•ŠŒŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ǯŵ
¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
Storage
ȱ‘ŽȱŽ—’—Žȱ ’••ȱ‹Žȱ˜žȱ˜ȱœŽ›Ÿ’ŒŽȱ˜›ȱ ˜ȱ–˜—‘œȱ˜›ȱ
more, use the following storage procedure:
ȱ ŗǯȱ •ŽŠ—ȱ‘ŽȱŽ¡Ž›’˜›ȱœž›ŠŒŽœȱ˜ȱ‘ŽȱŽ—’—Žǯ
ȱ Řǯȱ ‘Š—Žȱ‘Žȱ˜’•ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱœ’••ȱ Š›–ȱ
›˜–ȱ˜™Ž›Š’˜—ǯȱ˜›ȱž›‘Ž›ȱ’—˜›–Š’˜—ǰȱœŽŽȱ
Section 6, Lubrication System.
ȱ řǯȱ ‘ŽȱŽ—’—Žȱ–žœȱ‹Žȱ›ž—ȱž—’•ȱ‘ŽȱžŽ•ȱŠ—”ȱ’œȱ
completely emptied, or the gasoline must be
treated with a stabilizer to prevent deterioration.
ȱ¢˜žȱŒ‘˜˜œŽȱ˜ȱžœŽȱŠȱœŠ‹’•’£Ž›ǰȱ˜••˜ ȱ‘Žȱ
–Š—žŠŒž›Ž›ȇœȱ›ŽŒ˜––Ž—Š’˜—œǯȱ’••ȱ‘ŽȱžŽ•ȱ
tank with clean, fresh gasoline, and run the
Ž—’—Žȱ˜›ȱŘȬřȱ–’—žŽœȱ˜ȱŽȱœŠ‹’•’£ŽȱžŽ•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
˜™Ž—ȱĚŠ–Žǰȱœ™Š›”ǰȱ˜›ȱ™’•˜ȱ•’‘ȱœžŒ‘ȱŠœȱ˜—ȱŠȱ
water heater or on other appliances.
Thank you very much
for your reading. Please
Click Here Then Get
More Information.
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
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
*HQHUDO6SHFL¿FDWLRQVï
Žȱ˜ Ž›ȱǻȓȱřŜŖŖȱǼ
XT-6.................................................................................................................ŘǯŜȱ”ȱǻřǯśȱ
Ǽ
XT-7.................................................................................................................řǯŚȱ”ȱǻŚǯśȱ
Ǽ
ŽȱŽŠ”ȱ˜›šžŽȱǻȓȱŘŜŖŖȱǼ
XT-6.................................................................................................................Şȱȉ–ȱǻśǯşȱĞǯȱ•‹ǯǼ
XT-7.................................................................................................................şǯśȱȉ–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..................................................................................................................ŗŚşȱŒŒȱǻşǯŗȱŒžǯȱ’—ǯǼ
XT-7..................................................................................................................ŗŝřȱŒŒȱǻŗŖǯŜȱŒžǯȱ’—ǯǼ
Compression Ratio
XT-6..................................................................................................................ŞǯřDZŗ
XT-7..................................................................................................................ŞǯśDZŗ
Dry Weight
XT-6..................................................................................................................ŗŖǯŞȱ”ȱǻŘŚȱ•‹ǯǼ
XT-7..................................................................................................................ŗřǯŗȱ”ȱǻŘşȱ•‹ǯǼ
’•ȱŠ™ŠŒ’¢ȱǻ›Žę••Ǽ
XT-6.................................................................................................................ŖǯŜŖȱȱǻŘŖȱ˜£ǯǼ
XT-7.................................................................................................................ŖǯŜŖȬŖǯŜśȱȱǻŘŖȬŘŘȱ˜£ǯǼ
—•Žȱ˜ȱ™Ž›Š’˜—ȱȬȱŠ¡’–ž–ȱǻŠȱž••ȱ’•ȱŽŸŽ•Ǽȱ••ȱ’›ŽŒ’˜—œ................Řśǚȱ—Ž›–’ĴŽ—
Air Cleaner Base
’›ȱ•ŽŠ—Ž›ȱŠœŽȱŠœŽ—Ž›ȱ˜›šžŽ ......................................................................Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ
’›ȱ•ŽŠ—Ž›ȱŠœŽȱ˜ȱ›Š—”ŒŠœŽȱŠœŽ—Ž›ȱ˜›šžŽ...............................................Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ
Blower Housing
•˜ Ž›ȱ
˜žœ’—ȱžȱ˜›šžŽ........................................................................... ŗŖȱȉ–ȱǻŞŞȱ’—ǯȱ•‹ǯǼ
Brake
›Š”Žȱ˜ž—’—ȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................... şǯśȱȉ–ȱǻŞŚȱ’—ǯȱ•‹ǯǼ
Breather Cover
›ŽŠ‘Ž›ȱ˜ŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ ..................................................................... ŗŖȱȉ–ȱǻŞŞȱ’—ǯȱ•‹ǯǼ
Camshaft
End Play..................................................................................................................ŖǯŘȬŖǯŞȱ––ȱǻŖǯŖŖŝŞȬŖǯŖřŗŚȱ’—ǯǼ
Running Side Clearance.......................................................................................ŖǯŗśȬŖǯśŗȱ––ȱǻŖǯŖŖśşȬŖǯŖŘȱ’—ǯǼ
Carburetor
Š›‹ž›Ž˜›ȱžȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................... 9.0 N·m (80 in. lb.)

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Kohler courage xt 7 vertical crankshaft engine service repair manual

  • 2. 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
  • 3. 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“žœȱŠĞŽ›ȱœ˜™™’—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 ŠĞŽ›ȱ’ȱ’œȱž›—Žȱ˜ěǯȱŽŸŽ›ȱ˜™Ž›ŠŽȱ 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.
  • 4. 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 ‹ž’•’—ȱ˜›ȱŒ˜—ę—ŽȱŠ›ŽŠǯ 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 Ž—’—Žȱ’—ȱŠȱŒ•˜œŽȱ‹ž’•’—ȱ˜›ȱŒ˜—ę—Žȱ area. Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. ([SORVLYH)XHOFDQFDXVH¿UHVDQG severe burns. ˜ȱ—˜ȱę••ȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱ engine is hot or running. WARNING Explosive Fuel! Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱĚŠ––Š‹•ŽȱŠ—ȱ its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied ‹ž’•’—œǰȱŠ Š¢ȱ›˜–ȱœ™Š›”œȱ˜›ȱĚŠ–Žœǯȱ ˜ȱ—˜ȱę••ȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱ 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 Ž¡›Ž–Ž•¢ȱĚŠ––Š‹•Žǯȱ ŽŽ™ȱœ™Š›”œǰȱ ĚŠ–ŽœǰȱŠ—ȱ˜‘Ž›ȱœ˜ž›ŒŽœȱ˜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.
  • 5. 1.3 Section 1 Safety and General Information 1 (QJLQH,GHQWL¿FDWLRQ1XPEHUV When ordering parts, or in any communication involving an engine, always give the Model, ™ŽŒ’ęŒŠ’˜—ǰȱŠ—ȱŽ›’Š•ȱž–‹Ž› of the engine. —’—Žȱ’Ž—’ęŒŠ’˜—ȱ—ž–‹Ž›œȱŠ™™ŽŠ›ȱ˜—ȱŠȱŽŒŠ•ȱ ŠĜ¡Žȱ˜ȱ‘ŽȱŽ—’—Žȱœ‘›˜ž’—ǯȱŽŽȱ’ž›ŽȱŗȬŗǯȱ—ȱ Ž¡™•Š—Š’˜—ȱ˜ȱ‘ŽœŽȱ—ž–‹Ž›œȱ’œȱœ‘˜ —ȱ’—ȱ’ž›ŽȱŗȬŘǯ A. Model No. Courage Vertical Shaft Engine Numerical Designation )LUVWVSHFL¿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([SODQDWLRQRI,GHQWL¿FDWLRQ1XPEHUV ,GHQWL¿FDWLRQ/DEHO
  • 6. 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 Š—ȱŒ‘Š—’—ȱ˜’•ȱ›Žž•Š›•¢ǯȱŠ’•ž›Žȱ˜ȱžœŽȱ‘ŽȱŒ˜››ŽŒȱ oil, or using dirty oil, will cause premature engine wear and failure. Oil Type Use high quality detergent oil of ȱǻ–Ž›’ŒŠ—ȱ Ž›˜•Žž–ȱ—œ’žŽǼȱœŽ›Ÿ’ŒŽȱŒ•Šœœȱ
  • 7. ȱ˜›ȱ‘’‘Ž›. Select the viscosity based on the air temperature at the time ˜ȱ˜™Ž›Š’˜—ȱŠœȱœ‘˜ —ȱ’—ȱ’ž›ŽȱŗȬřǯ 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˜›ȱœ¢–‹˜•ȱ˜—ȱ˜’•ȱŒ˜—Š’—Ž›œȱ’Ž—’ęŽœȱ‘Žȱȱ œŽ›Ÿ’ŒŽȱŒ•ŠœœȱŠ—ȱȱŸ’œŒ˜œ’¢ȱ›ŠŽǯȱŽŽȱ’ž›ŽȱŗȬŚǯȱ 10W-30 A P I SERVIC 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! Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱĚŠ––Š‹•ŽȱŠ—ȱ’œȱŸŠ™˜›œȱŒŠ—ȱŽ¡™•˜Žȱ if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or ĚŠ–Žœǯȱ˜ȱ—˜ȱę••ȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱ‘˜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 ŒŠ™ŠŒ’¢ȱ˜ȱŘȱŠ••˜—œȱ˜›ȱ•Žœœȱ ’‘ȱŠȱ™˜ž›’—ȱœ™˜žȱ’œȱ recommended. Such a container is easier to handle and helps eliminate spillage during refueling. To ensure easy starting and minimize gum deposits in ‘ŽȱžŽ•ȱœ¢œŽ–ǰȱ˜ȱ—˜ȱžœŽȱŠœ˜•’—Žȱ•ŽĞȱ˜ŸŽ›ȱ›˜–ȱ‘Žȱ previous season. Do not add oil to the gasoline. Do not ˜ŸŽ›ę••ȱ‘ŽȱžŽ•ȱŠ—”Dzȱ•ŽŠŸŽȱ›˜˜–ȱ˜›ȱŽ¡™Š—œ’˜—ǯ Fuel Type ˜›ȱ‹Žœȱ›Žœž•œǰȱžœŽȱ˜—•¢ȱŒ•ŽŠ—ǰȱ›Žœ‘ǰȱž—•ŽŠŽȱ gasoline with a pump sticker octane rating of 86 or ‘’‘Ž›ǯȱ—ȱŒ˜ž—›’Žœȱžœ’—ȱ‘Žȱ›ŽœŽŠ›Œ‘ȱ–Ž‘˜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 Šœ˜‘˜•ȱǻž™ȱ˜ȱŗŖƖȱŽ‘¢•ȱŠ•Œ˜‘˜•ǰȱşŖƖȱž—•ŽŠŽȱ gasoline by volume) is approved as a fuel for Kohler Ž—’—Žœǯȱ‘Ž›ȱŠœ˜•’—ŽȦŠ•Œ˜‘˜•ȱ‹•Ž—œȱ’—Œ•ž’—ȱŘŖȱ 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 Šœ˜•’—Žȱ‹•Ž—œȱǻž™ȱ˜ȱ–Š¡’–ž–ȱ˜ȱŗśƖȱȱ‹¢ȱ volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved.
  • 8. 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 Š’•¢ȱ˜›ȱŽ˜›ŽȱŠ›’—ȱ —’—Ž ’••ȱžŽ•ȱŠ—”ǯ Check oil level. ‘ŽŒ”ȱŠ’›ȱ’—Š”ŽȱŠ—ȱŒ˜˜•’—ȱŠ›ŽŠœDzȱŒ•ŽŠ—ȱŠœȱ—ŽŒŽœœŠ›¢ǯŵ Yearly or Every 25 Hours Ž›Ÿ’ŒŽȱ˜›ȱ›Ž™•ŠŒŽȱ™›ŽŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ȱǻ’ȱŽšž’™™ŽǼǯŵ ‘ŽŒ”ȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ȱ˜›ȱ’›¢ǰȱ•˜˜œŽȱ˜›ȱŠ–ŠŽȱ™Š›œǯŵ Yearly or Every 50 Hours Ž™•ŠŒŽȱžŽ•ȱę•Ž›ǰȱ’ȱŽšž’™™Žǯ Change oil. ŽŠ›•¢ȱ˜›ȱŸŽ›¢ȱŗŖŖȱ‘˜ž›œ Replace spark plug and set gap. Ž™•ŠŒŽȱŠ’›ȱŒ•ŽŠ—Ž›ȱŽ•Ž–Ž—ǯŵ ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. Storage ȱ‘ŽȱŽ—’—Žȱ ’••ȱ‹Žȱ˜žȱ˜ȱœŽ›Ÿ’ŒŽȱ˜›ȱ ˜ȱ–˜—‘œȱ˜›ȱ more, use the following storage procedure: ȱ ŗǯȱ •ŽŠ—ȱ‘ŽȱŽ¡Ž›’˜›ȱœž›ŠŒŽœȱ˜ȱ‘ŽȱŽ—’—Žǯ ȱ Řǯȱ ‘Š—Žȱ‘Žȱ˜’•ȱ ‘’•Žȱ‘ŽȱŽ—’—Žȱ’œȱœ’••ȱ Š›–ȱ ›˜–ȱ˜™Ž›Š’˜—ǯȱ˜›ȱž›‘Ž›ȱ’—˜›–Š’˜—ǰȱœŽŽȱ Section 6, Lubrication System. ȱ řǯȱ ‘ŽȱŽ—’—Žȱ–žœȱ‹Žȱ›ž—ȱž—’•ȱ‘ŽȱžŽ•ȱŠ—”ȱ’œȱ completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. ȱ¢˜žȱŒ‘˜˜œŽȱ˜ȱžœŽȱŠȱœŠ‹’•’£Ž›ǰȱ˜••˜ ȱ‘Žȱ –Š—žŠŒž›Ž›ȇœȱ›ŽŒ˜––Ž—Š’˜—œǯȱ’••ȱ‘ŽȱžŽ•ȱ tank with clean, fresh gasoline, and run the Ž—’—Žȱ˜›ȱŘȬřȱ–’—žŽœȱ˜ȱŽȱœŠ‹’•’£ŽȱžŽ•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 ˜™Ž—ȱĚŠ–Žǰȱœ™Š›”ǰȱ˜›ȱ™’•˜ȱ•’‘ȱœžŒ‘ȱŠœȱ˜—ȱŠȱ water heater or on other appliances.
  • 9. Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 10. 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.
  • 11. 1.7 Section 1 Safety and General Information 1 *HQHUDO6SHFL¿FDWLRQVï Žȱ˜ Ž›ȱǻȓȱřŜŖŖȱǼ XT-6.................................................................................................................ŘǯŜȱ”ȱǻřǯśȱ Ǽ XT-7.................................................................................................................řǯŚȱ”ȱǻŚǯśȱ Ǽ ŽȱŽŠ”ȱ˜›šžŽȱǻȓȱŘŜŖŖȱǼ XT-6.................................................................................................................Şȱȉ–ȱǻśǯşȱĞǯȱ•‹ǯǼ XT-7.................................................................................................................şǯśȱȉ–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..................................................................................................................ŗŚşȱŒŒȱǻşǯŗȱŒžǯȱ’—ǯǼ XT-7..................................................................................................................ŗŝřȱŒŒȱǻŗŖǯŜȱŒžǯȱ’—ǯǼ Compression Ratio XT-6..................................................................................................................ŞǯřDZŗ XT-7..................................................................................................................ŞǯśDZŗ Dry Weight XT-6..................................................................................................................ŗŖǯŞȱ”ȱǻŘŚȱ•‹ǯǼ XT-7..................................................................................................................ŗřǯŗȱ”ȱǻŘşȱ•‹ǯǼ ’•ȱŠ™ŠŒ’¢ȱǻ›Žę••Ǽ XT-6.................................................................................................................ŖǯŜŖȱȱǻŘŖȱ˜£ǯǼ XT-7.................................................................................................................ŖǯŜŖȬŖǯŜśȱȱǻŘŖȬŘŘȱ˜£ǯǼ —•Žȱ˜ȱ™Ž›Š’˜—ȱȬȱŠ¡’–ž–ȱǻŠȱž••ȱ’•ȱŽŸŽ•Ǽȱ••ȱ’›ŽŒ’˜—œ................Řśǚȱ—Ž›–’ĴŽ— Air Cleaner Base ’›ȱ•ŽŠ—Ž›ȱŠœŽȱŠœŽ—Ž›ȱ˜›šžŽ ......................................................................Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ ’›ȱ•ŽŠ—Ž›ȱŠœŽȱ˜ȱ›Š—”ŒŠœŽȱŠœŽ—Ž›ȱ˜›šžŽ...............................................Şȱȉ–ȱǻŝŗȱ’—ǯȱ•‹ǯǼ Blower Housing •˜ Ž›ȱ ˜žœ’—ȱžȱ˜›šžŽ........................................................................... ŗŖȱȉ–ȱǻŞŞȱ’—ǯȱ•‹ǯǼ Brake ›Š”Žȱ˜ž—’—ȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................... şǯśȱȉ–ȱǻŞŚȱ’—ǯȱ•‹ǯǼ Breather Cover ›ŽŠ‘Ž›ȱ˜ŸŽ›ȱŠœŽ—Ž›ȱ˜›šžŽ ..................................................................... ŗŖȱȉ–ȱǻŞŞȱ’—ǯȱ•‹ǯǼ Camshaft End Play..................................................................................................................ŖǯŘȬŖǯŞȱ––ȱǻŖǯŖŖŝŞȬŖǯŖřŗŚȱ’—ǯǼ Running Side Clearance.......................................................................................ŖǯŗśȬŖǯśŗȱ––ȱǻŖǯŖŖśşȬŖǯŖŘȱ’—ǯǼ Carburetor Š›‹ž›Ž˜›ȱžȱŠœŽ—Ž›ȱ˜›šžŽ .................................................................... 9.0 N·m (80 in. lb.)
  • 12. 1.8 Section 1 Safety and General Information Connecting Rod ˜——ŽŒ’—ȱ˜ȱŠœŽ—Ž›ȱ˜›šžŽŶ.................................................................. ŗŘǯśȱȉ–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 ’œ˜—ȱ’—ȱ—ȱǯǯ New............................................................................................................... ŗŞǯŖŖŜȬŗŞǯŖŗŝȱ––ȱǻŖǯŝŖŞŞȬŖǯŝŖşřȱ’—ǯǼ ˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȱ˜›Žȱǯǯȱ New............................................................................................................... ŜǯŖŖŖȬŜǯŖŗŞȱ––ȱǻŖǯŘřŜŘȬŖǯŘřŜşȱ’—ǯǼȱ ˜—›˜•ȱ›ŠŒ”Žȱ˜ȱ›Š—”ŒŠœŽȱŠœŽ—Ž›ȱ˜›šžŽ ............................................. 8 N·m (70 in. lb.) Crankshaft End Play (free).................................................................................................... ŖǯŘŘśȬŗǯŗŚśȱ––ȱǻŖǯŖŖŞŞȬŖǯŖŚśŖŝȱ’—ǯǼ ›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ›Š—”ŒŠœŽȱǯǯ New.............................................................................................................. ŘŚǯşşŚȬŘśǯŖŖŖȱ––ȱǻŖǯşŞŚŖȬŖǯşŞŚŘȱ’—ǯǼȱ ›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ•˜œž›Žȱ•ŠŽȱǯǯ New.............................................................................................................. ŘśǯŚŖŖȬŘśǯŚŘŗȱ––ȱǻŖǯşşşşȬŗǯŖŖŖŞȱ’—ǯǼȱ •¢ ‘ŽŽ•ȱ—ȱŠ’—ȱŽŠ›’—ȱ
  • 13. ˜ž›—Š•ȱǯǯ 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 ›Š—”œ‘ŠĞȱ˜›Žȱ’—ȱ•˜œž›Žȱ•ŠŽȱž——’—ȱ•ŽŠ›Š—ŒŽȱ New.............................................................................................................. ŖǯŖŗśȬŖǯŖśŗȱ––ȱǻŖǯŖŖŖśȬŖǯŖŖŘȱ’—ǯǼ Crankcase ˜ŸŽ›—˜›ȱ›˜œœȱ‘ŠĞȱ˜›Žȱǯǯȱ New............................................................................................................... ŜǯŖŖŖȬŜǯŖŗŞȱ––ȱǻŖǯŘřŜŘȬŖǯŘřŜşȱ’—ǯǼ ›Š—”œ‘ŠĞȱ
  • 14. ˜ž›—Š•ȱ’—ȱ›Š—”ŒŠœŽȱž——’—ȱ•ŽŠ›Š—ŒŽȱ 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