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COURAGE XT-6, XT-7

1. Air Cleaner Base Optional Foam Precleaner Figure 4 1 Air Cleaner Assembly Exploded View Service Precleaner Wash or replace the optional precleaner yearly or every 25 hours of operation more often under extremely dusty or dirty conditions Follow these instructions to service 1 Loosen the air cleaner cover knob and remove the cover See Figure 4 1 2 Remove the precleaner and wash with detergent in warm water 3 Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring and allow the precleaner to air dry 4 Reinstall the precleaner 5 Reinstall the air cleaner cover and tighten the knob securely 4 1 Section 4 Air Cleaner and Air Intake System Service Paper Element Check the paper element for dirty loose or damaged parts every 25 hours of operation more often under extremely dusty or dirty conditions Yearly or every 100 hours of operation replace the paper element Follow these instructions to service 1 Loosen the air cleaner knob and remove the cover Remove the paper air cleaner element and the precleaner if equipped See Figure 4 1 2 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element 3 When servicing the air cleaner check the air cleaner base Make sure it is secured and not damaged Also
2. 5 500 5 512 mm 0 2165 0 2170 in ico 5 430 5 445 mm 0 2137 0 2143 in Values are in metric units English equivalents are shown in parentheses Do not lubricate threads unless otherwise indicated Apply lubricant to fastener threads before assembly Acceptable lubricants include 10W 30 engine oil Mobil Assembly Oil 450304 Dubois MPO 10 03013104 and WD 40 Apply thread sealant around three full threads before assembly No excess sealant allowed on inside or outside of joint Threads with pre applied sealant do not require the use of additional sealant Approved sealants include Perma Loc LH 150 Perma Loc MM 115 Perma Loc HH 120 Perma Loc HL 126 Check valve lash every 200 hours adjust as required Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 10 Property Class Noncritical i Into Aluminum Size 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 Ib or 10 Property Class Noncritical mes Into Aluminum 21 7 16 27 1 20 47 5 35 66 4 49 81 4 60 33 9 25 36 6 27 47 5
3. 2 Install the two crankcase dowels into the crankcase See Figure 10 11 Figure 10 13 Torque Sequence 7 Torque the oil pan screws to 12 3 N m 109 in Ib See Figure 10 14 3 Using the crankcase dowels as a guide install a new oil pan gasket onto the crankcase 4 Ensure the gasket oil pan and governor gear assembly have been accurately matched with the crankcase Guide the oil pan onto the crankcase ensuring the camshaft and governor gear align with their mating surfaces Rotate the crankshaft slightly to help engage the governor gear 5 Install and finger tighten the six hex flange screws securing the oil pan to the crankcase See Figure 10 12 Figure 10 14 Torquing Oil Pan Screws Figure 10 12 Installing Oil Pan Screws 10 4 Section 10 Reassembly Install Cylinder Head Assembly Install Cylinder Head Prior to assembly lubricate all the components with NOTE Do not reuse cylinder head screws or gasket engine oil including the tips of the valve stems and Always replace with new parts valve guides 1 Examine the sealing surfaces of the cylinder head and crankcase for nicks or burrs Install Valve Assembly 1 Install the INTAKE and the EXHAUST valves 2 into their respective positions in the cylinder head See Figure 10 15 Using the two cylinder head dowels as a guide install anew head gasket See Figure 10 17 43 gt ra St Ke EE EE Figure 10 17 Installing Cyli
4. NOTE Damaged worn or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure Tighten or replace all loose or damaged components Section 4 Air Cleaner and Air Intake System Air Intake Cooling System Clean Air Intake Cooling Areas To ensure proper cooling make sure the grass screen cooling fins blower housing and other external surfaces of the engine are kept clean at all times Under extremely dusty or dirty conditions pay extra attention to these areas NOTE Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating D 4 3 Section 4 Air Cleaner and Air Intake System 4 4 Section 5 Fuel System and Governor Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the 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 General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recom
5. valves and carburetor Several examples of normal and fouled plugs are shown in the photos on the following page 7 1 Section 7 Electrical System and Components Normal A plug taken from an engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be gapped again and reused Worn On a worn plug the center electrode will be rounded and the gap will be eroded 010 or more than the correct gap Replace a worn spark plug immediately Chalky White Deposits Chalky white colored deposits indicate overheating This condition is usually accompanied by excessive gap erosion Clogged grass screen cooling fins and lean carburetion are some causes of overheating Consider replacing the plug 7 2 Carbon Fouled Soft sooty black deposits indicate incomplete combustion This is usually caused by over rich carburetion weak ignition or poor compression Consider replacing the plug Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by operating the engine with too much choke or a dirty air filter Oil in the combustion chamber is usually caused by worn piston rings or valve guides A plug in this condition could be cleaned dried and then reused Section 7 Electrical System and Components Electronic Ignition System These engines are equipped with a depe
6. TEE 0 15 0 51 mm 0 0059 0 02 in Carburetor Carb retor Stud Lartener TOT C een 9 0 N m 80 in Ib 1 7 Section 1 Safety and General Information Connecting Rod Connecuns Kod Fastener ee ee en 12 5 N m 110 in Ib Connecting Rod to Crankpin Running Clearance KI 0 025 0 045 mm 0 0009 0 0017 in Connecting Rod to Crankpin Side Clearance sinne 0 13 0 37 mm 0 0051 0 0145 in Connecting Rod to Piston Pin Running Clearance eee eeeeees 0 008 0 025 mm 0 0003 0 0009 in Piston Pin End I D KT 18 006 18 017 mm 0 7088 0 7093 in Governor Cross Shaft Bore I D KS 6 000 6 018 mm 0 2362 0 2369 in Control Bracket to Crankcase Fastener Torque eese 8 N m 70 in Ib Crankshaft End day re TO aotareeseees 0 225 1 145 mm 0 0088 0 04507 in Crankshaft Bore in Crankcase I D a o 24 994 25 000 mm 0 9840 0 9842 in Crankshaft Bore in Closure Plate I D p C EINE 25 400 25 421 mm 0 9999 1 0008 in Flywheel End Main Bearing Journal O D ONO NEN AH E E 24 975 24 989 mm 0 9832 0 9838 in DIOR EDIT ee ne uox DINE 0 025 mm 0 0009 in Maxs Qurol ee EE 0 025 mm 0 0009 in PTO End Main Bearing Journal O D p ee ae er ee 25 370 25 385 mm 0 9988 0 9994 in IS I DE ee ee ee ee 0 025 mm 0 0009 in Mre OL OL ISOUFICI een een 0 025 mm 0 0009 in Crankshaft Bore in Closure Plate Running Clearance DW
7. nn nn hrottle Lever Figure 8 15 Disconnecting Carburetor Linkage 4 Slide off the carburetor s heat shield head spacer and spacer gasket noting the sequence See Figure 8 16 Hose Clamp Figure 8 13 Disconnecting Fuel Line 2 Slide carburetor to the end of the intake studs LI See Figure 8 14 K Spacer Gasket Head Spacer 4 Heat Shield Figure 8 16 Carburetor Gasket Sequence Remove Carburetor with Choke 1 Squeeze the hose clamp and slide it and the fuel hose off the carburetor See Figure 8 17 Figure 8 14 Removing Carburetor 3 Turn the throttle lever clockwise until it stops Gently push the rod and spring linkages up to disconnect them from the throttle lever See Figure 8 15 Figure 8 17 Disconnecting Fuel Line 8 5 Section 8 Disassembly 2 Slide carburetor to the end of the intake studs Remove Governor Spring See Figure 8 14 1 Disconnect the governor spring from the speed control bracket See Figure 8 20 3 Turn the throttle lever clockwise until it stops Gently push the rod and spring linkages up to disconnect them from the throttle lever See Figure 8 15 4 Rotate the carburetor until the choke linkage can be disconnected from the carburetor See Figure 8 18 Figure 8 20 Removing Governor Spring Remove Speed Control Bracket 1 Remove the two hex flange screws securing the speed control bracket See Figure 8 21 c EL A Choke Linkag
8. 23 Section 8 Disassembly xn Figure 8 24 Removing Fuel Tank Remove Ignition Module 1 Disconnect the kill lead from the ignition module See Figure 8 25 Figure 8 25 Disconnecting Kill Lead 2 Remove the hex flange screw and the stud securing the ignition module Mark the stud for identification during reassembly See Figure 8 26 m a met Se A Figure 8 26 Removing Ignition Module 8 7 Section 8 Disassembly Disconnect Flywheel Brake Spring 1 Grasp one end of the flywheel break spring with a pliers and stretch it to disconnect it See Figure 8 27 Figure 8 29 Removing Flywheel Top View 4 Remove the flywheel key from the crankshaft See Figure 8 30 Remove Breather Assembly 1 Remove the two hex flange screws securing the breather cover See Figure 8 30 Remove cover Figure 8 27 Disconnecting Flywheel Brake Spring Remove Flywheel 1 Using a flywheel strap wrench to hold the flywheel in place remove the hex nut inside the drive cup See Figure 8 28 2 Remove the breather spring disc and screen See Figure 8 31 Drive Cup Figure 8 28 Removing Flywheel Nut Top View 2 Remove the drive cup and lift off the fan noting orientation on the flywheel for reassembly 3 The flywheel is mounted on a tapered shaft To remove it use a rubber mallet to land a firm blow slightly off center on the flywheel See Figure 8 29 i aud Figure 8 31 Removing Spr
9. 35 82 7 61 116 6 86 139 7 103 61 0 45 58 3 43 76 4 55 131 5 97 184 4 136 219 7 162 94 9 70 Oil Drain Plug Tightening Torque N m English Equiv Torque Into Cast Iron Into Aluminum Conversions 4 5 40 in lb u 17 0 150 in Ib 11 3 100 in Ib SC _ SE CH 20 3 180 in Ib 13 6 120 in Ib in lb N m x 8 85 27 1 20 ft Ib 17 6 13 ft Ib ft Ib N m x 0 737 33 9 25 ft Ib 21 7 16 ft Ib X 708 1 27 1 33 9 20 25 ft Ib 27 1 33 9 20 25 ft Ib Section 2 Tools amp Aids Certain quality tools are designed to help perform specific disassembly repair and reassembly procedures By using tools designed for the job proper servicing of engines is easier faster and safer In addition customer satisfaction and service capabilities will be increased by shortening engine downtime Here is the list of tools and their sources Separate Tool Suppliers Kohler Tools SE Tools Design Technology Inc Contact your local Kohler 415 Howard St 768 Burr Oak Drive source of supply Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 2981 Fax 810 664 8181 Tools Source Part No Cylinder Leakdown Tester For checking combustion retention and if cylinder piston rings or valves are worn Kohler 25 761 05 5 Flywheel Strap Wrench To hold flywheel during removal SE Tools KLR 82409 Ignition System Tester For testing output on all
10. 9 5 N m 84 in Ib Governor Cross Shaft O D DI m 5 96 5 98 mm 0 2346 0 2354 in Governor Gear Shaft to Governor Gear Running Clearance 0 09 0 19 mm 0 0035 0 0074 in Governor Gear Shaft O D a 6 01 6 03 mm 0 2366 0 2374 in Ignition Spark Plug Type Champion or equivale otia tite e SE ann RC12YC Champion SPEER le Qo M E 0 762 mm 0 030 in Bp at lu Tora Cr 24 5 N m 217 in Ib lem on MO CS vu d E EE 0 254 mm 0 010 in lem oa Module Fastener Torte ee ae 10 N m 88 in Ib 1 9 Section 1 Safety and General Information Muffler Exhau st Stud eeneg 9 0 N m 80 in Ib Exhaust Stud Fastener Ee soca ssecasecsacs seensescunconczanotagucgse astesasnemnssaneesorstnes 9 5 N m 84 in Ib Cil Ol anSerW e 12 3 N m 109 in Ib Ebr NEE Tore ee M DN 13 5 N m 120 in Ib Piston Piston Rings and Piston Pin Piston Pin Bore I D p 9 18 000 18 008 mm 0 7086 0 7089 in Piston Pin O D Qc 17 990 17 996 mm 0 7082 0 7085 in Top Compression Ring to Groove Side Clearance une 0 02 0 06 mm 0 0007 0 0023 in Middle Compression Ring to Groove Side Clearance 0 02 0 06 mm 0 0007 0 0023 in Top and Middle Compression Ring End Gap NEW DON idu E rer 0 025 0 040 mm 0 0009 0 0
11. Heat Guard 8 3 Section 8 Disassembly 2 Slide the muftler off the studs See Figure 8 8 Hex Nuts Hex Flange Screw Figure 8 10 Removing Air Cleaner Base 4 Detach the breather hose from the crankcase See Figure 8 11 Figure 8 8 Removing Muffler 3 Remove the heat deflector gasket from the exhaust studs noting orientation Remove Air Cleaner Assembly 1 Unscrew the knob on the air cleaner assembly and remove the cover See Figure 8 9 5 Remove the air cleaner base and detach the primer hose from the carburetor primer bulb equipped models only See Figure 8 12 Air Cleaner Base Gasket Figure 8 9 Removing Air Cleaner Cover Primer 2 Remove the paper element and the foam Hose precleaner if equipped 3 Remove the two hex nuts and the hex flange screw securing the air cleaner base to the cylinder head and the crankcase See Figure 8 10 Ja cac Le ve A b A rA ee E v Q 1 i P D Ze Figure 8 12 Disconnecting Primer Hose 6 Remove the air cleaner base gasket from the carburetor noting orientation See Figure 8 12 8 4 Section 8 Disassembly Remove Carburetor Assembly ZU NOTE Ensure the fuel tank is empty by running the Spring Linkage engine until it stops and is completely out of E fuel Remove Choke less Carburetor M T e 1 Squeeze the hose clamp and slide it and the fuel e SZ hose off the carburetor See Figure 8 13 od A 27 a di j
12. ee A E E E R EAE 0 015 0 051 mm 0 0005 0 002 in Crankcase Governor Cross Shaft Bore I D KSE 6 000 6 018 mm 0 2362 0 2369 in Crankshaft Journal in Crankcase Running Clearance ES 0 005 0 025 mm 0 0002 0 0009 in Connecting Rod Journal O D KS 29 985 29 995 mm 1 1805 1 1809 in i Eb ol DE eT 0 010 mm 0 0004 in no Outo SOUL ee EA 0 010 mm 0 0004 in 1 8 Section 1 Safety and General Information Cylinder Bore Cylinder Bore I D KT 70 000 70 015 mm 2 7558 2 7564 in N e E E ee 12 7 microns 0 0005 in Mo OGO TOEIC een 12 7 microns 0 0005 in Cylinder Head Cylinder Head Fastener Teer 27 8 Nm 246 in Ib EE 0 08 mm 0 0031 in k cker Pivot Jon Nat Torge oe ee een 9 5 N m 84 in Ib Rock ram DU e Kee 13 6 N m 120 in Ib Dipstick Tube Fastener Dips ck be Ee 8 N m 71 in Ib Engine Cover Engme Cover to Valve Cover Fastener LL E 2 8 N m 25 in Ib Engine Cover Insert to Engine Cover Fastener Torque sesecsesersersseerseese 2 3 N m 20 in Ib Fan Flywheel EIyWBe NUET On susanne ee ee ee 51 5 N m 456 in Ib Fuel Tank Tank Bracket to C rankcase Stud Torque aan a 8 N m 71 in Ib Tank Bracket to Tank Fastener Torque nee 4 5 N m 40 in Ib Governor Governor Cross Shaft to Crankcase Running Clearance 0 020 0 058 mm 0 0007 0 0022 in Cow erin Lever Tastener Ke e TEE 9 5 Nm 84 in Ib Governor Gear Fastener Torte een ee
13. line Make sure the pinch clamp is closed 2 Start the engine and run at no load high idle speed 2800 to 3750 RPM 3 Open the clamp and note the water level in the Section 3 Troubleshooting tube The level in the engine side should be a minimum of 10 2 cm 4 in above the level in the open side If the level in the engine side is the same as the open side no vacuum or the level in the engine side is lower than the level in the open side pressure check for the conditions in the table below 4 Close the pinch clamp before stopping the engine To perform the test with the vacuum pressure gauge 1 Insert the stopper as in Step 1 2 Insert the barbed gauge fitting into the hole in the stopper Be sure the gauge needle is at 0 3 Run the engine as in Step 2 and observe the gauge reading Needle movement to the left of 0 is a vacuum and movement to the right indicates a pressure A minimum of 10 2 cm 4 in of vacuum should be present Compression Test These engines are equipped with an automatic compression release ACR mechanism Because of the ACR mechanism it is difficult to obtain an accurate compression reading As an alternate use the leakdown test described on Page 3 4 Incorrect Vacuum in Crankcase Possible Cause Selion Crankcase breather clogged or inoperative Seals and or gaskets leaking Loose or improperly torqued fasteners Piston blowby or leaky v
14. rest and the throttle is open as with a fixed speed engine primer bulb or in the FAST position as with a variable speed engine the tension of the governor spring holds the throttle plate open When the engine is operating and the governor gear assembly is rotating the force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin are in equilibrium during operation holding the engine speed constant When load is applied and the engine governor gear speed decreases the governor spring tension moves the governor arm to open the throttle plate wider This allows more fuel into the engine increasing engine speed This action takes place very Section 5 Fuel System and Governor rapidly so a reduction in speed is hardly noticed As 2 Move the governor lever away from the the speed reaches the governed setting the governor carburetor wide open throttle See Figure 5 19 spring tension and the force applied by the regulating Do not apply excess force that may flex or distort pin will again be in equilibrium This maintains the throttle link the engine speed at a relatively constant level The governed speed setting is determined by the position 3 Grasp the cross shaft with a pliers and turn the of the throttle control It can be variable or constant shaft clockwise as far as it will go Then torque depending on t
15. systems except CD Kohler 25 455 01 5 For testing output on capacitive discharge CD ignition system Kohler 24 455 02 5 Tachometer Digital Inductive Design Technology Inc For checking operating speed RPM of an engine DTI 110 Vacuum Pressure Tester Alternative to a water manometer Kohler 25 761 22 S Source Part No Camshaft Lubricant Valspar ZZ613 Kohler 25 357 14 S Dielectric Grease GE Novaguard G661 Kohler 25 357 11 5 RTV Silicone Sealant Perma Lok LH 150 Perma Lok MM 115 Perma Lok HH 120 Perma Lok HL 126 2 1 Section 2 Tools amp Aids 2 2 Section 3 Troubleshooting Troubleshooting Guide When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some common types of engine troubles are listed below Use these to help locate the possible cause s Engine Cranks But Will Not Start 1 Empty fuel tank Poor fuel dirt or water in fuel system Clogged fuel line Spark plug lead disconnected Kill switch in off position Faulty spark plug Faulty ignition module Choke not closing if equipped Engine not primed if equipped Meo ST me ame Engine Starts But Does Not Keep Running 1 Restricted fuel tank cap vent 2 Poor fuel dirt or water in fuel system 3 Faulty or incorrectly adjusted choke or throttle controls if equipped 4 Loose wires or connections s
16. tank bracket if removed Install fuel tank Install flywheel brake spring Install governor Install speed control bracket Install governor spring Install carburetor gaskets Install carburetor Reconnect carburetor linkage Reconnect fuel line Install primer hose if equipped Install air cleaner base Reconnect breather hose Install air filter s and cover Install dipstick tube Install muffler assembly Install blower housing Install recoil 10 1 Section 10 Reassembly Install Crankshaft 3 Aim the triangle on top of the piston towards the 1 Carefully install the crankshaft into the crankcase push rod chamber See Figure 10 3 through the front seal and fully seat into place See Figure 10 1 Rotate the crankshaft until the journal for the connecting rod is away from the cylinder Figure 10 3 Piston Orientation After Installation 4 Carefully guide the connecting rod with piston attached into the bore See Figure 10 4 Figure 10 1 Installing Crankshaft Install Piston and Connecting Rod NOTE Proper orientation of the piston and connecting rod inside the engine is extremely important Improper orientation can cause extensive wear or damage 1 Stagger the piston rings in the grooves until the end gaps are 120 apart Lubricate the cylinder bore crankshaft journal connecting rod journal piston and rings with engine oil 2 Compress the piston rings using a piston ring Figur
17. temperatures Replace corroded valves Overheating An exhaust valve subject to overheating willhave a dark discoloration in the area above the valve guide Worn guides and faulty valve springs may cause this condition Also check for clogged air intake and blocked fins when this condition is noted Section 9 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burned valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diameter Then using an outside micrometer measure the diameter of the valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance If the intake clearance exceeds 0 047 mm 0018 in or the exhaust clearance exceeds 0 082 mm 0032 in determine whether the valve stem or guide is responsible for the excessive clearance Figure 9 2 Typical Valve Seat Cutter Maximum I D wear on the intake valve guide is Lapping Valves 5 512 mm 0 2170 in while 5 512 mm 0 2170 in is the maximum allowed on the exhaust guide The guides are not removable If the guides are within limits but the valve stems are worn beyond limits replace the valves Reground or new valves must be lapped
18. test if primer bulb is spraying fuel into carburetor Check for kinks or leaks in primer hose Carburetor Courage XT engines are equipped with either a primer or choke carburetor See Figures 5 2 and 5 3 A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Never use gasoline as a cleaning agent Figure 5 2 Carburetor With Primer Troubleshooting Fuel System If fuel system related problems occur check the following areas before attempting to adjust or disassemble the carburetor 5 2 Fuel tank is filled with clean fresh gasoline Fuel cap vent is not blocked and operating properly If there is fuel at tip of spark plug fuel is reaching the combustion chamber If there is no fuel at tip of spark check for fuel flow from fuel tank Test 3 If fuel does flow from fuel line reconnect line and check for faulty fuel filter Test 3 If fuel does not flow from fuel line check for clogged fuel tank vent or fuel line If fuel does flow from the line check for faulty carburetor or clogged fuel line If the fuel line is unobstructed the fuel tank is faulty and must be replaced If no fuel spray is entering carburetor replace primer bulb or primer hose Figure 5 3 Carburetor With Choke Fuel is reaching carburetor via in line fuel filter if equip
19. the 2 Slide the air cleaner gasket onto the carburetor carburetor to the limit of its travel wide open studs See Figure 10 49 throttle and hold in this position Do not stress flex or distort the linkage Grasp the cross shaft with a pliers and turn the shaft clockwise as far as it will go while simultaneously tightening the hex nut See Figure 10 47 Torque the hex nut to 9 5 N m 84 in Ib Air Cleaner Base Gasket ijk a U A P E v Aa TN e B A ag a 2 u 3 put d gt y J D D a Figure 10 49 Installing Primer Hose If Equipped Figure 10 47 Adjusting Governor 10 13 Section 10 Reassembly 3 Slide the air cleaner base onto the carburetor 6 Install the paper element and the foam precleaner studs Attach the base by loosley screwing the if equipped into the air cleaner body See Figure two hex nuts onto the studs and the hex flange 10 52 Attach and hand tighten the knob screw into the crankcase See Figure 10 50 Hex Flange Screw Figure 10 50 Installing Air Cleaner Base Figure 10 52 Installing Air Cleaner 4 Attach the breather hose to the crankcase See Figure 10 51 Install Dipstick Tube 1 Install the dipstick tube to the crankcase See Figure 10 53 2 Torque the hex flange screw to 8 N m 71 in Ib 5 Secure the air cleaner base by torquing the two hex nuts and the hex flange screw to 8 N m 71 in Ib Figure 1
20. the FAST or high speed position NOTE The choke is placed ON by moving the throttle control slightly past the FAST position If the throttle control does not have a designated CHOKE position be sure to leave sufficient throttle control travel past the FAST position This will enable the choke to be placed ON 4 Manually move the control arm clockwise until it touches the speed control screw 5 Pull on the outer sheath of the throttle control cable to remove any slack 6 Tighten the cable clamp securely 5 8 Governor These engines are equipped with a centrifugal flyweight mechanical governor designed to hold the engine speed constant under changing load conditions The governor gear flyweight mechanism is mounted on the closure plate in the crankcase and driven off a gear on the crankshaft See Figure 5 18 Figure 5 18 Governor Assembly Operation As the governor gear rotates centrifugal force causes the flyweights to move outward as speed increases As the flyweights open they cause the regulating pin to protrude out The regulating pin contacts the tab on the cross shaft causing the shaft to rotate One end of the cross shaft protrudes through the side of the crankcase The governor lever is clamped on the protruding end of the shaft and connected with linkage to the throttle lever on the carburetor so any rotation of the shaft causes corresponding movement of the throttle plate When the engine is at
21. tube and then screw in the main jet See Figure 5 9 8 Install the fuel inlet needle float float pin O ring and fuel bowl See Figure 5 12 High Altitude Operation When operating the engine at altitudes above 1525 meters 5000 ft the main fuel mixture tends to become too rich When the mixture is too rich it can cause conditions such as black sooty exhaust smoke misfiring loss of speed and power poor fuel economy and poor or slow governor response To compensate for the effects of high altitude a high altitude main jet can be installed High altitude jets are sold in kits which include the jet and the necessary gaskets NOTE Ifa high altitude kit has been installed the engine must be reconverted to the original jet size before it is operated at lower altitudes or overheating and engine damage may result Engine Starting ng Engine With Primer Bulb For a Cold Engine firmly push the primer bulb 3 times See Figure 5 15 Pressing the primer bulb too many times can flood the engine For awarm engine no priming is required Also refer to the operating instructions of the equipment this engine powers Figure 5 15 Primer Bulb Section 5 Fuel System and Governor Move the equipment s blade control bar into the proper start position Pull the starter handle straight out with a smooth steady motion until the engine has started Starting Engine With Manual Choke Control 1 For a Cold Engine place the appli
22. walls ium Defective exhaust valve Defective intake valve Piston rings and cylinder in good condition dudum Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement e Rings and or cylinder have considerable wear Engine should be reconditioned or replaced Section 4 Air Cleaner and Air Intake System Air Cleaner This engine is equipped with a replaceable high density paper air cleaner An optional foam precleaner may also be included See Figure 4 1 Intake air is drawn in through the blower housing and passes through the precleaner if equipped the paper element and then into the carburetor The outer air cleaner cover is secured by one knob and removed by turning the knob counterclockwise Air Cleaner Element Air Cleaner Cover Check the air cleaner assembly daily or before starting the engine Check for any buildup of dirt and debris as well as loose or damaged components See Figure 4 1 D NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air in resulting in premature wear and failure
23. was not kept segregated from the two studs for mounting the fuel tank compare their lengths and choose the short one Install Fuel Tank 1 Attach the fuel tank bracket to the tank if removed with the two bracket screws See Figure 10 33 Torque the screws to 4 5 N m 40 in Ib Hex Flange Screw 3 Install the spacer onto the ignition module stud 2 Loosely attach the fuel tank bracket to the see Figure 10 31 crankcase with the hex flange nut See Figure 10 33 10 9 Section 10 Reassembly 3 Secure the top of the fuel tank to the crankcase by installing the two threaded studs Torque the studs to 10 N m 88 5 in Ib See Figure 10 34 Figure 10 36 Installing Governor Lever 2 Attach the throttle linkage and linkage spring to the top of the governor lever See Figure 10 37 G ns Linkage gs f 9 2 4 s TAAN Figure 10 34 Installing Fuel Tank Studs 4 Install spacers on both studs See Figure 10 34 5 Secure the fuel tank bracket to the crankcase by torquing the hex flange nut to 8 N m 71 in Ib See Figure 10 33 5 ka Install Flywheel Brake Spring Figure 10 37 Attaching Governor Linkage 1 Using a pliers attach the flywheel brake spring onto the bracket hook See Figure 10 35 Install Speed Control Bracket 1 Loosely attach the speed control bracket to the crankcase using the two shorter hex screws The long hex screw will be used later for attachment of the air cleane
24. 0 53 Installing Dipstick Tube 10 14 Section 10 Reassembly Install Muffler Assembly Install Blower Housing 1 Install the heat deflector gasket onto the exhaust 1 Install the blower housing onto the studs See mounting studs with the gasket folds facing the Figure 10 57 cylinder head See Figure 10 54 Figure 10 57 Installing Blower Housing Figure 10 54 Installing Muffler Heat Deflector 2 Slide the muffler onto the exhaust studs See Figure 10 55 Install Recoil 1 Place the recoil onto the studs protruding from the blower housing See Figure 10 58 Figure 10 55 Installing Muffler 3 Install the muffler guard onto the exhaust studs See Figure 10 56 Torque to 9 5 N m 84 in Ib Figure 10 56 Installing Muffler Guard 10 15 Section 10 Reassembly Install Engine Cover 1 Install the engine cover and secure it with the three hex nuts and two hex flange screws 2 Torque the nuts to 2 8 N m 25 in Ib See Figure 10 59 Figure 10 59 Installing Engine Cover 2 Install the engine cover insert onto the engine cover and secure with the four Torx screws See Figure 10 60 Torque to 2 3 N m 20 in Ib Figure 10 60 Installing Engine Cover Insert 10 16 Install Fuel Cap 1 Screw the fuel cap tightly onto the fuel tank See Figure 10 61 Figure 10 61 Installing Fuel Cap ISSUED 3 08 NGI N ES LITHO IN U S A FOR SALES AND SERVICE INFORMATION TA IN THE U S
25. 015 in Piston Thrust Face O D KT 69 96 69 98 mm 2 7543 2 7551 in Piston Thrust Face to Cylinder Bore Running Clearance p 0 020 0 055 mm 0 0007 0 0021 in Recoil Recoil Mounting Fastener Torque nenne 8 N m 71 in Ib Speed Control Speed Control Bracket Assembly Fastener Torque s 8 N m 71 in Ib Valve Cover Valve over Fastener en a coos esse rsne cs scevencceeanstenccossesaessgsesceet cetancesnessacssone 8 N m 71 in Ib Valves and Valve Lifters Intake Valve La ae een 0 0762 0 127 mm 0 003 005 in ExhaireYolvelah essen ee rue 0 0762 0 127 mm 0 003 005 in Intake Valve Minimum Lift over base ode 5 200 mm 0 2047 in Exhaust Valve Minimum Lift over base orcle sess 5 247 mm 0 2065 in Nonunal valve nee ee an 25 45 60 3 angles 1 10 Section 1 Safety and General Information Valves and Valve Lifters continued Intake Valve Stem to Valve Guide Running Clearance eee eee eee 0 020 0 047 mm 0 0007 0 0018 in EH Exhaust Valve Stem to Valve Guide Running Clearance 0 055 0 082 mm 0 0021 0 0032 in Intake Valve Guide I D pco EEE NEESIUERERNESR 5 500 5 512 mm 0 2165 0 2170 in Intake Valve Stem Diameter nc c 5 465 5 480 mm 0 2151 0 2157 in Exhaust Valve Guide I D h c e
26. 9 5 N m 7 ft Ib Bore PMO rH P 65 mm 2 56 in Pa 70 mm 2 75 in Stroke Pr 45 mm 1 8 in Pur d 45 mm 1 8 in Displacement Pul n 149 cc 9 1 cu in QM PUn 173 cc 10 6 cu in Compression Ratio Pg 8 3 1 P TE AIEEE EIIN A A E AEE M rer 8 5 1 Dry Weight See 10 8 kg 24 Ib d EE 13 1 kg 29 Ib Oil Capacity refill P qror 0 60 L 20 oz Pur 0 60 0 65 L 20 22 oz Angle of Operation Maximum at Full Oil Level All Directions 25 Intermittent Air Cleaner Base Air Cleaner Base NK ET 8 N m 71 in Ib Air Cleaner Base to Crankcase Fastener TOFQUE nee 8 N m 71 in Ib Blower Housing Blower Housing Stud FOU Oe sense een 10 N m 88 in Ib Brake Brake Mounting Faste er Teen 9 5 N m 84 in Ib Breather Cover Breather Over Fastener TOROS eoiosdoesiiepesmd totes Dion ttuER IPOD EoS ED MM EE 10 N m 88 in Ib Camshaft Ino ld T er 0 2 0 8 mm 0 0078 0 0314 in
27. AND CANADA CALL 1 800 544 2444 1PTP 2601 hun KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044
28. Choke Lever Pilot Jet 3 4 Lever Primer Vent A m Shaft p X Choke Throttle Plate nn Fuel Inlet Needle nn Emmulsion Tube Main Jet Tower Carburetor with Primer Carburetor with Choke Figure 5 12 Carburetor Exploded View 5 5 Section 5 Fuel System and Governor 6 Grasp the choke plate with a pliers and remove it from the choke plate shaft See Figure 5 13 Figure 5 13 Choke Plate Removal 7 Remove the choke shaft and disconnect the choke return spring noting their positions for accurate reassembly See Figure 5 14 Choke Return Spring Figure 5 14 Choke Return Spring Removal Carburetor Cleaning A WARNING Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition 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 All carburetor parts should be cleaned thoroughly using a commercial carburetor cleaner Make sure all gum deposits are removed from the following areas e Carburetor body and bore especially areas where throttle plate and shaft are seated 5 6 e Main fuel jet emulsion tube in main jet body fuel inlet needle and seat Float float hinge and fuel bowl NOTE Do not submerge the carburetor in cleaner or solvent when plastic fiber rubber foam seals or gaskets are installed Carburetor cle
29. SERVICE MANUAL KOHLER COURAGE vrte XT 7 VERTICAL CRANKSHAFT KOHLER ENGINES Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Contents Safety and General Information 2 eauus a00002an000nnnnnnnnnnnunnnnnnnnnnnnnunnnnnnnnnnnn TOOS ana M dle RED Biel e Air Cleaner and Air Intake System Fuel System and Governor Lubrication System Electrical System and Components Disassembly Inspection and Reconditioning section Reese leede EEN 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 A 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 A 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 precau
30. alves Confirm with cylinder leakdown test Restricted exhaust 1 Disassemble breather clean parts thoroughly reassemble and recheck pressure Replace all worn or damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary Recondition piston rings cylinder bore valves and valve guides Repair or replace restricted muffler exhaust system 3 3 Section 3 Troubleshooting Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly The cylinder leakdown tester is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect coupling for attaching the adapter hose and a holding tool Leakdown Test Instructions 1 Run the engine for 3 5 minutes to warm it up 2 Remove the spark plug 3 Rotate the crankshaft until the piston is at top dead center TDC of the compression stroke You will need to hold the engine in this position while testing The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible Slide the holding tool onto the crankshaft align the slot with one of the mounting holes on the PTO face and tighten it onto the crankshaft Install a 3 8 breaker bar int
31. an cause overheating e Check for obvious oil leaks and damaged components Excessive oil leakage can indicate a clogged or inoperative breather worn or damaged seals or gaskets or loose fasteners 3 2 e Check the air cleaner cover and base for damage or indications of improper fit and seal e Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate improper maintenance e Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner was not functioning properly e Check if the oil level is within the operating range on the dipstick If it is above sniff for gasoline odor e Check the condition of the oil Drain the oil into a container it should flow freely Check for metal chips and other foreign particles Sludge is a natural by product of combustion and small amounts of accumulation are normal Excessive sludge formation could indicate several problems The wrong type or weight of oil was used the oil was not changed at the recommended intervals an over rich fuel mixture or a weak ignition to name a few possible causes NOTE It is good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning Engine After inspecting the external condition of th
32. aner may damage these components Carburetor Inspection Complete carburetor inspection should include the following e Inspect carburetor body for cracks holes and other wear or damage e Inspect float for cracks and holes Check float hinge and pin for wear or damage e Inspect fuel inlet needle and seat for wear or damage e Inspect tip of low idle fuel adjustment needle for wear or grooves e Inspect throttle and choke shaft and plate assemblies for wear or excess play Gasket Replacement Always use new gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Always refer to the Kohler Parts Manual for the engine being serviced to ensure the correct repair kit is ordered Carburetor Reassembly 1 Install the throttle shaft into the carburetor body 2 Apply thread sealant around three full threads of the throttle plate screw before attaching the plate to the throttle shaft Wipe away any excess sealant 3 Attach the choke return spring to the choke shaft if equipped 4 Insert the choke shaft into the carburetor body 5 Noting the marks made earlier on the choke plate and the carburetor insert the choke plate into the slot in the choke shaft See Figure 5 11 The plate is held in the shaft by dimples on the plate s surface 6 Attach the choke return spring to the carburetor body and insert the choke shaft 7 Install the emmulsion
33. arately Replace the flywheel if the ring gear is damaged Cylinder Head and Valves Inspection and Service Carefully inspect the valve mechanism parts Inspect the valve springs and related hardware for excessive wear or distortion Check the valves and valve seats for evidence of deep pitting cracks or distortion The following diagram outlines valve running clearances between the valve stems and guides 9 1 Section 9 Inspection and Reconditioning Intake Valve d gt Seat Angle Guide Depth Guide I D Valve Head Diameter Valve Face Angle Valve Margin Min Valve Stem Diameter Figure 9 1 Valve Details 9 2 Exhaust Valve 22 6 mm 5 500 5 5 12 mm 25 875 26 125 mm 45 0 80 mm 5 465 5 480 mm 20 5 mm 5 5004 5 12 mm 23 875 24 125 mm 45 0 80 mm 5 465 5 480 mm Section 9 Inspection and Reconditioning Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the valves first After removal clean the valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations Normal Even after long hours of operation a valve Lea
34. brake spring Remove flywheel nut and drive cup Remove fan Remove flywheel Remove breather cover Remove breather spring disc and screen Remove spark plug Remove flywheel brake assembly Remove valve cover and gasket Remove jam nuts and rocker arm pivots Remove rocker arms Remove push rods Remove guide plate Remove rocker studs Remove cylinder head Remove valves Remove dipstick tube Remove oil pan and gasket Remove camshaft Remove governor gear and retainer Remove governor hitchpin and shaft Remove tappets Remove connecting rod cap Remove piston with connecting rod Remove crankshaft 8 1 Section 8 Disassembly Detailed Disassembly Sequence A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Never use gasoline as a cleaning agent Disconnect Spark Plug 1 Disconnect the spark plug lead Empty Fuel Tank 1 Ensure the fuel tank is empty by running the engine until it stops and is completely out of fuel 2 Remove the gas cap Drain Oil NOTE There are two ways to drain oil from this engine by inverting the dipstick tube and by removing the crankcase drain plug Drain Oil from Dipstick Tube 1 To keep dirt grass clippings and other debris out of the engine clean the area around the oil fill cap dipstick 2 Re
35. cation choke control into the ON position For a warm engine no choke is required Also refer to the operating instructions of the equipment this engine powers Move the equipment s blade control bar into the proper start position Pull the starter handle straight out with a smooth steady motion until the engine has started 5 After the engine starts move the choke control from the ON position to the OFF position Choke Cable Installation 1 Connect the Bowden cable to the engine choke control arm on the speed control bracket See Figure 5 16 Figure 5 16 Connect Bowden Cable 2 Set the choke control on the equipment this engine powers to the OPEN or OFF position Snap the plastic wire mount into the speed control bracket See Figure 5 16 5 7 Section 5 Fuel System and Governor Install Throttle Choke Control Cable Some engines are equipped with a dual throttle choke control arm This allows simultaneous adjustment of the throttle and choke together Dual Throttle Choke Control Installation 1 Loosen the cable clamp and insert the cable sheath through the clamp See Figure 5 17 LEN We vw geen a D Figure 5 17 Bowden Cable Connection 2 Connect the Bowden cable to the control arm on the speed control bracket For correct hole selection refer to the operating instructions of the equipment this engine powers See Figure 5 15 3 Place the throttle control lever of the equipment into
36. check the air cleaner cover for damage or improper fit Replace all damaged air cleaner components 4 If any loose dirt or debris fell into the air cleaner when the element was removed carefully remove it and wipe the base clean 5 Check the condition of the rubber seal on the paper element If the condition is questionable in any way replace the element 6 Reinstall the paper element and the optional precleaner if equipped Reattach the cover Disassembly The following procedure outlines complete disassembly of the air cleaner assembly Since removal of the air cleaner base also affects carburetor mounting and governor adjustment Step 4 should only be performed if required For further information see the Dissassembly and Reassembly sections of this manual 1 Loosen the air cleaner cover retaining knob and remove the air cleaner cover 2 Remove the foam precleaner if equipped and the paper air cleaner with the formed rubber seal 3 Disconnect the breather hose from the crankcase See Figure 4 2 4 2 4 Remove the two hex flange nuts from the mounting studs which secure the air cleaner base carburetor and gaskets Remove the third hex screw attaching the base to the crankcase 5 Remove the air cleaner base by swinging it out to the left and disconnecting the primer hose if equipped from the carburetor See Figure 4 3 Figure 4 3 Primer Bulb Hose Inspect Air Cleaner Components Whenever the ai
37. curing the governor gear See Figure 8 49 2 Using a flathead screwdriver as a wedge carefully separate the oil pan from the crankcase See Figure 8 47 8 12 Section 8 Disassembly Retainer S Remove Connecting Rod Cap S Ly 1 Rotate the crankshaft to allow access to the two hex flange screws on the connecting rod cap See EDI EN A 7 yf of Figure 8 52 Remove the screws and cap EU 2 Remove the hitchpin securing the governor shaft n es SH See Figure 8 50 Figure 8 52 Removing Connecting Rod Cap Remove Piston 1 Carefully guide the piston and the attached connecting rod out of the cylinder bore See Figure 8 53 Figure 8 50 Removing Governor Hitchpin Shaft Remove Tappets Figure 8 53 Removing Piston 1 Remove the tappets Mark them INTAKE and EXHAUST for reinstallation See Figure 8 51 5 Remove Crankshaft 1 Remove the crankshaft See Figure 8 54 e 2 a4 Figure 8 51 Removing Tappets Figure 8 54 Removing Crankshaft 8 13 Section 8 Disassembly 8 14 Section 9 Inspection and Reconditioning This section covers the operation inspection and repair reconditioning of major internal engine components The following components are not covered in this section They are covered in sections of their own Air Cleaner Section 4 Carburetor and Governor Section 5 Ignition Section 7 Clean all parts thoroughly Only clean parts can be accurately inspected and gauged f
38. del Specification and Serial Number of the engine Engine identification numbers appear on a decal affixed to the engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Section 1 Safety and General Information Figure 1 1 Identification Label A Model No XT 7 Courage Vertical Shaft Engine PEZ Numerical Designation Spec No XT173 0001 Engine Model T L First specification Model written in this XI 6 model series XT 7 Serial No 3723500328 Year Manufactured Code Factory Code Code Year 37 2007 38 2008 Figure 1 2 Explanation of Identification Numbers 1 3 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 and changing oil regularly Failure to use the correct oil or using dirty oil will cause premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute service class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in Figure 1 3 RECOMMENDED SAE GRADES 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 A
39. e Figure 8 18 Disconnecting Choke Linkage 5 Slide off the carburetor s heat shield head spacer and spacer gasket noting the sequence See Figure 8 19 N Figure 8 21 Removing Speed Control Bracket Spacer Gasket NOTE The fuel hose connecting the carburetor Head Spacer and the fuel tank is held in place by a plastic ring mounted on the back of Heat Shield the speed control bracket If the bracket is removed from the crankcase it will remain attached to the fuel hose by Figure 8 19 Carburetor Gasket Sequence the fuel filter not including California engines Should replacement of the speed bracket be required disconnect the fuel filter and slide the bracket off the hose Do not disconnect the fuel hose from the fuel tank 8 6 Remove Governor Lever 1 Loosen the governor lever hex nut and slide the lever off the governor shaft See Figure 8 22 Governor Lever Hex Nut Figure 8 22 Removing Governor Lever Remove Fuel Tank 1 Ensure the fuel tank is empty by running the engine until it stops and is completely out of fuel 2 Detach the fuel tank from the crankcase bracket by removing the two hex flange screws See Figure 8 23 3 Remove the two studs securing the top of the fuel tank and lift off the tank See Figure 8 24 NOTE Disassembly does not require the fuel tank bracket be removed from the bottom of the tank If removal is to be performed unscrew the two hex bracket screws See Figure 8
40. e 10 4 Installing Piston compressor 5ee Figure 10 2 l 5 Use the handle of a soft rubber grip hammer to tap the piston into the bore See Figure 10 5 Figure 10 2 Compressing Piston Rings Figure 10 5 Tapping Piston 10 2 6 Rotate the crankshaft to mate with the connecting rod Align the rod cap and connecting rod to match the marks Torque the screws to 12 5 N m 110 in Ib See Figure 10 6 Figure 10 6 Aligning Match Marks Install Tappets 1 Install the INTAKE and the EXHAUST tappets into their respective positions as previously marked See Figure 10 7 Figure 10 7 Installing Tappets Install Camshaft 1 Lubricate the camshaft and cam gear surfaces with light grease or oil 2 Install the camshaft and align the timing marks See Figure 10 8 Section 10 Reassembly Figure 10 8 Aligning Timing Marks Install Governor Gear Assembly 1 Install the governor gear and retainer and torque the hex flange screw to 9 5 N m 84 in Ib See Figure 10 9 Retainer Governor Gear Figure 10 9 Installing Governor Gear 2 Install the governor cross shaft and secure it with the hitch pin See Figure 10 10 Hitch Pin Figure 10 10 Installing Governor Shaft Hitch Pin 10 3 Section 10 Reassembly Install Oil Pan 6 Using the torque sequence shown in Figure 1 The sealing surfaces of the crankcase and oil pan 10 15 should be clean dry and free of any nicks or burrs
41. e engine clean the unit thoroughly before disassembling it Also clean individual components as the 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 the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Basic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating Pressure in the crankcase normally caused by a clogged or improperly operating breather can cause oil to be forced out at oil seals gaskets or other available spots Crankcase vacuum is best measured with a water manometer or vacuum pressure test gauge See Section 2 Tools and Aids Complete instructions are provided with the testers Test the crankcase vacuum with a manometer as follows 1 Insert the rubber stopper into the oil fill hole Be sure the pinch clamp is installed on the hose and use the tapered adapters to connect the hose between the stopper and one of the manometer tubes Leave the other tube open to the atmosphere Check that the water level in the manometer is at the 0
42. er 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 Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 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 gasoline blends up to maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ther blends are not approved Section 1 Safety and General Information Periodic Maintenance A 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 Fill fuel tank Daily or Before Starting Check oil level Engine Check air intake and cooling areas clean as necessary Service or replace precleaner element if equipped Yearly or Every 25 Hours Check air cleaner eleme
43. es or components while the engine is running They can be sources of electrical shock Spark Plug Engine misfire or starting problems are often caused by a spark plug that is in poor condition or has an improper gap setting The engine is equipped with the following spark plug Type Champion RC12YC Gap 0 762 mm 0 030 in Thread Size 14 mm 0 551 in Reach 19 1 mm 3A in Hex Size 15 9 mm 58 in Spark Plug Service Yearly or every 100 hours of operation remove the spark plug check its condition and reset the gap or replace with a new plug as necessary 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain on the spark plug and enter the engine causing extensive wear and damage 3 Check spark plug gap using a feeler gauge See Figure 7 1 Adjust the gap by carefully bending the ground electrode Gap the spark plug to 0 762 mm 0 030 in Electrode 7 Figure 7 1 Spark Plug Gap 4 Reinstall the spark plug into the cylinder head Torque the plug to 24 5 N m 217 in Ib Inspection Inspect the spark plug as soon as it is removed from the cylinder head The deposits on the tip are an indication of the general condition of the piston rings
44. g the cylinder head See Figure 8 40 3 Push the end of the intake valve Figure 8 42 to release the valve seal Figure 8 43 and remove both valves from the opposite end of the head Figure 8 40 Removing Cylinder Head Figure 8 44 Mark the valves INTAKE and EXHAUST for reinstallation 2 Remove the cylinder head noting the positioning of the dowels See Figure 8 41 NOTE Only the cylinder s intake valve has a seal There is no valve seal on the exhaust side O h otc Figure 8 41 Cylinder Head Dowels 3 Remove the head gasket and discard See Figure 8 40 Remove Valve Assembly 1 Push down on the valve spring keepers to release the valve springs from the valve stems See Figure 8 42 2 Remove the valve spring keepers and springs Figure 8 44 Removing Valves 8 11 Section 8 Disassembly Remove Dipstick Tube 1 Remove the hex flange screw securing the dipstick tube See Figure 8 45 Remove the tube Figure 8 47 Separating Oil Pan from Crankcase 3 Remove the old gasket and discard Figure 8 45 Removing Dipstick Tube Remove Camshaft 1 Remove the camshaft from the crankcase See Remove Oil Pan and Gasket Figure 8 48 1 Remove the six hex flange screws securing the oil pan See Figure 8 46 Figure 8 48 Removing Camshaft Figure 8 46 Removing Oil Pan Screws Remove Governor Gear and Shaft 1 Remove the hex flange screw and the retainer se
45. he application the hex nut to 9 5 N m 84 in Ib See Figure 5 20 Initial Governor Adjustment Make this initial adjustment whenever the governor arm is loosened or removed from the cross shaft To ensure proper adjustment make sure the throttle linkage is connected to both the governor arm and the throttle lever on the carburetor 1 Loosen the governor lever adjustment screw See Figure 5 19 Figure 5 20 Adjust Governor Lever Figure 5 19 Loosen Governor Lever 5 9 Section 5 Fuel System and Governor 5 10 Section 6 Lubrication System Oil Recommendations Check Oil Level Using the proper type and weight of oil in the The importance of checking and maintaining proper crankcase is extremely important So is checking oil oil level in the crankcase cannot be overemphasized daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine Check oil BEFORE EACH USE as follows wear and failure 1 Make sure the engine is stopped level and cool so the oil has had time to drain into the sump Oil Type Use high quality detergent oil of API American Petroleum Institute service class SJ or higher Select the viscosity based on the air temperature at the time of operation See Figure 6 1 2 Clean the area around the oil fill cap dipstick to keep dirt and grass clippings out of the engine 3 Unscrew and remove the oil fill cap dipstick wipe off oil Rein
46. hort ignition module s kill terminal to ground 5 Faulty cylinder head gasket 6 Faulty carburetor 7 Intake system leak Engine Starts Hard 1 Poor fuel dirt or water in fuel system Clogged fuel line Loose or faulty wires or connections Faulty or incorrectly adjusted choke or throttle controls if equipped Faulty spark plug Low compression Weak spark Engine overheated air circulation restricted Flywheel key sheared Intake system leak ps sm I9 E ur ae Engine Will Not Crank 1 2 9 Loose or faulty wires or connections Faulty key switch or ignition switch Seized internal engine components Engine Runs But Misses js E gucci DU Dirt or water in fuel system Spark plug faulty or fouled Poor quality of fuel Spark plug lead boot loose on plug Loose wires or connections intermittently short the ignition module s kill terminal to ground Engine overheated Faulty ignition module or improperly gapped Carburetor adjusted incorrectly Engine Will Not Idle 1 COND TWN Dirt or water in fuel system Stale fuel and or gum in carburetor Faulty spark plug Fuel supply inadequate Idle fuel adjusting needle improperly set Idle speed adjusting screw improperly set Low compression Restricted fuel tank cap vent Engine overheated cooling system air circulation problem Engine Overheats 1 SY he N Air intake grass screen cooling fins or cooling shroud c
47. imer hose and carburetor linkage 5 Remove carburetor noting gasket sequence See Figure 5 7 Heat Deflector Gasket Carburetor Notched Gasket Square Gasket Figure 5 7 Carburetor Gasket Sequence Exploded View Carburetor Disassembly 3 Unscrew the main jet from inside the tower 1 Remove the fuel bowl screw fuel bowl O ring A light tap on the tower will dislodge the and float pin See Figure 5 12 emmulsion tube See Figure 5 9 2 Slide the spring loaded fuel inlet needle out of the float See Figure 5 8 Fuel Inlet Needle ei R D D M r d D d Ke y a gt k D e d d es H u ee gt x 8 v D d o M bs Figure 5 9 Emmulsion Tube Removal 5 4 Section 5 Fuel System and Governor 4 Remove the throttle plate screw the throttle 5 To ensure accurate reassembly mark the choke plate and slide out the throttle shaft noting plate and the carburetor body with a waterproof throttle lever position See Figures 5 10 and 5 12 pen See Figure 5 11 Choke Lever Throttle Shaft Figure 5 10 Throttle Shaft Removal Figure 5 11 Mark Choke Plate and Carburetor gt s i UN er i 3 i s 1 i ug b j i C H l e EN z e i 1 z A I NOTE Throttle shaft wear is normally accompanied by corresponding wear to the carburetor body making repair impractical Replace the entire carburetor if the throttle shaft is worn Throttle
48. in to provide a good seal Use a hand valve grinder with suction cup for final lapping Lightly coat valve face with fine grade of grinding compound then rotate valve on seat with grinder Continue grinding until smooth surface is obtained on seat and on valve face Valve Seat Inserts Thoroughly clean cylinder head in soap and hot water Hardened steel alloy intake and exhaust valve to remove all traces of grinding compound After seat inserts are press fitted into the cylinder head drying cylinder head apply a light coating of engine The inserts are not replaceable but they can be oil to prevent rusting reconditioned if not too badly pitted or distorted If the seats are cracked or badly warped the cylinder head should be replaced Recondition the valve seat inserts following the instructions provided with the valve seat cutter being used A typical cutter is shown in Figure 9 2 The final cut should be made with an 90 cutter as specified for the valve seat angle in Figure 9 1 With the proper 45 valve face angle and the valve seat cut properly 44 5 as measured from center line when cut 90 this would result in the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the valve face and seat 9 5 Section 9 Inspection and Reconditioning 9 6 Section 10 Reassembly The following sequence is a step by step guide for complete engine reassembly This procedure assumes that all compone
49. in turn causes the voltage in the secondary coil to rise quickly This sharp rise in voltage breaks down the air to fuel mixture in the spark plug s gap and creates a spark that ignites fuel in the combustion chamber The system consists of the following components e Magnets permanently affixed to flywheel e Spark plug with metal boot e Electronic inductive discharge ignition module mounted on engine crankcase 7 4 ill Terminal e Kill switch or key switch grounds module to stop engine e Kill terminal mounted on the side of the module Troubleshooting and Testing Ignition Ignition problems are most often due to poor or loose connections Before beginning any test procedure check all external wiring Be certain all ignition related wires are connected and all terminal connections fit snugly Make sure the ignition switch is in the run position Both the CDI and IDI ignition systems are designed to be trouble free for the life of the engine Other than periodically checking or replacing the spark plug no maintenance or timing adjustment is necessary or possible The ignition module automatically controls the timing of the spark Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help systematically determine the cause of a reported problem Section 7 Electrical System and Components Ignition System Troubleshooting Guide emi ium D
50. ines Operation The fuel from the tank is moved through the in line filter and fuel lines by gravity Fuel then enters the carburetor float bowl and is moved into the carburetor body There the fuel is mixed with air This fuel air mixture is then burned in the engine combustion chamber Fuel Filter Optional Replace the fuel filter yearly or every 50 hours of operation Removing the air cleaner first will allow easy access to the fuel filter See Figure 5 1 P Fuel Filter A 2 Figure 5 1 Replacing Fuel Filter Air Cleaner Off Troubleshooting Use the guide on the following page to determine if fuel is reaching the combustion chamber 5 1 Section 5 Fuel System and Governor Fuel System Test Guide Test Conclusion Gasoline components oxidize over time resulting in lost volitility making starting more difficult Replace old gas with fresh gas Check for the following The fuel tank has fresh clean gas in it Make sure fuel cap vent is open Check for fuel in combustion chamber Disconnect and ground spark plug lead Close carburetor choke if equipped Turn engine over several times Remove spark plug and check for fuel at tip Check fuel flow from tank to optional fuel filter Disconnect fuel hose from filter if equipped Hold fuel line below tank and observe fuel flow Check for fuel flow to carburetor Remove fuel line from carburetor Remove air filter and
51. ing Disc and Screen 8 8 Remove Spark Plug 1 Remove the spark plug from the cylinder head See Figure 8 32 Figure 8 32 Removing Spark Plug Remove Flywheel Brake Assembly 1 Remove the two hex flange screws securing the flywheel brake assembly retain the spacers See Figure 8 33 Figure 8 33 Removing Flywheel Brake Assembly Section 8 Disassembly Remove Valve Cover 1 Remove the four hex flange screws from the valve cover 2 Remove the cover and the gasket See Figure 8 34 Figure 8 34 Removing Valve Cover Remove Jam Nuts and Pivots 1 Usea socket and wrench to remove the jam nuts and the rocker arm pivots from the rocker studs See Figure 8 35 Figure 8 35 Removing Jam Nuts and Pivots 8 9 Section 8 Disassembly Remove Rocker Arms Remove Rocker Studs 1 Noting orientation lift the rocker arms off of the 1 Unscrew and remove the rocker studs from the rocker studs See Figure 8 36 cylinder head See Figure 8 38 v Si Figure 8 36 Removing Rocker Arms Figure 8 38 Removing Rocker Studs Remove Push Rods 1 Remove the push rods and mark them for Remove Guide Plate reinstallation See Figure 8 37 1 Remove the guide plate from the rocker studs See Figure 8 39 D 2 m A af Figure 8 37 Removing Push Rods Figure 8 39 Removing Guide Plate 8 10 Section 8 Disassembly Remove Cylinder Head 1 Remove the four hex flange screws securin
52. jud N E O lt o O cC LLI Make sure spark plug lead is connected to the spark plug Check condition of spark plug Make sure gap is set to 0 762 mm 0 030 in Test for spark with ignition tester a Disconnect spark plug lead and connect to post terminal of tester See Figure 7 4 Connect clip to ground not to spark plug NOTE To maintain engine speeds obtained during cranking do not remove spark plug b Turn engine ignition switch to START position to initiate test Crank engine to minimum of 500 RPM and observe tester Visible and audible sparks should be produced Release switch to RUN position Visible and audible sparks should be produced Measure the resistance of module secondary using an ohmmeter See Figure 7 5 Zero ohmmeter before testing Connect one ohmmeter lead to laminations A Connect the other lead to the spark plug terminal C of high terminal lead With ohmmeter leads connected in this manner resistance of the CDI module secondary should be 4000 to 12 000 ohms Resistance of the IDI module secondary should be 2700 to 8600 ohms NOTE This test cannot be 1 Spark plug is not receiving ignition pulse If plug is in good condition check gap and adjust if necessary reinstall plug If visible and audible sparks are produced ignition module is OK If visible and audible sparks are not produced a Make sure ignition switch kill switch or key switch is in
53. k plug and torque it to 24 5 N m 217 in Ib 2 Install the breather cover and torque it to 10 N m 88 in Ib See Figure 10 27 10 7 Section 10 Reassembly Flywheel Key as bs Vr mee LS p Install Flywheel Assembly A WARNING Damaging Crankshaft and Flywheel can Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the flywheel NOTE Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean dry and completely free of lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the mounting nut is torqued to specification NOTE Make sure the flywheel key is installed properly in the keyway The flywheel can become cracked or damaged if the key is not properly installed NOTE Always use a flywheel strap wrench to hold the flywheel when tightening the flywheel fastener Do not use any type of bar or wedge to prevent the flywheel from rotating as these parts could become cracked or damaged 10 8 1 Install the key into the crankshaft keyway Make sure key is fully seated See Figures 10 27 and 10 28 2 Install the flywheel onto the crankshaft alig
54. kage A poor grind on a valve face or seat will can be reconditioned and reused if the face and allow leakage resulting in a valve burned on one side margin are in good shape If a valve is worn to where only the margin is less than 1 82 do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Bad Condition The valve depicted here should be Coking Coking is normal on intake valves and is not replaced Note the warped head margin damaged harmful If the seat is good the valve could be reused and too narrow These conditions could be attributed after cleaning to excessive hours or a combination of poor operating conditions 9 3 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures The white deposits seen here indicate very high combustion temperatures usually due to a lean fuel mixture Gum Gum deposits usually result from using stale gasoline This condition is often noted in applications where fuel is not drained out of tank during the off season Gum is a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition 9 4 Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating
55. ks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ienition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent AA WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition 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 2 A WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area 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 engine in a closed building or confined area A CAUTION Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Mo
56. logged Excessive engine load Low crankcase oil level High crankcase oil level Faulty carburetor Lean fuel mixture 3 1 Section 3 Troubleshooting Engine Knocks 1 Excessive engine load Low crankcase oil level Old or improper fuel type Internal wear or damage Quality of fuel Incorrect grade of oil oy Urge ce T9 Engine Loses Power Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in fuel system Excessive engine load Engine overheated Faulty spark plug Low compression Exhaust restriction Incorrect governor setting AIR Dacis Engine Uses Excessive Amount of Oil 1 Incorrect oil viscosity or type Clogged broken or inoperative breather Worn or broken piston rings Worn cylinder bore Worn valve stems or valve guides Crankcase overfilled Blown head gasket overheated E OLD Oil Leaks from Oil Seals Gaskets 1 Clogged broken or inoperative breather 2 Worn or broken piston rings 3 Piston blowby or leaky valves 4 Restricted exhaust External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled e Check for buildup of dirt and debris on the crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas c
57. logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 4 Figure 1 4 Oil Container Logo Refer to Section 6 Lubrication System for detailed oil check and oil change procedures Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the 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 General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling To ensure easy starting and minimize gum deposits in the fuel system do not use gasoline left over from the previous season Do not add oil to the gasoline Do not overfill the fuel tank leave room for expansion Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 86 or higher In countries using the research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamb
58. mended Such a container is easier to handle and helps eliminate spillage during refueling To minimize gum deposits in your fuel system and to ensure easy starting do not use gasoline left over from the previous season Do not add oil to the gasoline or overfill the fuel tank Be sure to leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it 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 Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline Alcohol blends including E20 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 gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Fuel System The typical fuel system and related components include the fuel tank in line fuel filter if equipped carburetor and fuel l
59. move the oil fill cap dipstick 3 Tilt the engine on its side with the air cleaner facing up See Figure 8 1 Drain the oil into an approved container Air Cleaner K Oil Flow Figure 8 1 Draining Oil from Dipstick Tube 8 2 4 After the crankcase is completely drained tilt the engine back to level Drain Oil Via Crankcase Plug If Accessible 1 To keep dirt grass clippings and other debris out of the engine clean the area around the oil fill cap dipstick and then remove it 2 Remove the crankcase plug on the bottom of the engine See Figure 8 2 EN r En Crankcase Plug e P ENT x Figure 8 2 Crankcase Plug 3 Drain the oil into an approved container Remove Engine Cover Insert and Cover 1 Remove the four Torx screws securing the engine cover insert See Figure 8 3 Figure 8 3 Removing Engine Cover Insert Section 8 Disassembly 2 Remove the three hex flange nuts and two hex Remove Blower Housing flange screws securing the engine cover See 1 Lift off the blower housing and retain the three Figure 8 4 stud spacers See Figure 8 6 3 Remove the engine cover Figure 8 6 Removing Blower Housing Figure 8 4 Removing Engine Cover Remove Muffler Assembly Remove Recoil Starter 1 Remove two hex flange nuts securing the heat 1 Lift off the recoil starter See Figure 8 5 guard to the cylinder head See Figure 8 7 Lim Figure 8 5 Removing Recoil Figure 8 7 Removing Muffler
60. ndable magneto ignition In a magneto ignition system electric energy is generated by the rotational motion between the magnets embedded in the flywheel and the ignition module This energy is stored in the ignition module coils The stored energy is then transferred via initiation of a semiconductor switch The resulting voltage build up in the primary coil causes a similar voltage build up in the high voltage secondary coil called transformer action This voltage initiates a spark that jumps across the spark plug s gap which ignites the fuel air mixture in the combustion chamber Two types of ignition modules are used on these engines capacitive discharge ignition CDI and inductive discharge ignition IDI See Figures 7 2 and 7 3 Spark Plug 2 Terminal C Air Gap 0 254 mm Ignition Module 0 010 in va ca Magnets Ignition Module Enlarged View Kill Switch or Off Position of Key Switch Figure 7 2 Capacitive Discharge Ignition System CDI CDI Module Operation The system consists of the following components As the flywheel rotates and the magnet passes the CDI ignition module the magnetic field induces current e Magnets permanently affixed to flywheel in the charging coil The current pulse is rectified by a diode and this signal charges a high voltage capacitor e Spark plug with rubber boot As the magnet completes its pass a change in polarity of the signal produced by the flywheel magnet turn
61. nder Dowels 3 Match the two sides of the head together and finger tighten the four hex screws See Figure 10 18 2 Install the intake valve seal onto the intake valve Next slide the valve springs onto both valves and lock them in place with the valve spring keepers See Figure 10 16 Figure 10 18 Torquing the Screws 4 Follow the torque sequence in Figure 10 18 and torque the head screws to 27 8 N m 246 in 1b 10 5 Section 10 Reassembly Install Push Rod Assembly 1 Install the rocker studs through the guide plate See Figure 10 19 EI f Figure 10 19 Installing Guide Plate and Studs 2 Torque the rocker studs to 13 6 N m 120 in Ib 3 Install the push rods into the intake and exhaust positions as previously marked See Figure 10 20 NOTE Installation and seating of the push rods into the tappet recesses during this sequence is critical To aid with proper installation of the push rods and rocker arms and for adjusting the valve lash position the engine with the cylinder head up When properly installed the push rods extend approximately 1 in 25 4 mm above the guide plate Figure 10 20 Installing Push Rods 4 Apply grease to the contact surfaces of the rocker arms and the pivots 5 Install the rocker arms onto the rocker studs Match the rocker arm dimples with the round push rod ends See Figure 10 21 10 6 FA ged T Figure 10 21 Installing R
62. ning the keyway with the key See Figure 10 28 Figure 10 28 Installing Flywheel 3 Align the teardrop slot on the fan with the raised teardrop on the flywheel Align the drive cup on the flywheel and install and hand tighten the nut 4 Using a flywheel strap wrench hold the flywheel still while simultaneously torquing the nut to 51 5 N m 456 in 1b See Figure 10 29 Section 10 Reassembly Install Ignition Module 4 Setthe air gap by placing a 0 254 mm 0 010 in 1 Rotate the flywheel so the ignition magnets are plastic feeler gauge between the magnet and the away from the ignition module legs Position module Loosen the stud and let the magnet draw the ignition module on the legs with the kill tab the module against the feeler gauge See Figure down See Figures 10 30 and 10 32 10 32 lorque the fasteners to 10 N m 88 in Ib Magnets Ignition Module Figure 10 30 Positioning Ignition Module Magnets 2 Loosely thread the stud in a mounting leg and 5 Rotate the flywheel to release the feeler gauge the hex flange screw in another leg See Figure and check that the module does not come in 10 31 Pull the module away from the flywheel contact with the magnet Recheck the air gap and tighten the stud to hold it in place Rotate the flywheel so the ignition magnet is aligned with 6 Connect the kill lead to the ignition module See the module Figure 10 32 NOTE If the stud for mounting the ignition module
63. nt for dirty loose or damaged parts Replace fuel filter if equipped Yearly or Every 50 Hours s u Change oil Replace spark plug and set gap Yearly or Every 100 hours Replace air cleaner element Perform these maintenance procedures more frequently under extremely dusty dirty conditions Storage 4 Remove the spark plug Add one tablespoon of If the engine will be out of service for two months or engine oil into the spark plug hole Reinstall the more use the following storage procedure plug but do not connect the plug lead Crank the engine two or three revolutions 1 Clean the exterior surfaces of the engine 5 Remove the spark plug Cover the spark plug 2 Change the oil while the engine is still warm hole with your thumb and turn the engine over from operation For further information see until the piston 1s at the top of 1ts stroke pressure Section 6 Lubrication System against the thumb is greatest Reinstall the spark plug but do not connect the plug lead 3 The engine must be run until the fuel tank is completely emptied or the gasoline must be 6 Store the engine ina clean dry place Never store treated with a stabilizer to prevent deterioration the machine or fuel container where there is an If you choose to use a stabilizer follow the open flame spark or pilot light such as on a manufacturer s recommendations Fill the fuel water heater or on other appliances tank with clean fresh ga
64. nts are new or have been reconditioned and all component subassembly work has been completed This procedure may vary to accommodate engine options or special equipment NOTE Properly clean all components BEFORE reassembly NOTE Remove all traces of cleaners before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil NOTE Assemble the engine using all specified torque values tightening sequences and clearances Failure to observe specifications could cause severe engine wear or damage NOTE Always use new gaskets Typical Reassembly Sequence Install crankshaft Install piston and connecting rod Attach connecting rod cap Install tappets Install camshaft Install governor gear Install crankcase dowels and gasket Install oil pan cover Install valves if removed Install cylinder head po e MD EEE qe xs 11 12 13 14 15 16 ibe 18 19 20 21 22 29 24 25 26 27 28 29 30 31 92 OD 34 Do 00 37 38 39 40 41 42 Install guide plate Install rocker studs Install push rods Install rocker arms Install rocker pivots Install jam nuts Install valve cover gasket and cover Install spark plug Install flywheel brake assembly Install breather cover Install flywheel key Install flywheel Install fan Install ignition module Install fuel
65. o the slot of the holding tool so it is perpendicular to both the holding tool and crankshatt or insert a shoulder bolt through the slot and thread it into the mounting hole Leakdown Test Results Air escaping from crankcase breather cece eeeeeeeeee Air escaping from exhaust system sess Airescaping Tom carburetor nn Gauge reading in low green Zone sees Gauge reading in moderate yellow zone Gauge reading in high red zone sss 3 4 If the flywheel end is more accessible you can use a breaker bar and socket on the flywheel nut screw to hold it in position You may need an assistant to hold the breaker bar during testing If the engine is mounted in a piece of equipment you may be able to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction Install the adapter into the spark plug hole but do not attach it to the tester at this time Connect an adequate air source 80 100 psi to the tester Turn the regulator knob in the increase clockwise direction until the gauge needle is in the yellow set area at the low right end of the scale Connect the tester quick disconnect to the adapter Note the gauge reading and listen for escaping air at the carburetor inlet exhaust outlet and or crankcase breather Check your test results against the table below esas Defective rings or worn cylinder
66. ocker Arms 6 Loosely install the pivots and the jam nuts onto the rocker studs See Figure 10 22 7 With the piston at top dead center of the compression stroke insert a 0 1 mm 004 in flat feeler gauge between one valve stem and rocker arm See Figure 10 23 Figure 10 23 Setting Valve Lash Valve Clearance Specifications Intake Valve 0 0762 0 127 mm 0 003 0 005 in Exhaust Valve 0 0762 0 127 mm 0 003 0 005 in Section 10 Reassembly 8 Tighten the rocker pivot with a wrench until a Install Flywheel Brake Assem bly slight drag is felt on the feeler gauge See Figure 1 Install the two spacers onto the two brake 10 23 Hold the nut in that position and torque assembly screws the jam nut to 9 5 N m 84 in 1b Perform the same adjustment procedure on the opposite 2 Torque them to 9 5 N m 84 in 1b See Figure valve 10 25 9 Position a new valve cover gasket on the cylinder head 10 Install the valve cover and finger tighten the four screws 11 Using the sequence shown in Figure 10 24 torque the cover screws to 8 N m 71 in Ib Figure 10 25 Installing Flywheel Brake Assembly RR Install Breather Assembly 1 Install the breather screen spring and disc See Figure 10 26 D L NC Figure 10 24 Valve Cover Torque Sequence Install New Spark Plug 1 Setthe gap on a new Champion RC12YC or equivalent to 0 762 mm 0 030 in 2 Install the spar
67. options included Thoroughly clean all engine parts during the disassembly process This allows for more accurate inspection and gauging of the engine for wear or damage Use a commercial cleaner to remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Remove all traces of cleaners before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Basic Disassembly Sequence 1 Disconnect spark plug lead 2 Ensure fuel tank is empty 3 Remove fuel cap 4 Drain oil from crankcase oF Remove engine cover insert 6 Remove engine cover 2 Remove recoil 8 Remove blower housing 9 Remove muffler guard 10 Remove muffler and heat deflector gasket 11 Remove air cleaner cover and filter s 12 Disconnect breather hose 13 Remove air cleaner base 14 Disconnect primer hose 15 Disconnect fuel line 16 Remove carburetor 17 Disconnect carburetor linkage 18 Remove carburetor gaskets 19 20 22 29 24 25 26 27 28 29 30 3 32 33 34 99 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Remove governor spring Remove speed control bracket Remove governor lever Remove fuel tank Disconnect kill lead from ignition module Remove ignition module Disconnect flywheel
68. or 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 the manufacturer s instructions and safety precautions carefully Use gasket remover to remove old material from the valve cover cylinder head crankcase and oil pan Do not scrape the gasket surfaces as this could cause damage resulting in leaks Make sure all traces of cleaning solvents are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments and deep scratches or nicks Check the cylinder wall for scoring In severe cases unburned fuel can dissolve lubricating oil off the piston and cylinder wall Without lubrication the piston rings would make metal to metal contact with the wall causing scuffing and scoring Scoring of the cylinder wall can also be caused by localized hot spots from blocked cooling fins or from inadequate or contaminated lubrication Flywheel Inspection Inspect the flywheel for cracks and check the keyway for wear or damage Replace the flywheel if cracked If the flywheel key is sheared or the keyway is damaged replace the crankshaft flywheel and key Inspect the ring gear for cracks or damage Ring gears are not available sep
69. ped and fuel lines Air cleaner base carburetor and gaskets are securely fastened and or torqued to engine Air cleaner element is clean and all air cleaner components are fastened securely Governor system exhaust system and throttle choke controls are operating properly Section 5 Fuel System and Governor Fuel System Troubleshooting Guide Engine runs rich indicated by black sooty smoke misfiring loss of speed and power and governor hunting 3 Engine runs lean indicated by misfiring loss of speed and power governor hunting 4 Fuel leaks from carburetor Carburetor Adjustments While this carburetor is designed to deliver the correct fuel to air mixture some adjustments may be necessary NOTE Adjust carburetor after engine is warmed up Idle Adjustment Screw Do not tampered with this screw on engines with a primer bulb since these models operate only at full speed and do not idle On engines with a choke the idle adjustment screw is used to fine tune engine idle Should an adjustment be required turn the screw clockwise to increase idle speed and counterclockwise to lower idle speed See Figure 5 4 Idle Adjustment E Zeg Screw Figure 5 4 Idle Adjustment Screw High Speed RPM Adjustment The recommended maximum no load high speed RPM for most engines is 3300 RPM The actual speed depends on the application A WARNING Overspeed is Hazardous Over speed is hazardous and could cause pe
70. r body See Figure 10 38 Figure 10 35 Attaching Flywheel Brake Spring Install Governor Assembly Ae E om A A 5 1 Install the governor lever onto the governor shaft N TEN S Je 5 with the lever section up See Figure 10 36 Figure 10 38 Installing Speed Bracket 10 10 Section 10 Reassembly NOTE There are three different speed bracket variations for this engine Figures 10 39 10 40 and 10 41 identity how different brackets connect to carburetors with and without choke Throttle Linkage Speed Control Bracket Governor Lever Throttle Lever Speed Control Bracket Governor Lever Governor Spring Figure 10 40 Fixed Speed with Choke Throttle SR gt GE Dual Throttle Choke Kee Ed QS Choke Control Lever N UE i Linkage Spring Throttle mn Choke Linkage Speed Control Screw e y i E u Governor Lever T Ses Speed Control Bracket Kees Rei Governor Spring Figure 10 41 Variable Speed with Choke 10 11 Section 10 Reassembly Install Governor Spring Install Carburetor with Primer 1 Install the governor spring between the governor 1 With the carburetor not yet mounted on the lever and the speed control bracket See Figure studs rotate it slightly to allow connection of the 10 42 and 10 39 throttle linkage and linkage spring to the throttle lever See Figure 10 44 Spring Linkage Throttle gt Linkage WF 2g m e v ke F 3 d Throttle Le
71. r cleaner cover is removed or the paper element or precleaner are serviced inspect the following areas Outer Air Cleaner Cover Make sure the air cleaner cover is in good condition not cracked damaged or missing the retaining knob which can affect the sealing ability of the air cleaner element Air Cleaner Base Make sure the base is properly secured and not cracked or damaged It is extremely important that the fasteners securing this component are tight at all times Primer Bulb Hose Make sure the hose is not cracked kinked or damaged and attached to both the air cleaner base and the carburetor See Figure 4 3 NOTE Before reinstalling an air cleaner base that has been removed make sure the metal bushings in the base mounting holes are present The bushings prevent damage to the base and help maintain the proper mounting torque Reassembly The following procedure outlines complete reassembly of all air cleaner components 1 Reconnect the primer bulb hose if equipped See Figure 4 3 2 Install the air cleaner base onto the mounting studs 3 Install the air cleaner base with the two hex flange nuts and the hex screw Torque all three to 8 1 N m 72 in 1b 4 Reconnect the breather hose See Figure 4 2 5 Install the air cleaner element with the pleated side out 6 Install the precleaner if equipped into the air cleaner cover 7 Reinstall the air cleaner cover and secure with the cover knob
72. rsonal injury Engine is out of fuel Air filter is clogged clean or replace Spark plug is faulty replace or test for spark Air filter is clogged clean or replace Carburetor is dirty disassemble and clean 3 Obstructed fuel supply check for clogs Air intake leak check for leaks 4 Dirt or debris in carb Disassemble and clean Loose fuel bowl or drain screw Disassemble and check for leaks Engines with Primer Bulb 1 Bend the adjustment tab on the speed control bracket up to increase engine speed and down to reduce speed See Figure 5 5 Figure 5 5 Engine Speed Adjustment Tab Engines With Choke 1 Turn the high speed adjustment screw clockwise to decrease engine speed and counterclockwise to increase RPMs See Figure 5 6 Speed Control Screw Hidden From View Figure 5 6 Speed Control Screw 5 3 Section 5 Fuel System and Governor Carburetor Removal NOTE Ensure fuel tank is empty prior to carburetor removal A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Never use gasoline as a cleaning agent Loosen air cleaner knob and remove cover Remove foam precleaner if equipped and paper element 1 2 3 Remove two hex flange nuts and hex flange screw securing air cleaner base 4 Disconnect breather hose pr
73. ry so the oil level is up to but not Figure 6 4 Dipstick over the FULL mark NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the 6 Reinstall the oil fill cap dipstick and tighten crankcase Never operate the engine with the securely oil level below the L or LOW mark or over the FULL mark on the dipstick Drain Oil Via Crankcase Plug If Accessible 1 Disable the engine by disconnecting the spark Oil Change plug Oil can be changed on this engine by either draining it from the dipstick tube or from the drain plug Change 2 Remove the oil fill cap dipstick the oil after the first three to five hours of operation After that change the oil yearly or every 50 hours of 3 Remove the crankcase plug on the bottom of the operation Refill with oil as specified in the Viscosity engine and drain oil into an approved container Grades Table Figure 6 1 See Figure 6 6 Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Drain Oil from Dipstick Tube Change the oil as follows 1 To keep dirt grass clippings and other debris out of the engine clean the area around the oil fill cap dipstick and then remove it 2 Tilt the engine on its side with the air cleaner facing up See Figure 6 5 Drain oil into an approved container Air Cleaner gt 4 Apply thread sealant around three full threads ER of the drain pl
74. s e Electronic capacitive discharge ignition module on the semiconductor switch and directly connects mounted on engine crankcase the charged capacitor to the primary coil of the transformer As the capacitor discharges energy the e Kill switch or key switch grounds module to low voltage at the primary winding is transformed stop engine to high voltage in the secondary winding of the module A high voltage pulse is then delivered to the e Kill terminal mounted on back of module spark plug where it arcs across the electrode gap and ignites the fuel in the combustion chamber 7 3 Section 7 Electrical System and Components Spark Plug Boot m I Magnets Air Gap 0 254 mm 0 010 in Ignition Spark Plug Spark Plug Terminal C Lamination A Ignition Module Enlarged View gt f Kill Switch or Off Position of Key Switch Figure 7 3 Inductive Discharge Ignition System IDI Module Operation As the flywheel rotates and the magnet passes the IDI ignition module the magnetic field induces current in the primary coil This stores energy in the coil s magnetic circuit As the ignition magnet completes its pass it induces current in a small triggering coil which then turns on a semiconductor switch This causes the previously induced magnetic field in the primary coil to collapse As the magnetic field begins to collapse the coil tries to resist the drop in electricity Transformer action
75. sert the dipstick into the tube and rest the oil fill cap on the tube DO NOT RECOMMENDED SAE VISCOSITY GRADES screw the cap into the tube See Figure 6 3 10W 30 SAE 30 Figure 6 1 Viscosity Grades Table NOTE Using oil other than service class SJ or higher or extending oil change intervals longer than recommended can cause engine damage Figure 6 3 Oil Fill Cap Dipstick A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 2 4 Remove the dipstick again and check the oil level Oil should be up to but not over the F or FULL mark on the dipstick See Figure 6 4 5 Ifthe level is low add the proper type of oil up to the FULL mark on the dipstick Always check the level with the dipstick before adding more oil 6 Reinstall the oil fill cap dipstick and tighten securely Figure 6 2 Oil Container Logo 6 1 Section 6 Lubrication System 3 After the crankcase is completely drained tilt the engine back to level 4 Fillthe crankcase with new oil of the proper type to the FULL mark on the dipstick See Figure 6 4 Always check the oil level with the dipstick 4905 before adding more oil Do not screw the dipstick Range in when checking oil level CX Operating 5 Testrun the engine to check for leaks Stop the Low Mark engine allow a minute for the oil to drain down and recheck the level on the dipstick Add more oil if necessa
76. soline and run the engine for 2 3 minutes to get stabilized fuel into the carburetor 1 5 Section 1 Safety and General Information OE AIR FILTER AND COVER VAI NS 13 140 amp DIPS FUEL FILL 171 94 6 769 i 263 63 D 10 379 Pu 248 22 8 773 PRIMER BULB IF EQUIPPED 4 781 FLYWHEEL VIEW Figure 1 5 Typical Engine Dimensions 1 6 ES Ji SS K N A vu SE NN 279 72 11 013 Mn I dasz LI IB ENGINE MOUNT ING SURFACE OIL DRAIN PLUG OIL FILL VIEW PRIMER BULB IF EQUIPPED ENGINE MOUNTING SURF ACE VALVE COVER VIEW DTE DRAIN PLUG 3 8 18 PTF SAE SHORT 203 19 8 000 08 75 v 27 00 344 1 063 2X 8 75 THRU 344 ROTATION PTO VIEW Dimensions in millimeters Inch equivalents shown in parentheses Section 1 Safety and General Information General Specifications Net Power 3600 RPM Pa A 2 6 kW 3 5 HD pq M 3 4 kW 4 5 HD Net Peak Torque 2600 RPM Par 8 N m 5 9 ft Ib Pun
77. the RUN position b Check wires and terminals of ignition module and other components for accidental grounding and damaged insulation If wires and terminals are OK ignition module is probably faulty and should be replaced Test module further using an ohmmeter Test 4 Check safety switches for example seat mounted kill switch and other components for accidental grounding NOTE For further information refer to the operating instructions for the equipment this engine powers If the resistance is low or 0 ohms the module secondary is shorted Replace the module If the resistance is high or infinity ohms the module secondary is open Replace the module If the resistance is within the specified range the module secondary is OK performed unless module has been fired at least once Refer to the Disassembly and Reassembly Sections for complete ignition module removal and installation procedures 7 5 Section 7 Electrical System and Components Figure 7 4 CDI and IDI Ignition Module Tester Figure 7 5 Testing CDI or IDI Ignition Modules 7 6 Section 8 Disassembly A 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 The following sequence is a step by step guide for complete engine disassembly This procedure may vary depending on the
78. tions should be followed at all times Failure to follow these precautions could result in injury to yourself and others AA WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug leads before servicing 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 A WARNING t 5 Rotating Parts can cause severe injury Stay away while engine is in operation 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 AA WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping 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 after it is turned off Never operate the engine with heat shields or guards removed 1 1 Section 1 Safety and General Information AA WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from spar
79. ug Clean up any excess sealant on the inside or outside of the joint Threads with pre applied sealant do not require the use of additional sealant Approved sealants include Perma Loc LH 150 Perma Loc MM 115 Perma Loc HH 120 Perma Loc HL 126 5 Reinstall the drain plug and torque to 13 6 N m Cil Flow 120 in Ib Figure 6 5 Tilted Engine With Air Cleaner Up 6 2 Section 6 Lubrication System Fill the crankcase with the recommended oil Splash Lubrication System to the FULL mark on the dipstick See Figure 6 4 Always check the oil level with the dipstick Operation before adding more oil Do not screw dipstick in This engine uses splash lubrication to deliver oil for when checking oil level internal lubrication The governor gear located near the bottom of the oil pan has a series of paddles on it that dip into crankcase oil and splash it onto internal engine parts Reinstall the oil fill cap dipstick and tighten securely Test run the engine to check for leaks Stop the engine allow a minute for the oil to drain down and recheck the level on the dipstick Add more oil as necessary so the oil level is up to but not over the FULL mark 6 3 Section 6 Lubrication System 6 4 Section 7 Electrical System and Components This section covers the operation service and repair of the electrical system and electrical system components A WARNING Electrical Shock Never touch electrical wir
80. ver Figure 10 42 Installing Governor Spring Figure 10 44 Installing Throttle Linkage 2 Slide the carburetor onto the mounting studs See Install Carburetor Gaskets Figure 10 45 Install the air cleaner gasket onto 1 Place the spacer gasket cylinder head spacer and the studs the heat deflector gasket on the carburetor studs in the order shown in Figure 10 43 Head Spacer Heat Shield Figure 10 43 Installing Carburetor Gaskets Install Carburetor with Choke 1 With the carburetor not yet mounted on the Install Carburetor Linkage studs rotate it slightly and slot the elbow at the end of the linkage into the choke lever See NOTE There are several different ways to attach Figure 10 46 the carburetor linkage depending on the carburetor and speed bracket used For more detailed illustrations refer to Figures 10 39 10 40 and 10 41 10 12 Section 10 Reassembly Connect Fuel Line 1 Slide the fuel line tight up against the carburetor and secure the connection with a hose clamp See Figure 10 48 Figure 10 46 Attaching Choke Linkage 2 Connect the throttle linkage and linkage spring to the throttle lever on the carburetor See Figure 10 44 Figure 10 48 Connecting Fuel Hose 3 Slide the carburetor onto the mounting studs See Figure 10 45 Install Air Cleaner Assembly 1 Attach the primer hose to the carburetor if Adjust Governor equipped See Figure 10 49 1 Move the governor lever away from

COURAGE XT-6, XT-7

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