Kohler Courage XT-6 User's Manual
Contents
1. Move fuel shut off valve to the ON position if equipped Refer to Figure 4 Turn the ignition switch to the ON position if equipped Refer to the operating instructions of the equipment this engine powers Start the engine by activating key switch release as soon as engine starts NOTE Do notcrank the engine continuously for more than 5 seconds at a time If the engine does not start wait 30 seconds before attempting to restart Failure to follow these guidelines may damage or overheat the starter motor 4 Once the engine starts adjust it to the equipment manufacturer s recommended operating speed if adjustable Recoil Start 1 Move the fuel shut off valve to the ON position if equipped Refer to Figure 4 2 Turn the ignition switch to the ON position if equipped Refer to the operating instructions of the equipment this engine powers 3 Pull the starter handle straight out with a smooth steady motion NOTE Extend the starting rope periodically and check its condition If the rope is frayed have it replaced immediately by a Kohler Authorized Service Center Once engine starts adjust it to the equipment manufacturer s recommended operating speed if adjustable A WARNING Accidental Starts Before extending and checking the retractable starter rope remove the spark plug lead to prevent the engine from starting accidentally Primer Bulb Start If Equipped E Move fuel shut off valve2. Air pump or pulse valve assembly if equipped Control distribution valve if equipped Distribution manifold if equipped Air hoses if equipped Vacuum lines if equipped LIMITATIONS This Emission Control System Warranty shall not cover any of the following a b c d e Ignition module s with high tension lead Gaseous fuel regulator if equipped Electronic control unit if equipped Carburetor or fuel injection system if equipped Fuel lines fuel line fittings and clamps if equipped Fuel metering valve if equipped Evaporative system if equipped Canister if equipped Canister filter if equipped Vapor hose if equipped Orifice connector if equipped Fuel tank if equipped Fuel cap if equipped Primer bulb canister if equipped Repair or replacement required because of misuse or neglect improper maintenance improper repairs or replacements not conforming to Kohler Co specifications that adversely affect performance and or durability and alterations or modifications not recommended or approved in writing by Kohler Co Replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement point Consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc Diagnosis and inspection fees that do not result in eligible warranty service being performed and Any add on
3. FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is any one authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our Web site www kohlerengines com and click on SERVICE AND SUPPORT to use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 EJ With the exception of countries governed by the European Union EU where a one 1 year warranty is required for commercial professional use 19 KOHLER CO FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WARRANTY SMALL OFF ROAD ENGINES The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Kohler Co are pleased to explain the Federal and California Emission Control Systems Warranty on your small off road equipment engine In California beginning in 2006 emissions means both exhaust and evaporative emissions For California engines produced
4. guards removed 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 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 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 California Proposition 65 Warning Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Congratulations on your purchase of a Kohler Courage XT Series engine Top notch performance is built into this tough reliable quality manufactured Kohler engine made by the company world renowned for Relentless Power and Legendary Performance Here are some of the innovative features of your Courage XT engine e Efficient overhead valv
5. information that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to the operator and others A 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 sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ienite 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 Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead before servicing Accidental Starts Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine by disconnecting the spark plug lead Safety Precautions A WARNING Es 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
6. or modified part or malfunction of authorized parts due to the use of add on or modified parts MAINTENANCE AND REPAIR REQUIREMENTS The owner is responsible for the proper use and maintenance of the engine Kohler Co recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise If the Lg engine is resold during the warranty period the maintenance records should be transferred to each subsequent owner Kohler Co reserves the right to deny warranty coverage if the engine has not been properly maintained however Kohler Co may not deny warranty repairs solely because of the lack of repair maintenance or failure to keep maintenance records Normal maintenance replacement or repair of emission control devices and systems may be performed by any repair establishment or individual however warranty repairs must be performed by a Kohler authorized service center Any replacement part or service that is equivalent in performance and durability may be used in non warranty maintenance or repairs and shall not reduce the warranty obligations of the engine manufacturer 17 NOTES KOHLER ENGINES FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FORM NO 14 590 02 ISSUED 1 09 REVISED RU 6 50531 85194 9
7. retail consumer or commercial end user Residential homeowner service means residential use by a retail consumer Commercial use means all other uses including use for commercial or rental purposes Once in commercial use the engine will thereafter be considered a commercial use engine for the purposes of this warranty Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective EXCLUSIONS Mufflers on engines used commercially non residential are warranted for 90 days from date of purchase This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers Kohler Co AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR
8. warm engine no choke is required Shutdown Engine To shutdown the engine turn ignition switch to OFF position if equipped Move the fuel shut off lever to OFF position if equipped See Figure 4 NOTE Ifthe engine is equipped with an optional blade brake clutch BBC the blade can be stopped without shutting down the engine For further information refer to operating instructions of the equipment this engine powers Engine Speed Unless the equipment this engine is mounted on has a variable speed control throttle the speed of this engine cannot be altered NOTE Do not tamper with governor or carburetor to increase engine speed Overspeed is hazardous and will void warranty Angle of Operation This engine will operate continuously at angles up to 20 and intermittently up to 25 in all directions for one minute or less Oil level must be at FULL mark on dipstick Refer to the operating instructions of the equipment this engine powers Due to equipment design or application there may be more stringent restrictions regarding the angle of operation NOTE Do not operate this engine continuously at angles exceeding 20 in any direction because engine damage could result from insufficient lubrication Overheating To avoid engine damage due to overheating remove grass and other built up debris after each use NOTE After running the engine for any length of time allow it to cool down sufficiently before at
9. 544 2444 Engine Specifications Model Stroke Displacement Net Peak Torque 2600 RPM Compression Ratio Weight Fuel Capacity Oil Capacity Refill Lubrication Charging System Figure 20 Specifications Table Power 3600 RPM KW Net HP3 oo Parts Ordering The engine model specification and serial numbers are required when ordering replacement parts from your Kohler Authorized Service Center These numbers are found on the identification plate which is affixed to the engine shrouding Include letter suffixes if there are any See Engine Identification Numbers Always insist on genuine Kohler replacement parts as they adhere to strict standards for fit reliability and performance See Figure 19 Kohler replacement parts for this engine include Part Number 14 083 09 S 14 050 16 S 25 111 40 5 14 083 01 S Precleaner 14 083 02 S Spark Plug XT 6 14 132 06 S Spark Plug XT 7 XTR 7 12 132 02 S Figure 19 Part List Table Part Description Foam Air Filter Fuel Filter Fuel Line Paper Air Filter XTR 7 70 mm 2 75 in 45 mm 1 8 in 173 10 6 cu in 3 4 kW 4 5 HP 9 5 7 ft Ibs 13 1 kg 29 Ib 1 4 L 3 8 gal Splash 0 5 Amp Kohler Co reserves the right to change product specifications designs and equipment without notice and without incurring obligation Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940 Actual engine horse
10. IO QUIC ee bester tum tunisie A 9 GarbUrel l oiii petentem idum 9 9 Maintenance Instructions 10 Oil Level 10 OI Chal B een 11 Air Cleaner System 11 Paper Air FCT NORTE 11 Foam Air Filter SNR 12 Precleaner ee een 12 Cooling Areas ei 12 SDark PIU cori te tere N 12 eiie AKENT a 13 Repairs an 13 Engine Specifications 13 Parts Ordering 13 Troubleshooting 14 OFAGE ai 14 Engine Warranties 15 17 Safety Precautions To ensure safe operation please read the following statements and understand their meaning Also refer to your equipment owner s manual for other important safety information This safety precautions contained in this manual are explained below 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
11. KOHLER COURAGE xr7 xrn 7 XT 6 XT 7 XTR 7 VERTICAL CRANKSHAFT OWNER S MANUAL XT 6 XT 7 XTR 7 CIG ENAL VERTICAL MANUAL DEL USUARIO XT 6 XT 7 XTR 7 VILEBREQUIN VERTICAL MANUEL DE PROPRIETAIRE KOHLER ENGINES Table of Contents Safety Precautions 2 3 Oil 5 GNI gt 5 Fuel Recommendations 5 General Fuel Recommendations 5 gi Eiot 5 Fuel Line Nee 6 Fuel Shut off Valve If Eguipped 6 Fuel Filter If Equipped 6 Engine Identification Numbers 6 Serial Number eee y Emission Compliance 7 Emission Compliance Period 7 Operating Instructions 7 Pre Start 7 Cold Weather Starting 7 Smart Choke If Equipped 7 Electric Start XTR 7 Only 8 Recoil Start RR 8 Primer Bulb Start If Equipped 8 Manual Choke 8 Shutdown Engine nee 9 Engine Speed een 9 Angle of Operation 9 COVOTT
12. N PRESNPTED APPLIBATIONS ER SPL Mo 1236 TYPE EPA EMISSIQ COMPLIANCE PERIOD HRS REFER TO OWNERS MANUAL FOR MAINTENANCE AND ADJUSTME KOHLER CO ICH LCS usa KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 AND EC STAGE II SN 3 AND CA 2008 AND LATER EXH EVP EMISSION REGS FOR SI SORE EVP CODE CO DOM FUEL BISPL SPEC TYPE EF EPA CARB EMISSION COMPLIANCE PERIOD HAS REFER TO OWNERS MANUAL FOR MAINTENANCE AND ADJUSTMENTS n1230 KOHLER KOHLER WISCONSIN usa KOHLER Figure 6 Air Cleaner Housing Labels Samples KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 EC STAGE II SN 3 EMISSION REGS FOR SI SORE NOT FOR SALE IN CALIFORNIA UNLESS PREEMPT PER SEC 209 e 1 of CAA KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 EC STAGE II SN 3 AND CA 2008 AND LATER EXH EVP EMISSION REGS FOR SI SORE EVP CODE CO FAMILY TYPE APP DISPL CC SPEC NO SERIAL NO BUILD DATE FAMILY TYPE APP DISPL CC SPEC NO SERIAL NO BUILD DATE EMISSION COMPLIANCE PERIOD CARB EMISSION COMPLIANCE PERIOD CERTIFIED ON REFER TO OWNER S MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS SAFETY MAINTENANCE AND ADJUSTMENTS KOHLER CO KOHLER WISCONSIN USA d cg Logis KOHLER Wise KOHLER CO KOHLER WIS WISCONSIN USA CERTIFIED ON REFER TO OWNER S MANUAL FOR HP RATING Figure 7 Engine Shrouding Labels Sampl
13. curely Precleaner 1 Wash or replace the optional precleaner Kohler part number 14 083 02 S yearly or every 25 hours of operation more often under extremely dusty dirty conditions 2 Loosen the air cleaner cover knob and remove the cover See Figure 17 3 Remove the precleaner and wash with detergent in warm water 4 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 5 Reinstall the precleaner 6 Reinstall the air cleaner cover and tighten the knob securely 7 When replacement is necessary use genuine Kohler parts Cooling Areas To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times NOTE Operating the engine with a blocked grass screen dirty or plugged cooling fins will cause engine damage due to overheating Spark Plug 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 The standard spark plug for model XT 6 is a Champion 8815 Kohler part number 14 132 06 S The standard spark plug for models XT 7 and XTR 7 is a Champion RC12YC Kohler part number 12 132 02 5 Equivalent alternative brand plugs can also be used 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debri
14. e design provides smooth powerful performance with lower fuel consumption and cleaner emissions e Commercial grade cast iron cylinder liner offers extra durability and extends engine life e Ball bearing flywheel reduces friction and pulling effort for fast smooth easy starts Extra bearing protection under high load conditions helps extend engine life e Routine maintenance areas are easy to access including air cleaner fuel filter oil spout and spark plug e Every engine is backed by a worldwide network of over 10 000 distributors and dealers that can be located on the Web at www kohlerEngines com Support staff can be reached by calling 1 800 544 2444 This manual covers the operation and maintenance of the Courage XT 6 7 and XTR 7 engines To keep your engine performing at its best closely follow the maintenance procedures outlined in this manual The information contained in this manual is based on the latest product information available at the time of publication Kohler Co reserves the right to alter the contents of this manual without prior notice and without incurring obligation No part of this manual may be reproduced in any way without the written permission of Kohler Co s Technical Publication s department Should this engine be transferred to another party this manual should be included as a permanent part of the engine NOTES Primer Bulb If Equipped Engine ID Lab
15. e 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 Fuel Recommendations Purchase gasoline in small quantities and storein clean approved containers Use a container with a capacity of two gallons or less with a pouring spout is recommended as it is easier to handle and helps eliminate spillage during refueling To minimize gum deposits in fuel system do not use gasoline left over from previous season Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with an 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 that the cylinder head may require more frequent service 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 should not be used Failures resulting from use of these fuels will not be warranted Gasoline Ether Blends Methyl Tertiary Butyl Ether MTBE and unleaded ga
16. el Example Fuel Valve Air Cleaner Figure 1 Courage XT 7 Vertical Shaft Engine 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 Refer to Oil Check Change maintenance instructions Oil Type Use high quality oil that ranks at or above the American Petroleum Institute s API SJ service class Select the oil s viscosity based on air temperature at the time of operation as shown in Figure 2 RECOMMENDED SAE VISCOSITY GRADES 10W 30 SAE 30 10W 30 F 20 32 40 60 100 C 30 0 10 20 40 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Figure 2 Viscosity Grades Table Use service class SJ rated oil or higher Do not extend the oil change intervals longer than recommended as this can cause engine damage and may void the warranty An API symbol on the oil container identifies the service class and SAE viscosity grade I 7 Figure 3 Oil Container Logos Retractable Starter Handle Engine ID Label Example Dipstick Muffler 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 th
17. er If Equipped Air Cleaner Cover gt u AU Air Cleaner Base Air Filter Figure 17 Air Cleaner Assembly Exploded View Check the air cleaner daily or before starting the engine for a buildup of dirt and debris Keep this area in and around the air cleaner clean Also check for loose or damaged components Replace all bent or damaged air cleaner components NOTE Operating engine with loose or damaged air cleaner components could allow unfiltered air into engine causing premature wear and failure Paper Air Filter Yearly or every 100 hours of operation replace the paper air filter Kohler part number 14 083 01 S Check the paper filter for dirty loose or damaged parts every 25 hours of operation more often under extremely dusty or dirty conditions 1 Remove the air cleaner cover the paper air filter and the precleaner if equipped See Figure 17 2 Check the condition of the rubber seal on the filter If the condition of the seal is questionable in any way replace the filter 3 Do not wash the paper filter or use pressurized air as this will damage the filter 4 When servici
18. es When ordering parts or in any communication concerning this engine always give the model name specification number and serial number including any letter suffixes Record all engine ID numbers for future reference Serial Number The serial number is etched into the engine block directly below the fuel tank When ordering parts or in any communication always provide model specification number and serial number Record the serial number for future reference See Figure 8 08 049 000008 Figure 8 Serial Number Location Additional engine identification numbers can be found on the engine ID labels See Figures 6 and 7 Emission Compliance The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet Federal and CARB emission requirements The hourly engine compliance period associated with the category description is located on the identification label See Figure 9 Emission Compliance Period Category C 125 hours Moderate 125 hours Figure 9 Emission Compliance Table CARB For engine displacement information refer to Figure 6 7 or Figure 20 specifications Exhaust Emission Control System for models XT 6 XT 7 and XTR 7 is EM Operating Instructions In addition to these instructions also read the instructions of equipment this engine powers Pre Start Checklist 1 C
19. gine is still warm and refill according to the Viscosity Grades Table Drain Oil from Dipstick Tube 1 keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick remove the oil fill cap dipstick 2 Tilt the engine on its side with the air cleaner facing up See Figure 15 Drain oil into approved container Cil Flow Direction Figure 15 Engine Tilted onto Side Air Cleaner Up 3 After the crankcase is completely drained tilt the engine back upright 4 the crankcase with new oil of the proper type to the FULL mark on the dipstick See Figure 14 Recheck oil level before adding more oil Do not screw dipstick in when checking oil level 5 Reinstall the oil fill cap dipstick tighten securely Drain Oil Via Crankcase Plug If Accessible 1 Disable engine by disconnecting spark plug 2 Remove crankcase plug on bottom of engine and drain oil into approved container See Figure 16 a Figure 16 Crankcase Plug NOTE Oil will drain easier and more quickly if the dipstick is removed 3 Apply thread sealant around three full threads of the drain plug and reinstall the drain plug torque to 13 6 N m 120 in Ib Air Cleaner System This engine is equipped with either a replaceable high density paper air filter or a foam air filter depending on the application In addition an optional foam precleaner may also be included See Figure 17 Preclean
20. heck oil level if low add oil Do not overfill 2 Check fuel level if low add fuel Do not overfill 3 Check cooling areas air intake areas and external surfaces of engine Make sure they are clean and unobstructed 4 Check that the air cleaner components and all shrouds equipment covers and guards are in place and securely fastened A WARNING 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 Cold Weather Starting Use the proper oil for the air temperature expected See Viscosity Table 1 Use fresh winter grade fuel Winter grade gasoline has higher volatility to improve starting Do not use gasoline left over from summer 2 Ensure the battery on XTR 7 only is in good condition A warm battery has much more starting capacity than a cold battery Smart Choke If Equipped 1 fuel shut off valve to the ON position if equipped Refer to Figure 4 2 Turn the ignition switch to the ON position Refer to the operating instructions of the equipment this engine powers 3 For Smart Choke auto choke engines start up adjustments are not necessary or possible Once engine starts adjust it to the equipment manufacturer s recommended operating speed if adjustable Electric Start XTR 7 Only 1
21. in 2006 and later must be designed built and equipped to meet the state s stringent anti smog standards In other states 1997 and later model year engines must be designed built and equipped to meet the U S EPA regulations for small non road engines The engine must be free from defects in materials and workmanship which cause it to fail to conform with U S EPA standards for the first two years of engine use from the date of sale to the ultimate purchaser Kohler Co must warrant the emission control system on the engine for the period of time listed above provided there has been no abuse neglect or improper maintenance The emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included are the hoses belts and connectors and other emission related assemblies Where a warrantable condition exists Kohler Co will repair the engine at no cost including diagnosis if the diagnostic work is performed at an authorized dealer parts and labor MANUFACTURER S WARRANTY COVERAGE Engines produced in 2006 or later are warranted for two years in California In other states 1997 and later model year engines are warranted for two years If any emission related part on the engine is defective the part will be repaired or replaced by Kohler Co free of charge OWNER S WARRANTY RESPONSIBILITIES a The engine owner is responsible for the performance of the required ma
22. intenance listed in the owner s manual Kohler Co recommends that you retain all receipts covering maintenance on the engine but Kohler Co cannot deny warranty solely for the lack of receipts or for your failure to assure that all scheduled maintenance was performed b Be aware however that Kohler Co may deny warranty coverage if the engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications c For warranty repairs the engine must be presented to a Kohler authorized service center as soon as a problem exists Call Kohler Co toll free at 1 800 544 2444 or access our Web site at www kohlerengines com for the names of the nearest service centers Warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding warranty rights and responsibilities you should contact Kohler Co at 1 920 457 4441 and ask for an engine service representative COVERAGE Kohler Co warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed built and equipped at the time of sale to meet all applicable regulations Kohler Co also warrants to the initial purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years Engines produced in 2006 or later are warranted for two years i
23. n California For 1997 and later model years EPA requires manufacturers to warrant engines for two years in all other states These warranty periods will begin on the date the engine is purchased by the initial purchaser If any emission related part on the engine is defective the part will be replaced by Kohler Co at no cost to the owner Kohler Co is liable for damages to other engine components caused by the failure of a warranted part still under warranty Kohler Co shall remedy warranty defects at any authorized Kohler Co engine dealer or warranty station Warranty repair work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective Continued on the next page 16 Listed below are the parts covered by the Federal and California Emission Control Systems Warranty Some of the parts listed may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part The warranted parts include the following if they were present in the engine purchased Oxygen sensor if equipped Intake manifold if equipped e Exhaust manifold if equipped Catalytic muffler if equipped Thermal reactor muffler if equipped e Spark advance module if equipped e Air filter fuel filter and spark plugs only to first scheduled replacement point e Crankcase breather Air injection system if equipped
24. ng the filter also check the air cleaner base and cover for damage air cleaner components should fit properly Replace all questionable air cleaner components 11 5 If any debris fell into the air cleaner when the filter was removed carefully remove and wipe the base clean 6 Reinstall the paper filter and the optional precleaner if equipped 7 Reinstall the air cleaner cover and tighten the knob securely 8 When replacement is necessary use genuine Kohler parts Foam Air Filter Yearly or every 100 hours of operation replace the foam air filter Kohler part number 14 083 09 S Check the foam filter for dirty loose or damaged parts every 25 hours of operation more often under extremely dusty or dirty conditions 1 Remove the air cleaner cover the foam air filter and the precleaner if equipped See Figure 17 2 Check the condition of the foam filter and the rubber seal on the filter If the condition of the filter or the seal is questionable in any way replace the filter 3 When replacement is necessary use genuine Kohler parts 4 When servicing filter also check the air cleaner base and cover for damage air cleaner components should fit properly Replace all questionable air cleaner components 5 If any debris fell into the air cleaner when the filter was removed carefully remove and wipe the base clean 6 Reinstall the foam filter the air cleaner cover and tighten the knob se
25. ortance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows Operating 1 Make sure the engine is stopped level and cool Range so the oil has had time to drain into the sump 2 Clean the area around the oil fill cap dipstick to Low Mark keep dirt and grass clippings out of the engine 3 Unscrew and remove the oil fill cap dipstick wipe off oil Reinsert the dipstick into the tube Figure 14 Oil Level Dipstick and rest the oil fill cap on the tube DO NOT screw the cap into the tube See Figure 13 5 If oil level is low add the correct type of oil up to the F or FULL mark on dipstick Always check the oil level with the dipstick before adding more Oil Fill Cap Dipstick 6 Reinstall oil fill cap dipstick and tighten securely NOTE To prevent extensive engine wear or damage always maintain proper oil level in crankcase Never operate engine with oil level below the L or LOW mark or over the F or FULL mark on dipstick Figure 13 Oil Fill Cap Dipstick 4 Remove dipstick again and check oil level Oil should be up to but not over F or FULL mark on dipstick See Figure 14 Oil Change Oil can be changed by either draining it from the dipstick tube or from the optional drain plug Change the oil after the first three to five hours of operation After that change the oil yearly or after every 50 hours of operation Change oil while en
26. plug lead Crank the engine two or three revolutions Storage If the engine will be out of service for two months or more follow these storage procedures Remove the spark plug Cover the spark plug hole with your thumb and turn the engine over 1 Clean the exterior surfaces of the engine 25 14 Change the oil while the engine is still warm from operation See Oil Change The engine must be run until the fuel tank is completely emptied or the gasoline must be treated with a stabilizer to prevent deterioration If a stabilizer is used follow the manufacturer s until the piston is at the top of its stroke pressure against the thumb is greatest Reinstall the spark plug but do not connect the spark plug lead Store the engine on a level surface in a clean dry place Never store the unit where there is an open flame spark or pilot light such as on a water heater or other appliances COURAGE ENGINE LIMITED WARRANTY Kohler Co warrants to the original retail consumer that each new COURAGE engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal residential homeowner service for a period of two 2 years from date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals If used commercially the COURAGE engine is covered by a 90 day limited warranty The warranty period begins on the date of purchase by the original
27. power is lower and affected by but not limited to accessories air cleaner exhaust charging cooling fuel pump etc application engine speed and ambient operating conditions temperature humidity and altitude Exhaust Emission Control System for models XT 6 XT 7 XTR 7 is EM 13 Troubleshooting When problems occur first check for simple reasons for a problem for example an empty fuel tank or the fuel shut off valve is turned off Additional troubleshooting tips can be found in Figure 21 PROBLEM Will Knocks Misfires Consumes Not Hard Lacks Operates Or Or Start Starting Suddenly Power Erratically Pings POSSIBLE Excess CAUSE Incorrect Oil Level Engine Overloaded Wrong Fuel Discharged Battery No Fuel Engine Flooded Fuel Valve Closed Faulty Spark Plug Engine Runs Rich Air Cleaner Blocked Debris in Fuel Line Cooling Areas Blocked Blown fuse Figure 21 Troubleshooting Table NOTE Do not attempt to service or replace major engine components or any items that require special timing or adjustment procedures This work should be performed by a Kohler 4 authorized service center instructions Fill the tank with fresh gasoline and run the engine for 2 3 minutes to ensure stabilized fuel has entered the carburetor Remove the spark plug Add one tablespoon of engine oil into the spark plug hole Reinstall the plug but do not connect the
28. retor serviced by a Kohler Authorized Service Center Maintenance Maintenance repair or replacement of the emission control devices and systems which are done at the customers expense may be performed by any non road engine repair establishment or individual Warranty repairs must be performed by a Kohler Authorized Service Center Required maintenance procedures should be performed at the frequency outlined in Figure 12 A WARNING Accidental Starts 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 Instructions Frequency Maintenance Required After First 3 5 Hours of Operation Change oil Fill fuel tank Daily or Before Starting Engine Check oil level Check air intake and cooling areas clean as necessary Service or replace precleaner element if equipped Yearly or Every 25 Hours Check paper air or foam filters for dirty loose or damaged parts Replace fuel filter if equipped Yearly or Every 50 Hours P t equipped Change oil Replace spark plug and set gap Replace paper air filter Yearly or Every 100 hours Replace foam air filter Adjust valves Clean combustion chamber Figure 12 Maintenance Table Perform these maintenance procedures more frequently under extremely dusty dirty conditions These procedures should be performed by a Kohler Authorized Service Center Oil Level Check The imp
29. s out of the engine 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable 3 Check the gap using a feeler gauge See Figure 18 Ground Electrode Figure 18 Spark Plug Gap NOTE Do not clean the spark plug in a machine using abrasive grit 5ome grit could remain in the spark plug and enter the engine causing extensive wear and damage 4 Adjust the gap by carefully bending the ground electrode Gap spark plug to 0 762 mm 0 030 in Reinstall the spark plug into the cylinder head Torque the plug to 22 24 N m 16 18 ft Ib Ignition This engine is equipped with a dependable maintenance free ignition system Other than periodically checking feplacing the spark plug no adjustments are necessary or possible with this system In the event starting problems should occur which are not corrected by replacing the spark plug see your Kohler Authorized Service Center Repairs Repair information is available in Kohler Engine service manuals which are available online or at Kohler Authorized Service Centers Major repairs generally require the services of a trained mechanic and the use of specialized tools and equipment Kohler Authorized Service Centers have the facilities training and genuine Kohler replacement parts necessary to perform these services For the nearest sales and service location visit our Web site at www KohlerEngines com or in the U S and Canada call 1 800
30. soline blends up to a maximum of 1576 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Fuel Line These engines use Low Permeation SAE 30 R7 rated fuel lines certified to meet emission requirements Standard fuel line may not be used Order replacement hose Kohler part number 25 111 40 S through a Kohler authorized service center Fuel Shut off Valve If Equipped Turn to ON fuel flow rotate fuel shut off valve towards the engine To turn OFF the fuel flow rotate the fuel shut off valve away from the engine See Figure 4 Fuel Shut off Valve Figure 4 Fuel Shut off Valve ON Position Shown NOTE Before transporting the engine ensure the fuel valve is in the OFF position to prevent fuel spillage Fuel Filter If Equipped Replace with a Kohler fuel filter yearly or every 50 hours of operation Kohler part number 14 050 16 5 Removing the air filter will allow easy access to the fuel filter for servicing See Figure 5 Fuel Filter If Equipped Figure 5 Fuel Filter Air Filter Removed Engine Identification Numbers Engine identification numbers will appear on one of several variations of labels affixed to the engine See Figures 6 and 7 See Figure 1 for Engine Identification Label locations IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 AND EC STAGE II SN 3 EMISSION REGS FOR SI SORE NOT TO BE SOLD IN CALIFORNIA UNLESS USED i
31. tempting to clean off debris A WARNING Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed Carburetor The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions It has been calibrated at the factory and is not adjustable NOTE To ensure correct engine operation at altitudes above 1525 meters 5000 ft it may be necessary to have a Kohler Authorized Service Center install a high altitude jet kit If a 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 If engine troubles appear to be fuel system related check the following areas before seeking service from a Kohler Authorized Service Center e Ensure the fuel tank is filled with clean fresh gasoline e Ensure the air cleaner and precleaner are clean and securely fastened e Ensure the fuel tank cap vent is not blocked and that it is operating properly e Ensure the in line fuel filter if equipped is clean and unobstructed Replace if necessary If after checking these items the engine is still hard to start runs roughly or stalls at low idle speed it may be necessary to have the carbu
32. to the ON position if equipped Refer to Figure 4 Turn the ignition switch to the ON position Refer to the operating instructions of the equipment this engine powers When the outside temperature is above 55 F 13 press CENTER of primer bulb three times before starting When outside temperature is below 55 F 13 press CENTER of primer bulb five times before starting See Figures 10 and 11 S Figure 10 Primer Bulb Cold Engine Start as follows Outside temperature Outside temperature below 55 F 13 Warm Engine Do not use primer Figure 11 Primer Bulb Quick Reference Table NOTE It is important to press the CENTER of the red primer bulb so the air hole is covered ensuring proper pressure NOTE Pressing the primer bulb more times than recommended will flood engine making starting more difficult 4 Once the engine starts adjust it to the equipment manufacturer s recommended operating speed if adjustable 5 To restart a warm engine no priming is required Manual Choke Start 1 Move fuel shut off valve to the ON position if equipped Refer to Figure 4 2 Turn the ignition switch to ON refer to the operating instructions of the equipment this engine powers 3 Turn the ignition switch to ON refer to the operating instructions of the equipment this engine powers 4 To start a cold engine move throttle choke lever to FAST CHOKE ON position To start a
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