KOHLER COURAGE Model XT 7 4.8HP Engine Full Service & Repair Manual

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

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

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

1.2 Section 1 Safety and General Information Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes, and never run the engine in a closed WARNING Electrical Shock can cause injury. Do not touch wires while engine is running. CAUTION Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the area. Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. severe burns. engine is hot or running. WARNING Explosive Fuel! its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent. Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. WARNING Flammable Solvents! Carburetor cleaners and solvents are away from the area. Follow the cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

1.3 Section 1 Safety and General Information 1 When ordering parts, or in any communication involving an engine, always give the Model, of the engine. A. Model No. Courage Vertical Shaft Engine Numerical Designation written in this model series B. Spec. No. Engine Model Model XT-6 XT-7 C. Serial No. Year Manufactured Code Code Year 37 2007 38 2008 Factory Code 3723500328 XT173-0001 XT 7

1.4 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the engine is extremely important, as is daily checking of oil level oil, or using dirty oil, will cause premature engine wear and failure. Oil Type Use high quality detergent oil of . Select the viscosity based on the air temperature at the time 10W-30 RECOMMENDED SAE VISCOSITY GRADES 10W-30, SAE 30 °F -20 0 20 32 40 60 80 100 °C -30 -20 -10 0 10 20 30 40 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Figure 1-3. Viscosity Grades Table. NOTE: Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage. 10W-30 A P I S E R V I C E S J Figure 1-4. Oil Container Logo. Refer to Section 6, Lubrication System, for detailed oil check and oil change procedures. Fuel Recommendations WARNING: Explosive Fuel! if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks 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 recommended. Such a container is easier to handle and helps eliminate spillage during refueling. To ensure easy starting and minimize gum deposits in previous season. Do not add oil to the gasoline. Do not Fuel Type gasoline with a pump sticker octane rating of 86 or 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 gasoline by volume) is approved as a fuel for Kohler 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 volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved.

1.5 Section 1 Safety and General Information 1 Periodic Maintenance WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine by disconnecting the spark plug lead. Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table. They should also be included as part of any seasonal tune-up. Frequency Maintenance Required Check oil level. Yearly or Every 25 Hours Yearly or Every 50 Hours Change oil. Replace spark plug and set gap. ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. Storage more, use the following storage procedure: Section 6, Lubrication System. completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. tank with clean, fresh gasoline, and run the 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 plug lead. Crank the engine two or three revolutions. 5. Remove the spark plug. Cover the spark plug hole with your thumb and turn the engine over until the piston is at the top of its stroke (pressure against the thumb is greatest). Reinstall the spark plug, but do not connect the plug lead. 6. Store the engine in a clean, dry place. Never store the machine or fuel container where there is an water heater or on other appliances.

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

KOHLER COURAGE Model XT 7 4.8HP Engine Full Service & Repair Manual

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