Kohler Courage XT-6 Manual de usuario

114 690 01 Rev. G KohlerEngines.com

XT-6, XTR-6, XT6.5, XT650, XT6.75, XT675,

XT-7, XTR-7, XT775, XT8

Service Manual

2 Safety

3 Maintenance

5Specications

10 Tools and Aids

13 Troubleshooting

17 Air Cleaner/Intake

18 Fuel System

24 Governor System

26 Lubrication System

27 Electrical System

31 Starter System

33 Disassembly/Inspection and Service

45 Reassembly

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

Safety

KohlerEngines.com 14 690 01 Rev. G

SAFETY PRECAUTIONS

WARNING: A hazard that could result in death, serious injury, or substantial property damage.

CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING

Explosive Fuel can cause

res and severe burns.

Do not ll fuel tank while

engine is hot or running.

Gasoline is extremely ammable

and its vapors can explode if

ignited. Store gasoline only in

approved containers, in well

ventilated, unoccupied buildings,

away from sparks or ames.

Spilled fuel could ignite if it comes

in contact with hot parts or sparks

from ignition. Never use gasoline

as a cleaning agent.

WARNING

Rotating Parts can cause

severe injury.

Stay away while engine

is in operation.

Keep hands, feet, hair, and

clothing away from all moving

parts to prevent injury. Never

operate engine with covers,

shrouds, or guards removed.

WARNING

Carbon Monoxide can

cause severe nausea,

fainting or death.

Avoid inhaling exhaust

fumes.

Engine exhaust gases contain

poisonous carbon monoxide.

Carbon monoxide is odorless,

colorless, and can cause death if

inhaled.

WARNING

Accidental Starts can

cause severe injury or

death.

Disconnect and ground

spark plug lead(s) before

servicing.

Before working on engine or

equipment, disable engine as

follows: 1) Disconnect spark plug

lead(s). 2) Disconnect negative (–)

battery cable from battery.

WARNING

Hot Parts can cause

severe burns.

Do not touch engine

while operating or just

after stopping.

Never operate engine with heat

shields or guards removed.

WARNING

Cleaning Solvents can

cause severe injury or

death.

Use only in well

ventilated areas away

from ignition sources.

Carburetor cleaners and solvents

are extremely ammable. Follow

cleaner manufacturer’s warnings

and instructions on its proper and

safe use. Never use gasoline as a

cleaning agent.

CAUTION

Electrical Shock can

cause injury.

Do not touch wires while

engine is running.

CAUTION

Damaging Crankshaft

and Flywheel can cause

personal injury.

Using improper procedures can

lead to broken fragments. Broken

fragments could be thrown from

engine. Always observe and use

precautions and procedures when

installing ywheel.

WARNING

Uncoiling Spring can

cause severe injury.

Wear safety goggles or

face protection when

servicing retractable

starter.

Retractable starters contain a

powerful, recoil spring that is

under tension. Always wear safety

goggles when servicing retractable

starters and carefully follow

instructions in Retractable Starter

for relieving spring tension.

Maintenance

14 690 01 Rev. G KohlerEngines.com

MAINTENANCE INSTRUCTIONS

WARNING

Before working on engine or equipment, disable engine as

follows: 1) Disconnect spark plug lead(s). 2) Disconnect

negative (–) battery cable from battery.

Accidental Starts can cause severe injury or

death.

Disconnect and ground spark plug lead(s)

before servicing.

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 dealer.

MAINTENANCE SCHEDULE

After rst 3-5 Hours

● Change oil. Lubrication System

Every 25 Hours or Annually¹

● Service/replace precleaner. Air Cleaner/Intake

● Check air cleaner for dirty, loose or damaged parts. Air Cleaner/Intake

Every 50 Hours or Annually

● Change oil. Lubrication System

● Replace fuel lter (if equipped).

Every 50 Hours or Annually¹

● Replace air cleaner element. Air Cleaner/Intake

Every 100 Hours or Annually¹

● Clean spark arrestor (if equipped).

Every 100 Hours or Annually²

● Have combustion chamber decarbonized.

Every 125 Hours or Annually¹

● Replace spark plug and set gap. Electrical System

1 Perform these procedures more frequently under severe, dusty, dirty conditions.

2 Have a Kohler authorized dealer perform this service.

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. To nd a local Kohler authorized

dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Maintenance

KohlerEngines.com 14 690 01 Rev. G

OIL RECOMMENDATIONS

We recommend use of Kohler oils for best performance.

Other high-quality detergent oils (including synthetic)

of API (American Petroleum Institute) service class SJ

or higher are acceptable. Select viscosity based on

air temperature at time of operation as shown in table

below.

FUEL RECOMMENDATIONS

WARNING

Explosive Fuel can cause res and severe

burns.

Do not ll fuel tank while engine is hot or

running.

Gasoline is extremely ammable and its vapors can

explode if ignited. Store gasoline only in approved

containers, in well ventilated, unoccupied buildings,

away from sparks or ames. Spilled fuel could ignite

if it comes in contact with hot parts or sparks from

ignition. Never use gasoline as a cleaning agent.

NOTE: E15, E20 and E85 are NOT approved and

should NOT be used; effects of old, stale or

contaminated fuel are not warrantable.

Fuel must meet these requirements:

● Clean, fresh, unleaded gasoline.

● Octane rating of 87 (R+M)/2 or higher.

● Research Octane Number (RON) 90 octane minimum.

● Gasoline up to 10% ethyl alcohol, 90% unleaded is

acceptable.

● Methyl Tertiary Butyl Ether (MTBE) and unleaded

gasoline blend (max 15% MTBE by volume) are

approved.

● Do not add oil to gasoline.

● Do not overll fuel tank.

● Do not use gasoline older than 30 days.

STORAGE

If engine will be out of service for 2 months or more

follow procedure below.

1. Add Kohler PRO Series fuel treatment or equivalent

to fuel tank. Run engine 2-3 minutes to get stabilized

fuel into fuel system (failures due to untreated fuel

are not warrantable).

2. Change oil while engine is still warm from operation.

Remove spark plug(s) and pour about 1 oz. of

engine oil into cylinder(s). Replace spark plug(s) and

crank engine slowly to distribute oil.

3. Disconnect negative (-) battery cable.

4. Store engine in a clean, dry place.

Specications

14 690 01 Rev. G KohlerEngines.com

ENGINE IDENTIFICATION NUMBERS

Kohler engine identication numbers (model, specication and serial) should be referenced for efcient repair,

ordering correct parts, and engine replacement.

Model.....................XT-6

Courage Engine

Vertical Shaft

Numerical Designation

Specication ...............XT149-0001

Serial .....................4223500328

Year Manufactured Code Factory Code

Code Year

42 2012

43 2013

44 2014

GENERAL SPECIFICATIONS3,6 XT-6, XTR-6

XT6.5, XT650,

XT6.75, XT675

XT-7, XTR-7,

XT775, XT8

Bore 65 mm (2.6 in.) 70 mm (2.8 in.)

Stroke 45 mm (1.8 in.)

Displacement 149 cc (9.1 cu. in.) 173 cc (10.6 cu. in.)

Oil Capacity (rell) 0.6 L (20 oz.)

Maximum Angle of Operation (@ full oil level)420°

TORQUE SPECIFICATIONS3,5 XT-6, XTR-6

XT6.5, XT650,

XT6.75, XT675

XT-7, XTR-7,

XT775, XT8

Air Cleaner Base

Stud Fastener 8 N·m (71 in. lb.)

Crankcase Fastener 8 N·m (71 in. lb.)

Blower Housing

Stud 10 N·m (88 in. lb.)

Nut 8 N·m (70 in. lb.)

Brake

Mounting Fastener 9.5 N·m (84 in. lb.)

Breather Cover

Fastener 10 N·m (88 in. lb.)

Carburetor

Stud Fastener 8 N·m (71 in. lb.)

3 Values are in Metric units. Values in parentheses are English equivalents.

4 Exceeding maximum angle of operation may cause engine damage from insufcient lubrication.

5 Lubricate threads with engine oil prior to assembly.

6 Any and all horsepower (hp) references by Kohler are Certied Power Ratings and per SAE J1940 & J1995 hp

standards. Details on Certied Power Ratings can be found at KohlerEngines.com.

Specications

KohlerEngines.com 14 690 01 Rev. G

TORQUE SPECIFICATIONS3,5 XT-6, XTR-6

XT6.5, XT650,

XT6.75, XT675

XT-7, XTR-7,

XT775, XT8

Connecting Rod

Cap Fastener (torque in increments) 12.5 N·m (110 in. lb.)

Crankcase

Oil Drain Plug713.6 N·m (120 in. lb.)

Oil Pan Screw 11.0 N·m (98 in. lb.) 14.7 N·m (130 in. lb.)

Cylinder Head

Fastener (torque in 2 increments) rst to 14 N·m (123 in. lb.)

nally to 27.8 N·m (246 in. lb.)

Flywheel

Retaining Nut 51.5 N·m (38 ft. lb.)

Fuel Tank

Bracket to Crankcase Stud 8 N·m (71 in. lb.)

Bracket to Tank Fastener 4.5 N·m (40 in. lb.)

Governor

Lever Fastener 9.5 N·m (84 in. lb.)

Gear Fastener 9.5 N·m (84 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

Module Fastener 10 N·m (88 in. lb.)

Screw 10 N·m (88 in. lb.)

Mufer

Exhaust Stud 5.0 N·m (44 in. lb.)

Exhaust Stud Nut Fastener 9.5 N·m (84 in. lb.)

Retractable Starter

Fastener 8 N·m (71 in. lb.)

Rocker Arm

Stud 13.6 N·m (120 in. lb.)

Pivot Jam Nut 9.5 N·m (84 in. lb.)

Speed Control

Bracket Assembly Fastener 8 N·m (71 in. lb.)

Valve Cover

Fastener 8 N·m (71 in. lb.)

3 Values are in Metric units. Values in parentheses are English equivalents.

5 Lubricate threads with engine oil prior to assembly.

7 Apply thread sealant around three full threads before assembly. No excess sealant allowed on inside or outside of

joint. Threads with preapplied sealant do not require use of additional sealant. Approved sealants include Perma-Loc

LH 150, Perma-Loc MM 115, Perma-Loc HH 120, Perma-Loc HL 126.

Specications

14 690 01 Rev. G KohlerEngines.com

CLEARANCE SPECIFICATIONS3XT-6, XTR-6

XT6.5, XT650,

XT6.75, XT675

XT-7, XTR-7,

XT775, XT8

Camshaft

End Play 0.3/0.85 mm (0.0118/0.0335 in.)

Running Clearance 0.013/0.0555 mm (0.00051/0.00217 in.)

Connecting Rod

Connecting Rod-to-Crankpin Running Clearance

New 0.025/0.045 mm (0.0009/0.0017 in.)

Connecting Rod-to-Crankpin Side Clearance

New 0.03/0.48 mm

(0.00118/0.0189 in.)

0.13/0.58 mm

(0.0051/0.0228 in.)

Connecting Rod-to-Piston Pin Running Clearance 0.008/0.025 mm (0.0003/0.0009 in.)

Piston Pin End I.D. New @ 21°C (70°F) 13.006/13.017 mm

(0.5120/0.5125 in.)

18.006/18.017 mm

(0.7088/0.7093 in.)

Crankcase

Governor Cross Shaft Bore I.D.

New 6.000/6.024 mm (0.2362/0.2372 in.)

Crankshaft

End Play (free) 0.427/1.298 mm (0.0168/0.05110 in.)

Bore in Oil Pan I.D.

Early Models

Later Models

25.400/25.421 mm (0.9999/1.0008 in.)

27.050/27.071 mm (1.06496/1.06578 in.)

Bore in Oil Pan Running Clearance

Early Models

Later Models

0.015/0.051 mm (0.0005/0.002 in.)

0.008/0.121 mm (0.0031/0.00476 in.)

Bearing (ywheel) Journal O.D.

Early Models

Later Models

Max. Taper

Max. Out-of-Round

24.975/24.989 mm

(0.9832/0.9838 in.)

25.005/25.019 mm

(0.9844/0.9850 in.)

0.025 mm (0.0009 in.)

24.975/24.989 mm

(0.9832/0.9838 in.)

24.975/24.989 mm

(0.9832/0.9838 in.)

0.025 mm (0.0009 in.)

Bearing (PTO) Journal O.D.

Early Models

Later Models

Max. Taper

Max. Out-of-Round

25.370/25.385 mm (0.9988/0.9994 in.)

26.95/26.97 mm (1.061/1.062 in.)

0.025 mm (0.0009 in.)

Connecting Rod Journal O.D.

New

Max. Taper

Max. Out-of-Round

25.985/25.995 mm

(1.0230/1.0234 in.)

0.010 mm (0.0004 in.)

29.985/29.995 mm

(1.1805/1.1809 in.)

0.010 mm (0.0004 in.)

Cylinder Bore

Bore I.D. 65.00/65.02 mm

(2.559/2.560 in.)

70.00/70.02 mm

(2.755/2.756 in.)

Max. Out-of-Round

Max. Taper

0.0127 mm (0.0005 in.)

Cylinder Head

Max. Out-of-Flatness 0.08 mm (0.003 in.)

3 Values are in Metric units. Values in parentheses are English equivalents.

Specications

KohlerEngines.com 14 690 01 Rev. G

CLEARANCE SPECIFICATIONS3XT-6, XTR-6

XT6.5, XT650,

XT6.75, XT675

XT-7, XTR-7,

XT775, XT8

Governor

Governor Cross Shaft -to-Crankcase Running Clearance 0.020/0.064 mm (0.0007/0.0025 in.)

Cross Shaft O.D.

New 5.96/5.98 mm (0.2346/0.2354 in.)

Gear Shaft O.D.

New 6.01/6.03 mm (0.2366/0.2374 in.)

Governor Gear Shaft-to-Governor Gear Running Clearance 0.09/0.19 mm (0.0035/0.0074 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.)

Module Air Gap 0.254 mm (0.010 in.)

Piston, Piston Rings, and Piston Pin

Pin Bore I.D. 13.002/13.008 mm

(0.5118/0.5121 in.)

18.000/18.008 mm

(0.7086/0.7089 in.)

Pin O.D. 12.990/12.996 mm

(0.5114/0.5116 in.)

17.990/17.996 mm

(0.7082/0.7085 in.)

Top and Center Compression Ring Side Clearance

New Bore, Before Serial No. 40244XXXXX

New Bore, After Serial No. 40243XXXXX

0.02/0.06 mm (0.0007/0.0023 in.)

0.001/0.020 mm (0.00004/0.00080 in.)

Top and Center Compression Ring End Gap

New Bore, Before Serial No. 40244XXXXX

Top and Center

New Bore, After Serial No. 40243XXXXX

Top

Center

0.25/0.40 mm

(0.0098/0.0157 in.)

0.1/0.25 mm

(0.0039/0.0098 in.)

0.61/0.76 mm

(0.0240/0.0299 in.)

0.25/0.40 mm

(0.0098/0.0157 in.)

0.1/0.25 mm

(0.0039/0.0098 in.)

0.3/0.5 mm

(0.0118/0.0197 in.)

Thrust Face O.D. 64.975/64.985 mm

(0.2558/0.2558 in.)

69.960/69.980 mm

(2.7543/2.7551 in.)

Piston Thrust Face-to-Cylinder Bore Running Clearance 0.025/0.035 mm

(0.0010/0.0014 in.)

0.020/0.060 mm

(0.0007/0.0024 in.)

Valves and Valve Lifters

Intake and Exhaust Valve Lash 0.0762/0.127 mm (0.003/0.005 in.)

Intake Valve Stem-to-Valve Guide Running Clearance 0.020/0.047 mm (0.0007/0.0018 in.)

Exhaust Valve Stem-to-Valve Guide Running Clearance 0.055/0.082 mm (0.0021/0.0032 in.)

Intake Valve Guide I.D. 5.500/5.512 mm (0.2165/0.2170 in.)

Intake Valve Stem Diameter 5.465/5.480 mm (0.2151/0.2157 in.)

Exhaust Valve Guide I.D. 5.500/5.512 mm (0.2165/0.2170 in.)

Exhaust Valve Stem Diameter 5.430/5.445 mm (0.2137/0.2143 in.)

Nominal Valve Face Angle 25°, 45°, 60°

3 Values are in Metric units. Values in parentheses are English equivalents.

Specications

14 690 01 Rev. G KohlerEngines.com

GENERAL TORQUE VALUES

Metric Fastener Torque Recommendations for Standard Applications

Property Class Noncritical

Fasteners

Into Aluminum

Size 4.8 5.8 8.8 10.9 12.9

Tightening Torque: N·m (in. lb.) ± 10%

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. lb.) ± 10%

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)

M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)

M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

Torque Conversions

N·m = in. lb. x 0.113 in. lb. = N·m x 8.85

N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

English Fastener Torque Recommendations for Standard Applications

Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners

Into Aluminum

Size Grade 2 Grade 5 Grade 8

Tightening Torque: N·m (in. lb.) ± 20%

8-32 2.3 (20) 2.8 (25) —2.3 (20)

10-24 3.6 (32) 4.5 (40) —3.6 (32)

10-32 3.6 (32) 4.5 (40) — —

1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)

1/4-28 9.6 (85) 15.8 (140) 22.6 (200) —

5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)

5/16-24 18.7 (165) 30.5 (270) — —

3/8-16 29.4 (260) ———

3/8-24 33.9 (300) ———

Tightening Torque: N·m (ft. lb.) ± 20%

5/16-24 — — 40.7 (30) —

3/8-16 —47.5 (35) 67.8 (50) —

3/8-24 —54.2 (40) 81.4 (60) —

7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —

7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —

1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —

1/2-20 94.9 (70) 142.4 (105) 223.7 (165) —

9/16-12 101.7 (75) 169.5 (125) 237.3 (175) —

9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —

5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —

5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —

3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —

3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Tools and Aids

10 14 690 01 Rev. GKohlerEngines.com

Certain quality tools are designed to help you perform specic disassembly, repair, and reassembly procedures. By

using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service

capabilities and customer satisfaction by decreasing engine downtime.

Here is a list of tools and their source.

SEPARATE TOOL SUPPLIERS

Kohler Tools

Contact your local Kohler source of

supply.

SE Tools

415 Howard St.

Lapeer, MI 48446

Phone 810-664-2981

Toll Free 800-664-2981

Fax 810-664-8181

Design Technology Inc.

768 Burr Oak Drive

Westmont, IL 60559

Phone 630-920-1300

Fax 630-920-0011

TOOLS

Description Source/Part No.

Alcohol Content Tester

For testing alcohol content (%) in reformulated/oxygenated fuels.

Kohler 25 455 11-S

Camshaft Endplay Plate

For checking camshaft endplay.

SE Tools KLR-82405

Camshaft Seal Protector (Aegis)

For protecting seal during camshaft installation.

SE Tools KLR-82417

Cylinder Leakdown Tester

For checking combustion retention and if cylinder, piston, rings, or valves are worn.

Individual component available:

Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)

Kohler 25 761 05-S

Design Technology Inc.

DTI-731-03

Dealer Tool Kit (Domestic)

Complete kit of Kohler required tools.

Components of 25 761 39-S:

Ignition System Tester

Cylinder Leakdown Tester

Oil Pressure Test Kit

Rectier-Regulator Tester (120 V AC/60Hz)

Kohler 25 761 39-S

Kohler 25 455 01-S

Kohler 25 761 05-S

Kohler 25 761 06-S

Kohler 25 761 20-S

Dealer Tool Kit (International)

Complete kit of Kohler required tools.

Components of 25 761 42-S:

Ignition System Tester

Cylinder Leakdown Tester

Oil Pressure Test Kit

Rectier-Regulator Tester (240 V AC/50Hz)

Kohler 25 761 42-S

Kohler 25 455 01-S

Kohler 25 761 05-S

Kohler 25 761 06-S

Kohler 25 761 41-S

Digital Vacuum/Pressure Tester

For checking crankcase vacuum.

Individual component available:

Rubber Adapter Plug

Design Technology Inc.

DTI-721-01

Design Technology Inc.

DTI-721-10

Electronic Fuel Injection (EFI) Diagnostic Software

For Laptop or Desktop PC.

Kohler 25 761 23-S

EFI Service Kit

For troubleshooting and setting up an EFI engine.

Components of 24 761 01-S:

Fuel Pressure Tester

Noid Light

90° Adapter

In-line "T" Fitting

Code Plug, Red Wire

Code Plug, Blue Wire

Shrader Valve Adapter Hose

Kohler 24 761 01-S

Design Technology Inc.

DTI-019

DTI-021

DTI-023

DTI-035

DTI-027

DTI-029

DTI-037

Flywheel Puller

For properly removing ywheel from engine.

SE Tools KLR-82408

Otros manuales para Courage XT-6

Este manual sirve para los siguientes modelos

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