Kohler Courage Manual de usuario

18 690 01 Rev. G KohlerEngines.com

SH255, SH265, SH270

Service Manual

2 Safety

3 Maintenance

5 Speciﬁcations

12 Tools and Aids

15 Troubleshooting

19 Air Cleaner/Intake

20 Fuel System

24 Governor System

25 Lubrication System

26 Electrical System

30 Starter System

33 Disassembly/Inspection and Service

43 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 18 690 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

ﬁres and severe burns.

Do not ﬁll fuel tank while

engine is hot or running.

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.

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. Never run engine

indoors or in enclosed

spaces.

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 ﬂammable. 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 ﬂywheel.

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

18 690 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 ﬁrst 5 Hours

●Change oil (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Lubrication System

Every 50 Hours or Annually

●Service/replace dual-element precleaner. Air Cleaner/Intake

Every 100 Hours or Annually¹

●Clean low-proﬁle air cleaner element. Air Cleaner/Intake

●Replace dual-element air cleaner element. Air Cleaner/Intake

●Change oil. Lubrication System

●Clean cooling areas. Air Cleaner/Intake

●Clean spark arrestor (if equipped).

●Replace fuel ﬁlter (if equipped).

Every 100 Hours2

●Check and adjust valve clearance when engine is cold. Reassembly

Every 125 Hours or Annually¹

●Replace spark plug and set gap. Electrical System

Every 200 Hours²

●Replace fuel line. Fuel System

Every 300 Hours

●Replace low-proﬁle air cleaner element. Air Cleaner/Intake

Every 300 Hours3

●Change oil (KOHLER PRO 10W-50 oil only). Lubrication System

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

2Have a Kohler authorized dealer perform this service.

3Option only if using KOHLER®PRO oil.

REPAIRS/SERVICE PARTS

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

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

Maintenance

KohlerEngines.com 18 690 01 Rev. G

OIL RECOMMENDATIONS

All-season KOHLER®PRO 10W-50 Synthetic Oil is the

ideal oil for KOHLER engines. It is speciﬁcally formulated

to extend the oil change interval to 300 Hours. Contact

your Kohler authorized dealer for availability.

300-Hour oil change intervals are exclusive to and only

authorized on KOHLER engines that utilize the KOHLER

PRO 10W-50 Synthetic Oil. Alternative engine oils may

be used with KOHLER engines but require 100-Hour oil

change intervals for proper maintenance. Oil must be

API (American Petroleum Institute) service class SJ or

higher. Select viscosity based on air temperature at time

of operation as shown below.

°F -20 020324060

50 80 100

°C -30 -20 -10 0 10 20 30 40

5W-30

10W-30

SAE 30

Kohler PRO 10W-50

FUEL RECOMMENDATIONS

WARNING

Explosive Fuel can cause ﬁres and severe

burns.

Do not ﬁll fuel tank while engine is hot or

running.

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. 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 overﬁll 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

(NOT required if using KOHLER PRO 10W-50

full-synthetic oil). 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.

Speciﬁcations

18 690 01 Rev. G KohlerEngines.com

369.40

[14.543]

113.44

[4.466]

273.97

[10.786]

88.00

[3.465]

339.90

[13.382]

106.00

[4.173]

30.00

[1.181]

METRIC FLANGE: 4X M8 X 1.25-6H THRU

SAE A FLANGE: 4X 5/16-24 UNF-2B THRU

METRIC FLANGE: 4X M8 X 1.25-6H 15.00 [0.591]

SAE A FLANGE: 4X 5/16-24 UNF-2B 15.00 [0.591]

162.00

[6.378]

342.20

[13.473]

65.05

[2.561]

32.53

[1.281]

66.00 [2.598]

32.53 [1.281]

65.05 [2.561]

318.66

[12.545]

STRAIGHT PTO

181.60

[7.150]

SPARK

PLUG

OIL FILL

DRAIN PLUG

37.98 [1.495]

37.50 [1.476]

78.00

[3.071]

2X Ø 10.00 [0.394]

2X 10.00 X 15.50

SLOT [0.394 X 0.610]

110.00 [4.331]

AIR CLEANER

COVER

REMOVAL

12.50

[0.492]

GAS CAP

REMOVAL

Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

Speciﬁcations

KohlerEngines.com 18 690 01 Rev. G

ENGINE IDENTIFICATION NUMBERS

Kohler engine identiﬁcation numbers (model, speciﬁcation and serial) should be referenced for eﬃcient repair,

ordering correct parts, and engine replacement.

Model. . . . . . . . . . . . . . . . . . . . . SH265

Courage Engine

Horizontal Shaft

Numerical Designation

Speciﬁcation . . . . . . . . . . . . . . . SH265-0001

Serial . . . . . . . . . . . . . . . . . . . . . 4923500328

Year Manufactured Code Factory Code

Code Year

49 2019

50 2020

51 2021

GENERAL SPECIFICATIONS4,7 SH255, SH265, SH270

Bore 68 mm (2.7 in.)

Stroke 54 mm (2.1 in.)

Displacement 196 cc (12.0 cu. in.)

Oil Capacity (reﬁll) 0.6 L (0.63 U.S. qt.)

Maximum Angle of Operation (@ full oil level)525°

TORQUE SPECIFICATIONS4,6 SH255, SH265, SH270

Air Cleaner

Mounting Screw (into intake manifold) 8 N·m (70.8 in. lb.)

Blower Housing and Sheet Metal

M6 Shoulder Screw 10 N·m (88.5 in. lb.)

M6 Nut 8 N·m (70.8 in. lb.)

Carburetor

Stud 10 N·m (88.5 in. lb.)

Primary Nut 8 N·m (70.8 in. lb.)

Secondary Nut 10 N·m (88.5 in. lb.)

Intake Cover Nut 4 N·m (35.4 in. lb.)

Connecting Rod

Cap Fastener (torque in increments) 12 N·m (106 in. lb.)

Crankcase

Oil Drain Plug 18 N·m (13 ft. lb.)

Closure Plate Screw 24 N·m (212 in. lb.)

Cylinder Head

Fastener (torque in 2 increments) ﬁrst to 12 N·m (106 in. lb.)

ﬁnally to 24 N·m (212 in. lb.)

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

5Exceeding maximum angle of operation may cause engine damage from insuﬃcient lubrication.

6Lubricate threads with engine oil prior to assembly.

7Any and all horsepower (hp) references by Kohler are Certiﬁed Power Ratings and per SAE J1940 & J1995 hp

standards. Details on Certiﬁed Power Ratings can be found at KohlerEngines.com.

Speciﬁcations

18 690 01 Rev. G KohlerEngines.com

TORQUE SPECIFICATIONS4,6 SH255, SH265, SH270

Flywheel

Retaining Nut 74 N·m (655 in. lb.)

Fuel Tank

Mounting Nut 24 N·m (212 in. lb.)

Mounting Screw 24 N·m (212 in. lb.)

Inlet Fitting 1.5 N·m (13.3 in. lb.)

Governor

Arm Nut 10 N·m (88.5 in. lb.)

Throttle Control Lever Nut 4.5-6 N·m (40-53 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

Module Fastener 8 N·m (70.8 in. lb.)

Module Screw 10 N·m (88.5 in. lb.)

Oil Sentry™Module Screw 8 N·m (70.8 in. lb.)

Muﬄer

M8 Exhaust Screw 24 N·m (212 in. lb.)

M6 Muﬄer Shield Screw 8 N·m (70.8 in. lb.)

M4 Muﬄer Shield Screw 2 N·m (17.7 in. lb.)

M5 Spark Arrestor Screw 3.5 N·m (31 in. lb.)

Retractable Starter

Cover Screw 5.4 N·m (47.8 in. lb.)

Screw 10 N·m (88.5 in. lb.)

Rocker Arm

Stud 13.6 N·m (120 in. lb.)

Pivot Jam Nut 10 N·m (88.5 in. lb.)

Valve Cover

Fastener 8 N·m (70.8 in. lb.)

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

6 Lubricate threads with engine oil prior to assembly.

Speciﬁcations

KohlerEngines.com 18 690 01 Rev. G

CLEARANCE SPECIFICATIONS4SH255, SH265, SH270

Camshaft

End Play 0.025/0.602 mm (0.0010/0.0237 in.)

Running Clearance 0.016/0.052 mm (0.0006/0.0020 in.)

Bore I.D.

New

Max. Wear Limit

14.000/14.018 mm (0.5512/0.5519 in.)

14.048 mm (0.5531 in.)

Connecting Rod

Crankpin End I.D. @ 21°C (70°F)

New

Max. Wear Limit

30.021/30.026 mm (1.1819/1.1821 in.)

30.08 mm (1.184 in.)

Connecting Rod-to-Crankpin Running Clearance

New

Max. Wear Limit

0.041/0.051 mm (0.002/0.002 in.)

0.12 mm (0.005 in.)

Connecting Rod-to-Crankpin Side Clearance

New

Max. Wear Limit

0.58/0.60 mm (0.023/0.024 in.)

1.10 mm (0.043 in.)

Connecting Rod-to-Piston Pin Running Clearance 0.01/0.027 mm (0.0004/0.0011 in.)

Piston Pin End I.D. @ 21°C (70°F)

New

Max. Wear Limit

18.010/18.015 mm (0.709/0.709 in.)

18.08 mm (0.712 in.)

Crankcase

Governor Cross Shaft Bore I.D.

New

Max. Wear Limit

6.000/6.018 mm (0.2362/0.2369 in.)

6.037 mm (0.2377 in.)

Crankshaft

End Play (free) 0.025/0.703 mm (0.0010/0.028 in.)

Ball Bearing 0.003/0.25 mm (0.0001/0.0010 in.)

Bore (in crankcase)

New, without Main Bearing 51.961/51.991 mm (2.0457/2.0469 in.)

Bore (in closure plate)

New, without Main Bearing 51.961/51.991 mm (2.0457/2.0469 in.)

Flywheel End Main Bearing Journal O.D.

O.D.-New

O.D.-Max. Wear Limit

Max. Taper

Max. Out-of-Round

24.975/24.989 mm (0.9833/0.9838 in.)

24.95 mm (0.9823 in.)

0.025 mm (0.0010 in.)

Closure Plate End Main Bearing Journal O.D.

O.D.-New

O.D.-Max. Wear Limit

Max. Taper

Max. Out-of-Round

24.975/24.989 mm (0.9833/0.9838 in.)

24.95 mm (0.9823 in.)

0.025 mm (0.0010 in.)

Connecting Rod Journal O.D.

O.D.-New

O.D.-Max. Wear Limit

Max. Taper

Max. Out-of-Round

Width

29.975/29.985 mm (1.1801/1.1805 in.)

29.920 mm (1.1779 in.)

0.025 mm (0.0010 in.)

25.02/25.08 mm (0.9850/0.9874 in.)

Runout (either end) 0.025 mm (0.0010 in.)

Main Bearing I.D. (Crankcase/Closure Plate)

New (installed) 24.994/25.000 mm (0.9840/0.9842 in.)

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

Speciﬁcations

18 690 01 Rev. G KohlerEngines.com

CLEARANCE SPECIFICATIONS4SH255, SH265, SH270

Cylinder Bore

Bore I.D.

New

Max. Wear Limit

Max. Out-of-Round

Max. Taper

70.027/70.035 mm (2.757/2.757 in.)

70.200 mm (2.764 in.)

12.7 microns (0.0005 in.)

Cylinder Head

Max. Out-of-Flatness 0.1 mm (0.0039 in.)

Governor

Governor Cross Shaft-to-Crankcase Running Clearance 0.013/0.075 mm (0.0005/0.0029 in.)

Governor Cross Shaft O.D.

New

Max. Wear Limit

5.95/5.98 mm (0.2342/0.2354 in.)

5.85 mm (0.2303 in.)

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

Governor Gear Shaft O.D.

New

Max. Wear Limit

6.028/6.043 mm (0.2373/0.2379 in.)

6.018 mm (0.2369 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.)

Module Air Gap 0.254 mm (0.0100 in.)

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance 0.009/0.016 mm (0.0003/0.0006 in.)

Piston Pin Bore I.D.

New

Max. Wear Limit

18.004/18.005 mm (0.7088/0.7089 in.)

18.05 mm (0.7106 in.)

Piston Pin O.D.

New

Max. Wear Limit

17.992/17.995 mm (0.7083/0.7084 in.)

17.95 mm (0.7067 in.)

Top and Center Compression Ring Side Clearance

New Bore

Used Bore (max.)

0.04 mm (0.002 in.)

0.15 mm (0.006 in.)

Top and Center Compression Ring End Gap

New Bore

Used Bore (max.)

0.325 mm/0.4 (0.013/0.016 in.)

1.00 mm (0.039 in.)

Top and Center Compression Ring Width

New Bore

Used Bore (max.)

1.5/1.51 mm (0.059/0.059 in.)

1.37 mm (0.054 in.)

Oil Control Ring-to-Groove Side Clearance 0.06/0.18 mm (0.0023/0.0071 in.)

Piston Thrust Face O.D.8

New

Max. Wear Limit

67.975/67.985 mm (2.6762/2.6766 in.)

67.85 mm (2.6712 in.)

Piston Thrust Face-to-Cylinder Bore Running Clearance

New 0.057/0.075 mm (0.0022/0.0029 in.)

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

8 Measure 15 mm (0.5905 in.) above bottom of piston skirt at right angles to piston pin.

Speciﬁcations

KohlerEngines.com 18 690 01 Rev. G

CLEARANCE SPECIFICATIONS4SH255, SH265, SH270

Valves and Valve Lifters

Intake Valve Lash 0.1 mm (0.0040 in.)

Exhaust Valve Lash 0.15 mm (0.0060 in.)

Intake Valve Stem-to-Valve Guide Running Clearance 0.020/0.044 mm (0.008/0.0017 in.)

Exhaust Valve Stem-to-Valve Guide Running Clearance 0.030/0.054 mm (0.0011/0.0021 in.)

Intake Valve Stem O.D.

New

Max. Wear Limit

5.480 mm (0.2157 in.)

5.32 mm (0.2094 in.)

Exhaust Valve Stem O.D.

New

Max. Wear Limit

5.47 mm (0.2153 in.)

5.305 mm (0.2088 in.)

Intake Valve Stem to Guide

New

Max. Wear Limit

0.024/0.039 mm (0.001/0.002 in.)

0.10 mm (0.0004 in.)

Exhaust Valve Stem to Guide

New

Max. Wear Limit

0.098/0.112 mm (0.0038/0.0044 in.)

0.12 mm (0.0005 in.)

Valve Guide Reamer Size

Standard Intake

Standard Exhaust

5.506 mm (0.2168 in.)

Valve Seat Width 0.800/2.00 mm (0.0315/0.787 in.)

Nominal Valve Face Angle 30°, 45°, 60°

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

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