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COURAGE XT-6, XT-7, XTR-7XT-6, XT-7, XTR-7 VERTICAL CRANKSHAFT OWNER'S MANUALENXT-6, XT-7, XTR-7 CIGÜEÑAL VERTICAL MANUAL DEL USUARIOESXT-6, XT-7, XTR-7 VILEBREQUIN VERTICAL MANUEL DE PROPRIÉTAIREFR1
Table of ContentsSafety Precautions .2-3Oil Recommendations. 5Oil Type. 5Fuel Recommendations . 5General Fuel Recommendations. 5Fuel Type . 5Fuel Line. 6Fuel Shut-off Valve (If Equipped). 6Fuel Filter (If Equipped) . 6(QJLQH ,GHQWL¿FDWLRQ 1XPEHUV. 6Serial Number. 7Emission Compliance . 7Emission Compliance Period. 7Operating Instructions . 7Pre-Start Checklist. 7Cold Weather Starting . 7Smart-Choke (If Equipped). 7Electric Start (XTR-7 Only) . 8Recoil Start . 8Primer Bulb Start (If Equipped). 8Manual Choke Start. 8Shutdown Engine . 9Engine Speed . 9Angle of Operation . 9Overheating . 9Carburetor . 9Maintenance. 9Maintenance Instructions. 10Oil Level Check. 10Oil Change. 11Air Cleaner System. 11Paper Air Filter. 11Foam Air Filter . 12Precleaner . 12Cooling Areas . 12Spark Plug. 12Ignition. 13Repairs . 13(QJLQH 6SHFL¿FDWLRQV . 13Parts Ordering . 13Troubleshooting . 14Storage . 14Engine Warranties .15-17Safety PrecautionsTo ensure safe operation, please read the following statements and understand their meaning. Also refer to yourequipment owner's manual for other important safety information. This safety precautions contained in thismanual are explained below:WARNINGWarning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantialproperty damage if the warning is ignored.CAUTIONCaution is used to indicate the presence of a hazard that will or can cause minor personal injury or propertydamage if the caution is ignored.NOTENote is used to notify people of installation, operation, or maintenance information that is important but nothazard-related.For Your Safety!These precautions should be followed at all times. Failure to follow these precautions could result in injury to the operatorand others.2
Safety PrecautionsWARNING ¡ ȱ ȱ ȱ ȱę ȱand severe burns. ȱ ȱę ȱ ȱ ȱ ȱ ȱ ȱengine is hot or running.Explosive Fuel! ȱ ȱ ¡ ȱĚ ȱ ȱits vapors can explode if ignited. Storegasoline only in approved containers,in well ventilated, unoccupied ǰȱ ȱ ȱ ȱ ȱĚ ǯȱ ȱ ȱę ȱ ȱ ȱ ȱ ȱ ȱengine is hot or running, since spilledfuel could ignite if it comes in contactwith hot parts or sparks from ignition.Do not start the engine near spilled ǯȱ ȱ ȱ ȱ ȱ ȱ ȱagent.WARNINGAccidental Starts can causesevere injury or death.Disconnect and ground spark pluglead before servicing.Accidental Starts!Accidental starting can cause severeinjury or death. Before working on theengine or equipment, disable the engineby disconnecting the spark plug lead.WARNINGHot Parts can cause severe burns.Do not touch engine while operating ȱ ȱ Ğ ȱ ǯHot Parts!Engine components can get extremelyhot from operation. To prevent severeburns, do not touch these areas whilethe engine is running, or immediately Ğ ȱ ȱ ȱ ȱ ěǯȱ ȱ ȱthe engine with heat shields or guardsremoved.CAUTIONElectrical Shock can cause injury.Do not touch wires while engine isrunning.Electrical Shock! ȱ ȱ ȱ ȱ ȱcomponents while the engine isrunning. They can be sources ofelectrical shock.WARNINGCarbon Monoxide can causesevere nausea, fainting or death.Avoid inhaling exhaust fumes, andnever run the engine in a closed ȱ ȱ ę ȱ ǯLethal Exhaust Gases!Engine exhaust gases containpoisonous carbon monoxide. Carbonmonoxide is odorless, colorless, andcan cause death if inhaled. Avoidinhaling exhaust fumes, and neverrun the engine in a closed building or ę ȱ ǯWARNINGRotating Parts can cause severeinjury.Stay away while engine is inoperation.Rotating Parts!Keep hands, feet, hair, and clothingaway from all moving parts to prevent ǯȱ ȱ ȱ ȱ ȱ ȱcovers, shrouds, or guards removed.CaliforniaProposition 65 WarningEngine exhaust from this productcontains chemicals known to theState of California to cause cancer,birth defects, or other reproductiveharm.3EN
Congratulations on your purchase of a Kohler Courage XT Series engine. Top-notch performance is built into thistough, reliable, quality-manufactured Kohler engine — made by the company world renowned for "RelentlessPower and Legendary Performance."Here are some of the innovative features of your Courage XT engine: Ĝ ǰȱ Ȭ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱcleaner emissions. Ȭ ǰȱ Ȭ ȱ ȱ ȱ ě ȱ ¡ ȱ ǰȱ ȱ ¡ ȱ ȱ ǯ Ȭ ȱĚ ȱ ȱ ȱ ȱ ȱ ě ȱ ȱ ǰȱ ǰȱ ȱ ǯȱ ¡ ȱ ȱ ȱunder high-load conditions helps extend engine life. ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱę ǰȱ ȱ ǰȱ ȱ ȱ ǯ Every engine is backed by a worldwide network of over 10,000 distributors and dealers that can be located ȱ ȱ ȱ ȱǯ ǯ ǯȱ ȱ ěȱ ȱ ȱ ȱ ȱ ȱŗȬŞŖŖȬśŚŚȬŘŚŚŚǯThis manual covers the operation and maintenance of the Courage XT-6, XT-7, and XTR-7 engines. To keep yourengine performing at its best, closely follow the maintenance procedures outlined in this manual. The informationcontained in this manual is based on the latest product information available at the time of publication. KohlerCo. reserves the right to alter the contents of this manual without prior notice and without incurring obligation. ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ǯȇ ȱ ȱPublication's department.Should this engine be transferred to another party, this manual should be included as a permanent part of theengine.NOTES4
Primer Bulb(If Equipped)Fuel CapEngineID Label(Example)RetractableStarterHandleDipstickFuel TankEngineID Label(Example)Air CleanerFuel Valve0XIÀHUFigure 1. Courage XT-7, Vertical Shaft Engine.Oil RecommendationsFuel RecommendationsUsing the proper type and weight of oil in the engineis extremely important, as is daily checking of oillevel and changing oil regularly. Failure to use thecorrect oil, or using dirty oil, will cause prematureengine wear and failure. Refer to Oil Check/Changemaintenance instructions.Oil TypeUse high-quality oil that ranks at or above theAmerican Petroleum Institute's (API) SJ service class.Select the oil's viscosity based on air temperature at ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱŘǯRE CO M M E N D E D S A E VIS C OS IT Y GRA D E S10W-30, SAE 3010W-30 F -20 C -30200-20-1032040601010080203040TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGEWARNING: Explosive Fuel! ȱ ȱ ¡ ȱĚ ȱ ȱ ȱ ȱ ȱ ¡ ȱif ignited. Store gasoline only in approved containers, inwell ventilated, unoccupied buildings, away from sparks orĚ ǯȱ ȱ ȱę ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱrunning since spilled fuel could ignite if it comes in contactwith hot parts or sparks from ignition. Do not start the ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱagent.General Fuel RecommendationsPurchase gasoline in small quantities and store inclean, approved containers. Use a container with acapacity of two gallons or less with a pouring spoutis recommended, as it is easier to handle and helpseliminate spillage during refueling. To minimize gum ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ Ğȱ ȱfrom previous season. Do not add oil to the gasoline. ȱ ȱ ę ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱexpand.Fuel TypeFigure 2. Viscosity Grades Table.Use service class SJ rated oil or higher. Do not extendthe oil change intervals longer than recommendedas this can cause engine damage, and may voidthe warranty. An API symbol on the oil container ę ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱSee Figure 3.APIRVICSAE30SJFigure 3. Oil Container Logos.SEENUnleaded gasoline is recommended as it leaves lesscombustion chamber deposits. Leaded gasoline maybe used in areas where unleaded is not available andexhaust emissions are not regulated. Be aware that thecylinder head may require more frequent service.E10W-30SJAPIRVICESEFor best results use only clean, fresh, unleaded ȱ ȱ ȱ ȱ ȱ ȱŞŝȱ ȱ ǯȱ ȱcountries using the Research method, it should be 90octane minimum.Gasoline/Alcohol BlendsGasohol (up to 10% ethyl alcohol, 90% unleadedgasoline by volume) is approved as a fuel for Kohler ǯȱ ȱ Ȧ ȱ ȱ ȱ ŘŖȱ ȱ Şśȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱuse of these fuels will not be warranted.5
Gasoline/Ether BlendsMethyl Tertiary Butyl Ether (MTBE) and unleaded ȱ ȱǻ ȱ ȱ ȱ ¡ ȱ ȱŗśƖȱ ȱ ȱvolume) are approved as a fuel for Kohler engines.Other gasoline/ether blends are not approved.(QJLQH ,GHQWL¿FDWLRQ 1XPEHUV ȱ ę ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĝ¡ ȱ ȱ ȱ ǯȱ ȱ ȱŜȱ ȱŝǯȱ ȱ ȱŗȱ ȱ ȱ ę ȱLabel locations.Fuel LineThese engines use Low Permeation SAE 30 R7 rated ȱ ǰȱ ę ȱ ȱ ȱ ȱ ǯȱStandard fuel line may not be used. Order replacementhose (Kohler part number 25 111 40-S) through aKohler authorized service center.Fuel Shut-off Valve (If Equipped)Turn to ONȱ ȱĚ ǰȱ ȱ ȱ Ȭ ěȱ ȱtowards the engine. To turn OFFȱ ȱ ȱĚ ǰȱ ȱ ȱ ȱ Ȭ ěȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŚǯFigure 6. Air Cleaner Housing Labels (Samples).Fuel Shut-off ValveIMPORTANT ENGINE INFORMATIONTHIS ENGINE MEETS U.S. EPA PH2, EC STAGE II(SN:3) AND CA 2008 AND LATER EXH/EVPEMISSION REGS FOR SI SORE. EVP CODE:COFAMILYTYPE APPDISPL. (CC)SPEC. NO.SERIAL NO.BUILD DATEFigure 4. Fuel Shut-off Valve (ON Position Shown).FAMILYTYPE APPDISPL. (CC)SPEC. NO.SERIAL NO.BUILD DATEEMISSION COMPLIANCE PERIOD:EPA:CARB:CERTIFIED ON:REFER TO OWNER'S MANUAL FOR HP RATING,SAFETY, MAINTENANCE AND ADJUSTMENTS.1-800-544-2444 kohlerengines.comKOHLER CO. KOHLER, WISCONSIN, USANOTE: Before transporting the engine, ensure thefuel valve is in the OFF position to preventfuel spillage.Fuel Filter (If Equipped) ȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱ ȱśŖȱhours of operation (Kohler part number 14 050 16-S). ȱ ȱ ȱę ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ǯȱ ȱ ȱśǯFuel Filter(If Equipped)Figure 5. Fuel Filter (Air Filter Removed).6IMPORTANT ENGINE INFORMATIONTHIS ENGINE MEETS U.S. EPA PH2, EC STAGE II(SN:3) EMISSION REGS FOR SI SORE. NOT FORSALE IN CALIFORNIA UNLESS PREEMPT PERSEC. 209(e)(1) of CAA.CRAFTED IN CHINAEMISSION COMPLIANCE PERIOD:EPA:CERTIFIED ON:REFER TO OWNER'S MANUAL FOR HP RATING,SAFETY, MAINTENANCE AND ADJUSTMENTS.1-800-544-2444 kohlerengines.comKOHLER CO. KOHLER, WISCONSIN, USACRAFTED IN CHINAFigure 7. Engine Shrouding Labels (Samples).When ordering parts, or in any communicationconcerning this engine, always give the model name, ę ȱ ǰȱ ȱ ȱ ȱȯȱ ȱ ȱ Ĵ ȱ Ĝ¡ ǯRecord all engine ID numbers for future reference.
Serial NumberOperating InstructionsThe serial number is etched into the engine block,directly below the fuel tank. When ordering parts,or in any communication, always provide model, ę ȱ ǰȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞǯIn addition to these instructions, also read the instructionsof equipment this engine powers.Fuel Tank08-049600608Figure 8. Serial Number Location.Pre-Start Checklistŗǯȱ ȱ ȱ Dzȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ę ǯŘǯȱ ȱ ȱ Dzȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ę ǯ3.Check cooling areas, air intake areas, and externalsurfaces of engine. Make sure they are clean andunobstructed.Śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱshrouds, equipment covers, and guards are inplace and securely fastened.WARNING: Lethal Exhaust Gases!Engine exhaust gases contain poisonous carbon monoxide.Carbon monoxide is odorless, colorless, and can cause deathif inhaled. Avoid inhaling exhaust fumes, and never run the ȱ ȱ ȱ ȱ ȱ ȱ ę ȱ ǯ ȱ ȱ ę ȱ ȱ ȱ ȱ ȱon the engine ID labels. See Figures 6 and 7.Cold Weather StartingEmission Compliance1.Use fresh winter grade fuel. Winter gradegasoline has higher volatility to improve starting. ȱ ȱ ȱ ȱ Ğȱ ȱ ȱ ǯŘǯȱ ȱ ȱ Ĵ ȱǻ ȱ Ȭŝȱ Ǽȱ ȱ ȱ ȱ ǯȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ǯThe Emission Compliance Period, referred to on theEmission Control or Air Index label, indicates thenumber of operating hours for which the engine hasbeen shown to meet Federal and CARB emissionrequirements. The hourly engine compliance periodassociated with the category description is located on ȱ ę ȱ ǯȱ ȱ ȱşǯUse the proper oil for the air temperature expected.See Viscosity Table.Smart-Choke (If Equipped)ŗǯȱ ȱ ȱ Ȭ ěȱ ȱ ȱ ȱON position (if Ǽǯȱ ȱ ȱ ȱŚǯŘǯȱ ȱ ȱ ȱ ȱ ȱ ȱON position. Referto the operating instructions of the equipment thisengine powers.Figure 9. Emission Compliance Table.3.For engine displacement information, refer to Figure 6,ŝȱ ȱ ȱŘŖȱǻ ę ǼǯFor Smart-Choke (auto choke) engines, start-upadjustments are not necessary or possible.Śǯȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱmanufacturer's recommended operating speed (ifadjustable).Emission Compliance PeriodEPACategory C - 125 hoursCARBModerate - 125 hoursExhaust Emission Control System for models XT-6,XT-7, and XTR-7 is EM.7EN
Electric Start (XTR-7 Only)ŗǯȱ ȱ ȱ Ȭ ěȱ ȱ ȱ ȱON position (if Ǽǯȱ ȱ ȱ ȱŚǯŘǯȱ ȱ ȱ ȱ ȱ ȱ ȱON position (ifequipped). Refer to the operating instructions ofthe equipment this engine powers.3.Start the engine by activating key switch; releaseas soon as engine starts.NOTE: Do not crank the engine continuously for ȱ ȱśȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱdoes not start, wait 30 seconds before Ĵ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱguidelines may damage or overheat thestarter motor.Śǯȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱmanufacturer's recommended operating speed (ifadjustable).Recoil Startŗǯȱ ȱ ȱ ȱ Ȭ ěȱ ȱ ȱ ȱON positionǻ ȱ Ǽǯȱ ȱ ȱ ȱŚǯŘǯȱ ȱ ȱ ȱ ȱ ȱ ȱON position (ifequipped). Refer to the operating instructions ofthe equipment this engine powers.3.Pull the starter handle straight out with a smooth,steady motion.NOTE: Extend the starting rope periodically andcheck its condition. If the rope is frayed, have itreplaced immediately by a Kohler AuthorizedService Center.Śǯȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱmanufacturer's recommended operating speed (ifadjustable).Primer BulbFigure 10. Primer Bulb.Cold Engine: Start as followsOutside temperature ȱśśǚ ȱǻŗřǚ ǼȽPrimerChoke3 pumpsONOutside temperature ȱśśǚ ȱǻŗřǚ ǼPrimerChokeśȱ ONWarm Engine: Do not use primerFigure 11. Primer Bulb Quick Reference Table.NOTE: It is important to press the CENTER of thered primer bulb so the air hole is covered,ensuring proper pressure.NOTE: Pressing the primer bulb more times than ȱ ȱĚ ȱ ǰȱ ȱ ȱ ȱ Ĝ ǯŚǯȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱmanufacturer's recommended operating speed (ifadjustable).śǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ǯManual Choke StartWARNING: Accidental Starts!Before extending and checking the retractable starter rope,remove the spark plug lead to prevent the engine fromstarting accidentally.ŗǯȱ ȱ ȱ Ȭ ěȱ ȱ ȱ ȱON position (if Ǽǯȱ ȱ ȱ ȱŚǯŘǯȱ ȱ ȱ ȱ ȱ ȱON (refer to theoperating instructions of the equipment thisengine powers).3.Turn the ignition switch to ON (refer to theoperating instructions of the equipment thisengine powers).Śǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ Ĵ Ȧ ȱ ȱto FAST/CHOKE ON position. To start a warmengine, no choke is required.Primer Bulb Start (If Equipped)ŗǯȱ ȱ ȱ Ȭ ěȱ ȱ ȱ ȱON position (if Ǽǯȱ ȱ ȱ ȱŚǯŘǯȱ ȱ ȱ ȱ ȱ ȱ ȱON position. Referto the operating instructions of the equipmentthis engine powers.řǯȱ ȱ ȱ ȱ ȱ ȱ ȱśśǚ ȱǻŗřǚ Ǽǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱbefore starting. When outside temperature is ȱśśǚ ȱǻŗřǚ Ǽǰȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱ ǯȱ ȱ ȱŗŖȱ ȱŗŗǯ8
Shutdown EngineCarburetorTo shutdown the engine, turn ignition switch to OFF ȱǻ ȱ Ǽǯȱ ȱ ȱ ȱ Ȭ ěȱ ȱ ȱOFFȱ ȱǻ ȱ Ǽǯȱ ȱ ȱŚǯThe carburetor is designed to deliver the correctfuel-to-air mixture to the engine under all operatingconditions. It has been calibrated at the factory and isnot adjustable.NOTE: If the engine is equipped with an optionalblade-brake clutch (BBC), the blade can be ȱ ȱ Ĵ ȱ ȱ ȱ ǯȱFor further information, refer to operatinginstructions of the equipment this enginepowers.Engine SpeedUnless the equipment this engine is mounted on has ȱ Ȭ ȱ ȱǻ Ĵ Ǽǰȱ ȱ ȱ ȱ ȱengine cannot be altered.NOTE: Do not tamper with governor or carburetorto increase engine speed. Overspeed ishazardous and will void warranty.Angle of OperationThis engine will operate continuously at angles up ȱŘŖǚǰȱ ȱ Ĵ ȱ ȱ ȱŘśǚȱ ȱ ȱ ȱ ȱone minute or less. Oil level must be at FULL markon dipstick. Refer to the operating instructions of theequipment this engine powers. Due to equipmentdesign or application, there may be more stringentrestrictions regarding the angle of operation.NOTE: Do not operate this engine continuously at ȱ ¡ ȱŘŖǚȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĝ ȱlubrication.OverheatingTo avoid engine damage due to overheating remove ȱ ȱ ȱ Ȭ ȱ ȱ Ğ ȱ ȱ ǯ DZȱ Ğ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ Ĝ ȱ ȱ Ĵ ȱ ȱ ȱ ěȱ ǯWARNING: Hot Parts!Engine components can get extremely hot from operation.To prevent severe burns, do not touch these areas while ȱ ȱ ȱ ǰȱ ȱ ȱ Ğ ȱ ȱ ȱ ȱ ěǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱremoved.NOTE: To ensure correct engine operation at ȱ ȱŗśŘśȱ ȱǻśŖŖŖȱĞǯǼǰȱ ȱ ȱbe necessary to have a Kohler AuthorizedService Center install a high-altitude jet kit.If a high-altitude kit has been installed, theengine must be reconverted to the original jetsize before it is operated at lower altitudes, oroverheating and engine damage may result.If engine troubles appear to be fuel-system related,check the following areas before seeking service froma Kohler Authorized Service Center. ȱ ȱ ȱ ȱ ȱę ȱ ȱ ǰȱ ȱgasoline. Ensure the air cleaner and precleaner are cleanand securely fastened. Ensure the fuel tank cap vent is not blocked andthat it is operating properly. ȱ ȱ Ȭ ȱ ȱę ǰȱ ȱ ǰȱ ȱ ȱand unobstructed. Replace if necessary. ȱ Ğ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱto start, runs roughly, or stalls at low-idle speed, itmay be necessary to have the carburetor serviced by aKohler Authorized Service Center.MaintenanceMaintenance, repair or replacement of the emissioncontrol devices and systems, which are done at thecustomers expense, may be performed by any nonroad engine repair establishment or individual.Warranty repairs must be performed by a KohlerAuthorized Service Center. Required maintenanceprocedures should be performed at the frequency ȱ ȱ ȱŗŘǯWARNING: Accidental StartsAccidental starting can cause severe injury or death. Beforeworking on the engine or equipment, disable the engine bydisconnecting the spark plug lead.9EN
Maintenance InstructionsFrequencyMaintenance RequiredAfter First 3-5 Hours of OperationChange oilFill fuel tankDaily or Before Starting EngineCheck oil level.Check air intake and cooling areas; clean as necessary¹Service or replace precleaner element (if equipped)¹Yearly or Every 25 Hours ȱ ȱ ȱ ȱ ȱę ȱ ȱ ǰȱ ȱ ȱ ȱ ŵ ȱ ȱę ȱǻ ȱ ǼYearly or Every 50 HoursChange oilReplace spark plug and set gap ȱ ȱ ȱę ŵ ȱ ȱ ȱę Yearly or Every 100 hoursAdjust valvesŘClean combustion chamberŘFigure 12. Maintenance Table.¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.2These procedures should be performed by a Kohler Authorized Service Center.Oil Level CheckThe importance of checking and maintainingthe proper oil level in the crankcase cannot beoveremphasized.Full MarkCheck oil BEFORE EACH USE as follows:1.Make sure the engine is stopped, level, and coolso the oil has had time to drain into the sump.Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ Ȧ ȱ ȱkeep dirt and grass clippings out of the engine.řǯȱ ȱ ȱ ȱ ȱ ȱę ȱ Ȧ Dzȱ ȱ ěȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱ ȱ ǯȱDO NOTscrew the cap into the tube. See Figure 13.OperatingRangeLow MarkFigure 14. Oil Level Dipstick.śǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱthe F or FULL mark on dipstick. Always check theoil level with the dipstick before adding more.Ŝǯȱ ȱ ȱę ȱ Ȧ ȱ ȱ ȱ ǯOil Fill Cap/DipstickNOTE: To prevent extensive engine wear or damage,always maintain proper oil level in crankcase.Never operate engine with oil level below theL or LOW mark, or over the F or FULL markon dipstick.Figure 13. Oil Fill Cap/Dipstick.Śǯȱ10 ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱshould be up to, but not over F or FULL mark on ǯȱ ȱ ȱŗŚǯ
Oil ChangeOil can be changed by either draining it from thedipstick tube, or from the optional drain plug. Change ȱ ȱ Ğ ȱ ȱę ȱ ȱ ȱę ȱ ȱ ȱ ǯȱ Ğ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ Ğ ȱ ȱśŖȱ ȱof operation. Change oil while engine is still warm, ȱ ę ȱ ȱ ȱ ȱ ȱ ȱ ǯDrain Oil from Dipstick Tube1. To keep dirt, grass clippings, etc., out of the ǰȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ Ȧ Dzȱ ȱ ȱ ȱę ȱ Ȧ ǯŘǯȱNOTE: Oil will drain easier and more quickly if thedipstick is removed.3. Apply thread sealant around three full threadsof the drain plug, and reinstall the drain plug;torque to 13.6 N·m (120 in. lb.).Air Cleaner SystemThis engine is equipped with either a replaceable, high ȱ ȱ ȱę ǰȱ ȱ ȱ ȱ ȱę ǰȱ ȱon the application. In addition, an optional foamprecleaner may also be included. See Figure 17. ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗśǯȱ ȱ ȱ ȱ ȱcontainer.Air CleanerPrecleaner (If Equipped)Air Cleaner CoverUpAir CleanerBaseAir FilterOil Flow DirectionFigure 15. Engine Tilted onto Side, Air Cleaner Up.ȱřǯȱ Ğ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱengine back upright.Śǯȱśǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱto the FULLȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŚǯȱRecheck oil level before adding more oil. Do notscrew dipstick in when checking oil level. ȱ ȱ ȱę ȱ Ȧ Dzȱ ȱ ǯDrain Oil Via Crankcase Plug (If Accessible)1. Disable engine by disconnecting spark plug.Řǯȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱdrain oil into approved container. See Figure 16.Crankcase PlugFigure 16. Crankcase Plug.Figure 17. Air Cleaner Assembly – Exploded View.Check the air cleaner daily or before starting theengine for a buildup of dirt and debris. Keep this areain and around the air cleaner clean. Also check forloose or damaged components. Replace all bent ordamaged air cleaner components.NOTE: Operating engine with loose or damaged air ȱ ȱ ȱ ȱ ę ȱair into engine, causing premature wear andfailure.Paper Air FilterYearly or every 100 hours of operation replace the ȱ ȱę ȱ(Kohler part number 14 083 01-S). ȱ ȱ ȱę ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱŘśȱ ȱ ȱ Dzȱ ȱ Ğ ȱ ȱextremely dusty or dirty conditions.ENŗǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱę ǰȱand the precleaner, if equipped. See Figure 17.Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱę ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱę ǯřǯȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱę ǯȱŚǯȱ ȱ ȱ ȱę ǰȱ ȱ ȱ ȱ ȱcleaner base and cover for damage. All air cleaner ȱ ȱę ȱ ǯȱ ȱ ȱquestionable air cleaner components.11
śǯȱŜǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ǰȱ ȱ ȱ ȱ ȱthe base clean. ȱ ȱ ȱę ȱ ȱ ȱ ȱprecleaner (if equipped).7.Reinstall the air cleaner cover and tighten theknob securely.Şǯȱ ȱ ȱ ȱ ǰȱ ȱ ȱKohler parts.Foam Air FilterYearly or every 100 hours of operation replace the ȱ ȱę ȱ(Kohler part number 14 083 09-S). ȱ ȱ ȱę ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱŘśȱ ȱ ȱ Dzȱ ȱ Ğ ȱ ȱextremely dusty or dirty conditions.Cooling AreasTo ensure proper cooling, make sure the grass screen, ȱę ǰȱ ȱ ȱ ¡ ȱ ȱ ȱ ȱ ȱare kept clean at all times.NOTE: Operating the engine with a blocked grass ǰȱ ǰȱ ȱ ȱ ȱę ȱ ȱcause engine damage due to overheating.Spark PlugYearly or every 100 hours of operation, remove thespark plug, check its condition and reset the gap orreplace with a new plug as necessary. The standardspark plug for model XT-6 is a Champion ȱŞŞŗśȱ(Kohler part number 14 132 06-S). The standard sparkplug for models XT-7 and XTR-7 is a Champion ŗŘ ȱ(Kohler part number 12 132 02-S).Equivalent, alternative brand plugs can also be used.ŗǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱę ǰȱand the precleaner, if equipped. See Figure 17.1.Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱ ȱ ȱ ȱ ȱę ǯȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱę ǯBefore removing the spark plug, clean the areaaround the base of the plug to keep dirt anddebris out of the engine.Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱthe plug if worn or reuse is questionable.řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŞǯ3.When replacement is necessary, use genuineKohler parts.Śǯȱ ȱ ȱę ǰȱ ȱ ȱ ȱ ȱ ȱbase and cover for damage. All air cleaner ȱ ȱę ȱ ǯȱ ȱ ȱquestionable air cleaner components.śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ǰȱ ȱ ȱ ȱ ȱthe base clean.Ŝǯȱ ȱ ȱ ȱę ǰȱ ȱ ȱ ȱ ȱ ȱtighten the knob securely.Precleaner1.Wash or replace the optional precleaner (Kohlerpart number 14 083 02-S)ȱ ȱ ȱ ȱŘśȱ ȱ ȱ Dzȱ ȱ Ğ ȱ ȱ ¡ ȱ ȱor dirty conditions.Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱcover. See Figure 17.3.Remove the precleaner and wash with detergentin warm water.Śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱof detergent are eliminated. Squeeze out excesswater (do not wring), and allow the precleaner toair dry.śǯȱ ȱ ȱ ǯ6.Reinstall the air cleaner cover and tighten theknob securely.7.When replacement is necessary, use genuineKohler parts.12Feeler GaugeSpark PlugGroundElectrodeGapFigure 18. Spark Plug Gap.NOTE: Do not clean the spark plug in a machineusing abrasive grit. Some grit could remain inthe spark plug and enter the engine causingextensive wear and damage.Śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱelectrode. Gap spark plug to 0.762 mm (0.030 in.).Reinstall the spark plug into the cylinder head.Torque the plug to ŘŘȬŘŚȱ ȉ ȱǻŗŜȬŗŞȱĞ. lb.).
IgnitionParts OrderingThis engine is equipped with a dependablemaintenance-free ignition system. Other thanperiodically checking/replacing the spa
5 EN 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
