Kohler Courage Service Manual

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Service manual (76 pages)

Table Of Contents

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SH255, SH265, SH270

Service Manual

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

Maintenance

Speciﬁ cations

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Fuel System

Governor System

Lubrication System

Electrical System

Starter System

Disassembly/Inspection and Service

Reassembly

18 690 01 Rev. G

KohlerEngines.com

Table of Contents

Summary of Contents for Kohler Courage

Page 1 SH255, SH265, SH270 Service Manual 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 Maintenance Speciﬁ...
Page 2: Safety Precautions
Safety 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. CAUTION WARNING WARNING...
Page 3: Maintenance Instructions
Option only if using KOHLER PRO oil. ® REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁ nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 18 690 01 Rev. G KohlerEngines.com...
Page 4: Oil Recommendations
PRO 10W-50 Synthetic Oil is the If engine will be out of service for 2 months or more ® ideal oil for KOHLER engines. It is speciﬁ cally formulated follow procedure below. to extend the oil change interval to 300 Hours. Contact 1.
Page 5: Specifications
Speciﬁ cations Engine Dimensions Dimensions in millimeters. 318.66 Inch equivalents shown in [ ]. [12.545] STRAIGHT PTO 181.60 [7.150] 369.40 [14.543] 113.44 [4.466] SPARK PLUG 273.97 [10.786] OIL FILL DRAIN PLUG 2X Ø 10.00 [0.394] 37.98 [1.495] 2X 10.00 X 15.50 37.50 [1.476] SLOT [0.394 X 0.610] 78.00...
Page 6: Engine Identification Numbers
Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certiﬁ ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certiﬁ ed Power Ratings can be found at KohlerEngines.com.
Page 7 Speciﬁ cations TORQUE SPECIFICATIONS 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.
Page 8: Clearance Specifications
Speciﬁ cations CLEARANCE SPECIFICATIONS SH255, 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. 14.000/14.018 mm (0.5512/0.5519 in.) Max. Wear Limit 14.048 mm (0.5531 in.) Connecting Rod Crankpin End I.D. @ 21°C (70°F) 30.021/30.026 mm (1.1819/1.1821 in.) Max.
Page 9 Speciﬁ cations CLEARANCE SPECIFICATIONS SH255, SH265, SH270 Cylinder Bore Bore I.D. 70.027/70.035 mm (2.757/2.757 in.) Max. Wear Limit 70.200 mm (2.764 in.) Max. Out-of-Round 12.7 microns (0.0005 in.) Max. Taper 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.)
Page 10 Speciﬁ cations CLEARANCE SPECIFICATIONS SH255, 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.
Page 11: General Torque Values
Speciﬁ cations GENERAL TORQUE VALUES 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)
Page 12: Tools And Aids
Shrader Valve Adapter Hose DTI-037 Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031 Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033 Flywheel Puller SE Tools KLR-82408 For properly removing ﬂ ywheel from engine.
Page 13 For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming. Reamer Handle Design Technology Inc. For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 AIDS Description Source/Part No.
Page 14 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A ﬂ ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft ﬂ ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 15: Troubleshooting Guide
Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at ﬁ rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some general common causes of engine troubles are listed below and vary by engine speciﬁ cation. Use these to locate causing factors.
Page 16 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...
Page 17: Crankcase Vacuum Test
Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Keep hands, feet, hair, and clothing away from all Engine exhaust gases contain poisonous carbon moving parts to prevent injury.
Page 18: Compression Test
Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is oﬀ , and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.
Page 19: Air Cleaner
Air Cleaner/Intake AIR CLEANER NOTE: Operating engine with loose or damaged air cleaner components could cause premature These systems are CARB/EPA certiﬁ ed and components wear and failure. Replace all bent or damaged should not be altered or modiﬁ ed in any way. components.
Page 20: Fuel Filter
3. Remove fuel shut-oﬀ cup. Low permeation fuel line must be installed on carbureted 4. Clean fuel shut-oﬀ cup with solvent and wipe dry. Kohler Co. engines to maintain EPA and CARB regulatory compliance. 5. Inspect for worn or damaged O-ring; replace as necessary.
Page 21 Fuel System CARBURETOR Gasoline is extremely ﬂ ammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause ﬁ res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or ﬂ ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
Page 22 Fuel System Troubleshooting-Carburetor Related Causes Condition Possible Cause Conclusion Engine starts hard, runs rough, or Low idle fuel mixture (some models)/ Adjust idle speed screw or clean stalls at idle speed. speed improperly adjusted. carburetor. Engine runs rich (indicated by black, Clogged air cleaner.
Page 23 If this engine is operated at an altitude of 4000 ft. (1219 meters) or above, a high altitude carburetor kit is required. To obtain high altitude carburetor kit information or to ﬁ nd a Kohler authorized dealer, visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).
Page 24: Governor System
Governor System GOVERNOR Governor Components Control Assembly Governor Spring Throttle Link Dampening Spring Throttle Control Lever Governor Lever Washer Governor Gear Governor Gear Shaft Governed speed setting is determined by position of ● When load is applied and engine speed and governor throttle control.
Page 25: Lubrication System
Lubrication System These engines use a splash lubrication system, supplying necessary lubrication to crankshaft, camshaft, connecting rod and valve train components. Lubrication Components Dipstick Oil Fill Plug Oil Drain Plug OIL RECOMMENDATIONS CHANGE OIL Refer to Maintenance. Change oil while engine is warm. CHECK OIL LEVEL 1.
Page 26: Electrical System
Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
Page 27: Electronic Ignition System
Electrical System Carbon Fouled ELECTRONIC IGNITION SYSTEM Inductive Discharge Ignition System Components Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich carburetion, weak ignition, or poor compression. Overheated Kill Switch/Oﬀ Position Air Gap 0.254 mm of Key Switch (0.010 in.) Flywheel...
Page 28 Electrical System Electronic Ignition Systems and Oil Sentry Tests ™ 1. Disconnect cap from spark plug and attach it to 4. Set an ohmmeter to Rx1 scale and zero meter. terminal end of spark tester. Attach tester spring clip Connect one ohmmeter lead to Oil Sentry ﬂ...
Page 29 Electrical System 6. Set an ohmmeter to Rx1 scale and zero meter. Test ignition/key switch as follows. a. Trace two black leads from on/oﬀ switch and separate them from any connections. Connect ohmmeter leads to switch leads, and check for continuity in both switch positions.
Page 30: Starter System
Starter System NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If engine develops suﬃ cient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine.
Page 31 Starter System 4. Use a known, good, fully-charged battery and jumper cables to test starter motor. Be sure transmission is in neutral and PTO is OFF. Remove heavy lead from post terminal on starter. Connect one end of positive jumper cable to post terminal and connect other end to positive terminal of battery.
Page 32: Retractable Starters
Starter System RETRACTABLE STARTERS WARNING Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing Uncoiling Spring can cause severe injury. retractable starters and carefully follow instructions in Wear safety goggles or face protection when Retractable Starter for relieving spring tension.
Page 33: Disassembly/Inspection And Service
Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
Page 34 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. 2. Remove muﬄ er assembly from exhaust outlet. Only clean parts can be accurately inspected 3. Remove exhaust gasket from exhaust outlet. and gauged for wear or damage. There are many commercially available cleaners that will quickly remove Remove Air Cleaner Assembly grease, oil, and grime from engine parts.
Page 35 Disassembly/Inspection and Service Remove air cleaner gasket and slide carburetor oﬀ Remove External Throttle, Governor and Choke mounting studs while disconnecting throttle linkage Linkage and dampening spring. Remove carburetor to insulator 1. Mark hole in which governor spring is attached and gasket, insulator, and insulator to cylinder head gasket.
Page 36 Disassembly/Inspection and Service Remove Valve Cover/Breather, Rocker Arms, Push Remove Valves Rods and Cylinder Head Assembly NOTE: Mark location of any part removed that will be NOTE: Mark location of push rods and any other part reused. removed that will be reused. 1.
Page 37 Disassembly/Inspection and Service Valve Details Item Dimension Intake Exhaust 25 mm + 0.1 mm 24 mm + 0.1 mm Head Diameter—Speciﬁ cation (0.9842 in. + 0.0039 in.) (0.9449 in. + 0.0039 in.) Head Diameter—Maximum 25.1 mm (0.9881 in.) 24.1 mm (0.9488 in.) Head Diameter—Service Limit 24.9 mm (0.9803 in.) 23.9 mm (0.9409 in.)
Page 38 Disassembly/Inspection and Service Inspection and Service Intake Valve Stem Seal After cleaning, check ﬂ atness of cylinder head and Some engines use a valve stem seal on intake valve. corresponding top surface of crankcase, using a surface Always use a new seal when valves are removed plate or piece of glass and feeler gauge.
Page 39 Disassembly/Inspection and Service Crankcase Components Closure Plate Oil Seal Closure Plate Bearing Closure Plate Gasket Oil Sentry Float Camshaft Crankshaft End Cap ™ Switch Connecting Rod Piston Pin Retainer Piston Pin Piston Piston Ring Set Tappet Governor Cup Governor Washer Governor Shaft Governor Gear Governor Cross Shaft...
Page 40 Disassembly/Inspection and Service 1. Manual (retractable) starting is much easier. Without Remove Camshaft and Valve Tappets ACR, manual starting would be virtually impossible. 1. Remove camshaft by pulling it straight out of 2. Electric start models can use a smaller starter and crankcase.
Page 41 Disassembly/Inspection and Service Detonation damage occurs when a portion of fuel charge 1. Use a micrometer and measure diameter of piston ignites spontaneously from heat and pressure shortly 15 mm (0.5905 in.) above bottom of piston skirt and after ignition. This creates 2 ﬂ ame fronts, which meet perpendicular to piston pin.
Page 42 Disassembly/Inspection and Service 1. Oil control ring assembly (bottom groove): Install Remove Crankcase and Closure Plate Seals and expander ﬁ rst then bottom rail and top rail last. Make Bearings sure ends of expander are not overlapped. Adjust 1. Remove oil seal from crankcase. ring gaps.
Page 43 Reassembly Crankcase Components Oil Seal Closure Plate Bearing Closure Plate Gasket Oil Sentry Float Camshaft Crankshaft End Cap ™ Switch Connecting Rod Piston Pin Retainer Piston Pin Piston Piston Ring Set Tappet Governor Cup Governor Washer Governor Shaft Governor Gear Governor Cross Shaft Crankcase Bearing Dowel Pin...
Page 44 Reassembly 5. Apply a light coating of lithium grease to seal lips NOTE: Install oil control ring assembly ﬁ rst, middle after installing. compression ring second, and top compression ring last. Oil control ring assembly is a three- Install Governor Assembly piece design, and consists of a top rail, 1.
Page 45 Reassembly Install Closure Plate Install Flywheel Torque Sequence 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 ﬂ ywheel. NOTE: Before installing ﬂ...
Page 46 Reassembly 8. Connect kill wire to ignition module bottom blade terminal and route wire lead across top of crankcase. Cylinder Head Components Valve Cover Adjusting Nut Rocker Arm Rocker Arm Stud Push Rod Guide Push Rod Valve Keeper Valve Spring Intake Valve Stem Cylinder Shroud Valve...
Page 47 Reassembly d. Hold adjuster from turning and tighten locknut. Valve Cover with RTV Torque locknut to 10 N·m (88.5 in. lb.). e. Recheck that clearance is correct. 5. Set gap of new spark plug to 0.76 mm (0.030 in.). 6. Install spark plug in cylinder head and torque to 27 N·m (20 ft.
Page 48 Reassembly Blower Housing/Control Panel Components Governor Lever Governor Spring Throttle Link Dampening Spring Control Assembly Carburetor Retractable Starter On/Oﬀ Wiring Oil Sentry Wiring ™ Harness Bullet Blower Housing Harness Bullet Oil Sentry Module ™ Connector Connector Oil Sentry Bracket ™ Install Throttle Plate Install Blower Housing Install throttle plate with screws.
Page 49 Reassembly Install Retractable Starter 1. Install retractable starter on blower housing using screws. Finger tighten screws only. 2. Pull rope handle to engage pawls and center starter to drive cup. Hold in this position and torque screws to 5.4 N·m (47.8 in. lb.). External Engine Components Oil Drain Plug Oil Fill Plug...
Page 50 Reassembly Install Throttle Lever, Governor Lever, Throttle Link, Dampening Spring, and Governor Spring 1. Install nylon washer and wave spring to throttle plate. 2. Connect spring to throttle lever and throttle plate. Install throttle lever to throttle plate. Install tabbed washer (with tab engaged in slot) and secure with nut.
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Page 52 Reassembly Install Oil Sentry Module Prepare Engine for Operation 1. Install Oil Sentry module and secure with screw. Engine is now reassembled. Before starting or operating ™ engine be sure to do following: 2. Connect electrical leads for Oil Sentry module.
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3000 series Sh series Sh255 Sh265 Sh270

Kohler Courage Service Manual

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