Kohler Courage XT-6 Service Manual

Vertical crankshaft

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Serge Boivin

July 9, 2025

the engine start for 2-3 second and stop

Summary of Contents for Kohler Courage XT-6

Page 1 ERVICE ANUAL COURAGE XT-6, XT-7 ERTICAL RANKSHAFT...
Page 3: Table Of 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.
Page 5: Section 1. Safety And General Information
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.
Page 6 Section 1 Safety and General Information WARNING severe burns. engine is hot or running. 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.
Page 7 Model, of the engine. A. Model No. Courage Vertical Shaft Engine Numerical Designation B. Spec. No. Engine Model Model XT-6 XT-7 C. Serial No. Year Manufactured Code Code Year 2007 2008 Safety and General Information...
Page 8 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.
Page 9 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.
Page 10 Section 1 Safety and General Information (IF EQUIPPED) (IF EQUIPPED) Dimensions in millimeters. Inch equivalents shown in parentheses. Figure 1-5. Typical Engine Dimensions.
Page 11 XT-6 ... XT-7 ... XT-6 ... XT-7 ... Bore XT-6 ... XT-7 ... Stroke XT-6 ... XT-7 ... Displacement XT-6 ... XT-7 ... Compression Ratio XT-6 ... XT-7 ... Dry Weight XT-6 ... XT-7 ... XT-6 ... XT-7 ... Air Cleaner Base...
Page 12 Section 1 Safety and General Information Connecting Rod Connecting Rod-to-Crankpin Running Clearance New... Connecting Rod-to-Crankpin Side Clearance... Connecting Rod-to-Piston Pin Running Clearance... New... New... Crankshaft End Play (free) ... New... New... O.D. – Max. Wear Limit ... Max. Taper ... Max.
Page 13 Cylinder Bore New... Max. Taper ... Max. Out of Round ... Cylinder Head Dipstick Tube Fastener Engine Cover Fan/Flywheel Fuel Tank Tank Bracket to Crankcase Stud Torque ... Governor New... New ... Ignition Spark Plug Type (Champion ® or equivalent)... Spark Plug Gap ...
Page 14 Section 1 Safety and General Information Exhaust Stud Torque ... 9.0 N·m (80 in. lb.) Oil Drain Plug Torque³... Piston, Piston Rings, and Piston Pin New... Piston Pin O.D. New... Top Compression Ring-to-Groove Side Clearance ... Middle Compression Ring-to-Groove Side Clearance ... Top and Middle Compression Ring End Gap New Bore...
Page 15 Valves and Valve Lifters (continued) Exhaust Valve Stem-to-Valve Guide Running Clearance ... New... New... New... Exhaust Valve Stem Diameter New... Values are in metric units. English equivalents are shown in parentheses. Do not lubricate threads unless otherwise indicated. ³ Apply thread sealant around three full threads before assembly. No excess sealant allowed on inside or outside of joint. Safety and General Information ®...
Page 16 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 10% Size Tightening Torque: N·m (ft. lb.) + or - 10% Size Oil Drain Plug Tightening Torque: N·m (English Equiv.) Size Into Cast Iron 1/8"...
Page 17: Section 2. Tools And Aids
Here is the list of tools and their sources: Separate Tool Suppliers: Kohler Tools Contact your local Kohler Tools Description Cylinder Leakdown Tester Flywheel Strap Wrench Ignition System Tester Tachometer (Digital Inductive) For checking operating speed (RPM) of an engine.
Page 18 Section 2 Tools & Aids...
Page 19: Section 3. Troubleshooting
Troubleshooting Guide When troubles occur, be sure to check the simple considered. For example, a starting problem could below. Use these to help locate the possible cause(s). Engine Cranks But Will Not Start 4. Spark plug lead disconnected. Engine Starts But Does Not Keep Running 4.
Page 20 Section 3 Troubleshooting Engine Knocks 4. Internal wear or damage. Engine Loses Power 8. Low compression. 9. Exhaust restriction. Engine Uses Excessive Amount of Oil 3. Worn or broken piston rings. Oil Leaks from Oil Seals, Gaskets 2. Worn or broken piston rings. 4.
Page 21 Basic Engine Tests Crankcase Vacuum Test crankcase when the engine is operating. Pressure Section 2, Tools and Aids. Complete instructions are Be sure the pinch clamp is installed on the hose and use the tapered adapters to connect manometer is at the “0” line. Make sure the pinch clamp is closed.
Page 22 Section 3 Troubleshooting Cylinder Leakdown Test Leakdown Test Instructions will need to hold the engine in this position while testing. The holding tool supplied with the tester accessible. holding tool, so it is perpendicular to both the bolt through the slot and thread it into the mounting hole.
Page 23: Section 4. Air Cleaner And Air Intake System
Air Cleaner and Air Intake System Air Cleaner This engine is equipped with a replaceable, high density paper air cleaner. An optional foam precleaner may also be included. See Figure 4-1. Intake air is drawn in through the blower housing, and passes through the precleaner (if equipped), the paper element and then into the carburetor.
Page 24: Service Paper Element
2. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a genuine Kohler element. 3. When servicing the air cleaner, check the air cleaner base. Make sure it is secured and not damaged.
Page 25 NOTE: Before reinstalling an air cleaner base that has been removed, make sure the metal bushings in the base mounting holes are present. The bushings prevent damage to the base and help maintain the proper mounting torque. Reassembly The following procedure outlines complete reassembly of all air cleaner components.
Page 26 Section 4 Air Cleaner and Air Intake System...
Page 27: Replacing Fuel Filter
Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 failures resulting from use of these fuels will not be warranted.
Page 28 Section 5 Fuel System and Governor Test c. Turn engine over several times. a. Remove fuel line from carburetor. spraying fuel into carburetor. Carburetor WARNING: Explosive Fuel! Figure 5-2. Carburetor With Primer. Troubleshooting — Fuel System carburetor. • Air cleaner element is clean, and all air cleaner components are fastened securely. Fuel System Test Guide Gasoline components oxidize over time resulting Replace old gas with fresh gas.
Page 29 Fuel System Troubleshooting Guide Engine starts hard, runs rough or stalls at idle. governor hunting). speed and power, governor hunting). Carburetor Adjustments While this carburetor is designed to deliver the necessary. Idle Adjustment Screw Do not tampered with this screw on engines with a primer bulb, since these models operate only at full speed, and do not idle.
Page 30 Section 5 Fuel System and Governor Carburetor Removal NOTE: WARNING: Explosive Fuel! 2. Remove foam precleaner (if equipped) and paper element. Square Gasket Figure 5-7. Carburetor Gasket Sequence (Exploded View). Carburetor Disassembly Figure 5-8. Fuel Inlet Needle Removal. Cylinder Head Spacer A light tap on the tower will dislodge the Emmulsion Tube Fuel-Inlet...
Page 31 Throttle Shaft Figure 5-10. Throttle Shaft Removal. by corresponding wear to the carburetor Throttle Lever Primer Vent Throttle Plate Screw Throttle Plate Tower Carburetor with Primer Figure 5-12. Carburetor (Exploded View). Fuel System and Governor plate and the carburetor body with a waterproof Figure 5-11.
Page 32 Inspect fuel inlet needle and seat for wear or damage. wear or grooves. Choke Return Spring assemblies for wear or excess play. Gasket Replacement the Kohler Parts Manual for the engine being serviced Carburetor Reassembly 2. Apply thread sealant around three full threads sealant. (if equipped). surface.
Page 33 High Altitude Operation become too rich. When the mixture is too rich it economy, and poor or slow governor response. size before it is operated at lower altitudes, or overheating and engine damage may result. Engine Starting Starting Engine With Primer Bulb 1.
Page 34 Section 5 Fuel System and Governor Install Throttle/Choke Control Cable Dual Throttle/Choke Control Installation 1. Loosen the cable clamp and insert the cable Control Arm Bowden Cable Figure 5-17. Bowden Cable Connection. selection, refer to the operating instructions of the equipment this engine powers. See Figure a designated CHOKE position, be sure to be placed ON.
Page 35 rapidly, so a reduction in speed is hardly noticed. As spring tension and the force applied by the regulating pin will again be in equilibrium. This maintains the engine speed at a relatively constant level. The depending on the application. Initial Governor Adjustment Figure 5-19.
Page 36 Section 5 Fuel System and Governor 5.10...
Page 37: Viscosity Grades Table.
Lubrication System Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure.
Page 38: Section 6 Lubrication System
Section 6 Lubrication System Operating Range Figure 6-4. Dipstick. NOTE: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the "L" or LOW mark, or over the FULL mark on the dipstick.
Page 39 6. Fill the crankcase with the recommended oil to the FULL mark on the dipstick. See Figure 6-4. Always check the oil level with the dipstick when checking oil level. securely. 8. Test run the engine to check for leaks. Stop the engine, allow a minute for the oil to drain down, and recheck the level on the dipstick.
Page 40 Section 6 Lubrication System...
Page 41: Section 7. Electrical System And Components
Electrical System and Components This section covers the operation, service, and repair of the electrical system and electrical system components. WARNING: Electrical Shock Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. Spark Plug Type: Champion...
Page 42 Section 7 Electrical System and Components Normal: Carbon Fouled: Wet Fouled: Worn: Chalky White Deposits:...
Page 43 Electronic Ignition System Air Gap 0.254 mm (0.010 in.) Flywheel Kill Switch or Off Position of Key Switch Figure 7-2. Capacitive Discharge Ignition System (CDI). CDI Module Operation the charged capacitor to the primary coil of the Electrical System and Components Spark Plug Boot Ignition Module Spark Plug...
Page 44 Section 7 Electrical System and Components Air Gap 0.254 mm (0.010 in.) Flywheel Kill Switch or Off Position of Key Switch Figure 7-3. Inductive Discharge IDI Module Operation Ignition Module Magnets Ignition Module (Enlarged View) Ignition System. stop engine. Troubleshooting and Testing Ignition position.
Page 45 Ignition System Troubleshooting Guide Problem Test 0.762 mm (0.030 in.). connect to post terminal of tester. Connect one ohmmeter lead to ohmmeter leads connected in this ohms ohms. Electrical System and Components are not ohmmeter (Test 4). If the resistance is low or 0 ohms If the resistance is 4000 to 12,000 2700 to 8600...
Page 46 Section 7 Electrical System and Components Figure 7-5. Testing CDI or IDI Ignition Modules. Figure 7-4. CDI and IDI Ignition Module Tester.
Page 47: Section 8. Disassembly
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. The following sequence is a step-by-step guide for complete engine disassembly. This procedure may vary depending on the options included.
Page 48 Section 8 Disassembly Detailed Disassembly Sequence WARNING: Explosive Fuel! Disconnect Spark Plug 1. Disconnect the spark plug lead. Empty Fuel Tank 1. Ensure the fuel tank is empty by running the engine until it stops, and is completely out of fuel.
Page 49 Figure 8-4. 3. Remove the engine cover. Figure 8-4. Removing Engine Cover. Remove Recoil Starter Figure 8-5. Removing Recoil. .001 Remove Blower Housing stud spacers. See Figure 8-6. Figure 8-6. Removing Blower Housing. .001 guard to the cylinder head. See Figure 8-7. Section 8 Disassembly...
Page 50 Section 8 Disassembly exhaust studs, noting orientation. Remove Air Cleaner Assembly 1. Unscrew the knob on the air cleaner assembly and remove the cover. See Figure 8-9. Figure 8-9. Removing Air Cleaner Cover. 2. Remove the paper element and the foam screw securing the air cleaner base to the cylinder head and the crankcase.
Page 51 Remove Carburetor Assembly NOTE: Ensure the fuel tank is empty by running the engine until it stops, and is completely out of fuel. Remove Choke-less Carburetor 1. Squeeze the hose clamp and slide it and the fuel Hose Clamp Figure 8-13. Disconnecting Fuel Line. 2.
Page 52 Section 8 Disassembly 2. Slide carburetor to the end of the intake studs. See Figure 8-14. Gently push the rod and spring linkages up Figure 8-15. 4. Rotate the carburetor until the choke linkage can be disconnected from the carburetor. See Figure 8-18.
Page 53 Remove Governor Lever 1. Loosen the governor lever hex nut and slide the Governor Lever Hex Nut Figure 8-22. Removing Governor Lever. Remove Fuel Tank 1. Ensure the fuel tank is empty by running the engine until it stops, and is completely out of fuel.
Page 54 Section 8 Disassembly Disconnect Flywheel Brake Spring a pliers and stretch it to disconnect it. See Figure 8-27. Figure 8-27. Disconnecting Flywheel Brake Spring. Remove Flywheel drive cup. See Figure 8-28. Figure 8-28. Removing Flywheel Nut (Top View). Figure 8-29. Removing Flywheel (Top View). See Figure 8-30.
Page 55 Remove Spark Plug 1. Remove the spark plug from the cylinder head. See Figure 8-32. Figure 8-32. Removing Spark Plug. Remove Flywheel Brake Assembly Figure 8-33. Figure 8-33. Removing Flywheel Brake Assembly. Remove Valve Cover cover. 2. Remove the cover and the gasket. See Figure 8-34. Figure 8-34.
Page 56 Section 8 Disassembly Remove Rocker Arms rocker studs. See Figure 8-36. Figure 8-36. Removing Rocker Arms. Remove Push Rods 1. Remove the push rods and mark them for reinstallation. See Figure 8-37. Figure 8-37. Removing Push Rods. 8.10 Remove Rocker Studs 1.
Page 57 Remove Cylinder Head cylinder head. See Figure 8-40. Figure 8-40. Removing Cylinder Head. 2. Remove the cylinder head, noting the positioning of the dowels. See Figure 8-41. Gasket Figure 8-41. Cylinder Head Dowels. 3. Remove the head gasket and discard. See Figure 8-40.
Page 58 Section 8 Disassembly Remove Dipstick Tube dipstick tube. See Figure 8-45. Remove the tube. Figure 8-45. Removing Dipstick Tube. Remove Oil Pan and Gasket pan. See Figure 8-46. Figure 8-46. Removing Oil Pan Screws. carefully separate the oil pan from the crankcase. See Figure 8-47.
Page 59 Retainer Figure 8-49. Removing Governor Gear, Retainer. See Figure 8-50. Hitchpin Figure 8-50. Removing Governor Hitchpin, Shaft. Remove Tappets EXHAUST for reinstallation. See Figure 8-51. Figure 8-51. Removing Tappets. Remove Connecting Rod Cap Figure 8-52. Remove the screws and cap. Gear Figure 8-52.
Page 60 Section 8 Disassembly 8.14...
Page 61: Section 9. Inspection And Reconditioning
Section 9 Inspection and Reconditioning Section 9 Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner, Section 4 Carburetor and Governor, Section 5 Ignition, Section 7...
Page 62 Section 9 Inspection and Reconditioning Intake Valve Dimension Guide Depth Guide I.D. Valve Head Diameter Valve Margin (Min.) Figure 9-1. Valve Details. Intake 90° 22.6 mm 5.500/5.5.12 mm 25.875/26.125 mm 45° 0.80 mm 5.465/5.480 mm Exhaust Valve Exhaust 90° 20.5 mm 5.500/5.5.12 mm 23.875/24.125 mm 45°...
Page 63 Hard starting, or loss of power accompanied by high fuel consumption, may be symptoms of faulty valves. removal, clean the valve heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for Normal: can be reconditioned and reused if the face and margin are in good shape.
Page 64 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures: The white deposits seen here indicate very high combustion temperatures, usually due to a lean fuel mixture. Gum: Gum deposits usually result from using stale season. Gum is a prevalent cause of valve sticking. The cure is to ream the valve guides and clean or replace the valves, depending on their condition.
Page 65 Valve Guides not guide the valve in a straight line. This may result in burned valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean the valve guide and, using a split- ball gauge, measure the inside diameter.
Page 66 Section 9 Inspection and Reconditioning...
Page 67: Section 10. Reassembly
The following sequence is a step-by-step guide for complete engine reassembly. This procedure assumes that all components are new or have been reconditioned, and all component subassembly work has been completed. This procedure may vary to accommodate engine options or special equipment. NOTE: Properly clean all components BEFORE reassembly.
Page 68 Section 10 Reassembly Install Crankshaft through the front seal, and fully seat into place. journal for the connecting rod is away from the cylinder. Figure 10-1. Installing Crankshaft. Install Piston and Connecting Rod NOTE: Proper orientation of the piston and connecting rod inside the engine is extremely important.
Page 69 rod. Align the rod cap and connecting rod to match the marks. Torque the screws to 12.5 N·m (110 in. lb.). See Figure 10-6. Match Marks Figure 10-6. Aligning Match Marks. Install Tappets 1. Install the INTAKE and the EXHAUST tappets into their respective positions, as previously marked.
Page 70 Section 10 Reassembly Install Oil Pan 1. The sealing surfaces of the crankcase and oil pan should be clean, dry and free of any nicks or burrs. 2. Install the two crankcase dowels into the crankcase. See Figure 10-11. Figure 10-11. Installing Crankcase Dowels. 3.
Page 71 Install Cylinder Head Assembly Prior to assembly, lubricate all the components with engine oil, including the tips of the valve stems and valve guides. Install Valve Assembly 1. Install the INTAKE and the EXHAUST valves into their respective positions in the cylinder head.
Page 72 Section 10 Reassembly Install Push Rod Assembly 1. Install the rocker studs through the guide plate. See Figure 10-19. Figure 10-19. Installing Guide Plate and Studs. 2. Torque the rocker studs to 13.6 N·m (120 in. lb.). 3. Install the push rods into the intake and exhaust positions, as previously marked.
Page 73 8. Tighten the rocker pivot with a wrench until a slight drag is felt on the feeler gauge. See Figure 10-23. Hold the nut in that position and torque the jam nut to 9.5 N·m (84 in. lb.). Perform the same adjustment procedure on the opposite valve.
Page 74 Section 10 Reassembly Flywheel Key Figure 10-27. Installing Breather Cover. Install Flywheel Assembly Flywheel can Cause Personal Injury! causes extensive engine damage, but can also cause personal dry and completely free of lubricants. The to be over stressed and damaged when the become cracked or damaged if the key is not properly installed.
Page 75 Install Ignition Module away from the ignition module legs. Position the ignition module on the legs with the kill tab down. See Figures 10-30 and 10-32. Ignition Module Figure 10-30. Positioning Ignition Module/Magnets 2. Loosely thread the stud in a mounting leg and and tighten the stud to hold it in place.
Page 76 Section 10 Reassembly 3. Secure the top of the fuel tank to the crankcase by installing the two threaded studs. Torque the studs to 10 N·m (88.5 in. lb.). See Figure 10-34. Spacer Figure 10-34. Installing Fuel Tank Studs. Install spacers on both studs. See Figure 10-34. Secure the fuel tank bracket to the crankcase by See Figure 10-33.
Page 77 Linkage Spring Throttle Lever Governor Spring Figure 10-39. Fixed Speed with Primer (No Choke). Throttle Linkage Spring Lever Choke Lever Choke Linkage Figure 10-40. Fixed Speed with Choke. Throttle Linkage Spring Lever Choke Lever Choke Linkage Speed Control Bracket Figure 10-41. Variable Speed with Choke. Throttle Linkage Throttle Linkage Governor Spring...
Page 78 Section 10 Reassembly Install Governor Spring 1. Install the governor spring between the governor lever and the speed control bracket. See Figure 10-42 and 10-39. Figure 10-42. Installing Governor Spring. Install Carburetor Gaskets 1. Place the spacer gasket, cylinder head spacer and in the order shown in Figure 10-43.
Page 79 Figure 10-46. Attaching Choke Linkage. 10-44. 3. Slide the carburetor onto the mounting studs. See Figure 10-45. Adjust Governor 1. Move the governor lever away from the carburetor to the limit of its travel (wide-open as it will go, while simultaneously tightening the hex nut.
Page 80 Section 10 Reassembly 3. Slide the air cleaner base onto the carburetor screw into the crankcase. See Figure 10-50. Hex Nuts Figure 10-50. Installing Air Cleaner Base. Figure 10-51. Figure 10-51. Attaching Breather Hose. 5. Secure the air cleaner base by torquing the two 8 N·m (71 in.
Page 81 mounting studs, with the gasket folds facing the cylinder head. See Figure 10-54. Figure 10-55. See Figure 10-56. Torque to 9.5 N·m (84 in. lb.). Install Blower Housing 1. Install the blower housing onto the studs. See Figure 10-57. Figure 10-57. Installing Blower Housing. Install Recoil 1.
Page 82 Section 10 Reassembly Install Engine Cover 1. Install the engine cover and secure it with the 2. Torque the nuts to 2.8 N·m (25 in. lb.). See Figure 10-59. Figure 10-59. Installing Engine Cover. 2. Install the engine cover insert onto the engine cover, and secure with the four Torx screws.
Page 84 FOR SALES AND SERVICE INFORMATION IN THE U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FORM NO.: TP-2601 ISSUED: 3/08 REVISED: LITHO IN U.S.A.

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