Kohler Courage XTR-7 Manuals

Manuals and User Guides for Kohler Courage XTR-7. We have 4 Kohler Courage XTR-7 manuals available for free PDF download: Service Manual, Owner's Manual

Kohler Courage XTR-7 Service Manual (57 pages)

XT series

Brand: Kohler | Category: Engine | Size: 6.17 MB

Contents
1
Safety Precautions
2
Maintenance Instructions
3
Maintenance Schedule
3
Repair/Service Parts
3
Oil Recommendations
4
Fuel Recommendations
4
Storage
4
Engine Identification Numbers
5
General Specifications
5
Torque Specifications
5
Clearance Specifications
7
General Torque Values
9
Tools and Aids
10
Description
10
Flywheel Holding Tool
12
Rocker Arm/Crankshaft Tool
12
Troubleshooting Guide
13
External Engine Inspection
14
Cleaning Engine
14
Crankcase Vacuum Test
15
To Test Crankcase Vacuum with Manometer
15
To Test Crankcase Vacuum with Vacuum/Pressure Gauge
15
Compression Test
16
Cylinder Leakdown Test
16
Air Cleaner/Intake
17
Air Cleaner Components
17
Paper Element
17
Foam Element
17
Fuel Line
18
Fuel Shut-Off (if Equipped)
18
Fuel System Tests
18
Carburetor
19
Typical One-Barrel Carburetor Components
19
Troubleshooting Checklist
19
Troubleshooting-Carburetor Related Causes
20
Carburetor Circuits
20
Carburetor Adjustments
20
Carburetor Servicing
20
High Altitude Operation
21
Auto Choke Troubleshooting (if Equipped)
21
Auto Choke Components-Vacuum/Diaphragm Design
21
Cover, Element, and Breather Cover
21
Diaphragm Assembly and Hose
22
Choke Plate and Bimetallic Spring Housing
22
Auto Choke Components-Link Design
23
Use These Steps to Check Function of Link Design Autochoke
23
Governor System
24
Governor Components
24
Initial Governor Adjustment
25
Lubrication System
26
Check Oil Level
26
Change Oil
26
Lubrication Components
26
Electrical System
27
Spark Plug
27
Service
27
Inspection
27
Electronic Ignition System
29
CDI Module Operation (Aluminum Flywheel)
29
IDI Module Operation (Cast Iron Flywheel)
29
Ignition System Components
29
Electronic Ignition Systems Tests
30
Test for Spark
30
Test Ignition Module
30
Starter System
31
Retractable Starter Components
31
Remove Starter
32
Rope Replacement
32
Pawls (Dogs) Replacement
32
Install Starter
32
Disassembly/Inspection and Service
33
External Engine Components
33
Disconnect Spark Plug
34
Drain Oil from Crankcase
34
Drain Oil from Dipstick Tube
34
Remove Engine Cover Insert (if Equipped) and Cover
34
Remove Retractable Starter
35
Remove Muffler Assembly
35
Remove Air Cleaner Assembly
35
Carburetor Components
35
Remove Carburetor with Auto Choke (if Equipped)
36
Control Components
36
Remove Speed Control Bracket
36
Flywheel/Ignition/Fuel Tank Components
37
Remove Fuel Tank
37
Remove Flywheel
37
Remove Breather Assembly
37
Cylinder Head Components
38
Remove Valve Cover
38
Remove Jam Nuts and Rocker Arm Pivots
38
Remove Rocker Arms & Studs
39
Remove Guide Plate
39
Valve Details
39
Remove Cylinder Head
39
Remove Valve Assembly
40
Valve Guides
40
Valve Seat Inserts
40
Lapping Valves
40
Crankcase Components
41
Remove Dipstick Tube (Extended Dipstick)
41
Remove Oil Pan
41
Remove Camshaft
42
Remove Governor Gear and Shaft
42
Remove Connecting Rod Cap
42
Remove Piston and Connecting Rod
42
Install New Piston Rings
43
Piston Ring Orientation
43
Remove Crankshaft
44
Inspection and Service
44
Reassembly
45
Install Crankshaft
45
Install Piston and Connecting Rod
46
Install Governor Gear Assembly
46
Install Oil Pan
46
Torque Sequence
46
Sealant Pattern
47
Install Cylinder Head Assembly
48
Install Valve Train
48
Install Cylinder Head
49
Install Push Rod Assembly
49
Install Valve Cover
49
Valve Cover with RTV
49
Install New Spark Plug
50
Install Flywheel Brake Assembly
50
Install Breather Assembly
50
Install Flywheel
51
Install Ignition Module
51
Install Fuel Tank
51
Install Flywheel Brake Spring
51
Install Governor Assembly
52
Speed Bracket Details
52
Install Speed Control Bracket
52
Install Governor Spring
53
Install Carburetor and Linkage
53
Auto Choke Components
53
Install Carburetor with Auto Choke (if Equipped)
54
Adjust Governor
54
Reconnect Fuel Line
54
Install Air Cleaner Assembly
55
Install Dipstick Tube (Extended Dipstick)
55
Install Muffler Assembly
55
Install Engine Cover
55

Kohler Courage XTR-7 Service Manual (84 pages)

XT-Series Engines for walk-behind mowers

Brand: Kohler | Category: Engine | Size: 5.83 MB

Kohler Courage XTR-7 Owner's Manual (19 pages)

Kohler Vertical Crankshaft Owner's Manual

Brand: Kohler | Category: Engine | Size: 0.38 MB

Table of Contents
2
Safety Precautions

3
Oil Recommendations

5
- Oil Type
  5
- Unit View
  5
Fuel Recommendations

5
- General Fuel Recommendations
  5
- Fuel Type
  5
- Fuel Line
  6
- Fuel Shut-Off Valve (if Equipped)
  6
- Fuel Filter (if Equipped)
  6
- Engine Identification Numbers
  6
- Serial Number
  7
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7
Emission Compliance

7
- Emission Compliance Period
  7
Operating Instructions

7
- Pre-Start Checklist
  7
- Cold Weather Starting
  7
- Smart-Choke
  7
- Smart-Choke (if Equipped)
  7
- Electric Start (XTR-7 Only)
  8
- Recoil Start
  8
- Primer Bulb Start (if Equipped)
  8
- Manual Choke Start
  8
- Shutdown Engine
  9
- Engine Speed
  9
Angle of Operation

9
- Overheating
  9
Carburetor

9
Maintenance

9
- Maintenance Instructions
  10
Oil Level Check

10
Oil Change

11
Air Cleaner System

11
- Paper Air Filter
  11
- Foam Air Filter
  12
- Precleaner
  12
- Cooling Areas
  12
Spark Plug

12
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13
Ignition

13
- Specifications
  13
Repairs

13
Parts Ordering

13
Troubleshooting

14
Storage

14
Engine Warranties

15

Kohler Courage XTR-7 Owner's Manual (24 pages)

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