Kohler Courage 3000 Series Service Manual Download Page 1

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18 690 01 Rev. F

KohlerEngines.com

SH255, SH265, SH270
Service Manual

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

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.

Summary of Contents for Courage 3000 Series

Page 1: ...stem 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 carefull...

Page 2: ...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...

Page 3: ...Intake Every 100 Hours or Annually Clean low pro le air cleaner element Air Cleaner Intake Replace dual element air cleaner element Air Cleaner Intake Change oil Lubrication System Clean cooling areas...

Page 4: ...ved and should NOT be used e ects 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 Oct...

Page 5: ...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...

Page 6: ...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...

Page 7: ...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 Mu er M8 Exhaust Screw 24 N m 212 in lb M6 Mu er Shield Screw 8 N m 70 8 in lb M4 Mu er Shield Screw 2...

Page 8: ...rankshaft 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 Ne...

Page 9: ...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...

Page 10: ...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...

Page 11: ...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 Ti...

Page 12: ...mestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Recti er Regulator Tester 120 V AC 60Hz Kohler 25 761 39 S...

Page 13: ...enoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed position while installing timing belt Kohler 28 761 01 S Valve Guide Reamer K...

Page 14: ...ng gear teeth Bosses will lock tool and ywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk con...

Page 15: ...to check simple causes which at 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...

Page 16: ...or indications of improper t and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow un ltered air into engine A dirty or clogged...

Page 17: ...Make sure pinch clamp is closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side I...

Page 18: ...ft Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If ywheel end is more accessible use a breaker bar and socket on ywheel nu...

Page 19: ...Element 1 Remove wing nut if equipped and paper element with precleaner 2 Separate precleaner from element service precleaner and replace element 3 Reinstall precleaner over paper element secure with...

Page 20: ...tank to carburetor 1 Stop engine 2 Turn fuel shut o lever to OFF position 3 Remove fuel shut o cup 4 Clean fuel shut o cup with solvent and wipe dry 5 Inspect for worn or damaged O ring replace as nec...

Page 21: ...rburetor 1 Make sure fuel tank is lled with clean fresh gasoline 2 Make sure fuel tank cap vent is not blocked and is operating properly 3 Make sure fuel is reaching carburetor This includes checking...

Page 22: ...through slow air bleed jets fuel is drawn through main jet and further metered through slow jet Air and fuel are mixed in body of slow jet and exit to idle progression transfer port chamber From idle...

Page 23: ...retor After main jet is removed main nozzles can be removed through bottom of main towers Note orientation direction of nozzles End with 2 raised shoulders should be out down adjacent to main jets 6 S...

Page 24: ...lever clockwise until it stops 5 Rotate governor shaft clockwise until it stops 6 Hold both in this position and torque governor lever nut to 10 N m 88 5 in lb Governed speed setting is determined by...

Page 25: ...OIL Change oil while engine is warm 1 Clean area around oil ll plug dipstick and drain plug 2 Remove drain plug and oil ll plug dipstick Drain oil completely 3 Reinstall drain plug Torque 18 N m 13 f...

Page 26: ...e feeler gauge Adjust gap to 0 76 mm 0 030 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip...

Page 27: ...erminal J Spark Plug Boot These engines are equipped with a dependable magneto breakerless ignition In such a system electrical energy is generated by cutting of magnetic ux lines generated from ignit...

Page 28: ...test resistance from small spade terminal to core of spark plug lead wire If resistance is not in this range replace module Resistance Chart Ignition Module 13 5 18 0 K ohms Cap 4 6 K ohms Spade Termi...

Page 29: ...connections Connect ohmmeter leads to switch leads and check for continuity in both switch positions Condition Conclusion Continuity should be indicated when and only when switch is in OFF position R...

Page 30: ...ttery Check speci c gravity of battery If low recharge or replace battery as necessary Wiring Check for corroded connections poor ground connection Transmission or Engine Make sure clutch or transmiss...

Page 31: ...ve it from starter for testing a Set an ohmmeter on Rx1 scale and zero meter Connect one ohmmeter lead to terminal of blue lead from relay Connect other ohmmeter lead to relay mounting bracket Conditi...

Page 32: ...ley counterclockwise until rope hole in pulley is aligned with rope guide bushing of starter housing 9 Insert unknotted end of new rope through rope hole in starter pulley and rope guide bushing of ho...

Page 33: ...ccidental Starts can cause severe injury or death Disconnect and ground spark plug lead s before servicing 18 690 01 Rev F KohlerEngines com External Engine Components D J E F G I C A H B K A Oil Drai...

Page 34: ...mple time for oil to drain from crankcase Remove Mu er and Heat Shield Assembly 1 Remove nuts lock washers and at washers 2 Remove mu er assembly from exhaust outlet 3 Remove exhaust gasket from exhau...

Page 35: ...arks from ignition Never use gasoline as a cleaning agent Remove air cleaner gasket and slide carburetor o mounting studs while disconnecting throttle linkage and dampening spring Remove carburetor to...

Page 36: ...seal hold block of wood against 1 at surface of valve cover Strike wood rnly with mallet If seal doesn t break loose after 1 or 2 attempts repeat procedure on other side 1 Remove screws and remove va...

Page 37: ...mm 2 4409 in 0 0059 in Valve Length Maximum 64 15 mm 2 5256 in 62 15 mm 2 4468 in Valve Length Service Limit 64 15 mm 2 5256 in 62 15 mm 2 4468 in D Face Seat Width Maximum 2 0 mm 0 079 in 2 0 mm 0 07...

Page 38: ...d or distorted If cracked or badly warped cylinder head should be replaced Recondition valve seat inserts following instructions provided with valve seat cutter being used Cutting proper valve face an...

Page 39: ...or Cross Shaft T Crankcase Bearing U Crankcase Oil Seal V Dowel Pin Remove Closure Plate NOTE Do not pry on gasket surface of crankcase or closure plate as this can cause damage and leakage 1 Remove s...

Page 40: ...fuel is blown out opened exhaust valve and does not hamper starting 5 Engines with ACR start much faster in cold weather than engines without ACR 6 Engines with ACR can be started with spark plugs th...

Page 41: ...to ring side clearance Compare clearance to Clearance Speci cations If side clearance is greater than speci ed a new piston must be used Measuring Piston to Bore Clearance Piston Detail A A 15 mm 0 59...

Page 42: ...Oil Sentry System 1 Remove nut securing Oil Sentry lead wire grommet assembly to crankcase 2 Pull grommet assembly from crankcase on inside 3 Remove screws securing Oil Sentry oat switch to crankcase...

Page 43: ...or press to make sure bearings are installed straight into their respective bore until fully seated 3 Using an appropriate seal driver install oil seal into closure plate to a depth of 5 5 mm 0 217 in...

Page 44: ...ring assembly rst middle compression ring second and top compression ring last Oil control ring assembly is a three piece design and consists of a top rail expander ring and bottom rail 1 Install pist...

Page 45: ...y is not installed properly 1 Install woodru key into keyway of crankshaft Be sure that key is properly seated and parallel with taper of shaft 2 Install ywheel onto crankshaft being careful not to sh...

Page 46: ...ker Arms NOTE Push rods should always be installed in original location 1 Install push rod guide plate aligning holes for rocker arm studs Install rocker arm studs and torque to 13 6 N m 120 in lb 2 D...

Page 47: ...l a new valve cover gasket followed by valve cover on head with screws and torque to 8 0 N m 71 in lb using sequence shown Valve Cover with RTV A A RTV Sealant NOTE Always use fresh sealant Using outd...

Page 48: ...nk E Dampening Spring F Control Assembly G Carburetor H Retractable Starter I On O Wiring Harness Bullet Connector J Blower Housing K Oil Sentry Wiring Harness Bullet Connector L Oil Sentry Module M O...

Page 49: ...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 D J E F G I C A H B K A Oil Drain Plug B Oil Fill P...

Page 50: ...e lever to throttle plate Install tabbed washer with tab engaged in slot and secure with nut 3 Torque nut to 5 4 N m 47 8 in lb 4 Install governor lever onto shaft 5 Connect dampening spring and throt...

Page 51: ...8 Spring Color Hole Spring Color Hole Spring Color Hole Spring Color Hole Spring Color Hole Spring Color Hole Spring Color Hole 3750 3950 None B 3100 3300 Gold C 3500 3700 Green A 3750 3950 Green B 36...

Page 52: ...cleaner onto air cleaner stud and secure with washer and wing nut if equipped 3 Install air cleaner cover and secure with wing nut Low Pro le 1 Install air cleaner base and secure with screws 2 Instal...

Page 53: ...53 18 690 01 Rev F KohlerEngines com...

Page 54: ...54 KohlerEngines com 18 690 01 Rev F...

Page 55: ...55 18 690 01 Rev F KohlerEngines com...

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Kohler Courage 3000 Series, Service Manual

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