Kohler Courage XT6.5 Service Manual Download Page 1

Page: 1 / 56

14 690 01 Rev. G

KohlerEngines.com

XT-6, XTR-6, XT6.5, XT650, XT6.75, XT675,

XT-7, XTR-7, XT775, XT8

Service Manual

Safety

Maintenance

Specifications

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 XT6.5

Page 1: ...ner Intake 18 Fuel System 24 Governor System 26 Lubrication System 27 Electrical System 31 Starter System 33 Disassembly Inspection and Service 45 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 ...

Page 2: ...NING 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 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engine with heat shields or g...

Page 3: ...rs or Annually Service replace precleaner Air Cleaner Intake Check air cleaner for dirty loose or damaged parts Air Cleaner Intake Every 50 Hours or Annually Change oil Lubrication System Replace fuel filter if equipped Every 50 Hours or Annually Replace air cleaner element Air Cleaner Intake Every 100 Hours or Annually Clean spark arrestor if equipped Every 100 Hours or Annually Have combustion c...

Page 4: ...pproved and should NOT be used effects 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 Octane Number RON 90 octane minimum Gasoline up to 10 ethyl alcohol 90 unleaded is acceptable Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blend max 15 MTBE by volume are approved Do not a...

Page 5: ... refill 0 6 L 20 oz Maximum Angle of Operation full oil level 4 20 TORQUE SPECIFICATIONS3 5 XT 6 XTR 6 XT6 5 XT650 XT6 75 XT675 XT 7 XTR 7 XT775 XT8 Air Cleaner Base Stud Fastener 8 N m 71 in lb Crankcase Fastener 8 N m 71 in lb Blower Housing Stud 10 N m 88 in lb Nut 8 N m 70 in lb Brake Mounting Fastener 9 5 N m 84 in lb Breather Cover Fastener 10 N m 88 in lb Carburetor Stud Fastener 8 N m 71 i...

Page 6: ...84 in lb Ignition Spark Plug 27 N m 20 ft lb Module Fastener 10 N m 88 in lb Screw 10 N m 88 in lb Muffler Exhaust Stud 5 0 N m 44 in lb Exhaust Stud Nut Fastener 9 5 N m 84 in lb Retractable Starter Fastener 8 N m 71 in lb Rocker Arm Stud 13 6 N m 120 in lb Pivot Jam Nut 9 5 N m 84 in lb Speed Control Bracket Assembly Fastener 8 N m 71 in lb Valve Cover Fastener 8 N m 71 in lb 3 Values are in Met...

Page 7: ...e in Oil Pan Running Clearance Early Models Later Models 0 015 0 051 mm 0 0005 0 002 in 0 008 0 121 mm 0 0031 0 00476 in Bearing flywheel Journal O D Early Models Later Models Max Taper Max Out of Round 24 975 24 989 mm 0 9832 0 9838 in 25 005 25 019 mm 0 9844 0 9850 in 0 025 mm 0 0009 in 0 025 mm 0 0009 in 24 975 24 989 mm 0 9832 0 9838 in 24 975 24 989 mm 0 9832 0 9838 in 0 025 mm 0 0009 in 0 02...

Page 8: ...ion Ring End Gap New Bore Before Serial No 40244XXXXX Top and Center New Bore After Serial No 40243XXXXX Top Center 0 25 0 40 mm 0 0098 0 0157 in 0 1 0 25 mm 0 0039 0 0098 in 0 61 0 76 mm 0 0240 0 0299 in 0 25 0 40 mm 0 0098 0 0157 in 0 1 0 25 mm 0 0039 0 0098 in 0 3 0 5 mm 0 0118 0 0197 in Thrust Face O D 64 975 64 985 mm 0 2558 0 2558 in 69 960 69 980 mm 2 7543 2 7551 in Piston Thrust Face to Cy...

Page 9: ... 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 2 3 20 10 24 3 6 32 4 5 40 3 6 32 10 32 3 6 32 4 5 40 1 4 20 7 9 70 13 0 115 18 7 165 7 9 70 1 4 28 9 6 85 15 8 140 22 6 200 5 16 18 17 0 150 28 3 250 ...

Page 10: ... leakdown test on XT 6 engines Kohler 25 761 05 S Design Technology Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier Regulator Tester 120 V AC 60Hz Kohler 25 761 39 S Kohler 25 455 01 S Kohler 25 761 05 S Kohler 25 761 06 S Kohler 25 761 20 S Dealer Tool Kit Intern...

Page 11: ...t available Starter Brush Holding Tool Solenoid 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 and M Series For properly sizing valve guides after installation Design Technology Inc DTI K828 Valve Guide Reamer O S Command Series For reaming worn valve g...

Page 12: ...ring gear teeth Bosses will lock tool and flywheel 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 connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard rod cap 2 Remove studs of a Posi Lock rod or grind off aligning steps of a Command rod so joint surface is...

Page 13: ...re to check simple causes which at first 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 specification Use these to locate causing factors Engine Will Not Crank Battery is discharged Faulty electric starter or solenoid Faulty key switch or ignition switch Int...

Page 14: ... indications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged element could indicate insufficient or improper maintenance Check carburetor throat for dirt Dirt in throat is further indication that air cleaner was not functioning properly Check if oil level is wi...

Page 15: ...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 If level in engine side is less than specified low no vacuum or level in engine side is lower than level in open side pressure check for conditions in table below 4 Close pinch clamp before stopping engine To test crankcase ...

Page 16: ...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 flywheel end is more accessible use a breaker bar and socket on flywheel nut screw to hold it in position An assistant may be needed to hold breaker bar during testing If engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a dri...

Page 17: ...low to air dry 3 Reinstall precleaner into cover aligning hole in precleaner with upper cover knob Paper Element 1 Remove paper element from base and replace 2 Install element with pleated side out and seat rubber seal onto edges of base Foam Element 1 Remove foam element from base and replace 2 Install element with foam side out and seat rubber seal onto edges of base Reinstall air cleaner cover ...

Page 18: ...lems Test fuel system by performing following tests 1 Check for fuel in combustion chamber a Disconnect and ground spark plug lead b Close choke on carburetor c Crank engine several times d Remove spark plug and check for fuel at tip 2 Check for fuel flow from tank to carburetor a Remove fuel line from inlet fitting of carburetor b Use an approved fuel container to catch fuel and hold line below b...

Page 19: ...uipped with a fixed main jet carburetor Carburetor is designed to deliver correct fuel to air mixture to engine under all operating conditions Idle mixture is set at factory and cannot be adjusted Troubleshooting Checklist When engine starts hard runs rough or stalls at low idle speed check these areas before adjusting or disassembling carburetor 1 Make sure fuel tank is filled with clean fresh ga...

Page 20: ...l 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 progression chamber air fuel mixture is metered through idle port passage At low idle air fuel mixture is controlled by setting of idle fuel adjusting screws This mixture is then mixed with main body of air and delivered to engine ...

Page 21: ...ed information High Altitude Operation Engines may require a high altitude carburetor kit to ensure correct engine operation at altitudes above 1219 meters 4000 ft To obtain high altitude kit information or to ﬁnd a Kohler authorized dealer visit KohlerEngines com or call 1 800 544 2444 U S and Canada This engine should be operated in its original configuration below 1219 meters 4000 ft as damage ...

Page 22: ...um of 15 of water If diaphragm assembly is unable to open choke plate check hose for cracks leaks or restrictions If necessary replace vacuum hose If hose is in working condition and choke plate fails to open with specified vacuum or diaphragm fails to hold choke plate open for a minimum of 3 seconds replace diaphragm assembly 6 Attach vacuum hose to carburetor vacuum fitting 7 Start engine Upon s...

Page 23: ...ition After engine warms up bimetallic spring overcomes choke shaft spring force and holds choke completely open Use these steps to check function of link design auto choke 1 Remove air cleaner cover and element 2 Choke plate should be fully close when engine is cold 3 There should be light spring tension holding choke closed 4 There should not be any binding when choke shaft assembly is rotated w...

Page 24: ...ts E C D I J F A B G K H A Control Spring B Intermediate Control Lever C Control Bracket D Governor Lever E Compression Spring F Linkage G Regulating Pin H Flyweight s I Governor Gear J Governor Gear Shaft K Governor Shaft Retainer As flyweights move outward they cause regulating pin to move outward Regulating pin contacts tab on cross shaft causing shaft to rotate One end of cross shaft protrudes...

Page 25: ...tment Make this initial adjustment whenever governor arm is loosened or removed from cross shaft To ensure proper adjustment make sure throttle linkage is connected to both governor arm and throttle lever on carburetor 1 Loosen governor lever adjustment screw 2 Move governor lever away from carburetor wide open throttle Do not apply excess force that may flex or distort throttle link 3 Grasp cross...

Page 26: ...CHANGE OIL Change oil while engine is warm Dipstick tube 1 Clean area around oil fill cap dipstick 2 Remove oil fill cap dipstick Tilt engine on its side with air cleaner facing up Drain oil into appropriate container 3 After crankcase is drained completely tilt engine upright 4 Fill crankcase with new oil Level should be at top of indicator on dipstick 5 Reinstall oil fill cap dipstick and tighte...

Page 27: ...g serviced Service Clean out spark plug recess Remove plug and replace 1 Check gap using wire feeler gauge Adjust gap to 0 76 mm 0 03 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 are an indication of general condition of piston rings valves and carburetor Normal and fouled plugs are show...

Page 28: ... restricted air cleaner over rich carburetion weak ignition or poor compression Overheated Chalky white deposits indicate very high combustion temperatures This condition is usually accompanied by excessive gap erosion Lean carburetor settings an intake air leak or incorrect spark timing are normal causes for high combustion temperatures ...

Page 29: ...ion IDI Both ignition systems are designed to be trouble free for life of engine Other than periodically checking replacing spark plugs no maintenance or timing adjustments are necessary or possible Mechanical systems do occasionally fail or break down Refer to Troubleshooting to determine root of a reported problem Reported ignition problems are most often due to poor connections Before beginning...

Page 30: ... sparks should be produced 4 Release switch to RUN position Visible and audible sparks should be produced Condition Possible Cause Conclusion Visible and audible sparks are produced Ignition Module Ignition module is OK Visible and audible sparks are not produced Ignition Module or Wiring and Connections Make sure ignition switch kill switch or key switch is in RUN position Check all safety and op...

Page 31: ...starters or retractable starters Inertia drive electric starters are not serviceable XT electric starters use brake switch for an interlock on ground When bail is held down switch in brake assembly completes circuit of ground for starter If there is a no crank situation cause could be brake assembly battery key switch wiring harness fuse or starter itself RETRACTABLE STARTERS WARNING Uncoiling Spr...

Page 32: ...shing of housing 10 Tie a slipknot approximately 12 in from free end of rope Hold pulley firmly and allow it to rotate slowly until slipknot reaches guide bushing of housing 11 Insert starter rope through starter handle and tie a double left hand knot at end of starter rope Insert knot into hole in handle 12 Untie slip knot and pull on starter handle until starter rope is fully extended Slowly ret...

Page 33: ...from battery Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s before servicing External Engine Components F G E D A K C B J H I K J H L H J L K A Engine Cover and Insert B Engine Cover C Engine Cover and Retractable Start D Retractable Starter E Blower Housing F Muffler Guard G Muffler H Air Cleaner Base I Breather Hose J Paper Element K Air Cleaner Cover ...

Page 34: ...ly as engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow manufacturer s instructions and safety precautions carefully Make sure all traces of cleaner are removed before engine is reassembled and placed into ...

Page 35: ...om crankcase 5 Remove air cleaner base and detach primer hose from carburetor primer bulb equipped models only 6 Remove air cleaner base gasket from carburetor noting orientation Carburetor Components Remove Carburetor with Primer or Carburetor with Choke if equipped D E B A C A Carburetor Stud s B Gasket and Spacer Kit C Gasket and Heat Shield Kit D Linkage E Carburetor NOTE Ensure fuel tank is e...

Page 36: ...sembly base securing it to top of muffler 7 Remove arm assembly from muffler Control Components D E F C B A A Flywheel Brake Spring B Speed Control Bracket C Linkage Spring D Governor Lever E Governor Spring F Throttle Linkage Remove Speed Control Bracket Disconnect governor spring from speed control bracket Remove Speed Control Bracket NOTE Fuel hose connecting carburetor and fuel tank is held in...

Page 37: ...wheel is mounted on a tapered shaft To break it loose use a rubber mallet to land a firm blow toward outer rim of flywheel Remove flywheel 4 Remove flywheel key from crankshaft Inspection Inspect flywheel for cracks and check keyway for wear or damage Replace flywheel if cracked If flywheel key is sheared or keyway is damaged replace crankshaft flywheel and key Inspect ring gear for cracks or dama...

Page 38: ...ve Cover with RTV Sealant NOTE Valve cover is sealed to cylinder head using RTV silicone sealant When removing valve cover use care not to damage gasket surfaces of cover and cylinder head To break RTV seal hold a block of wood against 1 flat face of valve cover Strike wood firmly with a mallet If seal doesn t break loose after 1 or 2 attempts repeat procedure on other side 1 Remove screws securin...

Page 39: ... push rods and mark them for reinstallation Remove Rocker Studs Unscrew and remove rocker studs from cylinder head Remove Guide Plate 1 Remove guide plate from rocker studs 2 Note orientation of guide plate tabs down for use during reassembly Remove Cylinder Head 1 Remove screws securing cylinder head 2 Remove cylinder head noting positioning of dowels 3 Remove head gasket and discard Valve Inspec...

Page 40: ... or guide is responsible for excessive clearance Maximum I D wear on intake valve guide is 5 512 mm 0 2170 in while 5 512 mm 0 2170 in is maximum allowed on exhaust guide Guides are not removable If guides are within limits but valve stems are worn beyond limits replace valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into cylinder head Inserts ...

Page 41: ... Shaft P Governor Gear Q Governor Washer R Governor Cup S Oil Pan T Oil Pan Oil Seal U Dipstick Tube V Screw Remove Dipstick Tube Extended Dipstick Remove screw securing dipstick tube Remove tube Remove Oil Pan NOTE Some engines have an oil pan gasket some engines use RTV to secure oil pan to crankcase 1 Remove screws securing oil pan 2 Using a flat blade screwdriver as a wedge carefully separate ...

Page 42: ...g Rod Cap Rotate crankshaft to allow access to 2 screws on connecting rod cap Remove screws and cap Remove Piston and Connecting Rod Carefully guide piston and attached connecting rod out of cylinder bore Connecting Rod Inspection and Service Check bearing area big end for excessive wear score marks running and side clearances Replace connecting rod and end cap if scored or excessively worn Servic...

Page 43: ...ail E Expander Ring F Bottom Rail Piston Ring Orientation A B C D E 60 A Oil Ring Expander Gap B Bottom Oil Rail Gap C Top Oil Rail Gap D Intermediate Compression Ring Gap E Top Compression Ring Gap NOTE Rings must be installed correctly Install oil control ring assembly bottom groove first middle compression ring center groove second and top compression ring top groove last Oil control ring assem...

Page 44: ... clearances are within specification and there is no evidence of scoring grooving etc no further reconditioning is necessary If bearing surfaces are worn or damaged crankcase and or closure plate will need to be replaced Inspect crankshaft keyway If worn or chipped replacement of crankshaft will be necessary Inspect crankpin for score marks or metallic pickup Slight score marks can be cleaned with...

Page 45: ...sure engine is assembled using all specified torque values tightening sequences and clearances Failure to observe specifications could cause severe engine wear or damage NOTE Always use new gaskets NOTE Make sure all components have been properly cleaned BEFORE reassembly NOTE Remove all traces of cleaners before engine is reassembled and placed into operation Even small amounts of these cleaners ...

Page 46: ...ton attached into bore 5 Use handle of a soft rubber grip hammer to tap piston into bore 6 Rotate crankshaft to mate with connecting rod Align rod cap and connecting rod to match marks Torque screws to 12 5 N m 110 in lb Install Tappets Install intake and exhaust tappets into their respective positions as previously marked Install Camshaft 1 Lubricate camshaft and cam gear surfaces with light grea...

Page 47: ...gasket onto crankcase RTV Refer to Tools and Aids for a listing of approved sealants Always use fresh sealant Using outdated sealant can result in leakage Using sealant pattern apply a 1 5 mm 1 16 in bead of sealant to sealing surface of oil pan 4 Guide oil pan onto crankcase ensuring camshaft and governor gear align with their mating surfaces Rotate crankshaft slightly to help engage governor gea...

Page 48: ... Intake Valve Seal L Spark Plug M Baffle N Cylinder Head O Valve P Dowel Pin Install Cylinder Head Assembly Prior to assembly lubricate all components with engine oil including tips of valve stems and valve guides Install Valve Train 1 Install intake and exhaust valves into their respective positions in cylinder head 2 Install intake valve seal onto intake valve Next slide valve springs onto both ...

Page 49: ...h round push rod ends 6 Loosely install pivots and jam nuts onto rocker studs 7 With piston at top dead center of compression stroke insert a 0 1 mm 0 004 in flat feeler gauge between 1 valve stem and rocker arm Valve Clearance Specifications Intake Valve 0 0762 0 127 mm 0 003 0 005 in Exhaust Valve 0 0762 0 127 mm 0 003 0 005 in 8 Tighten rocker pivot with a wrench until a slight drag is felt on ...

Page 50: ...sely install 2 brake assembly screws 2 Install a caliper between brake lever and bracket to establish a 50 mm 1 968 in gap pivoting on rear screw if necessary 3 Rotate brake lever clockwise around rear screw Torque screws to 9 5 N m 84 in lb Reinstall kill lead to ignition module or to bottom terminal on micro switch if equipped 4 Actuate brake arm and verify an audible click is heard from micro s...

Page 51: ...hold flywheel still while simultaneously tightening nut to 51 5 N m 38 ft lb Install Electric Starter if equipped Align and mount electric starter onto crankcase Install and torque screws to 9 5 N m 84 in lb Install Ignition Module NOTE If stud for mounting ignition module was not kept segregated from 2 studs for mounting fuel tank compare their lengths and choose short one 1 Rotate flywheel so ig...

Page 52: ...age Speed Bracket Details F E D G I H F J K E D G I H F J K E M L D G I H A B C A Fixed Speed with Primer No Choke B Fixed Speed with Choke C Variable Speed with Choke D Throttle Linkage E Linkage Spring F Throttle Lever G Governor Spring H Speed Control Bracket I Governor Lever J Choke Lever K Choke Linkage L Dual Throttle Choke Control M Speed Control Screw Install Speed Control Bracket NOTE The...

Page 53: ...OTE There are several different ways to attach carburetor linkage depending on carburetor and speed bracket used Install Carburetor with Primer if equipped 1 With carburetor not yet mounted on studs rotate it slightly to allow connection of throttle linkage and linkage spring to throttle lever 2 Slide carburetor onto mounting studs Install Carburetor with Choke 1 With carburetor not yet mounted on...

Page 54: ...nor Move governor lever away from carburetor to limit of its travel wide open throttle and hold in this position Do not stress flex or distort linkage Grasp cross shaft with a pliers and turn shaft clockwise as far as it will go hold and tighten nut Torque nut to 9 5 N m 84 in lb Reconnect Fuel Line Slide fuel line tight up against carburetor and secure connection with a hose clamp External Engine...

Page 55: ...xhaust mounting studs with gasket folds facing cylinder head 2 Slide muffler onto exhaust studs 3 Install muffler guard onto exhaust studs and secure with nuts Torque to 9 5 N m 84 in lb Install Blower Housing Install blower housing onto studs Install Retractable Starter Place retractable starter onto studs protruding from blower housing Install Engine Cover Engine Cover if equipped 1 Install engi...

Search results

Summary of Contents for Courage XT6.5

Reviews:

Related manuals for Courage XT6.5

Brands by name

Popular brands

Kohler Courage XT6.5, Service Manual

Search results

Summary of Contents for Courage XT6.5

Reviews:

Related manuals for Courage XT6.5

Brands by name

Popular brands