Kohler Courage Service Manual Download Page 65

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Reassembly

32 690 01 Rev. D

KohlerEngines.com

Install Crankshaft

1. Lubricate flywheel side main bearing surface and

lips of oil seal in crankcase with clean engine oil.

2. Carefully slide flywheel end of crankshaft through

main bearing in crankcase.

Install Connecting Rods with Pistons and Rings
Piston and Connecting Rod Details

Side 1

Side 2

NOTE: Cylinders are numbered on crankcase. Make

sure to install piston, connecting rod, and end

cap into its appropriate cylinder bore as

previously marked during disassembly. Do not

mix end caps and connecting rods.

NOTE: Proper orientation of piston/connecting rod

assemblies inside engine is extremely important.

Improper orientation can cause extensive wear

or damage. Be certain pistons and connecting

rods are assembled exactly as shown.

NOTE: Align chamfer of connecting rod with chamfer of

its mating end cap. When installed, flat faces of

connecting rods should face each other. Faces

with raised rib should be toward outside.

1. Stagger piston rings in grooves until end gaps are

120° apart. Oil ring rails should also be staggered.

2. Lubricate cylinder bore, piston, and piston rings with

engine oil. Compress rings using a piston ring

compressor.

3. Lubricate crankshaft journals and connecting rod

bearing surfaces with engine oil.

4. Make sure FLY stamping on piston is facing toward

flywheel side of engine. Use a hammer with a rubber

or wood grip and gently tap piston into cylinder. Be

careful oil ring rails do not spring free between

bottom of ring compressor and top of cylinder.

5. Install inner rod cap to connecting rod using screws.

Torque screws in increments to 11.3 N·m

(100 in. lb.). Illustrated instructions are provided in

service rod package.

6. Repeat above procedure for other connecting rod

and piston assembly.

Crankshaft/Governor Gear/Oil Pump Components

Governor Cross

Shaft

Crankshaft

Valve Tappets

Camshaft

Regulating Pin

Shaft

Governor Gear

Locking Tab Thrust

Washer

Oil Pan

Drain Plug

Oil Seal

Oil Feed Tube

(Filter to Pan)

Oil Pump

Gerotor Gears

Oil Feed Tube

(Oil Pump Outlet)

O-Rings

Oil Sentry

™

Oil Pump Torque

Summary of Contents for Courage

Page 1: ...1 Electrical System 43 Starter System 49 Emission Compliant Systems 52 Disassembly Inspection and Service 64 Reassembly 1 32 690 01 Rev D KohlerEngines com IMPORTANT Read all safety precautions and in...

Page 2: ...haust fumes Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled WARNING Accidental Starts can cause severe injury or death Disco...

Page 3: ...eaner element if not equipped with precleaner Air Cleaner Intake Every 100 Hours Replace air cleaner element if equipped with precleaner Air Cleaner Intake Change oil and filter Lubrication System Rem...

Page 4: ...proved 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...

Page 5: ...5 Specifications 32 690 01 Rev D KohlerEngines com Dimensions in millimeters Inch equivalents shown in Engine Dimensions...

Page 6: ...6 Specifications KohlerEngines com 32 690 01 Rev D Dimensions in millimeters Inch equivalents shown in Engine Dimensions...

Page 7: ...Cover Stud Outer Cover Hex Nut 10 7 N m 95 in lb into new hole 7 3 N m 65 in lb into used hole 6 2 N m 55 in lb into new hole 4 0 N m 35 in lb into used hole 1 3 N m 11 5 in lb Oil Drain Plug 13 6 N m...

Page 8: ...g 27 N m 20 ft lb Module Fastener 4 0 6 2 N m 35 55 in lb Rectifier Regulator Fastener 4 0 N m 35 in lb Intake Manifold Mounting Fastener torque in 2 increments first to 7 4 N m 66 in lb finally to 9...

Page 9: ...arance 0 025 0 063 mm 0 0010 0 0025 in Bore I D New Max Wear Limit 20 000 20 025 mm 0 7874 0 7884 in 20 038 mm 0 7889 in Bearing Surface O D New Max Wear Limit 19 962 19 975 mm 0 7859 0 7864 in 19 959...

Page 10: ...0 0010 in Connecting Rod Journal O D New O D Max Wear Limit Max Taper Max Out of Round 35 955 35 973 mm 1 4156 1 4163 in 35 94 mm 1 415 in 0 018 mm 0 0007 in 0 025 mm 0 0010 in T I R PTO End Crank in...

Page 11: ...re Max 0 25 0 56 mm 0 0100 0 0224 in 0 94 mm 0 037 in Thrust Face O D 7 New Max Wear Limit 82 947 mm 3 2656 in 82 802 mm 3 2599 in Piston Thrust Face to Cylinder Bore7 Running Clearance New 0 06 0 100...

Page 12: ...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 13: ...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...

Page 14: ...nt 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 be...

Page 15: ...ing 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...

Page 16: ...e 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 lis...

Page 17: ...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 e...

Page 18: ...s 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 i...

Page 19: ...t 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...

Page 20: ...base then remove base and gasket 6 Reverse procedure to reassemble components Torque nuts to 6 2 7 3 N m 55 65 in lb Torque blower housing screws to 4 0 N m 35 in lb and front HI LO screws to 2 8 N m...

Page 21: ...uel line from inlet fitting of fuel pump b Hold line below bottom of tank Open shut off valve if equipped and observe flow Performance Minimum fuel delivery rate must be 7 5 L hr 2 gal hr with a press...

Page 22: ...s Keihin One Barrel Carburetor Components J I H E F G D B C A A Idle Speed Screw B Idle Fuel Adjusting Screw C Carburetor Body D Idle Jet E Plug F Main Jet G Float H Shut off Solenoid Assembly I Fuel...

Page 23: ...dle clean needle and seat and blow with compressed air Bowl vent or air bleeds plugged Remove low idle fuel adjusting needle Clean vent ports and air bleeds Blow out all passages with compressed air L...

Page 24: ...ression holes As throttle plate opens further vacuum signal becomes great enough at venturi so main circuit begins to work Main high speed At high speeds loads engine operates on main circuit As a met...

Page 25: ...aterial before disassembling carburetor Remove bowl retaining screws or solenoid assembly on most single cylinder engines and carefully separate fuel bowl from carburetor Do not damage fuel bowl O rin...

Page 26: ...and choke control will have either a left side pull or a right side pull Governor Throttle Control Connections M C E I H I H A F J K B B E D C F A E G C A Left Side Pull B Cable Clamp C Speed Control...

Page 27: ...ilure to follow these guidelines can burn out starter motor NOTE If engine develops sufficient speed to disengage starter but does not keep running a false start engine rotation must be allowed to com...

Page 28: ...ernal throttle linkage When engine is at rest and throttle is in fast position tension of governor spring holds throttle plate open When engine is operating governor gear assembly is rotating Force ap...

Page 29: ...urface Reinstall drain plug Torque to 13 6 N m 10 ft lb 3 Place new filter in shallow pan with open end up Fill with new oil until oil reaches bottom of threads Allow 2 minutes for oil to be absorbed...

Page 30: ...o stop engine On vehicular applications lawn tractors mowers etc pressure switch can only be used to activate a low oil warning light or signal Installation 1 Apply pipe sealant with Teflon Loctite PS...

Page 31: ...e 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 a...

Page 32: ...Battery Size Recommendations Temperature Battery Required Above 32 F 0 C 200 cca minimum 0 F to 32 F 18 C to 0 C 250 cca minimum 5 F to 0 F 21 C to 18 C 300 cca minimum 10 F 23 C or below 400 cca min...

Page 33: ...Ignition Timing System Diagram H Q L G AD D D S T H M K F D J I G E C B A U V W X Y Z S R P Q Q N O AA AB AE AF AF AC AB AC AG A Starter Solenoid Tang B Solenoid Shift Starter Assembly C Inertia Driv...

Page 34: ...engine 2 spark plugs Wiring Diagram Digital Spark Advance Ignition DSAI System R N O U A B C E D F F I H G G B B J J L K M N J W X Y Z Q P B T V V U P B J N N S AB AD AF AE AC AA A Oil SentryTM Optio...

Page 35: ...e DSAM Ignition System W B R Z A B C E D F F H K G G J Q O N P Q S U T B X T B Q Y Y K L M I V AI AH AF AG AE AM AL AK AA AA AB AJ AC AD A Oil Sentry Optional B Green C Violet Charging D Rectifier Reg...

Page 36: ...kill lead connection for affected module DSAI and DSAM only Test for Spark NOTE If 2 testers are available testing can be performed simultaneously for both cylinders However if only 1 tester is avail...

Page 37: ...s in checking for timing advance Condition Possible Cause Conclusion All tests are OK but module has no spark or fails to advance Ignition Module Replace affected module Any test is BAD Ignition Modul...

Page 38: ...ween magnet and all three legs of module Ignition module air gap is critical to proper system performance Do not attempt to set it with a business card or folded microfiche card Use feeler gauge speci...

Page 39: ...black voltmeter lead directly to negative post of battery and test voltage again in both key positions If correct voltage is still not indicated check harness connector terminal for a good connection...

Page 40: ...layed starting with a 6 and progressing down to 1 followed by a P pass or F fail indicating condition of part 4 If you get a negative sign instead of numerical sequence and or an F at end of test cycl...

Page 41: ...end of tandem adapter lead 2 Connect tester ground lead with spring clamp to body of rectifier regulator 3 Connect red lead and 1 black lead to terminals on open end of tandem adapter lead connection...

Page 42: ...gulator steps 2 and 3 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter Condition Conclusion Voltage is 28 volts...

Page 43: ...dition Possible Cause Conclusion Starter does not energize Battery Check specific gravity of battery If low recharge or replace battery as necessary Wiring Clean corroded connections and tighten loose...

Page 44: ...cted position assemble inner halves of removal tool around armature shaft with retaining ring in inner groove Slide collar over inner halves to hold them in position 5 Thread center screw into removal...

Page 45: ...stall drive end cap over drive shaft and align with cutout starter frame 3 Installing new brushes carefully remove tape holding thrust washer cup in place against brushes Do not allow thrust washer cu...

Page 46: ...r fatigue or damage Measure length of each brush Minimum length for each brush is 7 6 mm 0 300 in Replace brushes if they are worn undersize or condition is questionable Armature Components and Detail...

Page 47: ...cing brushes brush holder assembly a Hold starter assembly vertically on end housing and carefully position assembled brush holder assembly with supplied protective tube against end of commutator arma...

Page 48: ...1 Use an ohmmeter set to audible or Rx2K scale and connect 2 ohmmeter leads to 2 large post terminals 2 Perform solenoid pull in coil plunger actuation test and check for continuity Ohmmeter should in...

Page 49: ...supplied canisters breather filter can be removed and cleaned with hot soapy water dried and reinstalled Do not oil breather screen This is done periodically or if system operation is suspect Carbon...

Page 50: ...through an inlet screen of secondary air valve Air is then drawn into exhaust manifold and muffler where it mixes with any unburned hydrocarbons which then burn in heat of muffler A hose is connected...

Page 51: ...let screen from secondary air valve assembly by grasping inlet screen at base and gently pulling away from valve assembly 2 Use a soft brush to remove debris from screen 3 Run water through inlet scre...

Page 52: ...plug lead s before servicing External Engine Components J X E P G W V E E F H K I L M N L O B A C D R Q S T U A Fixed Guard B Air Cleaner Access Door C Debris Screen D Blower Housing E Hose Clamp F F...

Page 53: ...rdware from engine Remove Fuel Pump if equipped WARNING Explosive Fuel can cause fires and severe burns Do not fill fuel tank while engine is hot or running Gasoline is extremely flammable and its vap...

Page 54: ...tach bushings to linkage following separation to avoid losing them Remove Electric Starter Motor 1 Disconnect leads from starter 2 Remove screws and starter 3 Pull out oil fill tube with lifting strap...

Page 55: ...G L M N O K P Q A Gasket B Valve C Cylinder Head D Spring Cap E Valve Stem Seal F Valve Spring G Valve Spring Retainer H Valve Spring Keeper I Stud J Spark Plug K Guide Plate L Push Rod M Rocker Arm...

Page 56: ...Guide I D 7 038 7 058 mm 0 2771 0 2779 in 7 038 7 058 mm 0 2771 0 2779 in E Valve Head Diameter 33 37 33 63 mm 1 3138 1 3240 in 29 37 29 63 mm 1 1563 1 1665 in F Valve Face Angle 45 45 G Valve Margin...

Page 57: ...can be reconditioned if not too badly pitted or distorted If cracked or badly warped cylinder head should be replaced Recondition valve seat inserts following instructions provided with valve seat cu...

Page 58: ...lywheel keyway for damage Replace flywheel if it is cracked Replace flywheel crankshaft and key if flywheel key is sheared or keyway is damaged Inspect ring gear for cracks or damage Kohler does not p...

Page 59: ...ting pin within governor gear flyweights assembly and slide both onto governor shaft until assembly locks into place Oil Pump Assembly Oil pump is mounted inside oil pan If service is required continu...

Page 60: ...s B A A 2 0 mm 0 0787 in B Governor Cross Shaft Seal 1 Remove retainer and washer from governor cross shaft 2 Remove cross shaft with small inner washer through inside of crankcase 3 Remove governor s...

Page 61: ...high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by ab...

Page 62: ...ns it will be necessary to replace crankshaft Remove Inner Breather Assembly Breather system is designed to control amount of oil in head area and still maintain necessary vacuum in crankcase When pis...

Page 63: ...der walls following boring and or honing is very critical to a successful overhaul Machining grit left in cylinder bore can destroy an engine in less than 1 hour of operation after a rebuild Final cle...

Page 64: ...ean and free of any nicks or burrs 2 Apply a light coat of engine oil to outside diameter of oil seal 3 Install oil seal into crankcase using a seal driver Make sure oil seal is installed straight and...

Page 65: ...de 1 Stagger piston rings in grooves until end gaps are 120 apart Oil ring rails should also be staggered 2 Lubricate cylinder bore piston and piston rings with engine oil Compress rings using a pisto...

Page 66: ...5 mm 0 02725 0 02875 in Blue 0 74295 0 78105 mm 0 02925 0 03075 in Red 0 79375 0 83185 mm 0 03125 0 03275 in Yellow 0 84455 0 88265 mm 0 03325 0 03475 in Green 0 89535 0 99345 mm 0 03525 0 03675 in Gr...

Page 67: ...st be installed within 5 minutes of sealant being applied for proper sealing to occur 4 Make sure end of governor cross shaft is lying against bottom of cylinder inside crankcase 5 Install oil pan to...

Page 68: ...der 2 single kill tab should be down away from you 3 Install each ignition module to crankcase bosses with screws Slide modules up as far away from flywheel as possible and snug screws to hold them in...

Page 69: ...P O Ring Q Valve Cover R Torque Sequence 5 Insert a 0 30 mm 0 012 in flat feeler gauge between magnet and ignition module Loosen screws enough to allow magnet to pull module against feeler gauge 6 Tor...

Page 70: ...mble Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to lip of valve stem seal valve stems and valve guides Install following items in order l...

Page 71: ...ers Stamped Steel Valve Cover RTV Sealant A A RTV Sealant Stamped Steel Valve Cover Torque Sequence 1 5 3 2 4 NOTE Always use fresh sealant Using outdated sealant can result in leakage Refer to Tools...

Page 72: ...ess Door C Debris Screen D Blower Housing E Hose Clamp F Fuel Pump G Hose Clip H Fuel Line I Fuel Filter J Oil Filter K Nipple L O Ring M Oil Feed Tube Oil Pump Outlet N Oil Feed Tube Filter to Pan O...

Page 73: ...rews as listed following step 2 2 Attach inner baffles including any lifting straps to cylinder head flanges and to 2 crankcase mounting bosses Lift strap should be outside outer baffle Secure with M5...

Page 74: ...l bracket assembly 2 Install main control bracket to cylinder heads using screws Two lower screws should also secure inner baffles Torque screws to 10 7 N m 95 in lb into new holes or 7 3 N m 65 in lb...

Page 75: ...16 18 head capscrews based on head design to secure muffler Torque nuts to 24 4 N m 216 in lb or capscrews to 16 9 N m 150 in lb Install Oil Filter and Fill Crankcase with Oil NOTE Make sure oil drain...

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Kohler Courage, Service Manual

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