XT-6, XTR-6, XT6.5, XT650, XT6.75, XT675, XT-7, XTR-7, XT775, XT8 Service Manual 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. 2 Safety 3 Maintenance 5 Specifications 10 Tools and Aids 13 Troubleshooting 17 Air Cleaner/Intake 18 Fuel System 24 Governor System 26 Lubrication System 27 Electrical System 31 Starter System 33 Disassembly/Inspection and Service 45 Reassembly 14 690 01 Rev. G KohlerEngines.com 1 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING WARNING CAUTION Explosive Fuel can cause Accidental Starts can Electrical Shock can fires and severe burns. cause severe injury or cause injury. Do not fill fuel tank while death. Do not touch wires while engine is hot or running. Disconnect and ground engine is running. Gasoline is extremely flammable spark plug lead(s) before and its vapors can explode if servicing. CAUTION ignited. Store gasoline only in approved containers, in well Before working on engine or Damaging Crankshaft ventilated, unoccupied buildings, equipment, disable engine as and Flywheel can cause away from sparks or flames. follows: 1) Disconnect spark plug personal injury. Spilled fuel could ignite if it comes lead(s). 2) Disconnect negative (–) in contact with hot parts or sparks battery cable from battery. from ignition. Never use gasoline as a cleaning agent. WARNING Using improper procedures can lead to broken fragments. Broken Hot Parts can cause fragments could be thrown from WARNING severe burns. engine. Always observe and use Rotating Parts can cause Do not touch engine precautions and procedures when severe injury. while operating or just installing flywheel. Stay away while engine after stopping. is in operation. Never operate engine with heat WARNING Keep hands, feet, hair, and shields or guards removed. Uncoiling Spring can clothing away from all moving cause severe injury. parts to prevent injury. Never operate engine with covers, WARNING Wear safety goggles or shrouds, or guards removed. Cleaning Solvents can face protection when cause severe injury or servicing retractable death. starter. WARNING Use only in well Retractable starters contain a Carbon Monoxide can ventilated areas away powerful, recoil spring that is cause severe nausea, from ignition sources. under tension. Always wear safety fainting or death. Carburetor cleaners and solvents goggles when servicing retractable Avoid inhaling exhaust are extremely flammable. Follow starters and carefully follow fumes. cleaner manufacturer’s warnings instructions in Retractable Starter for relieving spring tension. Engine exhaust gases contain and instructions on its proper and poisonous carbon monoxide. safe use. Never use gasoline as a Carbon monoxide is odorless, cleaning agent. colorless, and can cause death if inhaled. 2 KohlerEngines.com 14 690 01 Rev. G Maintenance MAINTENANCE INSTRUCTIONS WARNING Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing. Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer. MAINTENANCE SCHEDULE After first 3-5 Hours ● Change oil. Lubrication System Every 25 Hours or Annually¹ ● 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 Annually¹ ● Replace air cleaner element. Air Cleaner/Intake Every 100 Hours or Annually¹ ● Clean spark arrestor (if equipped). Every 100 Hours or Annually² ● Have combustion chamber decarbonized. Every 125 Hours or Annually¹ ● Replace spark plug and set gap. Electrical System 1 Perform these procedures more frequently under severe, dusty, dirty conditions. 2 Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 14 690 01 Rev. G KohlerEngines.com 3 Maintenance OIL RECOMMENDATIONS STORAGE We recommend use of Kohler oils for best performance. If engine will be out of service for 2 months or more Other high-quality detergent oils (including synthetic) follow procedure below. of API (American Petroleum Institute) service class SJ 1. Add Kohler PRO Series fuel treatment or equivalent or higher are acceptable. Select viscosity based on to fuel tank. Run engine 2-3 minutes to get stabilized air temperature at time of operation as shown in table fuel into fuel system (failures due to untreated fuel below. are not warrantable). 2. Change oil while engine is still warm from operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil. 3. Disconnect negative (-) battery cable. 4. Store engine in a clean, dry place. FUEL RECOMMENDATIONS 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 vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. NOTE: E15, E20 and E85 are NOT approved 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 add oil to gasoline. ● Do not overfill fuel tank. ● Do not use gasoline older than 30 days. 4 KohlerEngines.com 14 690 01 Rev. G Specifications ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model .....................XT-6 Courage Engine Vertical Shaft Numerical Designation Specification ...............XT149-0001 Serial .....................4223500328 Year Manufactured Code Factory Code Code Year 42 2012 43 2013 44 2014 GENERAL SPECIFICATIONS3,6 XT-6, XTR-6 XT6.5, XT650, XT-7, XTR-7, XT6.75, XT675 XT775, XT8 Bore 65 mm (2.6 in.) 70 mm (2.8 in.) Stroke 45 mm (1.8 in.) Displacement 149 cc (9.1 cu. in.) 173 cc (10.6 cu. in.) Oil Capacity (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, XT-7, XTR-7, XT6.75, XT675 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 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. 5 Lubricate threads with engine oil prior to assembly. 6 Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com. 14 690 01 Rev. G KohlerEngines.com 5 Specifications TORQUE SPECIFICATIONS3,5 XT-6, XTR-6 XT6.5, XT650, XT-7, XTR-7, XT6.75, XT675 XT775, XT8 Connecting Rod Cap Fastener (torque in increments) 12.5 N·m (110 in. lb.) Crankcase Oil Drain Plug7 13.6 N·m (120 in. lb.) Oil Pan Screw 11.0 N·m (98 in. lb.) 14.7 N·m (130 in. lb.) Cylinder Head Fastener (torque in 2 increments) first to 14 N·m (123 in. lb.) finally to 27.8 N·m (246 in. lb.) Flywheel Retaining Nut 51.5 N·m (38 ft. lb.) Fuel Tank Bracket to Crankcase Stud 8 N·m (71 in. lb.) Bracket to Tank Fastener 4.5 N·m (40 in. lb.) Governor Lever Fastener 9.5 N·m (84 in. lb.) Gear Fastener 9.5 N·m (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 Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly. 7 Apply thread sealant around three full threads before assembly. No excess sealant allowed on inside or outside of joint. Threads with preapplied sealant do not require use of additional sealant. Approved sealants include Perma-Loc LH 150, Perma-Loc MM 115, Perma-Loc HH 120, Perma-Loc HL 126.