Courage® XT-Series
XT-6, XTR-6, XT-7, XTR-7
Owner's 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.
Warranty coverage as outlined in the warranty card and on
KohlerEngines.com. Please review carefully as it provides you
specifi c rights and obligations.
Record engine information to reference when ordering parts or obtaining warranty coverage.
Engine Model
Specifi cation
Serial Number
Purchase Date
14 590 09 Rev. A KohlerEngines.com
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
Explosive Fuel
can cause fi res
and severe
burns.
Do not fi ll fuel
tank while
engine is hot or
running.
Gasoline is extremely
fl ammable and its vapors
can explode if ignited.
Store gasoline only in
approved containers, in
well ventilated, unoccupied
buildings, away from sparks
or fl ames. Spilled fuel
could ignite if it comes in
contact with hot parts or
sparks from ignition. Never
use gasoline as a cleaning
agent.
WARNING
Rotating Parts
can cause
severe injury.
Stay away while
engine is in
operation.
Keep hands, feet, hair,
and clothing away from all
moving parts to prevent
injury. Never operate engine
with covers, shrouds, or
guards removed.
WARNING
Carbon
Monoxide can
cause severe
nausea, fainting
or death.
Avoid inhaling
exhaust fumes.
Engine exhaust gases
contain poisonous carbon
monoxide. Carbon
monoxide is odorless,
colorless, and can cause
death if inhaled.
CAUTION
Electrical Shock
can cause injury.
Do not touch
wires while
engine is
running.
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) 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 guards
removed.
California Proposition 65 Warning
Engine exhaust from this product contains chemicals known
to State of California to cause cancer, birth defects, or other
reproductive harm.
2 14 590 09 Rev. AKohlerEngines.com
A
B
D
H
G
A Starter Handle B Fuel Cap C
E Air Cleaner F
Pre-Start Checklist
1. Check oil level. Add oil if low. Do not overfi ll.
2. Check fuel level. Add fuel if low. Check fuel system components and lines for leaks.
3. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly
after storage).
4. Check that air cleaner components and all shrouds, equipment covers, and guards are in place
and securely fastened.
5. Check spark arrestor (if equipped).
E
F
Fuel Shut-Off
Valve
Oil Fill Cap/
Dipstick
G Primer Bulb H Spark Plug
C
D Fuel Tank
14 590 09 Rev. A KohlerEngines.com
3
Starting
WARNING
Carbon Monoxide can cause
severe nausea, fainting or death.
Avoid inhaling exhaust fumes.
Engine exhaust gases contain poisonous
carbon monoxide. Carbon monoxide is
odorless, colorless, and can cause death if
inhaled.
4. Retractable Start: Slowly pull starter handle
until just past compression-STOP! Return
starter handle; fi rmly pull straight out to avoid
excessive rope wear from starter rope guide.
Electric Start: Key switch (refer to operating
instructions of equipment that this engine
powers).
5. Gradually return choke control to OFF
position after engine starts and warms up.
Engine/equipment may be operated during
warm up period, but it may be necessary to
leave choke partially on until engine warms
up.
WARNING
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
Keep hands, feet, hair, and clothing away
from all moving parts to prevent injury. Never
operate engine with covers, shrouds, or
guards removed.
NOTE: Over priming may make it diffi cult to
NOTE: Choke position for starting may vary
NOTE: Extend starter cord periodically to
1. Turn fuel shut-off valve to ON position
2. Turn engine on/off switch to ON position
3. Start engine as follows:
start engine. It is usually not necessary
to prime a warm engine.
depending upon temperature and other
factors. Once engine is running and
warm, turn choke to OFF position.
check its condition. If cord is frayed
have it replaced immediately by a
Kohler authorized dealer.
(if equipped).
(if equipped).
a. Primer Bulb Models: Place fi nger or
thumb on center of primer bulb. Push
primer 3 times.
or
b. Manual Choke Models:
Cold engine: Place throttle control to
FAST position. Pull choke control into
CHOKE/ON position.
Warm engine: place throttle control to
RUN/FAST position.
or
c. Smart-Choke
automatically adjusts choke on start-up.
Models: this feature
™
Cold Weather Starting Hints
1. Use proper oil for temperature expected.
2. Disengage all possible external loads.
3. Use fresh winter grade fuel. Winter grade
fuel has higher volatility to improve starting.
Stopping
1. If possible, remove load by disengaging all
PTO driven attachments.
2. If equipped, move throttle control to slow or
idle position; stop engine.
3. If equipped, close fuel shut-off valve.
Angle of Operation
Refer to operating instructions of equipment
this engine powers. Do not operate this engine
exceeding maximum angle of operation; see
specifi cation table. Engine damage could result
from insuffi cient lubrication.
Engine Speed
NOTE: Do not tamper with governor setting to
increase maximum engine speed.
Overspeed is hazardous and will void
warranty.
High Altitude Operation
This engine may require a high altitude
carburetor kit to ensure correct engine
operation at altitudes above 4000 ft.
(1219 meters). To obtain high altitude kit
information or to fi nd 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
confi guration below 4000 ft. (1219 meters) as
damage may occur if high altitude carburetor kit
is installed and operated below 4000 ft. (1219
meters).
4 14 590 09 Rev. AKohlerEngines.com
Maintenance Instructions
°F
-20
020324060
50 80 100
°C
-30 -20
-10 0
10 20 30
40
5W-30
10W-30
SAE 30
WARNING
Accidental Starts can cause
severe injury or death.
Disconnect and ground spark
Before working on engine or equipment, disable
engine as follows: 1) Disconnect spark plug
lead(s). 2) Disconnect negative (–) battery cable
from battery.
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 found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada).
Maintenance Schedule
After fi rst 3-5 Hours
● Change oil.
Every 25 Hours or Annually
1
● Service/replace precleaner.
● Check air cleaner for dirty, loose or damaged parts.
Every 50 Hours or Annually
● Change oil.
● Replace fuel fi lter (if equipped).
Every 50 Hours or Annually
1
● Replace air cleaner element.
Every 100 Hours or Annually
1
● Replace spark plug and set gap.
● Clean spark arrestor (if equipped).
Every 100 Hours or Annually
2
● Check and adjust valve clearance when engine is cold.
● Have combustion chamber decarbonized.
1
Perform these procedures more frequently under severe, dusty, dirty conditions.
2
Have a Kohler authorized dealer perform this service.
Oil Recommendations
We recommend use of Kohler oils for best
performance. Other high-quality detergent
oils (including synthetic) of API (American
Petroleum Institute) service class SJ or higher
are acceptable. Select viscosity based on air
temperature at time of operation as shown in
table below.
14 590 09 Rev. A KohlerEngines.com
Check Oil Level
NOTE: To prevent extensive engine wear or
damage, never run engine with oil level
below or above operating range
indicator on dipstick.
Ensure engine is cool. Clean oil fi ll cap/dipstick
areas of any debris.
1. Remove dipstick; wipe oil off.
a. 1/4 turn cap: reinsert dipstick into tube;
press completely down and turn 1/4 turn.
or
b. Threaded cap: reinsert dipstick into
tube; rest cap on tube, do not thread cap
onto tube.
2. Remove dipstick; check oil level. Level
should be at top of indicator on dipstick.
3. If oil is low on indicator, add oil up to top of
indicator mark.
4. Reinstall and secure dipstick.
5
Change Oil
Change oil while engine is warm.
Dipstick tube:
1. Clean area around oil fi ll cap/dipstick.
2. Remove oil fi ll 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 fi ll cap/dipstick and tighten
securely.
6. Dispose of used oil in accordance with local
ordinances.
Crankcase plug:
1. Disable engine by disconnecting spark plug.
2. Clean area around oil fi ll cap/dipstick.
Remove oil fi ll cap/dipstick.
3. Remove crankcase plug on bottom of
engine; drain oil into appropriate container.
4. Apply thread sealant around three full
threads of drain plug; reinstall drain plug.
Torque to 120 in. lb. (13.6 N·m).
5. Fill crankcase with new oil. Level should be
at top of indicator on dipstick.
6. Reinstall oil fi ll cap/dipstick and tighten
securely.
7. Dispose of used oil in accordance with local
ordinances.
Fuel Recommendations
WARNING
Explosive Fuel can cause fi res
and severe burns.
Do not fi ll fuel tank while engine is
hot or running.
Gasoline is extremely fl ammable and
its vapors can explode if ignited. Store
gasoline only in approved containers, in
well ventilated, unoccupied buildings, away
from sparks or fl ames. 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
Fuel must meet these requirements:
● Clean, fresh, unleaded gasoline.
● Octane rating of 87 (R+M)/2 or higher.
and should NOT be used; effects of
old, stale or contaminated fuel are not
warrantable.
● 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 overfi ll fuel tank.
● Do not use gasoline older than 30 days.
Add Fuel
WARNING
Explosive Fuel can cause fi res
and severe burns.
Do not fi ll fuel tank while engine is
hot or running.
Gasoline is extremely fl ammable and
its vapors can explode if ignited. Store
gasoline only in approved containers, in
well ventilated, unoccupied buildings, away
from sparks or fl ames. Spilled fuel could
ignite if it comes in contact with hot parts or
sparks from ignition. Never use gasoline as a
cleaning agent.
Ensure engine is cool.
1. Clean area around fuel cap.
2. Remove fuel cap. Fill to base of fi ller neck.
Do not overfi ll fuel tank. Leave room for fuel
to expand.
3. Reinstall fuel cap and tighten securely.
Fuel Line
Low permeation fuel line must be installed on
carbureted Kohler Co. engines to maintain EPA
and CARB regulatory compliance.
6 14 590 09 Rev. AKohlerEngines.com
Spark Plugs
CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine
is running.
Clean out spark plug recess. Remove plug and
replace.
1. Check gap using wire feeler gauge. Adjust
gap, see specifi cation table for adjustment.
2. Install plug into cylinder head.
3. Torque plug to 20 ft. lb. (27 N·m).
Air Cleaner
NOTE: Operating engine with loose or
damaged air cleaner components
could cause premature wear and
failure. Replace all bent or damaged
components.
NOTE: Paper element cannot be blown out
with compressed air.
Loosen knob and remove air cleaner cover.
Precleaner (if equipped):
1. Remove precleaner.
2. Replace or wash precleaner in warm water
with detergent. Rinse and allow 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 and secure with
knob.
Breather Tube
Ensure both ends of breather tube are properly
connected.
Air Cooling
WARNING
Hot Parts can cause severe
burns.
Do not touch engine while
operating or just after stopping.
Never operate engine with heat shields or
guards removed.
Proper cooling is essential. To prevent over
heating, clean screens, cooling fi ns, and other
external surfaces of engine. Avoid spraying
water at wiring harness or any electrical
components. See Maintenance Schedule.
Repairs/Service Parts
We recommend that you use a Kohler
authorized dealer for all maintenance,
service, and replacement parts for engine.
To fi nd a Kohler authorized dealer visit
KohlerEngines.com or call 1-800-544-2444
(U.S. and Canada).
Storage
If engine will be out of service for 2 months or
more follow procedure below.
1. Add Kohler PRO Series fuel treatment or
equivalent to fuel tank. Run engine 2-3
minutes to get stabilized fuel into fuel system
(failures due to untreated fuel 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.
14 590 09 Rev. A KohlerEngines.com
7
Troubleshooting
Do not attempt to service or replace major engine components, or any items that require special
timing or adjustment procedures. This work should be performed by a Kohler authorized dealer.
Possible Cause
Dirt In
No
Problem
Will Not Start
Hard Starting
Stops Suddenly
Lacks Power
Operates Erratically
Knocks or Pings
Skips or Misfi res
Backfi res
Overheats
High Fuel
Consumption
Engine Specifi cations
Model Bore Stroke Displacement
XT-6
XTR-6
XT-7
XTR-7
*Exceeding maximum angle of operation may cause engine damage from insuffi cient lubrication.
Additional specifi cation information can be found in service manual at KohlerEngines.com.
Exhaust Emission Control System for models
California, and Europe.
Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940
& J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
2.56 in.
(65 mm)
2.75 in.
(70 mm)
Improper
Fuel
Fuel
●●● ● ● ● ●
●● ●●●●
● ●●●●●●
●●●● ● ● ●
●●● ● ● ●
●● ● ●
●●● ● ●
●● ● ● ●
●●●● ● ●
9.1 cu. in.
1.8 in.
(45 mm)
(149 cc)
10.6 cu. in.
(173 cc)
Dirty
Fuel
Debris
Screen
Oil Capacity
Incorrect
Oil Level
(Refi ll)
20 oz.
(0.60 L)
Line
XT-6, XTR-6, XT-7, XTR-7 is EM for U.S. EPA,
Engine
Overloaded
Spark Plug
0.03 in.
(0.76 mm)
Dirty Air
Cleaner
●●●
Maximum Angle
Gap
(@ full oil level)*
Faulty
Spark
Plug
of Operation
20°
© 2011 by Kohler Co. All rights reserved.
14 590 09 Rev. AKohlerEngines.com
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