Kohler Courage SH265 User manual

Kohler Courage SH265 User manual
Courage
SH265
HORIZONTAL CRANKSHAFT OWNER'S MANUAL
EN
HORIZONTALE KURBELWELLE BETRIEBSANLEITUNG
DE
MANUALE DEL PROPRIETARIO ALBERO MOTORE ORIZZONTALE
IT
ÁRBOL DE CIGÜEÑAL HORIZONTAL MANUAL DEL OPERADOR
ES
VILEBREQUIN HORIZONTAL MANUEL DE L'UTILISATEUR
FR
1
B
A
C
D
K
J
G
I
F
H
F
E
2
E
4
A
A
A
B
B
C
3
5
A
A
B
B
2
6
9
A
A
7
10
A
A
8
11
A
A
3
12
STOP
15
A
B
A
C
D
E
13
F
G
A
H
16
14
A
A
D
C
4
B
17
20
A
B
A
C
18
21
A
B
A
C
B
19
A
22
E
L
P
IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA PH2, EC
STAGE II (SN:3) AND CA 2008 AND LATER
TER
EXH EMISSION REGS FOR SI SOR
SORE
B
FAMILY
TYPE APP
DISPL. (CC)
SPEC. NO.
SERIAL NO.
A
BUILD DATE
AM
11236
S
EMISSION
MISSION COM
COMPLIANCE PERIOD:
P
PA:
EPA:
CARB:
TIFIED ON:
CERTIFIED
REFER TO OWNER'S MANUAL FOR HP RATING,
SAFETY, MAINTENANCE AND ADJUSTMENTS.
E
L
P
M
SA
IMPORTANT ENGINE INFORMATION THIS
HIS ENGINE MEE
MEET
MEETS U.S. EPA
PH2, EC STAGE II (SN:3) AND CA 2008
08 AND LATER
LA
ATER EXH/EVAP
EX
EMISSION REGS FOR SI SORE EVP
VP
P CODE:CO DOM:
DOM
FUEL:
DISP:
SPEC:
P:
S
11236
TYPE:
EF:
EPA/CARB
EMISSION
EPA/CA
COMPLIANCE PERIOD:
HRS REFER TO
T OWNERS
MANUAL FO RMAINTENANCE
TENANCE
ENANCE AND ADJUCTMENTS
AD
A
KOHLER CO. KOHLER,
HLER, WISCO
WISCONSIN,
WISCON
USA
CRAFTED
RAFTED
D IN CHINA
1-800-544-2444 kohlerengines.com
KOHLER CO. KOHLER, WISCONSIN, USA
CRAFTED IN CHINA
Symbols Associated with This Product
23
Alert
On
Read
Manual
Off
Oil
Choke
Start
Slow
STOP
Stop
Fast
Fuel
5
Safety Precautions
To ensure safe operation, please read the following statements and understand their meaning. Also refer to
your equipment manufacturer's manual for other important safety information. This manual contains safety
precautions which are explained below. Please read carefully.
WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial
property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property
damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important but not
hazard-related.
For Your Safety!
These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and
others.
WARNING
WARNING
Carbon Monoxide can cause severe
nausea, fainting or death.
Avoid inhaling exhaust fumes, and
never run the engine in a closed
building or confined area.
Explosive Fuel can cause fires
and severe burns.
Do not fill the fuel tank while the
engine is hot or running.
Explosive Fuel!
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.
Do not fill the fuel tank while the engine is hot or running,
since spilled fuel could ignite if it comes in contact with hot
parts or sparks from ignition. Do not start the engine near
spilled fuel. Never use gasoline as a cleaning agent.
Lethal Exhaust Gases!
Engine exhaust gases contain poisonous carbon monoxide.
Carbon monoxide is odorless, colorless, and can cause death
if inhaled. Avoid inhaling exhaust fumes, and never run the
engine in a closed building or confined area.
WARNING
WARNING
Accidental Starts can cause severe
injury or death.
Disconnect and ground spark plug
lead(s) before servicing.
Accidental Starts!
Disabling engine. Accidental starting can cause severe injury
or death. Before working on the engine or equipment, disable
the engine as follows: 1) Disconnect the spark plug lead(s).
2) Disconnect negative (–) battery cable from battery.
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
Rotating Parts!
Keep hands, feet, hair, and clothing away from all moving
parts to prevent injury. Never operate the engine with covers,
shrouds, or guards removed.
CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
WARNING
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
Hot Parts!
Engine components can get extremely hot from operation. To
prevent severe burns, do not touch these areas while the engine
is running, or immediately after it is turned off. Never operate
the engine with heat shields or guards removed.
6
Electrical Shock!
Never touch electrical wires or components while the engine is
running. They can be sources of electrical shock.
Congratulations on your purchase of a Kohler Engine. Every part, every component, every system on a
Kohler engine is guided by our exclusive Performance Engineering philosophy:
• To operate on the leading edge of innovation
• To push the boundaries of cleaner, more efficient engines
• To manufacture the highest performing, most reliable engines on the market
You can rest assured that your Kohler Engine will provide maximum power and reliability in all operating
conditions. Also, Kohler engines are backed by a worldwide network of over 10,000 distributors and dealers.
For more information on Kohler Engines or to find a Kohler Service Center, visit KohlerEngines.com.
To keep your engine in top operating condition, follow the maintenance procedures in this manual.
Oil Recommendations
General Fuel Recommendations
Oil Type
Purchase gasoline in small quantities and store
in clean, approved containers. A container with a
capacity of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
Using the proper type and weight of oil in the engine
is extremely important, as is daily checking of oil level
and changing oil regularly. Failure to use the correct
oil, or using dirty oil, will cause premature engine
wear and failure.
Use high-quality oil that ranks at or above the
American Petroleum Institute's (API) SJ service class.
Select the oil's viscosity based on air temperature at
the time of operation, as shown in the viscosity grades
table.
Recommended SAE Viscosity Grades
SAE 30
5W-30
10
20
32
°C -17 -12
-6
0
40
60
10
Do not add oil to the gasoline.
Do not overfill the fuel tank (C). Leave room for the
fuel to expand.
For best results use only clean, fresh, unleaded
gasoline with an octane rating of 87 or higher. In
countries using the Research method, it should be 90
octane minimum.
10W-30
0
To minimize gum deposits in your fuel system and to
ensure easy starting, do not use gasoline left over from
the previous season.
Fuel Type
Kohler 10W-30
°F
See Figure 1
80
20
30
100
40
Use service class SJ rated oil or higher. Do not extend
the oil change intervals longer than recommended,
as this can cause engine damage and may void
the warranty. An API symbol on the oil container
identifies the service class and SAE viscosity grade.
Fuel Recommendations
WARNING
Explosive Fuel can cause fires
and severe burns.
Do not fill the fuel tank while the
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.
Do not fill the fuel tank while the engine is hot or running
since spilled fuel could ignite if it comes in contact with hot
parts or sparks from ignition. Do not start the engine near
spilled fuel. Never use gasoline as a cleaning agent.
Unleaded gasoline is recommended as it leaves
less combustion chamber deposits and reduces
harmful exhaust emissions. Leaded gasoline is not
recommended.
EN
Gasoline/Alcohol Blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends, including E20
and E85, should not be used. Failures resulting from
use of these fuels will not be warranted.
Gasoline/Ether Blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
Fuel Line
These engines use Low Permeation SAE 30 R7 rated
fuel lines, certified to meet emission requirements.
Standard fuel lines may not be used. Order
replacement hose through a Kohler Service Center.
Operating Instructions
Also read the operating instructions of equipment this
engine powers.
7
Check Oil Level
4.
The importance of checking and maintaining
the proper oil level in the crankcase cannot be
overemphasized.
Check Cooling Areas
See Figures 1 , 2 , 3 , and 4
Check oil BEFORE EACH USE as follows:
1.
Make sure the engine is stopped, level, and cool
so the oil has had time to drain into the sump.
2.
Clean the area around and beneath the dipstick
or the oil fill plug (F) before removing it. This will
help keep dirt, debris, and other foreign matter
out of the engine. See Figure 1.
NOTE:
The engine may be equipped with two
dipsticks or an oil fill plug and a dipstick.
These can be placed in either hole.
3.
Checking oil level with a dipstick (A): Unscrew
and remove the dipstick; wipe off oil. Reinsert the
dipstick into the oil fill tube and rest the dipstick
on the oil fill neck (B). Turn it counterclockwise
until the oil fill cap drops down to the lowest
point of the thread leads. Do not thread the
dipstick cap onto the tube. See Figure 2.
Checking oil level with an oil fill plug: Unscrew
and remove the oil fill plug (A). The level should
be up to, but not over, the point of overflowing
the filler neck (B). See Figure 3.
4.
5.
If the level is low, add oil of the proper type and
to the correct level. (Refer to Oil Type.) Always
check the level before adding more oil.
Reinstall the dipstick/oil fill plug (A) and gasket
(B), and tighten securely. See Figure 4.
NOTE:
Over tightening the dipstick/oil fill plug (A)
will distort the gasket (C) and may cause oil
weeping. See Figure 4.
Reinstall the fuel cap (B) and tighten securely. See
Figure 1.
To ensure proper cooling, make sure the recoil starter
screen, cooling fins, and other external surfaces of the
engine are kept clean at all times.
NOTE:
Operating the engine with a blocked screen,
dirty or plugged cooling fins, and/or cooling
shrouds removed, will cause engine damage
due to over heating.
Check Air Cleaner
See Figure 1
This engine is equipped with either a replaceable,
high-density paper air cleaner element. In addition, an
optional foam precleaner may also be included.
Check the air cleaner (A) for a buildup of dirt and
debris daily or before starting the engine. Keep the
area in and around the air cleaner clean. Also check
for loose or damaged components. Replace all worn or
damaged air cleaner components.
NOTE:
Operating the engine with loose or
damaged air cleaner components could
allow unfiltered air into the engine, causing
premature wear and failure.
Pre-Start Checklist
1.
Check oil level; if low, add oil. Do not overfill.
(Refer to Check Oil Level.)
NOTE:
Engines are shipped without oil. Do not start
engine with low or no oil. This will cause
damage to the engine and will not be covered
under warranty.
2.
Check fuel level; if low, add fuel. Do not overfill.
3.
NOTE:
To prevent extensive engine wear or damage,
always maintain the proper oil level in the
crankcase. Never operate the engine with the
oil level above the correct level.
Check cooling areas, air intake areas, and external
surfaces of engine. Make sure they are clean and
unobstructed.
4.
Add Fuel
Check that the air cleaner components and all
shrouds, equipment covers, and guards are in
place and securely fastened.
5.
Check that any clutches or transmissions are
disengaged or placed in neutral. This is especially
important on equipment with hydrostatic drive.
The shift lever must be exactly in neutral to
prevent resistance that could keep the engine
from starting.
See Figures 1 and 5
WARNING
Explosive Fuel can cause fires
and severe burns.
Do not fill the fuel tank while the
engine is hot or running.
1.
Make sure the engine is OFF, level, and is cool.
2.
Clean the area around the fuel cap (B). See
Figure 1.
3.
Remove the fuel cap. Fill to the base of the filler
neck (A). Do not overfill the fuel tank (B). Leave
room for the fuel to expand. See Figure 5.
8
Cold Weather Starting Hints
1.
Be sure to use the proper oil for the temperature
expected. (Refer to Oil Recommendations.)
2.
Declutch all possible external loads.
3.
Use fresh winter grade fuel.
NOTE:
Winter grade gasoline has higher volatility
to improve starting. Do not use gasoline left
over from summer.
4.
Electric Start Models: Be sure the battery is in
good condition. A warm battery has much more
starting capacity than a cold battery.
Starting
See Figures 6 , 7 , 8 , 9 , 10 , and 11
WARNING
Carbon Monoxide can cause severe
nausea, fainting or death.
Avoid inhaling exhaust fumes, and
never run the engine in a closed
building or confined area.
Engine exhaust gases contain poisonous carbon monoxide.
Carbon monoxide is odorless, colorless, and can cause death
if inhaled. Avoid inhaling exhaust fumes, and never run the
engine in a closed building or confined area.
1.
2.
Turn the fuel shut-off valve (A) to the ON
position. See Figure 6.
For a Cold Engine – Place the throttle control (A)
midway between the SLOW and FAST positions.
See Figure 7. Place the choke control (A) into the
ON position. See Figure 8.
For a Warm Engine (Normal Operating
Temperatures) – Place the throttle control (A)
midway between the SLOW and FAST positions.
A warm engine usually does not require the
choke on. See Figure 7.
NOTE:
The choke position for starting may vary
depending upon temperature and other
factors. Once engine is running and warm,
turn choke to OFF position (A). See Figure 9.
3.
Start the engine as follows:
For Retractable Start Engine – Turn engine On/
Off switch (A) to the ON position. See Figure 10.
SLOWLY pull the starter handle (A) until just
past compression – STOP! Return starter handle,
and pull firmly with a smooth, steady motion
to start. Pull the handle straight out to avoid
excessive rope wear from the starter rope guide.
See Figure 11.
NOTE:
Extend the starting rope periodically and
check its condition. If the rope is frayed,
have it replaced immediately by your Kohler
Engine Service Center.
4.
Gradually return the choke control to the OFF
position (A) after the engine starts and warms up.
See Figure 9.
The engine/equipment may be operated during
the warm-up period, but it may be necessary
to leave the choke partially on until the engine
warms up.
Stopping
See Figures 12 , 13 , and 14
1.
If possible, remove the load.
2.
Move the throttle control (A) to the SLOW or
LOW idle position. Allow the engine to run at
idle for 30–60 seconds. See Figure 12.
3.
Turn On/Off switch or key switch (A) to the OFF
position. Move throttle to the STOP position if
equipped. See Figure 13.
4.
Close the fuel shut-off valve (A). See Figure 14.
Operating
Angle of Operation
Continuous operation at angles up to 25° with 1/2‑full
fuel tank. Before operation check oil level to ensure
crankcase oil level is correct. (Refer to Check Oil Level.)
Intermittent operation, up to one minute at angles up
to 30° with 1/2‑full fuel tank. Check oil level to ensure
crankcase oil level is correct. (Refer to Check Oil Level.)
Refer to the operating instructions of the equipment
this engine powers. Because of equipment design or
application, there may be more stringent restrictions
regarding the angle of operation.
NOTE:
Do not operate this engine continuously
at angles exceeding 25° in any direction,
because engine damage could result from
insufficient lubrication.
Cooling
EN
WARNING
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
Engine components can get extremely hot from operation. To
prevent severe burns, do not touch these areas while the engine
is running, or immediately after it is turned off. Never operate
the engine with heat shields or guards removed.
NOTE:
If debris builds up on the recoil starter
screen or other cooling areas, stop the engine
immediately and clean. Operating the engine
with blocked or dirty air intake and cooling
areas can cause extensive damage due to
overheating. (Refer to Clean Air Intake/Cooling
Areas.)
To ensure proper cooling, make sure the recoil starter
screen, cooling fins, and other external surfaces of the
engine are kept clean at all times.
Before each season of operation, clean the cooling
fins and external surfaces as necessary. Reinstall the
blower housing and other cooling shrouds.
9
Engine Speed
NOTE:
Do not tamper with the governor setting
to increase the maximum engine speed.
Overspeed is hazardous and will void the
engine warranty. The maximum allowable
high‑idle speed for these engines is 3850
± 100 RPM, no load.
Carburetor
The carburetor is designed to deliver the correct
fuel‑to‑air mixture to the engine under all operating
conditions. It has been calibrated at the factory and is
not adjustable.
NOTE:
To ensure correct engine operation at
altitudes above 1525 meters (5000 ft.), it
may be necessary to have a Kohler Engine
Service Center install a high-altitude jet kit.
If a high-altitude kit has been installed, the
engine must be reconverted to the original jet
size before it is operated at lower altitudes, or
overheating and engine damage may result.
If engine troubles appear to be fuel-system related,
check the following areas before seeking service from
a Kohler Engine Service Center.
• Ensure the fuel tank is filled with clean, fresh
gasoline.
• Ensure the air cleaner and precleaner are clean
and securely fastened.
• Ensure that the fuel tank cap vent is not blocked
and that it is operating properly.
• Ensure the in-line fuel filter, if equipped, is clean
and unobstructed. Replace if necessary.
If after checking these items the engine is still hard
to start, runs roughly, or stalls at low-idle speed, it
may be necessary to have the carburetor serviced by a
Kohler Engine Service Center.
Maintenance Instructions
Maintenance, repair, or replacement of the emission control devices and systems, which are being done at the
customer's expense, may be performed by any non-road engine repair establishment or individual. Warranty
repairs must be performed by a Kohler Engine Service Center.
WARNING
Accidental Starts can cause severe
injury or death.
Disconnect and ground spark plug
lead(s) before servicing.
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the
engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table below. They
should also be included as part of any seasonal tune-up.
Frequency
Maintenance Required
Check oil level.
Fill fuel tank.
Check air intake and cooling areas; clean as necessary.1
Daily or Before Starting Engine
Check fuel screen.
Check air cleaner element and precleaner (if equipped).
Check spark arrestor (if equipped); clean as necessary.1
Yearly or Every 50 Hours
Clean or replace precleaner (if equipped).1
Replace air cleaner element.
Change oil (after first 5 hours, then yearly or 100 hours.)
Clean cooling areas.
Clean spark arrestor (if equipped).
Clean or replace spark plug, and set gap.
Yearly or Every 100 Hours
Clean fuel valve cup.
Replace fuel filter (if equipped).
Check and adjust valve clearance when engine is cold.2
Service starter motor drive (if equipped).2
Have combustion chamber decarbonized.2
Every 200 Hours or as Necessary Replace fuel line.
1
2
Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
These procedures should be performed by a Kohler Engine Service Center.
10
Oil Disposal
Protect and respect the environment. Dispose of oil
at your local recycling center or municipal collection
location in accordance with local ordinances.
Change Oil
See Figures 1 , 2 , 3 , and 4
For a new engine, change oil after the first 5 hours of
operation. Thereafter, change oil after every 100 hours
of operation.
For an overhauled engine, use Kohler 10W-30 service
class SJ or higher oil for the first 5 hours of operation.
Change the oil after this initial run-in period. Refill
with service class SJ or higher oil as specified in Oil
Type.
Change the oil while the engine is still warm. The
oil will flow freely and carry away more impurities.
Make sure the engine is level when filling, checking,
or changing the oil.
Change the oil as follows:
1.
To keep dirt, debris, etc., out of the engine, clean
the area around the dipstick/oil fill plug (F)
before removing it. See Figure 1.
2.
Remove the oil drain plug (E) and the dipstick/
oil fill plug (F). Allow ample time for complete
drainage. See Figure 1.
3.
Reinstall the drain plug (E) and tighten to 17.6
N·m (13 ft. lb.). See Figure 1.
4.
Fill the crankcase with new oil of the proper type,
up to the point of overflowing the filler neck.
(Refer to Oil Type). Always check the level before
adding more oil.
5.
Reinstall the dipstick/oil fill plug (A) and gasket
(B), and tighten securely. See Figures 2 and 3.
NOTE:
Over-tightening the dipstick/oil fill plug (A)
will distort the gasket (C) and may cause oil
weeping. See Figure 4.
Oil Sentry™
Some engines are equipped with an optional Oil
Sentry™ switch. This switch is designed to prevent
the engine from being started in a low-oil or no-oil
condition. The Oil Sentry™ may not shut down
a running engine before damage occurs. In some
applications this switch may activate a warning signal.
NOTE:
Check the oil level BEFORE EACH USE and
maintain to the correct level. This includes
engines equipped with Oil Sentry™.
Service Precleaner and Air Cleaner
Element
See Figure 15
These engines are equipped with a replaceable,
high‑density paper air cleaner element (F). Some
engines are also equipped with a pre-oiled, foam
precleaner (D), which surrounds the paper element.
Check the air cleaner daily or before starting the
engine. Check for a buildup of dirt and debris around
the air cleaner system. Keep this area clean. Also check
for loose or damaged components. Replace all bent or
damaged air cleaner components.
NOTE:
Operating the engine with loose or
damaged air cleaner components could
allow unfiltered air into the engine, causing
premature wear and failure.
Service Precleaner (If Equipped)
See Figure 15
Wash or replace the precleaner every 50 hours of
operation (more often under extremely dusty or dirty
conditions).
1.
Remove the top wing nut (A) and air cleaner
cover (B).
2.
Remove the wing nut (C) (some models) and
special washer (E).
3.
Remove the precleaner (D) from the paper
element (F).
4.
Wash the precleaner (D) in warm water with
detergent. Rinse the precleaner thoroughly until
all traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
to air dry. Do not oil precleaner.
5.
Reinstall the precleaner (D) over the paper
element (F).
6.
Slide the precleaner (D) and paper element (F)
onto the air cleaner stud (G). Secure with special
washer (E) and wing nut (C) (some models).
7.
Reinstall the air cleaner cover (B) and secure with
wing nut (A).
Service Air Cleaner Element
See Figure 15
Yearly or 100 hours (which ever comes first) of
operation (more often under extremely dusty or dirty
conditions), replace the paper element.
1.
Remove the top wing nut (A) and air cleaner
cover (B). Remove the wing nut (C) (some
models) and special washer (E).
2.
Separate the precleaner (D) from the element (F)
and service as outlined in Service Precleaner.
NOTE:
Do not wash the paper element (F) or use
pressurized air, as this will damage the
element. Replace a dirty, bent, or damaged
element with a genuine Kohler element.
Handle new elements carefully; do not use if
the sealing surfaces are bent or damaged.
3.
When servicing the air cleaner, check the air
cleaner base (H). Make sure it is secured and not
bent or damaged. Check the air cleaner cover/
housing (B) for damage or improper fit. Replace
all bent or damaged air cleaner components.
11
EN
4.
Slide the precleaner (D) and paper element (F)
onto the air cleaner stud (G). Secure with special
washer (E) and wing nut (C) (some models).
Replace with a Kohler fuel filter yearly or every
50 hours of operation. Removing the air filter cover
will allow easy access to the fuel filter for servicing.
5.
Reinstall the air cleaner cover (B) and secure with
wing nut (A).
Fuel Tank Screen
Ignition
This engine is equipped with a dependable
maintenance-free ignition system. Other than
periodically checking/replacing the spark plug,
no adjustments are necessary or possible with this
system.
In the event starting problems should occur that are
not corrected by replacing the spark plug, see your
Kohler Engine Service Center.
NOTE:
Some engines may be equipped with
components that comply with RFI
regulations.
Spark Plug
See Figures 1 and 16
Yearly or every 100 hours of operation, remove the
spark plug, check its condition, and reset the gap or
replace with a new plug as necessary. The original
spark plug is a Champion® RC12YC; the Kohler
equivalent is Kohler Part No. 12 132 02-S or for RFI
Kohler Part No. 25 132 14-S. Equivalent alternate
brand plugs can also be used.
1.
Before removing the spark plug (D), clean the
area around the base of the plug to keep dirt and
debris out of the engine. See Figure 1.
2.
Remove the plug (D) and check its condition.
Replace the plug if worn or if reuse is
questionable. See Figure 16.
3.
Check the gap (B) using a feeler gauge (A). See
Figure 16.
See Figure 17
A serviceable fuel tank screen is located under the fuel
tank cap, in the filler neck.
WARNING
Explosive Fuel can cause fires
and severe burns.
Do not fill the fuel tank while the
engine is hot or running.
Daily, or as required, clean screen of any accumulation
as follows:
1.
Remove the fuel tank cap (A) and screen (B).
2.
Clean the screen (B) with solvent. Replace if
damaged.
3.
Wipe the screen (B) and insert it into the filler
neck (C).
4.
Tighten the tank cap (A) securely.
Fuel Valve
See Figure 18
Engines are equipped with a fuel valve and integral
screen filter located at the inlet of the carburetor. It
controls and filters fuel flow from the tank to the
carburetor.
Every 100 hours of operation clean fuel valve cup
of any accumulated debris. If the screen becomes
clogged or damaged, replace it.
WARNING
Explosive Fuel can cause fires
and severe burns.
Do not fill the fuel tank while the
engine is hot or running.
NOTE:
Do not clean the spark plug in a machine
using abrasive grit. Some grit could remain in
the spark plug and enter the engine, causing
extensive wear and damage.
1.
Stop the engine.
4.
2.
Turn the fuel valve lever (A) to the OFF position.
3.
Remove the fuel valve cup (C).
4.
Clean the fuel valve cup (C) with solvent and
wipe it off.
5.
Check the O-ring (B). Replace if damaged.
6.
Place the O-ring (B) on the fuel valve cup (C).
Rotate the fuel valve cup until it is finger tight.
Turn with a wrench 1/2 to 3/4 full turn.
7.
Turn the fuel valve (A) to the ON position and
check for leaks. If fuel valve cup leaks repeat
steps 5 and 6.
8.
Tighten the tank cap securely.
5.
Adjust the gap (B) by carefully bending the
ground electrode (C). Gap spark plug to 0.76 mm
(0.030 in.). See Figure 16.
Reinstall the spark plug into the cylinder head.
Torque the plug to 20 N·m (14 ft. lb.).
Fuel Filter (If Equipped)
WARNING
Explosive Fuel can cause fires
and severe burns.
Do not fill the fuel tank while the
engine is hot or running.
12
Spark Arrestor
Carburetor Troubleshooting and
Adjustments
See Figure 19
Engines are equipped with a spark arrestor for
operational and environmental safety.
Every 100 hours of operation, remove and clean or
replace the spark arrestor following the instructions
below.
WARNING
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
1.
Remove the securing hardware (B) and the spark
arrestor (A).
2.
Clean the carbon deposits out of the screen using
a wire brush.
3.
Check the spark arrestor (A). Replace if
damaged.
4.
Reinstall the spark arrestor (A), securing with the
hardware (B) previously removed.
Clean Air Intake/Cooling Areas
To ensure proper cooling, make sure the recoil starter
screen, cooling fins, and other external surfaces of the
engine are kept clean at all times. Check daily.
Every 100 hours of operation (more often under
extremely dusty, dirty conditions), remove the blower
housing and other cooling shrouds. Clean the cooling
fins and external surfaces as necessary. Make sure the
cooling shrouds are reinstalled.
NOTE:
Operating the engine with a blocked grass
screen, dirty or plugged cooling fins, and/or
cooling shrouds removed, will cause engine
damage due to overheating.
See Figure 20
NOTE:
Carburetor adjustments should be made only
after the engine is at operating temperature.
The carburetor is designed to deliver the correct
fuel-to-air mixture to the engine under all operating
conditions. The idle mixture is set at the factory and
normally does not require adjustment.
If the engine is hard to start, runs roughly, or stalls
at low idle speed, it may be necessary to adjust or
service the carburetor. Engine must not exceed 3850
± 100 RPM if the high speed screw (A) is adjusted.
If engine troubles are experienced that appear to be
fuel system related, check the following areas before
adjusting the carburetor:
•Make sure the fuel tank is filled with clean,
fresh gasoline.
•Make sure that the fuel tank cap vent is not
blocked and that it is operating properly.
•Make sure the fuel shut-off valve is fully open.
•Make sure fuel shut-off valve strainer and
in-line fuel filter (if used) are clean and
unobstructed. Clean or replace as necessary.
•Make sure fuel is reaching the carburetor.
This includes checking the fuel lines and
components for restrictions or problems.
Replace as necessary.
•Make sure On/Off switch is functioning
properly.
EN
•Make sure the air cleaner element is clean and
all air cleaner components are fastened securely.
If, after checking the items listed above, the engine is
hard to start, runs roughly, or stalls at low‑idle speed,
it may be necessary to adjust or service the carburetor.
13
Troubleshooting
When problems occur, first check for simple reasons for a problem: for example, an empty fuel tank or the fuel
shut-off valve is turned off. Additional troubleshooting tips can be found in the troubleshooting table.
NOTE:
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 Engine Service Center.
Possible Cause
Problem
No
Fuel
Fuel
Valve
Closed/
Off
Improper
Dirt In
Fuel
Fuel Line
Dirty
Debris
Screen
Incorrect
Engine
Oil
Overloaded
Level
Dirty Air
Cleaner
Faulty
Spark
Plug
Will Not Start
Hard Starting
Stops
Suddenly
Lacks Power
Operates
Erratically
Knocks or
Pings
Skips or
Misfires
Backfires
Overheats
High Fuel
Consumption
Smokes
Storage
See Figures 1 and 6
6.
Remove the spark plug (D). Cover the spark plug
hole with your thumb and turn the engine over
until the piston is at the top of its stroke (pressure
against the thumb is greatest). Reinstall the spark
plug, but do not connect the spark plug lead. See
Figure 1.
Store the engine on a level surface in a clean, dry
place. Never store the unit where there is an open
flame, spark, or pilot light such as on a water
heater or other appliances.
If the engine will be out of service for two months or
more, follow these storage procedures:
1.
Clean the exterior surfaces of the engine.
2.
Change the oil while the engine is still warm from
operation. (Refer to Change Oil.)
7.
3.
The engine must be run until the fuel tank is
completely emptied, or the gasoline must be
treated with a stabilizer to prevent deterioration.
If a stabilizer is used, follow the manufacturer's
instructions. Fill the tank with fresh gasoline
and run the engine for 2–3 minutes to ensure
stabilized fuel has entered the carburetor.
Transport
To empty the system, run the engine until the
tank and system are empty.
4.
Before transporting the engine, ensure the fuel
valve (A) is in the OFF position to prevent fuel
spillage. See Figure 6.
5.
Remove the spark plug (D). Add one tablespoon
of engine oil into the spark plug hole. Reinstall
the plug, but do not connect the plug lead.
Turn the crank to rotate the engine two to three
revolutions. See Figure 1.
14
1.
Turn the fuel valve to the OFF position.
2.
Tighten the fuel cap.
3.
Read and follow the transport guidelines
provided by equipment manufacturer.
Repairs
Repair information is available in Kohler Engine
service manuals, which are available at
KohlerEngines.com, or at Kohler Engine Service
Centers. Major repairs generally require the services
of a trained mechanic and the use of specialized
tools and equipment. Kohler Engine Service Centers
have the facilities, training, and genuine Kohler
replacement parts necessary to perform these services.
For the nearest sales and service location, visit our
Web site at KohlerEngines.com, or in the U.S. and
Canada call 1-800-544-2444.
Emission Compliance
See Figure 22
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the
number of operating hours for which the engine has
been shown to meet Federal and CARB emission
requirements. The following table provides the Engine
Compliance Period (in hours) associated with the
category descriptor found on the certification label.
Emission Compliance Period
Parts Ordering
The engine model, specification, and serial numbers
are required when ordering replacement parts from
your Kohler Engine Service Center. These numbers
are found on the identification plate, which is affixed
to the engine shrouding. Include letter suffixes if there
are any. (Refer to Engine Identification Numbers.)
Always insist on genuine Kohler replacement parts, as
they adhere to strict standards for fit, reliability, and
performance. Visit KohlerEngines.com or your Kohler
Engine Service Center.
Engine Identification Numbers
See Figures 1 and 22
Engine identification numbers will appear on one
of several variations of labels affixed to the engine
(Figure 22). See Figure 1 for Engine Identification
Label location (H).
When ordering parts, or in any communication
concerning this engine, always give the model name,
specification number, and serial number — including
any letter suffixes.
EPA
Category C
Below 225 cc
125 hours
Refer to certification label for engine displacement.
Exhaust Emission Control System for model SH265 is
EM for U.S. EPA and Europe.
Engine Specifications*
Model
SH265
Bore
68 mm (2.7 in.)
Stroke
54 mm (2.1 in.)
Displacement
196 cc (12 cu. in.)
Gross Power @ 3600 RPM**
4.9 kW (6.5 HP)
Net Power @ 3600 RPM**
4.1 kW (5.5 HP)
Net Peak Torque @ 2800 RPM
Compression Ratio
Weight (Recoil Start)
11.5 N·m (8.5 ft. lb.)
8.5:1
16 kg (35.3 lb.)
Oil Capacity
.60 L (.63 qt.)
Record all engine ID numbers for future reference.
Fuel Capacity
3.6 L (3.8 qt.)
Serial Number and Spec Number
Exhaust Emission Control
System
See Figures 21 and 22
The spec number (A) and serial number (B) is etched
into the engine block, directly below the fuel tank.
When ordering parts, or in any communication,
always provide model, specification number (A), and
serial number (B). Record these numbers for future
reference. See Figure 21.
Additional engine identification numbers can be
found on the engine ID labels. See Figure 22.
EM for U.S. EPA and
Europe
*Kohler Co. reserves the right to change product specifications,
designs, and equipment without notice and without incurring
obligation.
**Horsepower ratings exceed Society of Automotive Engineers
Small Engine Test Code J1940. Actual engine horsepower is lower
and affected by, but not limited to, accessories (air cleaner, exhaust,
charging, cooling, fuel pump, etc.), application, engine speed, and
ambient operating conditions (temperature, humidity, and altitude).
15
EN
COURAGE® ENGINE LIMITED WARRANTY
Kohler Co. warrants to the original retail consumer that each new COURAGE® engine sold by Kohler Co. will be free from manufacturing
defects in materials or workmanship in normal residential homeowner service for a period of two (2) years from date of purchase,
provided it is operated and maintained in accordance with Kohler Co.’s instructions and manuals. If used commercially the COURAGE®
engine is covered by a 90-day1 limited warranty.
The warranty period begins on the date of purchase by the original retail consumer or commercial end user. “Residential homeowner
service” means residential use by a retail consumer. “Commercial use” means all other uses, including use for commercial, or rental
purposes. Once in commercial use, the engine will thereafter be considered a commercial use engine for the purposes of this warranty.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044,
or at a service facility designated by us of such parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for 90 days from date of purchase. This warranty does not apply
to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and necessary
maintenance.
The following items are not covered by this warranty: Engine accessories such as fuel tanks, clutches, transmissions, power-drive
assemblies, and batteries, unless supplied or installed by Kohler Co. These are subject to the warranties, if any, of their manufacturers.
Kohler Co. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES OF ANY KIND, including but not limited to labor costs or transportation charges in connection with the repair or replacement
of defective parts.
IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is
any one authorized to make any on our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our Web site, www.
KohlerEngines.com, consult your local telephone directory or telephone 1-800-544-2444. ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
With the exception of countries governed by the European Union (EU), where a one (1) year warranty is required for commercial/
professional use.
1
KOHLER CO.
FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS
LIMITED WARRANTY SMALL OFF-ROAD ENGINES
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the
Federal and California Emission Control Systems Warranty on your small off-road equipment engine. In California beginning in 2006,
“emissions“ means both exhaust and evaporative emissions. For California, engines produced in 2006 and later must be designed, built
and equipped to meet the state’s stringent anti-smog standards. In other states, 1997 and later model year engines must be designed,
built and equipped, to meet the U.S. EPA regulations for small non-road engines. The engine must be free from defects in materials and
workmanship which cause it to fail to conform with U.S. EPA standards for the first two years of engine use from the date of sale to the
ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period of time listed above, provided there
has been no abuse, neglect or improper maintenance.
The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter.
Also included are the hoses, belts and connectors and other emission related assemblies.
Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed
at an authorized dealer), parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
Engines produced in 2006 or later are warranted for two years in California. In other states, 1997 and later model year engines are
warranted for two years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of
charge.
Continued on the next page.
16
OWNER’S WARRANTY RESPONSIBILITIES
(a) The engine owner is responsible for the performance of the required maintenance listed in the owner’s manual. Kohler Co.
recommends that you retain all receipts covering maintenance on the engine, but Kohler Co. cannot deny warranty solely for the
lack of receipts or for your failure to assure that all scheduled maintenance was performed.
(b) Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
(c) For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists. Call 1-800-544-2444
or access our web site at: www.KohlerEngines.com, for the names of the nearest service centers. The warranty repairs should be
completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an
engine service representative.
COVERAGE
Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at
the time of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that
the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a
period of two years.
Engines produced in 2006 or later are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers
to warrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial
purchaser. If any emission related part on the engine is defective, the part will be replaced by Kohler Co. at no cost to the owner. Kohler
Co. is liable for damages to other engine components caused by the failure of a warranted part still under warranty.
Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at
an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.
Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require
scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts include the
following if they were present in the engine purchased:
•
•
•
•
•
•
•
•
•
•
•
•
Oxygen sensor (if equipped)
Intake manifold (if equipped)
Exhaust manifold (if equipped)
Catalytic muffler (if equipped)
Thermal reactor muffler (if equipped)
Spark advance module (if equipped)
Air filter, fuel filter, and spark plugs (only to first scheduled
replacement point)
Crankcase breather
Ignition module(s) with high tension lead
Gaseous fuel regulator (if equipped)
Electronic control unit (if equipped)
Carburetor or fuel injection system (if equipped)
• Fuel lines, fuel line fittings and clamps (if equipped)
• Fuel metering valve (if equipped)
• Air injection system (if equipped)
• Air pump or pulse valve assembly (if equipped)
• Control/distribution valve (if equipped)
• Distribution manifold (if equipped)
• Air hoses (if equipped)
• Vacuum lines (if equipped)
• Evaporative system (if equipped)
• Canister (if equipped)
• Canister filter (if equipped)
• Vapor hose (if equipped)
• Orifice connector (if equipped)
• Fuel tank (if equipped)
• Fuel cap (if equipped)
• Primer bulb canister (if equipped)
EN
LIMITATIONS
This Emission Control System Warranty shall not cover any of the following:
(a) Repair or replacement required because of misuse or neglect, improper maintenance, improper repairs, or replacements not
conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not
recommended or approved in writing by Kohler Co.,
(b) Replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled
replacement point,
(c) Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.,
(d) Diagnosis and inspection fees that do not result in eligible warranty service being performed, and
(e) Any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.
MAINTENANCE AND REPAIR REQUIREMENTS
The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records
covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period,
the maintenance records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if
the engine has not been properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair
maintenance or failure to keep maintenance records.
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 Service Center. Any replacement part or service
that is equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty
obligations of the engine manufacturer.
17
FORM NO.: 18 590 02
ISSUED:
REVISED:
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL 1-800-544-2444
KohlerEngines.com
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
11/09
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