Kohler Courage PRO User Manual

56
Disassembly/Inspection and Service
KohlerEngines.com 32 690 01 Rev. D
Disassemble Cylinder Heads
NOTE: On engines with valve stem seals on intake
valves; use a new seal whenever valve is
removed or if seal is deteriorated or damaged.
Never reuse an old seal.
1. Remove adjusters, pivots, rocker arms, studs, and
guide plate with adjusters from cylinder head.
2. Compress valve springs using a valve spring
compressor.
3. Once valve spring is compressed, remove following
items.
● Valve spring keepers.
● Valve spring retainers.
● Valve springs.
● Valve spring caps.
● Intake and exhaust valves (mark position).
● Valve stem seal (intake valve some models).
4. Repeat above procedure for other cylinder head. Do
not interchange parts from 1 cylinder head to
another.
Inspection and Service
Valve Details
H
E
F
A
C
D
F
E
G
A
H
D
A
B
B
G
Intake Valve
Exhaust Valve
Intake Insert
Exhaust Insert
Dimension Intake Exhaust
A Seat Angle 89° 89°
B Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.)
C Guide Depth 4 mm (0.1575 in.) 6.5 mm (0.2559 in.)
D 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 (Min.) 1.5 mm (0.0591 in.) 1.5 mm (0.0591 in.)
H Valve Stem Diameter 6.982/7.000 mm (0.2749/0.2756 in.) 6.970/6.988 mm (0.2744/0.2751 in.)
After cleaning, check atness of cylinder head and corresponding top surface of crankcase, using a surface plate or
piece of glass and feeler gauge. Maximum allowable out of atness is 0.076 mm (0.003 in.).
Carefully inspect valve mechanism parts. Inspect valve springs and related hardware for excessive wear or distortion.
Check valves and valve seat area or inserts for evidence of deep pitting, cracks, or distortion. Check clearance of
valve stems in guides. See valve details and specications.
Hard starting, or loss of power accompanied by high fuel consumption may be symptoms of faulty valves. Although
these symptoms could also be attributed to worn rings, remove and check valves rst. After removal, clean valve
heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for defects such as warped
head, excessive corrosion, or worn stem end. Replace valves found to be in bad condition.

Kohler Courage PRO Specifications

General

Governor Type	Mechanical
Compression Ratio	8.5:1
Fuel Type	Gasoline
Cooling System	Air Cooled
Ignition System	Electronic
Starting System	Electric start (optional recoil start)
Lubrication System	Splash lubrication