Kohler XT Series - User Manual

14 590 36 Rev. -- KohlerEngines.com
XT650, XT675, XT775
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 your specifi c rights and obligations.
To maintain compliance with applicable emission regulations, exhaust system
backpressure may not exceed limits which can be found on KohlerEngines.
com. Search by Model No., then select Specs tab.
Kohler Engines has published CO2 values on KohlerEngines.com website.
Record engine information to reference when ordering parts or obtaining warranty coverage.
Engine Model
Specifi cation
Serial Number
Purchase Date
EN
ESS
FRC

Summary

Safety Precautions

Explosive Fuel

Warning about fire and severe burns from fuel.

Carbon Monoxide

Warning about severe nausea, fainting, or death from exhaust fumes.

Accidental Starts

Warning about severe injury or death from unintended engine starts.

Rotating Parts

Warning about severe injury from moving engine parts.

Electrical Shock

Caution about injury from touching live wires.

Hot Parts

Warning about severe burns from hot engine components.

California Proposition 65 Warning

Warning about chemical exposure, cancer, and birth defects.

Starting Procedures

Cold Weather Starting

Tips for proper engine starting in cold temperatures.

Stopping the Engine

Instructions on how to safely stop the engine.

Engine Angle of Operation

Guidance on permissible engine tilt angles.

Engine Speed Management

Information on engine speed limits and governor settings.

High Altitude Operation

Requirements for operating the engine at high altitudes.

Maintenance Instructions

Maintenance Schedule

Recommended service intervals for engine maintenance tasks.

Oil Recommendations

Guidance on selecting the correct engine oil and viscosity.

Checking Oil Level

Steps for checking the engine oil level using the dipstick.

Engine Oil and Fuel

Changing Engine Oil

Procedures for draining and refilling engine oil.

Fuel Recommendations

Specifications for approved unleaded gasoline types.

Adding Fuel

Instructions for safely adding fuel to the tank.

Engine Components and Service

Spark Plug Maintenance

Procedures for spark plug inspection, gapping, and replacement.

Air Cleaner Servicing

Instructions for cleaning or replacing air cleaner elements.

Engine Storage

Guidelines for preparing the engine for long-term storage.

Troubleshooting and Specifications

Troubleshooting Guide

Common problems and their possible causes.

Engine Specifications

Technical details including bore, stroke, displacement, and oil capacity.

Emission Control System

Information on the exhaust emission control system compliance.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features
5. Safety Precautions

This document is an owner's manual for the KOHLER XT Series engines, specifically models XT650, XT675, and XT775. It provides essential information for the safe operation, maintenance, and troubleshooting of these small gasoline engines, commonly used in outdoor power equipment.

Function Description:

The KOHLER XT Series engines are internal combustion gasoline engines designed to power various types of outdoor equipment. They convert the chemical energy of gasoline into mechanical energy to drive machinery. The manual emphasizes safe operation and proper maintenance to ensure longevity and compliance with emission regulations.

Important Technical Specifications:

The manual provides a troubleshooting guide and engine specifications table.

• Models: XT650, XT675, XT775
• Bore:
  • XT650, XT675: 2.56 in. (65 mm)
  • XT775: 2.75 in. (70 mm)
• Stroke: 1.80 in. (45 mm) for all models
• Displacement:
  • XT650, XT675: 9.1 cu. in. (149 cc)
  • XT775: 10.6 cu. in. (173 cc)
• Oil Capacity (Refill): 20 oz. (0.60 L) for all models
• Spark Plug Gap: 0.030 in. (0.76 mm) for all models
• Maximum Angle of Operation (@ full oil level): 20° for all models. Exceeding this angle can cause engine damage due to insufficient lubrication.
• Fuel: Clean, fresh, unleaded gasoline with an octane rating of 87 (R+M)/2 or higher (RON 90 minimum). Gasoline up to 10% ethyl alcohol and MTBE blends (max 15% MTBE by volume) are acceptable. E15, E20, and E85 are NOT approved. Fuel older than 30 days should not be used.
• Oil Recommendations: Kohler oils are recommended. Other high-quality detergent oils (synthetic) of API service class SJ or higher are acceptable. Viscosity should be selected based on air temperature (e.g., 5W-30, 10W-30, SAE 30).
• Spark Plug Torque: 20 ft. lb. (27 N·m).
• Crankcase Drain Plug Torque: 120 in. lb. (13.6 N·m).
• Emission Control System: EM for U.S. EPA, California, and Europe. Tampering with the system voids certifications.

Usage Features:

• Starting Procedure:
  • Turn fuel shut-off valve to ON (if equipped).
  • Turn engine on/off switch to ON (if equipped).
  • Manual Choke Models: For cold engines, place throttle to FAST, pull choke to CHOKE/ON. For warm engines, place throttle to RUN/FAST.
  • Smart-Choke™ Models: Automatically adjusts choke on start-up.
  • Retractable Start: Slowly pull starter handle past compression-STOP, return, then firmly pull straight out.
  • Electric Start: Use key switch (refer to equipment instructions).
  • Gradually return choke to OFF after engine starts and warms up.
• Cold Weather Starting Hints: Use proper oil, disengage external loads, and use fresh winter-grade fuel.
• Stopping Procedure:
  • If possible, remove load by disengaging PTO attachments.
  • Move throttle to slow or idle, then stop engine (if equipped).
  • Close fuel shut-off valve (if equipped).
• High Altitude Operation: A high altitude carburetor kit is required for operation at 4000 ft. (1219 meters) or above. Operating without the correct configuration can increase emissions, decrease fuel efficiency, and damage the engine.
• Engine Speed: Do not tamper with governor settings to increase maximum engine speed; overspeeding is hazardous and voids warranty.

Maintenance Features:

The manual outlines a detailed maintenance schedule to ensure optimal performance and compliance.

• Pre-Start Checklist: Check oil and fuel levels, inspect for leaks, clean cooling and air intake areas, ensure all shrouds and guards are in place, and check the spark arrestor.
• Oil Change:
  • After first 3-5 Hours: Change oil.
  • Every 50 Hours or Annually: Change oil.
  • Change oil while the engine is warm.
  • Methods include draining via dipstick tube (tilting engine) or crankcase plug.
  • Ensure oil level is at the top of the indicator on the dipstick.
• Air Cleaner Service:
  • Every 25 Hours or Annually: Service/replace precleaner, check air cleaner for damage.
  • Every 50 Hours or Annually: Replace air cleaner element.
  • Precleaners can be washed in warm water with detergent and air-dried.
  • Paper elements cannot be blown out with compressed air and must be replaced.
  • Foam elements are also replaced.
• Fuel Filter:
  • Every 50 Hours or Annually: Replace fuel filter (if equipped).
• Spark Plugs:
  • Every 125 Hours or Annually: Replace spark plug and set gap.
  • Check gap using a wire feeler gauge and adjust as needed.
  • Torque to 20 ft. lb. (27 N·m).
• Spark Arrestor:
  • Every 100 Hours or Annually: Clean spark arrestor (if equipped).
• Combustion Chamber:
  • Every 100 Hours or Annually: Have a Kohler authorized dealer decarbonize the combustion chamber.
• Air Cooling: Clean screens, cooling fins, and external surfaces to prevent overheating.
• Breather Tube: Ensure both ends are properly connected.
• Storage: For storage longer than 2 months:
  • Add fuel treatment and run the engine for 2-3 minutes.
  • Change oil.
  • Remove spark plug(s), pour 1 oz. of engine oil into cylinder(s), replace plug(s), and crank slowly.
  • Disconnect negative (-) battery cable.
  • Store in a clean, dry place.
• Warranty and Service: Warranty repairs must be performed by a Kohler authorized dealer. Service parts information and dealer locator are available on KohlerEngines.com or by calling 1-800-544-2444 (U.S. and Canada).

Safety Precautions:

The manual highlights several critical safety warnings:

• Explosive Fuel: Gasoline is extremely flammable. Do not fill the fuel tank while the engine is hot or running. Store gasoline in approved containers in well-ventilated areas, away from sparks or flames.
• Carbon Monoxide: Engine exhaust contains poisonous carbon monoxide, which is odorless and colorless. Avoid inhaling exhaust fumes and never run the engine indoors or in enclosed spaces.
• Accidental Starts: Disconnect and ground spark plug lead(s) and disconnect the negative battery cable before servicing to prevent severe injury or death.
• Rotating Parts: Keep hands, feet, hair, and clothing away from moving parts while the engine is in operation. Never operate the engine with covers, shrouds, or guards removed.
• Hot Parts: Engine parts can cause severe burns. Do not touch the engine while operating or just after stopping. Never operate the engine with heat shields or guards removed.
• Electrical Shock: Do not touch wires while the engine is running.
• California Proposition 65 Warning: This product can expose users to chemicals including carbon monoxide and benzene, known to cause cancer and birth defects.

Kohler XT Series Specifications