Kohler XT-7 Generator Set

Tools: Pliers, Torque wrench

1. Loosen governor lever adjustment screw.
2. Move governor lever away from carburetor (wide open throttle). Do not apply excess force.
3. Grasp cross shaft with pliers and turn clockwise as far as it will go. Torque nut to 9.5 N·m (84 in. lb.).
4. Rotate governor shaft clockwise until it stops.
5. Hold both in this position and torque governor lever bolt to 10 N·m (88.5 in. lb.).

Tools: Vacuum gauge or manometer, Vacuum pump

1. Remove air cleaner cover, element, and breather cover from air cleaner base.
2. Check choke linkage for binding or debris; verify choke plate has full range of movement.
3. Remove vacuum hose from carburetor vacuum fitting; attach vacuum gauge. Run engine holding choke plate open. Minimum 15 in. of water.
4. If vacuum indicated is less than 15 in. of water, problem is not an auto choke issue.
5. Attach vacuum pump to vacuum hose; choke plate should open 1/2 to 3/4 with minimum 15 in. of water.
6. Check hose for cracks, leaks, or restrictions. Replace hose if needed; replace diaphragm assembly if it fails to hold choke plate for minimum 3 seconds.
7. Start engine; choke plate should be 1/2 to 3/4 open, gradually full open after 2 to 2-1/2 minutes.

⚠ Rotating Parts can cause severe injury. Stay away while engine is in operation.

⚠ Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes.

Tools: Water manometer or vacuum/pressure gauge, Rubber stopper, Pinch clamp

1. Insert rubber stopper into oil fill hole with pinch clamp installed; connect manometer hose.
2. Check water level at 0 line; ensure pinch clamp is closed.
3. Start engine and run at no-load high speed.
4. Open clamp and note water level. Engine side should be minimum 10.2 cm (4 in.) above open side.
5. Close pinch clamp before stopping engine.

Tools: Cylinder leakdown tester, Holding tool, Breaker bar, Air source (min 50 psi)

1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter from engine.
3. Rotate crankshaft until piston is at TDC of compression stroke. Hold engine in this position.
4. Install adapter into spark plug hole, but do not attach it to tester.
5. Turn regulator knob completely counterclockwise.
6. Connect an air source of at least 50 psi to tester.
7. Turn regulator knob clockwise until gauge needle is in yellow set area.
8. Connect tester to adapter; hold engine at TDC and gradually open tester valve.
9. Note gauge reading and listen for escaping air at intake, exhaust outlet, and crankcase breather.

⚠ Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running.

Tools: Approved fuel container

1. Check for fuel in combustion chamber: disconnect and ground spark plug lead, close choke, crank engine, remove plug and check for fuel at tip.
2. Check fuel flow from tank to carburetor: remove fuel line from inlet fitting, hold below tank and observe flow.
3. Check fuel shut-off valve: remove fuel sediment bowl, turn valve ON and OFF and observe operation.

⚠ Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing.

1. Disable engine by disconnecting spark plug.
2. Clean area around oil fill cap/dipstick. Remove oil fill 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 13.6 N·m (120 in. lb.).
5. Fill crankcase with new oil to top of indicator on dipstick.
6. Reinstall oil fill cap/dipstick and tighten securely.
7. Dispose of used oil in accordance with local ordinances.

1. Clean area around oil fill cap/dipstick.
2. Remove oil fill cap/dipstick.
3. Tilt engine on its side with air cleaner facing up. Drain oil into appropriate container.
4. After crankcase is drained completely, tilt engine upright.
5. Fill crankcase with new oil to top of indicator on dipstick.
6. Reinstall oil fill cap/dipstick and tighten securely.
7. Dispose of used oil in accordance with local ordinances.

⚠ Never run engine with oil level below or above operating range indicator on dipstick.

1. Ensure engine is cool. Clean oil fill cap/dipstick areas of any debris.
2. Remove dipstick; wipe oil off.
3. 1/4 turn cap: reinsert into tube, press completely down and turn 1/4 turn. Threaded cap: rest cap on tube, do not thread.
4. Remove dipstick; check oil level at top of indicator.
5. If oil is low, add oil up to top of indicator mark.
6. Reinstall and secure dipstick.

⚠ Electrical Shock can cause injury. Do not touch wires while engine is running.

Tools: Wire feeler gauge, Torque wrench

1. Clean out spark plug recess. Remove plug and replace.
2. Check gap using wire feeler gauge. Adjust gap to 0.76 mm (0.03 in.).
3. Install plug into cylinder head.
4. Torque plug to 27 N·m (20 ft. lb.).

1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system.
2. Change oil while engine is still warm from operation.
3. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s).
4. Replace spark plug(s) and crank engine slowly to distribute oil.
5. Disconnect negative (-) battery cable.
6. Store engine in a clean, dry place.

⚠ Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing.

Tools: Compressed air, Carburetor cleaner

1. Remove air cleaner and carburetor per Disassembly procedures.
2. Clean exterior surfaces; remove bowl retaining screws and separate fuel bowl. Save all parts.
3. Remove float pin and inlet needle. Inlet needle seat is not serviceable; do not remove.
4. Clean carburetor bowl and inlet seat areas as required.
5. Remove main jet; then remove main nozzles through bottom of main towers. Note orientation.
6. Clean slow jets using compressed air or carburetor cleaner; do not use wire.

Tools: Clamp, Torque wrench

1. Install a clamp to hold pulley in starter housing and prevent rotation.
2. Unscrew center screw and lift off drive plate.
3. Note positions of pawls and pawl springs before removing. Remove parts from pulley.
4. Install pawl springs and pawls into pawl slots of pulley. All parts must be dry.
5. Position drive plate over pawls, aligning actuating slots with raised sections on each pawl.
6. Torque center screw to 5-6 N·m (44-54 in. lb.).
7. Remove clamp and pull starter rope out part way to check operation of pawls.