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CH260-CH440 Service Manual

1. BS ESS A3 we SS A A IE X X RAN ALLES I CN SAGA N S ie YA D x JZ f KE A gt AA AS D N VL ui Y Yellow Oil Sensor Lead to Oil Alert Green Lead Red Leads from White Lead from Electronic Governor Electronic Governor Control to Red Stator Control to Ignition Switch Electronic Governor Control Wiring Assembly Harness Green Lead from Electronic Governor Ignition Switch Lead Control to Oil Alert to Ignition Kill Lead Black Lead Carburetor Stepper Motor Leads to Carburetor Assembly Ignition Switch Air Cleaner Cover Electronic Governor Control Leads i ae e I Stepper Motor Stepper Motor Cover I Stepper Motor Base Electronic governor regulates engine speed at varying loads This electronic governor includes e Electronic governor control e Stepper motor e Wiring assembly harness 30 KohlerEngines com 17 690 01 Rev H Governor System Electronic Governor Troubleshooting Flow Chart Engine shuts down immediately after startup OR Erratic engine speed under normal operation or when load is applied or released Inspect wiring harness for any broken or bad connections Repair Replace as necessary Move throttle shaft to idle position to check for smooth and consistent travel Continued
2. DN Quad Clean Cover nu Fuel Tank CH395 CH440 Muffler Assembly Breather Hose e Carburetor Shroud I Quad Clean Base Quad Clean Aa Oil Drain Plug Element Precleaner Low Profile Air Cleaner CH260 CH270 Muffler Assembly Fuel Line 17 690 01 Rev H KohlerEngines com 82 Install Oil Sentry Module NOTE If Oil Sentry module is mounted inside control panel skip this step 1 Install Oil Sentry module and secure with screw Torque screw to 3 5 N m 31 in Ib 2 Connect electrical leads for Oil Sentry module Install Fuel Tank 1 Position fuel tank on mounting brackets Secure with screws on inner mounting bracket and on PTO side strap 2 Install nuts on fuel tank studs Torque side strap screw to 10 N m 89 in Ib 4 Torque remaining screw and nuts to 24 Nm 212 in Ib 5 Position fuel line in clip on bottom of tank Connect fuel line to shut off valve on carburetor and secure with clamp gt Install Carburetor Cover If Equipped Install outer air cleaner cover onto studs over carburetor Secure with nuts and screws Torque nuts to 4 Nm 35 in Ib and screws to 1 3 N m 12 in lb Install Muffler and Heat Shield Assembly 1 Install anew exhaust gasket onto exhaust studs 2 Position muffler and heat shield assembly and install screw in support bracket and screws in exhaust outlet flange 3 Torque screws to CH260 CH270 24 N m 212 in Ib
3. 2 Position valve cover gasket assembly on head Install screw and torque to 10 N m 89 in Ib 17 690 01 Rev H Reassembly CH260 CH270 Blower Housing Control Panel Components ON Qm KO Y CR A Retractable Starter Be D Carburetor H Hex Flange Nut Lower Shield Governor Lever K Upper Shield E Blower Housing Throttle Linkage Throttle Lever Governor Spring E Dampening Spring E IN 71 KohlerEngines com 17 690 01 Rev H Reassembly CH395 CH440 Blower Housing Control Panel Components B Electric Starter Fuel Tank Brackets EN Throttle Lever Dampening Spring Throttle Linkage Lower Shield ES K Blower Housing A Retractable Starter B Carburetor KE M Governor Lever NJ Upper Shield Governor Spring Pivot Lever ut 17 690 01 Rev H KohlerEngines com 78 Reassembly CH395 CH440 Electronic Governor Blower Housing Control Panel Components III gt G PAY RY RE y Q AN V e JU N V 2 j Vw l i R Q A N 4 y gt G N VI nd 2 yo S 5 A S EA Ken Mf 5 Y 9 ES Le RV AN g tve p IN S A AY A x N Ow a e N SS cc B N o Carburetor 19 A D 7 4 MING Zao CRA X ANY V N ANA NN 1 ANO NA Lower Shield Stepper Motor KohlerEngines com Blower Housing A M B AS iS 2 7 Electric Governor Control E Qa NS oT Retractable Starte
4. 26 48 3 474 1 043 SPARK PLUG Nr m NI s m 5 gt d OIL R js A SSS dr TH I A DRAIN PLUG py NY MOUNTING H 5 If FACE 5 50 2X 10 00 0 217 0 394 39 33 L 2X 10 00 x 15 50 SLOT 1 548 0 394 x 0 610 35 70 7999 1 406 3 149 17 690 01 Rev H KohlerEngines com Specifications Dimensions in millimeters Inch equivalents shown in 373 53 14 706 m 118 03 7 4 647 384 87 15 153 LUUEBUDUEUUDS i 360 57 14 196 30 00 1 181 t s255 LL M8 x 1 25 6H 1 281 un 65 08 4X M8 x 1 25 6H 2 562 66 00 V 15 00 0 591 2 598 162 00 6 378 Specifications CH260 CH270 Engine Dimensions 4 65 70 l l m 10 461 Dimensions in millimeters Inch equivalents shown in JN LL MOTA EL wt 323 45 12 734 3 4 STRAIGHT PTO 434 13 26 48 17 092 1 043 MOUNTING 2X 10 00 X 15 50 SLOT 0 394 X 0 610 2X 10 00 5 50 0 395 0 217 u 39 33 1 548 CYLINDER 35 70 79 99 1 406 3 149 PPROXIMATE CENTER OF GRAVITY N KAN L COUNT E E OT e 30 00 kN e A 1 181 248 83 SAR A 9 796 65 10 A Ne 221 31 WE 7 H s Ve DA Je Z ea m j METRIC FLANGE M8 X 1 25 6H Y THRU SAE A FLANGE 4X 5 16 24 UNF 2B v 15 METRIC FLANGE 4X M8 X 1 25 6H Y 15 SAE A FLANGE 4X 5 16 24 UNF 2
5. 0 0003 0 0006 in Piston Pin Bore I D New 18 000 18 008 mm 20 000 20 008 mm 0 7087 0 7090 in 0 7874 0 7877 in Max Wear Limit 18 05 mm 0 7106 in 20 05 mm 0 7894 in Piston Pin O D 19 992 19 998 mm New 17 992 17 998 mm 0 7083 0 7084 in 0 7871 0 7873 in A sd Wear Limit 17 95 mm 0 7067 in 19 95 mm 0 7854 in Top and Eonia MERE Compression Ring Side Clearance New Bore 0 04 mm 0 07 mm 0 045 mm 0 002 in 0 003 in 0 0018 in Used Bore oa aen EE 0 15 mm 0 11 mm wi mm 0 006 in 0 004 in wi Top loss MEER Ring End Gap 0 325 0 400 mm 0 250 0 400 mm 0 010 0 016 in New Bore a 013 0 016 in Used Bore Max 1 00 mm 0 039 in Center Compression Ring End Gap 0 325 0 400 mm 0 650 0 800 mm 0 640 0 800 mm New Bore 0 013 0 016 in 0 026 0 032 in 0 025 0 032 in Used Bore Max 1 00 mm 1 50 mm 0 059 in 0 039 in Oil Control Ring to Groove Side Clearance 0 05 0 19 mm 0 0019 0 0075 in 0 09 0 15 mm 0 0035 0 0059 in ra Thrust Face O D New 69 975 69 995 mm 77 955 77 975 mm 88 955 88 975 mm 2 755 2 756 in 3 069 3 070 in 3 502 3 503 in Wear Limit 69 82 mm 77 82 mm E 82 mm 2 749 in 3 064 in 3 497 E Piston Thrust Face to d Bore Running 0 057 0 075 mm 0 033 0 067 mm 0 025 0 060 mm Clearance 0 002 0 003 in 0 001 0 003 in 0 001 0 002 in Values are in Metric units Values in parentheses are English equivalents Measure 21 8 2
6. 4 Hold pulley firmly and untie slipknot Allow pulley to rotate slowly as spring tension is released 5 When all spring tension on starter pulley is released remove rope from pulley 6 Tie a double left hand knot in one end of new rope 7 Rotate pulley counterclockwise to pre tension spring approximately 4 full turns of pulley 8 Continue rotating pulley counterclockwise until rope hole in pulley is aligned with rope guide bushing of starter housing 9 Insert unknotted end of new rope through rope hole in starter pulley and rope guide bushing of housing 10 Tie a slipknot approximately 12 in from free end of rope Hold pulley firmly and allow it to rotate slowly until slipknot reaches guide bushing of housing 11 Insert starter rope through starter handle and tie a double left hand knot at end of starter rope Insert knot into hole in handle 12 Untie slip knot and pull on starter handle until starter rope is fully extended Slowly retract starter rope into starter assembly If recoil spring is properly tensioned starter rope will retract fully and starter handle will stop against starter housing 17 690 01 Rev H Starter System Pawls dogs Replacement 1 Install a clamp to hold pulley in starter housing and prevent it from rotating 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
7. CH395 CH440 35 N m 310 in Ib Install Air Cleaner Element and Cover Install Quad Clean Air Cleaner Place air cleaner element with precleaner onto boss on air cleaner base 2 Position air cleaner cover as required for seasonal operation and engage both cover clips to secure it to base Install Low Profile Air Cleaner 1 Place foam element in air cleaner base 2 Position air cleaner cover onto base and secure with screw 17 690 01 Rev H Reassembly Prepare Engine for Operation Engine is now reassembled Before starting or operating engine be sure to do following 1 Make sure all hardware is properly torqued 2 Make sure oil drain plugs oil fill plugs and Oil Sentry wire lead bushing are tightened securely 3 Fill crankcase with correct oil Refer to Maintenance and Lubrication System for oil recommendations and procedures Testing Engine It is recommended engine be operated on a test stand or bench prior to installation on a piece of equipment 1 Set engine up on a test stand Check gas and oil levels Start engine and run for 5 10 minutes between idle and midrange Adjust carburetor settings as required Low idle speed should be set to 1800 RPM 150 or application specifications 2 Maximum no load high idle engine speed is 3750 RPM Adjust high idle speed adjusting stop screw as necessary KohlerEngines com 83 1P17 690 2015 by Kohler Co All rights reserved 50531 A 84 Koh
8. 2 861 mm 27 607 mm 1 097 in 1 087 in 32 154 mm 1 266 in 31 866 mm 1 255 in 32 032 mm 1 261 in 32 252 mm 1 270 in 17 690 01 Rev H EXHAUST CH395 Cam Lobe 32 408 mm a 1 276 in EXHAUST 32 12 mm 1 265 in CH440 Cam Lobe 32 286 mm NTARE 1 271 in 32 506 mm 1 280 in EXHAUST 64 KohlerEngines com Dimension B Cam Lobe Specifications CH260 Dimension C CH395 CH440 Camshaft Journal Specifications 13 975 mm 13 900 mm CH260 CH270 5 5500 in 0 5470 in 15 975 mm 15 900 mm CH395 CH440 06289 in 0 6260 in Inspect gear teeth of camshaft If teeth are badly worn chipped or some are missing replacement of camshaft will be necessary If unusual wear or damage is evident on either lobe or mating tappet camshaft and both tappets must be replaced Check condition and operation of ACR mechanism 17 690 01 Rev H Disassembly Inspection and Service Measure cam lobe profile A and B using an outside micrometer and compare with specifications listed Measure camshaft journals C which fit in ball bearings for wear using a micrometer Compare with specifications listed Remove Piston Connecting Rod and Crankshaft NOTE If a carbon ridge is present at top of cylinder bore use a ridge reamer to remove it before attempting to remove piston 1 Remove screws securing end cap to connecting rod Remove end cap Carefully guiding connecting
9. CARBURETOR A WARNING Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved Explosive Fuel can cause fires and severe containers in well ventilated unoccupied buildings away burns from sparks or flames Spilled fuel could ignite if it comes Do not fill fuel tank while engine is hot or in contact with hot parts or sparks from ignition Never use running gasoline as a cleaning agent These engines are equipped with a fixed main jet carburetor Carburetor is designed to deliver correct fuel to air mixture to engine under all operating conditions V Idle mixture is set at factory and cannot be adjusted Troubleshooting Checklist A gt s n OA Sen AL Aes ye B When engine starts hard runs rough or stalls at low DA idle speed check these areas before adjusting or disassembling carburetor 1 Make sure fuel tank is filled with clean fresh v gasoline 2 Make sure fuel tank cap vent is not blocked and is operating properly 3 Make sure fuel is reaching carburetor This includes checking fuel shut off valve fuel tank filter screen in line fuel filter fuel lines and fuel pump for restrictions or faulty components as necessary 4 Make sure air cleaner base and carburetor are securely fastened to engine using gaskets in good condition 5 Make sure air cleaner element including precleaner if equipped is clean and all air cleaner components are fast
10. Install Electronic Governor Control Electronic Governor Only 1 Place governor control in position on crankcase and secure with two screws Torque screws to 24 N m 212 in Ib 2 Install wires to control panel 3 Install wiring harness to electronic governor control Install Blower Housing 1 Position spark plug lead in molded clip in carburetor insulator 2 CH260 CH270 Install blower housing on crankcase with nuts and screws Torque nuts to 6 N m 71 in Ib and screws to 10 N m 89 in Ib CH395 CH440 Install blower housing on crankcase with screws Torque screws to 10 N m 89 in Ib Install Retractable Starter 1 Install retractable starter on blower housing using screws Finger tighten mounting screws only 2 Pull rope handle to engage pawls and center starter to drive cup Hold in this position and torque mounting screws to 5 4 N m 48 in Ib Install Throttle Link Governor Lever Governor Spring and Throttle Lever Mechanical Governor Only 1 Connect throttle linkage and dampening spring to arm of governor lever 2 Install governor lever onto shaft Assemble screw and locknut but do not tighten 3 CH260 CH270 Push governor lever in direction indicated and hold against stop Turn governor shaft clockwise until it stops Tighten nut on governor lever clamp bolt to lock lever on shaft Torque nut to 12 N m 106 in Ib CH395 CH440 Push governor lever in direction indicated a
11. KOHLER Command PRO CH260 CH440 Service Manual j UN P gt NZ LT 93 gt A Gy 7 24 LO SSS ee OO LX LY E A T ES gt HE 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 2 Safety 3 Maintenance 5 Specifications 18 Tools and Aids 21 Troubleshooting 25 Air Cleaner Intake 26 Fuel System 30 Governor System 39 Lubrication System 40 Electrical System 47 Starter System 52 Disassembly Inspection and Service 69 Reassembly 17 690 01 Rev H KohlerEngines com Safety SAFETY PRECAUTIONS A WARNING A hazard that could result in death serious injury or substantial property damage A 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 Explosive Fuel can cause fires and severe burns Do not fill fuel tank while 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 Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Never use gasoline as a cleaning agent Rotating Parts can
12. 0 323 in from outer surface 4 Using an appropriate seal driver install oil seal into crankcase to depth specified below Install to a depth of CH260 CH270 CH440 0 0 1 0 mm 0 0 0 039 in from outer surface CH395 2 0 mm 0 079 in from outer surface 5 Apply a light coating of lithium grease to seal lips after installing 17 690 01 Rev H Reassembly Install Governor Assembly Mechanical Governor Only CH260 CH270 Governor Details A Thrust Washer Governor Gear c Shafi 1 ES x e ES ri ne F Sear G Thrust Washer H mn Install governor shaft through gear and add thrust washer to shaft 2 Install governor gear assembly into crankcase using a press or a drift with light taps until tip of shaft is 78 862 mm 3 105 in below machined gasket surface of crankcase Install washer and cup on shaft 3 Install one thrust washer onto governor cross shaft and slide shaft up through inside of crankcase 4 Install second flat washer onto shaft Position shaft so flat index end of shaft faces left 9 o clock position and install hitch pin so end of pin comes in contact with raised boss on housing limiting inward movement of shaft KohlerEngines com 71 Reassembly CH395 CH440 Governor Details Governor Details E Ee C PnRm o Washer E Hitch Pin F Thrust Washer G Governor Cross NOTE Governor gear shaft is pressed into closure plate and should not
13. As throttle plate opening increases greater amounts of air fuel mixture are drawn in through fixed and metered idle progression holes As throttle plate opens further vacuum signal becomes great enough at venturi so main circuit begins to work Main high speed At high speeds loads engine operates on main circuit As a metered amount of air is drawn through air jet fuel is drawn through main jet Air and fuel are mixed in main nozzles then enters main body of airflow where further mixing of fuel and air occurs This mixture is then delivered to combustion chamber Carburetor has a fixed main circuit no adjustment is possible 28 KohlerEngines com Carburetor Adjustments NOTE Carburetor adjustments should be made only after engine has warmed up Carburetor is designed to deliver correct fuel to air mixture to engine under all operating conditions Main fuel jet is calibrated at factory and is not adjustable Idle fuel adjusting needles are also set at factory and are not adjustable Low Idle Speed RPM Adjustment NOTE Actual low idle speed depends on application Refer to equipment manufacturer s recommendations Low idle speed for basic engines is 1800 RPM 1 Place throttle control into idle or slow position Turn low idle speed adjusting screw in or out to obtain allow idle speed of 1800 RPM 75 RPM 17 690 01 Rev H High Idle Speed RPM Adjustment High Idle Speed TU Stop Screw NOTE High idle speed is
14. Valve Cover 10 N m 89 in Ib CLEARANCE SPECIFICATIONS CH260 CH270 CH395 CH440 Camshaft Running Clearance 0 007 0 043 mm 0 016 0 052 mm 0 0003 0 0017 in 0 0006 0 0020 in Bore TD New 14 000 14 018 mm 16 000 16 018 mm 0 6299 0 6306 in 0 5512 0 5519 in Max Wear Limit 14 018 mm 16 068 mm 0 6326 in 0 5519 in Camshaft Bearing Surface O D New 13 975 mm 15 975 mm 0 6289 in 0 5502 in Max Wear Limit 13 90 mm 15 90 mm 0 626 in 0 547 in Cam Lobe Profile minimum dimension measured from base circle to top of lobe Intake New 27 787 mm 32 408 mm 32 286 mm 1 094 in 1 276 in 1 271 in Max Wear Limit 27 533 mm 32 154 mm 032 mm 1 084 in 1 266 in 1 261 in Exhaust New 27 861 mm EE mm e mm 1 097 in 1 265 in 1 280 in Max Wear Limit 27 607 mm 31 866 mm 32 252 mm 1 087 in 1 255 in 1 270 in Connecting Rod Crankpin End I D 21 C 70 F New 30 020 30 030 mm 33 020 33 030 mm 37 020 37 030 mm 1 1819 1 1823 in 1 3000 1 3004 in 1 4575 1 4579 in Max Wear Limit 30 106 mm 33 07 mm 3 08 mm 1 185 in 1 302 in 1 460 in Connecting Rod to Crankpin Side Clearance MO O A New 0 58 0 60 mm 0 73mm 0 56 mm 0 023 0 024 in 0 029 in 0 022 in Max Wear Limit 1 10 mm 1 36 mm 1 06 mm 0 043 in 0 054 in 0 042 in Connecting Rod to Piston Pin Running Clearance 0 008 0 025 mm 0 006 0 028 mm 0 008 0 025 mm 0 0003 0 0010 in 0 0002 0 0011
15. is loosened or removed from cross shaft To ensure proper setting make sure throttle linkage is connected to governor lever and to carburetor throttle lever 1 Close fuel shut off valve 2 Remove air cleaner outer cover Then either reposition fuel tank to access governor cross shaft and lever joint or disconnect fuel line and remove tank from engine 3 Loosen governor lever mounting nut 4 CH260 CH270 Move governor lever clockwise until it stops Rotate governor cross shaft clockwise until it stops CH395 CH440 Move governor lever counterclockwise until it stops Rotate governor cross shaft counterclockwise until it stops 5 Hold both in this position and torque governor lever nut to 12 N m 106 in Ib 17 690 01 Rev H Lubrication System These engines use a Splash lubrication system supplying necessary lubrication to crankshaft camshaft connecting rod and valve train components Lubrication Components A Dipstick TE Oil Fill Plug EB Oil Drain Plug OIL RECOMMENDATIONS Refer to Maintenance 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 fill dipstick areas of any debris 1 Remove dipstick wipe oil off 2 Reinsert dipstick into tube rest on oil fill neck turn counterclockwise until cap drops down to lowest point of thread leads do not thread cap
16. over paper element Position air cleaner cover for normal operation sun decal out or cold weather operation snowflake decal out place latches under tabs on base lift up bails to secure cover Low Profile 1 Remove screw and air cleaner cover 2 Remove foam element from base 3 Wash foam element in warm water with detergent Rinse and allow to air dry 4 Lightly oil foam element with new engine oil squeeze out excess oil 5 Reinstall foam element into base 6 Reinstall cover and secure with screw BREATHER TUBE Ensure both ends of breather tube are properly connected AIR COOLING A WARNING 77 Hot Parts can cause severe burns m 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 fins and other external surfaces of engine Avoid spraying water at wiring harness or any electrical components Refer to Maintenance Schedule KohlerEngines com 25 Fuel System Typical carbureted fuel system and related components include e Fuel tank Fuel lines In line fuel filter Fuel tank filter Carburetor Fuel strainer screen in carburetor FUEL RECOMMENDATIONS Refer to Maintenance FUEL LINE Low permeation fuel line must be installed on carbureted Kohler Co engines to maintain EPA and CARB regulatory compliance FUEL FILTER Fuel Tank Filter if
17. sure key is properly seated and parallel with taper of shaft Install flywheel onto crankshaft being careful not to shift position of woodruff key Install flywheel shield and secure with one screw CH260 and CH270 only Install fan bosses into matching holes in flywheel Position drive cup on flywheel engaging boss on its base with corresponding hole in flywheel Hold in position and install nut Finger tighten to keep cup indexed Use a flywheel holding tool and torque wrench to tighten flywheel nut Torque nut to CH260 CH270 74 N m 655 in Ib CH395 CH440 113 N m 1000 in Ib Reassembly Install ignition module loosely to bosses with screws Move module as far away from flywheel as possible then tighten screws just enough to hold it in position Rotate flywheel until magnet is under one leg of ignition module Insert a 0 254 mm 0 010 in flat feeler gauge between leg of module and magnet Loosen nearest screw allowing magnet to draw module against feeler gauge Push against module to hold leg tight against feeler gauge while tightening screw Rotate flywheel until magnet is under other leg of module Loosen nearest screw allowing magnet to draw module against feeler gauge Push against module to hold leg tight against feeler gauge while tightening screw Torque first screw then second screw Go back and torque first screw one more time Torque both module screws to 10 N m 89 in Ib Install Ignitio
18. 2179 6 608 mm 0 2602 in i Valve Seat Width 0 80 d E rum 1 10 mm 0 0433 1 20 mm 0 0472 8 in Nominal Valve Face Angle 45 Values are in Metric units Values in parentheses are English equivalents 16 KohlerEngines com 17 690 01 Rev H Specifications GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners O Into Aluminum Size Grade 2 Grade 5 Grade 8 O Tightening Torgue N m in Ib 20 8 32 2 3 20 2 8 25 10 24 3 6 32 4 5 40 10 32 3 6 32 4 5 40 ST 1428 9 6 85 158 40 226 00 5 16 18 17 0 150 28 3 250 39 6 350 5 16 24 18 7 165 30 5 270 UU 3 8 16 29 4 260 3 8 24 33 9 300 SO ome AU AR Je kn A AU d NO N AN Les s NO Tightening Torque N m ft Ib 20 METAN A A O 28718 A 678 00 O O 3 amp 24 1 542 40 X 3A 814 00 716 44 AT 746 55 1085 80 Te 7 16 20 61 0 45 101 7 75 142 5 105 ooo y OO 1 213 67860 1085 80 185 9015 Te 1 2 20 94 9 70 142 4 105 223 7 165 o O 9 16 12 101 7 75 169 5 125 237 3 175 Eo o o O 916 18 135 6 100 223 7 165 20820 o 5 8 11 149 5 110 244 1 180 352 6 260 UU LS pM 5 8 18 189 8 140 311 9 230 447 5 330 3 4 10 199 3 147 332 2 245 474 6 350 3 4 16 271 2 20
19. S Command Series Kohler 25 455 12 S For reaming worn valve guides to accept replacement oversize valves Can be used in low speed drill press or with handle below for hand reaming Reamer Handle Design Technology Inc For hand reaming using Kohler 25 455 12 S reamer DTI K830 AIDS Description Source Part No RTV Silicone Sealant Loctite 5900 Heavy Body in 4 oz aerosol dispenser Kohler 25 597 07 S Only oxime based oil resistant RTV sealants such as those listed are approved Loctite 59109 for use Loctite Nos 5900 or 5910 are recommended for best sealing Loctite Ultra Black 598 characteristics Loctite Ultra Blue 587 Loctite Ultra Copper 5920 Spline Drive Lubricant Kohler 25 357 12 S 17 690 01 Rev H KohlerEngines com 19 Tools and Aids FLYWHEEL HOLDING TOOL A flywheel holding tool can be made out of an old junk flywheel ring gear and used in place of a strap wrench 1 Using an abrasive cut off wheel cut out a six tooth segment of ring gear as shown 2 Grind off any burrs or sharp edges 3 Invert segment and place it between ignition bosses on crankcase so tool teeth engage flywheel ring gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller ROCKER ARM CRANKSHAFT TOOL A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk connecting rod 1 Find a used connecting rod from a 10 HP or large
20. Sentry System 1 Mount Oil Sentry float switch into crankcase housing using two M6x18 screws and torque to 8 N m 71 in lb 2 Route wire lead grommet assembly through crankshaft housing 3 Install nut on grommet assembly external stud and torque to 10 N m 89 in Ib Install Crankshaft Carefully slide flywheel end of crankshaft through main ball bearing and seal Install Connecting Rod with Piston and Rings Connecting Rod Details Match Marks Offset 1 Make sure these are correct before installing a Locating mark on piston is down b Connecting rod offset is down and oil hole is in 4 o clock position shown Match marks should align as shown with dipper down 2 Stagger piston rings in grooves as shown 17 690 01 Rev H Reassembly 3 Lubricate cylinder bore piston piston pin and piston rings with engine oil Compress rings using a piston ring compressor 4 Lubricate crankshaft journal and connecting rod bearing surfaces with engine oil 5 Ensure Y stamping on piston is facing down toward base of engine Use a hammer handle or rounded wood dowel and gently tap piston into cylinder as shown Be careful oil ring rails do not spring free between bottom of ring compressor and top of cylinder 6 Install connecting rod cap to connecting rod so dipper is down and match marks are aligned 7 Torque both screws in increments to CH260 CH270 12 N m 106 in Ib CH395 CH440 20 N m 177 i
21. also specified by equipment manufacturer Set according to recommendations High idle speed for basic engines is 3600 RPM x 150 RPM 1 Sethigh idle speed by turning high idle speed adjusting stop screw in or out Do not exceed 3750 RPM Carburetor Servicing o 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 NOTE Main and slow jets are fixed and size specific and can be removed if required Fixed jets for high altitudes are available e Inspect carburetor body for cracks holes and other wear or damage e Inspect float for cracks holes and missing or damaged float tabs Check float hinge and shaft for wear or damage e Inspect fuel inlet needle and seat for wear or damage 1 Perform removal procedures for appropriate air cleaner and carburetor outlined in Disassembly 2 Clean exterior surfaces of dirt or foreign material before disassembling carburetor Remove bowl retaining screws and carefully separate fuel bowl from carburetor Do not damage fuel bowl O rings Transfer any remaining fuel into an approved container Save all parts Fuel can also be drained prior to bowl removal by loosening removing bowl drain screw 17 690 01 Rev H Fuel System 3 R
22. 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 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 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 A WARNING Hot Parts can cause A severe burns And wm DO not touch engine while operating or just after stopping Never operate engine with heat shields or guards removed A WARNING Cleaning Solvents can Cause severe injury or death Use only in well ventilated areas away from ignition sources Carburetor cleaners and solvents are extremely flammable Follow cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent KohlerEngines com A CAUTION 3 Electrical Shock can cause injury Do not touch wires while engine is running Mi Ro Damaging Crankshaft and Flywheel can cause ry personal injury Using improper procedures can lea
23. distortion Check clearance of valve stems in guides 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 first 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 Valve Guides If a valve guide is worn beyond specifications it will not guide valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption 17 690 01 Rev H Disassembly Inspection and Service To check valve guide to valve stem clearance thoroughly clean valve guide and using a split ball gauge measure inside diameter of guide Then using an outside micrometer measure diameter of valve stem at several points on stem where it moves in valve guide Use largest stem diameter to calculate clearance by subtracting stem diameter from guide diameter If intake or exhaust clearance exceeds specifications in Valve Specification table determine whether valve stem or guide is responsible for excessive clearance If guides are within limits but valve stems are worn beyond limits install new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into
24. e SMART SPARK malfunction e Spark plug lead s disconnected Engine Starts But Does Not Keep Running e Faulty carburetor Faulty cylinder head gasket Faulty or misadjusted choke or throttle controls Fuel pump malfunction vacuum hose clogged or leaking Intake system leak Loose wires or connections that intermittently ground ignition kill circuit e Quality of fuel dirt water stale mixture e Restricted fuel tank cap vent Engine Starts Hard e Clogged fuel line or fuel filter e Engine overheated e Faulty ACR mechanism e Faulty or misadjusted choke or throttle controls e Faulty spark plug s e Flywheel key sheared e Fuel pump malfunction vacuum hose clogged or leaking Interlock switch is engaged or faulty e Loose wires or connections that intermittently ground ignition kill circuit e Low compression e Quality of fuel dirt water stale mixture e Weak spark 17 690 01 Rev H Engine Will Not Crank Battery is discharged Faulty electric starter or solenoid Faulty key switch or ignition switch Interlock switch is engaged or faulty Loose wires or connections that intermittently ground ignition kill circuit Pawls not engaging in drive cup Seized internal engine components Engine Runs But Misses Carburetor adjusted incorrectly Engine overheated Faulty spark plug s Ignition module s faulty or improperly gapped Incorrect crankshaft position sensor air gap In
25. equipped A serviceable fuel tank filter is located under fuel tank cap in filler neck Daily or as required clean filter of any accumulation as follows 1 Remove fuel tank cap and filter 2 Clean filter with solvent replace if damaged 3 Wipe filter and insert it 4 Tighten fuel tank cap securely FUEL SYSTEM TESTS Fuel Valve Explosive Fuel can cause fires and severe burns Do not fill fuel tank while 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 Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Never use gasoline as a cleaning agent NOTE Models with a low profile air cleaner do not have fuel valve 1 Stop engine Remove securing hardware and carburetor cover panel Turn fuel valve lever to OFF position Remove fuel valve cup Clean fuel valve cup with solvent and wipe it off Check O ring replace if damaged Check screen for blockage or damage replace if necessary New screen must be located on pick up tube 7 Place O ring on screen followed by fuel valve cup Rotate fuel valve cup until it is finger tight Turn with a wrench 1 2 to 3 4 turn 8 Turn fuel valve to ON position and check for leaks If fuel valve cup leaks repeat step 7 9 Reinstall carburetor cover panel using hardware r
26. in 0 0003 0 0010 in Piston Pin End I D 21 C 70 F New 18 006 18 017 mm 20 006 20 017 mm 0 7089 0 7093 in 0 7876 0 7881 in Max Wear Limit 18 08 mm 0 712 in 20 03 mm 0 789 in Values are in Metric units Values in parentheses are English equivalents 17 690 01 Rev H KohlerEngines com 13 Specifications CLEARANCE SPECIFICATIONS CH260 CH270 CH395 CH440 Crankcase Governor Cross Shaft Bore I D 6 000 6 024 mm 8 000 8 024 mm 0 3150 0 3159 in New 0 2362 0 2372 in Max Wear Limit 6 037 mm 8 075 mm 0 3179 in 0 2377 in Crankshaft End Play free 0 0508 0 254 mm 0 002 0 010 in Ball Bearing Internal Clearance 0 003 0 025 mm 0 005 0 020 mm 0 006 0 020 mm 0 0001 0 0010 in 0 0002 0 0008 in 0 0002 0 0008 in Crankshaft O D new 29 975 29 989 mm 34 975 34 989 mm PTO end 24 975 24 989 mm 1 1801 1 1807 in 1 3770 1 3775 in ELS A end 0 9833 0 9838 in 014 30 027 mm 35 009 35 027 mm 1 1817 1 1822 in 1 3783 1 3790 in R Rod Journal O D New 29 975 29 985 mm 32 975 32 985 mm 36 975 36 985 mm 1 1801 1 1805 in 1 2982 1 2986 in 1 4557 1 4561 in Max Wear Limit 29 924 mm 32 92 mm 36 92 mm 1 1781 in 1 2961 in 1 4535 in Max Taper 2 5 microns 0 0001 in Max Out of Round 12 7 microns 0 0005 in Width 25 02 25 08 mm 30 30 30 36 mm 28 30 28 36 mm 0 9850 0 9874 in 1 1930 1 1953 in 1 1142 1 1165 in Runout either Runout eithe
27. one upside down over end of a small diameter dipstick manometer tube Leave other tube open to tube or directly into engine if a tube is not used atmosphere Check that water level in manometer is Insert barbed gauge fitting into hole in stopper at O line Make sure pinch clamp is closed 3 Run engine and observe gauge reading 2 Start engine and run no load high speed 3 0 Get EE ntb Analog tester needle movement to left of 0 is a A A A a En vacuum and movement to right indicates a pressure Level in engine side should be a minimum of 10 2 Digital tester depress test button on top of tester cm 4 in above level in open side H E ee Crankcase vacuum should be a minimum of 10 2 cm e Ge 4 in of water If reading is below specification or if st GE E nalen 3 pressure is present check table below for possible p p i causes and conclusions below 4 Close pinch clamp before stopping engine Condition Conclusion Crankcase breather clogged or inoperative NOTE If breather is integral part of valve cover and cannot be serviced separately replace valve cover and recheck pressure Disassemble breather clean parts thoroughly check sealing surfaces for flatness reassemble and recheck pressure Seals and or gaskets leaking Loose or improperly torque Replace all worn or damaged seals and gaskets Make fasteners sure all fasteners are tightened securely Use appropriate torque valves and sequences when necessa
28. pz f Ves I RO imal PO TH HL M b Me AR eh ee ERA AS A 9E Y Wi 431 72 APPROXIMATE 16 997 CENTER OF GRAVITY 58 31 2 296 LA P ERE T qai TEE zum Fi T r FI A m 75 AXI R Wi A xm adi Xero O AN 3 8 16 UNC 2B INCH 103 00 2X 11 25 13 00 v 18 MM FULL THREAD 4 055 0 512 m 0 443 a D G CYLINDER DENN A m T N Ki KA gen ae Bee ee 1 S m S N k ELE Zu d I nn NE oe SOIT 9 290 31 11 430 METRIC FLANGE _ 6X M8 X 1 25 6H TAP 18 MIN SAE B FLANGE 6X 5 16 24 UNF 2B INCH 18 MIN AX 45 105 4 134 195 50 7 697 KohlerEngines com 17 690 01 Rev H Specifications CH440 Engine Dimensions Dimensions in millimeters Inch equivalents shown in 411 13 16 186 a ar STRAIGHT PTO 344 91 13 579 SECONDARY MOUNTING FACE 155 00 3 75 6 102 0 148 fe 452 02 17 796 21 32 128 83 AIR CLEANER 5 072 COVER REMOVAL CENTER OF GRAVITY 40 00 1 575 6 00 GAS CAP 0 240 REMOVAL 2X 11 25 ALL AROUND 0 443 2X 11 00 X 28 00 SLOT 0 433 X 11 02 6 00 ore GAS CAP REMOVAL qg qu 438 41 17 260 HT CENTER OF 466 62 18 371 DEENS GRAVITY WITH US 6 500 35 00 441 93 50 STATE TA 1 378 17 399 GAS CAP 70 00 2 756 12
29. regulator Connect an ammeter from female terminal to positive terminal of battery Connect a DC voltmeter from female terminal to negative terminal of battery Leave other rectifier regulator leads connected in normal manner Run engine at 3600 RPM and read voltage on voltmeter If voltage is 14 0 volts or more place a minimum load of 5 amps turn on lights if 60 watts or more or place a 2 5 ohm 100 watt resistor across battery terminals on battery to reduce voltage Observe ammeter Voltage is 14 0 15 0 volts Charging system is OK and charge rate increases and battery was fully when load is applied charged Voltage is less than 14 0 Test stator steps 2 and volts or charge rate does 3 not increase when load is applied 2 Separate bullet connectors in AC white leads Connect an AC voltmeter across stator leads female terminals With engine running at 3600 RPM measure AC output from stator Voltage is 20 0 volts or Stator is OK Rectifier more regulator is faulty replace otator is probably faulty and should be replaced Test stator further using an ohmmeter step 3 Voltage is less than 20 0 volts 17 690 01 Rev H Electrical System 3 With engine stopped measure resistance from each stator lead to ground using an ohmmeter Resistance is infinity Stator is OK not shorted to ground Stator leads are shorted to ground replace To test charging system for battery contin
30. rod slide piston and connecting rod from cylinder bore 2 Remove crankshaft from crankcase Connecting Rods Inspection and Service Check bearing area big end for excessive wear score marks running and side clearances see Specifications and Tolerances Replace rod and cap if scored or excessively worn Service replacement connecting rods are available in STD size and 0 25 mm 0 010 in undersize 0 25 mm 0 010 in undersized rods have an identification marking on lower end of rod shank Always refer to appropriate parts information to ensure correct replacements are used Piston and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal engine temperatures approach welding point of piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of engine Normally very little wear takes place in piston boss piston pin area If original piston and connecting rod can be reused after new rings are installed original pin can also be reused but new piston pin retainers are required Piston pin is included as part of piston assembly if pin boss in piston or pin are worn or damaged a new piston assembly is required Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter combustion chamber where it is burned along with fuel High oil consump
31. rotation must be allowed to come to a complete stop before attempting to restart engine If starter is engages while flywheel is rotating starter pinion and flywheel ring gear may clash and damage starter NOTE If starter does not crank engine shut off starter immediately Check condition of inline fuse and do not make further attempts to start engine until condition is corrected NOTE Do not drop starter or strike starter housing Doing so can damage starter Engines in this series use inertia drive electric starters or retractable starters CH270 inertia drive electric starters are not serviceable Troubleshooting Starting Difficulties Condition Possible Cause Conclusion Starter does not energize Battery Check specific gravity of battery If low recharge or replace battery as necessary Check fuse condition Clean corroded connections and tighten loose connections Replace wires in poor condition and with frayed or broken insulation Starter Switch Check switch or relay operation If starter cranks normally or Solenoid replace faulty components Starter energizes but turns Battery Check specific gravity of battery If low recharge or replace slowly battery as necessary Check for corroded connections poor ground connection Transmission Make sure clutch or transmission is disengaged or placed in neutral This is especially important on equipment with hydrostatic drive Transmission must be exactly in neutral to prevent res
32. to blower housing and remove ignition module With black wire kill lead and spark plug cap removed test resistance from small spade terminal to core of spark plug lead wire If resistance is not in this Continuity should be Replace Oil Sentry range Te PAGE MOGU indicated control module for any Resistance Chart other results LE Module 13 5 18 0 K ohms em Terminal to Spark 9 5 12 9 K ohms Plug Lead Wire 42 KohlerEngines com 17 690 01 Rev H T Set an ohmmeter to Rx1 scale and zero meter Test ignition key switch as follows a Trace two black leads from on off switch and separate them from any connections Connect ohmmeter leads to switch leads and check for continuity in both switch positions Continuity should be Replace switch for any indicated when and only other results when switch is in OFF position b On electric start engines trace four leads red red white black black white from key switch and separate them from any connections Connect ohmmeter leads to black and black white leads and check for continuity in all three switch positions Then connect ohmmeter leads to red and red white leads and test again in all three switch positions Continuity should be Replace switch for any indicated between black other results and black white leads only when key switch is in OFF position There should be continuity between red and red white leads only in start position BATTERY CHARGIN
33. 0 440 7 325 637 3 470 Metric Fastener Torque Recommendations for Standard Applications Property Class Noncritica t info Alec M12 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 Torque Conversions N m in Ib x 0 113 in Ib N m x 8 85 N m ft Ib x 1 356 ft lb N m x 0 737 17 690 01 Rev H KohlerEngines com 17 Tools and Aids Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using these tools you can properly service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine downtime Here is a list of tools and their source SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc Contact your local Kohler source of 415 Howard St 768 Burr Oak Drive supply Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 2981 Fax 630 920 0011 Fax 810 664 8181 TOOLS Description Source Part No Alcohol Content Tester Kohler 25 455 11 S For testing alcohol content in reformulated oxygenated fuels Camshaft Endplay Plate SE Tools KLR 82405 For checking camshaft endplay Camshaft Seal Protector Aegis SE Tools KLR 82417 For protecting seal during camshaft installation Cylinder Leakdown Tester Kohler 25 761 05 S For checking combustion retention and if cylinder piston rings or valves are worn Individual compon
34. 2 2 mm 0 8583 0 8740 in above bottom of piston skirt at right angles to piston pin 5Measure 17 8 18 2 mm 0 7008 0 7165 in above bottom of piston skirt at right angles to piston pin Measure 29 8 30 2 mm 1 1732 1 1890 in above bottom of piston skirt at right angles to piston pin 17 690 01 Rev H KohlerEngines com 15 Specifications CLEARANCE SPECIFICATIONS CH260 CH270 CH395 CH440 Valves and Valve Lifters Intake and Exhaust Valve Lash 0 0762 0 127 mm 0 003 0 005 in Intake Valve Stem to Valve Guide Running Clearance 0 038 0 065 mm 0 025 0 055 mm 0 0010 0 0022 in 0 0015 0 0026 in Exhaust Valve Stem to Valve Guide Running Clearance 0 085 0 112 mm 0 040 0 07 mm 0 0016 0 0028 in 0 0033 0 0044 in n Valve Stem O D 5 50 mm 6 57 mm 0 259 in New 0 217 in Wear Limit 5 34 mm 6 40 mm 0 252 in 0 210 in Bas Valve a O D New 5 438 mm 6 55 mm 0 258 in 0 214 in A A Wear Limit 5 28 mm 6 41 mm 0 252 in 0 208 in Intake Valve lach NN to Guide New 0 024 0 039 mm 0 025 0 055 mm 0 0010 0 0022 in 0 0009 0 0015 in pee Wear Limit 0 10 mm 0 13 mm 0 14 mm 0 0039 in 0 0051 in 0 0055 in E ia Valve to Guide New 0 098 0 112 mm 0 040 0 070 mm 0 0016 0 0028 in 0 0038 0 0044 in Max Wear Limit 0 12 mm 0 10 mm 0 11 mm 0 0047 in 0 0039 in 0 0043 in Valve Guide Reamer Size 5 524 mm 0 2175 6 608 mm 0 2602 in Standard Intake M Standard Exhaust 5 536 mm 0
35. 3 Rotate crankshaft until piston of cylinder being tested is at top dead center TDC of compression stroke Hold engine in this position while testing Holding tool supplied with tester can be used if PTO end of crankshaft is accessible Lock holding tool onto crankshaft Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywheel nut screw to hold it in position An assistant may be needed to hold breaker bar during testing If engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a driven component Just be certain that engine cannot rotate off of TDC in either direction Install adapter into spark plug hole but do not attach it to tester at this time Turn regulator knob completely counterclockwise Connect an air source of at least 50 psi to tester Turn regulator knob clockwise increase direction until gauge needle is in yellow set area at low end of scale Connect tester quick connect to adapter hose While firmly holding engine at TDC gradually open tester valve Note gauge reading and listen for escaping air at combustion air intake exhaust outlet and crankcase breather m A O Condition Conclusion Gauge reading in moderate yellow zone Engine is still usable but there is some wear present Customer should start planning for overhaul or repla
36. 7 00 ce 5 000 CR LAM 133 50 H a 5 256 4X 3 8 16 UNC 2B INCH METRIC FLANGE V 18 MM FULL THREAD 4 134 6X M8 X 1 25 6H TAP Y 18 MIN 4X 45 6X 5 16 24 UNF 2B INCH 18 MIN 195 50 7 697 17 690 01 Rev H KohlerEngines com 9 Specifications CH440 Engine Dimensions 12 034 Dimensions in millimeters Inch equivalents shown in Sn y A a MN i 317 22 Na 12 489 PS 404 76 15 936 mcm 103 00 4 055 APPROXIMATE 515 54 CENTER OF 20 297 GRAVITY 165 10 39 70 4X 3 8 16 UNC 2B INCH T k 1 563 18 MM FULL THREAD 4X AN METRIC FLANGE DA M8 X 1 25 6H TAP Y 18 MIN 7 SAE B FLANGE l ast 195 50 6X 5 16 24 UNF 2B INCH Y 18 MIN APPROXIMATE gt 7 697 GRAVITY amp ERA a i e m ion E ap dul A a D WE gt T LI 2X 8 11 00 X 28 00 SLOT ZA Y 11 25 0 433 X 11 02 0 443 17 00 o 12 808 E CYLINDER 106 82 4 208 176 82 6 962 10 KohlerEngines com 17 690 01 Rev H Specifications ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers model specification and serial should be referenced for efficient repair ordering correct parts and engine replacement Command Engine Horizontal Shaft Numerical Designation Specification CH260 0001 4323500328 Factory Code Year 2013 44 2014 45 2015 GENERAL SPECIFICATIONS CH260 CH270 CH395 CH440 70 mm 2 8in 78mm 3 1 in 89
37. B Y 15 KohlerEngines com 17 690 01 Rev H CH395 Engine Dimensions Specifications Dimensions in millimeters Inch equivalents shown in SECONDARY Sid MOUNTING FACE 344 97 PRIMARY pr Te 13 566 MOUNTING i 117 67 AIR FACE 27 33 i 4 633 CLEANER 30 20 1 076 COVER 402 84 1 189 R MOVAL 15 860 CENTER av OF GRAVITY Viet 58 31 RES 147 11 2 296 Ke 1 IN STRAIGHT mee 427 53 ISS 16 832 i8 AMI HR iil 2X 11 00 X 24 00 SLOT HH 0 433 X 0 945 13 00 2X 511 25 0 512 0 443 40 50 CYLINDER 0 236 REMOVAL d 3 780 6 00 2 103 00 0 236 AN 4 055 U S 50 STATE Se REMOVAL qem 451 76 AY 17 79 WITH U S M nd 50 STATE mel a 165 10 m GAS CAP 6 500 ANN 411 63 AN 16 206 424 00 Z bs l 70 00 Re d 2 756 127 00 ASA 133 50 5 000 EN 5 256 A OS 4X 3 8 16 UNC 2B INCH METRIC FLANGE y 18 MM FULL THREAD 3X 450 105 00 6X M8 X 1 25 6H TAP 18 MIN 4 134 SAE B FLANGE 195 50 6X 5 16 24 UNF 2B INCH 18 MIN 7 697 17 690 01 Rev H KohlerEngines com Specifications CH395 Engine Dimensions 289 19 Dimensions in millimeters 11 385 Inch equivalents shown in LAN W u L T _ _ _ _ 289 88 11 413 378 40 14 898 1 STRAIGHT PTO Sek E m E H l a FT Al d T i
38. G SYSTEMS Wiring Diagram Retractable Starter A Ignition Module C Optional Red Ignition Switch E Oil Control Module 17 690 01 Rev H Electrical System NOTE Observe following guidelines to avoid damage to electrical system and components e Make sure battery polarity is correct A negative ground system is used e Make sure all ground connections are secure and in good condition e Disconnect both battery cables before doing electrical welding on equipment powered by engine Also disconnect other electrical accessories in common ground with engine e Prevent stator AC leads from touching or shorting while engine is running This could damage stator Most engines are equipped with a 3 4 10 or 18 amp regulated battery charging system 3 4 10 18 Amp Regulated Charging System Stator Stator is mounted on crankcase behind flywheel Should stator have to be replaced follow procedures in Disassembly Rectifier Regulator Rectifier Regulator Receptacle 10 Amp B 18 Amp B Charge Lead D Ground Lead E otator Leads NOTE When installing rectifier regulator push wiring harness plug into regulator receptacle until it locks into place Rectifier regulator is connected to engine with a matching wiring harness containing a plug in connector Grounded through wiring harness rectifier regulator is secured to equipment in a suitable location with two mounting screws To replace it disco
39. H395 CH440 Crankshaft Camshaft Closure Plate Components El Closure Plate Oil Seal D Closure Plate ES Closure Plate Bearing ES MEE p Balance Shaft F Governor Shaft Governor Washer Governor Washer Governor Gear Gear DEJO M Piston Pin Retainer N Piston Pin Te Piston Ring Set o Camshaft o Oil uns i Oil Sentry Wire El Tappet Crankcase Oil Seal Oil Seal 17 690 01 Rev H KohlerEngines com 63 Disassembly Inspection and Service Remove Closure Plate NOTE Do not pry on gasket surface of crankcase or closure plate as this can cause damage and leakage 1 Remove screws securing closure plate to crankcase 2 Remove closure plate gasket and dowel pins if required from crankcase 3 Remove shims from crankshaft and camshaft Inspection Inspect main bearing surface for wear or damage refer to Specifications Replace closure plate if required Remove Balance Shaft if equipped Remove balance shaft by pulling it straight out of crankcase Remove Camshaft and Valve Tappets 1 Remove camshaft by pulling it straight out of crankcase 2 Remove valve tappets by pulling them straight out of crankcase Mark their positions Automatic Compression Release ACR ACR Operation Details ee Camshaft B Exhaust Cam Lobe Decompression Weight o Return Spring E Am ACR mechanism consists of a spring loaded arm and sliding pin mounted to camshaft When e
40. Intake Every 300 Hours e Replace low profile air cleaner element Air Cleaner Intake e Check fuel filters tank outlet filter and in line filter clean or replace if needed if equipped Fuel System Every 300 Hours e Check and adjust valve clearance when engine is cold Reassembly Every 500 Hours or Annually e Replace spark plug and set gap Electrical System Perform these procedures more frequently under severe dusty dirty conditions 2 Have a Kohler authorized dealer perform this service REPAIRS SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers To find a local Kohler authorized dealer visit KohlerEngines com or call 1 800 544 2444 U S and Canada LA 17 690 01 Rev H KohlerEngines com Maintenance OIL RECOMMENDATIONS We recommend use of Kohler oils for best performance Other high quality detergent oils including synthetic or higher are acceptable Select viscosity based on air temperature at time of operation as shown in table below Explosive Fuel can cause fires and severe burns Do not fill fuel tank while 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 Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Never use gasoline as a cleaning ag
41. Kohler starter drive lubricant 6 Install shim on motor side of new drive assembly 7 Reassemble starter components in reverse order Torque 4 screws to 5 8 N m 51 in Ib Torque brush lead connector wire screw to 1 7 N m 15 in Ib 8 If starter assembly was removed from engine reinstall and torque mounting screws to 24 N m 212 in Ib 17 690 01 Rev H KohlerEngines com 49 Starter System RETRACTABLE STARTERS A WARNING Retractable starters contain a powerful recoil spring that is Uncoiling Spring can cause severe injury under tension Always wear safety goggles when servicing retractable starters and carefully follow instructions in RS nes AC Retractable Starter for relieving spring tension A CenterScrew B Drive Plate Friction Spring D Drive Pawl Dogs E Drive Pawl Springs F Pulley G Recoil Spring H Starter Rope MN Starter Handle Double Left Hand Knot 50 KohlerEngines com 17 690 01 Rev H Remove Starter 1 Remove screws securing starter to blower housing 2 Remove starter assembly Rope Replacement NOTE Do not allow pulley spring to unwind Enlist aid of a helper if necessary Rope can be replaced without complete starter disassembly 1 Remove starter assembly from engine 2 Pull rope out approximately 12 in and tie a temporary slip knot in it to keep it from retracting into starter 3 Pull knot end out of handle untie knot and slide handle off
42. Wire Crankcase Bearing Governor Cross Shaft Crankcase Oil Seal A OE a R U 17 690 01 Rev H KohlerEngines com 69 Reassembly CH395 CH440 Crankshaft Camshaft Closure Plate Components Closure Plate Oil Seal B Closure Plate H Closure Plate Bearing H ME Bor Balance Shaft F Governor Shaft Governor Washer Governor Washer Governor Gear Gear DOE omen A coreo IEC A P Piston Ring Sl FI Camshaft D Oi Seng oat n Oil Sentry Wire ES Tappet Crankcase Oil Seal 70 KohlerEngines com 17 690 01 Rev H NOTE Make sure engine is assembled using all specified torque values tightening sequences and clearances Failure to observe specifications could cause severe engine wear or damage Always use new gaskets Install Crankcase Bearings and Oil Seals Details NOTE Oil bearings liberally with engine oil when installing NOTE In steps 3 and 4 position oil seals with manufacturer s identification marks visible and facing you 1 Make sure there are no nicks burrs or damage in bores for bearings Crankcase and closure plate must be clean 2 Use an arbor press to make sure bearings are installed straight into their respective bores until fully seated 3 Using an appropriate seal driver install oil seal into closure plate to depth specified below Install to a depth of CH260 CH270 5 5 mm 0 217 in from outer surface CH395 7 0 mm 0 276 in from outer surface CH440 8 2 mm
43. al of battery to terminal of blue relay lead Connect another jumper lead from negative terminal of battery to relay mounting bracket When circuit is completed Results are other than applying 12 volts to indicated replace relay energizing coil an audible click should be heard as relay engages and ohmmeter should then indicate continuity between large terminals oquare Boot at Relay Solenoid Front of Starter is Serviced 48 KohlerEngines com 17 690 01 Rev H Starter System Relay Solenoid Replacement CH395 CH440 1 Disconnect all lead wires from relay solenoid Note location for reassembly 2 Remove screws securing relay solenoid and remove relay solenoid from starter assembly 3 Install new relay solenoid to starter assembly and secure with screws Torque screws to 3 2 N m 28 in Ib 4 Reconnect all lead wires to relay solenoid Torque nuts to 4 5 N m 40 in Ib Drive Replacement CH440 Type ll Starter NOTE If access is available to remove screws 4 and separate drive end from motor gear end starter removal is not necessary If access is not available remove starter assembly from engine 1 Disconnect all lead wires from starter Note location of each for reassembly 2 Move square boot to access and remove brush lead connector wire screw 3 Remove 4 screws and separate starter 4 Remove drive assembly and retain shim o Lubricate motor to drive assembly gears with
44. amber is usually caused by a restricted air cleaner a breather problem worn piston rings or valve guides 17 690 01 Rev H Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner over rich carburetion weak ignition or poor compression Overheated Chalky white deposits indicate very high combustion temperatures This condition is usually accompanied by excessive gap erosion Lean carburetor settings an intake air leak or incorrect spark timing are normal causes for high combustion temperatures BATTERY A 12 volt battery not furnished with a minimum current rating of 230 cold cranking amps 18 amp hours should be sufficient for cranking most electric start engine models Actual cold cranking requirement depends on engine size application and starting temperatures Cranking requirements increase as temperatures decrease and battery capacity shrinks Refer to equipment s operating instructions for specific battery requirements If battery charge is insufficient to turn over engine recharge battery Battery Maintenance Regular maintenance is necessary to prolong battery life Battery Test To test battery follow manufacturer s instructions 17 690 01 Rev H Electrical System ELECTRONIC IGNITION SYSTEM Inductive Discharge Ignition System A Ignition Module Kill Switch Off c Air 1001 0 mi Position of Key Switch Ignition Modul
45. and B1 are located in J1 Pin H shown below Repair Replace as necessary Disconnect K10 and B1 terminals on wiring harness and retest Start engine in normal manner as described in Owner s Manual Test control system of equipment diagnostic procedures for control system goveror contol and electronic END di YES goveror contol and control and retest Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control system Basic Wiring Harness Assembly Diagram 34 KohlerEngines com 17 690 01 Rev H Governor System Electronic Governor Troubleshooting Flow Chart Continued Engine cannot be shut down when overspeeding or loss of power Inspect wiring harness for any broken or bad connections Ensure electronic governor control is properly YES NO Repair Replace as necessary YES NO grounded to crankcase and retest OK Short ignition kill ere oe no Shon onon il Replace ignition Does engine stop module and retest OK Continued on next page Replace electronic governor control and retest Confirm return of normal engine operation Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control system 17 690 01 Rev H KohlerEngines com 35 Governor System Electronic Governor Troubleshooting Flow Chart Continued Continued from previou
46. ank bracket 2 Remove both fuel tank brackets by removing screws in each Remove threaded stud from left bracket and remove micro switch bracket Remove Electronic Governor Control Electronic Governor Only 1 Mark wire locations and remove wires from control panel 2 Remove wire harness from electronic governor control 3 Remove screws securing electronic governor control to crankcase Remove Control Panel and Electric Starter if equipped NOTE To ease reassembly label wires for proper reconnection as wiring colors may not match 1 Disconnect wires from control panel to starter Oil Sentry ignition module and rectifier regulator 2 Remove screws securing control panel bracket to crankcase and remove control panel Note 2 ground wires secured by one screw 3 Remove screws securing electric starter to crankcase and remove electric starter KohlerEngines com of Disassembly Inspection and Service A ValveCover B Adjuster Nut C Rocker Arm D Rocker Arm Stud E Push Rod Guide F Push Rod G Valve Keeper H Valve Spring d Valve Stem Seal Spark Plug K Cylinder Head l Cylinder Head ome ms 98 KohlerEngines com 17 690 01 Rev H Remove Valve Cover Breather Rocker Arms Push Rods and Cylinder Head Assembly NOTE Mark location of push rods and any other part removed being reused 1 Remove screw and washer and remove valve cover and gasket from engine Br
47. arefully Make sure all traces of cleaner are removed before engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down lubricating properties of engine oil Disconnect Spark Plug Lead Fuel Valve Details Fuel Shut Off Valve B Turn to Off Position NOTE Pull on boot only to prevent damage to spark plug lead NOTE Models with low profile air cleaner do not have fuel shut off valve Instead turn off fuel at fuel supply 1 Disconnect lead from spark plug 2 Push fuel shut off lever left to close fuel valve Drain Oil From Crankcase 1 Remove 1 oil drain plug and 1 oil fill plug 2 Allow ample time for oil to drain from crankcase Remove Muffler and Heat Shield Assembly 1 Remove screws from exhaust flange and muffler bracket 2 Remove muffler assembly from exhaust outlet 3 Remove exhaust gasket from outlet 17 690 01 Rev H Disassembly Inspection and Service Remove Air Cleaner Assembly Remove air cleaner components from air cleaner base Refer to Air Cleaner Intake Remove Quad Clean Base Remove air cleaner base from engine as follows 1 Remove nuts and screws securing carburetor shroud to engine 2 Remove shroud 3 Remove screw and nuts securing air cleaner base to carburetor 4 Disconnect one end of breather hose from valve cover or air cleaner base 5 Pullair cleaner base off studs 6 Remove air cleaner base gasket from mou
48. be removed 1 Assemble governor gear pin into governor gear so pin rim is held in place by weight retainers 2 Place thrust washer on governor gear shaft in closure plate Push governor gear onto shaft 3 Install one thrust washer onto governor cross shaft and slide shaft up through inside of crankcase 4 Install second flat washer onto shaft Position shaft DE Closure Plate mn so flat index end of shaft faces left 9 o clock Sealing Surface Shaft position and insert hitch pin from PTO side ES Height D PinRim EI Rng F Weights G Governor Gear H Thrust Washer i Wester J Hitch Pin E MERE ON a If shaft was removed in disassembly use an arbor press to install new shaft to a height of 16 025 mm 0 6309 in from closure plate sealing surface 2 Place washer onto shaft then place governor gear onto shaft 3 Press a new ring onto shaft about 1 8 in 12 KohlerEngines com 17 690 01 Rev H 4 Pull governor gear up until it makes contact with ring then place pin in cup retaining rim with weights 5 Push pin down snapping ring into shaft groove 6 Pull up slightly on governor gear to ensure assembly is installed correctly 7 Install one thrust washer onto governor cross shaft and slide shaft up through inside of crankcase 8 Install second flat washer onto shaft Position shaft so flat index end of shaft faces to left 9 o clock position and insert hitch pin from PTO side Install Oil
49. cement Gauge reading in high red zone Rings and or cylinder have considerable wear Engine should be reconditioned or replaced 24 KohlerEngines com 17 690 01 Rev H AIR CLEANER These systems are CARB EPA certified and components should not be altered or modified in any way Quad Clean Air Cleaner Components A iS Air Cleaner Cover B Bal E Air Cleaner Base Air Cleaner Cover Air Cleaner Base Foam Element 17 690 01 Rev H Air Cleaner Intake NOTE Running engine with cover positioned for cold weather operation in normal conditions can damage engine 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 Quad Clean Move bails on air cleaner cover down remove latches from under tabs on base remove cover Precleaner 1 Remove precleaner from paper element 2 Replace or wash precleaner in warm water with detergent Rinse and allow to air dry 3 Lightly oil precleaner with new engine oil squeeze out excess oil 4 Reinstall precleaner over paper element Paper Element 1 Separate precleaner from element service precleaner and replace paper element 2 Install new paper element on base install precleaner
50. cuffing and scoring of cylinder wall It washes necessary lubricating oils off piston and cylinder wall As raw fuel seeps down cylinder wall piston rings make metal to metal contact with wall Scoring of cylinder wall can also be caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If cylinder bore is badly scored excessively worn tapered or out of round resizing is necessary Use an inside micrometer to determine amount of wear refer to Specifications KohlerEngines com 67 Disassembly Inspection and Service Honing Crosshatch Detail 23 33 Crosshatch NOTE Kohler pistons are custom machined to exacting tolerances When over sizing a cylinder it should be machined exactly 0 25 mm 0 010 in over new diameter Specifications and Tolerances Oversize Kohler replacement piston will then fit correctly While most commercially available cylinder hones can be used with either portable drills or drill presses use of a low speed drill press is preferred as it facilitates more accurate alignment of bore in relation to crankshaft crossbore Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust stones so they are in contact with cylinder wall Use of a commercial cutting cooling agent is recommended 2 With lower edg
51. cylinder head Inserts are not replaceable but can be reconditioned if not too badly pitted or distorted If cracked or badly warped cylinder head should be replaced Recondition valve seat inserts following instructions provided with valve seat cutter being used Cutting proper valve face angle as specified in Valve Specification table and proper valve seat angle 89 5 90 will achieve desired 0 1 full cut interference angle where maximum pressure occurs on outside diameters of valve face and seat Lapping Valves Reground or new valves must be lapped in to provide proper fit Use a hand valve grinder with suction cup for final lapping Lightly coat valve face with fine grade of grinding compound then rotate valve on seat with grinder Continue grinding until smooth surface is obtained on seat and on valve face Thoroughly clean cylinder head in soap and hot water to remove all traces of grinding compound After drying cylinder head apply a light coating of SAE 10 oil to prevent rusting Valve Stem Seals These engines use valve stem seals on intake and exhaust valves Always use new seals when valves are removed from cylinder head Seals should also be replaced if deteriorated or damaged in any way Never reuse old seals KohlerEngines com 99 Disassembly Inspection and Service Valve Details CH260 CH270 Valve Specifications A Head Diameter 26 875 27 125 mm 24 875 25 125 mm 1 0581 1 0679 in 0 9793 0 9892
52. d to broken fragments Broken fragments could be thrown from engine Always observe and use precautions and procedures when installing flywheel Uncoiling Spring can cause severe injury Wear safety goggles or face protection when servicing retractable starter Retractable starters contain a powerful recoil spring that is under tension Always wear safety goggles when servicing retractable starters and carefully follow instructions in Retractable Starter for relieving spring tension 17 690 01 Rev H Maintenance MAINTENANCE INSTRUCTIONS A WARNING Accidental Starts can cause severe injury or Before working on engine or equipment disable engine as death follows 1 Disconnect spark plug lead s 2 Disconnect Disconnect and ground spark plug lead s NEC AES EEE MODS 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 MAINTENANCE SCHEDULE After first 5 Hours e Change oil Lubrication System Every 50 Hours or Annually e Service replace Quad Clean precleaner Air Cleaner Intake Every 100 Hours or Annually e Clean low profile air cleaner element Air Cleaner Intake e Change oil Lubrication System e Clean cooling areas Air Cleaner Intake Every 200 Hours e Replace Quad Clean air cleaner element Air Cleaner
53. e Enlarged View Spark Plug Boot Flywheel G Spark Pug S ES Spark Plug Terminal J Kill Terminal These engines are equipped with a dependable magneto breakerless ignition In such a system electrical energy is generated by cutting of magnetic flux lines generated from ignition magnet on engine flywheel via prescribed air gap as it passes ignition module This energy is transferred through ignition module laminations and is then converted in module electronics and stored in module primary coil as a current Stored energy is transferred at correct moment by triggering a semiconductor switch inside module Electrical break by switch initiates energy transfer by causing collapse of magnetic field at coil primary This includes a voltage at coil primary that is amplified via transformer action at coil secondary Amplitude of voltage at coil secondary is sufficient to jump gap at spark plug igniting fuel air mixture in gap and initiating combustion Note that by design these modules only will provide proper function if mounted in correct orientation This ignition system is designed to be trouble free for life of engine Other than periodically checking replacing spark plugs no maintenance or timing adjustments are necessary or possible Mechanical systems do occasionally fail or break down Refer to Troubleshooting to determine root of a reported problem Reported ignition problems are most often due to poor conn
54. e Remove module Remove Flywheel NOTE Whenever possible an impact wrench should be used to loosen flywheel retaining nut A flywheel strap wrench may be used to hold flywheel when loosening or tightening flywheel retaining nut NOTE Always use a puller to remove flywheel from crankshaft Do not strike flywheel or crankshaft as these parts could become cracked or damaged 1 Remove flywheel retaining nut 2 Remove drive cup and fan from flywheel 3 Remove screw and shield CH260 and CH270 only on right side of flywheel required for use of puller in next step 4 Remove flywheel from crankshaft using a suitable puller 5 Remove flywheel key from crankshaft keyway Inspection Inspect flywheel for cracks and flywheel keyway for damage Replace flywheel if it is cracked Replace flywheel crankshaft and key if flywheel key is sheared or keyway is damaged Remove Stator if equipped 1 Remove screw securing stator wire bracket and remove bracket 2 Remove screws securing stator to crankcase KohlerEngines com 61 Disassembly Inspection and Service CH260 CH270 Crankshaft Camshaft Closure Plate Components Closure Plate Closure Plate Bearing D Camshaft t pn pen m Governor Washer D Governor Shaft O Governor Gear P Oil A Tappet Oil Sentry Wire Ss Crankcase Bearing Governor Cross Shaft Crankcase Oil Seal 62 KohlerEngines com 17 690 01 Rev H Disassembly Inspection and Service C
55. e Uses Excessive Amount of Oil e Loose or improperly torqued fasteners e Blown head gasket overheated e Breather reed broken e Clogged broken or inoperative crankcase breather e Crankcase overfilled e Incorrect oil viscosity type e Worn cylinder bore e Worn or broken piston rings e Worn valve stems valve guides Oil Leaks from Oil Seals Gaskets e Breather reed broken Loose or improperly torqued fasteners Piston blow by or leaky valves Restricted exhaust Clogged broken or inoperative crankcase breather EXTERNAL ENGINE INSPECTION NOTE It is good practice to drain oil at a location away from workbench Be sure to allow ample time for complete drainage Before cleaning or disassembling engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside engines and cause when it is disassembled e Check for buildup of dirt and debris on crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas can cause overheating e Check for obvious fuel and oil leaks and damaged components Excessive oil leakage can indicate a clogged or inoperative breather worn or damaged seals or gaskets or loose fasteners e Check air cleaner cover and base for damage or indications of improper fit and seal e Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage
56. e in 2 increments First to 12 N m First to 18 N m 159 in Ib 106 in Ib Finally to 36 N m 319 in Ib Finally to 24 Nm Electric Starter Mounting Screw 24 N m 212 in lb Electric Starter Drive CH440 Type ll Starter 5 8 N m 51 in Ib Assembly Screw 5 mm r ee Brush Lead Connector Wire Screw 4 mm eo o ERU E 1 7 N m 15 in Ib Electric Starter Relay Solenoid CH395 CH440 Mounting Screw DEEP QN 3 2 N m 28 in Ib Nut 4 5 N m 40 in Ib Flywheel Retaining Nut 7 4 N m 113 N m 1000 in Ib 655 in Ib Fuel Tank Mounting Nut 24 N m 212 in lb Mounting Screw 24 N m 212 in lb Inlet Fitting 1 5 Nm 13 in Ib Governor Electronic Electronic Governor Control to Crankcase 24 N m 212 in lb Governor Mechanical 12 N m 106 in Ib Throttle Control Lever Nut 9 N m 80 in Ib Ignition Muffler Exhaust Screw M8 M10 Muffler Shield Screw M6 24 N m 212 in Ib ee 35 Nm 310 in Ib 8 N m 71 in Ib 2 Num 18 in Ib 3 5 N m 31 in Ib Spark Arrestor Screw M5 3 5 N m 31 in Ib Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly 12 KohlerEngines com 17 690 01 Rev H Specifications TORQUE SPECIFICATIONS CH260 CH270 CH395 CH440 Retractable Starter 5 4 N m 48 in Ib 10 N m 89 in Ib Rocker Arm 13 6 N m 120 in Ib Pivot Jam Nut 10 N m 89 in Ib
57. e of each stone positioned even with lowest edge of bore start drill and honing process Move hone up and down while resizing to prevent formation of cutting ridges Check size frequently 3 When bore is within 0 064 mm 0 0025 in of desired size remove coarse stones and replace them with burnishing stones Continue with burnishing stones until bore is within 0 013 mm 0 0005 in of desired size and then use finish stones 220 280 grit and polish bore to its final size A crosshatch should be observed if honing is done correctly Crosshatch should intersect at approximately 23 33 off horizontal Too flat an angle could cause rings to skip and wear excessively and too steep an angle will result in high oil consumption 4 After resizing check bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements These measurements should be taken at 3 locations in cylinder at top middle and bottom Two measurements should be taken perpendicular to each other at each location 68 KohlerEngines com Clean Cylinder Bore After Honing Proper cleaning of cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in cylinder bore can destroy an engine in less than one hour of operation after a rebuild Final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent ca
58. eather assembly is inside valve cover 2 Loosen and remove rocker arm lock and adjuster nuts Remove rocker arms and push rods 3 Remove spark plug Remove screws securing cylinder head 5 Remove cylinder head dowel pins and cylinder head gasket P Breather System Breather system is designed to control amount of oil in head area and still maintain necessary vacuum in crankcase When pistons move downward crankcase gases are pushed past reed through mesh filter into intake system Upward travel of pistons closes reed and creates a low vacuum in lower crankcase Any oil separated out through filter drains back into crankcase Remove Valves NOTE Mark locations of any part removed being reused 1 Supporting head of valve from below depress valve keeper and valve spring until keeper can be released from valve stem Remove valve spring and valve from head Repeat this procedure for remaining valve 2 Remove and replace valve stem seals whenever cylinder head is serviced or disassembled Inspection and Service After cleaning check flatness of cylinder head and corresponding top surface of crankcase using a surface plate or piece of glass and feeler gauge Maximum allowable out of flatness is 0 1 mm 0 0039 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
59. ections Before beginning test procedure check all external wiring Be certain all ignition related wires are connected including spark plug leads Be certain all terminal connections fit snugly Make sure ignition switch is in run position KohlerEngines com 41 Electrical System Electronic Ignition Systems and Oil Sentry Tests 1 Disconnect cap from spark plug and attach it to 5 Set an ohmmeter to Rx1 scale and zero meter terminal end of spark tester Attach tester spring clip Connect one ohmmeter lead to Oil Sentry float to a good ground not to spark plug Turn ignition key switch lead yellow with green sleeve and touch switch ON and crank engine while observing firing other lead to a bare spot on crankcase ground tip of tester Drain oil from crankcase and repeat test With oil at proper level no continuity should have aan Ara been indicated After oil was drained continuity Tester is firing Ignition system is good should have been indicated No continuity indicated Remove closure plate Install anew spark plug and try to start engine If it still will not start check other possible causes fuel compression etc Tester doesn t fire Go to step 2 from engine and remove float switch for further testing steps 5a and 5b 2 On electric start engines remove starter cover a If continuity was indicated with and without oil panel Locate black white kill lead coming from above check if insulati
60. emove float pin and inlet needle Seat for inlet needle is not serviceable and should not be removed 4 Clean carburetor bowl and inlet seat areas as required 5 Carefully remove main jet from carburetor After main jet is removed main nozzles can be removed through bottom of main towers Note orientation direction of nozzles End with 2 raised shoulders should be out down adjacent to main jets 6 Save parts for cleaning and reuse unless a jet kit is also being installed Clean slow jets using compressed air or carburetor cleaner do not use wire NOTE There are 2 O rings on body of idle jet Carburetor is now disassembled for appropriate cleaning and installation of parts in overhaul kit See instructions provided with repair kits for more detailed information High Altitude Operation Engines may require a high altitude carburetor kit to ensure correct engine operation at altitudes above 1219 meters 4000 ft To obtain high altitude kit information or to find a Kohler authorized dealer visit KohlerEngines com or call1 800 544 2444 U S and Canada This engine should be operated in its original configuration below 1219 meters 4000 ft as damage may occur if high altitude carburetor kit is installed and operated below 1219 meters 4000 ft KohlerEngines com 29 Governor System GOVERNOR These engines are equipped with an electronic governor or a mechanical governor ELECTRONIC GOVERNOR Components
61. emoved in step 2 to secure N O When engine starts hard or turns over but will not start fuel system might be causing problems Test fuel system by performing following test 1 Check for fuel in combustion chamber a Disconnect and ground spark plug lead b Close choke on carburetor c Crank engine several times d Remove spark plug and check for fuel at tip 2 Check for fuel flow from tank to carburetor a Remove fuel line from inlet fitting of carburetor Condition Fuel at tip of spark plug No fuel at tip of spark plug b Use an approved fuel container to catch fuel and hold line below bottom of tank to observe fuel flow 3 Check operation of fuel shut off valve a Remove fuel sediment bowl under inlet fitting of carburetor b Turn fuel shut off valve ON and OFF and observe operation Conclusion Fuel is reaching combustion chamber Check fuel flow from fuel tank step 2 No fuel flow from fuel line Check fuel tank vent in line filter threaded into tank and fuel line Correct any observed problem and reconnect line Check for dirt and water in sediment bowl and screen Fuel flows from fuel line Check operation of fuel shut off valve step 3 Fuel flows from valve Clean bowl and screen as needed Check for faulty carburetor refer to Carburetor No fuel flows from valve Check for a restriction in fuel shut off valve or inlet elbow 26 KohlerEngines com 17 690 01 Rev H Fuel System
62. ened securely 6 Make sure ignition system governor system exhaust system and throttle and choke controls are operating properly 9 A FuelShut Off B WaveWasher SO Ignition if equipped Adjusting Screw EI ideJet___ F Fuel Shut Off Gasket G Main Nozzle Tube H MainJet I BowlGaske J Fuellnlet Needle K Spring L HigePin M Float N FuelBow Bowl Retaining Screw m 17 690 01 Rev H KohlerEngines com 2f Fuel System Troubleshooting Carburetor Related Causes Condition Possible Cause Conclusion Engine starts hard runs rough or Low idle fuel mixture some models Adjust idle speed screw or clean stalls at idle speed speed improperly adjusted carburetor Engine runs rich indicated by Clogged air cleaner Clean or replace air cleaner black sooty exhaust smoke Choke partially closed during Check choke lever linkage to ensure misfiring loss of speed and power operation choke is operating properly Dirt under fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vent or air bleeds plugged Clean vent ports and air bleeds Blow out all passages with compressed air Leaky cracked or damaged float Submerge float to check for leaks governor hunting or excessive throttle opening Engine runs lean indicated by Intake air leak misfiring loss of speed and power governor hunting or excessive thrott
63. ent NOTE E15 E20 and E85 are NOT approved and should NOT be used effects of old stale or contaminated fuel are not warrantable Fuel must meet these requirements e Clean fresh unleaded gasoline e Octane rating of 87 R M 2 or higher e Research Octane Number RON 90 octane minimum e Gasoline up to 10 ethyl alcohol 90 unleaded is acceptable e Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blend max 15 MTBE by volume are approved e Do not add oil to gasoline e Do not overfill fuel tank e Do not use gasoline older than 30 days KohlerEngines com STORAGE If engine will be out of service for 2 months or more follow procedure below of API American Petroleum Institute service class SJ 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 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 Disconnect negative battery cable Store engine in a clean dry place 17 690 01 Rev H CH260 CH270 Engine Dimensions GAS CAP REMOVAL 106 00 AIR CLEANER 12 50 4 173 COVER REMOVAL 0 492 d cr Ou MOOD SEO 58 75 2 313 322 25 STRAIGHT PTO 12 687 163 28 155 03 6 428 6 104 88 23
64. ent available Design Technology Inc Adapter 12 mm x 14 mm Required for leakdown test on XT 6 engines DTI 731 03 Dealer Tool Kit Domestic Kohler 25 761 39 S Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Kohler 25 455 01 S Cylinder Leakdown Tester Kohler 25 761 05 S Oil Pressure Test Kit Kohler 25 761 06 S Rectifier Regulator Tester 120 V AC 60Hz Kohler 25 761 20 S Dealer Tool Kit International Kohler 25 761 42 S Complete kit of Kohler required tools Components of 25 761 42 S Ignition System Tester Kohler 25 455 01 S Cylinder Leakdown Tester Kohler 25 761 05 S Oil Pressure Test Kit Kohler 25 761 06 S Rectifier Regulator Tester 240 V AC 50Hz Kohler 25 761 41 S Digital Vacuum Pressure Tester Design Technology Inc For checking crankcase vacuum DTI 721 01 Individual component available Design Technology Inc Rubber Adapter Plug DTI 721 10 Electronic Fuel Injection EFI Diagnostic Software Kohler 25 761 23 S For Laptop or Desktop PC EFI Service Kit Kohler 24 761 01 S For troubleshooting and setting up an EFI engine Components of 24 761 01 S Design Technology Inc Fuel Pressure Tester DTI 019 Noid Light DTI 021 90 Adapter DTI 023 In line T Fitting DTI 035 Code Plug Red Wire DTI 027 Code Plug Blue Wire DTI 029 Shrader Valve Adapter Hose DTI 037 Flywheel Puller SE Tools KLR 82408 For properly removing flywheel from engine 18 KohlerEngines com 17 690 01 Rev H Tools a
65. in B Valve Length 63 3 63 9 mm 2 4921 2 5157 63 3 63 9 mm 2 4921 2 5157 Stem Diameter 5 5 mm 0 217 in 5 438 mm 0 214 in D Face Seat Width Maximum 2 0 mm 0 079 in 2 0 mm 0 079 in E Face Seat Angle 89 5 90 5 89 5 90 5 CH395 Valve Specifications A Head Diameter 30 875 31 125 mm 26 875 27 125 mm 1 2156 1 2254 in 1 0581 1 0679 in Valve Length 85 34 85 54 mm 85 19 84 99 mm 3 3598 3 3677 in 3 3461 3 3539 in C Stem Diameter 6 560 6 575 mm 6 560 6 575 mm 0 2583 0 2589 in 0 2583 0 2589 in D Face Seat Width Maximum 1 5 mm 0 059 in 1 5 mm 0 059 in E Face Seat Angle 89 5 90 5 89 5 90 5 CH440 Valve Specifications A Head Diameter 35 875 36 125 mm 32 875 33 125 mm 1 4124 1 4222 in 1 2943 1 3041 in Valve Length 86 175 86 375 mm 86 341 86 541 mm 3 3927 3 4006 in 3 3993 3 4071 in C Stem Diameter 6 560 6 575 mm 6 545 6 560 mm 0 2583 0 2589 in 0 2577 0 2583 in D Face Seat Width Maximum 1 5 mm 0 059 in 1 5 mm 0 059 in E Face Seat Angle 89 5 90 5 89 5 90 5 60 KohlerEngines com 17 690 01 Rev H CH260 CH270 Flywheel Ignition Components A Nut Ignition Module A Flywheel Fan D Ignition Module E Flywheel F Stator G Flywheel Shield 17 690 01 Rev H Disassembly Inspection and Service Remove Ignition Module Remove screws securing ignition module to crankcas
66. istance which could keep engine from starting Check for seized engine components such as bearings connecting rod and piston Electric Starting System Tests 1 Test battery on unit 2 Remove electric starter cover panel and check fuse a Connect a DC voltmeter across battery terminals inside plastic holder Fuse outside holder is a spare to b Turn key switch to start position and read battery voltage again Turn switch OFF Pues DOWN See E Ge and replace fuse Try to Voltage less than 12 volts Charge battery start engine If it still won t start go to step 3 Battery voltage should not If it does battery may be fall below 9 volts during faulty or there may be a 3 cranking short in starting circuit Have battery load tested If battery passes load test check circuitry Disconnect blue relay lead Be sure transmission is in neutral and PTO is OFF Connect one end of a jumper lead to positive terminal of battery Connect other end to terminal of relay Relay engages and starter Key switch is faulty or begins to crank there is a wiring problem to from key switch Check wiring and test key switch circuits with an onmmeter 17 690 01 Rev H KohlerEngines com 47 Starter System A Use a known good fully charged battery and INERTIA DRIVE ELECTRIC STARTERS w jumper cables to test starter motor Be sure transmission is in neutral and PTO is OFF Remove heavy lead from post terminal
67. it off shaft 2 If governor gear shaft is bent or damaged remove it by pulling straight out 3 Remove hitch pin and washer from governor cross shaft 4 Remove cross shaft from inside crankcase Inspection Inspect governor gear teeth Replace gear if it is worn chipped or if any teeth are missing Inspect governor weights They should move freely in governor gear 17 690 01 Rev H Disassembly Inspection and Service Remove Crankcase and Closure Plate Seals and Bearings NOTE Inspect bearings for signs of wear by rotating inner race and examine for marring or cracks Check to make sure race moves easily and is not sloppy If bearing is tight and rotates smoothly removal is not necessary If you feel any roughness or chattering or bearing is sloppy it should be replaced 1 Remove oil seal from crankcase 2 Using a suitable press push crankshaft bearing from crankcase 3 Remove oil seal from closure plate 4 Using a suitable press push crankshaft bearing from closure plate Crankcase Inspection and Service Cylinder Bore Detail NOTE A0 25 mm 0 010 in oversize piston is available if resizing is selected Initially resize using a boring bar then follow procedures for honing cylinder Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Check cylinder bore for scoring In severe cases unburned fuel can cause s
68. ked in oil If wear limits are exceeded as stated in Specifications it will be necessary to replace crankshaft Remove Oil Sentry System 1 Remove nut securing Oil Sentry lead wire grommet assembly in crankcase 2 Pull grommet assembly from inside of crankcase 3 Remove screws securing Oil Sentry float switch to crankcase Remove float switch assembly Remove Governor Assembly Mechanical Governor Only CH260 CH270 NOTE Mark orientation of all parts as governor assembly is removed 1 Remove cup and washer from governor gear 2 Using a suitable drift drive governor gear shaft from crankcase 3 Remove hitch pin and washer from governor cross shaft 4 Remove cross shaft from inside crankcase CH395 NOTE Governor gear shaft is pressed into closure plate and should not be removed NOTE Take note of orientation of governor gear components 1 Governor gear is located in closure plate To remove governor gear pull governor gear off shaft 2 Remove hitch pin and washer from governor cross shaft 3 Remove cross shaft from inside crankcase CH440 NOTE Do not pry on gasket surface of closure plate as this can cause damage and leakage NOTE Take note of orientation of governor gear components NOTE Governor gear shaft is pressed into closure plate and should not be removed unless damaged 1 Governor gear is located in closure plate To remove governor gear pry underneath gear to lift
69. le opening Check if carburetor is loose or one of intake gaskets is leaking Idle holes plugged dirt in fuel delivery Clean main fuel jet and all passages channels blow out with compressed air Float damaged Submerge float to check for leaks Replace float Dirt under fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vents plugged Blow out with compressed air Carburetor bowl gasket leaks Replace gasket Fuel leaks from carburetor Carburetor Circuits Float Fuel level in bowl is maintained by float and fuel inlet needle Buoyant force of float stops fuel flow when engine is at rest When fuel is being consumed float will drop and fuel pressure will push inlet needle away from seat allowing more fuel to enter bowl When demand ceases buoyant force of float will again overcome fuel pressure rising to predetermined setting and stop flow Slow and Mid Range At low speeds engine operates only on slow circuit As a metered amount of air is drawn through slow air bleed jets fuel is drawn through main jet and further metered through slow jet Air and fuel are mixed in body of slow jet and exit to idle progression transfer port chamber From idle progression chamber air fuel mixture is metered through idle port passage At low idle air fuel mixture is controlled by setting of idle fuel adjusting screws This mixture is then mixed with main body of air and delivered to engine
70. lerEngines com 17 690 01 Rev H
71. m 32 If resistance value higher or infinity Ohms If resistance value is OK Remove stepper motor and retest See page 37 for disassembly and reassembly instructions Rotate carburetor throttle shaft to check for smooth and consistent travel Does it catch or bind Continued on next page Replace carburetor assembly and retest Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control system KohlerEngines com 17 690 01 Rev H Governor System Electronic Governor Troubleshooting Flow Chart Continued Continued from previous page Manually attempt to rotate stepper motor in both directions e Reconnect connector with stepper motor removed e Start engine in normal manner as described in Owner s Manual Does stepper motor run clockwise Replace electronic governor control and retest Reassemble stepper motor Retest engine OK OK YES YES Test control system of equipment Refer to Equipment Manufacturer s diagnostic Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control system procedures for control system 17 690 01 Rev H KohlerEngines com 33 Governor System Electronic Governor Troubleshooting Flow Chart Continued Engine starts but does not keep running Inspect wiring harness for any broken or bad connections Terminal K10
72. mm 3 5 in 54 mm 2 1 in 58mm 2 3in 69 mm 2 7 in Displacement 208 cc 277 cc 429 cc 12 7 cu in 16 9 cu in 26 2 Cu in Oil Capacity refill 0 6L 1 1L 1 9 1 0 63 U S qt 1 16 U S qt 1 37 U S qt Maximum Angle of Operation full oil level TORQUE SPECIFICATIONS CH260 CH270 CH395 CH440 Air Cleaner Quad Clean Air Cleaner Base Mounting Screw 8 0 N m 71 in Ib Low Profile Air Cleaner Base Mounting Screw 6 7 N m 59 in Ib Blower Housing and Sheet Metal 10 N m 89 in Ib M6 Nut 8 0 N m 71 in Ib Carburetor Stud 10 N m 89 in Ib Primary Nut 8 Nm 71 in Ib Intake Cover Nut 4 N m 35 in Ib Intake Cover Screw 1 3 Nm 12 in Ib Connecting Rod Cap Fastener torque in increments 12 Nm 20 Nm 177 in lb 106 in Ib Values are in Metric units Values in parentheses are English equivalents Exceeding maximum angle of operation may cause engine damage from insufficient lubrication Lubricate threads with engine oil prior to assembly 2 Any and all horsepower hp references by Kohler are Certified Power Ratings and per SAE J1940 amp J1995 hp standards Details on Certified Power Ratings can be found at KohlerEngines com 17 690 01 Rev H KohlerEngines com 11 Specifications TORQUE SPECIFICATIONS CH260 CH270 CH395 CH440 Crankcase Oil Drain Plug 18 N m 13 ft Ib Closure Plate Screw 24 N m 212 in lb Cylinder Head Fastener torqu
73. n Ib Install Balance Shaft if equipped 1 Position crankshaft so timing mark on larger crankgear is in 8 o clock position 2 Install balance shaft aligning timing mark with timing mark on larger crankgear Install Valve Tappets and Camshaft 1 Lubricate face and stem of each tappet with engine oil Install each into their respective bores 2 Lubricate camshaft bearing surfaces and cam lobes as well as camshaft bore in crankcase with engine oil 3 Rotate crankshaft to TDC so timing mark dimple on smaller crankgear is in 4 o clock position Install camshaft into crankcase aligning timing marks on two gears 4 Install original shims on crankshaft and camshaft Install Closure Plate CH260 CH270 Torque Sequence KohlerEngines com 13 Reassembly CH395 CH440 Flywheel Ignition Components o E Flywheel Retainin NOTE Make sure governor lever is against cup on Nut B DriveCup overnor gear assembly AM e i Flywheel Fan D Ignition Module 1 Check to make sure sealing surfaces of crankcase and closure plate are clean and free of nicks burrs E Flywheel EI Stator 2 Install two dowel pins into locations shown in G Flywheel Shield H Torque Sequence crankcase Install new closure plate gasket dry onto dowel pins 3 Install closure plate to crankcase Carefully seat ends of camshaft and balance shaft into their mating bearings Rotate crankshaft slightly to help engage In
74. n Module 7 Rotate flywheel back and forth checking to make NOTE Ensure ignition module is correctly oriented sure magnet does not strike module TA vane Cover JE Push Rod Guide F Push Rod Valve Stem Seal Spark Plug 17 690 01 Rev H where ignition module will be installed l Cylinder Head METIO e x terminal and route wire lead to top of crankcase Rocker Arm D Rocker Arm Stud Valve Keeper H Valve Spring KohlerEngines com 19 Reassembly Assemble Cylinder Head NOTE Engine utilizes valve stem seals on valves Always use a new Seal when valves are installed in cylinder head Never reuse old seals 1 Install valves into their respective positions 2 Install new valve seals on stem of valves 3 Install valve springs and retainers into their respective locations in cylinder head Support valve heads from underneath Using hand pressure compress each valve spring and slide each retainer onto valve stem to lock in place Install Cylinder Head 1 Check to make sure there are no nicks or burrs on sealing surfaces of cylinder head or crankcase 2 Rotate crankshaft to position piston at TDC on compression stroke 3 Install dowel pins into recesses around lower cylinder head bolt holes 4 Install a new cylinder head gasket o Install cylinder head and start screws Torque screws in increments using sequence shown Torque screws following table Model Initial Torq
75. nd Aids TOOLS Description Source Part No Hydraulic Valve Lifter Tool Kohler 25 761 38 S For removing and installing hydraulic lifters Ignition System Tester Kohler 25 455 01 S For testing output on all systems including CD Inductive Tachometer Digital Design GER Inc For checking operating speed RPM of an engine Offset Wrench K and M Series m E 04 5 For removing and reinstalling ide barrel retaining nuts Oil Pressure Test Kit Kohler 25 761 06 S For testing verifying oil pressure on pressure lubricated engines Rectifier Regulator Tester 120 volt current Kohler 25 761 20 S Rectifier Regulator Tester 240 volt current Kohler 25 761 41 S For testing rectifier regulators Components of 25 761 20 S and 25 761 41 S Design Technology Inc CS PRO Regulator Test Harness DTI 031 Special Regulator Test Harness with Diode DTI 033 Spark Advance Module SAM Tester Kohler 25 761 40 S For testing SAM ASAM and DSAM on engines with SMART SPARK Starter Servicing Kit All Starters SE Tools KLR 824 11 For removing and reinstalling drive retaining rings and brushes Individual component available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82416 Triad OHC Timing Tool Set Kohler 28 761 01 S For holding cam gears and crankshaft in timed position while installing timing belt Valve Guide Reamer K and M Series Design Technology Inc For properly sizing valve guides after installation DTI K828 Valve Guide Reamer O
76. nd hold in this position Turn governor shaft counterclockwise until it stops Tighten nut on go mior lever clamp bolt to lock lever on shaft orque nut to 12 N m 106 in Ib 4 Install spring on governor and throttle levers in holes LEN marked in disassembly Install throttle ever and a fender washer on threaded stud of fuel tank bracket o Install a nylon washer wave spring and tabbed washer with tab engaged in slot on stud above throttle lever and secure with nut Torque nut to 9 N m 80 in Ib 17 690 01 Rev H Reassembly CH260 CH270 Governor Lever Hole Position RPM CH440 Governor Lever Hole Position RPM Chart Ch j 6 12 Droo 3 6 Droo Engine 8 12 Droop 5 8 Droop E i p 2 p Speed S Hol S Hol p Spring Hole Spring Hole BM an RPM Color Combination Color Combination aa Ee 3801 4000 None 28 3801 4000 3 A 3601 3800 None 42B White 42A 3601 3800 Red 3 A Yellow 2A res REALEN BA onsen Nome 8 2801 3001 White sa CH395 Governor Lever Hole Position RPM Chart Engine Speed Spine Hole Spring Hole ul 3801 4000 Yellow 428 J 3601 3800 Yelow ep Pupie MA 3401 3600 Yellow 428 3201 3400 Yellow op II 2801 3001 Yetow ap 17 690 01 Rev H KohlerEngines com 81 Reassembly External Engine Components Le RN E Wh Je 1297 19227 L MU AB LN Ge E TA S UA S d N HO
77. ne using abrasive grit Some grit could remain in spark plug and enter engine causing extensive wear and damage Engine misfire or starting problems are often caused by a spark plug that has improper gap or is in poor condition Engine is equipped with following spark plugs 0 76 mm 0 03 in Thread Size 19 1 mm 3 4 in 15 9 mm 5 8 in Refer to Maintenance for Repairs Service Parts Service Clean out spark plug recess Remove plug and replace 1 Check gap using wire feeler gauge Adjust gap to 0 76 mm 0 03 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft Ib 40 KohlerEngines com Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip are an indication of general condition of piston rings valves and carburetor Normal and fouled plugs are shown in following photos Normal Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits If center electrode is not worn plug can be set to proper gap and reused Worn u m ia dii a On a worn plug center electrode will be rounded and gap will be greater than specified gap Replace a worn spark plug immediately Wet Fouled A wet plug is caused by excess fuel or oil in combustion chamber Excess fuel could be caused by a restricted air cleaner a carburetor problem or operating engine with too much choke Oil in combustion ch
78. ngine is rotating at low cranking speeds arm holds pin so it protrudes above heel of exhaust cam This holds exhaust valve off of its seat during first part of compression stroke After engine speed increases centrifugal force causes spring loaded arm to move outward causing pin to retract When in this position pin has no effect on exhaust valve and engine operates at full compression and power Benefits As a result of reduced compression at cranking speeds several important benefits are obtained 1 Manual retractable starting is much easier Without ACR manual starting would be virtually impossible 2 Electric start models can use a smaller starter and battery more practical for application 3 ACR eliminates need for a spark retard advance mechanism A spark retard advance mechanism would be required on engines without ACR to prevent kickback which would occur during starting ACR eliminates this kickback making manual starting safer 4 Choke control setting is less critical with ACR In event of flooding excess fuel is blown out opened exhaust valve and does not hamper starting 5 Engines with ACR start much faster in cold weather than engines without ACR 6 Engines with ACR can be started with worn or fouled spark plugs Engines without ACR are more difficult to start with those same spark plugs Inspection and Service Dimension A CH260 CH270 Cam Lobe 27 787 mm 2 533 mm INTAKE 1 094 in 1 084 in
79. nnect plug and remove two mounting screws Rectifier regulator converts AC voltage coming from stator to DC voltage while also monitoring and controlling battery voltage There are two different rectifier regulators which are used an 18 amp and a 10 amp assembly Although externally similar internal circuits differ and two should not be interchanged KohlerEngines com 43 Electrical System Rectified Only non regulated Systems Some engines are equipped with a rectified only non regulated charging system with output ranging from 3 amps to 4 amps Rectifier is normally connected to engine with a matching wiring harness and secured inside control panel Grounding is achieved through wiring harness Rectifier converts AC voltage coming from stator to DC voltage only Wiring Diagram 3 4 Amp Charging System Rectified Only AT Doe e ser o EI OilFloatSwith F Oil Control Module G Key Switch I Relay J BatteryFuse K 12 Volt Battery Ignition Module D Spark Plug H Starter Motor 44 KohlerEngines com 17 690 01 Rev H 3 4 10 18 Amp Battery Charging Systems NOTE Zero ohmmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3600 RPM no load Battery must be fully charged Check specific gravity of battery If low recharge or replace battery as necessary To test charging system for no charge to battery 1 Separate bullet connector in white lead from rectifier
80. ns Always use new piston rings when installing pistons Never use old rings Some important points to remember when servicing piston rings 1 Cylinder bore must be deglazed before service ring sets are used 2 If cylinder bore does not need reboring and if old piston is within wear limits and free of score or scuff marks old piston may be reused 3 Remove old rings and clean up grooves Never reuse old rings 4 Before installing new rings on piston place top 2 rings each in turn in its running area in cylinder bore and check end gap Refer to Specifications 5 After installing new compression top and middle rings on piston check piston to ring side clearance Refer to Specifications If side clearance is greater than specified a new piston must be used Install New Piston Rings A Top Compression Middle Compression Ring Ring Oil Control Ring D Top Rail E Expander Ring F Bottom Rail 66 KohlerEngines com Piston Ring Orientation Bottom Oil Rail Gap Top Oil Rail Gap 2nd Ring Gap C Oil Ring Expander Gap E Top Ring Gap NOTE Rings must be installed correctly Install bottom oil control ring first and top compression ring last Use a piston ring expander to install rings 1 Oil control ring bottom groove Install expander and then rails Make sure ends of expander are not overlapped 2 Middle compression ring center groove Install center ring using a pi
81. nting studs 7 Loosely install nuts on studs to temporarily hold carburetor on engine Remove Low Profile Air Cleaner Base Remove air cleaner base from engine as follows 1 Remove screw and nuts securing air cleaner base to carburetor 2 Disconnect one end of breather hose from valve cover or air cleaner base 3 Remove base 4 Remove air cleaner base gasket from mounting studs 5 Loosely install nuts on studs to temporarily hold carburetor on engine Remove Fuel Tank if equipped NOTE If no fuel tank is equipped loosen clamp and disconnect fuel line from inlet of carburetor 1 Ensure fuel tank is empty 2 Loosen clamp and disconnect fuel line from inlet of shut off valve 3 Remove screws and nuts securing fuel tank to engine brackets and remove tank from engine KohlerEngines com 93 Disassembly Inspection and Service CH260 CH270 Blower Housing Control Panel Components ey D Carburetor H Hex Flange Nut Lower Shield Governor Lever K Upper Shield ES Blower Housing Throttle Linkage Throttle Lever LE EM v O O c o Clete S ajz D O G LUS el Ee ei Cl E Oo amp O Sio G gt S E 6 oO 4 cao 17 690 01 Rev H KohlerEngines com 54 Disassembly Inspection and Service CH395 CH440 Blower Housing Control Panel Components D Electric Starter CH Throttle Lever Dampening Spring Throttle Linkage Lower Shield Fuel Bracket
82. ntrifugal force acting on rotating governor gear assembly causes flyweights to move outward as speed increases Governor spring tension moves them inward as speed decreases e As flyweights move outward they cause regulating pin to move outward e Regulating pin contacts tab on cross shaft causing shaft to rotate e One end of cross shaft protrudes through crankcase Rotating action of cross shaft is transmitted to throttle lever of carburetor through external throttle linkage 38 KohlerEngines com e When engine is at rest and throttle is in fast position tension of governor spring holds throttle plate open When engine is operating governor gear assembly is rotating Force applied by regulating pin against cross shaft tends to close throttle plate Governor spring tension and force applied by regulating pin balance each other during operation to maintain engine speed When load is applied and engine speed and governor gear speed decreases governor spring tension moves governor arm to open throttle plate wider This allows more fuel into engine increasing engine speed As speed reaches governed setting governor spring tension and force applied by regulating pin will again offset each other to hold a steady engine speed Governor Adjustments NOTE Make sure carburetor is mounted and secured in place when adjustment is being made checked Initial Adjustment Procedure Make this initial adjustment whenever governor lever
83. on YES Is there smooth and consistent travel next page REMOVE PSP page d ei Rotate carburetor throttle shaft to check for smooth and disassembly and reassembly instructions consistent travel Replace carburetor Manually Does it catch or bind attempt to assembly and retest rotate stepper motor in both directions Replace stepper motor and YES retest See page 37 for YES disassembly and reassembly instructions Does it catch or bind Replace carburetor assembly and retest Hes Test control system of equipment Refer to Equipment Manufacturer s OK diagnostic procedures for control system OK YES Test control system Test control system of equipment of equipment Refer to Equipment Refer to Equipment Manufacturer s diagnostic Manufacturer s procedures for control diagnostic procedures system for control system 17 690 01 Rev H KohlerEngines com 31 Governor System Electronic Governor Troubleshooting Flow Chart Continued Continued from previous page Disconnect connector between stepper motor and wiring harness Perform resistance test between orange and pink wires and then from yellow to blue wires Resistance should measure at 25 Ohms 5 Replace stepper motor and retest See page 3 7 for disassembly and reassembly instructions Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control syste
84. on has been scraped off ignition module inside blower housing Disconnect float switch lead Switch continuity should If not replace it be as indicated Spark is now present Check for a shorted lead b With float switch removed connect one Still no spark Go to step 3 ohmmeter lead to float switch lead terminal and 3 Disconnect bullet connector where Oil Sentry inverted Repeat test 2 or 3 times in each control module step 4 and ignition module step 6 terminal and connect other lead into spark plug cap bullet connector where kill lead plugs into harness Repeat spark test step 1 in kill circuit or a faulty connect other lead to mounting bracket Test control module joins lead from Oil Sentry float direction Spark is now present Control module or float float switch step 5 If there 6 Set an ohmmeter to Rx1K or Rx10K scale and zero a Remove cap from spark plug lead and test es Lead wire is bare Allowing it to short repair with electrical tape or replace float switch switch step 7 resistance with switch in normal position and switch yellow leads Repeat spark test again switch is faulty Test is still no spark test Connect one ohmmeter lead to kill lead black white resistance of cap alone A Set an ohmmeter to Rx1 scale and zero meter Connect black ohmmeter lead to yellow Oil Sentry b If resistances are other than specified remove control module lead and touch red ohmmeter lead
85. on starter Connect one end of positive jumper cable to post terminal and connect other end to positive terminal Accidental Starts can cause severe injury or of battery death Connect one end of negative jumper cable to Disconnect and ground spark plug lead s negative terminal of battery Touch other end of before servicing negative jumper cable to a bare surface on crankcase or to starter housing Before working on engine or equipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery Relay engages and starter Key switch is faulty or begins to crank there is a wiring problem to from key switch Check Type I Starter CH395 CH440 wiring and test key switch circuits with an ohmmeter 5 Disconnect leads from starter relay and remove it from starter for testing a Set an ohmmeter on Rx1 scale and zero meter Connect one ohmmeter lead to terminal of blue lead from relay Connect other ohmmeter lead to relay mounting bracket Meter reading less than Relay is faulty and must 3 4 ohms or an open be replaced circuit is indicated infinity ohms Round Boot on Relay Solenoid b With ohmmeter still on Rx1 scale connect leads Top of Starter is Serviced to two large post terminals Meter should indicate an open circuit infinity ohms no continuity c Leave ohmmeter leads connected to large terminals Connect a jumper lead from positive termin
86. onto tube a Remove dipstick check oil level Level should be at top of indicator on dipstick Or b Remove oil fill plug Level should be up to point of overflowing filler neck 3 If oil is low add oil up to point of overflowing filler neck 4 Reinstall dipstick or oil fill plug and tighten securely 17 690 01 Rev H CHANGE OIL Change oil while engine is warm 1 Clean area around oil fill plug dipstick and drain plug 2 Remove drain plug and oil fill plug dipstick Drain oil completely 3 Reinstall drain plug Torque to 18 N m 13 ft Ib 4 Fill crankcase with new oil up to point of overflowing filler neck 5 Reinstall oil fill plug dipstick and tighten securely 6 Dispose of used oil in accordance with local ordinances OIL SENTRY if equipped This switch is designed to prevent engine from starting in a low oil or no oil condition Oil Sentry may not shut down a running engine before damage occurs In some applications this switch may activate a warning signal Read your equipment manuals for more information For testing procedures refer to Electronic Ignition Systems and Oil Sentry Tests KohlerEngines com 39 Electrical System SPARK PLUGS A CAUTION p Electrical Shock can cause injury We Do not touch wires while engine is running Spark Plug Component and Details A WireGauge B SparkPlug Ground Electrode D Gap NOTE Do not clean spark plug in a machi
87. pable of breaking down machining oil while maintaining a good level of suds If suds break down during cleaning discard dirty water and start again with more hot water and detergent After scrubbing rinse cylinder with very hot clear water dry it completely and apply a light coating of engine oil to prevent rusting Measuring Piston to Bore Clearance Piston Details Mode Dimensiona NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer Before installing piston into cylinder bore it is necessary that clearance be accurately checked This step is often overlooked and if clearances are not within specifications engine failure will usually result Use following procedure to accurately measure piston to bore clearance 1 Usea micrometer and measure diameter of piston above bottom of piston skirt and perpendicular to piston pin 2 Use an inside micrometer telescoping gauge or bore gauge and measure cylinder bore Take measurement approximately 7 0 mm 0 2760 in below top of bore and perpendicular to piston pin 3 Piston to bore clearance is difference between bore diameter and piston diameter step 2 minus step 1 17 690 01 Rev H Reassembly CH260 CH270 Crankshaft Camshaft Closure Plate Components Closure Plate Bearing D Camshaft PistonPn H Piston open Oil Sentry Float een SER Tappet Oil Sentry
88. pawls into pawl slots of pulley All parts must by dry o Position drive plate over pawls aligning actuating slots in place with raised sections on each drive pawl Torque center screw to 5 6 N m 44 54 in Ib 6 Remove clamp and pull starter rope out part way to check operation of pawls Install Starter 1 Install retractable starter onto blower housing leaving screws slightly loose 2 Pull starter handle out until pawls engage in drive cup Hold handle in this position and tighten screws securely KohlerEngines com 51 Disassembly Inspection and Service Accidental Starts can cause severe injury or Before working on engine or equipment disable engine as death follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery Disconnect and ground spark plug lead s before servicing External Engine Components ae e Vi CH395 CH440 Oil Drain Plug D Muffler Assembly Breather Hose D Quad Clean Cover e E E Quad Clean Base Carburetor Shroud Fuel Tank CH260 CH270 Low Profile Air 52 KohlerEngines com 17 690 01 Rev H Clean all parts thoroughly as engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow manufacturer s instructions and safety precautions c
89. r B Upper Shield EA 17 690 01 Rev H Reassembly Install Fuel Tank Supports and Shut Down Switch with Bracket CH260 CH270 1 Position both tank support brackets on crankcase and loosely install with screws 2 Position shut down switch with bracket on tank bracket and install threaded stud to secure 3 Torque tank support bracket hardware to 24 N m 212 in Ib CH395 CH440 NOTE Threaded stud and bracket with shut down switch should not be removed Position both tank support brackets on crankcase and install with screws Torque to 24 N m 212 in Ib Install Carburetor 1 Install a new insulator to cylinder head gasket onto carburetor studs followed by insulator and carburetor to insulator gasket 2 Push carburetor onto studs 3 Connect throttle link and dampening spring into their respective holes in throttle lever Install Carburetor with Stepper Motor Electronic Governor Only 1 Install a new insulator to cylinder head gasket onto carburetor studs followed by insulator and carburetor with stepper motor to insulator gasket 2 Push carburetor onto studs 3 Connect wiring harness to stepper motor Install Engine Shields and Air Cleaner Base CH260 CH270 1 Install SE shield on cylinder engaging tab hole on fuel tank bracket stud 2 Install screw in rear of top air shield but do not tighten at this time 3 Install a new carburetor to air cleaner base gasket onto carburetor moun
90. r engine Remove and discard rod cap 2 Remove studs of a Posi Lock rod or grind off aligning steps of a Command rod so joint surface is flat 3 Find a 1 in long capscrew with correct thread size to match threads in connecting rod 4 Use a flat washer with correct I D to slip on capscrew and approximately 1 in O D Assemble capscrew and washer to joint surface of rod 20 KohlerEngines com 17 690 01 Rev H TROUBLESHOOTING GUIDE Troubleshooting When troubles occur be sure to check simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below and vary by engine specification Use these to locate causing factors Engine Cranks But Will Not Start Battery connected backwards Blown fuse Carburetor solenoid malfunction Choke not closing Clogged fuel line or fuel filter Diode in wiring harness failed in open circuit mode DSAI or DSAM malfunction Empty fuel tank Faulty electronic control unit Faulty ignition coil s Faulty spark plug s Fuel pump malfunction vacuum hose clogged or leaking Fuel shut off valve closed Ignition module s faulty or improperly gapped Insufficient voltage to electronic control unit Interlock switch is engaged or faulty Key switch or kill switch in OFF position Low oil level Quality of fuel dirt water stale mixture
91. r end 0 025 mm 0 001 in Main Bearing I D Crankcase Closure Plate New installed 24 992 25 000 mm 29 990 30 000 mm 34 988 35 000 mm 0 9839 0 9842 in 1 1807 1 1811 in 1 3775 1 3779 in Cylinder Bore SC I D 70 020 70 035 mm 78 000 78 015 mm 89 000 89 015 mm New 2 7570 2 7573 in 3 0709 3 0714 in 3 5039 3 5045 in Max Wear Limit 70 200 mm 78 185 mm 89 185 mm 2 764 in 3 0781 in 3 5112 in Max Out of Round 12 7 microns 0 0005 in Max Taper 12 7 microns 0 0005 in Cylinder Head Max Out of Flatness 0 08 mm 0 1 mm 0 0039 in 0 003 in Governor Mechanical Governor Cross Shaft to Crankcase Running 0 020 0 069 mm 0 0008 0 0027 in Clearance Governor Cross Shaft O D 5 955 5 980 mm 7 955 7 980 mm New 0 2344 0 2354 in 0 3132 0 3142 in Max Wear Limit 5 942 mm 7 900 mm 0 3110 in 0 2339 in Governor Gear Shaft to Governor Gear Running 0 022 0 134 mm 0 0009 0 0053 in Clearance Governor Gear Shaft O D New 6 016 6 028 mm 0 2368 0 2373 in Max Wear Limit 6 003 mm 0 2363 in Values are in Metric units Values in parentheses are English equivalents 14 KohlerEngines com 17 690 01 Rev H Specifications CLEARANCE SPECIFICATIONS CH260 CH270 CH395 CH440 Ignition Spark Plug Gap 0 76 mm 0 030 in Module Air Gap 0 254 mm 0 010 in Piston Piston Rings and Piston Pin Piston to Piston Pin Running Clearance 0 009 0 016 mm 0 002 0 016 mm 0 0001 0 0006 in
92. r lever mounting pull carburetor outward and off mounting studs Tilt carburetor and disconnect throttle link and dampening spring from throttle lever Disconnect throttle link and dampening spring from carburetor Remove carburetor carburetor gasket insulator and insulator gasket from studs Remove Carburetor with Stepper Motor Electronic Governor Only NOTE Carburetor and stepper motor should be removed as an assembly Separate carburetor and stepper motor only if additional service is required Refer to Governor System Disconnect wiring harness from stepper motor Remove carburetor with stepper motor carburetor gasket insulator and insulator gasket from studs Remove Retractable Starter Remove screws securing retractable starter to blower housing Remove starter 17 690 01 Rev H Disassembly Inspection and Service Remove Blower Housing and Shields 1 Remove screws and nuts CH260 and CH270 only securing blower housing 2 Remove blower housing 3 Remove screws securing upper shield and remove shield 4 Remove screws securing lower shield and remove shield Remove Electrical Wiring Micro Shut Down Switch and Bracket and Fuel Tank Brackets NOTE For CH395 and CH440 it is not required and not recommended to remove threaded stud and micro switch bracket 1 Disconnect wiring harness bullet connectors for Oil Sentry float switch and module Remove mounting screw securing module to fuel t
93. ry Piston blow by or leaky valves confirm by inspecting Recondition piston rings cylinder bore valves and components valves guides Restricted exhaust Check exhaust screen spark arrestor if equipped Clean or replace as needed Repair or replace any other damaged restricted muffler or exhaust system parts 17 690 01 Rev H KohlerEngines com 23 Troubleshooting COMPRESSION TEST For Command Twins A compression test is best performed on a warm engine Clean any dirt or debris away from base of spark plug s before removing them Be sure choke is off and throttle is wide open during test Compression should be at least 160 psi and should not vary more than 15 between cylinders All other models These engines are equipped with an automatic compression release ACR mechanism It is difficult to obtain an accurate compression reading because of ACR mechanism As an alternative use cylinder leakdown test described below CYLINDER LEAKDOWN TEST A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing combustion chamber from an external air source you can determine if valves or rings are leaking and how badly Cylinder leakdown tester is a relatively simple inexpensive leakdown tester for small engines This tester includes a quick connect for attaching adapter hose and a holding tool 1 Run engine for 3 5 minutes to warm it up 2 Remove spark plug s and air filter from engine
94. s IN K Blower Housing LE E A Retractable Starter Carburetor Upper Shield Governor Spring Pivot Lever N Hex Flange Nut Governor Lever 55 KohlerEngines com 17 690 01 Rev H ZA G Zug A Lower Shield Stepper Motor Blower Housing CH395 CH440 Electronic Governor Blower Housing Control Panel Components Disassembly Inspection and Service Retractable Starter B o Carburetor Electric Governor Control m Upper Shield m 17 690 01 Rev H KohlerEngines com 56 Remove External Throttle Governor and Choke Linkage Mechanical Governor Only 1 Mark which hole location governor spring is in on each side Remove nut and washer securing throttle control lever to crankcase Unhook spring and remove lever 2 Loosen nut securing governor lever to governor shaft Lift off governor lever and remove carburetor throttle link and dampening spring Remove Carburetor Explosive Fuel can cause fires and severe burns Do not fill fuel tank while 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 Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Never use gasoline as a cleaning agent NOTE To remove carburetor without disturbing governo
95. s page Y Shut off engine Disconnect lead at kill tab Test continuity at B1 and J1 Pin H See page 34 for illustration Replace ignition YES OK Repair Replace wiring harness module and AS and retest continuity retest aster of normal engine oP OMD operation 1 Replace ignition module and retest Does engine stop Replace electronic governor control and retest Confirm return of normal engine operation Confirm return of normal engine Does engine stop operation Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control system Replace electronic governor control and retest Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control system 36 KohlerEngines com 17 690 01 Rev H Governor System Stepper Motor Electronic Governor Control Stepper Motor Components Electronic Governor Control Components A Stepper Motor Cover C Stepper Motor Bracket E Stepper Motor Post CH395 B CH440 Electronic Governor chao o e emer Wiring Harness Connector Electronic Governor Control Servicing Stepper Motor Servicing Disassembly NOTE Itis not necessary to remove stepper motor base from carburetor assembly when replacing stepper motor 1 Disconnect connector between stepper motor and wiring harness Disassembly 1 Mark wire locations and remove wires from con
96. stall Stator If Equipped 1 Position stator aligning mounting holes so leads are in 3 o clock position governor gear teeth 2 Install and torque screws to 10 N m 89 in Ib in 4 Install screws securing closure plate to crankcase sequence of 1 2 3 4 and then torque 1 again Torque screws in sequence shown to 24 N m 3 Route stator leads along crankcase and out notch on 212 in Ib side CH260 CH270 Flywheel Ignition Components 4 Position bracket over stator leads and install and torque screw to 10 N m 89 in Ib A Install Flywheel Damaging Crankshaft and Flywheel can cause personal injury Using improper procedures can lead to broken fragments Broken fragments could be thrown from a 4 y Peso oec Em 2 engine Always observe and use precautions and Flywheel Fan D Ignition Module procedures when installing flywheel EI Flywheel F Stator o NOTE Before installing flywheel make sure crankshaft Flywheel Shield taper and flywheel hub bore are clean dry and CE H S x completely free of lubricants Presence of lubricants can cause flywheel to be over stressed and damaged when nut is torqued to specification NOTE Make sure flywheel key is installed properly in keyway Flywheel can become cracked or damaged if key is not installed properly NOTE CH395 CH440 has a boss on fan and a hole in drive cup 74 KohlerEngines com 17 690 01 Rev H Install woodruff key into keyway of crankshaft Make
97. ston ring expander tool Make sure identification mark is up or colored dye stripe if contained is left of end gap 3 Top compression ring top groove Install top ring using a piston ring expander tool Make sure identification mark is up or colored dye stripe if contained is to left of end gap Crankshaft Inspection and Service Inspect gear teeth of crankshaft If teeth are badly worn chipped or some are missing replacement of crankshaft will be necessary Inspect crankshaft bearing surfaces for scoring grooving etc Measure running clearance between crankshaft journals and their respective bearing bores Use an inside micrometer or telescoping gauge to measure inside diameter of both bearing bores in vertical and horizontal planes Use an outside micrometer to measure outside diameter of crankshaft main bearing journals Subtract journal diameters from their respective bore diameters to get running clearances Check results against values in Specifications and Tolerances If running clearances are within specification and there is no evidence of scoring grooving etc no further reconditioning is necessary If bearing surfaces are worn or damaged crankcase and or closure plate will need to be replaced 17 690 01 Rev H Inspect crankshaft keyways If worn or chipped replacement of crankshaft will be necessary Inspect crankpin for score marks or metallic pickup Slight score marks can be cleaned with crocus cloth soa
98. terlock switch is engaged or faulty Loose wires or connections that intermittently ground ignition kill circuit Quality of fuel dirt water stale mixture Spark plug lead s disconnected Spark plug lead boot loose on plug Spark plug lead loose Engine Will Not Idle Engine overheated Faulty spark plug s Idle fuel adjusting needle s improperly set Idle speed adjusting screw improperly set Inadequate fuel supply Low compression Quality of fuel dirt water stale mixture Restricted fuel tank cap vent Engine Overheats Cooling fan broken Excessive engine load Fan belt failed off Faulty carburetor High crankcase oil level Lean fuel mixture Low cooling system fluid level Low crankcase oil level Radiator and or cooling system components clogged restricted or leaking Water pump belt failed broken Water pump malfunction Engine Knocks Excessive engine load Hydraulic lifter malfunction Incorrect oil viscosity type Internal wear or damage Low crankcase oil level Quality of fuel dirt water stale mixture KohlerEngines com 21 Troubleshooting Engine Loses Power e Dirty air cleaner element e Engine overheated e Excessive engine load e Restricted exhaust e Faulty spark plug s e High crankcase oil level e Incorrect governor setting e Low battery e Low compression e Low crankcase oil level e Quality of fuel dirt water stale mixture Engin
99. that could allow unfiltered air into engine A dirty or clogged element could indicate insufficient or improper maintenance e Check carburetor throat for dirt Dirt in throat is further indication that air cleaner was not functioning properly e Check if oil level is within operating range on dipstick If it is above sniff for gasoline odor e Check condition of oil Drain oil into a container it should flow freely Check for metal chips and other foreign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate over rich fuel settings weak ignition overextended oil change interval or wrong weight or type of oil was used CLEANING ENGINE Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Carburetor cleaners and solvents are extremely flammable Follow cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent After inspecting external condition of engine clean engine thoroughly before disassembly Clean individual components as engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow manufacturer s instructions and safety precautions caref
100. ting studs followed by air cleaner base Attach breather hose onto air cleaner base connection port Connect opposite end of breather hose to valve cover 4 Secure base with nuts on mounting studs and screw through top heat shield into crankcase housing Torque hardware to 8 N m 71 in Ib 5 Install lower heat shield and secure with screws CH395 CH440 NOTE When securing low profile air cleaner screw is installed through base into blower housing Torque to 6 7 N m 59 in Ib 1 Install upper shield on cylinder and secure with screws Torque to 8 N m 71 in Ib 2 Install lower shield on cylinder and secure with screws Torque to 8 N m 71 in Ib 3 Install a new carburetor to air cleaner base gasket onto carburetor mounting studs followed by air cleaner base Attach breather hose onto air cleaner base connection port Connect opposite end of breather hose to valve cover 4 Secure base with nuts on mounting studs and screw 71 le housing Torque hardware to 8 N m in Ib 80 KohlerEngines com Install Electric Starter and Control Panel if equipped 1 Align and mount electric starter onto crankcase Install and torque screws to 24 N m 212 in Ib 2 Connect electrical leads for Oil Sentry ignition module key switch relay and starter 3 Mount control panel to crankcase and secure with screws Ensure ground wires are placed between screw and bracket Torque screws to 24 N m 212 in Ib
101. tion can also occur when piston ring end gap is incorrect because ring cannot properly conform to cylinder wall under this condition Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates 2 flame fronts which meet and explode to create extreme hammering pressures on a specific area of piston Detonation generally occurs from using low octane fuels Preignition or ignition of fuel charge before timed spark can cause damage similar to detonation Preignition damage is often more severe than detonation damage KohlerEngines com 65 Disassembly Inspection and Service Preignition is caused by a hot spot in combustion chamber such as glowing carbon deposits blocked cooling fins an improperly seated valve or wrong spark plug s Replacement pistons are available in STD bore size and 0 25 mm 0 010 in oversize Replacement pistons include new piston ring sets and new piston pins Replacement ring sets are also available separately for STD and 0 25 mm 0 010 in oversize pisto
102. trol 2 Release clips on sides of stepper motor cover and panel remove cover 2 Remove wire harness from electronic governor 3 Remove screw securing stepper motor to stepper control motor bracket l 3 Remove screws securing electronic governor control 4 Remove stepper motor to crankcase Reassembly Reassembly 1 Install stepper motor into bracket and position on 1 Place governor control in position on crankcase and stepper motor base Secure with screw and tighten secure with two screws Torque screws to 24 N m 2 Route wire harness so that it feeds through stepper 212 in Ib motor cover Install cover 2 Install wires to control panel 3 Reconnect connector between stepper motor and 3 Install wiring harness to electronic governor control wiring harness 17 690 01 Rev H KohlerEngines com 3 Governor System MECHANICAL GOVERNOR Governor Components Flyweight B Regulating Pin Cross Shaft D Governor Lever _ E Throttle Linkage F Throttle Lever Governed speed setting is determined by position of throttle control It can be variable or constant depending on engine application Governor is designed to hold engine speed constant under changing load conditions Most engines are equipped with a centrifugal flyweight mechanical governor Governor gear flyweight mechanism of mechanical governor is mounted inside crankcase and is driven off gear on camshaft This governor design works as follows e Ce
103. ue Final Torque CH260 CH270 12 N m 106 in Ib 24 N m 212 in Ib CH395 CH440 18 N m 159 in Ib 36 N m 319 in Ib Install Push Rods and Rocker Arms NOTE Push rods should always be installed in original location 76 KohlerEngines com 1 Identify proper position of each push rod Dip ends of push rods in engine oil and install them in their respective locations seating each into tappet socket 2 Install push rod guide plate aligning holes for rocker arm studs Screw in rocker arm studs and torque to 13 6 N m 120 in Ib 3 Assemble rocker arms adjusters and locknuts onto studs and push rods Finger tighten rocker arm pivot jam locknuts 4 Adjust valve tappet clearance as follows a Make sure piston is still at top of compression stroke b Insert a flat feeler gauge between rocker arm and valve stem Recommended valve to rocker arm clearance for both intake and exhaust is 0 076 0 127 mm 0 003 0 005 in Cold c Adjust clearance as required by loosening locknut and turning adjuster Turn clockwise to decrease clearance Turn counterclockwise to increase clearance d Hold adjuster from turning and tighten locknut Torque locknut to 10 N m 89 in Ib e Recheck clearance is correct 5 Set gap of a new spark plug to 0 76 mm 0 030 in 6 Install spark plug in cylinder head and torque to 27 N m 20 ft Ib Install Valve Cover 1 Install a new valve cover gasket onto valve cover
104. ully Make sure all traces of cleaner are removed before engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down lubricating properties of engine oil 22 KohlerEngines com 17 690 01 Rev H Troubleshooting CRANKCASE VACUUM TEST Ac CP Carbon Monoxide can cause severe nausea fainting or death r Avoid inhaling exhaust fumes Engine exhaust gases contain poisonous carbon Keep hands feet hair and clothing away from all monoxide Carbon monoxide is odorless colorless moving parts to prevent injury Never operate engine and can cause death if inhaled with covers shrouds or guards removed Rotating Parts can cause severe injury Stay away while engine is in operation A partial vacuum should be present in crankcase when engine is operating Pressure in crankcase normally caused by a clogged or improperly assembled breather can cause oil to be forced out at oil seals gaskets or other available spots Crankcase vacuum is best measured with either a water manometer or a vacuum gauge Complete instructions are provided in kits To test crankcase vacuum with manometer To test crankcase vacuum with vacuum pressure gauge 1 Insert rubber stopper into oil fill hole Be sure pinch 1 Remove dipstick or oil fill plug cap clamp is installed on hose and use tapered adapters 5 Install adapter into oil fill dipstick tube opening to connect hose between stopper and
105. uously charging at high rate 1 Separate bullet connector in white lead from rectifier regulator Connect an ammeter from female terminal to positive terminal of battery Connect a DC voltmeter from female terminal to negative terminal of battery Leave other rectifier regulator leads connected in normal manner Run engine at 3600 RPM and read voltage on voltmeter If voltage is 14 0 volts or more place a minimum load of 5 amps turn on lights if 60 watts or more or place a 2 5 ohm 100 watt resistor across battery terminals on battery to reduce voltage Observe ammeter Voltage is 15 0 volts or Charging system is OK less Battery is unable to hold a charge service or replace Voltage is more than 15 0 Faulty rectifier regulator volts replace ohms no continuity Resistance or continuity is measured KohlerEngines com 45 Electrical System Wiring Diagram 10 18 Amp Charging System with Rectifier Regulator Rectifier Regulator BH Stator Spark Plug E Ignition Module D E Oil Float Switch DES Oil Control Module G Key Switch H Starter Motor 46 KohlerEngines com 17 690 01 Rev H Starter System NOTE Do not crank engine continuously for more than 10 seconds Allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out starter motor NOTE If engine develops sufficient speed to disengage starter but does not keep running a false start engine

CH260-CH440 Service Manual

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