CH245-CH440 Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service.
Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. 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. WARNING 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.
Maintenance MAINTENANCE INSTRUCTIONS WARNING 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.
Maintenance OIL RECOMMENDATIONS All-season KOHLER® PRO 10W-50 Synthetic Oil is the ideal oil for KOHLER engines. It is specifically formulated to extend the oil change interval to 300 Hours. Contact your Kohler authorized dealer for availability. 300-Hour oil change intervals are exclusive to and only authorized on KOHLER engines that utilize the KOHLER PRO 10W-50 Synthetic Oil. Alternative engine oils may be used with KOHLER engines but require 100-Hour oil change intervals for proper maintenance.
Specifications CH245/CH255 Engine Dimensions Gas Cap Removal 12.50 (0.492) Dimensions in millimeters. Inch equivalents shown in [ ]. 88.30 (3.476) 358.46 (14.113) 29.70 (1.169) 65.05 (2.561) 317.62 (12.505) 106.00 (4.173) 32.53 (1.281) M10 OIL DRAIN PLUG 32.53 (1.281) METRIC FLANGE: M8 X 1.25-6H THRU SAE A FLANGE: 5/16-24 UNF-2B THRU 65.05 (2.561) METRIC FLANGE: 4X M8 X 1.25-6H 15 SAE A FLANGE: 4X 5/16-24 UNF-2B 15 66.0 (2.598) 162.0 (6.378) AIR CLEANER COVER REMOVAL 80.0 (3.150) 2.96 (0.
Specifications CH260/CH270 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 6 KohlerEngines.com 17 690 01 Rev.
Specifications CH260/CH270 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 17 690 01 Rev. L KohlerEngines.
Specifications CH395 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 8 KohlerEngines.com 17 690 01 Rev.
Specifications CH395 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 17 690 01 Rev. L KohlerEngines.
Specifications CH440 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 10 KohlerEngines.com 17 690 01 Rev.
Specifications CH440 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 17 690 01 Rev. L KohlerEngines.
Specifications ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model . . . . . . . . . . . . . . . . . . . . . CH260 Command Engine Horizontal Shaft Numerical Designation Specification . . . . . . . . . . . . . . . CH260-0001 Serial . . . . . . . . . . . . . . . . . . . . .
Specifications TORQUE SPECIFICATIONS4,6 CH245/CH255 CH260/CH270 Crankcase Oil Drain Plug Closure Plate Screw Cylinder Head Fastener (torque in 2 increments) CH395 CH440 18 N·m (13 ft. lb.) 24 N·m (212 in. lb.) First to 12 N·m (106 in. lb.) Finally to 24 N·m (212 in. lb.) Electric Starter Mounting Screw First to 18 N·m First to 25 N·m (159 in. lb.) (221 in. lb.) Finally to Finally to 36 N·m 57.5 N·m (319 in. lb.) (509 in. lb.) 24 N·m (212 in. lb.
Specifications TORQUE SPECIFICATIONS4,6 CH245/CH255 Muffler Exhaust Screw M8 M10 Muffler Shield Screw M6 M4 Spark Arrestor Screw M5 CH260/CH270 24 N·m (212 in. lb.) --- --35 N·m (310 in. lb.) 5.4 N·m (48 in. lb.) 10 N·m (89 in. lb.) Rocker Arm Stud Pivot Jam Nut 13.6 N·m (120 in. lb.) 10 N·m (89 in. lb.) Valve Cover Fastener 8 N·m (71 in. lb.) CLEARANCE SPECIFICATIONS4 Camshaft Running Clearance Bore I.D. New Max. Wear Limit Camshaft Bearing Surface O.D. New Max.
Specifications CLEARANCE SPECIFICATIONS4 CH245/CH255 CH260/CH270 Connecting Rod Crankpin End I.D. @ 21°C (70°F) New CH395 30.021/30.026 mm 30.020/30.030 mm 33.020/33.030 mm (1.1819/1.1823 in.) (1.1819/1.1823 in.) (1.3000/1.3004 in.) Max. Wear Limit 30.08 mm 30.106 mm 33.07 mm (1.184 in.) (1.185 in.) (1.302 in.) Connecting Rod-to-Crankpin Side Clearance New 0.58/0.60 mm 0.58/0.60 mm 0.73 mm (0.023/0.024 in.) (0.023/0.024 in.) (0.029 in.) Max. Wear Limit 1.10 mm 1.10 mm 1.36 mm (0.043 in.) (0.043 in.
Specifications CLEARANCE SPECIFICATIONS4 Cylinder Bore Bore I.D. New Max. Wear Limit Max. Out-of-Round Max. Taper Cylinder Head Max. Out-of-Flatness CH245/CH255 CH260/CH270 CH395 CH440 70.027/70.035 mm 70.020/70.035 mm 78.000/78.015 mm 89.000/89.015 mm (2.7570/2.7573 in.) (2.7570/2.7573 in.) (3.0709/3.0714 in.) (3.5039/3.5045 in.) 70.200 mm (2.764 in.) 78.185 mm 89.185 mm (3.0781 in.) (3.5112 in.) 12.7 microns (0.0005 in.) 12.7 microns (0.0005 in.) 0.10 mm (0.0039 in.) 0.08 mm (0.003 in.) 0.1 mm (0.
Specifications CLEARANCE SPECIFICATIONS4 CH245/CH255 CH260/CH270 CH395 Piston, Piston Rings, and Piston Pin (continued) Oil Control Ring-to-Groove Side Clearance 0.05/0.19 mm (0.0019/0.0075 in.) Piston Thrust Face O.D. New 67.975/67.985 mm 69.975/69.995 mm 77.955/77.975 mm (2.6762/2.6766 (2.755/2.756 in.)9 (3.069/3.070 in.)10 in.)8 Max. Wear Limit 67.85 mm 69.82 mm 77.82 mm (2.6712 in.) (2.749 in.) (3.064 in.) Piston Thrust Face-to-Cylinder 0.057/0.075 mm 0.057/0.075 mm 0.033/0.
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 Into Aluminum Size Grade 2 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 10-24 3.6 (32) 10-32 3.6 (32) 1/4-20 7.9 (70) 1/4-28 9.6 (85) 5/16-18 17.0 (150) 5/16-24 18.7 (165) 3/8-16 29.4 (260) 3/8-24 33.9 (300) Grade 5 Grade 8 2.8 (25) 4.5 (40) 4.5 (40) 13.0 (115) 15.8 (140) 28.3 (250) 30.
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. NOTE: Not all tools listed are required to service this engine. SEPARATE TOOL SUPPLIERS Kohler Tools Contact your local Kohler source of supply.
Tools and Aids TOOLS Description Flywheel Puller For properly removing flywheel from engine. Flywheel Anchor Bolts, Washers, Nuts Tool Used with Flywheel Puller for properly removing flywheel from 5400 Series engine. Hose Removal Tool, Dual Size/End (also available in EFI Service Kit) Used to properly remove fuel hose from engine components. Hydraulic Valve Lifter Tool For removing and installing hydraulic lifters. Ignition System Tester For testing output on all systems, including CD.
Tools and Aids AIDS Description Camshaft Lubricant (Valspar ZZ613) Dielectric Grease (GE/Novaguard G661) Dielectric Grease Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler Electric Starter Drive Lubricant (Solenoid Shift) RTV Silicone Sealant Loctite® 5900® Heavy Body in 4 oz. aerosol dispenser. Only oxime-based, oil resistant RTV sealants, such as those listed, are approved for use. Permatex® the Right Stuff® 1 Minute Gasket™ or Loctite® Nos.
Troubleshooting TROUBLESHOOTING GUIDE 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.
Troubleshooting 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. Engine Loses Power ● Dirty air cleaner element. ● Engine overheated. ● Excessive engine load. ● Restricted exhaust. ● Faulty spark plug. ● High crankcase oil level. ● Incorrect governor setting. ● Low battery. ● Low compression. ● Low crankcase oil level.
Troubleshooting CRANKCASE VACUUM TEST WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. WARNING Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury.
Troubleshooting COMPRESSION TEST 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.
Air Cleaner/Intake 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 A B B C C D D E E A Air Cleaner Cover B Bail C Precleaner D Paper Element E Air Cleaner Base Low-Profile Air Cleaner Components I NOTE: Operating engine with loose or damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.
Air Cleaner/Intake Oil Bath Some engines are equipped with an oil bath air cleaner. Follow maintenance and oil change information specified in this section and in Maintenance Schedule. Earlier design had a single foam filter that was later replaced by 2 foam elements. A A B B C C D D E E F K E E G I I G H H C C J J A 6. Make sure O-ring is in place on air cleaner base. Set oil reservoir cup on base. 7. Fill oil reservoir cup up to oil level mark with same grade of oil as in crankcase.
Fuel System Typical carbureted fuel system and related components include: ● 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 equipped) A serviceable fuel tank filter is located under fuel tank cap, in filler neck.
Fuel System CARBURETOR WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. These engines are equipped with a fixed main jet carburetor. Carburetor is designed to deliver correct fuelto-air mixture to engine under all operating conditions. Idle mixture is set at factory and cannot be adjusted.
Fuel System Troubleshooting-Carburetor Related Causes Condition Engine starts hard, runs rough, or stalls at idle speed. Engine runs rich (indicated by black, sooty exhaust smoke, misfiring, loss of speed and power, governor hunting, or excessive throttle opening). Possible Cause Low idle fuel mixture (some models)/ speed improperly adjusted. Clogged air cleaner. Choke partially closed during operation. Dirt under fuel inlet needle. Bowl vent or air bleeds plugged. Leaky, cracked, or damaged float.
Fuel System High Idle Speed (RPM) Adjustment (if equipped) A A High Idle Speed Adjusting Stop Screw NOTE: High idle speed is also specified by equipment manufacturer. Set according to recommendations. High idle speed for basic engines is 3600 RPM (± 150 RPM). 1. Set high idle speed by turning high idle speed adjusting stop screw in or out. Do not exceed 3750 RPM. Carburetor Servicing WARNING 3. Remove float pin and inlet needle. Seat for inlet needle is not serviceable and should not be removed. 4.
Governor System GOVERNOR These engines are equipped with an electronic governor or a mechanical governor.
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. NO YES Repair/Replace as necessary. YES Move throttle shaft to idle position to check for smooth and consistent travel. Remove stepper motor. See page 39 for disassembly and reassembly instructions. Replace carburetor assembly and retest.
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. If resistance value is OK? If resistance value higher or infinity Ohms? Replace stepper motor and retest. See page 39 for disassembly and reassembly instructions.
Governor System Electronic Governor Troubleshooting Flow Chart Continued Continued from previous page. Manually attempt to rotate stepper motor in both directions. • Reconnect connector with stepper motor removed. • Start engine in normal manner as described in Owner’s Manual. Does stepper motor run clockwise? NO YES Reassemble stepper motor. Retest engine. Replace electronic governor control and retest. OK? OK? YES END 17 690 01 Rev. L NO YES Test control system of equipment.
Governor System Electronic Governor Troubleshooting Flow Chart Continued Engine starts but does not keep running. Inspect wiring harness for any broken or bad connections. NO YES Repair/Replace as necessary. Terminal K10 and B1 are located in J1, Pin H (shown below). 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. Refer to Equipment Manufacturer’s diagnostic procedures for control system.
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. END Replace ignition module and retest. Ensure electronic governor control is properly grounded to crankcase and retest. NO YES Repair/Replace as necessary. YES OK? YES NO Short ignition kill wire to ground. Does engine stop? NO OK? Continued on next page. YES Confirm return of normal engine operation.
Governor System Electronic Governor Troubleshooting Flow Chart Continued Continued from previous page. Shut off engine. Disconnect lead at kill tab. Test continuity at B1 and J1, Pin H. See page 36 for illustration. Replace ignition module and retest. OK? YES Confirm return of normal engine operation. Does engine stop? YES NO Repair/Replace wiring harness and retest continuity. Does engine stop? YES Replace ignition module and retest. NO NO END Confirm return of normal engine operation.
Governor System Stepper Motor Electronic Governor Control Stepper Motor Components Electronic Governor Control Components A A D E B B D C D E E C F E A Stepper Motor Cover B Stepper Motor C Stepper Motor Bracket D Stepper Motor Base E Stepper Motor Post F Carburetor Stepper Motor Servicing Disassembly NOTE: It is not necessary to remove stepper motor base from carburetor assembly when replacing stepper motor. 1. Disconnect connector between stepper motor and wiring harness. 2.
Governor System ● One end of cross shaft protrudes through crankcase. Rotating action of cross shaft is transmitted to throttle lever of carburetor through external throttle linkage. ● 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 System 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.
Lubrication System These engines use a splash lubrication system, supplying necessary lubrication to crankshaft, camshaft, connecting rod and valve train components. Lubrication Components A B C A Dipstick C B Oil Fill 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 and level. Clean oil fill/dipstick areas of any debris. 1.
Electrical System SPARK PLUGS CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. Spark Plug Component and Details 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 A B Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits.
Electrical System ELECTRONIC IGNITION SYSTEM Carbon Fouled Inductive Discharge Ignition System H G I C A Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich carburetion, weak ignition, or poor compression. Overheated D 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.
Electrical System Electronic Ignition Systems and Oil Sentry™ Tests 1. Disconnect cap from spark plug and attach it to terminal end of spark tester. Attach tester spring clip to a good ground, not to spark plug. Turn ignition/key switch ON and crank engine while observing firing tip of tester. Condition Tester is firing. Tester doesn't fire. Conclusion Condition Ignition system is good. Install a new spark plug and try to start engine.
Electrical System BATTERY CHARGING SYSTEMS CH245, CH255 Wiring Diagram-Retractable Starter B A C Most engines are equipped with a 3,4,10, or 18 amp regulated battery charging system. F E D A NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Make sure all ground connections are secure and in good condition.
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.
Electrical System 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 rectifierregulator. Connect an ammeter from female terminal to positive (+) terminal of battery.
Electrical System Wiring Diagram-10/18 Amp Charging System, with Rectifier-Regulator A D C B J G K I E F H A Rectifier-Regulator B Stator C Ignition Module D Spark Plug E Oil Float Switch F Oil Control Module G Key Switch H Starter Motor I Relay J Battery Fuse K 12 Volt Battery 17 690 01 Rev. L KohlerEngines.
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 rotation must be allowed to come to a complete stop before attempting to restart engine.
Starter System 4. Use a known, good, fully-charged battery and jumper cables to test starter motor. Be sure transmission is in neutral and PTO is OFF. Remove heavy lead from post terminal on starter. Connect one end of positive jumper cable to post terminal and connect other end to positive terminal of battery. Connect one end of negative jumper cable to negative terminal of battery. Touch other end of negative jumper cable to a bare surface on crankcase or to starter housing.
Starter System G I E I H F I E Drive Assembly is Serviced F Shim G Relay (Solenoid) Nuts H Motor to Starter Drive Assembly I Four Screws 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. lb.). 4.
Starter System RETRACTABLE STARTERS WARNING 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.
Starter System 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. 4.
Gear Reduction System WARNING 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. Some engines are equipped with either a 6:1 or a 2:1 gear reduction system. ● 6:1 Gear reduction system reduces PTO shaft RPM by 6:1; crankshaft turns 6 times to 1 time of PTO shaft.
Gear Reduction System This reduction system uses an internal pinion and ring gear system, independent of, and separated from main crankcase lubrication. Check and maintain oil level using oil level/drain plug hole in gear box (reduction) case. Change reduction system oil at interval in maintenance schedule (see Maintenance). Oil capacity of this gear box is 0.12 L (0.13 U.S. qt.). Disassembly NOTE: Place a drain pan under gear reduction unit to catch any residual oil when cover is removed.
Gear Reduction System 8. Remove reduction case gasket between reduction case and closure plate. Clean all gasket surfaces. K K Reduction Case Gasket Inspection Remove all gaskets and clean all gasket surfaces. Do not nick or damage surfaces. Clean and inspect condition of all gears for any abnormal wear or damage. Replace as necessary. Rotate bearings and check for any roughness. Inspect bearing surfaces for any damage or irregularities. Replace as necessary.
Gear Reduction System CH270 2:1 Gear Reduction System Components A E B C D H 4 1 K I J F G 2 L 3 5 A Oil Seal B Chain Cover C Chain Cover Gasket D Ball Bearing E Spring Washer F PTO Sprocket Shaft G Chain H Flat Washer I Splined Pinion Gear J Pinion Spacer K Closure Plate L Torque Sequence This reduction system is lubricated by engine crankcase oil. No special maintenance or service is necessary.
Gear Reduction System 4. Remove cover and gasket. Ensure two dowel pins remain in place. 7. If necessary, remove rear pinion spacer from crankshaft. Note position of spring washer on outer side of PTO sprocket shaft. J E B E B J Pinion Spacer Inspection Remove gaskets and clean all gasket surfaces. Do not nick or damage surfaces. Clean and inspect condition of all gears and chain for wear, chips, or damage. Replace as necessary. Rotate bearings and chain and check for any roughness.
Gear Reduction System CH245, CH255, CH270 2:1 with Clutch Gear Reduction System Components C A G H I J AA K L B M N P Q D S U O E V W F R X T Y A Z B A Oil Seal B Drain Plug C Reduction Cover D Crankshaft Bearing E PTO Shaft F Chain G Reduction Case Cover Gasket H Retainer Ring I Weight Holder Pin J Clutch Holder Spring K Weight Holder L Clutch Weight M Weight Retainer N Pressure Plate O Clutch Plate P Friction Disc Q Clutch Center Gear R Clutch Cup S
Gear Reduction System 3. Remove screws securing reduction cover to reduction case. 7. Separate clutch assembly components. Note order of disassembly. P N R O C C Q Reduction Cover 4. Remove reduction cover and gasket. Ensure two dowel pins remain in place. 5. Remove screw and lock washer securing clutch assembly to crankshaft. N Pressure Plate O Clutch Plate P Friction Disc Q Clutch Center Gear R Clutch Cup 8. Disassembly of pressure plate assembly is not recommended.
Gear Reduction System 10. If servicing requires reduction case removal, remove screws securing case to closure plate. 11. Carefully separate reduction case and gasket from closure plate. Y V V Reduction Case Y Closure Plate Inspection NOTE: Disassembly of pressure plate is not recommended and if worn or damaged, should be replaced as an assembly. Remove gaskets and clean all gasket surfaces. Do not nick or damage surfaces.
Gear Reduction System CH395/CH440 6:1 Gear Reduction System Components K L A B J I A H G C D E F A Oil Seal B Reduction Cover C Reduction Cover Bearing D PTO Shaft E Ball Bearing F Spacer G Reduction Cover Gasket H Flat Washer I Drive Gear J Countershaft Gear Assembly K PTO Flange Adapter L Closure Plate This reduction system is lubricated by engine crankcase oil. No special maintenance or service is necessary.
Gear Reduction System 5. Remove PTO shaft from bearing in closure plate. D D PTO Shaft 6. Remove screw, flat washer and lock washer securing drive gear to PTO shaft. Slide gear off of PTO shaft splines. I H Flat Washer Inspection Remove all gaskets and clean all gasket surfaces. Do not nick or damage surfaces. Clean and inspect condition of all gears and teeth for any abnormal wear or damage. Replace as necessary. Rotate bearings and check for any roughness.
Gear Reduction System CH395/CH440 2:1 with Clutch Gear Reduction System Components A F D H Z I B C K E G J M N L O P Q R S U T Y V X W A Oil Seal B Reduction Cover C Weight Holder Pin D Retaining Ring E Clutch Holder Spring F Weight Holder G Clutch Weight H Weight Retainer I Clutch Center Gear J Square Key K Pressure Plate L Clutch Plate M Friction Disc N Clutch Cup O Drive Gear P Thrust Washer S Reduction Case T Ball Bearing W Closure Plate X Drain P
Gear Reduction System Disassembly NOTE: Place a drain pan under gear reduction unit to catch any residual oil when cover is removed. Dispose of used oil in accordance with local ordinances. NOTE: Bearing in cover can be removed if necessary using a bearing puller. Crankshaft bearing removal requires closure plate removal. Refer to Disassembly/Inspection and Service for procedure. 1. Remove any drive coupling and key from reduction assembly PTO shaft. Clean shaft and keyway of any burrs/damage. 2.
Gear Reduction System 9. If servicing requires reduction case removal, remove screws securing case to closure plate. 10. Carefully separate reduction case and gasket from closure plate. W S S Reduction Case W Closure Plate Inspection NOTE: Disassembly of pressure plate is not recommended and if worn or damaged, should be replaced as an assembly. Remove gaskets and clean all gasket surfaces. Do not nick or damage surfaces.
Disassembly/Inspection and Service WARNING 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.
Disassembly/Inspection and Service 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 carefully. Make sure all traces of cleaner are removed before engine is reassembled and placed into operation.
Disassembly/Inspection and Service CH245/CH255 Blower Housing/Control Panel Components J F I D G E H B C A A Retractable Starter B Blower Housing C Cylinder Head Shield D Carburetor E Linkage Spring F Throttle Linkage G Governor Lever H Hex Flange Nut I Governor Spring J Speed Control Assembly 70 KohlerEngines.com 17 690 01 Rev.
Disassembly/Inspection and Service CH260/CH270 Blower Housing/Control Panel Components F H G I E J D K C B A A Retractable Starter B Blower Housing C Lower Shield D Carburetor E Dampening Spring F Throttle Linkage G Governor Lever H Hex Flange Nut I Governor Spring J Throttle Lever K Upper Shield 17 690 01 Rev. L KohlerEngines.
Disassembly/Inspection and Service CH395/CH440 Blower Housing/Control Panel Components L N M J I K F G G H E D B C A A Retractable Starter B Blower Housing C Lower Shield D Electric Starter E Upper Shield F Carburetor G Fuel Brackets H Throttle Lever I Pivot Lever J Governor Spring K Dampening Spring L Throttle Linkage M Governor Lever N Hex Flange Nut 72 KohlerEngines.com 17 690 01 Rev.
Disassembly/Inspection and Service CH395/CH440 Electronic Governor Blower Housing/Control Panel Components E F G D B C A E F G D B C A A Retractable Starter B Blower Housing C Lower Shield E Upper Shield F Electric Governor Control G Stepper Motor 17 690 01 Rev. L KohlerEngines.
Disassembly/Inspection and Service 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 Blower Housing and Shields 1.
Disassembly/Inspection and Service CH245/CH255 Cylinder Head Components K M I J H D C N O L G B E F A A Valve Cover B Hex Jam Nut C Rocker Arm Pivot D Rocker Arm E Rocker Arm Stud F Push Rod G Push Rod Guide H Valve Keeper I Valve Spring J Valve Stem Seal K Spark Plug L Cylinder Head M Valve N Dowel Pin O Cylinder Head Gasket CH260-CH440 Cylinder Head Components J L I H M G N K D C A B F E A Valve Cover B Adjuster Nut C Rocker Arm D Rocker Arm Stud
Disassembly/Inspection and Service 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. NOTE: CH245/CH255 valve cover is sealed to cylinder head using RTV silicone sealant. When removing valve cover, use care not to damage sealing surfaces of cover and cylinder head. To break RTV seal, hold a block of wood against 1 flat face of valve cover. Strike wood firmly with a mallet.
Disassembly/Inspection and Service Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press-fitted into 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.
Disassembly/Inspection and Service CH395 Valve Specifications Item Dimension Intake Exhaust A Head Diameter 30.875-31.125 mm (1.2156-1.2254 in.) 26.875-27.125 mm (1.0581-1.0679 in.) B Valve Length 85.34-85.54 mm (3.3598-3.3677 in.) 85.19-84.99 mm (3.3461-3.3539 in.) C Stem Diameter 6.560-6.575 mm (0.2583-0.2589 in.) 6.560-6.575 mm (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.
Disassembly/Inspection and Service CH245/CH255 Flywheel/Ignition Components D C Remove Ignition Module Remove screws securing ignition module to crankcase. Remove module. E B A F A Flywheel Retaining Nut B Drive Cup C Flywheel Fan D Ignition Module E Flywheel F Flywheel Shield CH260/CH270 Flywheel/Ignition Components E A Inspection Inspect flywheel for cracks and flywheel keyway for damage. Replace flywheel if it is cracked.
Disassembly/Inspection and Service CH245/CH255 Crankshaft/Camshaft/Closure Plate Components T V U Q O N P M R W F L H S I E J K G D B A C A Closure Plate Oil Seal B Closure Plate Bearing C Closure Plate D Camshaft E Crankshaft F Connecting Rod End Cap G Connecting Rod H Piston Pin Retainer I Piston Pin J Piston K Piston Ring Set L Oil Sentry™ Float Switch M Oil Sentry™ Wire N Governor Cup O Governor Washer P Governor Shaft Q Governor Gear R Tappet S Cra
Disassembly/Inspection and Service CH260/CH270 Crankshaft/Camshaft/Closure Plate Components V W O L M R S N U Q T P I J E H G C F D K A B A Closure Plate Oil Seal B Closure Plate C Closure Plate Bearing D Camshaft E Crankshaft F Piston Pin Retainer G Piston Pin H Piston I Connecting Rod End Cap J Connecting Rod K Piston Ring Set L Governor Cup M Governor Washer N Governor Shaft O Governor Gear P Oil Sentry™ Float Switch Q Tappet R Oil Sentry™ Wire S Crankcase
Disassembly/Inspection and Service CH395/CH440 Crankshaft/Camshaft/Closure Plate Components Y U Z V S T X W R Q H I F G K J D L E C M N O P A B A Closure Plate Oil Seal B Closure Plate C Closure Plate Bearing D Closure Plate Balance Shaft Bearing E Balance Shaft F Governor Shaft G Governor Washer H Governor Gear I Governor Cup J Crankshaft K Connector Rod End Cap L Connector Rod M Piston Pin Retainer N Piston Pin O Piston P Piston Ring Set Q Camshaft R O
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. NOTE: Some engines have a closure plate gasket; some engines use RTV to secure closure plate to crankcase. 1. Remove screws securing closure plate to crankcase. 2. Remove closure plate, gasket (if equipped), and dowel pins (if required) from crankcase. Note position of dowel pins for reassembly. Discard old gasket (if equipped). 3.
Disassembly/Inspection and Service Inspection and Service Dimension A Dimension B B A Cam Lobe Specifications CH245/CH255 Cam Lobe Valve Dimension A Service Limit INTAKE 27.608 mm (1.087 in.) 27.354 mm (1.067 in.) EXHAUST 27.770 mm (1.093 in.) 27.516 mm (1.083 in.) CH260/CH270 Cam Lobe Valve Dimension A Service Limit INTAKE 27.787 mm (1.094 in.) 27.533 mm (1.084 in.) EXHAUST 27.861 mm (1.097 in.) 27.607 mm (1.087 in.) Engine Model CH245, CH255 CH260, CH270 32.408 mm (1.276 in.) 32.
Disassembly/Inspection and Service Dimension C C Camshaft Journal Specifications Engine Model Dimension C Limit CH245, CH255 13.975 mm (0.5500 in.) 13.966 mm (0.5498 in.) CH260, CH270 13.975 mm (0.5500 in.) 13.900 mm (0.5470 in.) CH395, CH440 15.975 mm (0.6289 in.) 15.900 mm (0.6260 in.) Inspect gear teeth of camshaft. If teeth are badly worn, chipped, or some are missing, replacement of camshaft will be necessary.
Disassembly/Inspection and Service 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.
Disassembly/Inspection and Service Remove Governor Assembly (Mechanical Governor Only) Crankcase Inspection and Service Cylinder Bore Detail CH245, CH255, 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.
Disassembly/Inspection and Service Honing Crosshatch Detail 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.
Reassembly CH245/CH255 Crankshaft/Camshaft/Closure Plate Components T V U Q O N P W M R W F L H S I E J K G D B A C A Closure Plate Oil Seal B Closure Plate Bearing C Closure Plate D Camshaft E Crankshaft F Connecting Rod End Cap G Connecting Rod H Piston Pin Retainer I Piston Pin J Piston K Piston Ring Set L Oil Sentry™ Float Switch M Oil Sentry™ Wire N Governor Cup O Governor Washer P Governor Shaft Q Governor Gear R Tappet S Crankcase T Governor C
Reassembly CH260/CH270 Crankshaft/Camshaft/Closure Plate Components W X U O L M R S U N V Q T P I J E H G C F D K A B A Closure Plate Oil Seal B Closure Plate C Closure Plate Bearing D Camshaft E Crankshaft F Piston Pin Retainer G Piston Pin H Piston I Connecting Rod End Cap J Connecting Rod K Piston Ring Set L Governor Cup M Governor Washer N Governor Shaft O Governor Gear P Oil Sentry™ Float Switch Q Tappet R Oil Sentry™ Wire S Crankcase Bearing T Closur
Reassembly CH395/CH440 Crankshaft/Camshaft/Closure Plate Components AA U Z V Y S T Y X W R Q H I F G K J D L E C M N O P A B A Closure Plate Oil Seal B Closure Plate C Closure Plate Bearing D Closure Plate Balance Shaft Bearing E Balance Shaft F Governor Shaft G Governor Washer H Governor Gear I Governor Cup J Crankshaft K Connector Rod End Cap L Connector Rod M Piston Pin Retainer N Piston Pin O Piston P Piston Ring Set Q Camshaft R Oil Sentry™ Float S
Reassembly 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 Governor Assembly (Mechanical Governor Only) CH245, CH255, CH260/CH270 Governor Details Install Crankcase Bearings and Oil Seals Details A A D B E C B C F A Outer Surface C Depth B Seal NOTE: Oil bearings liberally with engine oil when installing.
Reassembly CH440 Governor Details CH395 Governor Details B A C A C B D E D E F H F G G I J A Thrust Washer B Governor Gear C Pin Rim D Washer E Hitch Pin F Thrust Washer G Governor Cross NOTE: Governor gear shaft is pressed into closure plate and should not 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.
Reassembly 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.
Reassembly 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 Closure Plate CH245/CH255/CH260/CH270 Torque Sequence 1 6 Install Valve Tappets and Camshaft Timing Mark Detail 3 4 B 2 A 5 CH395/CH440 Torque Sequence 6 1 5 B 4 A 3 2 7 CH245/255 Sealant Pattern A 1. 2. 3. 4.
Reassembly CH260/270 Sealant Pattern CH395 Sealant Pattern NOTE: Make sure governor lever is against cup on governor gear assembly. NOTE: Some engines have a closure plate gasket; some engines use RTV to secure closure plate to crankcase. 1. Check to make sure sealing surfaces of crankcase and closure plate are clean, dry, and free of nicks/ burrs. 2. Install two dowel pins into crankcase (if removed) as noted in disassembly. 3. CLOSURE PLATE GASKET: Install new closure plate gasket (dry) onto dowel pins.
Reassembly CH260/CH270 Flywheel/Ignition Components 1 Install Flywheel 3 CAUTION H 4 2 E Damaging Crankshaft and Flywheel can cause personal injury.
Reassembly Install Ignition Module NOTE: Ensure ignition module is correctly oriented. 1. Turn flywheel so magnet is away from location where ignition module will be installed. 2. 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. 3. Rotate flywheel until magnet is under one leg of ignition module. 4. Insert a 0.254 mm (0.010 in.) flat feeler gauge between leg of module and magnet.
Reassembly CH260-CH440 Cylinder Head Components 3 1 J 4 2 L I H M G N K D C A B F E A Valve Cover B Adjuster Nut C Rocker Arm D Rocker Arm Stud E Push Rod Guide F Push Rod G Valve Keeper H Valve Spring I Valve Stem Seal J Spark Plug K Cylinder Head L Valve M Dowel Pin N Cylinder Head Gasket O Torque Sequence Assemble Cylinder Head NOTE: Engine utilizes valve stem seals on valves. Always use a new seal when valves are installed in cylinder head.
Reassembly Install Push Rods and Rocker Arms NOTE: Push rods should always be installed in original location. 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. lb.). 3. Assemble rocker arms, adjusters, and locknuts onto studs and push rods.
Reassembly CH245/CH255 Blower Housing/Control Panel Components J F I D G E H B C A A Retractable Starter B Blower Housing C Cylinder Head Shield D Carburetor E Linkage Spring F Throttle Linkage G Governor Lever H Hex Flange Nut I Governor Spring J Speed Control Assembly 17 690 01 Rev. L KohlerEngines.
Reassembly CH260/CH270 Blower Housing/Control Panel Components F H G I E J D K C B A A Retractable Starter B Blower Housing C Lower Shield D Carburetor E Dampening Spring F Throttle Linkage G Governor Lever H Hex Flange Nut I Governor Spring J Throttle Lever K Upper Shield 102 KohlerEngines.com 17 690 01 Rev.
Reassembly CH395/CH440 Blower Housing/Control Panel Components L N M J I K F G G H E D B C A A Retractable Starter B Blower Housing C Lower Shield D Electric Starter E Upper Shield F Carburetor G Fuel Tank Brackets H Throttle Lever I Pivot Lever J Governor Spring K Dampening Spring L Throttle Linkage M Governor Lever N Nut 17 690 01 Rev. L KohlerEngines.
Reassembly CH395/CH440 Electronic Governor Blower Housing/Control Panel Components E F G D B C A E F G D B C A A Retractable Starter B Blower Housing C Lower Shield E Upper Shield F Electric Governor Control G Stepper Motor 104 KohlerEngines.com D Carburetor 17 690 01 Rev.
Reassembly Install Fuel Tank Supports and Shut Down Switch with Bracket (if equipped) 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. lb.). 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.
Reassembly 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. lb.). 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. lb.). Install Electronic Governor Control (Electronic Governor Only) 1.
Reassembly CH245/CH255 Governor Lever Hole Position/RPM Chart A B C Engine Speed RPM 3801-4000 8-13% Droop Spring Color Black Hole B CH260/CH270 Governor Lever Hole Position/RPM Chart 3 2 1 Engine Speed RPM 2800-3000 3001-3200 3201-3400 3401-3600 3601-3800 3601-3800 3801-4000 A B C 5-8% Droop 5-10% Droop 8-12% Droop Spring Hole Spring Hole Spring Hole Color Combination Color Combination Color Combination Yellow #1-B Green #3-C Black #3-C Yellow #1-A Yellow #2-A Red #2-A Yellow #2-A White #3-A Black
Reassembly CH395 Governor Lever Hole Position/RPM Chart 1 2 3 Engine Speed RPM 2800-3000 3001-3200 3201-3400 3401-3600 3601-3800 3801-4000 A B C 3-8% Droop 6-10% Droop 7-12% Droop Spring Hole Spring Hole Spring Hole Color Combination Color Combination Color Combination Yellow #1-B Black #1-B Yellow #1-B Yellow #1-B Yellow #2-B Purple #1-A Red #1-B Yellow #2-B Yellow #2-B CH440 Governor Lever Hole Position/RPM Chart 1 2 3 4 Engine Speed RPM 3801-4000 3601-3800 3401-3600 3201-3400 3001-3200 2801-3001
Reassembly External Engine Components N H I K J D M L E F G B C O A A Oil Drain Plug B CH395, CH440 Muffler Assembly C Breather Hose D CH260-CH440 Quad-Clean™ Cover E CH260-CH440 Quad-Clean™ Element/Precleaner F CH260-CH440 Quad-Clean™ Base G CH260-CH440 Carburetor Shroud H CH245-CH255 Quad-Clean™ Cover I CH245-CH255 Quad-Clean™ Element/Precleaner J CH245-CH255 Quad-Clean™ Base K Fuel Tank L Fuel Line M CH260, CH270 Muffler Assembly N CH245, CH255 Muffler Assembly O Low-Prof
Reassembly 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. lb.). 2. Connect electrical leads for Oil Sentry™ module. Install Fuel Tank CH260-CH440 (if equipped) 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. 3. Torque side strap screw to 10 N·m (89 in. lb.). 4.
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