Kohler Command PRO CH440 Service Manual
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Kohler Command PRO CH440 Service Manual

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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.
2
Safety
3
Maintenance
5
Specifi cations
19
Tools and Aids
22
Troubleshooting
26
Air Cleaner/Intake
28
Fuel System
32
Governor System
42
Lubrication System
43
Electrical System
50
Starter System
55
Gear Reduction System
68
Disassembly/Inspection and Service
89
Reassembly
17 690 01 Rev. L
KohlerEngines.com
1

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  • Page 1 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 Maintenance Specifi cations Tools and Aids Troubleshooting Air Cleaner/Intake...

  • Page 2: Safety Precautions

    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. CAUTION WARNING WARNING...

  • Page 3: Maintenance Instructions

    Option only if using KOHLER PRO oil. ® REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 17 690 01 Rev. L KohlerEngines.com...

  • Page 4: Oil Recommendations

    PRO 10W-50 Synthetic Oil is the ® follow procedure below. ideal oil for KOHLER engines. It is specifi cally formulated 1. Add Kohler PRO Series fuel treatment or equivalent to extend the oil change interval to 300 Hours. Contact to fuel tank. Run engine 2-3 minutes to get stabilized your Kohler authorized dealer for availability.
  • Page 5 Specifi cations CH245/CH255 Engine Dimensions Dimensions in millimeters. Gas Cap Removal Inch equivalents shown in [ ]. 88.30 12.50 (3.476) (0.492) 358.46 (14.113) 317.62 (12.505) 29.70 (1.169) 65.05 (2.561) 106.00 32.53 (4.173) (1.281) M10 OIL DRAIN PLUG 32.53 METRIC FLANGE: (1.281) M8 X 1.25-6H THRU...
  • Page 6 Specifi cations CH260/CH270 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. KohlerEngines.com 17 690 01 Rev. L...
  • Page 7 Specifi cations CH260/CH270 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 17 690 01 Rev. L KohlerEngines.com...
  • Page 8 Specifi cations CH395 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. KohlerEngines.com 17 690 01 Rev. L...
  • Page 9 Specifi cations CH395 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 17 690 01 Rev. L KohlerEngines.com...
  • Page 10 Specifi cations CH440 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. KohlerEngines.com 17 690 01 Rev. L...
  • Page 11 Specifi cations CH440 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 17 690 01 Rev. L KohlerEngines.com...

  • Page 12: Engine Identification Numbers

    Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
  • Page 13 Specifi cations TORQUE SPECIFICATIONS CH245/CH255 CH260/CH270 CH395 CH440 Crankcase Oil Drain Plug 18 N·m (13 ft. lb.) Closure Plate Screw 24 N·m (212 in. lb.) Cylinder Head Fastener (torque in 2 increments) First to 12 N·m (106 in. lb.) First to 18 N·m First to 25 N·m Finally to 24 N·m (212 in.

  • Page 14: Clearance Specifications

    Specifi cations TORQUE SPECIFICATIONS CH245/CH255 CH260/CH270 CH395 CH440 Muffl er Exhaust Screw 24 N·m (212 in. lb.) 35 N·m (310 in. lb.) Muffl er Shield Screw 8 N·m (71 in. lb.) 2 N·m (18 in. lb.) 3.5 N·m (31 in. lb.) Spark Arrestor Screw M5 3.5 N·m (31 in.
  • Page 15 Specifi cations CLEARANCE SPECIFICATIONS CH245/CH255 CH260/CH270 CH395 CH440 Connecting Rod Crankpin End I.D. @ 21°C (70°F) 30.021/30.026 mm 30.020/30.030 mm 33.020/33.030 mm 37.020/37.030 mm (1.1819/1.1823 in.) (1.1819/1.1823 in.) (1.3000/1.3004 in.) (1.4575/1.4579 in.) Max. Wear Limit 30.08 mm 30.106 mm 33.07 mm 37.08 mm (1.184 in.) (1.185 in.)
  • Page 16 Specifi cations CLEARANCE SPECIFICATIONS CH245/CH255 CH260/CH270 CH395 CH440 Cylinder Bore Bore I.D. 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.) Max. Wear Limit 70.200 mm (2.764 in.) 78.185 mm 89.185 mm (3.0781 in.) (3.5112 in.) Max.
  • Page 17 Specifi cations CLEARANCE SPECIFICATIONS CH245/CH255 CH260/CH270 CH395 CH440 Piston, Piston Rings, and Piston Pin (continued) Oil Control Ring-to-Groove Side 0.09/0.15 mm Clearance 0.05/0.19 mm (0.0019/0.0075 in.) (0.0035/0.0059 in.) Piston Thrust Face O.D. 67.975/67.985 mm 69.975/69.995 mm 77.955/77.975 mm 88.955/88.975 mm (2.6762/2.6766 (2.755/2.756 in.) (3.069/3.070 in.)

  • Page 18: General Torque Values

    Specifi cations 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 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
  • Page 19 Shrader Valve Adapter Hose DTI-037 Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031 Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033 K-Line Adapter Jumper Lead Wiring Harness Kohler 25 176 23-S Kohler Wireless Diagnostic System Module (Bluetooth®)
  • Page 20 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 KohlerEngines.com 17 690 01 Rev. L...
  • Page 21 Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S Dielectric Grease Loctite ® 51360 Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S RTV Silicone Sealant ® ®...

  • Page 22: Troubleshooting Guide

    Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at fi rst, 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 specifi cation. Use these to locate causing factors.
  • Page 23 Troubleshooting Sludge is a natural by-product of combustion; a small Engine Loses Power accumulation is normal. Excessive sludge formation ● Dirty air cleaner element. could indicate over rich fuel settings, weak ignition, ● Engine overheated. overextended oil change interval or wrong weight or ●...

  • Page 24: Crankcase Vacuum Test

    Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Keep hands, feet, hair, and clothing away from all Engine exhaust gases contain poisonous carbon moving parts to prevent injury.

  • Page 25: Compression Test

    Troubleshooting COMPRESSION TEST These engines are equipped with an automatic compression release (ACR) mechanism. It is diffi cult 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.

  • Page 26: Air Cleaner

    Air Cleaner/Intake NOTE: Operating engine with loose or damaged air AIR CLEANER cleaner components could cause premature These systems are CARB/EPA certifi ed and components wear and failure. Replace all bent or damaged should not be altered or modifi ed in any way. components.

  • Page 27: Breather Tube

    Air Cleaner/Intake 6. Make sure O-ring is in place on air cleaner base. Set Oil Bath oil reservoir cup on base. Some engines are equipped with an oil bath air cleaner. 7. Fill oil reservoir cup up to oil level mark with same Follow maintenance and oil change information specifi...

  • Page 28: Fuel Filter

    Low permeation fuel line must be installed on carbureted ignition. Never use gasoline as a cleaning agent. Kohler Co. engines to maintain EPA and CARB regulatory compliance. NOTE: Models with a low-profi le air cleaner do not have fuel valve.
  • Page 29 Fuel System CARBURETOR Gasoline is extremely fl ammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fi res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 30 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.
  • Page 31 To obtain high altitude carburetor kit engines is 3600 RPM (± 150 RPM). information or to fi nd a Kohler authorized dealer, visit 1. Set high idle speed by turning high idle speed KohlerEngines.com or call 1-800-544-2444 (U.S. and adjusting stop screw in or out.

  • Page 32: Electronic Governor

    Governor System GOVERNOR These engines are equipped with an electronic governor or a mechanical governor. ELECTRONIC GOVERNOR Components Yellow Oil Sensor Wiring Assembly Electronic Governor Carburetor Assembly Lead to Oil Alert Harness Control Green Lead Green Lead from Red Leads from White Lead from Electronic Governor Ignition Switch Lead...
  • Page 33 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.
  • Page 34 Governor System Electronic Governor Troubleshooting Flow Chart Continued Continued from • Disconnect connector between stepper motor and wiring harness. previous page. • 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 infi...
  • Page 35 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? Replace electronic governor Reassemble stepper motor.
  • Page 36 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 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.
  • Page 37 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 Repair/Replace as necessary. grounded to crankcase and retest. Short ignition kill wire to ground.
  • Page 38 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 Repair/Replace wiring harness module and and retest continuity.
  • Page 39 Governor System Stepper Motor Electronic Governor Control Stepper Motor Components Electronic Governor Control Components Stepper Motor Stepper Motor Cover Stepper Motor Stepper Motor Base Bracket Stepper Motor Post Carburetor CH395 CH440 Electronic Governor Stepper Motor Servicing CH270 Control Disassembly Wiring Harness NOTE: It is not necessary to remove stepper motor Connector base from carburetor assembly when replacing...

  • Page 40: Mechanical Governor

    Governor System ● One end of cross shaft protrudes through crankcase. MECHANICAL GOVERNOR Rotating action of cross shaft is transmitted to throttle CH245/CH255 Governor Components 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.
  • Page 41 Governor System tension of governor spring holds throttle plate open. CH260-CH440 Governor Components 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.

  • Page 42: Check Oil Level

    Lubrication System These engines use a splash lubrication system, supplying necessary lubrication to crankshaft, camshaft, connecting rod and valve train components. Lubrication Components Dipstick Oil Fill Plug Oil Drain Plug OIL RECOMMENDATIONS CHANGE OIL Refer to Maintenance. Change oil while engine is warm. CHECK OIL LEVEL 1.

  • Page 43: Spark Plugs

    Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...

  • Page 44: Electronic Ignition System

    Electrical System ELECTRONIC IGNITION SYSTEM Carbon Fouled Inductive Discharge Ignition System Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich carburetion, weak ignition, or poor compression. Overheated Ignition Module Magnet Kill Switch/Off Air Gap 0.252 mm Position of Key (0.010 in.) Switch...
  • Page 45 Electrical System Electronic Ignition Systems and Oil Sentry Tests ™ 1. Disconnect cap from spark plug and attach it to 5. With crankcase oil at proper level, set an ohmmeter terminal end of spark tester. Attach tester spring clip to Rx1 scale and zero meter. Connect one to a good ground, not to spark plug.
  • Page 46 Electrical System BATTERY CHARGING SYSTEMS NOTE: Observe following guidelines to avoid damage to electrical system and components: CH245, CH255 Wiring Diagram-Retractable Starter ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Make sure all ground connections are secure and in good condition.
  • Page 47 Electrical System Rectifi ed Only (non-regulated) Systems Some engines are equipped with a rectifi ed only, non-regulated charging system, with output ranging from 3 amps to 4 amps. Rectifi er is normally connected to engine with a matching wiring harness and secured inside control panel. Grounding is achieved through wiring harness.
  • Page 48 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 specifi c gravity of battery. If low, recharge or replace battery as necessary.
  • Page 49 Electrical System Wiring Diagram-10/18 Amp Charging System, with Rectifi er-Regulator Rectifi er-Regulator Stator Ignition Module Spark Plug Oil Float Switch Oil Control Module Key Switch Starter Motor Relay Battery Fuse 12 Volt Battery 17 690 01 Rev. L KohlerEngines.com...
  • Page 50 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 suffi cient 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.
  • Page 51 Starter System 4. Use a known, good, fully-charged battery and INERTIA DRIVE ELECTRIC STARTERS jumper cables to test starter motor. Be sure transmission is in neutral and PTO is OFF. WARNING 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 Accidental Starts can cause severe injury or of battery.
  • Page 52 3. Remove 4 screws and separate starter. 4. Remove drive assembly and retain shim. 5. Lubricate motor to drive assembly gears with Kohler starter drive lubricant. 6. Install shim on motor side of new drive assembly. 7. Reassemble starter components in reverse order.

  • Page 53: Retractable Starters

    Starter System RETRACTABLE STARTERS 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 Wear safety goggles or face protection when Retractable Starter for relieving spring tension.
  • Page 54 Starter System Remove Starter Pawls (dogs) Replacement 1. Remove screws securing starter to blower housing. 1. Install a clamp to hold pulley in starter housing and prevent it from rotating. 2. Remove starter assembly. 2. Unscrew center screw and lift off drive plate. Rope Replacement 3.
  • Page 55 Gear Reduction System WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 56 Gear Reduction System This reduction system uses an internal pinion and ring 5. Remove PTO shaft from reduction case. 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).
  • Page 57 Gear Reduction System 8. Remove reduction case gasket between reduction case and closure plate. Clean all gasket surfaces. 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.
  • Page 58 Gear Reduction System CH270 2:1 Gear Reduction System Components Oil Seal Chain Cover Chain Cover Gasket Ball Bearing Spring Washer PTO Sprocket Shaft Chain Flat Washer Splined Pinion Gear Pinion Spacer Closure Plate Torque Sequence This reduction system is lubricated by engine crankcase 3.
  • Page 59 Gear Reduction System 4. Remove cover and gasket. Ensure two dowel pins 7. If necessary, remove rear pinion spacer from remain in place. crankshaft. Note position of spring washer on outer side of PTO sprocket shaft. Spring Washer Pinion Spacer Chain Cover Inspection Remove gaskets and clean all gasket surfaces.
  • Page 60 Gear Reduction System CH245, CH255, CH270 2:1 with Clutch Gear Reduction System Components Oil Seal Drain Plug Reduction Cover Crankshaft Bearing Reduction Case PTO Shaft Chain Retainer Ring Cover Gasket Weight Holder Pin Clutch Holder Spring Weight Holder Clutch Weight Weight Retainer Pressure Plate Clutch Plate...
  • Page 61 Gear Reduction System 3. Remove screws securing reduction cover to 7. Separate clutch assembly components. Note order reduction case. of disassembly. Pressure Plate Clutch Plate Reduction Cover Friction Disc Clutch Center Gear Clutch Cup 4. Remove reduction cover and gasket. Ensure two dowel pins remain in place.
  • Page 62 Gear Reduction System 10. If servicing requires reduction case removal, remove Reassembly screws securing case to closure plate. NOTE: Use new gaskets when assembling. 11. Carefully separate reduction case and gasket from NOTE: Lightly lubricate metal clutch plate surfaces, all closure plate.
  • Page 63 Gear Reduction System CH395/CH440 6:1 Gear Reduction System Components Reduction Cover Oil Seal Reduction Cover PTO Shaft Bearing Reduction Cover Ball Bearing Spacer Flat Washer Gasket Countershaft Gear Drive Gear PTO Flange Adapter Closure Plate Assembly This reduction system is lubricated by engine crankcase 4.
  • Page 64 Gear Reduction System Inspection 5. Remove PTO shaft from bearing in closure plate. 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.
  • Page 65 Gear Reduction System CH395/CH440 2:1 with Clutch Gear Reduction System Components Oil Seal Reduction Cover Weight Holder Pin Retaining Ring Clutch Holder Spring Weight Holder Clutch Weight Weight Retainer Clutch Center Gear Square Key Pressure Plate Clutch Plate Friction Disc Clutch Cup Drive Gear Thrust Washer...
  • Page 66 Gear Reduction System Disassembly 6. Carefully remove clutch assembly, chain, and PTO NOTE: Place a drain pan under gear reduction unit to shaft with spring washer from unit as an assembly. catch any residual oil when cover is removed. Dispose of used oil in accordance with local ordinances.
  • Page 67 Gear Reduction System 9. If servicing requires reduction case removal, remove Reassembly screws securing case to closure plate. NOTE: Use new gaskets when assembling. 10. Carefully separate reduction case and gasket from NOTE: Lightly lubricate metal clutch plate surfaces, all closure plate.
  • Page 68 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 69 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Quad-Clean Base Only clean parts can be accurately inspected ™ Remove air cleaner base from engine as follows: and gauged for wear or damage. There are many commercially available cleaners that will quickly remove CH245/CH255 grease, oil, and grime from engine parts.
  • Page 70 Disassembly/Inspection and Service CH245/CH255 Blower Housing/Control Panel Components Retractable Starter Blower Housing Cylinder Head Shield Carburetor Linkage Spring Throttle Linkage Governor Lever Hex Flange Nut Speed Control Governor Spring Assembly KohlerEngines.com 17 690 01 Rev. L...
  • Page 71 Disassembly/Inspection and Service CH260/CH270 Blower Housing/Control Panel Components Retractable Starter Blower Housing Lower Shield Carburetor Dampening Spring Throttle Linkage Governor Lever Hex Flange Nut Governor Spring Throttle Lever Upper Shield 17 690 01 Rev. L KohlerEngines.com...
  • Page 72 Disassembly/Inspection and Service CH395/CH440 Blower Housing/Control Panel Components Retractable Starter Blower Housing Lower Shield Electric Starter Upper Shield Carburetor Fuel Brackets Throttle Lever Pivot Lever Governor Spring Dampening Spring Throttle Linkage Governor Lever Hex Flange Nut KohlerEngines.com 17 690 01 Rev. L...
  • Page 73 Disassembly/Inspection and Service CH395/CH440 Electronic Governor Blower Housing/Control Panel Components Retractable Starter Blower Housing Lower Shield Carburetor Electric Governor Stepper Upper Shield Control Motor 17 690 01 Rev. L KohlerEngines.com...
  • Page 74 Disassembly/Inspection and Service Remove External Throttle, Governor and Choke Remove Blower Housing and Shields Linkage (Mechanical Governor Only) 1. Remove screws and nuts (CH260 and CH270 only) 1. Mark which hole location governor spring is in on securing blower housing. each side.
  • Page 75 Disassembly/Inspection and Service CH245/CH255 Cylinder Head Components Valve Cover Hex Jam Nut Rocker Arm Pivot Rocker Arm Rocker Arm Stud Push Rod Push Rod Guide Valve Keeper Valve Spring Valve Stem Seal Spark Plug Cylinder Head Cylinder Head Valve Dowel Pin Gasket CH260-CH440 Cylinder Head Components Valve Cover...
  • Page 76 Disassembly/Inspection and Service Inspection and Service Remove Valve Cover/Breather, Rocker Arms, Push After cleaning, check fl atness of cylinder head and Rods, and Cylinder Head Assembly corresponding top surface of crankcase, using a surface plate or precision straight edge and feeler gauge. NOTE: Mark location of push rods and any other part Maximum allowable out of fl...
  • Page 77 Disassembly/Inspection and Service Lapping Valves Valve Seat Inserts NOTE: Exhaust valves that are black in color cannot be Hardened steel alloy intake and exhaust valve seat ground and do not require lapping. inserts are press-fi tted into cylinder head. Inserts are not replaceable but can be reconditioned if not too badly Reground or new valves must be lapped in, to provide pitted or distorted.
  • Page 78 Disassembly/Inspection and Service CH395 Valve Specifi cations Item Dimension Intake Exhaust 30.875-31.125 mm 26.875-27.125 mm Head Diameter (1.2156-1.2254 in.) (1.0581-1.0679 in.) 85.34-85.54 mm 85.19-84.99 mm Valve Length (3.3598-3.3677 in.) (3.3461-3.3539 in.) 6.560-6.575 mm 6.560-6.575 mm Stem Diameter (0.2583-0.2589 in.) (0.2583-0.2589 in.) Face/Seat Width - Maximum 1.5 mm (0.059 in.) 1.5 mm (0.059 in.)
  • Page 79 Disassembly/Inspection and Service CH245/CH255 Flywheel/Ignition Components Remove Ignition Module Remove screws securing ignition module to crankcase. Remove module. Remove Flywheel NOTE: Whenever possible, an impact wrench should be used to loosen fl ywheel retaining nut. A fl ywheel strap wrench may be used to hold fl ywheel when loosening or tightening fl...
  • Page 80 Disassembly/Inspection and Service CH245/CH255 Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Bearing Closure Plate Camshaft Connecting Rod Crankshaft Connecting Rod Piston Pin Retainer End Cap Oil Sentry Float Piston Pin Piston Piston Ring Set ™ Switch Oil Sentry Wire Governor Cup Governor Washer...
  • Page 81 Disassembly/Inspection and Service CH260/CH270 Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Closure Plate Bearing Camshaft Crankshaft Piston Pin Retainer Piston Pin Piston Connecting Rod Connecting Rod Piston Ring Set Governor Cup End Cap Oil Sentry Float Governor Washer Governor Shaft Governor Gear ™...
  • Page 82 Disassembly/Inspection and Service CH395/CH440 Crankshaft/Camshaft/Closure Plate Components Closure Plate Balance Closure Plate Oil Seal Closure Plate Closure Plate Bearing Shaft Bearing Balance Shaft Governor Shaft Governor Washer Governor Gear Connector Rod Governor Cup Crankshaft Connector Rod End Cap Piston Pin Retainer Piston Pin Piston Piston Ring Set...
  • Page 83 Disassembly/Inspection and Service ACR mechanism consists of a spring-loaded arm and Remove Closure Plate sliding pin mounted to camshaft. When engine is rotating NOTE: Do not pry on gasket surface of crankcase or at low cranking speeds, arm holds pin so it protrudes closure plate, as this can cause damage and above heel of exhaust cam.
  • Page 84 Disassembly/Inspection and Service Inspection and Service Dimension B Dimension A Cam Lobe Specifi cations CH245/CH255 Cam Lobe Engine Valve Dimension B Service Limit Valve Dimension A Service Limit Model 27.608 mm 27.354 mm 22.2 mm 21.8 mm INTAKE INTAKE (1.087 in.) (1.067 in.) (0.874 in.) (0.858 in.)
  • Page 85 Disassembly/Inspection and Service Dimension C Piston and Rings Inspection Scuffi ng 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.
  • Page 86 Disassembly/Inspection and Service 4. Before installing new rings on piston, place top 2 2. Middle compression ring (center groove): Install rings, each in turn, in its running area in cylinder center ring using a piston ring expander tool. Make bore and check end gap. Refer to Specifi cations. sure identifi...
  • Page 87 Disassembly/Inspection and Service Crankcase Inspection and Service Remove Governor Assembly (Mechanical Governor Cylinder Bore Detail Only) 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.
  • Page 88 Measuring Piston-to-Bore Clearance Piston Details 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 (Specifi cations and Tolerances).
  • Page 89 Reassembly CH245/CH255 Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Bearing Closure Plate Camshaft Connecting Rod Crankshaft Connecting Rod Piston Pin Retainer End Cap Oil Sentry Float Piston Pin Piston Piston Ring Set ™ Switch Oil Sentry Wire Governor Cup Governor Washer Governor Shaft ™...
  • Page 90 Reassembly CH260/CH270 Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Closure Plate Bearing Camshaft Crankshaft Piston Pin Retainer Piston Pin Piston Connecting Rod Connecting Rod Piston Ring Set Governor Cup End Cap Oil Sentry Float Governor Washer Governor Shaft Governor Gear ™...
  • Page 91 Reassembly CH395/CH440 Crankshaft/Camshaft/Closure Plate Components Closure Plate Balance Closure Plate Oil Seal Closure Plate Closure Plate Bearing Shaft Bearing Balance Shaft Governor Shaft Governor Washer Governor Gear Connector Rod Governor Cup Crankshaft Connector Rod End Cap Piston Pin Retainer Piston Pin Piston Piston Ring Set Oil Sentry...
  • Page 92 Reassembly NOTE: Make sure engine is assembled using all Install Governor Assembly (Mechanical Governor specifi ed torque values, tightening sequences, Only) and clearances. Failure to observe specifi cations CH245, CH255, CH260/CH270 could cause severe engine wear or damage. Always use new gaskets. Governor Details Install Crankcase Bearings and Oil Seals Details...
  • Page 93 Reassembly CH395 CH440 Governor Details Governor Details Thrust Washer Governor Gear Pin Rim Washer Hitch Pin Thrust Washer 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.
  • Page 94 Reassembly 4. Pull governor gear up until it makes contact with Install Connecting Rod with Piston and Rings ring, then place pin in cup, retaining rim with weights. Connecting Rod Details 5. Push pin down, snapping ring into shaft groove. 6.
  • Page 95 Reassembly Install Balance Shaft (if equipped) Install Closure Plate 1. Position crankshaft so timing mark on larger CH245/CH255/CH260/CH270 Torque Sequence 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 Timing Mark Detail CH395/CH440 Torque Sequence CH245/255 Sealant Pattern...
  • Page 96 Reassembly NOTE: Make sure governor lever is against cup on CH260/270 Sealant Pattern 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.
  • Page 97 Reassembly CH260/CH270 Flywheel/Ignition Components Install Flywheel CAUTION Damaging Crankshaft and Flywheel can cause personal injury. Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing fl ywheel. Flywheel Retaining Drive Cup NOTE: Before installing fl...
  • Page 98 Reassembly Install Ignition Module NOTE: Ensure ignition module is correctly oriented. 1. Turn fl ywheel 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 fl ywheel as possible, then tighten screws just enough to hold it in position.
  • Page 99 Reassembly CH260-CH440 Cylinder Head Components Valve Cover Adjuster Nut Rocker Arm Rocker Arm Stud Push Rod Guide Push Rod Valve Keeper Valve Spring Valve Stem Seal Spark Plug Cylinder Head Valve Cylinder Head Dowel Pin Torque Sequence Gasket CH245, CH255, CH260, CH270, CH395 Assemble Cylinder Head 5.
  • Page 100 Reassembly Install Push Rods and Rocker Arms CH245/CH255 Valve Cover with RTV 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.
  • Page 101 Reassembly CH245/CH255 Blower Housing/Control Panel Components Retractable Starter Blower Housing Cylinder Head Shield Carburetor Linkage Spring Throttle Linkage Governor Lever Hex Flange Nut Speed Control Governor Spring Assembly 17 690 01 Rev. L KohlerEngines.com...
  • Page 102 Reassembly CH260/CH270 Blower Housing/Control Panel Components Retractable Starter Blower Housing Lower Shield Carburetor Dampening Spring Throttle Linkage Governor Lever Hex Flange Nut Governor Spring Throttle Lever Upper Shield KohlerEngines.com 17 690 01 Rev. L...
  • Page 103 Reassembly CH395/CH440 Blower Housing/Control Panel Components Retractable Starter Blower Housing Lower Shield Electric Starter Upper Shield Carburetor Fuel Tank Brackets Throttle Lever Pivot Lever Governor Spring Dampening Spring Throttle Linkage Governor Lever 17 690 01 Rev. L KohlerEngines.com...
  • Page 104 Reassembly CH395/CH440 Electronic Governor Blower Housing/Control Panel Components Retractable Starter Blower Housing Lower Shield Carburetor Electric Governor Stepper Upper Shield Control Motor KohlerEngines.com 17 690 01 Rev. L...
  • Page 105 Reassembly Install Fuel Tank Supports and Shut Down Switch Install Engine Shields and Air Cleaner Base with Bracket (if equipped) CH245, CH255 1. Install a new carburetor to air cleaner base gasket CH260, CH270 onto carburetor mounting studs followed by air 1.
  • Page 106 Reassembly Install Electric Starter and Control Panel (if Install Fuel Tank CH245/CH255 (if equipped) 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 ™...
  • Page 107 Reassembly CH245/CH255 Governor Lever Hole Position/RPM Chart 8-13% Droop Engine Speed RPM Spring Color Hole 3801-4000 Black CH260/CH270 Governor Lever Hole Position/RPM Chart 5-8% Droop 5-10% Droop 8-12% Droop Engine Speed Spring Hole Spring Hole Spring Hole Color Combination Color Combination Color Combination...
  • Page 108 Reassembly CH395 Governor Lever Hole Position/RPM Chart 3-8% Droop 6-10% Droop 7-12% Droop Engine Speed Spring Hole Spring Hole Spring Hole Color Combination Color Combination Color Combination 2800-3000 Yellow #1-B 3001-3200 Black #1-B Yellow #1-B 3201-3400 Yellow #1-B 3401-3600 Yellow #2-B 3601-3800 Purple #1-A...
  • Page 109 Reassembly External Engine Components CH395, CH440 CH260-CH440 Oil Drain Plug Breather Hose Muffl er Assembly Quad-Clean Cover ™ CH260-CH440 CH260-CH440 CH260-CH440 CH245-CH255 Quad-Clean Quad-Clean Base Carburetor Shroud Quad-Clean Cover ™ Element/Precleaner ™ ™ CH245-CH255 CH245-CH255 Quad-Clean Fuel Tank Fuel Line Quad-Clean Base ™...
  • Page 110 Reassembly Install Oil Sentry Module Prepare Engine for Operation ™ NOTE: If Oil Sentry module is mounted inside control Engine is now reassembled. Before starting or operating ™ panel, skip this step. engine be sure to do following: 1. Install Oil Sentry module and secure with screw.
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  • Page 112 © 2021 by Kohler Co. All rights reserved. KohlerEngines.com 17 690 01 Rev. L...

This manual is also suitable for:

Command pro ch245Command pro ch255Command pro ch260Command pro ch270Command pro ch395

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