Kohler CH 270 User Manual

CH260-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 Specications 18 Tools and Aids 21 Troubleshooting 25 Air Cleaner/Intake 26 Fuel System 30 Governor System 31 Lubrication System 32 Electrical System 39 Starter System 43 Disassembly/Inspection and Service 58 Reassembly

117 690 01 Rev. E KohlerEngines.com

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 res and severe burns.

Do not ll fuel tank while engine is hot or running.

Gasoline is extremely ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent.

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. Never operate engine with covers, shrouds, or guards removed.

WARNING

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.

Hot Parts can cause severe burns.

Do not touch engine while operating or just after stopping.

Never operate engine with heat shields or guards removed.

Cleaning Solvents can cause severe injury or death.

Use only in well ventilated areas away from ignition sources.

Carburetor cleaners and solvents are extremely ammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

WARNING

Electrical Shock can cause injury.

Do not touch wires while engine is running.

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 ywheel.

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.

CAUTION

WARNING

KohlerEngines.com 17 690 01 Rev. E

Maintenance

MAINTENANCE INSTRUCTIONS

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead(s) 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 rst 5 Hours

● Change oil. Lubrication System

Every 50 Hours or Annually

● Service/replace Quad-Clean

precleaner. Air Cleaner/Intake

™

Every 100 Hours or Annually¹

● Clean low-prole air cleaner element. Air Cleaner/Intake

● Change oil. Lubrication System

● Clean cooling areas. Air Cleaner/Intake

● Replace spark plug and set gap. Electrical System

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.

Every 200 Hours²

● Check and adjust valve clearance when engine is cold. Reassembly

Every 200 Hours

● Replace Quad-Clean

air cleaner element. Air Cleaner/Intake

™

Every 300 Hours

● Replace low-prole air cleaner element. Air Cleaner/Intake

● Check fuel lters (tank outlet lter and in-line lter) clean or replace if needed (if equipped).

Perform these procedures more frequently under severe, dusty, dirty conditions.

Have a Kohler authorized dealer perform this service.

Fuel System

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. To nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

17 690 01 Rev. E KohlerEngines.com

Maintenance

OIL RECOMMENDATIONS

We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below.

FUEL RECOMMENDATIONS

WARNING

Explosive Fuel can cause res and severe burns.

Do not ll fuel tank while engine is hot or running.

STORAGE

If engine will be out of service for 2 months or more follow procedure below.

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).

2. 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.

3. Disconnect negative (-) battery cable.

4. Store engine in a clean, dry place.

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:

● Clean, fresh, unleaded gasoline.

● Octane rating of 87 (R+M)/2 or higher.

● Research Octane Number (RON) 90 octane minimum.

● Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable.

● Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved.

● Do not add oil to gasoline.

● Do not overll fuel tank.

● Do not use gasoline older than 30 days.

KohlerEngines.com 17 690 01 Rev. E

CH260/CH270 Engine Dimensions

Specications

Dimensions in millimeters.

Inch equivalents shown in [ ].

17 690 01 Rev. E KohlerEngines.com

Specications

CH260/CH270 Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

KohlerEngines.com 17 690 01 Rev. E

CH395 Engine Dimensions

Specications

Dimensions in millimeters.

Inch equivalents shown in [ ].

17 690 01 Rev. E KohlerEngines.com

Specications

CH395 Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

KohlerEngines.com 17 690 01 Rev. E

CH440 Engine Dimensions

Specications

Dimensions in millimeters.

Inch equivalents shown in [ ].

17 690 01 Rev. E KohlerEngines.com

Specications

CH440 Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

KohlerEngines.com 17 690 01 Rev. E

Specications

ENGINE IDENTIFICATION NUMBERS

Kohler engine identication numbers (model, specication and serial) should be referenced for efcient repair, ordering correct parts, and engine replacement.

Model . . . . . . . . . . . . . . . . . . . . . CH260

Command Engine

Horizontal Shaft

Numerical Designation

Specication . . . . . . . . . . . . . . . CH260-0001

Serial . . . . . . . . . . . . . . . . . . . . . 3923500328

Year Manufactured Code Factory Code Code Year 39 2009 40 2010 41 2011

GENERAL SPECIFICATIONS

3,6

CH260/CH270 CH395 CH440

Bore 70 mm (2.8 in.) 78 mm (3.1 in.) 89 mm (3.5 in.) Stroke 54 mm (2.1 in.) 58 mm (2.3 in.) 69 mm (2.7 in.) Displacement 208 cc

(12.7 cu. in.)

Oil Capacity (rell) 0.6 L

(0.63 U.S. qt.)

Maximum Angle of Operation (@ full oil level)

TORQUE SPECIFICATIONS

3,5

CH260/CH270 CH395 CH440

277 cc

(16.9 cu. in.)

1.1 L

(1.16 U.S. qt.)

25°

429 cc

(24.7 cu. in.)

1.3 L

(1.37 U.S. qt.)

Air Cleaner

Quad-Clean

Air Cleaner Base Mounting Screw 8.0 N·m (71 in. lb.)

™

Low-Prole Air Cleaner Base Mounting Screw 6.7 N·m (59 in. lb.)

Blower Housing and Sheet Metal

M6 Screw 10 N·m (89 in. lb.) M6 Nut 8.0 N·m (71 in. lb.)

Carburetor

Stud 10 N·m (89 in. lb.) Primary Nut 8 N·m (71 in. lb.) Intake Cover Nut 4 N·m (35 in. lb.) Intake Cover Screw 1.3 N·m (12 in. lb.)

Connecting Rod

Cap Fastener (torque in increments) 12 N·m

20 N·m (177 in. lb.)

(106 in. lb.)

Values are in Metric units. Values in parentheses are English equivalents.

Exceeding maximum angle of operation may cause engine damage from insufcient lubrication.

Lubricate threads with engine oil prior to assembly.

Any and all horsepower (hp) references by Kohler are Certied Power Ratings and per SAE J1940 & J1995 hp

standards. Details on Certied Power Ratings can be found at KohlerEngines.com.

17 690 01 Rev. E KohlerEngines.com

Specications

TORQUE SPECIFICATIONS

3,5

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 (159 in. lb.)

Finally to 36 N·m (319 in. lb.)

Finally to 24 N·m

(212 in. lb.)

Electric Starter

Mounting Screw 24 N·m (212 in. lb.)

Flywheel

Retaining Nut 74 N·m

113 N·m (1000 in. lb.)

(655 in. lb.)

Fuel Tank

Mounting Nut 24 N·m (212 in. lb.) Mounting Screw 24 N·m (212 in. lb.) Inlet Fitting 1.5 N·m (13 in. lb.)

Governor

Lever Nut 12 N·m (106 in. lb.) Throttle Control Lever Nut 9 N·m (80 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.) Module Fastener 10 N·m (89 in. lb.) Oil Sentry Oil Sentry Oil Sentry

Float Switch Screw 8 N·m (71 in. lb.)

™

Module Screw 3.5 N·m (31 in. lb.)

™

Wire Lead Nut 10 N·m (89 in. lb.)

™

Mufer

Exhaust Screw M8 M10

24 N·m (212 in. lb.)

---

35 N·m (310 in. lb.)

Mufer Shield Screw M6 8 N·m (71 in. lb.)

M4 2 N·m (18 in. lb.) 3.5 N·m (31 in. lb.) Spark Arrestor Screw M5 3.5 N·m (31 in. lb.)

Retractable Starter

Cover Screw 5.4 N·m (48 in. lb.) Center Screw 10 N·m (89 in. lb.)

Rocker Arm

Stud 13.6 N·m (120 in. lb.) Pivot Jam Nut 10 N·m (89 in. lb.)

Values are in Metric units. Values in parentheses are English equivalents.

Lubricate threads with engine oil prior to assembly.

KohlerEngines.com 17 690 01 Rev. E

Specications

TORQUE SPECIFICATIONS

3,5

CH260/CH270 CH395 CH440

Valve Cover

Fastener 10 N·m (89 in. lb.)

CLEARANCE SPECIFICATIONS

CH260/CH270 CH395 CH440

Camshaft

Running Clearance 0.007/0.043 mm

(0.0003/0.0017 in.)

0.016/0.052 mm

(0.0006/0.0020 in.)

Bore I.D. New 13.991/14.009 mm

16.000/16.018 mm (0.6300/0.6310 in.)

(0.5508/0.5515 in.)

Max. Wear Limit 14.018 mm

16.068 mm (0.6289 in.)

(0.5519 in.)

Camshaft Bearing Surface O.D. New 13.975 mm

15.975 mm (0.63 in.)

(0.55 in.)

Max. Wear Limit 13.90 mm

15.90 mm (0.626 in.)

(0.547 in.)

Cam Lobe Prole (minimum dimension, measured from base circle to top of lobe) Intake - New 31.966 mm

(1.259 in.)

Max. Wear Limit 31.72 mm

(1.249 in.)

Exhaust - New 31.966 mm

(1.259 in.)

Max. Wear Limit 31.72 mm

(1.249 in.)

32.544 mm (1.281 in.)

32.11 mm (1.264 in.)

32.256 mm (1.270 in.)

31.79 mm (1.252 in.)

33.266 mm (1.310 in.)

32.26 mm (1.270 in.)

32.642 mm (1.285 in.)

31.61 mm (1.245 in.)

Connecting Rod

Crankpin End I.D. @ 21°C (70°F) New 30.021/30.026 mm

(1.1819/1.1821 in.)

Max. Wear Limit 30.08 mm

(1.184 in.)

33.020/33.030 mm (1.3000/1.3004 in.)

33.07 mm (1.302 in.)

37.08 mm (1.460 in.)

Connecting Rod-to-Crankpin Side Clearance New 0.58/0.60 mm

(0.023/0.024 in.)

Max. Wear Limit 1.10 mm

(0.043 in.)

Connecting Rod-to-Piston Pin Running Clearance 0.008/0.025 mm

(0.0003/0.0010 in.)

0.73 mm

(0.029 in.)

1.36 mm

(0.054 in.)

0.006/0.028 mm

(0.0002/0.0011 in.)

0.56 mm

(0.022 in.)

1.06 mm

(0.042 in.)

0.008/0.025 mm

(0.0003/0.0010 in.)

Piston Pin End I.D. @ 21°C (70°F) New 18.010/18.015 mm

(0.7091/0.7093 in.)

18.004/18.020 mm (0.7088/0.7094 in.)

20.000/20.008 mm (0.7874/0.7874 in.)

Max. Wear Limit 18.08 mm (0.712 in.) 20.05 mm

(0.789 in.)

Crankcase

Governor Cross Shaft Bore I.D. New

Max. Wear Limit 6.037 mm

6.000/6.024 mm

(0.2362/0.2372 in.)

8.000/8.024 mm (0.3150/0.3159 in.)

8.074 mm (0.7118 in.)

(0.2377 in.)

Values are in Metric units. Values in parentheses are English equivalents.

17 690 01 Rev. E KohlerEngines.com

Specications

CLEARANCE SPECIFICATIONS

CH260/CH270 CH395 CH440

Crankshaft

End Play (free) 0.0508/0.254 mm (0.002/0.010 in.) Ball Bearing Internal Clearance 0.003/0.025 mm

(0.0001/0.0010 in.)

Crankshaft O.D. (new) 24.975/24.989 mm

(0.9833/0.9838 in.)

0.005/0.020 mm

(0.0002/0.0008 in.)

29.975/29.989 mm (1.1801/1.1807 in.)

0.006/0.020 mm

(0.0002/0.0008 in.)

34.975/34.989 mm (1.3770/1.3775 in.)

Connecting Rod Journal O.D. New 30.020/30.030 mm

(1.1819/1.1823 in.)

Max. Wear Limit 30.08 mm

(1.1842 in.)

Max. Taper Max. Out-of-Round

Width 24.5/24.9 mm

(0.9646/0.9803 in.)

32.975/32.985 mm (1.2982/1.2986 in.)

32.92 mm

(1.2961 in.)

2.5 microns (0.0001 in.)

12.7 microns (0.0005 in.)

30.30/30.36 mm

(1.1930/1.1953 in.)

36.975/36.985 mm (1.4557/1.4561 in.)

28.30/28.36 mm

(1.1142/1.1165 in.) Runout (either end) 0.025 mm (0.001 in.) Main Bearing I.D. (Crankcase/Closure Plate)

New (installed) 24.992/25.000 mm

(0.9839/0.9842 in.)

29.990/30.000 mm

1.1807/1.1811 in.)

34.990/35.000 mm (1.3776/1.3780 in.)

Cylinder Bore

Bore I.D. New

Max. Wear Limit 70.200 mm

Max. Out-of-Round Max. Taper

70.027/70.035 mm (2.757/2.757 in.)

(2.764 in.)

77.98/78.02 mm

(3.0701/3.0717 in.)

78.185 mm (3.0781 in.)

12.7 microns (0.0005 in.)

89.00/89.02 mm

(3.5039/3.5045 in.)

36.92 mm

(1.4535 in.)

89.185 mm (3.5112 in.)

Cylinder Head

Max. Out-of-Flatness 0.08 mm

0.1 mm (0.004 in.)

(0.003 in.)

Governor

Governor Cross Shaft -to-Crankcase Running

0.020/0.069 mm (0.0008/0.0027 in.)

Clearance Governor Cross Shaft O.D.

New Max. Wear Limit 5.942 mm

5.955/5.980 mm

(0.2344/0.2354 in.)

7.955/7.980 mm

(0.3132/0.3142 in.)

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 Max. Wear Limit

6.016/6.028 mm (0.2368/0.2373 in.)

6.003 mm (0.2363 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.) Module Air Gap 0.254 mm (0.010 in.)

Values are in Metric units. Values in parentheses are English equivalents.

KohlerEngines.com 17 690 01 Rev. E

Specications

CLEARANCE SPECIFICATIONS

CH260/CH270 CH395 CH440

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.)

(0.0003/0.0006 in.)

Piston Pin Bore I.D. New 18.004/18.005 mm

(0.7088/0.7089 in.)

18.000/18.008 mm (0.7087/0.7090 in.)

20.000/20.008 mm (0.7874/0.7877 in.)

Max. Wear Limit 18.05 mm (0.7106 in.) 20.05 mm

(0.7894 in.)

Piston Pin O.D. New 17.992/17.995 mm (0.7083/0.7084 in.)

19.992/19.998 mm (0.7871/0.7873 in.)

Max. Wear Limit 17.95 mm (0.7067 in.) 19.95 mm

(0.7854 in.)

Top and Center Compression Ring Side Clearance New Bore 0.04 mm

(0.002 in.)

Used Bore (Max.) 0.15 mm

(0.006 in.)

Top Compression Ring End Gap New Bore

0.325/0.400 mm (0.013/0.016 in.)

0.07 mm

(0.003 in.)

0.11 mm

(0.004 in.)

0.045 mm

(0.0018 in.)

0.10 mm

(0.004 in.)

0.250/0.400 mm (0.010/0.016 in.)

Used Bore (Max.) 1.00 mm (0.039 in.) Center Compression Ring End Gap

New Bore Used Bore (Max.) 1.00 mm

0.325/0.400 mm (0.013/0.016 in.)

0.650/0.800 mm

(0.026/0.032 in.)

1.50 mm (0.059 in.)

0.640/0.800 mm (0.025/0.032 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.)

Piston Thrust Face O.D. New 69.970/69.960 mm

(2.755/2.754 in.)

Max. Wear Limit 69.82 mm

(2.749 in.)

Piston Thrust Face-to-Cylinder Bore Running Clearance

0.057/0.075 mm

(0.002/0.003 in.)

77.955/77.975 mm

(3.071/3.070 in.)

77.82 mm (3.064 in.)

0.033/0.067 mm

(0.001/0.003 in.)

88.955/88.975 mm

(3.502/3.503 in.)

88.82 mm (3.497 in.)

0.025/0.060 mm

(0.001/0.002 in.)

Values are in Metric units. Values in parentheses are English equivalents.

Measure 21.8-22.2 mm (0.8583-0.8740 in.) above bottom of piston skirt at right angles to piston pin.

Measure 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. E KohlerEngines.com

Specications

CLEARANCE SPECIFICATIONS

CH260/CH270 CH395 CH440

Valves and Valve Lifters

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 (0.0016/0.0026 in.)

(0.0033/0.0044 in.)

Intake Valve Stem O.D. New

5.50 mm

(0.217 in.)

Max. Wear Limit 5.34 mm

(0.210 in.)

Exhaust Valve Stem O.D. New 5.438 mm

(0.214 in.)

Max. Wear Limit 5.28 mm

(0.208 in.)

Intake Valve Stem to Guide New 0.024/0.039 mm

0.025/0.055 mm (0.0010/0.0022 in.)

(0.0009/0.0015 in.)

Max. Wear Limit 0.10 mm

(0.0039 in.)

0.13 mm

(0.0051 in.)

Exhaust Valve Stem 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

(0.0047 in.)

Valve Guide Reamer Size Standard Intake

5.524 mm (0.2175 in.)

0.10 mm

(0.0039 in.)

Standard Exhaust 5.536 mm (0.2179

in.)

Valve Seat Width 0.80 mm (0.0315

1.10 mm (0.0433

in.)

Nominal Valve Face Angle 45°

6.57 mm (0.259 in.)

6.40 mm (0.252 in.)

6.55 mm (0.258 in.)

6.41 mm (0.252 in.)

0.14 mm

(0.0055 in.)

0.11 mm

(0.0043 in.)

6.608 mm (0.2602 in.)

1.20 mm (0.0472

in.)

Values are in Metric units. Values in parentheses are English equivalents.

KohlerEngines.com 17 690 01 Rev. E

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

Size Grade 2 Grade 5 Grade 8

Tightening Torque: N·m (in. lb.) ± 20%

8-32 2.3 (20) 2.8 (25) — 2.3 (20) 10-24 3.6 (32) 4.5 (40) — 3.6 (32) 10-32 3.6 (32) 4.5 (40) — —

1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)

1/4-28 9.6 (85) 15.8 (140) 22.6 (200) — 5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150) 5/16-24 18.7 (165) 30.5 (270) — —

3/8-16 29.4 (260) — — —

3/8-24 33.9 (300) — — —

Tightening Torque: N·m (ft. lb.) ± 20%

5/16-24 — — 40.7 (30) —

3/8-16 — 47.5 (35) 67.8 (50) —

3/8-24 — 54.2 (40) 81.4 (60) — 7/16-14 47.5 (35) 74.6 (55) 108.5 (80) — 7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —

1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —

1/2-20 94.9 (70) 142.4 (105) 223.7 (165) — 9/16-12 101.7 (75) 169.5 (125) 237.3 (175) — 9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —

5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —

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 (200) 440.7 (325) 637.3 (470) —

Specications

Into Aluminum

Metric Fastener Torque Recommendations for Standard Applications

Size

4.8

5.8

Property Class

8.8

10.9 12.9

Noncritical

Fasteners

Into Aluminum

Tightening Torque: N·m (in. lb.) ± 10%

M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18) M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35) M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60) M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)

Tightening Torque: N·m (ft. lb.) ± 10%

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25) M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45) M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

Torque Conversions

N·m = in. lb. x 0.113 in. lb. = N·m x 8.85

N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

17 690 01 Rev. E KohlerEngines.com

Tools and Aids

Certain quality tools are designed to help you perform specic 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 Contact your local Kohler source of supply.

TOOLS

Description Source/Part No.

Alcohol Content Tester

For testing alcohol content (%) in reformulated/oxygenated fuels.

Camshaft Endplay Plate

For checking camshaft endplay.

Camshaft Seal Protector (Aegis)

For protecting seal during camshaft installation.

Cylinder Leakdown Tester

For checking combustion retention and if cylinder, piston, rings, or valves are worn. Individual component available: Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)

Dealer Tool Kit (Domestic)

Complete kit of Kohler required tools. Components of 25 761 39-S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectier-Regulator Tester (120 V AC/60Hz)

Dealer Tool Kit (International)

Complete kit of Kohler required tools. Components of 25 761 42-S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectier-Regulator Tester (240 V AC/50Hz)

Digital Vacuum/Pressure Tester

For checking crankcase vacuum. Individual component available: Rubber Adapter Plug

Electronic Fuel Injection (EFI) Diagnostic Software

For Laptop or Desktop PC.

EFI Service Kit

For troubleshooting and setting up an EFI engine. Components of 24 761 01-S Fuel Pressure Tester Noid Light 90° Adapter In-line "T" Fitting Code Plug, Red Wire Code Plug, Blue Wire Shrader Valve Adapter Hose

Flywheel Holding Tool (CS)

For holding ywheel of CS series engines.

Flywheel Puller

For properly removing ywheel from engine.

Flywheel Strap Wrench

For holding ywheel during removal.

SE Tools 415 Howard St. Lapeer, MI 48446 Phone 810-664-2981 Toll Free 800-664-2981 Fax 810-664-8181

Design Technology Inc. 768 Burr Oak Drive Westmont, IL 60559 Phone 630-920-1300 Fax 630-920-0011

Kohler 25 455 11-S

SE Tools KLR-82405

SE Tools KLR-82417

Kohler 25 761 05-S

Design Technology Inc.

DTI-731-03

Kohler 25 761 39-S

Kohler 25 455 01-S Kohler 25 761 05-S Kohler 25 761 06-S Kohler 25 761 20-S

Kohler 25 761 42-S

Kohler 25 455 01-S Kohler 25 761 05-S Kohler 25 761 06-S Kohler 25 761 41-S

Design Technology Inc.

DTI-721-01

Design Technology Inc.

DTI-721-10

Kohler 25 761 23-S

Kohler 24 761 01-S

Design Technology Inc.

DTI-019 DTI-021 DTI-023 DTI-035 DTI-027 DTI-029 DTI-037

SE Tools KLR-82407

SE Tools KLR-82408

SE Tools KLR-82409

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Tools and Aids

TOOLS

Description Source/Part No.

Hydraulic Valve Lifter Tool

For removing and installing hydraulic lifters.

Ignition System Tester

For testing output on all systems, including CD.

Inductive Tachometer (Digital)

For checking operating speed (RPM) of an engine.

Offset Wrench (K and M Series)

For removing and reinstalling cylinder barrel retaining nuts.

Oil Pressure Test Kit

For testing/verifying oil pressure on pressure lubricated engines.

Radiator Tester

For pressure testing radiator and cap on Aegis liquid-cooled engines.

Rectier-Regulator Tester (120 volt current) Rectier-Regulator Tester (240 volt current)

For testing rectier-regulators. Components of 25 761 20-S and 25 761 41-S CS-PRO Regulator Test Harness Special Regulator Test Harness with Diode

Spark Advance Module (SAM) Tester

For testing SAM (ASAM and DSAM) on engines with SMART-SPARK

™

Starter Servicing Kit (All Starters)

For removing and reinstalling drive retaining rings and brushes. Individual component available: Starter Brush Holding Tool (Solenoid Shift)

Triad/OHC Timing Tool Set

For holding cam gears and crankshaft in timed position while installing timing belt.

Valve Guide Reamer (K and M Series)

For properly sizing valve guides after installation.

Valve Guide Reamer O.S. (Command Series)

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

For hand reaming using Kohler 25 455 12-S reamer.

Valve Guide Service Kit (Courage, Aegis, Command, OHC)

For servicing worn valve guides.

Kohler 25 761 38-S

Kohler 25 455 01-S

Design Technology Inc.

DTI-110

Kohler 52 455 04-S

Kohler 25 761 06-S

Kohler 25 455 10-S

Kohler 25 761 20-S Kohler 25 761 41-S

Design Technology Inc.

DTI-031 DTI-033

Kohler 25 761 40-S

SE Tools KLR-82411

SE Tools KLR-82416

Kohler 28 761 01-S

Design Technology Inc.

DTI-K828

Kohler 25 455 12-S

Design Technology Inc.

DTI-K830

SE Tools KLR-82415

AIDS Description Source/Part No.

Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S 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

Loctite Only oxime-based, oil resistant RTV sealants, such as those listed, are approved

5900® Heavy Body in 4 oz. aerosol dispenser.

for use. Loctite® Nos. 5900® or 5910® are recommended for best sealing characteristics.

Kohler 25 597 07-S

Loctite® 5910

Loctite® Ultra Black 598™

Loctite® Ultra Blue 587™

Loctite® Ultra Copper 5920™

Spline Drive Lubricant Kohler 25 357 12-S

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Tools and Aids

FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL

A ywheel holding tool can be made out of an old junk ywheel 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 ywheel ring gear teeth. Bosses will lock tool and ywheel in position for loosening, tightening, or removing with a puller.

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 larger 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 at.

3. Find a 1 in. long capscrew with correct thread size to match threads in connecting rod.

4. Use a at washer with correct I.D. to slip on capscrew and approximately 1 in. O.D. Assemble capscrew and washer to joint surface of rod.

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Troubleshooting

TROUBLESHOOTING GUIDE

When troubles occur, be sure to check simple causes which, at 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 specication. 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 lter.

● 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.

● Insufcient 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).

● SMART-SPARKTM malfunction.

● Spark plug lead(s) disconnected.

Engine Starts But Does Not Keep Running

● 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.

● Quality of fuel (dirt, water, stale, mixture).

● Restricted fuel tank cap vent.

Engine Starts Hard

● Clogged fuel line or fuel lter.

● Engine overheated.

● Faulty ACR mechanism.

● Faulty or misadjusted choke or throttle controls.

● Faulty spark plug(s).

● Flywheel key sheared.

● Fuel pump malfunction-vacuum hose clogged or leaking.

● Interlock switch is engaged or faulty.

● Loose wires or connections that intermittently ground ignition kill circuit.

● Low compression.

● Quality of fuel (dirt, water, stale, mixture).

● Weak spark.

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.

● Interlock 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 uid 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).

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Troubleshooting

Engine Loses Power

● Dirty air cleaner element.

● Engine overheated.

● Excessive engine load.

● Restricted exhaust.

● Faulty spark plug(s).

● High crankcase oil level.

● Incorrect governor setting.

● Low battery.

● Low compression.

● Low crankcase oil level.

● Quality of fuel (dirt, water, stale, mixture).

Engine Uses Excessive Amount of Oil

● Loose or improperly torqued fasteners.

● Blown head gasket/overheated.

● Breather reed broken.

● Clogged, broken, or inoperative crankcase breather.

● Crankcase overlled.

● Incorrect oil viscosity/type.

● Worn cylinder bore.

● Worn or broken piston rings.

● Worn valve stems/valve guides.

Oil Leaks from Oil Seals, Gaskets

● Breather reed broken.

● Clogged, broken, or inoperative crankcase breather.

● Loose or improperly torqued fasteners.

● Piston blow by, or leaky valves.

● Restricted exhaust.

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.

● Check for buildup of dirt and debris on crankcase, cooling ns, grass screen, and other external surfaces. Dirt or debris on these areas can cause overheating.

● 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.

● Check air cleaner cover and base for damage or indications of improper t and seal.

● Check air cleaner element. Look for holes, tears, cracked or damaged sealing surfaces, or other damage that could allow unltered air into engine. A dirty or clogged element could indicate insufcient or improper maintenance.

● Check carburetor throat for dirt. Dirt in throat is further indication that air cleaner was not functioning properly.

● Check if oil level is within operating range on dipstick. If it is above, sniff for gasoline odor.

● Check condition of oil. Drain oil into a container; it should ow 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

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 ammable. 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 carefully.

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.

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