CH260-CH440 Service Manual - Kohler Engines

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Reassembly4. Pull governor gear up until it makes contact withring, then place pin in cup, retaining rim withweights.5. Push pin down, snapping ring into shaft groove.6. Pull up slightly on governor gear to ensure assemblyis installed correctly.7. Install one thrust washer onto governor cross shaftand slide shaft up through inside of crankcase.8. Install second flat washer onto shaft. Position shaftso flat index end of shaft faces to left (9 o'clockposition) and insert hitch pin from PTO side.Install Oil Sentry System1. Mount Oil Sentry float switch into crankcasehousing using two M6x18 screws and torque to8 N·m (71 in. lb.).2. Route wire lead grommet assembly throughcrankshaft housing.3. Install nut on grommet assembly external stud andtorque to 10 N·m (89 in. lb.).Install CrankshaftCarefully slide flywheel end of crankshaft through mainball bearing and seal.Install Connecting Rod with Piston and RingsConnecting Rod DetailsA3. Lubricate cylinder bore, piston, piston pin, and pistonrings with engine oil. Compress rings using a pistonring compressor.4. Lubricate crankshaft journal and connecting rodbearing surfaces with engine oil.5. Ensure ▼ stamping on piston is facing down towardbase of engine. Use a hammer handle or roundedwood dowel and gently tap piston into cylinder asshown. Be careful oil ring rails do not spring freebetween bottom of ring compressor and top ofcylinder.6. Install connecting rod cap to connecting rod sodipper is down, and match marks are aligned.7. Torque both screws in increments to:CH260, CH270 12 N·m (106 in. lb.)CH395, CH440 20 N·m (177 in. lb.)Install Balance Shaft (if equipped)1. Position crankshaft so timing mark on largercrankgear is in 8 o'clock position.2. Install balance shaft, aligning timing mark with timingmark on larger crankgear.Install Valve Tappets and Camshaft1. Lubricate face and stem of each tappet with engineoil. Install each into their respective bores.2. Lubricate camshaft bearing surfaces and cam lobesas well as camshaft bore in crankcase with engineoil.3. Rotate crankshaft to TDC so timing mark (dimple) onsmaller crankgear is in 4 o’clock position. Installcamshaft into crankcase, aligning timing marks ontwo gears.4. Install original shims on crankshaft and camshaft.Install Closure PlateCH260/CH270 Torque SequenceD61ABC43A Match Marks B OffsetC Dipper D Oil Hole1. Make sure these are correct before installing.a. Locating mark on piston is down.b. Connecting rod offset is down and oil hole is in 4o’clock position shown. Match marks should alignas shown with dipper down.2. Stagger piston rings in grooves as shown.2562KohlerEngines.com17 690 01 Rev. E
ReassemblyCH395/CH440 Torque SequenceCH395/CH440 Flywheel/Ignition Components6113HG542D43C2NOTE: Make sure governor lever is against cup ongovernor gear assembly.1. Check to make sure sealing surfaces of crankcaseand closure plate are clean and free of nicks/burrs.2. Install two dowel pins into locations shown incrankcase. Install new closure plate gasket (dry)onto dowel pins.3. Install closure plate to crankcase. Carefully seatends of camshaft and balance shaft into their matingbearings. Rotate crankshaft slightly to help engagegovernor gear teeth.4. Install screws securing closure plate to crankcase.Torque screws in sequence shown to 24 N·m(212 in. lb.).CH260/CH270 Flywheel/Ignition Components14A32BCHEAFlywheel RetainingNutB Drive CupC Flywheel Fan D Ignition ModuleE Flywheel F StatorG Flywheel Shield H Torque SequenceFDG7ABEAFlywheel RetainingNutB Drive CupC Flywheel Fan D Ignition ModuleE Flywheel F StatorG Flywheel Shield H Torque SequenceInstall Stator (If Equipped)1. Position stator aligning mounting holes so leads arein 3 o'clock position.2. Install and torque screws to 10 N·m (89 in. lb.) insequence of 1, 2, 3, 4 and then torque 1 again.3. Route stator leads along crankcase and out notch onside.4. Position bracket over stator leads and install andtorque screw to 10 N·m (89 in. lb.).Install FlywheelCAUTIONDamaging Crankshaft and Flywheel cancause personal injury.Using improper procedures can lead to brokenfragments. Broken fragments could be thrown fromengine. Always observe and use precautions andprocedures when installing flywheel.NOTE: Before installing flywheel make sure crankshafttaper and flywheel hub bore are clean, dry, andcompletely free of lubricants. Presence oflubricants can cause flywheel to be overstressed and damaged when nut is torqued tospecification.NOTE: Make sure flywheel key is installed properly inkeyway. Flywheel can become cracked ordamaged if key is not installed properly.NOTE: CH395, CH440 has a boss on fan and a hole indrive cup.F17 690 01 Rev. E KohlerEngines.com63
Page 1 and 2:
CH260-CH440Service ManualIMPORTANT:
Page 3 and 4:
MaintenanceMAINTENANCE INSTRUCTIONS
Page 5 and 6:
SpecificationsCH260/CH270 Engine Di
Page 7 and 8:
SpecificationsCH395 Engine Dimensio
Page 9 and 10:
SpecificationsCH440 Engine Dimensio
Page 11 and 12: SpecificationsENGINE IDENTIFICATION
Page 13 and 14: SpecificationsTORQUE SPECIFICATIONS
Page 15 and 16: SpecificationsCLEARANCE SPECIFICATI
Page 17 and 18: SpecificationsGENERAL TORQUE VALUES
Page 19 and 20: Tools and AidsTOOLSDescriptionHydra
Page 21 and 22: TroubleshootingTROUBLESHOOTING GUID
Page 23 and 24: TroubleshootingCRANKCASE VACUUM TES
Page 25 and 26: Air Cleaner/IntakeAIR CLEANERThese
Page 27 and 28: Fuel SystemCARBURETORWARNINGExplosi
Page 29 and 30: Fuel System● Inspect carburetor b
Page 31 and 32: Lubrication SystemThese engines use
Page 33 and 34: Electrical SystemCarbon FouledELECT
Page 35 and 36: Electrical System7. Set an ohmmeter
Page 37 and 38: Electrical System3/4/10/18 Amp Batt
Page 39 and 40: Starter SystemNOTE: Do not crank en
Page 41 and 42: Starter SystemRETRACTABLE STARTERSW
Page 43 and 44: Disassembly/Inspection and ServiceW
Page 45 and 46: Disassembly/Inspection and ServiceC
Page 47 and 48: Disassembly/Inspection and ServiceR
Page 49 and 50: Disassembly/Inspection and ServiceV
Page 51 and 52: Disassembly/Inspection and ServiceC
Page 53 and 54: Disassembly/Inspection and ServiceR
Page 55 and 56: Disassembly/Inspection and ServiceP
Page 57 and 58: Disassembly/Inspection and ServiceH
Page 59 and 60: ReassemblyCH395/CH440 Crankshaft/Ca
Page 61: ReassemblyCH395Governor DetailsCH44
Page 65 and 66: ReassemblyAssemble Cylinder HeadNOT
Page 67 and 68: ReassemblyCH395/CH440 Blower Housin
Page 69 and 70: ReassemblyCH260/CH270 Governor Leve
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CH260-CH440 Service Manual - Kohler Engines

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