Kohler CH440 Engine Repair Service Manual

1 17 690 01 Rev. E KohlerEngines.com CH260-CH440 Service Manual 2 Safety 3 Maintenance 5 Speciﬁcations 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 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 KohlerEngines.com 17 690 01 Rev. E 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. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. 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. 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. WARNING 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. WARNING Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. Carburetor cleaners and solvents are extremely flammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. 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 flywheel. 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.

3 Maintenance 17 690 01 Rev. E KohlerEngines.com MAINTENANCE INSTRUCTIONS WARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. 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 first 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-profile air cleaner element. Air Cleaner/Intake ● Change oil. Lubrication System ● Clean cooling areas. Air Cleaner/Intake ● Replace spark plug and set gap. Electrical System 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-profile air cleaner element. Air Cleaner/Intake ● Check fuel filters (tank outlet filter and in-line filter) clean or replace if needed (if equipped). Fuel System 1 Perform these procedures more frequently under severe, dusty, dirty conditions. 2 Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

4 Maintenance KohlerEngines.com 17 690 01 Rev. E 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 fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. NOTE: 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 overfill fuel tank. ● Do not use gasoline older than 30 days. 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.

5 Speciﬁcations 17 690 01 Rev. E KohlerEngines.com CH260/CH270 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

6 Speciﬁcations KohlerEngines.com 17 690 01 Rev. E CH260/CH270 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

7 Speciﬁcations 17 690 01 Rev. E KohlerEngines.com CH395 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

8 Speciﬁcations KohlerEngines.com 17 690 01 Rev. E CH395 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

9 Speciﬁcations 17 690 01 Rev. E KohlerEngines.com CH440 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

10 Speciﬁcations KohlerEngines.com 17 690 01 Rev. E CH440 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

Kohler CH440 Engine Repair Service Manual

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