Kohler RH265 Engine Full Service Repair Manual

1 18 690 06 Rev. B KohlerEngines.com RH255, RH265 Service Manual 2 Safety 3 Maintenance 5 Speciﬁcations 12 Tools and Aids 15 Troubleshooting 19 Air Cleaner/Intake 20 Fuel System 24 Governor System 25 Lubrication System 26 Electrical System 32 Starter System 36 Disassembly/Inspection and Service 45 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 18 690 06 Rev. B 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. 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 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 18 690 06 Rev. B 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 (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Lubrication System Every 100 Hours or Annually¹ ● Clean/replace foam element. Air Cleaner/Intake ● Replace paper element. Air Cleaner/Intake ● Change oil. Lubrication System ● Clean cooling areas. Air Cleaner/Intake ● Clean spark arrestor (if equipped). ● Replace fuel filter (if equipped). Every 300 Hours 2 ● Change oil (KOHLER PRO 10W-50 oil only). Lubrication System 1 Perform these procedures more frequently under severe, dusty, dirty conditions. 2 Option only if using KOHLER ® PRO oil. 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 18 690 06 Rev. B 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. Oil must be API (American Petroleum Institute) service class SJ or higher. Select viscosity based on air temperature at time of operation as shown below. °F -20 0 20 32 40 60 50 80 100 °C -30 -20 -10 0 10 20 30 40 5W-30 10W-30 SAE 30 Kohler PRO 10W-50 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 (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). 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 18 690 06 Rev. B KohlerEngines.com Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 329.53 [12.974] FUEL CAP REMOVAL 10.50 [0.413] 65.05 [2.561] 32.53 [1.281] 162.00 [6.378] 32.53 [1.281] 65.05 [2.561] 66.00 [2.598] METRIC FLANGE: 4X M8 X 1.25-6H 15.00 [0.591] SAE FLANGE: 4X 5/16-24 UNF-2B 15.00 [0.591] 297.37 [11.707] 106.00 [4.173] 5.00 [0.197] 15.24 [0.600] 40.00 [1.575] 35.71 [1.406] 80.50 [3.169] 1.16 [0.046] 3.89 [0.153] 61.24 [2.411] MOUNTING FACE Ø 19.0 [0.75] 4.74 [0.187] 2X Ø 10.00 [0.394] 2X Ø 10.00 [0.394] X 15.00 [0.590] SLOT CYLINDER C L Ø 19.0 [0.75] 5/16-24 UNF-2B 24.5 3/4” STRAIGHT SHAFT SAE 242.84 [9.561] 249.68 [9.830] 310.92 [12.241] 248.54 [9.785] 61.24 [2.411] 355.66 [14.002] 109.37 [4.306] AIR CLEANER COVER OPENING SWING DIRECTION MOUNTING FACE

6 Specifications KohlerEngines.com 18 690 06 Rev. B ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model . . . . . . . . . . . . . . . . . . . . . RH265 2000 Series Engine Numerical Designation Specification . . . . . . . . . . . . . . . RH265-0001 Serial . . . . . . . . . . . . . . . . . . . . . 4923500328 Year Manufactured Code Factory Code Code Year 49 2019 50 2020 51 2021 GENERAL SPECIFICATIONS 3,6 RH255, RH265 Bore 68 mm (2.7 in.) Stroke 54 mm (2.1 in.) Displacement 196 cc (12.0 cu. in.) Oil Capacity (refill) 0.6 L (0.63 U.S. qt.) Maximum Angle of Operation (@ full oil level) 4 25° TORQUE SPECIFICATIONS 3,5 RH255, RH265 Air Cleaner Base/Carburetor Mounting Nut 8 N·m (70.8 in. lb.) Stud 10 N·m (88.5 in. lb.) Blower Housing/Retractable Starter Assembly and Sheet Metal M6 Screw 8 N·m (70.8 in. lb.) M6 Nut 8 N·m (70.8 in. lb.) Connecting Rod Cap Fastener (torque in increments) 12 N·m (106 in. lb.) 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.) finally to 24 N·m (212 in. lb.) Flywheel Retaining Nut 74 N·m (655 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. 5 Lubricate threads with engine oil prior to assembly. 6 Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com.

7 Speciﬁcations 18 690 06 Rev. B KohlerEngines.com TORQUE SPECIFICATIONS 3,5 RH255, RH265 Fuel Tank Mounting Screw 4.5 N·m (40 in. lb.) Outlet Filter Fitting 2.0 N·m (17.7 in. lb.) Governor Arm Nut 7 N·m (62 in. lb.) Throttle Control Lever Nut 4.5-6 N·m (40-53 in. lb.) Ignition Spark Plug 27 N·m (20 ft. lb.) Module Fastener 8 N·m (70.8 in. lb.) Muﬄer M6 Exhaust Screw 9.5 N·m (84 in. lb.) Rocker Arm Stud 24 N·m (212 in. lb.) Pivot Jam Nut 10 N·m (88.5 in. lb.) Valve Cover Fastener 8 N·m (70.8 in. lb.) CLEARANCE SPECIFICATIONS 3 RH255, RH265 Camshaft End Play 0.025/0.602 mm (0.0010/0.0237 in.) Running Clearance 0.016/0.052 mm (0.0006/0.0020 in.) Bore I.D. New Max. Wear Limit 14.000/14.018 mm (0.5512/0.5519 in.) 14.048 mm (0.5531 in.) Connecting Rod Crankpin End I.D. @ 21°C (70°F) New Max. Wear Limit 30.021/30.026 mm (1.1819/1.1821 in.) 30.08 mm (1.184 in.) Connecting Rod-to-Crankpin Running Clearance New Max. Wear Limit 0.041/0.051 mm (0.002/0.002 in.) 0.12 mm (0.005 in.) Connecting Rod-to-Crankpin Side Clearance New Max. Wear Limit 0.58/0.60 mm (0.023/0.024 in.) 1.10 mm (0.043 in.) Connecting Rod-to-Piston Pin Running Clearance 0.01/0.027 mm (0.0004/0.0011 in.) Piston Pin End I.D. @ 21°C (70°F) New Max. Wear Limit 18.010/18.015 mm (0.709/0.709 in.) 18.08 mm (0.712 in.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly.

8 Speciﬁcations KohlerEngines.com 18 690 06 Rev. B CLEARANCE SPECIFICATIONS 3 RH255, RH265 Crankcase Governor Cross Shaft Bore I.D. New Max. Wear Limit 6.000/6.018 mm (0.2362/0.2369 in.) 6.037 mm (0.2377 in.) Crankshaft End Play (free) 0.025/0.703 mm (0.0010/0.028 in.) Bore (in crankcase) New 51.961/51.991 mm (2.0457/2.0469 in.) Bore (in closure plate) New 51.961/51.991 mm (2.0457/2.0469 in.) Flywheel End Main Bearing Journal O.D. O.D.-New O.D.-Max. Wear Limit Max. Taper Max. Out-of-Round 24.975/24.989 mm (0.9833/0.9838 in.) 24.95 mm (0.9823 in.) 0.025 mm (0.0010 in.) 0.025 mm (0.0010 in.) Closure Plate End Main Bearing Journal O.D. O.D.-New O.D.-Max. Wear Limit Max. Taper Max. Out-of-Round 24.975/24.989 mm (0.9833/0.9838 in.) 24.95 mm (0.9823 in.) 0.025 mm (0.0010 in.) 0.025 mm (0.0010 in.) Connecting Rod Journal O.D. O.D.-New O.D.-Max. Wear Limit Max. Taper Max. Out-of-Round Width 29.975/29.985 mm (1.1801/1.1805 in.) 29.920 mm (1.1779 in.) 0.025 mm (0.0010 in.) 0.025 mm (0.0010 in.) 25.02/25.08 mm (0.9850/0.9874 in.) Runout (either end) 0.025 mm (0.0010 in.) Cylinder Bore Bore I.D. New Max. Wear Limit Max. Out-of-Round Max. Taper 68.015/68.030 mm (2.677/2.678 in.) 68.195 mm (2.685 in.) 12.7 microns (0.0005 in.) 12.7 microns (0.0005 in.) Cylinder Head Max. Out-of-Flatness 0.1 mm (0.0039 in.) Governor Governor Cross Shaft-to-Crankcase Running Clearance 0.013/0.075 mm (0.0005/0.0029 in.) Governor Cross Shaft O.D. New Max. Wear Limit 5.95/5.98 mm (0.2342/0.2354 in.) 5.85 mm (0.2303 in.) Governor Gear Shaft-to-Governor Gear Running Clearance 0.09/0.19 mm (0.0035/0.0074 in.) Governor Gear Shaft O.D. New Max. Wear Limit 6.028/6.043 mm (0.2373/0.2379 in.) 6.018 mm (0.2369 in.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly.

9 Speciﬁcations 18 690 06 Rev. B KohlerEngines.com CLEARANCE SPECIFICATIONS 3 RH255, RH265 Ignition Spark Plug Gap 0.76 mm (0.030 in.) Module Air Gap 0.254 mm (0.0100 in.) Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.006/0.018 mm (0.0002/0.0007 in.) Piston Pin Bore I.D. New Max. Wear Limit 18.002/18.008 mm (0.7087/0.7090 in.) 18.05 mm (0.7107 in.) Piston Pin O.D. New Max. Wear Limit 17.990/17.996 mm (0.7083/0.7085 in.) 17.95 mm (0.7067 in.) Top Compression Ring Side Clearance New Bore Used Bore (max.) 0.030/0.070 mm (0.0012/0.0028 in.) 0.15 mm (0.0059 in.) Center Compression Ring Side Clearance New Bore Used Bore (max.) 0.020/0.060 mm (0.0008/0.0024 in.) 0.15 mm (0.0059 in.) Top Compression Ring End Gap New Bore Used Bore (max.) 0.147/0.344 mm (0.0058/0.0136 in.) 1.00 mm (0.0394 in.) Center Compression Ring End Gap New Bore Used Bore (max.) 0.347/0.594 mm (0.0137/0.0234 in.) 1.50 mm (0.0591 in.) Top and Center Compression Ring Width New Bore Used Bore (max.) 1.47/1.49 mm (0.0579/0.0587 in.) 1.35 mm (0.0531 in.) Oil Control Ring-to-Groove Side Clearance 0.040/0.200 mm (0.0016/0.0079 in.) Piston Thrust Face O.D. 7 New Max. Wear Limit 67.965/67.985 mm (2.6758/2.6766 in.) 67.85 mm (2.6713 in.) Piston Thrust Face-to-Cylinder Bore Running Clearance New 0.030/0.065 mm (0.0012/0.0026 in.) 3 Values are in Metric units. Values in parentheses are English equivalents. 7 Measure 15 mm (0.5905 in.) above bottom of piston skirt at right angles to piston pin.

10 Speciﬁcations KohlerEngines.com 18 690 06 Rev. B CLEARANCE SPECIFICATIONS 3 RH255, RH265 Valves and Valve Lifters Intake Valve Stem-to-Valve Guide Running Clearance 0.020/0.044 mm (0.008/0.0017 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance 0.030/0.054 mm (0.0011/0.0021 in.) Intake Valve Stem O.D. New Max. Wear Limit 5.480 mm (0.2157 in.) 5.32 mm (0.2094 in.) Exhaust Valve Stem O.D. New Max. Wear Limit 5.47 mm (0.2153 in.) 5.305 mm (0.2088 in.) Intake Valve Stem to Guide New Max. Wear Limit 0.024/0.039 mm (0.001/0.002 in.) 0.10 mm (0.0004 in.) Exhaust Valve Stem to Guide New Max. Wear Limit 0.098/0.112 mm (0.0038/0.0044 in.) 0.12 mm (0.0005 in.) Valve Guide Reamer Size Standard Intake Standard Exhaust 5.506 mm (0.2168 in.) 5.506 mm (0.2168 in.) Valve Seat Width 0.800/2.00 mm (0.0315/0.787 in.) Nominal Valve Face Angle 30°, 45°, 60° 3 Values are in Metric units. Values in parentheses are English equivalents.

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Kohler RH265 Engine Full Service Repair Manual

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