Kohler Command PRO CH270 Service Manual Download Page 18

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1.14

Section 1
Safety and General Information

Connecting Rod

Connecting Rod Screw Torque (torque in increments)

CH270 ........................................................................................................ 12 N·m (106 in. lb.)

CH395,CH440 ........................................................................................... 20 N·m (177 in. lb.)

Crankpin End I.D. @ 21°C (70°F)

New

CH270

................................................................................................. 30.021/30.026

(1.1819/1.1821 in.)

CH395,CH440 .................................................................................... 33.020/33.030 mm (1.3000/1.3004 in.)

Max. Wear Limit

CH270 ................................................................................................. 30.08 mm (1.184 in.)

CH395 ................................................................................................. 33.07 mm (1.302 in.)

CH440 ................................................................................................. 37.08 mm (1.460 in.)

Connecting Rod-to-Crankpin Side Clearance
New
CH270

................................................................................................. 0.58/0.60

(0.023/0.024 in.)

CH395 ................................................................................................. 0.73 mm (0.029 in.)

CH440 ................................................................................................. 0.56 mm (0.022 in.)

Max. Wear Limit

CH270 ................................................................................................. 1.10 mm (0.043 in.)

CH395 ................................................................................................. 1.36 mm (0.054 in.)

CH440 ................................................................................................. 1.06 mm (0.042 in.)

Connecting Rod-to-Piston Pin Running Clearance

CH270,CH440 ........................................................................................... 0.008/0.025 mm (0.0003/0.0010 in.)

CH395 ........................................................................................................ 0.006/0.028 mm (0.0002/0.0011 in.)

Piston Pin End I.D. @ 21°C (70°F)
New
CH270

................................................................................................. 18.010/18.015

(0.7091/0.7093 in.)

CH395

................................................................................................. 18.004/18.020

(0.7088/0.7094 in.)

CH440

................................................................................................. 20.000/20.008

(0.7874/0.7874 in.)

Max. Wear Limit

CH270,CH395 .................................................................................... 18.08 mm (0.712 in.)

CH440 ................................................................................................. 20.05 mm (0.789 in.)

Crankcase

Governor Cross Sha

Bore I.D.

New

CH270

................................................................................................. 6.000/6.024

(0.2362/0.2372 in.)

CH395,CH440

.................................................................................... 8.000/8.024

(0.3150/0.3159 in.)

Max. Wear Limit

CH270 ................................................................................................. 6.037 mm (0.2377 in.)

CH395,CH440 .................................................................................... 8.074 mm (0.7118 in.)

Oil Drain Plug Torque

CH270 ........................................................................................................ 18 N·m (159 in. lb.)

CH395,CH440 ........................................................................................... 23 N·m (204 in. lb.)

Closure Plate Screw Torque ...........................................................................

24 N

m (212 in. lb.)

Crankshaft

End Play (Free) ................................................................................................ 0.0508/0.254 mm (0.002/0.010 in.)

¹ Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil

prior to assembly.

Summary of Contents for Command PRO CH270

Page 1: ...SERVICE MANUAL HORIZONTAL CRANKSHAFT CH270 CH395 CH440 ...

Page 2: ......

Page 3: ...ting Section 4 Air Cleaner and Air Intake System Section 5 Fuel System and Governor Section 6 Lubrication System Section 7 Retractable Starter Section 8 Electrical System and Components Section 9 Disassembly Section 10 Inspection and Reconditioning Section 11 Reassembly 1 2 3 4 5 6 7 8 9 10 11 ...

Page 4: ......

Page 5: ... people of installation operation or maintenance information that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others Accidental Starts can cause severe injury or death Disconnect and ground spark plug leads before servicing WARNING Accidental Starts Disabling engine ...

Page 6: ...n monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Electrical Shock can cause injury Do not touch wires while engine is running CAUTION Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock WARNING Explosive Gas can cause...

Page 7: ...hrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Figure 1 2 Explanation of Engine Identification Numbers A Model No C H 270 B Spec No Command Engine C Serial No Year Manufactured Code Code Year 39 2009 40 2010 41 2011 CH270 0001 Complete Spec Number Incorporating Model No with Variation No of Basic Spec Factory Code 3924895008 Numerical Designation Horizontal Cranksha...

Page 8: ...xhaust emissions are regulated Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends u...

Page 9: ...eaner element Section 4 Check and adjust valve clearance when engine is cold 2 Section 11 Service starter motor drive if so equipped Section 8 Yearly or Every 300 Hours Replace low profile air cleaner element Section 4 Check fuel filters tank outlet filter and in line filter and clean or replace if needed if equipped Section 5 To empty the system run the engine until the tank and the system are em...

Page 10: ...VER REMOVAL 106 00 4 173 58 75 2 313 322 25 12 687 STR AIGHT PTO 163 28 6 428 155 03 6 104 26 48 1 043 88 23 3 474 O IL F ILL O IL D R A IN P LU G M O U N T IN G FAC E 2X 0 10 00 0 394 2X 0 10 00 x 15 50 SLOT 0 394 x 0 610 79 99 3 149 35 70 1 406 39 33 1 548 5 50 0 217 162 00 6 378 66 00 2 598 65 08 2 562 32 55 1 281 88 00 3 465 360 57 14 196 30 00 1 181 106 00 4 173 M8 x 1 25 6H TH RU 4X M8 x 1 2...

Page 11: ...3 MOUNTIN G FACE APPROXIMATE CENTER OF GRAVITY 47 11 1 855 2X Ø 10 00 0 395 79 99 3 149 C YLINDER 35 70 1 406 39 33 1 548 5 50 0 217 2X Ø 10 00 X 15 50 SLOT 0 394 X 0 610 APPROXIMATE C ENTER OF GRAVITY 221 31 8 713 30 00 1 181 106 00 4 173 66 00 2 598 162 00 6 378 65 10 2 563 32 55 1 281 248 83 9 796 65 10 2 563 32 55 1 281 88 00 3 465 39 37 1 550 METRIC FLANGE 4X M8 X 1 25 6H 15 SAE A FLANGE 4X 5...

Page 12: ...FULL THREAD 4X 45º 105 00 4 134 195 50 7 697 METRIC FLANGE 6X M8 X 1 25 6H TAP 18 MIN SAE B FLANGE 6X 5 16 24 UNF 2B INCH 18 MIN 411 63 16 206 35 00 1 378 133 50 5 256 70 00 2 756 103 00 4 055 2X 30º 424 00 16 693 57 52 2 265 40 50 1 594 13 00 0 512 CYLINDER 2X 11 25 0 443 96 00 3 780 117 67 4 633 AIR CLEANER COVER REMOVAL 27 33 1 076 SECONDARY MOUNTING FACE 3 75 0 148 PRIMARY MOUNTING FACE CENTER...

Page 13: ...4 00 SLOT 0 433 X 11 02 58 31 2 296 APPROXIM ATE CENTER OF GRAVITY 27 33 1 076 2X Ø 11 25 0 443 CYLINDER C L 96 00 3 780 431 72 16 997 379 80 14 953 291 28 11 468 289 19 11 385 289 88 11 413 378 40 14 898 Ø 1 STRAIGHT PTO 264 30 10 406 195 50 7 697 105 00 4 134 4X 45 4X 3 8 16 UNC 2B IN CH 18 M M FULL TH READ 103 00 4 055 290 31 11 430 METRIC FLANGE 6X M8 X 1 25 6H TAP 18 MIN SAE B FLANGE 6X 5 16 ...

Page 14: ... 82 6 962 106 82 4 206 73 82 2 906 17 00 0 669 195 50 7 697 105 00 4 134 4X 45 4X 3 8 16 UNC 2B INCH 18 M M FULL THR EAD 70 00 2 756 133 50 5 256 127 00 5 000 165 10 6 500 CEN TER OF GRAVITY 35 00 1 378 441 93 17 399 466 62 18 371 W ITH US 50 STATE GAS CAP 438 41 17 260 6 00 0 236 US 50 STATE GAS CAP REM OVAL 103 00 4 055 55 80 2 20 6 00 0 240 Ø GAS C AP REM OVAL ALL AROUND 2X 30 M ETRIC FLAN GE 6...

Page 15: ...197 METRIC FLAN GE 6X M8 X 1 25 6H TAP 18 MIN SAE B FLAN GE 6X 5 16 24 UNF 2B INCH 18 M IN 70 00 2 756 278 16 10 951 35 00 1 378 133 50 5 256 103 00 4 055 APPROXIMATE CENTER OF GRAVITY 176 82 6 962 106 82 4 206 73 82 2 906 17 00 0 669 2X Ø 11 00 X 28 00 SLOT 0 433 X 11 02 C L CYLINDER 2X Ø 11 25 0 443 40 00 1 575 APPR OXIMATE CEN TER OF GRAVITY 39 70 1 563 Dimensions in millimeters Inch equivalent...

Page 16: ...2 8 in CH395 78 mm 3 1 in CH440 89 mm 3 5 in Stroke Stroke CH270 54 mm 2 1 in CH395 58 mm 2 3 in CH440 69 mm 2 7 in Displacement Displacement C CH270 208 cc 12 7 cu in CH395 277 cc 16 9 cu in CH440 40 429 cc 24 7 cu in 429 cc 24 7 cu in Compression Ratio Compression Ratio C CH270 8 5 1 CH395 8 2 1 CH440 8 1 8 1 Weight Approx Weight Approx CH CH270 17 5 kg 38 5 lb CH395 27 8 kg 61 5 lb CH440 34 0 k...

Page 17: ...m 0 63 in Max Wear Limit CH270 13 90 mm 0 547 in CH395 CH440 15 90 mm 0 626 in Cam Lobe Profile Minimum Dimension Measured From Base Circle To Top Of Lobe Intake New CH270 31 966 mm 1 259 in CH395 32 544 mm 1 281 in CH440 CH440 33 266 mm 1 310 in 33 266 mm 1 310 in Exhaust New CH270 31 966 mm 1 259 in CH395 32 256 mm 1 270 in CH440 32 642 mm 1 285 in Intake Wear Limit CH270 31 72 mm 1 249 in CH395...

Page 18: ...ing Clearance CH270 CH440 0 008 0 025 mm 0 0003 0 0010 in CH395 0 006 0 028 mm 0 0002 0 0011 in Piston Pin End I D 21 C 70 F New CH270 18 010 18 015 mm 0 7091 0 7093 in CH395 18 004 18 020 mm 0 7088 0 7094 in CH440 20 000 20 008 mm 0 7874 0 7874 in Max Wear Limit CH270 CH395 18 08 mm 0 712 in CH440 20 05 mm 0 789 in Crankcase Governor Cross Shaft Bore I D New CH270 6 000 6 024 mm 0 2362 0 2372 in ...

Page 19: ...crons 0 0005 in Width CH270 24 5 24 9 mm 0 9646 0 9803 in CH395 30 30 30 36 mm 1 1930 1 1953 in CH440 28 30 28 36 mm 1 1142 1 1165 in Crankshaft Runout Either End 0 025 mm 0 001 in Cylinder Bore Cylinder Bore I D New CH270 70 027 70 035 mm 2 757 2 757 in CH395 77 98 78 02 mm 3 0701 3 0717 in CH440 CH440 89 00 89 02 mm 3 5039 3 5045 in 89 00 89 02 mm 3 5039 3 5045 in Max Wear Limit CH270 70 200 mm ...

Page 20: ...in Governor Gear Shaft O D New 6 016 6 028 mm 0 2368 0 2373 in Max Wear Limit 6 003 mm 0 2363 in Governor Lever Nut Torque 12 N m 106 in lb Throttle Control Lever Nut Torque 9 N m 80 in lb Ignition Spark Plug Type Champion or Equivalent RC12YC Spark Plug Gap 0 76 mm 0 030 in Spark Plug Torque 22 27 N m 195 239 in lb Ignition Module Air Gap 0 254 mm 0 010 in Ignition Module Fastener Torque 10 N m 8...

Page 21: ...395 18 000 18 008 mm 0 7087 0 7090 in CH440 20 000 20 008 mm 0 7874 0 7877 in Max Wear Limit CH270 CH395 18 05 mm 0 7106 in CH440 CH440 20 05 mm 0 7894 in 20 05 mm 0 7894 in Piston Pin O D New CH270 CH395 17 992 17 995 mm 0 7083 0 7084 in CH440 19 992 19 998 mm 0 7871 0 7873 in Max Wear Limit CH270 CH395 17 95 mm 0 7067 in CH440 19 95 mm 0 7854 in Top and Center Compression Ring Side Clearance New...

Page 22: ...0 CH4404 0 025 0 060 mm 0 001 0 002 in 0 025 0 060 mm 0 001 0 002 in Rocker Arm Rocker Arm Stud Torque 13 6 N m 120 in lb Rocker Arm Pivot Jam Nut Torque 10 N m 89 in lb Retractable Starter Retractable Starter Cover Screw Torque 5 4 N m 48 in lb Retractable Starter Center Screw Torque 10 N m 89 in lb Valve Cover Valve Cover Fastener Torque 10 N m 89 in lb Valves and Valve Lifters Intake Valve Stem...

Page 23: ...95 CH440 0 025 0 055 mm 0 0010 0 0022 in Max Wear Limit CH270 0 10 mm 0 0039 in CH395 0 13 mm 0 0051 in CH440 0 14 mm 0 0055 in Exhaust Valve Stem to Guide New CH270 0 098 0 112 mm 0 0038 0 0044 in CH395 CH440 0 040 0 070 mm 0 0016 0 0028 in Max Wear Limit CH270 0 12 mm 0 0047 in CH395 0 10 mm 0 0039 in CH440 0 11 mm 0 0043 in Valve Guide Reamer Size Standard Intake CH270 5 524 mm 0 2175 in CH395 ...

Page 24: ... 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 or 10 Property Class Noncritical Fasteners Into Aluminum 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 55 131 5 97 184 4 136 219 7 162 94 9 70 5 8 8 8 10 9 12 9 4 8 5 8 10 9 12 9 4 8 8 8 General Torque Values Metric F...

Page 25: ... 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 4 105 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 2 110 244 1 180 352 6 260 5 8 18 189 8 140 311 9 230 447 5 330 3 4 10 199 3 150 332 2 245 474 6 350 3 4 16 271 2 200 440 7 325 637 3 470 Tighteni...

Page 26: ...1 22 Section 1 Safety and General Information ...

Page 27: ...Plug Blue Wire Design Technology Inc DTI 019 DTI 021 DTI 023 DTI 025 DTI 027 DTI 029 Flywheel Holding Tool CS Series SE Tools KLR 82407 Flywheel Puller To remove flywheel from engine SE Tools KLR 82408 Flywheel Strap Wrench To hold flywheel during removal SE Tools KLR 82409 Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using tools d...

Page 28: ...S Individual Components Available CS PRO Regulator Test Harness Special Regulator Test Harness with Diode Design Technology Inc DTI 031 DTI 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines with SMART SPARK Kohler 25 761 40 S Starter Servicing Kit All Starters To remove and reinstall drive retaining rings and brushes SE Tools KLR 82411 Individual Component Available Star...

Page 29: ... 52 357 01 S Electric Starter Drive Lubricant Solenoid Shift Kohler 52 357 02 S RTV Silicone Sealant Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as those listed are approved for use Loctite Nos 5900 or 5910 are recommended for best sealing characteristics Loctite 5910 Loctite Ultra Black 598 Loctite Ultra Blue 587 Loctite Ultra Copper Kohler 2...

Page 30: ...he rod cap 2 Remove the studs of a Posi Lock rod or grind oﬀ the aligning steps of a Command rod so the joint surface is flat 3 Find a 1 in long capscrew with the correct thread size to match the threads in the connecting rod 4 Use a flat washer with the correct I D to slip on the capscrew and approximately 1 in O D Kohler Part No 12 468 05 S Assemble the capscrew and washer to the joint surface o...

Page 31: ... 8 Low oil level Engine Starts Hard 1 PTO drive is engaged 2 Dirt or water in the fuel system 3 Clogged fuel line 4 Loose or faulty wires or connections 5 Faulty or misadjusted choke or throttle controls 6 Faulty spark plug 7 Low compression 8 Weak spark 9 Engine overheated cooling air circulation restricted 10 Quality of fuel 11 Flywheel key sheared 12 Intake system leak Engine Will Not Crank 1 P...

Page 32: ...cause when it is disassembled Check for buildup of dirt and debris on the crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas are causes of higher operating temperatures and overheating Check for obvious fuel and oil leaks and damaged components Excessive oil leakage can indicate a clogged breather worn damaged seals and gaskets or loose or improperly torq...

Page 33: ... engine clean the engine thoroughly before disassembling it Also clean individual components as the 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 the manufacturer s instructions and safety precautions c...

Page 34: ...nnect to the adapter hose while firmly holding the engine at TDC Note the gauge reading and listen for escaping air at the carburetor intake exhaust outlet and crankcase breather 8 Check the test results against the following table Compression Test A compression test is best performed on a warm engine Clean any dirt or debris away from the base of the spark plug before removing it Be sure the chok...

Page 35: ...round the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air cleaner components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Service Precleaner If Equipped Wash the precleaner every 50 hours of operation more often under extremely d...

Page 36: ...r Intake Muffler Air Cleaner Cover Bail Bail Latch Latch Tabs Muffler Figure 4 4 Cold Weather Operation Position of Air Cleaner Cover 7 Reinstall and secure the air cleaner cover Align the air cleaner cover latches with the tabs on the base Place the latches under the tabs and lift up on the bails See Figure 4 5 Figure 4 5 Air Cleaner Cover Installation Service Paper Element Every 200 hours of ope...

Page 37: ...ce the latches under the tabs and lift up on the bails See Figure 4 5 Low Profile Air Cleaner General The low profile air cleaner contains an oiled foam element The low profile air cleaner is shown in Figure 4 6 The system is CARB EPA certified and the components should not be altered or modified in any way Figure 4 6 Low Profile Air Cleaner Service Check the air cleaner daily or before starting t...

Page 38: ...which are bent or damaged 6 Install the element into the air cleaner base 7 Reinstall the cover and secure with the screw NOTE Do not operate engine without the air cleaner element excessive piston and or cylinder wear may result Air Intake Cooling System To ensure proper cooling make sure the grass screen cooling fan fins and external surfaces of the engine are kept clean at all times Every 100 h...

Page 39: ...arburetor Operation The fuel tank outlet is located above the carburetor inlet allowing gravity to feed fuel through the in line filter and fuel line to the carburetor Fuel then enters the carburetor through a fuel shut oﬀ valve and a fine screen sediment bowl and then to the carburetor float bowl Fuel is drawn into the carburetor body and is mixed with air This fuel air mixture is then burned in ...

Page 40: ...ied to comply with California and U S EPA evaporative emission requirements Fuel lines that do not meet these requirements may not be used Order replacement hose through a Kohler Service Center Fuel Filters Fuel Tank Filter If Equipped A serviceable fuel tank filter is located under the fuel tank cap in the filler neck Daily or as required clean filter of any accumulation as follows 1 Remove the f...

Page 41: ...e only in approved containers in well ventilated unoccupied buildings away from sparks or flames 1 Stop the engine 2 Remove the securing hardware and the carburetor cover panel See Figure 5 4 Cover Nuts Screw Screw Fuel Valve Lever Figure 5 4 Carburetor Cover Panel 3 Turn the fuel valve lever to the OFF position 4 Remove the fuel valve cup See Figure 5 5 Fuel Valve Lever Screen O ring Fuel Valve C...

Page 42: ...f the tank to observe fuel flow 3 If fuel does flow from the line proceed to Test 4 If fuel does not flow from the line check the fuel tank vent in line filter threaded into tank and fuel line Correct any observed problem and reconnect the line 4 Check the operation of fuel shut oﬀ valve a Remove the fuel sediment bowl under the inlet fitting of carburetor b Turn fuel shut oﬀ valve ON and OFF and ...

Page 43: ...ents plugged Blow out with compressed air d Carburetor bowl gasket leaks Replace gasket Carburetor These engines are equipped with a fixed main jet carburetor The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The idle mixture is set at the factory and cannot be adjusted The low idle fuel adjusting needle is also set at the factory an...

Page 44: ...TE The high idle speed is also specified by the equipment manufacturer Set according to recommendations The high idle speed for basic engines is 3600 RPM 150 RPM Figure 5 8 High Speed Screw Carburetor Servicing If symptoms described in the carburetor troubleshooting guide indicate a problem within the carburetor the following steps can be used to remove the carburetor from the engine and provide t...

Page 45: ... head gasket and replace as needed See Figure 5 10 Figure 5 10 Carburetor Gaskets Disassembly Overhaul 1 Clean the exterior surfaces of dirt or foreign material before disassembling the carburetor Remove the center fuel bowl screw and carefully separate the fuel bowl from the carburetor Transfer any remaining fuel into an approved container Remove and discard the old O ring s 2 Remove the float pi...

Page 46: ...ft assembly fuel inlet seat and bowl chamber baﬄe are non serviceable items and should not be removed 7 Clean the carburetor body jets vent ports seats etc using a good commercially available carburetor solvent Use clean dry compressed air to blow out the internal channels and ports Inspect and thoroughly check the carburetor for cracks wear or damage Inspect the fuel inlet seat for wear or damage...

Page 47: ...weights move outward they cause the regulating pin to extend from the governor gear assembly See Figure 5 17 Figure 5 17 Action of a Governor Gear The regulating pin contacts the tab on the cross shaft causing the shaft to rotate when the engine speed changes One end of the cross shaft protrudes through the side of the closure plate Through external linkage attached to the cross shaft the rotating...

Page 48: ... Governor Lever Governor Governor Shaft Shaft Figure 5 19 Governor Adjustment 4 Move the governor lever clockwise until it stops 5 Rotate the governor shaft clockwise until it stops 6 Hold both in this position and tighten the governor lever nut to 12 N m 106 in lb CH395 CH440 1 Close the fuel shut oﬀ valve 2 Remove the air cleaner outer cover Then either reposition the fuel tank to access governo...

Page 49: ... 1 NOTE Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 2 5W 20 5W 30 R E C O M M E N D E D S A E V I S C O S IT Y G R A D E S F 20 0 20 32 40 60 50 80 100 C 30 20 10 0 10 20 30 40 TEMPERATURE RANGE EXPECTED BEFOR...

Page 50: ...ap into the tube See Figure 6 5 Dipstick Low Oil Level Upper Oil Level Oil Fill Neck Bottom Edge Engine Oil Engine Oil Oil Fill Neck Bottom Edge Upper Oil Level Oil Fill Plug Engine Oil Engine Oil Figure 6 3 Location of Dipstick Oil Fill Plug and Oil Drain Plugs NOTE The engine may be equipped with two dipsticks or an oil fill plug and a dipstick These can be placed in either hole See Figure 6 4 F...

Page 51: ... 5 Reinstall the dipstick oil fill plug and tighten securely See Figure 6 8 NOTE Over tightening the dipstick oil fill plug will distort the gasket and may cause oil weeping Oil Fill Plug Engine Oil Engine Oil Dipstick Oil Drain Plug Oil Drain Plug Figure 6 7 Dipstick Oil Level Check 2 Remove the oil drain plug and the dipstick oil fill plug Allow ample time for complete drainage 3 Reinstall the d...

Page 52: ...6 4 Section 6 Lubrication System ...

Page 53: ...Exploded View To Remove Starter 1 Remove the three hex flange screws securing the starter assembly to the blower housing 2 Remove the starter assembly To Install Starter 1 Align the retractable starter with the mounting locations on the blower housing and install the hex flange screws Leave the screws slightly loose See Figure 7 2 Screws Screws Figure 7 2 Installing Retractable Starter Starter Hou...

Page 54: ...eased 5 When all spring tension on the starter pulley is released remove the rope from the pulley 6 Tie a double left hand knot in one end of the new rope See Figure 7 4 Knot Knot Figure 7 4 Left hand Knot 7 Rotate the pulley counterclockwise to pre tension the spring approximately 4 full turns of pulley 8 Rotate the pulley until the rope hole in the pulley is aligned with the rope guide bushing o...

Page 55: ...ction is worn by all persons in the area 1 Release coil spring tension by loosening the center screw approximately 1 turn Rotate the pulley against spring tension until the pulley rope hole with knot is adjacent to outlet in housing Lift up the slack in the rope between the pulley and the housing slowly allow the pulley to unwind releasing the spring tension Count the number of rotations for reass...

Page 56: ...n Spring Spring Drive Plate Drive Plate Figure 7 8 Center Screw and Drive Plate 7 Rehook the slack in the rope into the notch of the pulley and rotate the pulley counterclockwise viewed from pawl side to re tension the spring approximately 4 full turns ...

Page 57: ... the following spark plugs Type The standard spark plug is a Champion RC12YC Equivalent alternate brand plugs can also be used Gap 0 76 mm 0 030 in Thread Size 14 mm Reach 19 1 mm 3 4 in Hex Size 15 9 mm 5 8 in Spark Plug Service Every 100 hours of operation remove the spark plug check its condition and reset the gap or replace it with a new plug as necessary To service the plugs perform the follo...

Page 58: ...this condition could be set to the proper gap and reused Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner over rich carburetion weak ignition or poor compression Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by a restricted air cleaner a carburetor problem or operating the engine ...

Page 59: ...by design these modules only will provide proper function if mounted in the correct orientation This system consists of the following components see Figure 8 2 Magnets permanently aﬃxed to the flywheel Inductive discharge ignition module IDI mounted on the engine crankcase Includes a shut down kill terminal mounted at the side of the module Includes a secondary lead wire from the coil to a termina...

Page 60: ...he lead from the Oil Sentry float switch yellow leads Repeat spark test again 3 If spark is now present the control module or float switch is faulty Test the control module Step 4 and the float switch Step 5 If there is still no spark test the ignition module Step 6 4 Set an ohmmeter to the Rx1 scale and zero the meter Connect the black ohmmeter lead to the yellow Oil Sentry control module lead an...

Page 61: ... to the Rx1 scale and zero the meter Test the ignition key switch as follows a Trace the two black leads from the ON OFF switch and separate them from any connections Connect the ohmmeter leads to the switch leads and check for continuity in both switch positions b On electric start engines trace the four leads red red white black black white from the key switch and separate them from any connecti...

Page 62: ...am for troubleshooting and servicing your system Figure 8 5 Wiring Diagram Retractable Starter Figure 8 6 Wiring Diagram 3 4 Amp Charging System Rectified Only Ignition Module Ignition Module Spark Plug Spark Plug Oil Float Switch Oil Float Switch Oil Control Module Oil Control Module Optional Micro Shut Down Switch Optional Red Ignition Switch Key Switch Battery Fuse Relay Starter Motor 12 Volt B...

Page 63: ...n 9 Disassembly Rectifier Regulator The rectifier regulator is connected to the engine with a matching wiring harness containing a plug in connector Grounded through the wiring harness the rectifier regulator is secured to the equipment in a suitable location with two mounting screws To replace it disconnect the plug and remove the two mounting screws NOTE When installing the rectifier regulator p...

Page 64: ...em with output ranging from 3 amps to 4 amps The rectifier is normally connected to the engine with a matching wiring harness and secured inside the control panel Grounding is achieved through the wiring harness The rectifier converts AC voltage coming from the stator to DC voltage only Troubleshooting Guide Battery Charging System NOTE Zero ohmmeters on each scale to ensure accurate readings Volt...

Page 65: ...te does not increase when load is applied test stator Tests 2 and 3 2 Separate the bullet connectors in the AC white leads Connect an AC voltmeter across the stator leads female terminals With engine running at 3600 RPM measure the AC output from the stator 2 If voltage is 20 0 volts or more stator is OK Rectifier regulator is faulty Replace the rectifier regulator If voltage is less than 20 0 vol...

Page 66: ...s while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage of the starter NOTE If the starter does not crank the engine shut oﬀ the starter immediately Check the condition of the inline fuse and do not make further attempts to start the engine until the condition is corrected NOTE Do not drop the starter or strike the starter housing Doing so can damag...

Page 67: ... terminal and connect the other end to the positive terminal of the battery Connect one end of the negative jumper cable to the negative terminal of the battery Touch the other end of the negative jumper cable to a bare surface on the crankcase or to the starter housing 4 When negative jumper cable is touched to crankcase or starter housing starter motor should operate If it does continue with Ste...

Page 68: ... hours of operation or annually whichever occurs first clean and lubricate the geartrain If the gears are worn or have chipped or broken teeth the starter must be replaced It is not necessary to completely dissemble the starter to service the geartrain Service the starter as follows 1 Remove the starter from the engine 2 Remove the housing screws and the drive end cap screw See Figure 8 11 Figure ...

Page 69: ... 8 15 Reinstall Dust Cover and Drive Pinion 9 Assemble the drive end cap onto the drive pinion See Figure 8 16 Figure 8 16 Reinstall Drive End Cap 10 Reinstall and securely tighten the housing and drive end cap screws See Figure 8 17 Figure 8 17 Reinstall Housing and Drive End Cap Screws Drive Pinion Dust Cover Housing Screws Drive End Cap Screw ...

Page 70: ...8 14 Section 8 Electrical System and Components ...

Page 71: ...heat shield assembly 5 Remove air cleaner assembly 6 Remove fuel tank 7 Remove external throttle governor and choke linkage 8 Remove carburetor 9 Remove retractable starter 10 Remove blower housing and shields 11 Remove electrical wiring micro shut down switch bracket and fuel tank brackets 12 Remove control panel and electric starter 13 Remove valve cover breather rocker arms push rods and cylind...

Page 72: ...ts from the air cleaner base as outlined in Section 4 Remove the Quad Clean Base Remove the air cleaner base from the engine as follows 1 Remove the hex flange nuts and screws securing the carburetor shroud to the engine See Figure 9 7 Oil Fill Plug Oil Fill Plug Oil Drain Plug Oil Drain Plug Figure 9 3 Oil Drain Plug 2 Allow ample time for the oil to drain from the crankcase Remove Muffler and He...

Page 73: ... 7 Loosely install two hex flange nuts on the studs to temporarily hold the carburetor on the engine Remove the Low Profile Air Cleaner Base Remove the air cleaner base from the engine as follows 1 Remove one hex flange screw and two hex flange nuts securing the air cleaner base to the carburetor See Figure 9 9 Figure 9 9 Remove Hex Nuts and Screw 2 Disconnect one end of the breather hose from the...

Page 74: ...ernor Levers 2 Loosen the hex flange nut securing the governor lever to the governor shaft Lift oﬀ the governor lever and remove the carburetor throttle link and dampening spring See Figures 9 14 or 9 15 Remove Fuel Tank If Equipped NOTE If no fuel tank is equipped loosen the clamp and disconnect the fuel line from the inlet of the carburetor 1 Ensure that the fuel tank is empty 2 Loosen the clamp...

Page 75: ...nd fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks open flames and other sources of ignition away from the engine 1 Disconnect the throttle link and dampening spring from the carburetor Remove the carburetor carburetor gasket insulator and insulator gasket from the studs See Figure 9 16 Insulator Insulator Gaskets Gaskets Figure 9 16 Carburetor Removal...

Page 76: ...ctors for the Oil Sentry float switch and module Remove the mounting screw securing the module to the fuel tank bracket See Figure 9 25 Hex Hex Screw Screw Figure 9 20 Remove CH395 CH440 Blower Housing Hex Flange Screw Under Cylinder Head 2 Remove the blower housing 3 Remove the hex flange screws securing the upper shield and remove the shield See Figures 9 21 or 9 22 Figure 9 21 Remove CH270 Uppe...

Page 77: ...tank brackets by removing the two screws in each Remove the threaded stud from the left bracket and remove the micro switch bracket See Figure 9 26 NOTE For CH395 and CH440 it is not required and not recommended to remove the threaded stud and micro switch bracket Fuel Tank Brackets Fuel Tank Brackets Micro Switch Micro Switch Bracket Bracket Figure 9 26 Fuel Tank Bracket Removal Remove Control Pa...

Page 78: ...ter Adjuster Nuts Nuts Figure 9 31 Rocker Arm Removal 3 Remove the spark plug 4 Remove the four hex flange screws securing the cylinder head See Figure 9 32 Hex Hex Screws Screws Figure 9 32 Remove Cylinder Head Mounting Screws 5 Remove the cylinder head dowel pins 2 and cylinder head gasket See Figure 9 33 Head Head Gasket Gasket Dowel Pins Dowel Pins Figure 9 33 Remove Cylinder Head Dowel Pins a...

Page 79: ...rews securing the ignition module to the crankcase Remove the module See Figure 9 36 Hex Screws Hex Screws Figure 9 36 Remove Ignition Module Screws Remove Flywheel NOTE Whenever possible an impact wrench should be used to loosen the flywheel retaining nut A flywheel strap wrench may be used to hold the flywheel when loosening or tightening the flywheel retaining nut 1 Remove the flywheel retainin...

Page 80: ...x Screw Screw Shield Shield Figure 9 41 Removing Flywheel Shield 4 Remove the flywheel from the crankshaft using a suitable puller See Figure 9 42 NOTE Always use a puller to remove the flywheel from the crankshaft Do not strike the flywheel or crankshaft as these parts could become cracked or damaged Figure 9 42 Using Puller to Remove Flywheel 5 Remove the flywheel key from the crankshaft keyway ...

Page 81: ...e gasket and dowel pins if required from the crankcase See Figures 9 46 and 9 47 NOTE Do not pry on the gasket surface of the crankcase or closure plate as this can cause damage and leakage Dowel Pins Dowel Pins Figure 9 46 CH270 Closure Plate Gasket and Dowel Pins Figure 9 47 CH395 CH440 Closure Plate Dowel Pins 3 Remove the shims from the crankshaft and camshaft Remove Balance Shaft If Equipped ...

Page 82: ...necting rod Remove the end cap Carefully guiding the connecting rod slide the piston and connecting rod from the cylinder bore See Figure 9 50 NOTE If a carbon ridge is present at the top of the cylinder bore use a ridge reamer to remove it before attempting to remove the piston Connecting Connecting Rod End Cap Rod End Cap Hex Hex Screws Screws Figure 9 50 Removing Piston and Connecting Rod 2 Rem...

Page 83: ...he governor gear shaft from the crankcase See Figure 9 55 Governor Governor Shaft Shaft Figure 9 55 Remove Governor Gear Shaft NOTE Mark the orientation of all parts as the governor assembly is removed See Figure 9 56 Figure 9 56 CH270 Governor Assembly Components 3 Remove the hitch pin and washer from the governor cross shaft See Figure 9 57 Figure 9 57 Removing Governor Cross Shaft Hitch Pin 4 R...

Page 84: ...cated in the closure plate To remove the governor gear pry underneath the gear to lift it oﬀ the shaft See Figure 9 61 NOTE Do not pry on the gasket surface of the closure plate as this can cause damage and leakage Figure 9 61 Pry Governor Gear to Remove NOTE Take note of the orientation of the governor gear components See Figure 9 62 Figure 9 62 CH440 Governor Assembly Components NOTE The governo...

Page 85: ...ng Crankcase Crankshaft Bearing 3 Remove the oil seal from the closure plate See Figure 9 66 Figure 9 66 Closure Plate Seal Removal 4 Using a suitable press push the crankshaft bearing from the closure plate See Figure 9 67 Figure 9 67 Closure Plate Bearing Removal NOTE Inspect the bearings for signs of wear by rotating the inner race and examine for marring or cracks Check to make sure the race m...

Page 86: ...9 16 Section 9 Disassembly ...

Page 87: ...tripper or lacquer thinner to remove any gasket residue Apply the solvent allow time for it to work and then brush the surface with a brass wire brush Clean the surface with isopropyl alcohol lacquer thinner or aerosol electrical contact cleaner Refer to A Guide to Engine Rebuilding TP 2150 A for additional information Measurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also ...

Page 88: ... be started with spark plugs that are worn or fouled Engines without ACR are more diﬃcult to start with those same spark plugs Camshaft Tappets Inspection and Service Inspect the gear teeth of the camshaft If the teeth are badly worn chipped or some are missing replacement of the camshaft will be necessary If unusual wear or damage is evident on either lobe or the mating tappet the camshaft and bo...

Page 89: ...ication and there is no evidence of scoring grooving etc no further reconditioning is necessary If the bearing surfaces are worn or damaged the crankcase and or closure plate will need to be replaced Inspect the crankshaft keyways If worn or chipped replacement of the crankshaft will be necessary Inspect the crankpin for score marks or metallic pickup Slight score marks can be cleaned with crocus ...

Page 90: ...es more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so that the stones are in contact with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the ...

Page 91: ...n to Bore Clearance Before installing the piston into the cylinder bore it is necessary that the clearance be accurately checked This step is often overlooked and if the clearances are not within specifications engine failure will usually result NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer Use the following procedu...

Page 92: ...meter 30 875 31 125 mm 1 2156 1 2254 in 26 875 27 125 mm 1 0581 1 0679 in B Valve Length 85 34 85 54 mm 3 3598 3 3677 in 85 19 84 99 mm 3 3461 3 3539 in C Stem Diameter 6 560 6 575 mm 0 2583 0 2589 in 6 560 6 575 mm 0 2583 0 2589 in D Face Seat Width Maximum 1 5 mm 0 059 in 1 5 mm 0 059 in E Face Seat Angle 89 5 90 5 89 5 90 5 CH440 Valve Specifications Item Dimension Intake Exhaust A Head Diamete...

Page 93: ...the valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations Normal Even after long hours of operation a valve can be reconditioned and reused if the face and margin are i...

Page 94: ... and faulty valve springs may cause this condition Also check for clogged air intake and blocked fins when this condition is noted Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the ...

Page 95: ...reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is included as part of the piston assembly if the pin boss in the piston or the pin are worn or damaged a new piston assembly is required Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter the co...

Page 96: ...ston Detonation generally occurs from using low octane fuels Pre ignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Pre ignition damage is often more severe than detonation damage Pre ignition is caused by a hot spot in the combustion chamber such as glowing carbon deposits blocked cooling fins an improperly seated valve or wrong spark plug s See ...

Page 97: ...g the new rings on the piston place the top two rings each in turn in its running area in the cylinder bore and check the end gap See Figure 10 13 Compare the ring gap to the measurements in Section 1 Specifications and Tolerances Figure 10 13 Measuring Piston Ring End Gap 5 After installing the new compression top and middle rings on the piston check the piston to ring side clearance Compare the ...

Page 98: ...Piston Ring Expander Service replacement connecting rods are available in STD size and 0 25 mm 0 010 in undersize The 0 25 mm 0 010 in undersized rods have an identification marking on the lower end of the rod shank Always refer to the appropriate parts information to ensure that correct replacements are used Closure Plate Assembly Inspection Inspect the main bearing surface for wear or damage Ref...

Page 99: ...nition module 12 Assemble cylinder head 13 Install cylinder head 14 Install push rods and rocker arms 15 Install valve cover 16 Install fuel tank supports and shut down switch with bracket 17 Install carburetor 18 Install engine shrouds and air cleaner base 19 Install electric starter and control panel 20 Install blower housing 21 Install retractable starter 22 Install throttle link governor lever...

Page 100: ...tall the governor shaft through the gear and add the thrust washer to the shaft See Figures 11 6 and 11 7 Depth Depth Seal Seal Outer Outer Surface Surface Figure 11 3 Closure Plate Oil Seal Installation Depth Figure 11 4 Install Closure Plate Oil Seal 4 Using an appropriate seal driver install the oil seal into the crankcase to the depth specified below See Figure 11 5 Figure 11 6 Governor Gear A...

Page 101: ...e shaft See Figure 11 9 Gasket Surface Figure 11 9 Installing Thrust Washer and Hitch Pin CH395 1 Assemble the governor gear pin into the governor gear so the pin rim is held in place by the weight retainers See Figure 11 10 Figure 11 10 Governor Gear Assembly 2 Place the thrust washer on the governor gear shaft in the closure plate Push the governor gear onto the shaft See Figure 11 11 Figure 11 ...

Page 102: ...to a height of 16 025 mm 0 6309 in from the closure plate sealing surface See Figure 11 14 Figure 11 14 Install Governor Gear Shaft 2 Place the washer onto the shaft then place the governor gear onto the shaft 3 Press a new ring onto the shaft about 1 8 in 4 Pull the governor gear up until it makes contact with the ring then place the pin in the cup retaining the rim with the weights See Figure 11...

Page 103: ... Mounting Install Crankshaft 1 Carefully slide the flywheel end of the crankshaft through the main ball bearing and seal See Figure 11 20 Figure 11 16 Installing Governor Shaft 8 Install the second flat washer onto the shaft Position the shaft so the flat index end of the shaft faces to the left 9 o clock position and insert the hitch pin from the PTO side See Figure 11 17 Figure 11 17 Installing ...

Page 104: ... Oil Hole Oil Hole Location Location Figure 11 22 Connecting Rod Details 2 Stagger the piston rings in the grooves as shown in Figure 11 23 Oil Ring Expander Gap Top Ring Ring Gap Gap 2nd Ring Gap Bottom Oil Rail Gap Top Oil Rail Gap Figure 11 23 Piston Ring Orientation 3 Lubricate cylinder bore piston piston pin and piston rings with engine oil Compress the rings using a piston ring compressor 4 ...

Page 105: ...quipped 1 Position the crankshaft so the timing mark on the larger crankgear is in the 8 o clock position 2 Install the balance shaft aligning the timing mark with the timing mark on the larger crankgear See Figure 11 27 Figure 11 27 Aligning Timing Marks Install Valve Tappets and Camshaft 1 Lubricate the face and stem of each tappet with engine oil Install each into their respective bores See Fig...

Page 106: ...o the crankcase Torque hex flange screws to 24 N m 212 in lb See Figure 11 31 or 11 32 for the torque sequence 6 6 2 2 4 4 1 1 5 5 3 3 Figure 11 31 CH270 Closure Plate Torque Sequence Figure 11 29 Aligning Crankshaft and Camshaft Timing Marks 4 Install the original shims on the crankshaft and camshaft Install Closure Plate 1 Check to make sure the sealing surfaces of the crankcase and closure plat...

Page 107: ...ssing and damage when the flange nut is torqued to specification See Figure 11 35 Figure 11 35 Clean and Dry Taper of Crankshaft and Flywheel Bore NOTE In the following step make sure the flywheel key is installed properly in the keyway The flywheel can become cracked or damaged if the key is not installed properly Figure 11 32 CH395 CH440 Closure Plate Torque Sequence Install Stator If Equipped 1...

Page 108: ... Figure 11 37 Install Flywheel Shield 4 Install the fan bosses into the matching holes in the flywheel See Figure 11 38 Cup Boss Cup Boss Insert Boss Insert Boss Here Here Figure 11 38 Install Flywheel Fan 5 Position the drive cup on the flywheel engaging the boss on its base with the corresponding hole in the flywheel Hold in position and install the hex flange nut Finger tighten to keep cup inde...

Page 109: ...le screws to 10 N m 89 in lb 7 Rotate the flywheel back and forth checking to make sure the magnet does not strike the module 8 Connect the kill wire to the ignition module bottom blade terminal and route the wire lead to the top of the crankcase See Figure 11 43 Magnet Magnet Feeler Feeler Gauge Gauge Figure 11 41 Install Ignition Module 2 Install the ignition module loosely to the bosses with th...

Page 110: ...hex flange screws following the table Model Initial Torque Final Torque CH270 12 N m 106 in lb 24 N m 212 in lb CH395 CH440 18 N m 159 in lb 36 N m 319 in lb Figure 11 43 Connect Kill Wire To Module Assemble Cylinder Head 1 Install the valves into their respective positions 2 Install new valve seals on the stem of the valves See Figure 11 44 Module Terminal Module Terminal Route Wire Here Route Wi...

Page 111: ...ocknuts onto the studs and push rods Finger tighten the rocker arm pivot jam locknuts See Figure 11 49 Guide Guide Plate Plate Rocker Arm Rocker Arm Studs Studs Install Push Rods Install Push Rods Figure 11 49 Installing Rocker Arms Adjusters and Locknuts 4 Adjust the valve tappet clearance as follows a Make sure the piston is still at the top of the compression stroke b Insert a flat feeler gauge...

Page 112: ...the hex flange screw and torque to 10 N m 89 in lb See Figure 11 53 Figure 11 53 Torquing Valve Cover Screw Install Fuel Tank Supports and Shut Down Switch with Bracket CH270 1 Position both tank support brackets on the crankcase and loosely install with four hex head screws See Figure 11 54 Valve Cover Valve Cover Screw Screw Figure 11 54 Install Fuel Tank Brackets 2 Position the shut down switch...

Page 113: ...1 Install a new insulator to cylinder head gasket onto the carburetor studs followed by the insulator and the carburetor to insulator gasket See Figure 11 57 2 Push the carburetor all the way onto the studs See Figure 11 58 Figure 11 58 Install Carburetor 3 Connect the throttle link and dampening spring into their respective holes in the throttle lever See Figure 11 59 Throttle Link Throttle Link ...

Page 114: ...the air cleaner base connection port Connect the opposite end of the breather hose to the valve cover See Figure 11 62 Hex Screw Hex Screw Figure 11 62 Air Cleaner Base Installation 4 Secure the base with the two hex flange nuts on the mounting studs and one hex flange screw through the top heat shield into the crankcase housing Torque hardware to 8 N m 71 in lb See Figure 11 62 5 Install the lowe...

Page 115: ...hex flange screw into the crankcase housing Torque hardware to 8 N m 71 in lb See Figure 11 66 NOTE When securing the low profile air cleaner the hex flange screw is installed through the base into the blower housing Torque to 6 7 N m 59 in lb Hex Screws Hex Screws Figure 11 66 Air Cleaner Base Installation Install Electric Starter and Control Panel If Equipped 1 Align and mount the electric start...

Page 116: ...Installing Blower Housing CH395 CH440 2 Install the blower housing on the crankcase with the hex flange screws Torque screws to 10 N m 89 in lb See Figure 11 72 Hex Screws 3 Mount the control panel to the crankcase and secure with two hex flange screws Ensure the ground wires are placed between the screw and the bracket Torque the screws to 24 N m 212 in lb See Figure 11 69 Hex Screws Hex Screws H...

Page 117: ...ft Torque the nut to 12 N m 106 in lb Figure 11 76 Governor Lever Adjustment 4 Install the spring on the governor and throttle levers in the holes previously marked in disassembly Install the throttle lever and a fender washer on the threaded stud of the fuel tank bracket See Figures 11 77 and 11 78 Push Push Lever Lever Tighten Tighten Nut Nut Turn Turn Governor Governor Shaft Shaft Push Push Lev...

Page 118: ... Governor Lever Throttle Control Lever Governor Lever and Hole Position RPM Chart CH270 Engines Washer Tab Washer Tab In Slot In Slot Figure 11 78 Install Throttle Lever for CH395 CH440 5 Install a nylon washer wave spring and tabbed washer with tab engaged in slot on the stud above the throttle lever and secure with a hex flange nut Torque the hex flange nut to 9 N m 80 in lb See Figure 11 79 Fig...

Page 119: ...Yellow 2 B 3201 3400 Yellow 1 B 3001 3200 Yellow 1 B Black 1 B 2801 3001 Yellow 1 B CH395 Engines Throttle Control Lever 1 2 3 4 A B C Governor Lever Throttle Control Pivot Lever Engine Speed RPM 6 12 Droop 3 6 Droop Spring Color Hole Combination Spring Color Hole Combination 3801 4000 None 2 B 3601 3800 None 2 B White 2 A 3401 3600 None 2 B 3201 3400 White 3 A 3001 3200 White 3 A Green 1 B 2801 3...

Page 120: ...on the fuel line in the clip on the bottom of the tank Connect the fuel line to the shut oﬀ valve on the carburetor and secure with the clamp See Figure 11 84 Figure 11 80 Reconnect Electrical Leads 2 Connect the electrical leads for the Oil Sentry module See Figure 11 80 Install Fuel Tank 1 Position the fuel tank on the mounting brackets Secure with hex screws on the inner mounting bracket and on...

Page 121: ...ly 1 Install a new exhaust gasket onto the exhaust studs 2 Position the muﬄer and heat shield assembly and install one hex flange screw in the support bracket and two hex flange screws in the exhaust outlet flange See Figures 11 86 11 87 and 11 88 3 Torque three hex flange screws to CH270 24 N m 212 in lb CH395 CH440 35 N m 310 in lb Hex Nuts Hex Nuts Screws Screws Figure 11 86 Install CH270 Muffl...

Page 122: ...on on a piece of equipment 1 Set the engine up on a test stand Check gas and oil levels Start the engine and run for 5 10 minutes between idle and midrange Adjust the carburetor settings as required Low idle speed should be set to 1800 RPM 150 or application specifications See Figure 11 92 Element Element Install Air Cleaner Element and Cover Install the Quad Clean Air Cleaner 1 Place the air clea...

Page 123: ...w Idle Speed Low Idle Speed Adjustment Screw Adjustment Screw Figure 11 92 Low Idle Speed Adjustment Screw 2 The maximum no load high idle engine speed is 3750 RPM Adjust the high speed stop screw as necessary See Figure 11 93 High Speed High Speed Stop Screw Stop Screw ...

Page 124: ...11 26 Section 11 Reassembly ...

Page 125: ......

Page 126: ...90 01 Rev D ISSUED 5 10 REVISED 1 11 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 2011 by Kohler Co All rights reserved ...

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