Kohler CH245 Generator Set

⚠ Make sure carburetor is mounted and secured in place when adjustment is made/checked

1. Close fuel shut-off valve.
2. Remove air cleaner outer cover; access governor shaft and lever joint.
3. Loosen governor lever mounting nut.
4. CH260, CH270: Move governor lever clockwise until it stops. Rotate governor cross shaft clockwise until it stops.
5. CH395, CH440: Move governor lever counterclockwise until it stops. Rotate governor cross shaft counterclockwise until it stops.
6. Hold both in this position and torque governor lever nut to 12 N·m (106 in. lb.).

Tools: Flat feeler gauge, Torque wrench

1. Dip ends of push rods in engine oil and install in their respective locations, seating each into tappet socket.
2. Install push rod guide plate, aligning holes for rocker arm studs. Screw in rocker arm studs and torque to 13.6 N·m (120 in. lb.).
3. Assemble rocker arms, adjusters, and locknuts onto studs and push rods; finger tighten rocker arm pivot jam locknuts.
4. Make sure piston is at top of compression stroke.
5. Insert a flat feeler gauge between rocker arm and valve stem. Clearance for intake and exhaust is 0.076-0.127 mm (0.003-0.005 in.) cold.
6. Loosen locknut and turn adjuster to adjust clearance; turn clockwise to decrease, counterclockwise to increase.
7. Hold adjuster from turning and tighten locknut. Torque locknut to 10 N·m (89 in. lb.).
8. Recheck clearance is correct.

⚠ Voltage tests should be made with engine running at 3600 RPM - no load. Battery must be fully charged.

Tools: Ammeter, DC voltmeter, AC voltmeter, Ohmmeter, 2.5 ohm 100 watt resistor (for load)

1. Separate bullet connector in white lead from rectifier-regulator. Connect ammeter from female terminal to battery positive; DC voltmeter from female terminal to battery negative.
2. Run engine at 3600 RPM and read voltage. If 14.0 volts or more, apply minimum 5 amp load and observe ammeter.
3. If voltage is less than 14.0 volts or charge rate does not increase, test stator: separate bullet connectors in AC (white) leads and measure AC output across stator leads at 3600 RPM.
4. With engine stopped, measure resistance from each stator lead to ground using an ohmmeter.

⚠ Carbon Monoxide can cause severe nausea, fainting or death. Never run engine indoors or in enclosed spaces.

⚠ Rotating Parts can cause severe injury. Stay away while engine is in operation.

Tools: Water manometer or vacuum/pressure gauge (inches of water gauge), Rubber stopper and adapter

1. Insert rubber stopper into oil fill hole with pinch clamp installed on hose; connect hose between stopper and one manometer tube.
2. Start engine and run no-load high speed.
3. Open clamp and note water level in tube. Engine side should be minimum 10.2 cm (4 in.) above open side.
4. Close pinch clamp before stopping engine.
5. If vacuum is low/no vacuum or pressure is present, check breather, seals/gaskets, piston blow by or leaky valves, and restricted exhaust.

Tools: Cylinder leakdown tester, Holding tool, 3/8 in. breaker bar

1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter from engine.
3. Rotate crankshaft until piston being tested is at top dead center (TDC) of compression stroke. Hold engine in this position.
4. Install adapter into spark plug hole, but do not attach it to tester at this time.
5. Turn regulator knob completely counterclockwise.
6. Connect an air source of at least 50 psi to tester.
7. Turn regulator knob clockwise until gauge needle is in yellow set area at low end of scale.
8. Connect tester quick-connect to adapter hose; gradually open tester valve while holding engine at TDC.
9. Note gauge reading and listen for escaping air at combustion air intake, exhaust outlet, and crankcase breather.

Tools: DC voltmeter, Jumper leads, Ohmmeter

1. Test battery on unit: connect DC voltmeter across battery terminals and read voltage (key switch OFF), then turn key switch to start position and read again.
2. Remove electric starter cover panel and check fuse inside plastic holder.
3. Disconnect blue relay lead. Be sure transmission is in neutral and PTO is OFF. Connect jumper lead from battery positive to relay terminal.
4. Use a known good fully-charged battery and jumper cables to test starter motor.
5. Disconnect leads from starter relay and remove it for testing with an ohmmeter.

⚠ Electrical Shock can cause injury. Do not touch wires while engine is running.

Tools: Spark tester, Ohmmeter

1. Disconnect cap from spark plug and attach to spark tester; attach tester spring clip to good ground. Turn ignition switch ON and crank engine while observing firing tip.
2. If tester doesn't fire, on electric start engines disconnect black/white kill lead bullet connector inside blower housing and repeat spark test.
3. Disconnect bullet connector where Oil Sentry™ control module joins yellow lead from float switch; repeat spark test.
4. Set ohmmeter to Rx1 and check continuity between yellow Oil Sentry™ control module lead and black wire.
5. With crankcase oil at proper level, check continuity between Oil Sentry™ float switch lead (yellow with green sleeve) and crankcase ground.
6. Check resistance from kill lead (black/white) terminal to spark plug cap: should be 13.5-18.0 K ohms; with kill lead removed, small spade terminal to spark plug cap should be 9.5-12.9 K ohms.
7. Test ignition/key switch continuity in all switch positions.

Tools: Approved fuel container

1. Check for fuel in combustion chamber: disconnect and ground spark plug lead, close choke, crank engine several times, remove spark plug and check for fuel at tip.
2. Check for fuel flow from tank to carburetor: remove fuel line from inlet fitting of carburetor, hold line below bottom of tank into an approved container and observe flow.
3. Check operation of fuel shut-off valve: remove fuel sediment bowl under inlet fitting, turn fuel shut-off valve ON and OFF and observe operation.

Tools: Flat feeler gauge 0.254 mm (0.010 in.)

1. Turn flywheel so magnet is away from location where ignition module will be installed.
2. Install ignition module loosely to bosses with screws; move module as far away from flywheel as possible and tighten screws just enough to hold position.
3. Rotate flywheel until magnet is under one leg of ignition module.
4. Insert a 0.254 mm (0.010 in.) flat feeler gauge between leg of module and magnet; loosen nearest screw allowing magnet to draw module against feeler gauge.
5. Rotate flywheel until magnet is under other leg of module; repeat adjustment on second screw.
6. Torque first screw, then second screw, then torque first screw one more time to 10 N·m (89 in. lb.).
7. Rotate flywheel back and forth, checking magnet does not strike module.
8. Connect kill wire to ignition module bottom blade terminal and route wire lead to top of crankcase.

⚠ Change oil while engine is warm

1. Clean area around oil fill plug/dipstick and drain plug.
2. Remove drain plug and oil fill plug/dipstick. Drain oil completely.
3. Reinstall drain plug. Torque to 18 N·m (13 ft. lb.).
4. Fill crankcase with new oil to specified level on dipstick or filler neck threads.
5. Reinstall oil fill plug/dipstick and tighten securely.
6. Dispose of used oil in accordance with local ordinances.

⚠ Never run engine with oil level below or above operating range indicator on dipstick

1. Ensure engine is cool and level. Clean oil fill/dipstick areas of any debris.
2. Remove dipstick; wipe oil off.
3. Reinsert dipstick into tube; rest on oil fill neck; turn counterclockwise until cap drops to lowest point of thread leads; do not thread cap onto tube.
4. Remove dipstick; check oil level. CH260/CH270: middle of indicator. All other models: top of indicator.
5. If oil is low, add oil to specified level on dipstick or filler neck threads.
6. Reinstall dipstick or oil fill plug and tighten securely.

⚠ Failures due to untreated fuel are not warrantable

1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system.
2. Change oil while engine is still warm. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s).
3. Replace spark plug(s) and crank engine slowly to distribute oil.
4. Disconnect negative (-) battery cable.
5. Store engine in a clean, dry place.