Kohler RH265 Generator Set

Tools: Flat feeler gauge

1. Be sure piston is at top of compression stroke.
2. Insert a flat feeler gauge between rocker arm and valve stem.
3. Adjust clearance by loosening locknut and tightening adjuster. Turn clockwise to decrease clearance, counterclockwise to increase.
4. Hold adjuster from turning and tighten locknut. Torque locknut to 10 N·m (88.5 in. lb.).
5. Recheck that clearance is correct.

1. Remove air cleaner cover.
2. Reposition fuel tank to access governor shaft and lever joint, or disconnect fuel line and remove tank from engine.
3. Loosen governor lever mounting nut.
4. Move governor lever clockwise until it stops.
5. Rotate governor shaft clockwise until it stops.
6. Hold both in this position and torque governor lever nut to 7 N·m (62 in. lb.).

⚠ Carburetor adjustments should be made only after engine has warmed up.

1. Place throttle control into idle or slow position.
2. Turn low idle speed adjusting screw in or out to obtain a low idle speed of 1800 RPM (± 75 RPM).

⚠ 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

1. Separate bullet connector in white lead from rectifier-regulator. Connect ammeter from female terminal to positive (+) battery terminal and DC voltmeter to negative (-) terminal. Run engine at 3600 RP
2. If voltage is 14.0 volts or more, place a minimum load of 5 amps on battery to reduce voltage and observe ammeter.
3. Separate bullet connectors in AC (white) leads. Connect an AC voltmeter across stator leads. With engine running at 3600 RPM, measure AC output from stator.
4. With engine stopped, measure resistance from each stator lead to ground using an ohmmeter.

Tools: Compression tester

1. Perform on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them.
2. Be sure choke is off, and throttle is wide open during test.
3. Compression should be at least 160 psi and should not vary more than 15% between cylinders.

⚠ Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts.

Tools: Water manometer, Rubber stopper, Tapered adapters

1. Insert rubber stopper into oil fill hole. Be sure pinch clamp is installed on hose and use tapered adapters to 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.
4. Close pinch clamp before stopping engine.

Tools: Cylinder leakdown tester, Air source (at least 50 psi)

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 of cylinder being tested is at TDC of compression stroke. Hold engine in this position while testing.
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. While firmly holding engine at TDC, gradually open tester valve. Note gauge reading and listen for escaping air.

⚠ Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts.

Tools: DC voltmeter, Jumper cables, Ohmmeter

1. Test battery on unit: connect DC voltmeter across battery terminals and read voltage (switch OFF). Turn switch to start and read again.
2. Remove electric starter cover panel and check fuse inside plastic holder; fuse outside holder is a spare.
3. Disconnect blue relay lead. Be sure transmission is in neutral and PTO is OFF. Jumper positive battery terminal 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 on Rx1 scale.

Tools: Spark tester, Ohmmeter

1. Disconnect cap from spark plug and attach it to terminal end of spark tester. Attach tester spring clip to a good ground, not to spark plug. Turn ignition switch ON and crank engine while observing fi
2. If tester doesn't fire, unplug switch wire from ignition module and retest. If no spark is present go to step 2.
3. Set an ohmmeter to Rx1 scale and zero meter. Trace two black leads from on/off switch and separate them. Connect ohmmeter leads to switch leads and check continuity in both 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, use approved fuel container to catch fuel, hold line below bottom of tank and observe fuel flow.

Tools: Torque wrench

1. Check for nicks or burrs on sealing surfaces of cylinder head or crankcase.
2. Rotate crankshaft to position piston at TDC on compression stroke.
3. Install dowel pins into recesses around lower cylinder head bolt holes and install a new cylinder head gasket.
4. Install cylinder head and start screws. Tighten screws initially to 12 N·m (106 in. lb.) in several increments using sequence shown.
5. Tighten to a final torque of 24 N·m (212 in. lb.).

Tools: Flat feeler gauge (0.254 mm / 0.010 in.), Torque wrench

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, then tighten screws just enough to hold it in position.
3. Rotate flywheel clockwise until magnet is under 1 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. Push against module to hold leg tight again
5. Repeat for other leg of module. Torque both module screws to 8 N·m (70.8 in. lb.).
6. Rotate flywheel back and forth, checking to make sure magnet does not strike module.
7. Connect kill wire to ignition module bottom blade terminal.