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Kohler Courage SV540S

General Technical Data

Kohler SV540S Engine Specifications

Engine Model ................... Kohler Courage SV540S
Engine Type ................... Gasoline, single-cylinder, vertical shaft air-cooled
Number of Cylinders ................... 1
Displacement, cc (cu.in) ................... 535 (32.6)
Engine Bore, mm (in) ................... 89.0 (3.50)
Engine Stroke, mm (in) ................... 86.0 (3.38)
Rated Engine Power, hp (kW) ................... 18.0 (13.4)
Rated Engine Speed, rpm ................... 3600
Maximum Torque, Nm (ft-lbs) ................... 39.1 (29.0)
Torque Speed, rpm ................... 2800
Compression ................... 8.5:1
Lubrication ................... Full pressure
Oil filter ................... Full-flow type
Air Cleaner ................... Replaceable, paper element
Oil Capacity, L (qts) ................... 1.9 (2.0)
Electrical System Rating, Volts ................... 12
Starter Type ................... Electric
Battery Rating ................... 12V, 400 CCA

Fuel System

Fuel System Type ................... Carburetor
Carburetor Model ................... Walbro
Carburetor Type ................... Fixed main jet
Fuel Pump ................... Pulse type
Fuel Filter ................... In-line
Governor ................... Mechanical

Dimensions

Length, mm (in) ................... 490 (19.4)
Width, mm (in) ................... 415 (16.4)
Height, mm (in) ................... 325 (12.9)
Net weight, kg (lbs) ................... 35.8 (79)

Kohler SV540S Maintenance Data

Cylinder Block and Valves

Cylinder Bore I.D. (Maximum), mm (in) ................... 89.073 (3.507)
Cylinder Head (Max. Out-of-Flatness), mm (in) ................... 0.8 (0.003)
Intake Valve Clearance (Cold), mm (in) ................... 0.038-0.076 (0.0015-0.0030)
Exhaust Valve Clearance (Cold), mm (in) ................... 0.050-0.088 (0.0020-0.0035)

Engine Oil

Engine Oil Type (Summer) ................... SAE 10W-30
Engine Oil Type (Winter) ................... SAE 5W-20, 5W-30
Oil Classification ................... SG, SH, SJ or higher
Oil Capacity (with Filter), L (qts) ................... 1.5 (1.6)

Carburetor Adjustment

Main Fuel ................... Not adjustable
Idle Fuel ................... Adjust by needle and spring with limiter cap
Low Idle Speed, rpm ................... 1500±75
High Idle Speed, rpm ................... 3600±50

Ignition System

Spark Plug Type ................... Champion RC12YC or QC12YC
Spark Plug Gap, mm (in) ................... 0.76 (0.030)
Module Air Gap, mm (in) ................... 0.203-0.305 (0.008-0.012)
Thread Size, mm (in) ................... 14 (0.55)
Reach, mm (in) ................... 19.1 (0.75)
Spark Plug Torque, Nm (ft-lbs) ................... 24-30 (18-22)

Service Intervals

Service Precleaner Element ................... Every 25 hours
Replace Air Cleaner Element ................... Every 100 hours
Change Engine Oil ................... Every 100 hours
Change Oil Filter ................... Every 100 hours
Clean Cooling Areas ................... Every 100 hours
Replace Fuel Filter ................... Every 100 hours
Check Carburetor Adjustment ................... Every 100 hours
Check Spark Plug Gap ................... Every 200 hours
Replace Spark Plug ................... Every 400 hours
Check and Adjust Valve Clearance ................... Every 400 hours

Kohler SV540S Service Specifications

Cylinder Block

Cylinder Bore I.D (Std), mm (in) ................... 89.000-89.025 (3.504-3.505)
Cylinder Bore I.D (Wear Limit), mm (in) ................... 89.073 (3.507)
Cylinder Bore (Max. Taper), mm (in) ................... 0.05 (0.002)
Cylinder Bore (Max. Out of Round), mm (in) ................... 0.12 (0.0047)
Cylinder Head (Max. Out-of-Flatness), mm (in) ................... 0.8 (0.003)
Cam Gears End Play, mm (in) ................... 0.5-1.5 (0.019-0.059)
Cam Gears Running Side Clearance, mm (in) ................... 0.02-0.13 (0.001-0.005)
Cam Gear-to-Camshaft Running Assembly, mm (in) ................... 0.02-0.10 (0.001-0.004)
Connecting Rod-to-Crankpin Clearance, mm (in) ................... 0.03-0.055 (0.0012-0.0022)
Connecting Rod-to-Crankpin Side Clearance, mm (in) ................... 0.25-0.59 (0.0098-0.0232)
Connecting Rod-to-Piston Pin Clearance, mm (in) ................... 0.015-0.028 (0.0006-0.0011)

Valves and Valve Lifters

Valve Lash, mm (in) ................... 0.076 (0.003)
Intake Valve Minimum Lift, mm (in) ................... 8.9 (0.350)
Exhaust Valve Minimum Lift, mm (in) ................... 8.9 (0.350)
Nominal Valve Seat Angle, deg ................... 45
Intake Valve Stem-to-Valve Guide Clearance, mm (in) ................... 0.038-0.076 (0.0015-0.003)
Exhaust Valve Stem-to-Valve Guide Clearance, mm (in) ................... 0.050-0.88 (0.0020-0.0035)
Intake Valve Guide I.D, mm (in) ................... 6.038-6.058 (0.2377-0.2385)
Intake Valve Stem Diameter, mm (in) ................... 5.982-6.0 (0.2355-0.2362)
Exhaust Valve Guide I.D, mm (in) ................... 6.038-6.058 (0.2377-0.2385)
Exhaust Valve Stem Diameter, mm (in) ................... 5.970-5.988 (0.235-0.2357)

Crankshaft

Crankshaft End Play (free), mm (in) ................... 0.225-1.025 (0.0089-0.040)
Crankshaft Bore in Crankcase I.D, mm (in) ................... 41.965-41.990 (1.6521-1.6531)
Crankshaft Bore in Closure Plate I.D, mm (in) ................... 44.965-44.990 (1.7703-1.7713)
Flywheel End Main Bearing Journal O.D, mm (in) ................... 44.913-44.935 (1.7682-1.7691)
Flywheel End Main Bearing Journal (Max. Taper), mm (in) ................... 0.0220 (0.0009)
Flywheel End Main Bearing Journal (Max. Out of Round), mm (in) ................... 0.025 (0.001)
PTO End Main Bearing Journal O.D, mm (in) ................... 41.913-41.935 (1.6501-1.6510)
PTO End Main Bearing Journal (Max. Taper), mm (in) ................... 0.020 (0.0008)
PTO End Main Bearing Journal (Max. Out of Round), mm (in) ................... 0.025 (0.001)
Crankshaft Bore in Closure Plate Clearance, mm (in) ................... 0.03-0.077 (0.0012-0.003)
Crankshaft Bore in Crankcase Clearance, mm (in) ................... 0.03-0.077 (0.0012-0.003)
Connecting Rod Journal O.D, mm (in) ................... 40.982-41.000 (1.6134-1.6141)
Connecting Rod Journal (Max. Taper), mm (in) ................... 0.012 (0.0005)
Connecting Rod Journal (Max. Out of Round), mm (in) ................... 0.025 (0.001)
Crankshaft T.I.R (PTO End, Crankshaft in Engine), mm (in) ................... 0.15 (0.0059)
Crankshaft T.I.R (Entire Crankshaft, in V-Blocks), mm (in) ................... 0.10 (0.0039)
Crankshaft Eccentrics O.D, mm (in) ................... 66.940-66.970 (2.6354-2.6366)
Balance Weight Bearing Surface I.D, mm (in) ................... 67.011-67.086 (2.6382-2.6412)
Guide Pin O.D, mm (in) ................... 11.950-11.975 (0.4705-0.4715)
Guide Shoe Width, mm (in) ................... 17.85-17.90 (0.703-0.705)
Guide Shoe Hole I.D, mm (in) ................... 12.000-12.025 (0.4724-0.4734)

Piston and Piston Rings

Piston Pin Bore I.D, mm (in) ................... 22.006-22.012 (0.8685-0.8666)
Piston Pin O.D, mm (in) ................... 21.995-22.0 (0.8659-0.8661)
Piston Pin End I.D, mm (in) ................... 22.015-22.023 (0.8667-0.8670)
Top Compression Ring-to-Groove Side Clearance, mm (in) ................... 0.04 (0.0016)
Middle Compression Ring-to-Groove Side Clearance, mm (in) ................... 0.04 (0.0016)
Top Compression Ring End Gap, mm (in) ................... 0.15-0.40 (0.006-0.016)
Middle Compression Ring End Gap, mm (in) ................... 0.30-0.55 (0.012-0.022)
Piston Thrust Face O.D, mm (in) ................... 88.948-88.962 (3.5018-3.5024)
Piston Thrust Face-to-Cylinder Bore Clearance, mm (in) ................... 0.0575 (0.0023)

Kohler SV540S Tightening Torque Specifications

Cylinder Head ................... 20.5-41.0 Nm (15-30 ft-lb)
Rocker Arm Pivot Stud ................... 13.5 Nm (10 ft-lb)
Rocker Arm Adjustment Nut Set Screw ................... 5.5 Nm (4.2 ft-lb)
Flywheel Retaining Screw ................... 66.5 Nm (49 ft-lb)
Connecting Rod Cap ................... 11.5 Nm (8.5 ft-lb)
Cam Lever ................... 7.5 Nm (5.4 ft-lb)
Oil Drain Plug ................... 14.0 Nm (10.4 ft-lb)
Fuel Bowl Retaining Screw Torque ................... 5.1-6.2 Nm (3.8-4.6 ft-lb)
Balance Weight Screw ................... 10.0 Nm (7.5 ft-lb)
Air Cleaner Base Mounting Screw ................... 8.0 Nm (5.8 ft-lb)
Electric Starter Mounting Nut ................... 3.6 Nm (2.7 ft-lb)
Ignition Module ................... 6.0 Nm (4.5 ft-lb)
Muffler Retaining Nuts ................... 24.4 Nm (18 ft-lb)
Oil Filter ................... 10-13 Nm (7.5-10.1 ft-lb)
Oil Pump Mounting Screw ................... 4.0 Nm (2.9 ft-lb)
Rectifier-Regulator Mounting Screw ................... 6.0 Nm (4.5 ft-lb)
Speed Control Bracket Assembly ................... 11.0 Nm (8.2 ft-lb)
Governor Control Lever ................... 7.0-8.5 Nm (5.2-6.3 ft-lb)