The Kohler SV540 is a 535 cc, (32.6 cu·in) for models SV540-00XX and SV540-01XX or 597 cc, (36.4 cu·in) for models SV540-02XX and higher, natural aspirated single-cylinder four-stroke air-cooled small gasoline engine with a vertical shaft from the Courage series, manufactured by Kohler Co for general-purpose applications.
The cylinder bore is 89.0 mm (3.50 in) for SV540-00XX and SV540-01X engines or 94.0 mm (3.70 in) for models SV540-02XX and higher and the piston stroke is 86.0 mm (3.39 in). The compression ratio rating is 8.5:1.
The Kohler Courage SV540 engine produced 18.2 PS (13.4 KW; 18.0 HP) at 3,600 rpm of maximum output power and 43.5 Nm (4.44 kg·m; 32.1 ft·lb) of peak torque.
The Kohler SV540 features:
- OHV design
- Aluminum head and crankcase with cast iron cylinder liner
- Micro-polished crankshaft bearings
- Electronic ignition system
- Carburetor with fixed main jet (Nikki or Walbro)
- Centrifugal governor
- Full pressure lubrication with full-flow filter
- Forced air cooling system
- Electric starter
General information
| Engine Specifications | |
| Engine model | Courage SV540 |
| Engine type | 4-stroke, OHV, single-cylinder |
| Displacement | SV540-00XX and SV540-01XX: 535 cm3, (32.6 cu·in) SV540-02XX and higher: 597 cm3, (36.4 cu·in) |
| Max. horsepower | 18.2 PS (13.4 KW; 18.0 HP) at 3,600 rpm |
| Max. torque | 43.5 Nm (4.44 kg·m; 32.1 ft·lb) |
| Cooling system | Forced air |
| Air cleaner | Replaceable, paper element |
| Lubricating system | Pressurized lubrication |
| Ignition system | Electronic ignition system |
| Fuel system | Carburetor with fixed main jet (Nikki or Walbro) |
| Fuel consumption | – |
| Fuel tank capacity | – |
| Fuel used | Unleaded gasoline (octane number 86 or higher) |
| Starting system | Electric starter |
| Dimensions (L x W X H) | 493 x 416 x 328 mm (19.4 x 16.4 x 12.9 in) |
| Dry weight | 35.8 kg (78.9 lbs) |
Cylinder Block and Head
| Cylinder block | |
| Compression ratio: | 8.5:1 |
| Cylinder bore: | SV540-00XX and SV540-01XX: 89.0 mm (3.50 in) SV540-02XX and higher: 94.0 mm (3.7 in) |
| Piston stroke: | 86.0 mm (3.39 in) |
| Cylinder internal diameter: | SV540-00XX and SV540-01XX: 89.010-89.035 mm (3.5040-3.5050 in.) SV540-02XX and higher: 94.010-94.035 mm (3.7012-3.7022 in) |
| Number of piston rings (compression / oil): | 2/1 |
| Piston pin diameter: | 21.995-22.000 mm (0.8659-0.8661 in) |
| Side clearance (Top): | 0.040 mm (0.0016 in) |
| Side clearance (Second): | 0.040 mm (0.0016 in) |
| Ring end gap (Top): | 0.150-0.400 mm (0.0059-0.0157 in) |
| Ring end gap (Second): | 0.300-0.550 mm (0.0118-0.0217 in) |
| Crankshaft main journal diameter: | Before S/N 3703200003 Flywheel End: 44.913-44.935 mm (1.768-1.769 in) PTO End: 41.913-41.935 mm (1.650-1.651 in) After SN 3703200013 |
| Crankpin journal diameter: | 40.982-41.000 mm (1.6135-1.6142 in) |
| Crankshaft center distance: | 43 mm (1.695 in) |
| Cylinder head | |
| Valve arrangement: | OHV |
| Valves: | 2 |
| Valve head diameter (INTAKE): | 37.375-37.625 mm (1.4715-1.4813 in) |
| Valve head diameter (EXHAUST): | 32.125-32.375 mm (1.2648-1.2746 in) |
| Valve steam diameter (INTAKE): | 5.982-6.000 mm (0.2355-0.2362 in) |
| Valve steam diameter (EXHAUST): | 5.970-5.988 mm (0.235-0.2357 in) |
Service Data
| Valve clearance | |
| Intake valve lash: | 0.127 mm (0.005 in) |
| Exhaust valve lash: | 0.178 mm (0.007 in) |
| Oil system | |
| Lubrication system: | Pressurized lubrication |
| Oil type: | SJ or higher |
| Recommended oil: | SAE 10W-30 |
| Oil capacity: | 1.5 L (1.59 US. qt, 1.32 Imp. qt.) |
| Fuel system | |
| Type: | Carburetor with fixed main jet (Nikki or Walbro) |
| Ignition system | |
| Type: | Electronic ignition system |
| Spark plug: | Champion RC12YC |
| Spark plug gap: | 0.76 mm (0.0299 in) |
| Spark plug torque: | 27 N·m (2.8 kg·m, 19.9 ft·lb) |
Tightening torque specifications
| Valve clearance | |
| 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) |
Applications
| Manufacturer or Brand | Models |
| Lawn tractors | |
| Cub Cadet | i1042, LT1040 |
| Toro | LX420 |
References
1. Kohler Courage SV470-SV620 service manual. Kohler Co. 2020.
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