Kohler SV540

Kohler SV540The 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):
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
Flywheel End:44.870-44.895 mm (1.766-1.767 in)
PTO End: 41.855-41.880 mm (1.648-1.649 in)

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)


Manufacturer or Brand Models
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1. Kohler Courage SV470-SV620 service manual. Kohler Co. 2020.

Author: Sergei Wers
About: Co-founder and CEO of a multi-brand auto repair shop (engine repair, chassis repair, body repair and painting) for over 15 years. I have been developing internet sites with technical specifications for more than seven years.

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