Kohler Courage SV540 (18.0 HP) engine specs, service data

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 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)

Applications

Manufacturer or Brand	Models
Lawn tractors
Cub Cadet	i1042, LT1040
Toro	LX420

References

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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Kohler SV540