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Kohler SV540S Specifications

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• Kohler SV540S Engine Specifications
• Kohler SV540S Engine Maintenance
• Kohler SV540S Engine Troubleshooting

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

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)

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

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

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

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

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