Kawasaki FC540V

Kawasaki FC540VThe Kawasaki FC540V is a 535 cc (32.65 cu-in) single-cylinder air-cooled 4-stroke internal combustion small gasoline engine with vertical shaft manufactured by Kawasaki Heavy Industries LTd., for general-purpose applications.

The FC540V engine has an OHV (overhead valve) design; cast-iron cylinder liner; reciprocating balancer; float type carburetor with fixed main jet; flywheel magneto transistor type ignition system; mechanical governor; low tone muffler; electric shift-type starter with an automatic compression release.

The engine uses semi cyclone-type air cleaner with the dual element; full pressure lubrication system with spin-on oil filter and pulse type fuel pump with the inline fuel filter. The Kawasaki FC540V could be equipped with 12V (3A or 15A) charging coil.

Bore and stroke are 89.0 mm (3.5 in) and 86.0 mm (3.39 in), respectively. Compression ratio rating is 8.3:1. The Kawasaki FC540V motor produced 17.3 PS (12.7 kW; 17.0 HP) at 3,600 rpm of horsepower and 36.7 Nm (3.74 kg·m; 27.08 ft·lb) at 2,400 rpm of torque.

General information

Engine Specifications
Model FC540V
Type 4-stroke, OHV, single cylinder
Displacement 535 cm 3 (32.65 cu-in)
Max. horsepower 17.3 PS (12.7 KW; 17.0 HP) at 3,600 rpm
Max. torque 36.7 Nm (3.74 kg·m; 27.08 ft·lb) at 2,400 rpm
Carburetor Float type with fixed main jet
Cooling system Forced-air
Ignition system Flywheel magneto transistor type
Lubricating system Full pressurized
Starting system Electric starter (shift type)
Fuel used Unleaded gasoline (octane number 86 or higher)
Fuel tank capacity
Fuel consumption 245 g/HPh
PTO shaft rotation Counterclockwise (from PTO shaft side)

Dimensions and Weight

Kawasaki FC540V
Length 490 mm (19.3 in)
Width 447 mm (17.6 in)
Height 438 mm (17.2 in)
Dry weight 45.4 kg (100.1 lbs)
Cylinder block
Compression ratio: 8.3:1
Cylinder bore: 89.0 mm (3.5 in)
Piston stroke: 86.0 mm (3.39 in)
Cylinder internal diameter (standard): 89.076 mm (3.5069 in)
Number of piston rings (compression / oil): 2/1
Connecting rod big end diameter (standard): 41.068 mm (1.6168 in)
Connecting rod small end diameter (standard): 22.059 mm (0.8685 in)
Piston pin diameter: 21.977 mm (0.8652 in)
Side clearance (Top): 0.170 mm (0.0067 in)
Side clearance (Second): 0.150 mm (0.0059 in)
Side clearance (Oil): 0.200 mm (0.0079 in)
Ring end gap (Top): 0.900 mm (0.0354 in)
Ring end gap (Second): 0.900 mm (0.0354 in)
Number of main bearings: 2
Crankshaft main journal diameter: PTO side: 37.904 mm (1.4923 in)
Flywheel side: 34.945 mm (1.3758 in)
Crankpin journal diameter: 40.928 mm (1.6113 in)
Crankshaft center distance: 43.0 mm (1.695 in)
Cylinder head
Valve arrangement: OHV
Valves: 2
Valve steam diameter (INTAKE): 6.930 mm (0.2728 in)
Valve steam diameter (EXHAUST): 6.915 mm (0.2722 in)
Valve spring free length (INTAKE): 37.5 mm (1.4764 in)
Valve spring free length (EXHAUST): 37.5 mm (1.4764 in)
Camshaft lobe height (INTAKE): 37.10 mm (1.4606 in)
Camshaft lobe height (EXHAUST): 37.10 mm (1.4606 in)
Camshaft journal diameter : 20.912 mm (0.8233 in)

Service Information

Engine
Maximum speed 3,500 ± 100 rpm
Idle speed 1,500 ± 150 rpm
Cylinder compression 5.0 kg/cm2 (70 psi)
Valve clearance
Intake valve 0.15 mm (0.006 in)
Exhaust valve 0.15 mm (0.006 in)
Oil system
Oil type 4-stroke or an equivalent (SF, SE, SD)
Recommended oil SAE 10W-30, 10W-40
Oil capacity 1.6 L (1.7 US. qt)
Ignition system
Spark plug NGK: BPR5ES;
Spark plug gap 0.7-0.8 mm (0.028-0.031 in)
Ignition coil air gap 0.3 mm (0.012 in)

Tightening torque specs

Tightening torque specs
Cylinder head 52 Nm; 5.2 kg·m; 38.3 ft·lb
Connecting rod 20 Nm; 2.0 kg·m; 14.7 ft·lb
Flywheel 172 Nm; 17.5 kg·m; 127 ft·lb
Crankcase cover 26 Nm; 2.6 kg·m; 19.2 ft·lb
Oil drain plug 23 Nm; 2.3 kg·m; 16.7 ft·lb
Valve clearance lock nut 20 Nm; 2.0 kg·m; 14.7 ft·lb
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We try to use verified sources and official documentation, however, differences between sources or errors in entering information may occur. We do not provide advice on technical issues related to the engines operation or repair. We do not recommend using provided information for engines repairing engines or spare parts ordering, use only official service manuals and spare-parts catalogs.

15 Comments

  1. I have a John Deere 180 with the Kawasaki Fc540v having issues with it charging, I replaced the regulator and that didn’t change anything, voltmeter says 12.4 across the battery when running..how do I check the stator to see if that’s the problem?? Thank you…

    • Test the stator using the wires coming from under the flywheel with ohmeter. Should be13_14 volts. Stator may be bad or very dirty.

    • If you only have 12.4 while running then you have A bad stator while running you should be getting almost 13.8 to 14.2 volts while running you can check that at the battery connections. 12.4 is not enough to charge your battery. You might also check you wiring that comes from the stator unerneth the battery tray Is where those wires come back and go to the voltage regulator . Make sure you don’t have any bad connections or bRe or broke wires..but sound to me like bad stator

  2. I have a John Deere 260 and run a 30 inch tiller on it. It had a 540 on it but decided to quit running and all i could find locally is a 420. Since i have changed engine my tiller now runs backwards. Any ideas on what has caused this issue? Both engines have same rotation direction.

  3. I have a 540 V engine. In my John Deere trying to test my coil. Don’t know the resistance numbers or voltage numbers just was hoping somebody could help me with the specifications on the coil. So I can check to see if it’s bad or good. Also, I have no spark don’t know why could be the coil though.

    • Did you ever find the resistance numbers? I have same motor and need the same numbers thank you

  4. I have a 1993 john deere gt262 with Kaw 17hp. I currently have no spark. I cleaned the plug, tried another plug. No spark. I have the cover off & the coil reads 10.66 ohms with the meter set at 20K. Is this within spec. IF so where is the stator & how do I check that?

  5. FC540V has no spark through many new plugs but has a perfectly looking, regular spark through a test light. I thought coils either worked at 100% or didn’t work. Could it be that it is not generating enough power for the spark plug to fire?

  6. Hey people have a 185 Deere with a 540 v while running remove oil fill cap oil sprays out is this normal on a Kawasaki engine this rob

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