Kohler SV540

Kohler SV540The Kohler SV540 is a single-cylinder air-cooled four-stroke internal combustion gasoline engine from the Courage series, manufactured by Kohler Co. The displacement of this engine is 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.

The Kohler SV540 engine has an OHV (overhead valve) design, aluminum head and crankcase with cast iron cylinder liner, vertical PTO-shaft, and pressurized lubrication system. This engine is equipped with a carburetor with a fixed main jet and an electronic ignition system.

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. The piston stroke is 86.0 mm (3.39 in) for all versions. The compression ratio rating is 8.5:1. The SV540 engine produced 18.2 PS (13.4 KW; 18.0 HP) at 3,600 rpm of horsepower and 43.5 Nm (4.44 kg·m; 32.1 ft·lb) of torque.

The breakdown of the engine code is as follows:

  • S – Courage series
  • V – Vertical PTO shaft
  • 540 – Numerical designation

General information

Engine Specifications
ModelCourage SV540
Type4-stroke, OHV, single-cylinder
Displacement SV540-00XX, SV540-01XX: 535 cm3 (32.6 cu·in)
SV540-02XX and higher: 597 cm3 (36.4 cu-in)
Max. horsepower18.2 PS (13.4 KW; 18.0 HP) at 3,600 rpm
Max. torque43.5 Nm (4.44 kg·m; 32.1 ft·lb)
Fuel systemCarburetor with a fixed main jet
Cooling systemForced-air
Ignition systemElectronic ignition system
Lubricating systemPressurized lubrication
Starting systemElectric starter
Fuel usedUnleaded gasoline (octane number 86 or higher)
Fuel tank capacity

Cylinder Block and Head

Cylinder block
Compression ratio:8.5:1
Bore x Stroke SV540-00XX, SV540-01XX: 89.0 X 86.0 mm (3.50 x 3.39 in)
SV540-02XX and higher: 94.0 X 86.0 mm (3.70 x 3.39 in)
Sleeve internal diameter SV540-00XX, SV540-01XX: 89.010-89.035 mm (3.504-3.505 in.)
SV540-02XX and higher: 94.010-94.035 mm (3.701-3.702 in)
Number of piston rings (compression / oil):2 / 1
Piston pin outer diameter21.995-22.000 mm (0.8659-0.8661 in)
Main journal diameterFlywheel End Before S/N 3703200003: 44.913-44.935 mm (1.7682-1.7691 in)
After S/N 3703200013: 44.870-44.895 mm (1.7665-1.7675 in)
PTO End Before S/N 3703200003: 41.913-41.935 mm (1.6501-1.6510 in)
After S/N 3703200013: 41.855-41.880 mm (1.6478-1.6488 in)
Cylinder Head
Valve Arrangement:OHV
Valves:2 (2 per cylinder)
Valve head diameter:INTAKE37.375-37.625 mm (1.4715-1.4813 in)
EXHAUST32.125-32.375 mm (1.2648-1.2746 in)
Stem outer diameter:INTAKE5.982-6.000 mm (0.2355-0.2362 in)
EXHAUST5.970-5.988 mm (0.235-0.2357 in)

Tightening torque specs

Tightening torque specs
Cylinder head bolt Step 1: 20.5 Nm (2.1 kg·m; 15.1 ft·lb)
Step 2: 41.0 Nm (4.2 kg·m; 30.3 ft·lb)
Flywheel M12: 88.0 Nm (9.0 kg·m; 65.0 ft·lb)
M10: 66.5 Nm (6.7 kg·m; 48.7 ft·lb)
Spark plug27 Nm (2.75 kg·m; 20.0 ft·lb)

Service Information

Valve clearance
Intake valve clearance0.127 mm (0.005 in)
Exhaust valve clearance0.178 mm (0.007 in)
Oil system
Oil typeAPI SJ or higher
Recommended oilSAE 10W-30
Oil capacity1.5 L (1.59 US. qt, 1.32 Imp. qt.)
Ignition system
Spark plugChampion RC12YC
Spark plug gap0.76 mm (0.030 in)
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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1 Comment

  1. My engine through a rod. I have been trying to get another engine. I hae been told this model has been discontinued. I am wanting to know what is the recommend replacement engine.

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