Kohler Small Engine Repair Manual

1 COURAGE ™ SERIES SV470-600 SERVICE MANUAL VERTICAL CRANKSHAFT

Contents Section 1. Safety and General Information ............................................................................ Section 2. Special Tools ........................................................................................................... Section 3. Troubleshooting ..................................................................................................... Section 4. Air Cleaner and Air Intake System ........................................................................ Section 5. Fuel System and Governor .................................................................................... Section 6. Lubrication System ................................................................................................ Section 7. Electrical System and Components ...................................................................... Section 8. Disassembly ............................................................................................................ Section 9. Inspection and Reconditioning ............................................................................. Section 10. Reassembly .......................................................................................................... 1 2 3 4 5 6 7 8 9 10

1.1 Section 1 Safety and General Information 1 Section 1 Safety and General Information SV470-600 Safety Precautions To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored. CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored. NOTE Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related. For Your Safety! These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others. Rotating Parts can cause severe injury. Stay away while engine is in operation. WARNING Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed. Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. WARNING Hot Parts! Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running, or immediately after it is turned off. Never operate the engine with heat shields or guards removed. Accidental Starts can cause severe injury or death. Disconnect and ground spark plug leads before servicing. WARNING Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery.

1.2 Section 1 Safety and General Information Carbon Monoxide can cause severe nausea, fainting or death. Do not operate engine in closed or confined area. WARNING Electrical Shock can cause injury. Do not touch wires while engine is running. CAUTION Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. Explosive Gas! Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. Explosive Fuel can cause fires and severe burns. Stop engine before filling fuel tank. WARNING Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent. Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. WARNING Flammable Solvents! Carburetor cleaners and solvents are extremely flammable. Keep sparks, flames, and other sources of ignition away from the area. Follow the cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. WARNING Explosive Gas can cause fires and severe acid burns. Charge battery only in a well ventilated area. Keep sources of ignition away.

1.3 Section 1 Safety and General Information 1 A. Model No. Courage™ Vertical Shaft Engine Numerical Designation Version Code S = Electric Start First spec written in this model series B. Spec. No. Engine Model Model SV470 SV480 SV530 SV540 SV590 SV600 C. Serial No. Year Manufactured Code Code Year 32 2002 33 2003 34 2004 Factory Code 3205810334 Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification, and Serial Numbers of the engine. The engine identification numbers appear on a decal affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2. Figure 1-2. Explanation of Engine Identification Numbers. SV540-0001 Figure 1-1. Engine Identification Decal Location. Identification Decal MODEL NO. SPEC. NO. SERIAL NO. REFER TO OWNER'S MANUAL FOR SAFETY, MAINTENANCE SPECS AND ADJUSTMENTS. FOR SALES AND SERVICE IN US/CANADA CALL: 1-800-544-2444. www.kohlerengines.com KOHLER CO. KOHLER, WI USA A B C SV 540 S

Kohler Small Engine Repair Manual

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