2002-2004 Kohler Courage Series Vertical Crankshaft Engines (SV470/SV480/SV530/SV540/SV590/SV600) OEM Service & 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

1.4 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important, as is checking oil daily and changing oil regularly. Failure to use the correct oil or using dirty oil causes premature engine wear and failure. Oil Type Use high-quality detergent oil of API (American Petroleum Institute) service class SG, SH, SJ or higher. Select the viscosity based on the air temperature at the time of operation as shown below. NOTE: Using other than service class SG, SH, SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage. A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 1-3. Fuel Recommendations 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. General Recommendations Purchase gasoline in small quantities and store in clean, approved containers. A container with a capacity of 2 gallons or less with a pouring spout is recommended. Such a container is easier to handle and helps eliminate spillage during refueling. Do not use gasoline left over from the previous season, to minimize gum deposits in your fuel system and to ensure easy starting. Do not add oil to the gasoline. Do not overfill the fuel tank. Leave room for the fuel to expand. Fuel Type For best results, use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum. Unleaded gasoline is recommended, as it leaves less combustion chamber deposits. Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated. Be aware however, that the cylinder head will require more frequent service. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved. Figure 1-3. Oil Container Logo. Refer to Section 6 - “Lubrication System” for detailed oil check, oil change, and oil filter change procedures. *Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F). **Synthetic oils will provide better starting in extreme cold below -23°C (-10°F). ***30 weight acceptable above 0°C (32°F). *** ** *

1.5 Section 1 Safety and General Information 1 Periodic Maintenance 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. Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table. They should also be included as part of any seasonal tune-up. Storage If the engine will be out of service for two months or more, use the following storage procedure: 1. Clean the exterior surfaces of the engine. 2. Change the oil and oil filter while the engine is still warm from operation. See “Change Oil and Oil Filter” in Section 6. 3. The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. If you choose to use a stabilizer, follow the manufacturer’s recommendations, and add the correct amount for the capacity of the fuel system. Fill the fuel tank with clean, fresh gasoline. Run the engine for 2-3 minutes to get stabilized fuel into the carburetor. To empty the system, run the engine until the tank and system are empty. 4. Due to the deep recess around the spark plug, blow out the cavity with compressed air. Remove the spark plug. The spark plug is most accessible when the blower housing is removed for cleaning. Add one tablespoon of engine oil into the spark plug hole. Install the plug, but do not connect the plug lead. Crank the engine two or three revolutions. Connect the plug lead. 5. Reinstall the blower housing, if removed previously, and torque the blower housing screws to 7.5 N·m (65 in. lb.). 6. Store the engine in a clean, dry place. ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service. Daily or Before Starting Engine Maintenance Required Frequency • Fill fuel tank. • Check oil level. • Check air cleaner for dirty¹, loose, or damaged parts. • Check air intake and cooling areas, clean as necessary¹. Every 2 Months or 25 Hours • Service precleaner element¹ (if equipped). • Service air cleaner element¹ (if not equipped with precleaner). • Replace air cleaner element¹ (if equipped with precleaner). • Change oil and filter (refer to Viscosity Table, Page 1.4, based on seasonal temperatures). • Remove blower housing and clean cooling areas. • Check that all fasteners are in place and components are properly secured. • Replace fuel filter. • Have bendix starter drive serviced². • Have valve lash checked/adjusted 2 . Every 200 Hours Annually or Every 100 Hours Every 500 Hours • Replace spark plug. • Check spark plug condition and gap. Every 2 Years or 200 Hours

1.6 Section 1 Safety and General Information Figure 1-4. Typical Engine Dimensions. Dimensions in millimeters. Inch equivalents shown in ().

1.7 Section 1 Safety and General Information 1 General Specifications¹ Power (@ 3600 RPM, corrected to SAE J1940) SV470 ................................................................................................. 11.2 kW (15 HP) SV480 ................................................................................................. 11.9 kW (16 HP) SV530 ................................................................................................. 12.7 kW (17 HP) SV540 ................................................................................................. 13.4 kW (18 HP) SV590 ................................................................................................. 14.1 kW (19 HP) SV600 ................................................................................................. 14.9 kW (20 HP) Peak Torque SV470 @ 2600 RPM ............................................................................ 34.3 N·m (25.0 ft. lb.) SV480 @ 2800 RPM ............................................................................ 34.6 N·m (25.5 ft. lb.) SV530 @ 2600 RPM ............................................................................ 37.8 N·m (27.9 ft. lb.) SV540 @ 2800 RPM ............................................................................ 39.1 N·m (29.0 ft. lb.) SV590 @ 2600 RPM ............................................................................ 42.3 N·m (31.2 ft. lb.) SV600 @ 2800 RPM ............................................................................ 44.2 N·m (32.0 ft. lb.) Bore SV470S, SV480S ................................................................................. 84 mm (3.30 in.) SV530S, SV540S ................................................................................. 89 mm (3.50 in.) SV590S, SV600S ................................................................................. 94 mm (3.70 in.) Stroke ......................................................................................................... 86 mm (3.38 in.) Displacement SV470S, SV480S ................................................................................. 477 cc (29.1 cu. in.) SV530S, SV540S ................................................................................. 535 cc (32.6 cu. in.) SV590S, SV600S ................................................................................. 597 cc (36.4 cu. in.) Compression Ratio ...................................................................................... 8.5:1 Dry Weight .................................................................................................. 35.8 kg (79 lb.) Oil Capacity (with filter) .............................................................................. 1.5 L (1.6 qt.) Angle of Operation - Maximum (at Full Oil Level) All Directions .................... 25° Intermittent Air Cleaner Base Hex. Nut Fastener Torque ........................................................................... 5.5 N·m (48 in. lb.) Mounting Screw Fastener Torque (Install Dry - DO NOT OIL) ....................... 8.0 N·m (70 in. lb.) Into new as-cast hole 5.5 N·m (48 in. lb.) Into used hole Blower Housing and Sheet Metal M6 Fasteners Torque .................................................................................. 7.5 N·m (65 in. lb.) Cam Lever Cam Lever Fastener Torque ......................................................................... 7.5 N·m (65 in. lb.) Cam Gears End Play ..................................................................................................... 0.5/1.5 mm (0.019/0.059 in.) Running Side Clearance .............................................................................. 0.02/0.13 mm (0.001/0.005 in.) 1 Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly, EXCEPT for air cleaner base thread forming screw - install dry.

1.8 Section 1 Safety and General Information Cam Gears (cont'd.) Cam Gear-to-Cam Shaft Running Assembly ............................................. 0.02/0.10 mm (0.001/0.004 in.) Carburetor Fuel Bowl Retaining Screw Torque ........................................................... 5.1-6.2 N·m (45-55 in. lb.) Closure Plate Closure Plate Fastener Torque ................................................................ 24.5 N·m (216 in. lb.) Balance Weight Guide Channel Width New .................................................................................................. 17.95/18.05 mm (0.707/0.711 in.) Max. Wear Limit ............................................................................... 18.13 mm (0.714 in.) Connecting Rod Cap Fastener Torque (torque in 2 increments) ......................................... 5.5, 11.5 N·m (50, 100 in. lb.) Connecting Rod-to-Crankpin Running Clearance New ................................................................................................... 0.03/0.055 mm (0.0012/0.0022 in.) Max. Wear Limit ................................................................................ 0.07 mm (0.0025 in.) Connecting Rod-to-Crankpin Side Clearance ............................................ 0.25/0.59 mm (0.0098/0.0232 in.) Connecting Rod-to-Piston Pin Running Clearance .................................... 0.015/0.028 mm (0.0006/0.0011 in.) Piston Pin End I.D. New ................................................................................................... 22.015/22.023 mm (0.8667/0.8670 in.) Max. Wear Limit ................................................................................ 22.036 mm (0.8675 in.) Crankcase Governor Cross Shaft Bore I.D. New ................................................................................................... 6.025/6.05 mm (0.2372/0.2382 in.) Max. Wear Limit ................................................................................ 6.063 mm (0.2387 in.) Oil Drain Plug Torque ............................................................................... 14.0 N·m (125 in. lb.) Crankshaft End Play (free) ......................................................................................... 0.225/1.025 mm (0.0089/0.040 in.) Crankshaft Bore in Crankcase I.D. New .................................................................................................. 41.965/41.990 mm (1.6521/1.6531 in.) Max. Wear Limit ............................................................................... 42.016 mm (1.654 in.) Crankshaft Bore in Closure Plate I.D New .................................................................................................. 44.965/44.990 mm (1.7703/1.7713 in.) Max. Wear Limit ............................................................................... 45.016 mm (1.7723 in.) Flywheel End Main Bearing Journal O.D. – New ....................................................................................... 44.913/44.935 mm (1.7682/1.7691 in.) O.D. – Max. Wear Limit .................................................................... 44.84 mm (1.765 in.) Max. Taper ........................................................................................ 0.0220 mm (0.0009 in.) Max. Out of Round ............................................................................ 0.025 mm (0.001 in.)

2002-2004 Kohler Courage Series Vertical Crankshaft Engines (SV470/SV480/SV530/SV540/SV590/SV600) OEM Service & Repair Manual

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