
calcActive())">
2002-2004 Kohler Courage Series Vertical Crankshaft Engines (SV470/SV480/SV530/SV540/SV590/SV600) OEM Service & Repair Manual
What's Included?

Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your 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.)
You're Reading a Preview
What's Included?

Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$28.99
Viewed 53 Times Today

Loading...
Secure transaction
What's Included?

Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$28.99
These comprehensive manuals provide essential information for both professional mechanics and DIY enthusiasts working on the 2002-2004 Kohler Courage Series Vertical Crankshaft Engines. Specifically designed for models SV470, SV480, SV530, SV540, SV590, and SV600, this OEM Service & Repair Manual covers detailed repair and maintenance procedures to ensure optimal engine performance.
- 2002-2004 Kohler Courage Series Vertical Crankshaft Engines (SV470, SV480, SV530, SV540, SV590, SV600)
This manual is an invaluable resource offering detailed guidance, technical instructions, and expert information for efficient and effective engine repair and maintenance.