The Kohler KS540 is a 541 cc, (33.0 cu·in) single-cylinder air-cooled four-stroke internal combustion gasoline engine from the 5400 series, manufactured by Kohler Co.
The Kohler KS540 engine has an OHV (overhead valve) design, vertical PTO-shaft, and pressurized lubrication system. This engine is equipped with a one-barrel carburetor and an electronic ignition system.
The cylinder bore is 94.0 mm (3.70 in) and the piston stroke is 78.0 mm (3.10 in). The compression ratio rating is 8.8:1.
The KS540 engine produced 18.2 PS (13.4 KW; 18.0 HP) at 3,600 rpm of horsepower and 40.9 Nm (4.17 kg·m; 30.18 ft·lb) at 2,600 rpm of torque.
The breakdown of the engine code is as follows:
- KS – 5400 Series
- 540 – Numerical designation
General information
| Engine Specifications | |
| Model | KS540 |
| Type | 4-stroke, OHV, single-cylinder |
| Displacement | 541 cm 3 (33.0 cu-in) |
| Max. horsepower | 18.2 PS (13.4 KW; 18.0 HP) at 3,600 rpm |
| Max. torque | 40.9 Nm (4.17 kg·m; 30.18 ft·lb) at 2,600 rpm |
| Fuel system | One-barrel carburetor |
| Cooling system | Forced-air |
| Ignition system | Electronic ignition system |
| Lubricating system | Pressurized lubrication |
| Starting system | Electric starter |
| Fuel used | Unleaded gasoline (octane number 86 or higher) |
| Dimensions (L x W x H) | 457 x 394 x 360 mm (18 x 15.5 x 14.2 in) |
| Dry weight | 34.0 kg (75.0 lbs) |
Cylinder Block and Head
| Cylinder block | ||
| Compression ratio: | 8.8:1 | |
| Bore x Stroke | 94.0 X 78.0 mm (3.70 x 3.10 in) | |
| Sleeve internal diameter | 94.010-94.035 mm (3.7012-3.7022 in) | |
| Piston skirt outer diameter (standard) | 93.975-93.989 mm (3.6998-3.7003 in) | |
| Number of piston rings (compression / oil): | 2 / 1 | |
| Piston pin outer diameter | 21.995-22.000 mm (0.8659-0.8661 in) | |
| Ring-to-groove side clearance: | Top | 0.025-0.065 mm (0.0010-0.0026 in) |
| Second | 0.040-0.080 mm (0.0016-0.0032 in) | |
| Oil | 0.090-0.210 mm (0.0035-0.0083 in) | |
| Ring end gap: | Top | 0.150-0.400 mm (0.0059-0.0157 in) |
| Second | 1.000-1.250 mm (0.0394-0.0492 in) | |
| Main bearing journal outer diameter | Flywheel End | 40.913-40.935 mm (1.6107-1.6116 in) |
| PTO End | 40.913-40.935 mm (1.6107-1.6116 in) | |
| Connecting rod journal outer diameter | 40.982-41.000 mm (1.6135-1.6142 in) | |
| Cylinder Head | ||
| Valve Arrangement: | OHV | |
| Valves: | 2 (2 per cylinder) | |
| Valve head diameter: | INTAKE | 35.875-36.125 mm (1.412-1.422 in) |
| EXHAUST | 32.875-33.125 mm (1.294-1.304 in) | |
| Stem outer diameter: | INTAKE | 5.982-6.000 mm (0.2355-0.2362 in) |
| EXHAUST | 5.970-5.988 mm (0.235-0.2357 in) | |
| Valve lift (min): | INTAKE | 9.4 mm (0.370 in) |
| EXHAUST | 9.3 mm (0.366 in) | |
Tightening torque specs
| Tightening torque specs | |
| Cylinder head (torque in 2 increments) |
Step 1: 24.4 Nm (2.5 kgf·m; 18.0 ft·lb) Step 2: 42.7 Nm (4.4 kgf·m; 31.5 ft·lb) |
| Connecting rod (torque in 2 increments) |
Step 1: 5.5 Nm (0.6 kgf·m; 4.1 ft·lb) Step 2: 11.8 Nm (1.2 kgf·m; 8.7 ft·lb) |
| Flywheel | 115.0 (11.7 kgf·m; 84.9 ft·lb) |
| Spark plug | 27 Nm (2.75 kg·m; 20.0 ft·lb) |
Service Information
| Valve clearance | |
| Intake valve clearance | 0.101-0.152 mm (0.004-.006 in) |
| Exhaust valve clearance | 0.101-0.152 mm (0.004-.006 in) |
| Oil system | |
| Oil type | API SJ or higher |
| Recommended oil | SAE 10W-30 |
| Oil capacity | 1.4 liters (1.5 US.qts, 1.23 Imp. qts) |
| Ignition system | |
| Spark plug | Champion RC12YC |
| Spark plug gap | 0.76 mm (0.030 in) |
| Module air gap | 0.203-0.305 mm (0.008-0.012 in) |
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