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Kohler SV540S Troubleshooting

Engine Model: Kohler Courage SV540S
Engine Type: 4-cycle 1-cylinder air-cooled gasoline engine
Total Displacement: 32.6 (535 cc)
Rated Engine Power: 18.0 Hp (13.4 kW) at 3600 rpm
Carburetor Type: Fixed main jet


Engine will not start or difficult to start

No gasoline in tank - Add fuel.
Wrong grade of gasoline - Use quality gasoline.
Dirty fuel system - Check and clean.
Loose or disconnected spark plug wire - Check spark plug wiring connection, repair or change.
Damaged spark plug - Spark plug need to be replaced.
Clogged fuel filter - Fuel filter needs changing.
Brake pedal not depressed - Press the brake pedal.
Wrong carburetor adjustment - Adjusting carburetor correctly.
Low compression - Check and replace worn parts.
Choke cable is not adjusted properly or worn - Change cable or adjust properly.

Unstable engine running

Air intake screen is blocked - Wash or clean as required.
Defective ignition - Inspect ignition system and change failed components.
Stuck or defective choke cable - Service or change the cable.
Air filter is blocked - Service or replace air filter.
Clogged or damaged fuel pump - Test fuel pump and replace if necessary.

Engine starts but immediately stops

Defective spark plug - Change spark plug as required.
Clogged or faulty carburetor - Service or repair carburetor.
Defective ignition coil - Replace ignition coil as necessary.
Valve springs are broken or bad - Change valve springs.
Stuck valves - Service the valves.

Engine overheating

Insufficient engine oil - Check oil level and add oil as required.
Excessive engine load - Reduce load.
Air intake screen is blocked - Clean and wash as required.
Carburetor is running lean - Adjust carburetor correctly.
Incorrect ignition timing - Adjust ignition timing as required.
Wrong valve setting - Valves needs to be adjusted properly.

Abnormal engine knocking or noise

Stale or low octane fuel - Change gasoline.
Engine is running overloaded - Reduce engine load.
Engine oil level is low - Fill up the engine oil.
Incorrectly set low idle speed - Correct idle settings.
Fuel pump is dirty or defective - Test fuel pump and replace if necessary.
Crankshaft or main bearings are worn out - Install new parts as as required.
Improper valve clearance - Check and adjust.
Piston rings or cylinder bore are worn - Change faulty parts.

Engine lacks power

Clogged or incorrectly adjusted carburetor - Service or correctly adjust carburetor.
Air filter is blocked - Service or change air filter.
Fuel pump is defective or dirty - Check fuel pump and change if required.
Ignition system is defective - Check ignition and replace faulty components.
Damaged cylinder-head gasket - Change cylinder head gasket.
Valves are stuck or burned - Clean or replace valves.
Worn or bent push rod - Replace push rod.
Worn cylinder block components - Defective components need to be replaced.
Oil filter is dirty (if equipped) - Service or replace oil filter.

Engine using too much gasoline

Choke is not fully open - Check choke cable and adjust it.
Carburetor main jet adjustment is incorrect - Adjust main jet as required.
Loose or defective spark plug - Tighten or replace spark plug.
Stuck, burned, or worn valves - Service or change valves.
Worn sleeve, piston, or rings - Replace faulty parts as required.
Valve clearance is incorrect - Adjust to proper valve clearance.

Engine oil consumption is too high

Worn seals or gaskets - Defective components must be replaced.
Worn valve stems and valve guides - Replace defective valves.
Seized or wear piston rings - Piston rings replacement required.
Piston or cylinder liner is scuffed - Inspect liner and piston, change as necessary.
Breather pipe or hose is blocked - Replace or clean.