The Kohler KS540 is a 541 cc (33.0 cu·in) natural aspirated single-cylinder four-stroke air-cooled small gasoline engine with a vertical shaft from the 5400 series, manufactured by Kohler Co for general-purpose applications.
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 Kohler KS540 engine produced 18.2 PS (13.4 KW; 18.0 HP) at 3,600 rpm of maximum output power and 40.9 Nm (4.17 kg·m; 30.18 ft·lb) at 2,600 rpm of peak torque.
The Kohler KS540 features:
- OHV design
- Electronic ignition system
- One-barrel carburetor
- Centrifugal governor
- Pressure lubrication with full-flow filter
- Forced air cooling system
- Electric starter
General information
| Engine Specifications | |
| Engine model | KS540 |
| Engine type | 4-stroke, OHV, single-cylinder |
| Displacement | 541 cm3, (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 |
| Cooling system | Forced air |
| Air cleaner | Replaceable, paper element |
| Lubricating system | Pressurized lubrication |
| Ignition system | Electronic ignition system |
| Fuel system | One-barrel carburetor |
| Fuel used | Unleaded gasoline (octane number 86 or higher) |
| Starting system | Electric starter |
| 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 |
| Cylinder bore: | 94.0 mm (3.70 in) |
| Piston stroke: | 78.0 mm (3.10 in) |
| Cylinder internal diameter (standard): | 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 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) |
| Ring-to-groove side clearance (Second): | 0.040-0.080 mm (0.0016-0.0032 in) |
| Ring-to-groove sing end gap (Oil): | 0.090-0.210 mm (0.0035-0.0083 in) |
| Ring end gap (Second): | 0.150-0.400 mm (0.0059-0.0157 in) |
| Ring end gap (Oil): | 1.000-1.250 mm (0.0394-0.0492 in) |
| Crankshaft main journal diameter: | 40.913-40.935 mm (1.6107-1.6116 in) |
| Crankpin journal diameter: | 40.982-41.000 mm (1.6135-1.6142 in) |
| Cylinder head | |
| Valve arrangement: | OHV |
| Valves: | 2 |
| Valve head diameter (INTAKE): | 35.875-36.125 mm (1.412-1.422 in) |
| Valve head diameter (EXHAUST): | 32.875-33.125 mm (1.294-1.304 in) |
| Seat angle (INTAKE): | 44.5° |
| Seat angle (EXHAUST): | 44.5° |
| Valve face angle (INTAKE): | 45° |
| Valve face angle (EXHAUST): | 45° |
| Valve steam diameter (INTAKE): | 5.982-6.000 mm (0.2355-0.2362 in) |
| Valve steam diameter (EXHAUST): | 5.970-5.988 mm (0.2350-0.2357 in) |
| Minimal valve lift (INTAKE): | 9.4 mm (0.370 in) |
| Minimal valve lift (EXHAUST): | 9.4 mm (0.370 in) |
Tightening torque specifications
| Valve clearance | |
| Cylinder Head | 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) |
| Rocker Arm Pivot Stud | 13.5 Nm (1.4 kgf·m; 10 ft-lb) |
| Rocker Arm Adjustment Nut Set Screw | 5.5 Nm (0.6 kgf·m; 4.2 ft-lb) |
| Flywheel Retaining Screw | 115.0 (11.7 kgf·m; 84.9 ft·lb) |
| Connecting Rod Cap | 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) |
| Cam Levers | 12.5 Nm (1.3 kgf·m; 9.2 ft·lb) |
| Oil Drain Plug | 14.0 Nm (1.4 kgf·m; 10.4 ft-lb) |
| Ignition Module | Into new hole: 8.8 Nm (0.9 kgf·m; 6.5 ft-lb) Into used hole: 3.4 Nm (0.3 kgf·m; 2.5 ft-lb) |
| Muffler Retaining Nuts | 27.8 Nm (2.8 kgf·m; 20.5 ft-lb) |
Service Data
| Valve clearance | |
| Intake valve lash: | 0.101-0.152 mm (0.004-.006 in) |
| Exhaust valve lash: | 0.101-0.152 mm (0.004-.006 in) |
| Oil system | |
| Lubrication system: | Pressurized lubrication |
| Oil type: | SJ or higher |
| Recommended oil: | KOHLER PRO 10W-50 or SAE 10W-30 |
| Oil capacity: | 1.4 liters (1.5 US.qts, 1.23 Imp. qts) |
| Fuel system | |
| Type: | One-barrel carburetor |
| Ignition system | |
| Type: | Electronic ignition system |
| Spark plug: | Champion RC12YC |
| Spark plug gap: | 0.76 mm (0.0299 in) |
| Spark plug torque: | 27 N·m (2.8 kg·m, 19.9 ft·lb) |
| Module air gap: | 0.203-0.305 mm (0.008-0.012 in) |
References
1. Kohler 5400 series KS530-KS595 service manual. Kohler Co. 2020.
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