Instruction/ maintenance manual of the product SV470 Kohler
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1 20 690 01 Rev . F KohlerEngines.com SV470-SV620 Service Manual 2 Safety 3 Maintenance 5 Speci fi cations 13 T ools and Aids 16 T roubleshooting 20 Air Cleaner/Intake 21 Fuel System 31 Governor Syst.
2 Safety KohlerEngines.com 20 690 01 Rev . F SAFETY PRECAUTIONS W ARNING: A hazard that could result in death, serious injury , or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information.
3 Maintenance 20 690 01 Rev . F KohlerEngines.com MAINTENANCE INSTRUCTIONS W ARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery . Accidental Starts can cause severe injury or death.
4 Maintenance KohlerEngines.com 20 690 01 Rev . F OIL RECOMMENDA TIONS We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable.
5 Speci fi cations 20 690 01 Rev . F KohlerEngines.com Dimensions in millimeters. Inch equivalents shown in [ ]. Engine Dimensions.
6 Speci fi cations KohlerEngines.com 20 690 01 Rev . F Model . . . . . . . . . . . . . . . . . . . . . SV470 Courage Engine V ertical Shaft Numerical Designation Speci fi cation . . . . . . . . . . . . . . . SV470-0001 Serial . . . . . . . . . . . .
7 Speci fi cations 20 690 01 Rev . F KohlerEngines.com TORQUE SPECIFICA TIONS 3,5 SV470-SV480 SV530-SV540 SV590-SV620 Carburetor Fuel Bowl Retaining Screw W albro Nikki 5.1-6.2 N·m (45-55 in. lb.) 10.8-12.8 N·m (96-1 13 in. lb.) Closure Plate Fastener 24.
8 Speci fi cations KohlerEngines.com 20 690 01 Rev . F TORQUE SPECIFICA TIONS 3,5 SV470-SV480 SV530-SV540 SV590-SV620 Speed Control Bracket Assembly Fastener 1 1.0 N·m (95 in. lb.) into new hole 7.5 N·m (65 in. lb.) into used hole Stator Mounting Screw 6.
9 Speci fi cations 20 690 01 Rev . F KohlerEngines.com CLEARANCE SPECIFICA TIONS 3 SV470-SV480 SV530-SV540 SV590-SV620 Crankcase Governor Cross Shaft Bore I.D. New Max. Wear Limit 6.025/6.05 mm (0.2372/0.2382 in.) 6.063 mm (0.2387 in.) Crankshaft End Play (free) 0.
10 Speci fi cations KohlerEngines.com 20 690 01 Rev . F CLEARANCE SPECIFICA TIONS 3 SV470-SV480 SV530-SV540 SV590-SV620 Cylinder Bore Cylinder Bore I.D. New --- --- 94.010/94.035 mm (3.701/3.702 in.) Spec. 00XX: 84.010/84.035 mm (3.307/3.308 in.) 89.
11 Speci fi cations 20 690 01 Rev . F KohlerEngines.com CLEARANCE SPECIFICA TIONS 3 SV470-SV480 SV530-SV540 SV590-SV620 Piston, Piston Rings, and Piston Pin (Continued) T op and Middle Compression Ring End Gap New Bore T op Ring Middle Ring Used Bore (max.
12 Speci fi cations KohlerEngines.com 20 690 01 Rev . F GENERAL T ORQUE V ALUES Metric Fastener T orque Recommendations for Standard Applications Property Class Noncritical Fasteners Into Aluminum Size 4.8 5.8 8.8 10.9 12.9 Tightening T orque: N·m (in.
T ools and Aids 13 20 690 01 Rev . F KohlerEngines.com Certain quality tools are designed to help you perform speci fi c disassembly , repair , and reassembly procedures.
T ools and Aids 14 20 690 01 Rev . F KohlerEngines.com TOOLS Description Source/Part No. Hydraulic V alve Lifter T ool For removing and installing hydraulic lifters. Kohler 25 761 38-S Ignition System T ester For testing output on all systems, including CD.
T ools and Aids 15 20 690 01 Rev . F KohlerEngines.com FL YWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A fl ywheel holding tool can be made out of an old junk fl ywheel ring gear and used in place of a strap wrench. 1. Using an abrasive cut-off wheel, cut out a six tooth segment of ring gear as shown.
T roubleshooting 16 20 690 01 Rev . F KohlerEngines.com Engine Cranks But Will Not Start ● Battery connected backwards. ● Blown fuse. ● Carburetor solenoid malfunction. ● Choke not closing. ● Clogged fuel line or fuel fi lter . ● Diode in wiring harness failed in open circuit mode.
17 20 690 01 Rev . F KohlerEngines.com T roubleshooting Engine Loses Power ● Dirty air cleaner element. ● Engine overheated. ● Excessive engine load. ● Restricted exhaust. ● Faulty spark plug(s). ● High crankcase oil level. ● Incorrect governor setting.
T roubleshooting 18 20 690 01 Rev . F KohlerEngines.com Condition Conclusion Crankcase breather clogged or inoperative. NOTE: If breather is integral part of valve cover and cannot be serviced separately , replace valve cover and recheck pressure.
19 20 690 01 Rev . F KohlerEngines.com T roubleshooting COMPRESSION TEST For Command T wins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test.
20 Air Cleaner/Intake KohlerEngines.com 20 690 01 Rev . F BREA THER TUBE Ensure both ends of breather tube are properly connected. AIR COOLING W ARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed.
21 Fuel System 20 690 01 Rev . F KohlerEngines.com T ypical carbureted fuel system and related components include: ● Fuel tank. ● Fuel lines. ● In-line fuel fi lter . ● Fuel pump. ● Carburetor . Fuel from tank is moved through in-line fi lter and fuel lines by fuel pump.
22 Fuel System KohlerEngines.com 20 690 01 Rev . F FUEL SYSTEM TESTS When engine starts hard or turns over but will not start, fuel system might be causing problems. T est fuel system by performing following test. 1. Check for fuel in combustion chamber .
23 Fuel System 20 690 01 Rev . F KohlerEngines.com CARBURETOR W ARNING Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or fl ames.
24 Fuel System KohlerEngines.com 20 690 01 Rev . F These engines are equipped with either a W albro or Nikki fi xed main jet carburetor . Carburetors will have a low idle speed adjustment screw , and either fi xed idle, or a limiter cap on idle fuel adjustment needle.
25 Fuel System 20 690 01 Rev . F KohlerEngines.com FUEL SYSTEM Fuel Shut-off Solenoid Most carburetors are equipped with a fuel shut-off solenoid. Solenoid is attached to fuel bowl. Solenoid has a spring-loaded pin that retracts when 12 volts is applied to lead, allowing fuel fl ow to main jet.
26 Fuel System KohlerEngines.com 20 690 01 Rev . F 1. Place throttle control into idle or slow position. Adjust low idle speed to 1200 RPM. Follow Low Idle Speed (RPM) Adjustment. 2. Low idle fuel needle(s) setting: place throttle into idle or slow position.
27 Fuel System 20 690 01 Rev . F KohlerEngines.com Choke Adjusting Screw Details A A Choke Adjusting Screw NOTE: Choke is placed ON by moving throttle control slightly past fast position. If throttle control does not have a designated choke ON position, be sure to leave suf fi cient throttle control travel past fast position.
28 Fuel System KohlerEngines.com 20 690 01 Rev . F Starting an Engine Equipped with Unitized Throttle and Choke Control Starting Throttle Control Details A A Cold Engine or W arm Engine NOTE: Do not crank engine continuously for more than 10 seconds at a time.
29 Fuel System 20 690 01 Rev . F KohlerEngines.com 4. Loosen speed control bracket mounting screws. Slide bracket forward or backward, until desired high speed (RPM) is reached. Check speed with a tachometer . T o increase high speed (RPM), move bracket toward carburetor .
30 Fuel System KohlerEngines.com 20 690 01 Rev . F Throttle Control Installation 1. Loosen two cable clamp screws on speed control bracket assembly . 2. Move application throttle control lever to maximum full (fast) throttle position, and then move it back 3/16" or 4.
31 Governor System 20 690 01 Rev . F KohlerEngines.com GOVERNOR Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application. Governor is designed to hold engine speed constant under changing load conditions.
32 Governor System KohlerEngines.com 20 690 01 Rev . F Governor Sensitivity Adjustment Governor sensitivity is adjusted by repositioning governor spring in holes in governor lever . If speed surging occurs with a change in load, governor is set too sensitive.
33 Lubrication System 20 690 01 Rev . F KohlerEngines.com OIL RECOMMENDA TIONS Refer to Maintenance. CHECK OIL LEVEL NOTE: T o prevent extensive engine wear or damage, never run engine with oil level below or above operating range indicator on dipstick.
34 Lubrication System KohlerEngines.com 20 690 01 Rev . F OIL SENTR Y ™ (if equipped) This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry ™ may not shut down a running engine before damage occurs. In some applications this switch may activate a warning signal.
35 Electrical System 20 690 01 Rev . F KohlerEngines.com SP ARK PLUGS CAUTION Electrical Shock can cause injury . Do not touch wires while engine is running. Spark Plug Component and Details B A C D A Wire Gauge B Spark Plug C Ground Electrode D Gap NOTE: Do not clean spark plug in a machine using abrasive grit.
36 Electrical System KohlerEngines.com 20 690 01 Rev . F Carbon Fouled Soft, sooty , black deposits indicate incomplete combustion caused by a restricted air cleaner , over rich carburetion, weak ignition, or poor compression. Overheated Chalky , white deposits indicate very high combustion temperatures.
37 Electrical System 20 690 01 Rev . F KohlerEngines.com Electronic Ignition System T ests NOTE: Ignition tester must be used to test ignition on these engines.
38 Electrical System KohlerEngines.com 20 690 01 Rev . F BA TTER Y CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used.
39 Electrical System 20 690 01 Rev . F KohlerEngines.com 3 Amp/70 W att Lighting Stator NOTE: Zero ohmmeter on each scale to ensure accurate readings. V oltage tests should be made with engine running at full throttle with no load. Battery must be fully charged.
40 Electrical System KohlerEngines.com 20 690 01 Rev . F 3 Amp/70 W att Braking Stator NOTE: Zero ohmmeter on each scale to ensure accurate readings. V oltage tests should be made with engine running at full throttle with no load. Battery must be fully charged.
41 Electrical System 20 690 01 Rev . F KohlerEngines.com Wiring Diagram-9 or 15 Amp Regulated Battery Charging System H G D R S J N P L Q E C T O U A M F I K J T P Q B B V AC AC B+ A Red B Green C Vio.
42 Electrical System KohlerEngines.com 20 690 01 Rev . F 9/15 Amp Regulated Battery Charging System NOTE: Zero ohmmeter on each scale before testing to ensure accurate readings. V oltage tests should be made with engine running at full throttle with no load.
43 Electrical System 20 690 01 Rev . F KohlerEngines.com As Kohler blade stop stator brake circuit often is operated in conjunction with other application circuits, relay in Kohler circuit is specially con fi gured with a 680 ohm resistor in parallel with relay coil.
44 Starter System KohlerEngines.com 20 690 01 Rev . F NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts.
45 Starter System 20 690 01 Rev . F KohlerEngines.com When power is applied to starter , armature rotates. As armature rotates, drive pinion moves out on splined drive shaft and into mesh with fl ywheel ring gear . When pinion reaches end of drive shaft, it rotates fl ywheel and cranks engine.
46 Starter System KohlerEngines.com 20 690 01 Rev . F Starter Disassembly 1. Remove drive components following instructions for servicing drive. 2. Remove nut and insulating washer from positive (+) brush lead stud. 3. Remove thru bolts and recessed nuts.
47 Emission Compliant Systems 20 690 01 Rev . F KohlerEngines.com EV APORA TIVE EMISSION COMPLIANT SYSTEM Carbon Canister System A Fuel T ank Cap B Fuel T ank C Roll Over V alve (ROV) D Carbon Canister E Canister Breather Filter F T o Carburetor A B C D E F Operation Fuel vapors travel from fuel tank through tubing to carbon canister .
48 Emission Compliant Systems KohlerEngines.com 20 690 01 Rev . F SECONDAR Y EMISSION COMPLIANT SYSTEM T win Secondary Air Induction System A Hose T o Exhaust Manifold B Inlet Screen C Secondary Air V.
49 Emission Compliant Systems 20 690 01 Rev . F KohlerEngines.com Remove Inlet Screen Inlet Components A B C A Secondary Air V alve Assembly B Barb C Inlet Screen 1. Remove inlet screen from secondary air valve assembly by grasping inlet screen at base and gently pulling away from valve assembly .
50 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F W ARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery . Accidental Starts can cause severe injury or death.
51 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Clean all parts thoroughly as engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove grease, oil, and grime from engine parts.
52 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F Flywheel/Ignition Components G F H I B C D E A A Flywheel Screw B W asher C Fan Mounting Plate D Fan E Magnet F Flywheel G Ignition Module H Stator I Flywheel Key Remove Ignition Module 1.
53 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Disassemble Cylinder Head NOTE: Before disassembly , mark all valve train components that will be reused, to assure they are reassembled on same side. 1. Remove spark plug. 2. Remove adjustment nuts, pivots and rocker arms from pivot studs.
54 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F Model SV470/480/530/540/590/600/610 V alve Details A A E D F G G E D F B B C C Dimension Intake Exhaust A Seat Angle 89° 89° B Guide Depth 10.20 mm 6.2 mm C Guide I.D. 6.038/6.
55 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Inspection and Service Carefully inspect valve mechanism parts. Inspect valve springs and related hardware for excessive wear or distortion. Check valves and valve seats for evidence of deep pitting, cracks, or distortion.
56 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F 4. If wiring harness needs to be separated from closure plate, pry open clamps and pull out through slot. Disassemble Closure Plate NOTE: Governor gear is held onto shaft by small molded tabs in gear .
57 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com 1. Remove thrust washer(s) and cam gears from cam shafts. Later models will have a thrust washer on exhaust side only . 2. Remove screws securing cam levers to crankcase. Mark cam levers for proper reassembly .
58 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F Balance Weight/Piston Assembly Components A B C E F G P O H K L N M J I D A Crankshaft Gear B Crankshaft C Crank Gear Key D Th.
59 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Piston and Rings Inspection Piston and Rings Components and Details A Piston Ring B End Gap C Identi fi cation Mark D Piston .
60 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F T o install piston rings, proceed as follows: 1. Oil control ring (bottom groove): Install expander and then rails. Make sure ends of expander are not overlapped. 2. Compression ring (center groove): Install center ring using a piston ring installation tool.
61 Disassembly/Inspection and Service 20 690 01 Rev . F KohlerEngines.com Measuring Balance Weight to Crankshaft Eccentric Ring(s) Clearance 1. Use an inside micrometer , telescoping gauge, or bore gauge and measure inside diameter of balance weight bearing surface.
62 Disassembly/Inspection and Service KohlerEngines.com 20 690 01 Rev . F Clean Cylinder Bore after Honing Proper cleaning of cylinder walls following honing is critical. Grit left in cylinder bore can destroy an engine in less than one hour of operation after a rebuild.
63 Reassembly 20 690 01 Rev . F KohlerEngines.com NOTE: Make sure engine is assembled using all speci fi ed torque values, torque sequences, and clearances. Failure to observe speci fi cations could cause severe engine wear or damage. Always use new gaskets.
64 Reassembly KohlerEngines.com 20 690 01 Rev . F Install PTO Side Oil Seal PTO Seal Depth Details A B A Oil Seal B Seal Depth 5.5 mm (0.216 in.) Use a seal driver and install to a depth of 5.5 mm (0.216 in.) into crankcase. Install Governor Cross Shaft 1.
65 Reassembly 20 690 01 Rev . F KohlerEngines.com 5. Install intake cam shaft down into crankcase boss. Seat rubber oil pump outlet seal into machined pocket. If an open style outlet seal is used, check to make sure small feed hole is open and aligned with lower main bearing oil feed hole.
66 Reassembly KohlerEngines.com 20 690 01 Rev . F Cam/Closure Plate Components G F H L G O N K J I M P B C D E A A Oil Seal B Closure Plate C Oil Passage Cover D Gasket E Cam Gears F Thrust W asher G .
67 Reassembly 20 690 01 Rev . F KohlerEngines.com Install Flywheel Side Oil Seal Lubricate outside diameter and lip of fl ywheel end oil seal. Support closure plate and install oil seal. Using a seal driver , drive seal to a depth of 5 mm (0.196 in.) in seal bore.
68 Reassembly KohlerEngines.com 20 690 01 Rev . F Assemble Cylinder Head Prior to assembly , lubricate all components with engine oil, including tips of valve stems and valve guides. Using a valve spring compressor , install following items in order listed.
69 Reassembly 20 690 01 Rev . F KohlerEngines.com 1. Check to make sure there are no nicks or burrs on sealing surfaces of cylinder head or crankcase. 2. If engine uses a drain back check ball, install it into keyhole slot in top of crankcase. 3. Install a new cylinder head gasket.
70 Reassembly KohlerEngines.com 20 690 01 Rev . F Flywheel/Ignition Components G F H I J B C D E A A Flywheel Screw B W asher C Fan Mounting Plate D Fan E Magnet F Flywheel G Ignition Module H Stator I Flywheel Key J Pulse Line Fitting Install Stator and Wiring Harness Install Stator 1.
71 Reassembly 20 690 01 Rev . F KohlerEngines.com Install Electric Starter Install electric starter to closure plate and secure with nuts. Make sure wires are clear of any moving parts and torque nuts to 3.6 N·m (32 in. lb.). Install Ignition Module 1.
72 Reassembly KohlerEngines.com 20 690 01 Rev . F Install Spark Plug 1. Check gap using wire feeler gauge. Adjust gap to 0.76 mm (0.03 in.). 2. Install plug into cylinder head. 3. T orque plug to 27 N·m (20 ft. lb.). Install Heat De fl ector , Carburetor , Linkage and Air Cleaner Base 1.
73 Reassembly 20 690 01 Rev . F KohlerEngines.com Early Style Governor Spring Location A B High Speed RPM Governed Idle RPM Governor Lever Hole Throttle Lever Hole White Spring Green Spring Black Spri.
74 Reassembly KohlerEngines.com 20 690 01 Rev . F Install Fuel Pump (if equipped) NOTE: If fuel pump is attached to air cleaner base, fuel lines and pulse line should still be connected to fuel pump. Connect pulse line to pulse fi tting and secure with clamp.
75 20 690 01 Rev . F KohlerEngines.com.
76 KohlerEngines.com 20 690 01 Rev . F © 201 1 by Kohler Co. All rights reserved..
An important point after buying a device Kohler SV470 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kohler SV470 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kohler SV470 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kohler SV470 you will learn all the available features of the product, as well as information on its operation. The information that you get Kohler SV470 will certainly help you make a decision on the purchase.
If you already are a holder of Kohler SV470, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kohler SV470.
However, one of the most important roles played by the user manual is to help in solving problems with Kohler SV470. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kohler SV470 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
