Kohler Courage PRO SV840 User Manual

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Service Manual

SV710-SV740

SV810-SV840

2 Safety

3 Maintenance

5 Speciﬁ cations

14 Tools and Aids

17 Troubleshooting

21 Air Cleaner/Intake

22 Fuel System

30 Governor System

31 Lubrication System

33 Electrical System

45 Starter System

51 Emission Compliant Systems

54 Disassembly/Inspection and Service

68 Reassembly

132 690 01 Rev. G KohlerEngines.com

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

Table of Contents

Questions and Answers:

A
Alexander BassAug 17, 2025
How to fix Kohler Courage PRO SV840 that cranks but won't start?
- C
  Christy VaughnAug 17, 2025
  If your Kohler Engine cranks but doesn't start, here are several things to check: * Ensure the fuel shut-off valve is open. * Refill the fuel tank if it's empty. * Make sure the key switch or kill switch is in the ON position. * Check battery connections and replace any blown fuses. * Use clean, fresh fuel. Also, inspect the choke, fuel line, fuel filter, carburetor solenoid, diode in the wiring harness, DSAI or DSAM, electronic control unit, ignition coils, and spark plugs. Repair or replace any faulty components.
Z
zwhiteAug 20, 2025
How to troubleshoot a Kohler Courage PRO SV840 that starts hard?
- D
  Douglas WilliamsAug 20, 2025
  If your Kohler Engine is starting hard, consider these potential causes: * Ensure you're using clean, fresh fuel. * Check or replace the interlock switch. * Allow the engine to cool down if it's overheated. * Clean or replace the clogged fuel line or fuel filter. Also, inspect the spark plugs, ACR mechanism, choke and throttle controls, and flywheel key. Secure any loose wires and check the engine compression.
E
Erik AndrewsAug 22, 2025
Why does my Kohler Courage PRO SV840 start but not keep running?
- S
  Steven SmithAug 22, 2025
  If your Kohler Engine starts but doesn't keep running, the issue might be due to: * Using poor quality fuel. Try using clean, fresh fuel. * A restricted fuel tank cap vent. Clear the vent. Additionally, inspect the carburetor, cylinder head gasket, choke and throttle controls, and fuel pump. Fix any intake system leaks and secure any loose wires.
A
anthonyfaulknerAug 26, 2025
How do I troubleshoot a Kohler Engine that won't idle?
- G
  gmathisAug 26, 2025
  If your Kohler Engine will not idle, consider the following: * Ensure you're using clean, fresh fuel. * Clear the restricted fuel tank cap vent. * Check for and rectify adequate fuel supply. * Allow the engine to cool down if it overheated. Also, inspect the spark plugs, and adjust the idle fuel adjusting needle(s) and idle speed adjusting screw. Check engine compression.
P
piercemarkAug 28, 2025
What causes a Kohler Engine to use an excessive amount of oil?
- B
  Brandon WilliamsonAug 28, 2025
  If your Kohler Engine uses an excessive amount of oil, several factors could be responsible: * Ensure correct oil viscosity/type is used. * Drain excess oil from the crankcase if it is overfilled. Also, inspect for a broken breather reed, a clogged crankcase breather, and worn cylinder bore, piston rings, valve stems or valve guides. Tighten any loose fasteners and repair or replace the blown head gasket.
C
clarkvictorAug 30, 2025
Why is my Kohler Courage PRO SV840 losing power?
- J
  James LoveAug 31, 2025
  Your Kohler Engine might be losing power due to several reasons. Check the following: * Ensure the air cleaner element is clean or replace it if dirty. * Make sure the engine isn't overheating. * Reduce the engine load if it's excessive. * Remove any restrictions from the exhaust. * Use clean, fresh fuel. Also, inspect the spark plugs, battery, and crankcase oil level. Adjust the governor setting and check the engine compression.
J
Jeremy LambertSep 2, 2025
What to do if my Kohler Courage PRO SV840 overheats?
- J
  jlewisSep 2, 2025
  If your Kohler Engine is overheating, try the following: * Reduce the engine load. * Add oil to the crankcase if the oil level is low. * Check and refill the cooling system fluid if the level is low. Also, inspect the cooling fan, fan belt, carburetor, and water pump. Clean or replace the radiator and cooling system components, and adjust the crankcase oil level and fuel mixture.
M
Miguel LucasSep 5, 2025
What causes a Kohler Engine to not crank?
- P
  plarsonSep 5, 2025
  If your Kohler Engine will not crank, consider these potential issues: * The battery may be discharged. Charge or replace the battery. * The key switch or ignition switch may be faulty. Replace the switch. * The interlock switch may be engaged or faulty. Check or replace the interlock switch. Also, inspect the electric starter, solenoid, and pawls. Secure any loose wires and inspect for seized internal engine components.
J
James WilliamsSep 8, 2025
How to fix a Kohler Courage PRO SV840 Engine that runs but misses?
- F
  fryelizabethSep 8, 2025
  If your Kohler Engine runs but misses, check these potential causes: * Ensure you are using clean, fresh fuel. * Reconnect any disconnected spark plug leads and tighten any loose leads. * Allow the engine to cool down if it overheated. Also, inspect the carburetor, spark plugs, and ignition module(s). Adjust the crankshaft position sensor air gap, and check or replace the interlock switch. Secure any loose wires.

Kohler Courage PRO SV840 Specifications

General

Compression Ratio	8.5:1
Fuel System	Carburetor
Cooling System	Air-cooled
Starter	Electric
Power	27 hp (20.1 kW) @ 3600 RPM

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