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TABLE OF CONTENTS - C & C Distributors, Inc.

1. POLARIZED CONNECTOR Fig 11 Testing Ground Wire ENGINE WIRING HARNESS DIAGRAM GROUND WIRE HARNESS CARBURETOR SOLENOID DIODE EL DIODE ENGINE ENGINE HARNESS CONNECTOR RAISED RIB ON CONNECTOR INDICATES GROUND SIDE EQUIPMENT SWITCH DIODE FAILURE DIAGNOSIS SWITCH ON SWITCH OFF CAUSE Engine Runs Shuts Off OK 1 Closed Diode On 1 Cylinder Engine Runs Only One Cylinder Both Cylinders Off 1 Open Diode Won t Run No Spark 2 Closed Diodes Engine Runs Both Cylinders Engine Won t Shut Off 2 Open Diodes Section 3 Carburetion Section Contents Page GENERAL EE ERR 2 REMOVE INTAKE MANIFOLD AND CARBURETOR 2 DISASSEMBLE CARBURETOR 3 CARBURETOR CLEANING RECOMMENDATIONS 4 Check Throttle Choke Shaft And Body For Wear 5 ASSEMBLE CARBURETOR 5 ASSEMBLE CARBURETOR INTAKE MANIFOLD 7 INSTALL INTAKE MANIFOLD AND CARBURETOR 7 ADJUST GOVERNOR Static Governor Adjustment 05622 en urhe rrr n rh eR
2. 3 Amature M E hata UL E 2 Air Gap Installation Removal Testing Also See Check Ignition 1 Battery cuneate tet ete seu be eee fes ee a ee 6 Cables Charging Checking Recommendation Also See Checking 7C CANNING ree 10 Checking Installation Removal Breallief oes fedus 8 Checking Installation Removal Camshaft CHECKING ew 11 13 All aS LT 13 Garb retot oso SRO PURUS a ea Pu adusta E attest 3 Adjustment Anti Afterfire System Assembly Disassembly Remove Carburetor Controls 4 Charging System See Alternators 7C Coils See Armature ss uses Rem x eR UR nd e ene ho 2 Compression Testing 1 Connecting Rod 642 Td tus s ru RU Res dot 12 MV dui EE
3. BLACK TEST LEAD A GOOD fr GROUND SURFACE Fig 10 Testing AC Output 5 Attach BLACK test lead clip to engine ground 6 With engine running at 3600 RPM AC output should be no less than 14 volts 7 If no or low output is found replace the stator DC ONLY ALTERNATOR The DC alternator provides DC current for charging a 12 volt battery The current from the alternator is unregulated and is rated at 3 amps The output rises from 2 amps at 2400 RPM to 3 amps at 3600 RPM Recommended battery sizes range from 30 ampere hour for warm temperature service to 50 ampere hour in coldest service WHEN CHECKING ALTERNATOR COMPONENTS MAKE THE TEST IN THE FOLLOWING SEQUENCE Alternator Output Test 1 Insert RED test lead into 10 A receptacle in meter Insert BLACK test lead into receptacle in meter Rotate selector to DC amps position Attach RED test lead clip to DC output terminal Fig 11 Attach BLACK test lead clip to positive battery termi nal With engine running at 3600 RPM output should be be tween 2 4 amps DC a Output will vary with battery voltage If battery volt age is at its maximum output will be approximately 2 amps 7 or low output is found test diode RED TEST LEAD OUTPUT PIN TERMINAL BLACK TEST LEAD THE BATTERY MUST BE IN TO POSITIVE BAT
4. 1 Fuel iPump o nro 3 General Information 1 GOVOCINON 05202 eed aa oa tien ee 4 Adjustment Governed Idle Also See Governed Idle 3 13 Ground Wire Harness ee eed e derer a 2 DIM 2 Specifications Also See Check Ignition 1 Keyswitch Testing 2 6 Maintenance Schedule 1 Muffler Supplied By Equipment Manufacturer adel 1 eT 1 8 T TUTTI 1 Oil Pressure RU ea les alee A de debct 8 e T 4 8 Oil Recommendations 1 8 Oe ee 10 PISTON e fess tte tees LM ECL IH 9 ASSOMDIY EE 12 12 FREMOVAl iore dte E A
5. 2 DISASSEMBLE CYLINDER HEAD 4 INSPECT AND REPAIR Cylinder Head Meee Ess Meee ee a 5 Valve GuideS 5 a eee 5 ASSEMBLE CYLINDER HEAD 6 INSTALL CYLINDER HEAD 8 ADJUST VALVES nace o done eid RO ET Dec 8 RHEASSEMBLE ore eed ne E DEDE Ep 9 ADJUST GOVERNOR a 10 Overhead Valve Train 9905 1 REMOVE CYLINDER HEADS Disconnect exhaust system from cylinder heads and disconnect choke and throttle control cables 1 Remove the following parts from engine Fig 1 a Air cleaner cover cartridge and pre cleaner b Rotating screen c Blower housing d Spark plugs 2 Disconnect fuel line at carburetor and breather tube at air horn a Disconnect fuel solenoid wires at carburetor b Remove intake manifold and carburetor c Disconnect governor link from governor lever 3 Loosen governor lever nut 4 Remove governor control bracket and governor lever 5 Remove No 1 cylinder shield with fuel pump and brack et Note L
6. 8 Dynamic Governor Adjustment 8 Governed Idle gaE Re 9 Adjust Top No Load Speed FUEL SHUT OFF SOLENOID oe x RR EORR UE 3 pcd noe nai nn 10 TESTING SOLENOID 09 252 3 89 30 E Mn cire rn acid Qe OR Qe 10 TESTING EQUIPMENT WIRING E ER Rn 10 TESTING ENGINE WIRING Rude 3 WoRi 10 FUEL PUMP eR RN RR BR UR E 11 Inline Fuel Filter Service 11 9905 SEE SECTION 1 FOR AIR CLEANER MAINTENANCE PROCEDURES GENERAL INFORMATION The Intek OHV V twin utilizes a fixed jet two barrel side draft flo jet carburetor Except for idle speed the carburetor is non adjustable The carburetor incorporates a fuel shut off solenoid which controls fuel flow to the fuel metering system The solenoid is controlled by the ignition switch REMOVE INTAKE MANIFOLD AND CARBURETOR 1 Disconnect choke and throttle control cables 2 Remove air cleaner cover cartridge and pre cleaner 3 Remove rotating screen and blower housing a Disconnect breather tube at air horn 4 Disconnect fuel line at carburetor 5 Disconnect wiring connector at solenoid 6 Remove intake manifold screws a Disc
7. RR 9 Piston RINS eee be Ede UR 12 Assembly Removal Checking Pressure LUD CETT 8 Regulator Rectifler 1 sua SECTION REFERENCE Continued SECTION Remote Controls vada a ERO 4 Adjustment Governed Idle Wire Travel NE ec och aun 1 SPECHICATIONS E 1 Speed Control 4 Starters Electi 222222222025 cna don eadera edv qa aatia rct dU c 6 Assemble Disassemble Starter Assemble Disassemble Starter Drive Keyswitch Testing Replace Brushes Test Equipment Testing Troubleshooting Stop Switch See Ground Wire Harness 2 Fastener And Torque Specifications 1 Troubleshooting 1 5 mmm T 5 Adjust Valve Clearances Refacing Seals Seats Valves Installation Removal English to Metric Conversion Table Fraction Decimal mm 9 16 0 5625 14 2875 ___ yO 19 32 0 5938 15 0812 39 64 0 6094 15 4781 EENEVS 5
8. Fig 4 Tri Circuit Stator RED CONNECTOR CONNECTOR GREEN BLACK CONNECTOR YELLOW WIRE STATOR ASSEMBLY REGULATOR RECTIFIER 5 or 9 amp DC regulated for charging battery Alternator output 5 or 9 amp is determined by fly wheel alternator magnet size Uses same stator as Tri Circuit system One black lead from stator Green connector Fig 5 5 or 9 Amp Regulated Stator STATOR ASSEMBLY RED CONNECTOR OUT PUT LEAD ALTERNATOR TWO BLACK LEADS YELLOW CONNECTOR REGULATOR TWO YELLOW RECTIFIER LEADS 10 or 16 amp DC regulated for charging battery Two black leads from stator Fig 7 Alternator Magnets Yellow connector with two pin terminals Two yellow leads to regulator rectifier Small Magnet 22 mm x 17 mm 7 8 x 21 32 One red lead from regulator rectifier to red Large Magnet 22 mm x 23 mm 7 8 x 29 32 connector output lead Table 2 identifies the magnet size to be used with a specific 10 and 16 amp system use the same stator alternator system color coding and regulator rectifier Alternator output is determined by the flywheel al ternator magnet size TABLE NO 2 Fig 6 10 or 16 Amp Regulated Stator Flywheel Identification Intek OHV Twin Cylinder Flywheels have a single ring of magnets which provide the magnetic field for the various alternator systems There are two 2 sizes of alternator magnets The size of the magnet determines the al
9. 13 Checking MC oda ee 10 Installation Bee 13 Crankshaft 11 End Play ages 13 Installation REMOVAl 2 daro datae Sese o nuce 13 SECTION REFERENCE Continued SECTION 2 e dcn d aded onda a As 13 Dod 5 BDUR 10 Bearings Resizing Bore Cylinder Balance Test 1 Cylinder Leakdown Test 1 Engine Identification System 1 Engine Specifications Preface Exhaust System Supplied By Equipment Manufacturer Flywheel 2 Installation Removal Also See Flywheel Identification 7 3 Fuel Recommendations
10. Fig 7 Install Mag Bearing 4 Stake bearing from both sides with 1 4 round punch to prevent bearing from turning Fig 8 a Install new oil seal with sealing lips facing in b Use cylinder support Tool 19227 and press oil seal until flush with cylinder Fig 8 Stake Bearing Check Camshaft Bearings Check camshaft bearings in cylinder and sump for damage or wear Reject Dimension 6275 15 93 mm If bearings are damaged or worn the cylinder or crankcase cover must be replaced Check PTO Bearing Check PTO bearing for damage or wear Reject Dimension 1 629 41 37 mm If PTO bearing is damaged or worn the sump must be replaced Fig 10 Check PTO Bearing Install PTO Oil Seal Always install new oil seals whenever engine is disas sembled for major servicing When installing new PTO oil seal use cylinder support Tool 19227 and press oil seal slightly below mounting surface Always lubricate sealing lips with engine oil to prevent damaging seal when installing crankshaft Fig 11 Install Oil Seal Honing Fixture 3 15 16 100 mm 4 8 15 16 227 d 125 4 mm 11 32 Thru Hole 3 8 7 mm 6 2 27 16 406 Material Wood 2 x6 x16 Long Cylinder Mounting Hardware Fasteners Required 3 Crankcase Cover Screws 8 Flat Washers 5 16 I D Section 11 Crankshaft And Camshaft Section Contents Checking Crankshaf
11. RR ies eke 2 TEST STARTER MOTOR Remove Starter Motor esceunersens 3 Testing Starter ics cence 3 Starter Motor Specifications 2522 25 3 Conditions Affecting Starter Motor Performance 4 STARTER DRIVE Checking Starter Motor Drive 2 bre ra sense 4 Disassemble Starter Motor Drive 4 Assemble Starter Motor Drive 6 DISASSEMBLE STARTER MOTOR 5 Inspect Armature 6 Inspect in RE RRERERARACAMERRERSRRSARRRRRARREFARRAREERES 6 ASSEMBLE STARTER canes dete 6 Install Starter Motor RR RR ER ENNE 7 REPLACE RING GEAR 7 BATTERY INFORMATION 8 Installation rh ER ERE RR ORE EAR 8 CHECKING Ballefy 8 Testing Battery ees AREE 9
12. 3 ENGINE WIRING HARNESS Red Be tease 4 Testing Ground Wire Harness 5e eoo hr ur RR Rr 4 Engine Wiring Harness Diagram 5 Diode Fallure Diagnosis 5 SPECIFICATIONS FOR ALL INTEK OHV V TWIN CYLINDER ENGINE MODELS Basic Armature Flywheel Holder Flywheel Puller Flywheel Nut Torque Model Series Air Gap Part No Part No Ft Lbs Nm 405777 008 to 012 19489 or 19433 20 to 30 mm See Section 1 For Spark Plug Maintenance And Specifications GENERAL INFORMATION Briggs amp Stratton OHV V Twin engines use MAGNETRONG ignition an ignition armature with a self contained transistor mod ule no moving parts Two MAGNETRON f ignition armatures are used with a flywheel containing a permanent magnet NOTE Magnetron ignition system requires a minimum of 350 RPM to produce spark ARMATURES Armature Testing The condition of the ignition armatures can accurately diagnosed using ignition tester Tool 19368 as described in Trouble shooting in Section 1 9905 1 Removing Armatures 1 Remove spark plug leads and spark plugs 2 Remove rotating screen and blower housing 3 Remove armature screws and lift off armature s Fig 1 a Disconnect stop switch wires at armatures Note The flywheel does not need t
13. RETAINER TOOL 19436 C DO NOT ALIGN DRIVE PINS WITH NOTCH Fig 8 Removing C Ring Assemble Starter Drive 1 Assemble clutch drive to starter shaft and rotate clutch until it drops into place Fig 9 2 Install pinion gear with beveled side of teeth up Then install return spring making sure spring is in recess of starter gear 3 Install soring washer with concave side up Install retainer 4 Place C Ring over chamfered end of shaft Align one of the slots of Tool 19435 with open end of C Ring 5 Press or drive C Ring on until it snaps into groove in shaft Fig 10 DISASSEMBLE STARTER MOTOR See Fig 11 for exploded view of starter motor To aid in reassembly scribe a mark on drive end cap and starter housing for alignment purposes 1 Remove thru bolts 2 Remove drive end cap assembly Replace drive end cap if bushing is worn or damaged RETAINER CLUTCH a SPRING WASHER 9 p GEAR Fig 9 Assemble Starter Drive a TOOL 19435 Fig 10 Install C Ring RETAINER C lt SPRING SPRING WASHER 9 cnNG GEAR CLUTCH NS A DRIVE P NS THRUST WASHER DRIVE END CAP SPRING WASHER ARMATURE END CAP 7 BRUSH RETAINER Fig 11 Exploded View 3 Hold the armature and commutator against work surface while sliding housing off the a
14. Remove pressure switch or 1 8 NPTF plug in oil filter adapter Install oil pressure gauge Fig 6 Start and run engine for approximately 5 minutes Check oil pressure at 3000 RPM Oil Pressure 70 F 21 C 15 50 psi 1 0 3 5 Bar See chart below for troubleshooting guide Low Oil Pressure Engine RPM Too Low Wrong Viscosity or Diluted Oil Low Oil Level Broken Pressure Relief Spring oR Ww Missing Pressure Relief Plunger Damaged Or Defective Oil Pump Fig 5 Checking Pressure Switch OIL PRESSURE Fig 6 Checking Oil Pressure High Oil Pressure Wrong Viscosity Oil Plugged Oil Galleries Stuck Pressure Relief Plunger CRANKCASE BREATHER The crankcase breather is equipped with a reed valve to control and maintain a partial vacuum in the crankcase The breather is vented to the intake elbow The breather chamber contains a removable oil vapor collector Oil vapor is condensed on the collector material and drains back into the crankcase which minimizes the amount of oil vapor entering the breather CHECK BREATHER Remove rotating screen blower housing and flywheel See Section 2 1 Disconnect breather tube from intake elbow remove three screws and breather Discard gasket 2 Check to see that reed valve is not deformed Fig 8 Note Reed valve must make a complete seal around vent hole 3 Remove oil vapor collector and retainer 4 Check collector for deteri
15. 14 4 9 amp ENGINE DISASSEMBLY Drain oil remove oil filter and remove engine from equipment Remove spark plugs Remove cylinder heads See Section 5 Remove flywheel disconnect stop switch wires at armatures and remove armatures See Section 2 1 Remove the following parts Fig 1 Back plate Air guide Starter motor Oil and dipstick Stop switch wiring harness Breather and oil vapor collector Alternator 2 Remove oil pump Fig 2 a Oil pump cover b Inner rotor c Outer rotor d Drive shaft 3 Remove sump and discard gasket Fig 3 a Remove governor gear and thrust washer 4 Rotate crankshaft and camshaft until timing marks align and remove camshaft Fig 4 a Remove tappets Fig 4 Align Timing Marks Note Remove any carbon or ridge at the top of cylinder bores to prevent breaking rings when removing piston and connecting rod assemblies 5 Remove No 2 connecting rod cap and push connecting rod and piston assembly out of cylinder a Reassemble cap to rod to prevent interchanging 6 Repeat for other cylinder 7 Remove crankshaft CLEAN ALL SURFACES OF GASKET MATERIAL RE MOVE OIL SEALS AND THOROUGHLY CLEAN COM PONENTS IN SOLVENT ORGANIZE COMPONENTS KEEPING PARTS WHICH ARE AN ASSEMBLY TO GETHER Fig 6 Remove Crankshaft Section 10 Cylinder And Crankcase Cover Inspection And Repair Section Contents Page CYLINDER Checking Cylinde
16. 2 Insert BLACK test lead into receptacle in me ter 3 Rotate selector toV AC volts position 4 Insert RED and BLACK test lead probes into output terminals in yellow connector as shown in Fig 21 Meter test clip leads may be attached to either termi nal YELLOW CONNECTOR YELLOW CONNECTOR BLACK TEST LEAD RED TEST VA LEAD AC OUTPUT PINS Fig 21 Testing AC Output 5 With the engine running at 3600 RPM output should be no less than 20 Volis 10 Amp System 30 Volts 16 amp System f alternator output test indicates 16 amp system see special instructions for testing regulator rectifier 6 If no or low output is found check for bare wires or any other obvious defects If shorted leads are not visible replace the stator Test Regulator Rectifier NOTE The Digital Multimeter will withstand DC input of 10 20 amps for up to 30 seconds When checking DC output on 16 amp regulated system use DC Shunt Tool 19468 to avoid blowing fuse in meter See special instructions for installation procedure on 16 amp system NOTE Regulator rectifier will not function unless it is grounded to engine Make sure the regulator rectifier is securely mounted to engine When testing regulator rectifier for amperage output a 12 volt battery with a minimum charge of 5 volts is required There will be no charging output if battery voltage is below 5 vo
17. BE er 708 1702 6745 17 13 mm Piston Pin 6721 6726 17 07 17 08 mm 6718 17 06 mm Piston Pin Bearing Piston 63 97997 0720 9 esl OCT 6745 17 13 mm Piston Ring Ring End Gap Top 005 013 0 13 0 33 030 0 76 mm 0147 022 0 35 0 56 030 0 76 Oll 005 017 0 13 0 43 mm 030 0 76 mm Ring Side Clearance All 002 003 0 05 0 07 mm 005 0 12 mm 11 Section 2 IGNITION Section Contents Page SPECIFICATIONS assonnate neaei E n E E E aea S E e E E E se 1 GENERAL INFORMATION 1 ARMATURES Testing teat reset NU ERES 1 hon 2 Install 2 Adjust Arinature Alt Gap 2 FLYWHEEL Remove FIYWHEG occ icc teers rier a RARE SR 2 Inspect Flywheel Key and Keyways 3 Install Flywheel 1x te RR CR terse
18. Stratton source of supply Order Part No 19449 Fig 2 Digital Multimeter DC Shunt Use with Digital Multimeter The DC Shunt is required when checking starter motor current draw on 12 volt starter motors Order as Tool 19359 Fig 3 Fig 3 DC Shunt Tool No 19359 A tachometer is available from your Briggs amp Stratton source of supply Order as Tool 19200 The tachometer measures from 800 to 50 000 RPM Fig 4 O PESO O m Fig 4 Tachometer Test Bracket A starter motor test bracket may be made as shown in Fig 5 A growler or armature tester is available from an Automobile Diagnostic service supplier TEST STARTER MOTOR Remove Starter Motor It is recommended that the starter motor be removed from the engine when testing starter motor performance Remove rotating screen and blower housing Remove two starter motor mounting screws Assemble starter to test bracket and clamp test bracket in vise Fig 6 EXTRA HOLE DRILL TWO HOLES 3 8 FOR MOUNTING 9 5 MM DIA STARTER BRACKETS FOR MOUNTING STARTER 2 1 4 DRILL AND TAP TWO HOLES 57 2 MM FOR MOUNTING DEN B amp S 19200 101 6 MM 7 lt TACHOMETER USE 7 DRILL AND TAP HOLE FOR 490 NC SCREWS 88 9 MM 25 4 MM 10 METAL STOCK 254 MM 1 4 6 4 MM THICK STEEL 7 50 8 MM Fig 5 Test Bracket IMPOR
19. Vertical Shaft 6 to 1 CCW Rotation 38 7 Vertical Shaft 7 Plain Bearing 40 Flo Jet Carburetor Pressure Lubrication on 42 Pneumatic or Mechanical Vertical Shaft 43 Governor 8 Plain Bearing 44 8 Vertical Shaft Auxiliary Drive PTO 46 Flo Jet Carburetor Perpendicular to Crankshaft 52 Mechanical Governor 9 Plain Bearing 58 9 Vertical Shaft Auxiliary Drive Pulsa Jet Carburetor Pneumatic or Mechanical Governor Parallel to Crankshaft The type number identifies certain unique features such as the crankshaft or governed speed used on an engine The code number identifies the assembly date of the engine In some instances it is necessary to know the code number as well as the model and type number when performing adjustments repairs or ordering replacement parts for an engine Here is how it works Example 99052115 The first two digits 99 indicate the calendar year 1999 B The second two digits 05 indicate the calendar month May C The third two digits 21 indicate the calendar month day D The last two digits 15 indicate the assembly line or manufacturing plant 5 Hours 25 Hours or 50 Hours or 100 Hours or Check oil levels Los qu o 1d ee eee Change oil filter E T Change air cleaner pre cleaner Clean cooling system si Clean cooling system si system Inspect clean spark arrester accessory Replace spark plugs epee Remove combustion ch
20. a Measure cylinder bore in 6 points at right angles as shown Fig 3 b If cylinder bore is worn more than 003 0 075 mm or more than 0015 0 035 mm out of round it must be resized CENTER OF PISTON RING TRAVEL Fig 2 Check Cylinder Bore 9905 Note If cylinder bores are within specification and show no signs of scoring or other damage new piston rings be installed providing the cylinder bores are reconditioned using a rigid hone with finishing stones to restore the proper cross hatch angle in the cylinder bores The proper cylinder cross hatch ensures proper lubrication and piston ring break in Refer to Page 2 Cylinder Finish Cross Hatch for correct procedure for installing cross hatch Resizing Always resize to exactly 010 25 mm or 020 51 mm or 030 76 mm over standard bore size If this is done accurately the service oversize rings and pistons will fit perfectly and proper clearances will be maintained Cylinders can be quickly resized with a good hone such as Briggs amp Stratton Tool 19205 Contact your Briggs amp Stratton source of supply Use the stones and lubrication recommended by the hone manufacturers to produce the Eng Or MOUNTING correct cylinder cross hatch NOTE Automatic transmission fluid is an acceptable honing oil Another acceptable honing oil can be made by mixing 4 parts No 30 weight oil with 1 part kerosene If a boring bar is used a hone must
21. must be replaced TANG BENDER Fig 29 Adjusting Top No Load Speed FUEL SHUT OFF SOLENOID The fuel shut off solenoid is controlled by the equipment ignition switch When the equipment switch is in the Off position the solenoid valve plunger closes stopping fuel flow through the fixed main jet When the switch is in the On and Start position the solenoid valve opens allowing normal fuel flow Solenoid is operating properly if a click is heard when equipment ignition switch is turned and Off Note Anti afterfire solenoid requires a minimum of 9 volts DC to function TESTING SOLENOID If solenoid does not click the problem may be in equipment wiring engine wiring harness or solenoid To determine whether problem is with wiring or solenoid perform the following tests in the order shown Test Equipment The digital multimeter Tool 19390 is required to test the solenoid equipment wiring The following tests will be performed with the meter in the V DC volts position Fig 30 TESTING EQUIPMENT WIRING 1 With keyswitch in OFF position disconnect equipment wiring harness connector from engine wiring harness 2 Attach red meter test lead into equipment wiring harness connector side opposite raised rib 3 Attach black test lead to a good ground Fig 31 4 Turn keyswitch to ON position a Meter should display battery voltage at connector If meter does not
22. 0 6250 15 8750 ___ 05406 21 32 0 6562 16 6688 43 64 0 6719 17 0656 Lp 11 16 0 6875 17 4625 4 yO 7 32 0 2188 5 5562 23 32 0 7188 18 2562 15 64 0 2344 5 9531 47 64 0 7344 18 6531 SSS 1 4 0 2500 6 3500 3 0 7500 19 0500 EE ux e 0 2656 0 7656 9 32 0 2812 7 1438 25 32 0 7812 19 8438 19 64 0 2969 7 5406 51 64 0 7969 20 2406 __ gt _ ee 205375 ___ 3 8 0 3750 9 5250 0 8750 22 2250 Pd ee 25 64 0 3906 9 9219 57 64 0 8906 22 6219 13 32 0 4062 10 3188 29 32 0 9062 23 0188 27 64 0 4219 10 7156 59 64 0 9219 23 4156 _ 238125 E 60 040 59 041 58 042 57 043 56 0465 55 052 54 055 53 0595 1 16 0625 52 0635 51 067 50 070 49 073 48 076 5 64 0781 47 0785 46 081 45 082 44 086 43 089 42 0935 3 32 0938 41 096 40 098 VI Drill Size Decimal Equivalent In Inches 39 0995 38 1015 37 104 36 1065 7 64 1094 35 110 34 111 33 113 32 116 31 120 1 8 125 30 1285 29 136 28 1405 9 64 1406 27 144 26 147 25 1495 24 152 23 154 5 32 1562 22 157 21 159 20 161 19 166 18 1695 11 64 1719 17 173 16 177 15 180 14 182 13 185 3 16 1875 12 189 11 191 10 1935
23. 13 mm Note 020 undersize connecting rods are available for use on a reground crankpin journal See illus trated parts list ASSEMBLE PISTON AND CONNECTING ROD Lubricate parts with engine oil and assemble 1 piston and connecting rod Fig 8 1 Arrow on piston must face flywheel side 2 Number 1 on connecting rod must face PTO side op posite arrow on piston a Install piston pin locks with needle nose pliers Lubricate parts with engine oil and assemble 2 piston and connecting rod Fig 9 1 Arrow on piston must face flywheel side 2 Number 2 on connecting rod must face PTO side op posite arrow on piston a Install piston pin locks with needle nose pliers PISTON PIN BEARING ARROW TOWARD FLYWHEEL SIDE ARROW TOWARD FLYWHEEL SIDE Fig 9 Assemble 2 Rod And Piston ASSEMBLE PISTON RINGS TO PISTON Models 405700 1 Install piston rings using ring expander Tool 19340 Fig 10 a Install oil ring coil expander making sure wire is in serted fully into coil b Install oil ring c Install center compression ring then top compres sion ring Note Top compression ring may be installed with either side up ASSEMBLE PISTON RINGS TO PISTON Models 445700 1 Install piston rings using ring expander Tool 19340 Fig 11 a Install oil ring coil expander making sure wire is in serted fully into coil b Install oil ring c Install center compression ring then top compres sion
24. 15 Assemble Brushes 3 Hold armature and end cap against work surface 4 Slide housing over armature aligning notch in housing with terminal on brush retainer Fig 16 5 Assemble spring washer and thrust washer to armature shaft and install drive end cap Fig 17 a Torque thru bolts to 50 in lbs 6 0 Nm 6 Install starter drive Install Starter Motor Install starter motor and torque screws to 140 in lbs 16 0 Nm REPLACE RING GEAR File or grind off rivet heads from top side of flywheel Fig 18 Then drive out rivets with 3 16 punch Pry off old ring gear Carefully align holes in ring gear with holes in flywheel Use a flat plate and press on new ring gear Then fasten new ring gear to flywheel using screws and locknuts provided with new gear Fig 18 ALIGN NOTCH WITH TERMINAL THRUST pd WASHER d SPRING WASHER FILE OR GRIND OFF RIVET HEADS FROM THIS SIDE LOCK NUT Fig 18 Replacing Ring Gear BATTERY INFORMATION The battery used to operate starter motors on Briggs amp Stratton Twin Cylinder engines is 12 volt lead acid wet cell type This type is available as a wet charge or dry charge battery The wet charged maintenance free battery is filled with electrolyte and sealed at the time of manufacture The level of electrolyte cannot be checked The dry charge battery is manufactured with fully charged plates Electrolyte must be added at the time that the battery is p
25. 9 196 8 199 7 201 13 64 2031 6 204 5 2055 4 2209 3 213 7 32 2188 2 221 1 228 A 234 15 64 2344 B 238 C 242 D 246 E 1 4 250 257 G 261 17 64 2656 H 266 272 J 277 K 281 9 32 2812 1 290 M 295 19 64 2969 N 302 5 16 3125 O 316 P 323 21 64 3281 Q 332 R 339 11 32 3438 S 348 T 358 23 64 3594 U 368 3 8 375 V 377 W 386 25 64 3906 X 397 Y 404 13 32 4062 Z 413 27 64 4219 7 16 4375 29 64 4531 15 32 4688 31 64 4844 1 2 500 Section 1 GENERAL INFORMATION Section Contents Page IN THE INTEREST SAFETY 2 BRIGGS amp STRATTON NUMERICAL IDENTIFICATION SYSTEM 3 MAINTENANCE Maintenance Schedule a iicccscccccteescr cies a anes 4 Fuel And Oil Recommendations 4 iie ac E A aa EE E 5 Change Oll Filter 22255 5 Clean System rete 5 Replace Spark 5 Cleaner
26. Battery Recommendations iaa En RR EON RR ERR ROS 9 Battery Cable Recommendations 9 GENERAL INFORMATION The starter motor uses a gear type engagement method similar to an automobile starter When the starter motor is activated the pinion gear engages a ring gear attached to the engine flywheel and cranks the engine The pinion gear and flywheel ring gear are replaceable Fig 1 Starter Motor 9905 1 TROUBLESHOOTING NOTE If a starting problem is encountered the engine itself should be thoroughly checked to eliminate it as the cause of starting difficulty It is a good practice to check the engine for freedom of rotation by removing the spark plugs and turning the crankshaft over slowly by hand to be sure it rotates freely WARNING DO NOT ROTATE ENGINE WITH ELECTRIC STARTER WITH SPARK PLUGS REMOVED ARCING AT THE SPARK PLUG ENDS MAY IGNITE THE GASOLINE VAPOR EXITING THE SPARK PLUG HOLE Engine Cranks Slowly a Additional load affecting performance see note above Discharged battery Faulty electrical connection battery circuit Discharged battery see alternators Dirty or worn starter motor commutator bearing weak magnets etc Worn brushes or weak brush spring Wrong oil viscosity for temperature expected Battery leads too long or wire too small Battery too small L Engine Will Not Crank
27. Charge Indicator It is important that the test procedure be done in a systematic manner to identify whether the problem is related to the regulator rectifier or the charging indicator wiring system Follow test procedure in the sequence listed A known good battery is required for this test BEFORE TESTING THE CHARGING INDICATOR SYS TEM TEST THE ALTERNATOR AND REGULATOR REC TIFIER FOR CORRECT OUTPUT NOTE Output values are the same as the 10 amp and 16 amp system Symptom Charge Indicator Light Will Not Light Key Switch On Engine Not Running A jumper wire is required for this test Make sure key switch is in OFF position before connecting jumper wire IMPORTANT Before disconnecting output harness from connector mark or identify the charging indicator wire in the output harness If jumper wire contacts charging output wire during test while key switch is in ON position wiring harness may be damaged 1 Disconnect output harness at white connector 2 Attach one end of jumper wire to a good ground 3 Attach other end of jumper wire to charge indicator ter minal in harness connector Fig 25 a Turn keyswitch to ON position b If bulb lights charge indicator wiring system is OK Replace regulator rectifier c If bulb does not light replace bulb d If new bulb does not light the problem must be a broken wire open circuit in charging indicator cir cuit Refer to typical wiring diagram page 13 CONNECTOR CHARGE INDIC
28. DC Charging Unregulated 14 Volts AC Lights Unregulated 5 Amps DC Charging 5 Amps DC Lights 1 5 Amps DC Charging 10 Regulated 1 9 Amps DC Charging 10 Regulated 1 10 Amps DC Charging 11 Regulated 1 16 Amps DC Charging 12 Regulated Alternator output is determined by flywheel alternator magnet size STATOR ASSEMBLY ONE BLACK LEAD FROM STATOR WHITE CONNECTOR OUTPUT LEAD e 14 Volts AC for lighting circuit e One black lead from stator e White connector output lead Fig 1 AC Only Stator ONE RED LEAD FROM STATOR d K Ex 2 RED CONNECTOR OUTPUT LEAD 3 amp DC unregulated for charging battery One red lead from stator Diode encased at connector Red connector output lead Fig 2 DC Only Stator BLACK LEAD AC OUTPUT RED LEAD DC OUTPUT STATOR ASSEMBLY DC CHARGING CIRCUIT RED LEAD WHITE LEAD AC FOR LIGHTS 7 WHITE CONNECTOR 3 amp DC unregulated for charging battery ONE red lead from stator 14 Volts AC for lighting circuit ONE black lead from stator Diode encased at connector White connector with two pin terminals Fig Dual Circuit Stator STATOR ASSEMBLY ONE BLACK 5 AMPS DC TO LIGHTS WHITE LEAD v RED LEAD 5 AMPS DC TO BATTERY AND CLUTCH CIRCUIT CONNECTOR 10 amp AC One black lead from stator Green connector Two diodes encased in wire harness Red and white output leads
29. DC charging lead limiting the charging current to approximately 3 amps when the clutch is not engaged When the clutch is engaged the resistor is bypassed allowing full output to the battery and clutch NOTE The 1 OHM 20 WATT resistor is supplied by the equipment manufacturer The battery is not used for the lights so lights are available even if the battery is disconnected or removed Current for the lights is available as long as the engine is running The output depends upon engine RPM so the brightness of the lights changes with engine speed Alternator Output Test Insert RED test lead into V receptacle in meter Insert BLACK test lead into receptacle in meter 2 3 Rotate selector to V AC volts position 4 Attach RED test lead clip to output terminal Fig 16 RED TEST LEAD TO AC OUTPUT PIN GREEN CONNECTOR BLACK TEST LEAD TO A GOOD GROUND SURFACE Fig 16 Testing Alternator Output Attach BLACK test lead clip to engine ground With engine running at 3600 RPM output should be no less than 28 volts AC If no output or low output is found replace stator If alternator output is good test diodes located in wiring harness oo Diode Test NOTE One diode is for the charging circuit and the other diode is for the lighting circuit In the Diode Test position the meter will display the forwa
30. See illustrated parts list for correct fuel filter COVER AND PULSE LINE NIPPLE DIAPHRAGM PLASTIC DIAPHRAGM GASKET FUEL INLET SBD NIPPLE amp eo Fig 34 Exploded View 11 Section 4 GOV CONTROLS amp GOVERNOR Section Contents Page GENERAL INFORMATION aes 1 REMOTE GOVERNOR CONTROLS Speed Regulation Ime 1 Governed 25h RRIARAGRRRERREAREESRRRREIAGRRERRRERRRERREZSRARRERRERR 2 Remote Control Wire Travel rx Rma Rer 2 Choke Control Adjustment 22 2 uis tri 2 GOVERNOR Disa ssemble vee RACE GE 3 Check Governor Gear And 4 Install Governor Shaft BUSHING ee rrr eR hr ees 4 Reassemble send ened eee ene cena 5 ADJUST GOVERNOR Static Governor Ad USIMENE 4 RRRREERRYRREERRRTEIERERRRSERERAR 6 Dynamic Governor Adjustment Rh ee one 6 Governed idle Adjustment a EIC 7 Adjust Top No Load Speed or mph nima RR ERR ERRARE 7 GENERAL INFORMATION The purpose of the governor is to maintain within certain limits a desired engine speed even though loads m
31. TOR ASSEMBLY 1 Install intake manifold and carburetor assembly using new gaskets Fig 21 a Torque screws to 80 in Ibs 9 0 Nm b Assemble governor link to governor lever c Connect solenoid wire to solenoid d Connect breather tube to air horn Note Route armature ground wire between breather tube and air horn Fig 21 Install Intake Manifold And Carburetor INSTALL BLOWER HOUSING 1 Assemble blower housing to engine a Torque screws to 80 in lbs 9 0 Nm 2 Install rotating screen a Torque screws to 20 in 165 2 0 Nm Assemble air cleaner and install spark plugs ADJUST GOVERNOR WARNING BEFORE STARTING OR RUNNING ENGINE static adjustment of the governor must be completed Failure to make the static adjust ments first could result in engine overspeeding which may result in engine damage property damage or personal injury Static Governor Adjustment 1 With governor lever nut loose rotate governor control swivel counter clockwise as far as it will go wide open throttle and hold in this position 2 Rotate governor shaft clockwise as far it will go Fig 23 a Torque governor nut to 130 in lbs 15 0 Nm 3 Install throttle and choke control cables and check for proper operation 4 Install exhaust manifold a Torque screws to 140 in lbs 16 0 Nm Note Exhaust manifold and exhaust system supplied by equipment manufacturer Dynamic Governor Adjustment ALL ADJUSTMENTS MUST BE MADE WITH
32. Use Resin Core solder when installing new harness Use shrink tubing or tape all connections DO NOT USE CRIMP CONNECTORS DUAL CIRCUIT ALTERNATOR Dual circuit alternators use a single polarized plug with two pins One pin is for charging the battery and the second is for the AC light circuit The dual circuit alternator provides DC current for battery charging and an independent AC circuit for headlights The battery is not used for lights so lights are available even if battery is disconnected or removed Current for lights is available as long as the engine is running The output depends upon engine speed so brightness of the lights changes with engine speed 12 volt lights with a total rating of 60 to 100 watts may be used With lights rated at 70 watts the voltage rises from 8 volts at 2400 RPM to 12 volts at 3600 RPM The current from the DC side of the alternator is unregulated and is rated at 3 amps The output rises from 2 amps at 2400 RPM to 3 amps at 3600 RPM Alternator Output Test 1 Insert RED test lead into 10 A receptacle in meter Insert BLACK test lead into receptacle in meter 2 3 Rotate selector to A DC amps position 4 Attach RED test lead clip to DC output pin in connector Fig 13 BLACK LEAD POSITIV BATTERY xm UN A THE BATTERY MUST BE IN GOOD CONDITION FOR THIS TEST RED TEST LEAD TO DC OUTPUT PIN RED WIRE RAISED RIB ON CO
33. an accurate reading without special equipment It has been determined through testing a simple and accurate indication of compression can be made as follows Remove both spark plugs and insert a compression gauge into either cylinder one cylinder at a time Turn engine over with engine starter until there is no further increase in pressure Record this reading Repeat procedure on other cylinder and record that reading The difference between both cylinders should not exceed 25 More than 25 indicates loss of compression in the cylinder with lower pressure See example Example Cyl 2 Diff Diff Eng 41 65PSI 60PSI 5 PSI 7 696 Eng 42 75 51 55PSI 20PSI 26 7 If compression is poor look for Loose cylinder head bolts Blown head gasket Burned valves valve seats and or loose valve seats Insufficient valve clearance Warped cylinder head Warped valve stems Worn bore and or rings Broken connecting rods Cylinder Leakdown Test The cylinder leakdown tester Tool 19545 may be used to test the sealing capability of the compression components of each cylinder and quickly identify the problem compo nent Cylinder Balance Test If the engine is hard starting runs rough misses or lacks power perform a oylinder balance test to determine whether both cylinders are operating to their full potential Tools Required 1 Tachometer Tool 419200 or 19389 2 Two 19368 Ignition Testers 3 Screwdriver with in
34. and inder OIL FILL Fig 9 Route Wires 5 Install back plate a Torque screws to 100 in 105 11 0 Nm Note Route armature ground wire under back plate and between starter motor mounting bosses on cylinder as shown Fig 10 6 Install starter motor a Torque screws to 140 in lbs 16 0 Nm 7 Install oil vapor collector and retainer 8 Install breather a Torque screws to 55 in lbs 6 0 Nm STARTER MOTOR INSTALL FLYWHEEL CLEAN flywheel and crankshaft taper removing all oil dirt or grease 1 Assemble flywheel to crankshaft and align keyways 2 Insert flywheel key into crankshaft 3 Assemble fan and retainer to flywheel Fig 12 a Torque screws to 140 in lbs 16 0 Nm 4 Install washer and flywheel nut 5 Assemble flywheel holder Tool 19321 to retainer Fig 13 a Torque flywheel nut to 150 ft Ibs 203 0 Nm Fig 13 Install Flywheel ADJUST ARMATURE AIR GAP 1 Rotate flywheel until magnet is under armature lamina tions THICKNESS 2 Place thickness gauge 008 012 0 20 30 mm be tween magnet and armature laminations Fig 14 3 Loosen mounting screw so magnet will pull armature down against thickness gauge a Torque screws to 25 Ibs 3 0 Nm 4 Rotate flywheel to remove thickness gauge 5 Repeat for second armature INSTALL CYLINDER HEADS 1 Place cylinder head gasket over alignment dowels on cylinder block 2 Install cylinder head
35. be used after the boring operation to produce the proper cylinder cross hatch Honing is done with a variable speed 1 2 portable drill and a honing fixture See page 5 for dimensions to make your own honing fixture UNWORN Use three crankcase cover mounting screws and fasten cylinder to a honing fixture Fig 3 Clamp honing fixture and cylinder securely in a vise at a convenient work height Place hone drive shaft in chuck of portable drill and tighten Cut a wood block and place inside cylinder to prevent hone from extending further than 3 4 to 1 19 mm to 25 mm EXTREME below cylinder bore PONG Place hone in middle of cylinder bore Tighten adjusting AT knob with finger until stones fit snugly against cylinder wall DO FORCE Connect drive shaft to hone Be sure that cylinder and hone are centered and aligned with drive shaft and drill spindle 3 4 TO 1 Fig 3 Lubricate hone as recommended by hone manufacturer The recommended drill speed is 300 to 700 RPM MAXIMUM and 40 60 strokes per minute Because cylinder bores normally wear only in the area of ring travel the cylinder bore will be round above and below ring travel Fig 3 Start drill and as hone spins move it up and down at the bottom of the cylinder bore Gradually increase the length of the strokes until hone travels full length of cylinder bore and no more than 3 4 to 1 above cylinder bore Fig 3 Lubricate hone frequently to prevent
36. display battery voltage problem is with wiring harness Check for loose or broken wire If meter displays battery voltage test engine wiring harness TESTING ENGINE WIRING SOLENOID CONNECTOR 1 With keyswitch in OFF position re connect equipment GRAY WIRE wiring harness to engine wiring harness and disconnect harness at solenoid 2 Insert red meter test lead into GRAY wire in solenoid con nector 3 Attach black test lead to a good ground Fig 32 4 Turn keyswitch to ON position a Meter should display battery voltage at connector If meter does not display battery voltage problem is with engine wiring harness Replace If meter displays battery voltage problem is with solenoid Replace solenoid Fig 32 Checking Wiring 10 FUEL PUMP The fuel pump mounted on the No 1 cylinder shield allows remote fuel tank installations The fuel pump will prime at 12 30 5 cm maximum lift Fuel pump pressure is 1 5 psi 0 1 Bar The pump is operated by pulsating crankcase vacuum from the engine The vacuum pulse line is installed on the No 1 cylinder valve cover Fig 33 Note Fuel pump is available as an assembly only Replace fuel lines and vacuum pulse line if stiff and brittle Note An air leak at the fuel pump pulse line hose connections will result in improper fuel flow Inline Fuel Filter Service Replace inline fuel filter yearly or every 100 hours whichever occurs first Replace filter if dirt or water are present
37. indicate that carburetor is out of adjustment Leak in spark plug wire Head gasket Intake manifold a Aleakat either end of the intake manifold will only affect one cylinder not both Valves Rings Piston Cylinder The cylinder balance test will also detect a cylinder that is not functioning When grounding out one cylinder there will be no RPM loss When the other cylinder is grounded out the engine will stop NOTE A twin cylinder engine will run well on one cylinder as long as the power required for the application does not exceed the power produced by the one cylinder Equipment Affecting Engine Operation Frequently what appears to be a problem with engine operation such as hard starting vibration etc may be the fault of the equipment powered rather than the engine itself Since many types of equipment are powered by Briggs amp Stratton engines it is not possible to list all of the various conditions that may exist Listed are the most common effects of equipment problems and what to look for as the most common cause Hard Starting or Will Not Start 1 Loose belt a loose belt like a loose blade can cause backlash effect which will counteract engine cranking effort 2 Starting under load see if the unit is disengaged when engine is started or if engaged should not have a heavy starting load 3 Check remote control assembly for proper adjustment 4 Check interlock syste
38. replaced TANG BENDER A Fig 28 Adjust No Load Speed
39. ring with ID mark up COIL EXPANDER Fig 10 Piston Ring Installation Model 405700 ID MARK in ID MARK COIL EXPANDER Fig 11 Piston Ring Installation Model 445700 Section 13 Engine Assembly Section Contents Page INSTALL CRANKSHAFT x ERE 1 INSTALL PISTON AND CONNECTING ROD 2 INS TALE CAMSHAFT 52212 50 IIR 2 INSTALE 242 tes rises 3 GENERAL ASSEMBLY Rates 3 INSTALE FLYWHEEL 4 ADJUST ARMATURE AIR GAP 5 INSTALL CYLINDER HEAD tenes E RR Rn 5 ADJUST VALVES 5 INSTALL CYLINDER SHIELDS 6 INSTALL GOVERNOR CONTROL BRACKET 6 INSTALL INTAKE MANIFOLD AND CARBURETOR ASSEMBLY 6 INSTALE BLOWER HOUSING tec esas 7 ADJUST GOVERNOR Static Governor Adjustment 7 Dynamic Governor Adjustment 7 Governed Adjustment Re RR E
40. seals O rings inlet needles seats or pump diaphragms should never be placed in commercial carburetor cleaner To prevent eye injury always wear eye protection WEAR suitable skin protection when using clean ers FOLLOW instructions on container Disassemble carburetor 2 Remove and discard all old gaskets seals and sealing when using compressed air _ mE material 5 Use only compressed air blowing in both directions to 3 Use commercial carburetor cleaning solvents such as clean out all openings and passages Briggs amp Stratton Spray Cleaner Part 100041 or Note Do not use wires drills or any other devices to 100042 to clean carburetor parts and body clean out metering holes or passages 4 When cleaning non metallic parts plastic nylon Min lon etc do not leave in commercial carburetor cleaner Check Throttle Choke Shaft And Body For Wear 1 Lay carburetor on flat surface and check throttle and choke shaft clearance as shown in Fig 11 Throttle shaft and choke shaft clearance must not exceed 0107 25 Fig 11 Checking Clearance 2 Inspect throttle shaft and choke shaft for wear Fig 12 Replace if worn If carburetor body is worn replace carburetor Fig 12 Checking Throttle And Choke Shaft ASSEMBLE CARBURETOR When assembling carburetor use new seals and gaskets 1 Assemble new seal to throttle shaft and insert into car buretor body Importa
41. 0 will result in hard starting and possible engine bore damage due to inadequate lubrication IMPORTANT DO NOT OVERFILL Check and maintain oil level regularly Change oil after first eight 8 hours of operation Thereafter change oil every fifty 50 hours of operation Change oil more often if engine is operated in dirty or dusty conditions or if engine is operated under heavy loads or in high ambient air temperatures Remove oil drain plug and drain oil while engine is still warm Fig 1 Replace drain plug Remove dipstick and refill slowly with new oil of proper service classification and viscosity grade Refill to full mark on dipstick When checking oil level dipstick must be screwed all the way in for accurate readings Start and run engine to check for oil leaks Change Oil Filter Replace oil filter every 100 hours Before installing new filter lightly oil filter gasket with fresh clean engine oil Screw filter on by hand until gasket contacts filter adapter Tighten 1 2 3 4 turn farther Fig 1 Start and run engine at idle for 30 seconds and stop engine Recheck oil level and add if required Restart engine and check for oil leaks Fig 1 Clean Cooling System Grass particles chaff or dirt can clog the air cooling system especially after prolonged service in cutting dry grass or very dirty air Continued operation with a clogged cooling System can cause severe overheating and possible eng
42. 3 Lubricate oil pump components with engine oil and as semble to sump Fig 16 Make sure drive shaft is en gaged in camshaft a Install drive shaft b Install inner rotor c Install outer rotor d Install oil pump cover with new O ring e Torque screws to 50 Ibs 6 0 Nm 4 Reassemble governor lever to governor shaft Fig 17 DO NOT tighten nut at this time GOVERNOR Fig 17 Install Governor Lever 5 Install push rods in their original positions a Compress valve springs and insert push rods into recess in rocker arm adjustment screws Fig 18 Note Intake push rods are aluminum 4 Install valve covers with new gaskets Fig 19 a Torque screws to 100 in lbs 11 0 Nm ADJUST GOVERNOR WARNING BEFORE STARTING or running en gine static adjustment of the governor must be completed Failure to make the static adjustments first could result in engine overspeeding which may result in engine damage property damage or personal injury Static Governor Adjustment 1 With governor lever nut loose rotate governor control swivel counter clockwise as far as it will go wide open throttle and hold in this position 2 Rotate governor shaft clockwise as far it will go Fig 20 a Torque governor nut to 130 in lbs 15 0 Nm Dynamic Governor Adjustment ALL ADJUSTMENTS MUST BE MADE WITH AIR CLEAN ER ASSEMBLY INSTALLED Assemble remote controls and check for proper adjust ment The following tool
43. 8 with controls mounted in equipment Fig 3 Speed Control Wire Adjustment 1 Loosen control casing clamp at governor control brack et 2 Move speed control lever to FAST position 3 Move control casing and wire in direction shown by ar row until governor control swivel is at end of travel Fig 4 4 Tighten casing clamp screw Choke Control Adjustment Place choke control lever on equipment in CHOKE position Loosen control casing clamp screw Move control casing and wire until choke is completely closed Tighten casing clamp screw Fig 5 GOVERNED IDLE SPRING Fig 2 Throttle Restrictor 2 1 8 MIN 54 MM 1 3 8 MIN TRAVEL THROTTLE STOP PULL TO CHOKE WIRE AND CASING Fig 5 Choke Control Adjustment GOVERNOR Disassemble Drain oil and remove engine from equipment Remove spark plugs Remove valve covers depress springs and remove push rods Mark push rods so that they may be reassembled in their original position If push rods are mixed it may be necessary to readjust valve clearances NSS RIE Note Intake push rods are aluminum OL 1 Loosen governor lever nut gt W R 0 E Remove governor lever from shaft Fig 6 UO 2 Remove oil pump Fig 7 a Remove oil pump cover b Remove inner rotor c Remove outer rotor d Remove drive shaft 3 Remove sump and discard gasket Fig 8 a Remove governor gear and thru
44. 80 in Ibs 9 0 Nm Flywheel 150 ft Ibs 203 0 Nm Governor Control Bracket 80 in 105 9 0 Nm Governor Nut 130 lbs 15 0 Nm Head Bolts 220 in lbs 25 0 Nm 5 0 Nm 9 0 Nm 14 0 Nm 6 0 Nm 11 0 Nm 7 0 Nm Intake Air Horn 45 in lbs Intake Manifold to cyl head 3 8 T 30 80 in 108 Oil Drain Plug 3 8 Square Drive internal 125 in Ibs Oil Pump Cover 50 in Ibs Rocker Arm 100 in 105 Rocker Arm Lock Nut 60 in lbs Rocker Arm Adjustment Screw Rotating Screen 5 16 20 in Ibs Spark Plugs 5 8 mm Deep 180 in lbs 20 0 Nm 2 0 Nm Starter Motor 1 2 T 40 140 in lbs 16 0 Nm 5 16 50 in los 6 0 Nm 200 in lbs 23 0 Nm 45 lbs 5 0 Nm 100 in Ibs 11 0 Nm 10 Common Specifications Model Series Bore Stroke Displacement 52222100 2297 O5 Apt 2169 700 40 0 656 2 890 73 40 44 2 724 Armature Air Gap 008 012 0 20 0 30 mm Crankshaft End Play 002 030 0 05 0 76 mm Governed Idle Speed all models 1750 RPM Spark Gap 030 0 76 mm Valve Clearance Cold Int 0047 006 0 10 0 15 Governed Speed See Briggs amp Stratton Service Engine Sale
45. AIR CLEAN ER ASSEMBLY INSTALLED The following tools are required when making governor adjustments Fig 24 1 Tachometer Tool 19200 or 19389 2 Tang bender Tool 19480 Start and run engine for approximately 5 minutes to allow engine to warm up CONTROL SWIVEL GOVERNOR SHAFT Fig 23 Adjust Governor Static ues Tiny TACHOMETER Tach DIGITAL TACH amp HOURMETER TANG BENDER Fig 24 Tools Governed Idle Adjustment Perform adjustments exactly in order shown 1 Move equipment control lever to SLOW position 2 Hold throttle lever against idle speed adjustment screw and adjust idle speed to 1200 RPM Fig 25 Release throttle lever CARBURETOR THROTTLE LEVER 3 Bend governed idle tang to obtain 1750 RPM Fig 26 GOVERNED IDLE TANG New C 4 With engine running at governed idle RPM bend throttle restrictor tang so that tang just contacts gover nor lever Fig 27 Adjust Top No Load Speed Refer to Service Engine Sales Microfiche MS 6225 or Service Engine Sales Manual MS 4052 for Top No Load RPM by engine model and type number 1 Move equipment control to FAST position and check RPM a Bend tang to obtain correct RPM Fig 28 Note Governor spring tension adjustment must not C exceed 200 RPM or the governor spring must
46. ATOR WIRE TERMINAL OUTPUT HARNESS Fig 25 Testing Charge Indicator Symptom Charge Indicator Light Stays On Engine Running NOTE Indicator light will remain on if battery voltage is below 12 volts 1 Check indicator light wiring a If wiring is grounded light will remain on when en gine is running b If wiring is OK replace regulator rectifier 14 BATTERIES The battery is of the 12 volt lead acid wet cell type This type is available as a maintenance free or a dry charged battery The maintenance free battery is filled with electrolyte at the time of manufacture The level of electrolyte cannot be checked Fig 26 Fig 26 Typical Wet Charge Battery The dry charged battery is manufactured with fully charged plates Electrolyte must be added at the time that the battery is placed in service Before activating a dry charged battery read and follow the manufacturer s recommended proce dure Recommended battery sizes range from a minimum 30 ampere hour for warm temperature service to 50 ampere hour in coldest service WARNING BATTERIES PRODUCE HYDRO GEN AN EXPLOSIVE GAS Do not store charge or use a battery near an open flame or devices which utilize a pilot light or can create a spark Installation 1 Before installing battery connect all equipment to be operated Fig 27 2 Place battery in holder with a flat base Tighten hold downs evenly until snug DO NOT overtighten 3 Connect po
47. Fig 24 ADJUST VALVES 1 Set No 1 cylinder at 1 4 6 4mm past TDC compres sion stroke a Adjust valves and check Fig 25 Valve Clearance cold IN and EX 005 0 13 mm b Torque nut and adjusting screw to 60 Ibs 7 0 Nm 2 Set No 2 cylinder at 1 4 6 4mm past TDC compres sion stroke a Repeat for No 2 cylinder ALIGNMENT DOWELS Fig 23 Install Cylinder Head Assembly Fig 25 Adjust Valve Clearances 3 Install valve covers with new gaskets Fig 26 a Torque screws to 100 in Ibs 11 0 Nm REASSEMBLE 1 Install No 1 cylinder shield and fuel pump assembly Fig 27 a Torque 1 4 20 screw to 80 in lbs 7 0 Nm b Assemble solenoid harness ground wire to 10 24 screw and torque to 45 165 5 0 Nm 2 Install No 2 cylinder shield Fig 28 a Torque 1 4 20 screw to 80 in lbs 7 0 Nm b Torque 10 24 screw to 45 in lbs 5 0 Nm Install governor control bracket and assemble gover nor lever to governor shaft DO NOT tighten nut at this time a Torque control bracket screws to 80 in lbs 7 0 Nm 1 DO NOT TIGHTEN Fig 29 Install Governor Control Bracket 4 Install intake manifold and carburetor assembly using new gaskets Fig 30 a Assemble governor link to governor lever b Torque screws to 80 in lbs 9 0 Nm c Connect solenoid wire to solenoid d Connect breather tube to air horn Note Route armature ground wir
48. Maintenance sete 6 Remove Combustion Chamber Deposits 6 TROUBLESHOOTING ride aee 6 Check Ignition With Electric 7 Check Ignition Engine Running Rh RERR RR RR 7 Checking For Fouled Spark Plug 7 Check Carburetlon i eos i ens RR eae 8 Check Compression ces 8 Gyllnder Leakdown ERR 8 Cylinder Balance 8 Equipment Affecting Engine Operation 9 FASTENER SPECIFICATIONS asians 10 COMMON SPECIFICATIONS arp annin non enna 11 STANDARD AND REJECT DIMENSIONS 11 9905 1 the Interest of Safety This safety alert symbol indicates that this FT You are not ready to operate this engine if you message involves personal safety Words L have not read and understood the following danger warning and caution indicate degree of safety items Read this entire owner s manual hazar
49. NNECTOR INDICATES DC OUTPUT PIN SIDE Fig 13 Testing DC Output 5 Attach BLACK test lead clip to positive battery termi nal 6 With engine running at 3600 RPM output should be be tween 2 4 amps DC a Output will vary with battery voltage If battery volt age is at its maximum output will be approximately 2 amps 7 If no output or low output is found test diode Diode Test In the Diode Test position the meter will display the forward voltage drop across the diode s If the voltage drop is less than 0 7 volts the meter will Beep once as well as display the voltage drop A continuous tone indicates continuity shorted diode An incomplete circuit open diode will be displayed as OL 1 Insert RED test lead into receptacle in meter Insert BLACK test lead into receptacle in meter Rotate selector to n Diode Test position Attach RED test lead clip to point A and BLACK test lead clip to point B Fig 14 It may be necessary to pierce wire with a pin as shown a If meter Beeps once diode is OK b If meter makes a continuous tone diode is defec tive shorted Replace diode If meter displays OL proceed to step 5 5 Reverse test leads a If meter Beeps once diode is installed back wards Replace diode b If meter still displays OL diode is defective open Replace diode ABO 6 If diode tests OK check stator for bare wires or other obvious defec
50. OD 1 Remove piston rings using ring expander Tool 19340 Fig 1 a Then remove coil expander Fig 1 Remove Rings 9905 1 2 Disassemble piston from connecting rod Fig 2 a Remove piston pin locks b Piston pin is a slip fit in piston and connecting rod Keep pistons and connecting rods together as an assem bly Do not mix CHECKING PISTON AND RINGS If the cylinder is not going to be resized and the piston shows no signs of scoring the piston should be checked 1 Check side clearance of ring grooves using NEW rings Fig 3 a 005 0 12 mm feeler gauge can be inserted the ring groove is worn The piston must be replaced 2 Check ring end gap Fig 4 a Clean carbon from end of rings and insert approxi mately 1 25 mm into cylinder Reject Dimension all 030 0 76 mm Check piston pin bore Fig 5 a Replace if greater than 6745 17 13 mm or 0005 01 mm out of round Fig 2 Remove Piston Pin Locks NEW PISTON RING Fig 4 Checking Ring End Gap Fig 5 Check Piston Pin Bore CHECKING PISTON PIN AND CONNECTING ROD 1 Check piston pin Fig 6 a Replace if less than 6718 17 06 mm or 0005 01 mm out of round 2 Check connecting rod bearings Note If crankpin bearing is scored or worn the connecting rod must be replaced Connecting Rod Reject Size Crankpin Bearing Piston Pin Bearing 1 5015 38 13 mm 6745 17
51. OUBLESHOOTING Most complaints concerning engine operation can be classified as one or a combination of the following Overheating High oil consumption NOTE What appears to be an engine malfunction may be a fault of the powered equipment rather than the engine If equipment is suspect see Equipment Affecting Engine Operation Systematic Check 1 Will not start 2 Hard starting 3 Lack of power 4 Runs rough 5 Vibration 6 7 If the engine will not start and the cause of malfunction is not readily apparent perform a systematic check in the following order 1 Ignition 2 Carburetion 3 Compression This check up performed in a systematic manner can usually be done in a matter of minutes It is the quickest and surest method of determining the cause of failure The basic check up procedure is the same for all engine models while any variation by model will be shown under the subject heading Check Ignition With Electric Starter NOTE Magnetron ignition system requires a minimum of 350 RPM to produce spark With spark plugs installed attach a 19368 ignition tester to each spark plug lead and ground the other end of the tester as shown in Fig 5 Spin the flywheel rapidly with engine starter If spark jumps the tester gaps you may assume the ignition system is functioning satisfactorily A WARNING ON MAGNETRON EQUIPPED EN GINES spark will still occur with a sheared flywheel key A severe shock or kick
52. PISRRERGGS 6 OUIDUE TOS ee E EEUU 6 DG ONLY ALTERNATOR 6 Alternator Output EP RET ERI Ei m RE IRE RE 6 Diode TES ata sam e kx ied ad br d RS KG RPG GER RR ROGA ROLE Ea aaa ee 6 DUAE CIRCUIT ALTERNATOR auc Ere yt RETI cs 7 Alternator Output Test site ERE 7 Diode 7 AC Output Test 8 TRI CIRCUIT ALTERNATOR rh Rar RR 8 Alternator Output Test 5 5525 555 6 5585 6 5 6 86 8 Diode Test sews ssbensn edhe 8 Charging Circuit Red Wire 1 5 coeur ro 8 Lighting Circuit White Wire 2 lt 5 58585 5 5 8 6 6 9 5 amp 9 AMP REGULATED ALTERNATOR s rh rh rr hn Ra a TR 9 Alternator TeSt E rera Rus Redux EE baa 9 Testing Regulator Rectitier ah nra ERR rx ERROR n 10 10 amp 16 AMP REGULATED ALTERNATOR 10 Alternator Output TeSt dee 10 Tes
53. RI RR wes 8 Adjust No Load Speed 2 4 4 24 85 RR IIR x Re urs 8 INSTALL CRANKSHAFT Lubricate mag bearing and lips of oil seal with engine oil and install crankshaft Fig 1 Installing Crankshaft 9905 1 INSTALL PISTON AND CONNECTING ROD Note Install 1 piston and connecting rod first 1 Oil piston rings piston skirt and compress rings with Ring Compressor Tool 19070 Fig 2 a Place piston and ring compressor upside down on bench with projections on compressor facing up b Tighten ring compressor evenly until rings are fully compressed c Then loosen ring compressor very slightly so that compressor can be rotated on piston skirt while holding connecting rod Fig 2 PROJECTIONS TOOL 19070 2 Lubricate cylinder bores and crankpin and rotate crank ARRONTOWARD shaft until it as at bottom of stroke FLYWHEEL SIDE 3 Install 1 piston with_arrow towards flywheel side Fig 3 a Push piston down by hand until connecting rod is seated on crankpin 4 Assemble connecting rod cap to rod with match marks aligned Fig 4 a Torque screws to 100 in lbs 11 0 Nm 5 Rotate crankshaft two revolutions to check for binding Rod should also be free to move sideways on crankpin Repeat for 2 cylinder Note The number 1 on 1 connecting rod and the number 2 on 2 connecting rod must be facing PTO side Important Failure to use a torque wrench can result in loose connecting rod screws causing
54. TABLE OF CONTENTS For Section Reference See Pages through IV GENERAL INFORMATION aes aro Da IGNIHON PTT CARBURETION neke GOVERNOR CONTROLS amp GOVERNOR CYLINDER HEAD amp VALVES nua ated Oca iaa rue a ELECTRIC STARTER ko x AGI raa ALTERNATORS OR Ar Ep OR PR OR aC oe EORR e LUBRICATION ENGINE DISASSEMBLY CYLINDER 8 CRANKCASE COVER INSPECTION amp REPAIR ite eo ama CRANKSHAFT amp CAMSHAFT uk a Eo Re CR CR a RR PISTON RINGS amp CONNECTING ROD INSPECTION amp ASSEMBLY atas etra par ENGINE ASSEMBLY ba tiny donee EROR ra Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 Section 11 Section 12 Section 13 SECTION REFERENCE By Subject SECTION Air tented Ad bk a e Rd 1 Maintenance Air Guides 5 Installation Alternators 2 2 xw Sad esed 7 Identification Test Equipment Testing Output Troubleshooting Anti Afterfire Solenoid
55. TANT DO NOT clamp motor housing in a vise or strike with a steel hammer Starter motors contain two ceramic magnets which can be broken or cracked if the motor housing is hit deformed or dented Testing Starter Motor A fully charged 12 volt battery is required 1 The DC Shunt MUST be installed on the negative battery terminal as shown in Fig 6 2 Insert RED test lead into V gt receptacle in meter and connect to RED post terminal on shunt 3 Insert BLACK test lead into receptacle in meter and connect to BLACK post terminal on shunt Rotate selector to 300mV position Activate the starter motor and note reading on meter and tachometer RPM Note Take reading after meter stabilizes approxi mately 2 3 seconds 6 A starter motor in good condition will be within specifications listed Starter Motor Specifications Minimum RPM 6500 Maximum Amperes 35 as If 12 volt starter motor does not perform satisfactorily see Conditions Affecting Starter Motor Performance RED TEST LEAD V stack test FROM METER LEAD FROM STARTER SWITCH OPTIONAL NOTE RPM OF STARTER MOTOR Fig 6 Testing Starter Motor Conditions Affecting Starter Motor Performance 1 A binding or seizing condition in the starter motor bear ings 2 A shorted open or grounded armature a Shorted armature wire insulation worn and wires touching one another Wil
56. TERY GOOD CONDITION FOR TERMINAL THIS TEST Fig 11 Testing DC Output Diode Test In the Diode Test position the meter will display the forward voltage drop across the diode s If the voltage drop is less than 0 7 volts the meter will Beep once as well as display the voltage drop A continuous tone indicates continuity shorted diode An incomplete circuit open diode will be displayed as OL 1 Insert RED test lead into gt receptacle in meter Insert BLACK test lead into receptacle in meter Rotate selector to 2 n Diode Test position Attach RED test lead clip to point and BLACK test lead clip to point B Fig 12 It may be necessary to pierce wire with a pin as shown a If meter Beeps once diode is OK b If meter makes a continuous tone diode is defec tive shorted Replace diode If meter displays OL proceed to step 5 5 Reverse test leads ABO If meter Beeps once diode is installed back wards Replace diode b If meter still displays OL diode is defective open Replace diode 6 If diode tests OK check stator for bare wires or other obvious defects If grounded leads are not visible re place the stator RED LEAD output LEAD m FROM STATOR BLACK LEAD x Fig 12 Testing Diode NOTE Service replacement diode harnesses are avail able
57. TEST LEAD POSITIVE BATTERY TERMINAL Fig 20 Testing Regulator Rectifier 5 Attach BLACK test lead clip to positive battery termi nal 6 With the engine running at 3600 RPM The output should be 3 5 Amps 5 Amp System 3 9 Amps 9 Amp System 10 Depending upon battery voltage For example if the battery voltage was below 11 volts the output reading would be 5 or 9 amps depending upon the alternator system being tested If battery voltage is at its maximum the amperage will be less 7 If no or low output is found be sure that regulator recti fier is grounded properly and all connections are clean and secure If there is still no or low output replace the regulator rectifier 10 amp 16 AMP REGULATED ALTERNATOR The 10 or 16 amp regulated alternator system provides AC current through two output leads to the regulator recti fier The regulator rectifier converts the AC current to DC and regulates the current to the battery The charging rate will vary with engine RPM and temperature Alternator output 10 or 16 amp is determined by flywheel alternator magnet size Therefore stator and regulator rectifier are the same for the 10 and 16 amp system WHEN CHECKING THE ALTERNATOR COMPONENTS MAKE THE TESTS IN THE FOLLOWING SEQUENCE Alternator Output Test Temporarily disconnect stator wire harness from regula tor rectifier 1 Insert RED test lead into gt receptacle in meter
58. WAY OIL GALLERIES KEYWAY OIL GALLERY LOBES Fig 3 Checking Camshaft Section 12 Piston Rings And Connecting Rod Inspection And Assembly Section Contents Page GENERAL INFORMATION 1 DISASSEMBLE PISTON AND CONNECTING ROD 1 CHECKING PISTON AND 8 ies td 2 CHECKING PISTON PIN AND CONNECTING 3 ASSEMBLE PISTON AND CONNECTING ROD 3 ASSEMBLE PISTON RINGS TO PISTON 4 GENERAL INFORMATION It is recommended that new piston rings be installed whenever the engine is disassembled for major servicing or overhaul providing that cylinder bores are within specification Remove any carbon or ridge at the top of the cylinder bore This will prevent breaking the rings when removing the piston and connecting rod from the engine Remove the connecting rod cap Push the piston and connecting rod out through the top of the cylinder Measure cylinder bores before checking pistons and rings See Section 10 If cylinder bore s require re sizing it will not be necessary to check pistons and rings since a new oversized piston assembly will be used If the cylinder bore is more than 08 mm 003 oversize or 04 mm 0015 out of round it must be resized DISASSEMBLE PISTON AND TOOL 9340 CONNECTING R
59. a Faulty safety interlocks b Discharged or defective battery Faulty electrical connections Faulty starter motor switch open circuit Open circuit in starter motor Brushes sticking etc Faulty solenoid Starter Motor Spins But Does Not Crank Engine Sticking pinion gear due to dirt Damaged pinion or ring gear Starter clutch slipping Battery faulty or damaged Incorrect rotation due to reversed motor polar ity all motors rotate counterclockwise viewed from pinion gear o m Starter Motor Spins But Will Not Stop a Defective starter switch TEST EQUIPMENT The following is a list of equipment recommended to test and repair starter motors Digital Multimeter The Digital Multimeter is available from your Briggs amp Stratton source of supply Order as Tool 19357 or 19390 The meter may be used to read volts ohms amperes and test diodes rectifiers Fig 2 The Digital Multimeter will withstand DC input of 10 20 Amps for up to 30 seconds When checking current draw of 12 volt starter motors the DC Shunt Tool 19359 is required NOTE The Digital Multimeter is equipped with two fuses to prevent damage to the meter in the event that the input limits are exceeded If the meter displays a reading of 0 00 when testing DC output check fuses in meter Refer to FLUKE Operators Manual for procedure for checking fuses Replacement fuse is available from your Briggs amp
60. amber deposits Change oil after first 8 hours then after every 50 hours or every season Exhaust system supplied by equipment manufacturer Note 1 Change oil every 25 hours when operating under heavy load or in high temperatures Note 2 Clean more often under dusty conditions or when airborne debris is present Replace air cleaner parts if very dirty FUEL AND OIL RECOMMENDATIONS Gasoline We recommend the use of clean fresh lead free gasoline and the use of BRIGGS amp STRATTON GASOLINE ADDITIVE PART 5041 Leaded gasoline may be used if it is commercially available and if lead free is not available A minimum of 85 octane is recommended The use of lead free gasoline results in fewer combustion deposits and longer valve life NOTE Some fuels called oxygenated or reformulated gasolines are gasolines blended with alcohols or ethers Excessive amounts of these blends can damage the fuel System or cause performance problems Do not use gasoline which contains Methanol If any undesirable operating symptoms occur use gasoline with a lower percentage of alcohol or ether We also recommend gasoline be purchased in small quantities not more than a 30 day supply FRESH gasoline minimizes gum deposits and also will ensure fuel volatility tailored for the season in which the engine will be operated Lubrication Oil has four purposes It cools cleans seals and lubri cates During normal operation small particl
61. assembly Fig 15 a Torque head bolts in sequence shown to 220 in lbs 25 0 Nm 3 Install push rods Make sure push rods are inserted in recess in tappets Note Intake push rods are aluminum Fig 15 Install Cylinder Head 4 Compress valve springs and insert push rods into re cess in rocker arm adjustment screws Fig 16 ADJUST VALVES 1 Set 1 cylinder at 1 4 6 4mm past TDC compres sion stroke a Adjust valves and check Fig 17 Valve Clearance cold IN and EX 005 0 13 mm b Torque adjusting screws and jam nuts to 60 Ibs 7 0 Nm 2 Set No 2 oylinder at TDC compression stroke a Repeat for No 2 cylinder Fig 17 Adjust Valves 3 Install valve covers with new gaskets Fig 18 a Torque screws to 100 in 105 11 0 Nm INSTALL CYLINDER SHIELDS 1 Install No 1 cylinder shield and fuel pump assembly Fig 19 a Torque 1 4 20 screw to 80 in lbs 7 0 Nm b Assemble solenoid harness ground wire to 10 24 screw and torque to 45 165 5 0 Nm 2 Install No 2 cylinder shield a Torque 1 4 20 screw to 80 in lbs 7 0 Nm b Torque 10 24 screw to 45 in lbs 5 0 Nm INSTALL GOVERNOR CONTROL BRACKET TORQUE 80IN 1 Install governor control bracket and assemble governor posi lever to governor shaft Fig 20 DO NOT tighten nut at this time a Torque control bracket screws to 80 in lbs 7 0 Nm DO NOT TIGHTEN INSTALL INTAKE MANIFOLD AND CARBURE
62. ay vary The gover nor spring tends to pull the throttle open The force of the counterweights which are operated by centrifugal force tends to close the throttle The engine speed at which these two forces balance is called the governed speed The governed speed can be varied by changing the governor spring or governor spring tension Governor spring tension adjustment must not exceed 200 RPM or the governor spring must be replaced If a governor spring must be replaced consult the appropriate Illustrated Parts List Select the proper governor springs by engine type number WARNING AFTER NEW GOVERNOR SPRING IS INSTALLED CHECK ENGINE TOP GOVERNED SPEED WITH AN ACCURATE TACHOMETER REMOTE GOVERNOR CONTROLS Briggs amp Stratton Intek OHV V Twin engines are equipped for remote governor controls Speed Regulation Remote governor controls Supplied by equipment manufacturer control engine speed by increasing or decreasing tension on governor spring s to obtain desired engine speed at all positions Fig 1 Fig 1 Remote Governor Control 9905 1 Governed Idle Intek OHV Twin cylinder engines have a governed idle system A throttle restrictor permits the engine to maintain engine speed when a light load is applied with the equipment control in the SLOW position Fig 2 ote Control Wire Travel In order to make proper remote control adjustments the travel of the remote control wire must not be less than 35 mm 1 3
63. back hazard may exist NOTE Engines equipped with Magnetron ignition sys tem will still display spark at tester with a partially or fully sheared flywheel key A partially sheared flywheel key will affect ignition timing and engine performance SPARK PLUG LEAD SPARK PLUG Fig 5 Checking for Spark If spark does not occur look for Improperly operating interlock system Shorted equipment stop switch wire Two closed diodes in ground wire harness Incorrect armature air gap Armature failure Check Ignition Engine Running If engine runs but misses during operation a quick check to determine if ignition is or is not at fault can be made by installing Tool 19368 tester between the spark plug lead and each spark plug Fig 6 A spark miss will be readily apparent when the engine is running If spark is good but engine misses check for a fouled spark plug 19368 TESTER SPARK PLUG Fig 6 Running Check Check Ignition Fouled Plug or Other Causes To check for a fouled spark plug or a non functioning cylinder attach Tool 19368 tester between the spark plug lead and each spark plug Start and run engine at top no load speed Now ground one spark plug Fig 7 The engine should continue to run on the other cylinder Repeat this test with the other cylinder If the engine will not continue to run when making this test the cylinder that is NOT grounded is not functioning and or the spark plug is fo
64. breakage or tight connecting rod screws causing scoring INSTALL CAM SHAFT Lubricate tappets cam shaft journals and lobes with engine oil Assemble timing gear to crankshaft 1 Install tappets 2 Align timing marks on cam shaft and crankshaft gear and install cam shaft Fig 5 Lubricate thrust washer governor gear and governor cup and assemble to shaft TIMING Fig 5 Installing Camshaft INSTALL SUMP Lubricate PTO and cam shaft bearing 1 Install sump with new gasket a Torque screws in sequence shown to 200 in Ibs 23 0 Nm Fig 6 2 Check crankshaft end play Specification 002 030 0 020 0 30 mm 3 Lubricate oil pump components with engine oil and as semble to sump Fig 7 Make sure drive shaft is en gaged in camshaft Install drive shaft Install inner rotor Install outer rotor Install oil pump cover with new O ring Torque screws to 50 in lbs 6 0 Nm GENERAL ASSEMBLY 1 Install armatures and ground wire assembly Note Push armatures away from crankshaft as far as they will go and temporarily tighten screws 2 Install air guide a Torque screws to 45 in lbs 5 0 Nm 3 Install alternator a Torque screws to 20 165 2 0 Nm 4 Assemble oil fill tube to cylinder and crankcase cover Fig 9 a Route alternator wires between oil fill tube mount ing boss on cylinder and oil fill tube bracket b Route wiring harness between oil fill tube
65. build up on stones As cutting tension decreases stop hone and tighten adjusting knob following hone manufacturer s recommendations Check cylinder bore frequently Cylinder Finish Cross Hatch The finishing stones are used after the cylinder bore has been resized to within 0015 04 mm of the desired size or when reconditioning a cylinder bore The finishing stones will produce the correct cross hatch necessary for proper lubrication The correct cross hatch angle is approximately 45 degrees Fig 4 It is recommended that the cylinder bores be reconditioned to restore the cross hatch when new piston rings are to be installed in a cylinder that is within specification Be careful not to hone oversize or it will be necessary to resize the cylinder NOTE To produce the proper cross hatch finish use a drill speed of approximately 200 RPM and 40 60 strokes per Fig 4 Cylinder Cross Hatch minute Lubricate hone liberally to prevent build up on finishing stones APPROXIMATELY 45 Cleanin IT IS MOST IMPORTANT THAT THE ENTIRE CYLINDER AND CRANKCASE BE THOROUGHLY CLEANED AFTER HONING First wash the cylinder and crankcase carefully in a solvent such as kerosene or commercial solvent Then thoroughly wash cylinder and crankcase using a stiff brush with soap and hot water Rinse thoroughly with hot running water Repeat washing and rinsing until all traces of honing grit are gone Honing grit is highly abrasive and will cause rapid wea
66. c clutch not working Inline fuse blown if equipped Tri Circuit Alternator e Loose or corroded wires Open shorted or grounded wires between output connector and electric clutch e Defective diode open or shorted red output lead side e NOTE Battery will also not charge e Defective electric clutch switch e Open shorted or grounded clutch circuit e Low magnetic flux or damaged alternator magnets TEST EQUIPMENT Testing Alternator Output The following equipment is recommended to test and When checking alternators make the tests in the following repair alternators sequence Digital Multimeter 1 Test alternator output The Digital Multimeter is available from your Briggs amp 2 Test diode s or regulator rectifier if equipped Stratton source of supply Order as Tool 19464 The meter may be used to read volts ohms or amperes and test diodes when leads are inserted in the appropriate receptacle Fig 8 The Digital Multimeter will withstand DC input of 10 20 amps for up to 30 seconds When checking DC output on 16 and 20 amp regulated system use the DC shunt Tool 19468 to avoid blowing fuse in meter Fig 9 NOTE The Digital Multimeter is equipped with two fuses to prevent damage to the meter in the event that the input limits are exceeded If the meter displays a reading of 0 00 when testing DC output A check fuses in meter Refer to FLUKE Operators Manual for procedure for checking fuses Replacement
67. d Death personal injury and or property and the operating instructions of the damage may occur unless instructions are equipment this engine powers followed carefully The Briggs amp Stratton engine is made of the finest material in a state of the art manufacturing facility Please understand that Briggs amp Stratton sells engines to original equipment manufacturers It also sells to others in the distribution chain who may sell to the ultimate consumer an equipment manufacturer another distributor or a dealer As a result Briggs amp Stratton does not necessarily know the ap plication on which the engine will be placed For that reason carefully read and understand the operating instructions of the equipment before you repair or operate it You should also understand that there are equipment applications for which Briggs amp Stratton does not approve the use of its engines Briggs amp Stratton engines are not to be used on vehicles with less than 4 wheels They include motor bikes aircraft products and All Terrain Vehicles Moreover Briggs amp Stratton does not approve of its engines being used in competitive events FOR THAT REASON BRIGGS amp STRATTON ENGINES ARE NOT AUTHORIZED FOR ANY OF THESE APPLICATIONS Failure to follow this warning could result in death serious injury including paralysis or property damage DO run engine in an enclosed area K Exhaust gases contain carbon monoxide odo
68. der head for cracks or damage b Use a surface plate or straight edge and check cylinder head mounting surface for distortion If mounting surfaces are distorted more than 004 0 1 mm the cylinder head must be replaced It is not recommended that cylinder head mounting surfaces be resurfaced 2 Check valve guide bushings for wear using reject gauge Tool 19381 Fig 13 If valve guides are worn the cylinder head must be replaced 3 Valve seats may be reconditioned using valve seat cut ter tool 19547 If valve seat is wider than dimension shown in Fig 14 narrowing cutter should be used to ensure that contact area of valve seat is centered on face of valve a Use a 60 cutter to narrow seat from bottom and a 15 cutter to narrow seat from top Fig 18 Note If valve seat is loose or cracked replace cylinder head 4 Valve faces may be resurfaced to 45 See Fig 15 for dimensions for valves Lap valves and seats with valve lapping tool 19258 and valve lapping compound tool 94150 0 8 MM TO 1 2 MM 1 16 3 64 45 74 VALVE SEAT DIMENSIONS 60 CUTTER 15 CUTTER Fig 14 Valve Seat Dimensions 1 32 1 2 MM TO 1 6 MM 3 64 1 16 SEATING AREA CENTERED ON VALVE FACE Fig 15 Valve Dimensions 5 Measure valve stem diameter at specified distance from end of valve as shown in Fig 16 Replace if less than 233 5 92 mm 1 600 40 MM F
69. e between breather tube and air horn 5 Assemble blower housing to engine a Torque screws to 80 in 165 9 0 Nm 6 Install rotating screen a Torque screws to 20 in lbs 2 0 Nm Assemble air cleaner and install spark plugs ADJUST GOVERNOR WARNING BEFORE STARTING or running en gine static adjustment of the governor must be completed Failure to make the static adjustments first could result in engine overspeeding which may result in engine damage property damage or personal injury Static Governor Adjustment 1 Rotate governor control swivel counter clockwise as far as it will go wide open throttle and hold in this position 2 Rotate governor shaft clockwise as far it will go a Torque governor nut to 130 in lbs 15 0 Nm Install throttle and choke control cables and check for proper operation Install exhaust manifold b Torque screws to 140 in lbs 16 0 Nm Note Exhaust manifold and exhaust system sup plied by equipment manufacturer 10 A IA MSN CONTROL SWIVEL ue IL S L LX b H GOVERNOR SHAFT Fig 32 Adjust Governor Section 6 Electric Starters Section Contents Page GENERAL INFORMATION ER Lr IEEE E EE RER LIE DERE REIR Ea 1 TROUBLESHOOTING 2 TEST EQUIPMENT
70. e is how it works FIRST DIGIT SECOND DIGIT THIRD DIGIT FOURTH DIGIT AFTER DISPLACEMENT AFTER DISPLACEMENT AFTER DISPLACEMENT AFTER DISPLACEMENT PTO BEARING CRANKSHAFT REDUCTION GEAR CUBIC INCH BASIC CARBURETOR AUXILIARY DRIVE DISPLACEMENT DESIGN SERIES GOVERNOR LUBRICATION TYPE OF STARTER 6 0 0 Horizontal Shaft 0 Plain Bearing DU 0 Without Starter 8 1 Diaphragm Carburetor Non Flange Mount 1 Rope Starter 2 LIE Bearing 2 Rewind Starter Horizontal Sha ange Mounting _ 1 4 Vacu Jet Carburetor 2 Sleeve Bearing 3 12 5 Pneumatic Governor Flange Mounting 13 6 4 Electric Starter Generator 16 7 2 Horizontal Shaft Splash Lube 12 Volt Belt Drive Pulsa Jet Carburetor 3 Ball Bearing 17 8 Pneumatic or Mechanical Flange Mountin 5 Electric Starter Only Governor Splash Lube 9 12 Volt Gear Drive 20 3 Horizontal Shaft 4 Ball Bearing 6 Alternator Only Flo Jet Carburetor FI Mounti 7 Electric Starter 22 ange Mounting 23 Pneumatic Governor Pressure Lubrication on 12 Volt Gear Drive 24 4 Horizontal Shaft Horizontal Shaft With Alternator 25 Flo Jet Carburetor 5 Plain Bearing 8 Vertical Pull Starter or 26 Mechanical Governor Gear Reduction Side Pull Starter 28 5 Vertical Shaft 6 to 1 CW Rotation 9 Mechanical Starter 29 Vacu Jet Carburetor Flange Mounting 30 Pneumatic or Mechanical 6 Plain Bearing 31 Governor Gear Reduction E 6
71. ed on the negative terminal of the battery Fig 23 All connections must be clean and tight for correct amperage readings Connect stator wire harness to regulator rectifier 1 Install shunt on negative battery terminal 2 Insert RED test lead into V receptacle in meter and insert into RED terminal on shunt Fig 23 3 Insert BLACK test lead into receptacle in meter and insert into BLACK terminal on shunt 4 Rotate selector to 300 position BLACK TERMINAL Fig 23 Testing Regulator Rectifier 16 Amp System With DC Shunt 5 With the engine running at 3600 RPM the output should be 3 16 Amps 16 Amp System Depending upon battery voltage For example if the battery voltage was below 11 volts the output reading would be 16 amps If battery voltage is at its maximum the amperage will be less 6 If no or low output is found be sure that regulator rectifi er is grounded properly and all connections are clean and secure If there is still no or low output replace the regulator rectifier 11 Regulator Rectifier With Charge Indicator Regulator rectifier Part 493219 Fig 24 is used by some equipment manufacturers that have a charging indicator light instead of an ammeter In addition to the red DC output wire the regulator rectifier is equipped with a blue wire which is used to activate a charging indicator light when ba
72. es of metal from the cylinder walls pistons bearings and combustion deposits will gradually contaminate the oil Dust particles from the air also contaminate the oil forming an abrasive mixture which can cause wear to all of the internal moving parts of the engine if the oil is not changed regularly Fresh oil also assists in cooling Old oil gradually becomes thick and loses its cooling ability as well as its lubricating qualities Briggs amp Stratton Intek OHV V Twin engines are lubri cated with a gear driven oil pump Oil Recommendations We recommend the use of a high quality detergent oil classified For Service SE SF or SG such as Briggs amp Stratton 30 Weight Oil Part 100005 or 100028 Deter gent oils keep the engine cleaner and retard the formation of gum and varnish deposits No special additives should be used with recommended oils Change Oil The crankcase capacity of Intek OHV V Twin cylinder engines is approximately 4 Pints 1 9 liters with filter 3 3 4 Pints 1 8 liters without filter RECOMMENDED SAE VISCOSITY GRADES 4 Cycle Intek V Twin OHV Gasoline Engines 20 30 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE Air cooled engines run hotter than automotive engines Use of multi viscosity oils 10W 30 etc above 4 C 40 F will result in high oil consumption and possible engine damage Check oil level more frequently if using these types of oils SAE 30 oil if used below 49 4
73. fuse is available from your Briggs amp Stratton source of supply Order Part No 19449 or Fig 8 Digital Multimeter 19571 Fig 9 DC Shunt Tool 19468 NOTE Before testing the alternator s output volts amps first use an accurate tachometer and temporarily adjust the engine speed to 3600 RPM WARNING UPON COMPLETION of the alterna tor output test always readjust the engine rpm to its correct top no load governed speed Otherwise engine may exceed safe operating speed which could cause personal injury Correct speed is found in the Service Engine Sales Manual Micro fiche MS 6225 or the Service Sales Manual MS 4052 AC ONLY ALTERNATOR The AC alternator provides current for headlights only Current for the lights is available as long as the engine is running The output depends upon engine speed 12 volt lights with a total rating of 60 to 100 watts may be used With lights rated at 70 watts the voltage rises from 8 volts at 2400 RPM to 12 volts at 3600 RPM so the brightness of the light changes with the engine speed AC Output Test 1 Insert RED test lead into V Q gt F receptacle in meter Insert BLACK test lead into receptacle in meter 2 3 Rotate selector toV AC volts position 4 Attach RED test lead clip to AC output terminal Fig 10 WHITE CONNECTOR RED TEST LEAD TO OUTPUT PIN TERMINAL
74. g harness diagram page 5 Testing Ground Wires The Digital Multimeter Tool 19464 is recommended to test the ground wires Fig 10 The digital multimeter is available from your Briggs amp Stratton source of supply The following test will be made with the meter in the jj Diode Test position In the Diode Test position the meter will display the forward voltage drop across the diode s If the voltage drop is less than 0 7 volts the meter will Beep once as well as display the voltage drop A continuous tone indicates continuity shorted diode An incomplete circuit open diode will be displayed as OL 1 Insert RED test lead into V receptacle in meter Insert BLACK test lead into receptacle in meter Rotate selector to gt Diode Test position Insert RED test lead clip into connector A black wire Fig 11 Leave attached for remainder of test Touch BLACK test lead probe to terminal B a If meter Beeps once diode is OK b If meter makes a continuous tone diode is defec tive shorted Replace ground harness c If meter displays OL diode is defective open Replace ground harness 6 Now repeat test for terminal C Results must be the same O See Diode Failure Diagnosis page 5 GROUND W EYELET N SOLENOID CONNECTOR N DIODES Ce TO ARMATURES POLARIZED CONNECTOR a Fig 9 Engine Wiring Harness
75. he engine These particles are highly abrasive and will cause the piston rings and cylinder bore to wear quickly As the rings and cylinder bore become worn these abrasive particles enter the crankcase and contaminate the oil forming an abrasive mixture which will cause wear on all of the internal moving parts The air cleaner on every engine brought in for a check up or repair should be examined and serviced If the air cleaner shows signs of neglect show it to the customer before replacement Instruct the customer on proper care to assure long engine life NOTE Replace air cleaner gaskets and mounting gaskets that are worn or damaged to prevent dirt and dust entering engine due to improper sealing Service Dual Element Air Cleaners Remove and service foam pre cleaner every 25 hours or every season whichever occurs first Service cartridge every 100 hours or every season whichever occurs first To Service Pre Cleaner Remove air cleaner cover Fig 4 Remove cartridge and foam pre cleaner Wash pre cleaner in liquid detergent and water Squeeze it dry in a clean cloth Saturate it in engine oil Wrap it in clean absorbent cloth and squeeze to remove excess oil Reinstall pre cleaner with mesh screen up Reinstall air cleaner cartridge Reinstall air cleaner cover NOTE Be sure tabs on blower housing are engaged in slots on air cleaner cover To Service Cartridge Remove air cleaner c
76. ig 16 Measure Valve Stem Diameter Cylinder Head Cylinder Head Gasket Valve Spring Retainer Locks Valve Spring Retainer Valve Spring Valve Valve Stem Seal Rocker Arm Rocker Arm Support Rocker Arm Support Screw Push Rod ASSEMBLE CYLINDER HEAD 1 2 3 4 5 6 he 8 9 Fig 17 Cylinder Head Components 1 Use valve guide driver Tool 19416 and install new VALVE STEM SEAL take valve stem seal 4 CUTAWAY VIEW a Oil inner surface and lip of valve stem seal b Press seal on to valve guide bushing until it bot toms Fig 18 Fig 18 Install Valve Stem Seals 2 Install valves Note Lightly coat valve stems with Valve Guide Lubricant 93963 before installing valves 3 Install valve springs with valve spring compressor Tool 19347 Fig 20 4 Assemble rocker arms and supports to cylinder head TORQUE TO 100 IN LAS Fig 21 Apply Loctite 242 or similar sealant to threads 1 2 NM a Torque screws to 100 in Ibs 11 0 Nm Fig 21 Install Rocker Arms INSTALL CYLINDER HEAD 1 Place cylinder head gasket over alignment dowels on cylinder block Fig 22 2 Install cylinder head assembly Fig 23 a Torque head bolts in sequence shown to 220 in lbs 25 0 Nm 3 Install push rods Make sure push rods are inserted in recess in tappets Note Intake push rods are aluminum 4 Compress valve springs and insert push rods into re cess in rocker arm adjustment screws
77. ine damage Remove rotating screen and blower housing Fig 2 Cover intake elbow to prevent dirt entering carburetor Clean all debris and dirt from rotating screen cooling fins flywheel cylinder and cylinder shields This should be a regular maintenance operation per formed yearly or every 100 hours whichever comes first ROTATING SCREEN BLOWER HOUSING Replace Spark Plugs Replace spark plugs every 100 hours of operation or every season whichever occurs first Replace spark plugs if electrodes show signs of wear or the porcelain is cracked Set spark plug gap at 76 mm 030 for all models Fig 3 Torque spark plugs to 20 Nm 180 in Ibs Spark plugs recommended by Briggs amp Stratton for OHV Twin engines are B amp S Spark Plug Type Part No Champion Resistor Plug 491055 RC12YC Resistor Plug 496018 RC14YC Fig 3 Checking Plug Gap NOTE Do not blast clean spark plugs Spark plugs should be cleaned by scraping or hand wire brushing and washing in a commercial solvent Air Cleaner Maintenance WARNING NEVER operate engine with air clean er assembly or air cleaner cartridge removed fire may result A properly serviced air cleaner protects internal parts of the engine from dirt and dust particles in the air If air cleaner instructions are not carefully followed dirt and dust will be drawn into t
78. l be indicated by low or no RPM b Open armature wire broken will be indicated by low or no RPM and excessive current draw c Grounded armature wire insulation worn and wire touching armature lamination or shaft Will be in dicated by excessive current draw or no RPM 3 A defective starter motor switch 4 Broken damaged or weak magnets 5 Starter drive dirty or binding STARTER DRIVE Checking Starter Motor Drive When the starter motor is activated the pinion gear should engage the flywheel ring gear and crank the engine If the starter motor drive does not react properly inspect the helix and pinion gear for freedom of operation Fig 7 The pinion gear should be inspected for damaged teeth Pinion gear must move freely on helix The parts may be washed in a solvent such as Stanisol or Varsol Disassemble Starter Motor Drive WARNING TO PREVENT EYE INJURY always wear eye protection when removing C ring 1 Place counterbore side of Tool 19436 over retainer and align drive pins with open end of C Ring Fig 8 Important If retainer has a notch as shown DO NOT align drive pins with notch If necessary rotate notch away from open end of C Ring 2 Place palm of hand over tool and push down evenly on tool to compress spring washer 3 While applying pressure turn knurled knob clockwise until C Ring pops off Discard C Ring 4 Remove retainer return spring spring washer pinion gear and starter clutch
79. laced in service Before activating a dry charge battery read and follow the manufacturer s recommended proce dure WARNING WEAR EYE PROTECTION when servicing the battery Avoid skin contact If contact does occur flush with cold water and consult a physician A CAUTION BEFORE SERVICING BATTERY dis connect negative battery cable first then positive cable second Arcing can occur when improperly disconnecting cables which could cause a fire A WARNING BATTERIES PRODUCE HYDRO GEN AN EXPLOSIVE GAS Do not store or charge a battery near an open flame or devices which utilize a pilot light or can create a spark igniting a fire or explosion Installation 1 Before installing battery connect all equipment to be operated 2 Place battery in holder with flat base Tighten holder down evenly until snug DO NOT overtighten 3 Connect positive terminal to positive post FIRST to pre vent sparks from accidental grounding Tighten con nectors securely 4 Install protective cover over positive battery terminal ends 5 Then connect negative terminal to negative battery terminal Tighten connectors securely ANTI AFTERFIRE STOP SOLENOID SWITCH KEY SWITCH SOLENOID TAB TERMINAL STARTER PA TERMINAL SOLENOID LIGHT SWITCH TERMINAL STARTER 12 VOLT MOTOR BATTERY Fig 19 Typical 12 V Wiring Diagram Checking Battery 1 Physical check clean if necessary a Corrosion b Dirt c Ter
80. lts NOTE Connect test leads before starting engine Be sure connections are secure If a test lead vibrates loose while engine is running the regulator rectifier may be damaged Testing Regulator Rectifier 10 Amp System Connect stator wire harness to regulator rectifier 1 Insert RED test lead into 10 A receptacle in meter Insert BLACK test lead into receptacle in meter 2 3 Rotate selector to A DC amp position 4 Attach RED test lead clip to red DC output terminal on regulator rectifier Fig 22 BLACK TEST LEAD TO POSITIVE BATTERY TERMINAL RED DC OUTPUT CONNECTOR RED TEST LEAD Fig 22 Testing Regulator Rectifier 5 Attach BLACK test lead clip to positive battery termi nal 6 With the engine running at 3600 RPM The output should be 3 10 Amps 10 Amp System Depending upon battery voltage For example if the battery voltage was below 11 volts the output reading would be 10 amps If battery voltage is at its maximum the amperage will be less 7 If or low output is found be sure that regulator rectifi er is grounded properly and all connections are clean and secure If there is still no or low output replace the regulator rectifier Testing Regulator Rectifier 16 Amp System To avoid blowing fuse in meter when testing DC output of 16 amp system the DC Shunt Tool 19468 is required The DC Shunt must be install
81. lywheel nut Turn nut down flush with top of threads 19203 5 Install flywheel puller Tool 19203 id dc 6 Tighten puller screws equally until flywheel loosens Fig 5 A DO NOT strike flywheel with a hard object or a metal tool as this may cause flywheel to shatter in operation Always use approved flywheel removal tools Inspect Flywheel Key Keyways Flywheel and Crankshaft Check flywheel key for damage Check flywheel for cracks broken fins or keyway damage Also check crankshaft keyways and taper for damage Fig 6 Replace crank shaft if damaged Install Flywheel CLEAN flywheel and crankshaft taper removing all oil dirt or grease 1 Assemble flywheel to crankshaft and align keyways p 2 Insert flywheel key into crankshaft TN 3 Assemble fan and retainer to flywheel Fig 7 7 Torque screws to 140 in lbs 16 0 Nm En 4 Install washer and flywheel nut 5 Assemble flywheel holder Tool 19489 to retainer Fig 8 or use fllywheel holder Tool 19433 a Torque flywheel nut to 150 ft Ibs 203 0 Nm Fig 8 Torquing Flywheel Nut ENGINE WIRING HARNESS The engine wiring harness consists of a ground wire with a diode for each armature and a separate wire for the carburetor solenoid Fig 9 The engine wiring harness is connected to the wiring harness provided by the equipment manufacturer A raised rib on the polarized connector indicates the ground side See engine wirin
82. m for shorted wires loose or cor roded connections or defective modules or switches Engine Won t Stop Check equipment ignition stop switch 2 Check for loose or disconnected equipment stop switch wire 3 Check ground wire harness a See Section 3 for test procedure Vibration 1 Cutter blade bent or out of balance remove and balance 2 Mounting bolts loose tighten Power Loss 1 Bind or drag in unit if possible disengage engine and operate unit manually to feel for any binding action 2 Grass cuttings build up under deck 3 No lubrication in transmission or gear box 4 Excessive drive belt tension may cause seizure Noise 1 Cutter blade coupling or pulley an oversize or worn coupling can result in knocking usually under accel eration Check for fit or tightness 2 No lubricant in transmission or gear box Fastener Specifications Description Wrench Socket Size Torque Alternator stator 20 in 108 Armature 25 in 105 Back Plate to cylinder 100 in lbs 2 0 Nm 3 0 Nm 11 0 Nm 9 0 Nm 6 0 Nm 7 0 Nm 11 0 Nm 9 0 Nm 5 0 Nm Blower Housing 80 in 165 Breather 55 in Ibs Carburetor to manifold 65 in Ibs Connecting Rod 100 in 105 Cylinder Shield 80 in lbs 45 in lbs Exhaust Manifold 140 in lbs 16 0 Nm Fan Retainer 140 in lbs 16 0 Nm Fuel Pump to bracket 80 in lbs 9 0 Nm Fuel Pump Bracket to cyl shield
83. minal and clamps secure good condition 2 Bring battery to full charge DO NOT EXCEED CHARGE RATE of 1 10 AMPERE for every ampere of battery rating CONSULT BATTERY MANUFACTURER for CHARGE RECOMMENDATIONS Overcharging may cause battery failure a Use a taper charge automatically reduces charge rate b Fill battery cells with distilled water or tap water after charging for batteries that have been in service NOTE If battery gets Hot to the touch or is spitting acid gassing excessively unplug charger periodically 3 With battery fully charged check specific gravity readings of each cell with a Battery Hydrometer and record read ings Fig 20 All readings should be above 1 250 com pensating for temperature If specific gravity readings varied 50 or if all cells read less than 1 225 replace bat tery CHECK ALL CELLS AFTER COMPENSATED HYDROMETER Hog gg og Eon d og 22626265 d5e3e3e e REPLACE IF READINGS ARE BELOW 1 225 OR IF CELLS VARY BY MORE THAN 50 Fig 20 Checking 12 Battery Cells Lead Acid Wet Cell With Fill Caps Testing Battery Use Digital Multimeter Tool 19464 Set meter to read DC Volts Attach RED meter test clip to positive battery terminal Attach BLACK meter test lead to negative battery terminal With ignition switch OFF press starter button If ignition switch and starter switch are the same switch disconnect wires from spark plugs a
84. n as shown Insert BLACK test lead probe into harness connector a If meter Beeps once diode is OK b If meter makes a continuous tone diode is defec tive shorted Replace harness c If meter displays OL proceed to step 6 Reverse test leads a If meter Beeps once diode is installed back wards Replace harness b If meter still displays OL diode is defective open Replace harness Fig 18 Diode Testing Lighting Circuit NOTE Service replacement diode harnesses are avail able 5 amp 9 AMP REGULATED ALTERNATOR The 5 amp 9 amp regulated alternator systems provide AC current through a single lead to the regulator rectifier The regulator rectifier converts the AC current to DC and regulates current to the battery The charging rate will vary with engine RPM and temperature Alternator output 5 or 9 amp is determined by the flywheel alternator magnet size The stator and regulator rectifier are the same for the 5 and 9 amp system The 5 amp 9 amp regulated system and the Tri Circuit system use the same stator WHEN CHECKING ALTERNATOR COMPONENTS MAKE TESTS IN THE FOLLOWING SEQUENCE Alternator Output Test Temporarily disconnect stator wire harness from regula tor rectifier 1 Insert RED test lead into V gt receptacle in meter Insert BLACK test lead into receptacle in meter 2 3 Rotate selector t
85. nd ground ignition using two Ignition Testers Tool 19368 Turn switch to START METER SHOULD DISPLAY 9 VOLTS OR MORE WHILE CRANKING ENGINE If less than 9 volts replace battery DO NOT CRANK STARTER for more than 15 SECONDS without allowing starter to COOL at least 2 MINUTES The starter motor could be damaged Battery Recommendations These battery size recommendations are based on minimum temperature expected and correct weight of oil being used See Section 1 30 Amp Hr 20 F 6 C or higher 40 Amp Hr 5 F 20 C or higher 50 Amp Hr 15 F 26 C or higher Battery Cable Recommendations These cable sizes are based on total length of cable from battery positive post to starter switch or solenoid and to starter plus ground return to battery negative post 6 AWG 4 ft 1 21 m or less 5 AWG 5 ft 1 52 m or less 4 AWG 6 ft 1 82 m or less Section 7 ALTERNATORS Section Contents Page ALTERNATOR IDENTIFICATION 22 seen nee ee 2 FLYWHEEL IDENTIFICATION ee eee 4 TROUBLESHOOTING REDE RARE EE 5 TEST EQUIPMENT Digital Multimeter And DC Shunt 5 ALTERNATOR OUTPUT TESTING 5 AG ONLY ALTERNATOR PTERTERESEREERRRIESSRRSsRr UERERReP
86. nt Install one throttle plate at a time Check throttle shaft for freedom of operation before installing other throttle plate Note Use LOCTITE 222 on screw threads 2 Install cover plate with new gasket Fig 14 Install Cover Plate 3 Install nozzle body with new gasket NOZZLE a Tighten screw securely 4 Assemble new seal to choke shaft and insert into carbu retor body a Install choke plate Note Use LOCTITE 222 on screw threads 5 Install emulsion tube body with new gasket a Tighten screw securely EMULSION 7 TUBE BODY 6 Assemble inlet needle to float and install float a Assemble bowl gasket to body INLET NEEDLE Fig 18 Install Float 7 Install fixed main jet according to engine model Main Jet Identification MAIN JET Model 405770 No 132 HOUSING a Model 445770 No 140 8 Assemble fuel solenoid to float bowl and main jet hous ing 9 Position main jet housing so that main jet is opposite float hinges a Use 1 2 thin profile wrench and carburetor socket Tool 19458 14 mm or 19459 16 mm Note Use care when tightening solenoid to prevent damage to fixed main jet and housing Quo MAIN JET 405770 132 445770 140 10 Assemble governor link to throttle lever on carburetor from inside out 11 Assemble choke link to choke lever on carburetor from outside in INSTALL CHOKE LINK FROM OUTSIDE INSTALL GOV IN ERNOR LINK FROM INSIDE Fig 20 A
87. o V AC volts position 4 Attach RED test lead clip to output terminal Fig 19 RED TEST LEAD OUTPUT PIN GREEN CONNECTOR BLACK TEST LEAD TO A GOOD GROUND SURFACE Fig 19 Testing AC Output 5 Attach BLACK test lead clip to engine ground 6 With the engine running at 3600 RPM AC output should be no less than 28 Volts AC 5 Amp System 40 Volts AC 9 Amp System 7 If no or low output is found replace the stator Test Regulator Rectifier NOTE Regulator rectifier will not function unless it is grounded to engine Make sure the regulator rectifier is securely mounted to engine When testing regulator rectifier for amperage output a 12 volt battery with a minimum charge of 5 volts is required There will be no charging output if battery voltage is below 5 volts NOTE Connect test leads before starting engine Be sure connections are secure If a test lead vibrates loose while engine is running the regulator rectifier may be damaged Connect stator wire harness to regulator rectifier 1 Insert RED test lead into 10 A receptacle in meter Insert BLACK test lead into receptacle in meter 2 3 Rotate selector to A DC amps position 4 Attach RED test lead clip to red DC output terminal on regulator rectifier Fig 20 RED TEST LEAD RED DC OUTPUT CONNECTOR BLACK
88. o be removed to service MAGNETRON ignition except to check the flywheel key Install Armatures 1 Turn flywheel so magnet is away from armature 2 Install ground wire onto tab terminal on armature Note Make sure wires are routed over armature mounting posts and away from flywheel 3 Assemble armature to engine Fig 2 a Mounting holes in armature are slotted Push armature away from flywheel as far as possible and tighten one screw to hold armature in place 4 Repeat for second armature Adjust Armature Air Gap 1 Rotate flywheel until magnet is under armature lamina tions 2 Place thickness gauge 008 012 0 20 30 mm be tween magnet and armature laminations Fig 3 3 Loosen mounting screw so magnet will pull armature down against thickness gauge a Torque screws to 25 in lbs 3 0 Nm 4 Rotate flywheel to remove thickness gauge 5 Repeat for second armature Note Route armature ground wire between breather tube and air horn FLYWHEEL Remove Flywheel Note For engines not equipped with fan retainer use flywheel holder Tool 19433 First remove armatures 1 Place flywheel holder Tool 19489 on fan retainer with lugs of flywheel holder engaging slots on the fan retain er Fig 4 2 Remove flywheel nut and washer 3 Remove fan retainer and fan STOP SWITCH O WIRES A m 55 GAUGE 19321 FLYWHEEL HOLDER Fig 4 Removing Flywheel Nut 4 Reinstall f
89. onnect governor link from governor lever b Remove intake manifold and carburetor assem bly c Discard gaskets 7 Remove four nuts and air horn a Discard gasket 8 Use Torx socket Tool 19455 and remove carburetor mounting studs carburetor and spacer a Discard gaskets AIR HORN Fig 3 Remove Carburetor DISASSEMBLE CARBURETOR 1 Remove two screws and float bowl a Discard O ring 2 Disassemble fuel solenoid from float bowl Discard gas ket a Use 1 2 thin profile wrench and carburetor socket Tool 19458 14 mm or 19459 16 mm b Remove fixed main jet Note Use care when removing solenoid to prevent damage to fixed main jet and housing 3 Remove float hinge pin float and inlet needle 4 Remove emulsion tube body and gasket Discard gasket Remove cover plate Discard gasket SOLENOID EMULSION TUBE BODY Las Fig 7 Remove Cover Plate 5 Remove screws and choke plate a Remove choke shaft Discard seal 6 Remove nozzle body Discard gasket 7 Mark throttle plates before removing so that they may be re installed in the same position Sides of throttle plate are beveled THROTTLE 8 Remove screws throttle plates and throttle shaft with FERNER Seal a Discard seal This completes the carburetor disassembly procedure Fig 10 Remove Throttle Shaft CARBURETOR CLEANING RECOMMENDATIONS more than 15 minutes Note Parts containing rubber such as
90. oration and replace if neces sary INSTALL BREATHER 1 Install oil vapor collector and retainer Note Push oil vapor collector and retainer in until it bottoms 2 Install breather with new gasket Fig 9 a Torque screws to 55 in Ibs 7 0 Nm b Assemble breather tube to intake elbow 4 A VAPOR ET COLLECTOR Fig 8 Checking Breather 20 Fig 9 Install Breather VAPOR OLLECTOR DISASSEMBLE OIL PUMP Drain oil and remove oil filter Remove engine from equippment Remove spark plugs The oil pump can be inspected or replaced without removing the sump 1 Remove the following parts Fig 10 a Remove oil pump cover b Remove inner rotor c Remove outer rotor d Remove shaft e Remove and discard O ring 2 Check rotors and shaft for any obvious wear and or damage Fig 11 Replace as necessary If pump housing is worn or damaged the sump must be replaced ASSEMBLE OIL PUMP 1 Lubricate oil pump components with engine oil and as semble to sump Fig 12 Make sure drive shaft is en gaged in camshaft a Install drive shaft b Install inner rotor c Install outer rotor d Install new O ring e Install oil pump cover 2 Torque screws to 50 in lbs 6 0 Nm The oil pump is virtually trouble free and requires very little maintenance Fig 10 Remove Oil Pump Fig 12 Assembling Oil Pump Section 9 Engine Disassembly p FAN ex mms Poa nt St 9905
91. over Fig 4 a Remove and inspect cartridge Replace if dam aged or dirty b NOTE DO NOT use petroleum solvents such as kerosene to clean paper cartridge They may cause cartridge to deteriorate DO NOT oil paper cartridge DO NOT use pressurized air to clean or dry paper cartridge c Reinstall cartridge and air cleaner cover Fig 4 NOTE Be sure tabs on blower housing are engaged in slots on air cleaner cover Fig 4 Dual Element Air Cleaner Remove Combustion Chamber Deposits Combustion chamber deposits should be removed every 500 hours or whenever cylinder heads are removed See Section 2 for removal procedure Remove combustion chamber deposits from combustion chamber and around valves using a soft hand wire brush or scraper With piston at Top Dead Center remove combustion chamber deposits from top of piston Use care to prevent combustion chamber deposits from entering push rod or oil return cavity in cylinder Take care not to damage cylinder top of piston cylinder head and cylinder head gasket surfaces NOTE Remove only the combustion chamber deposits It is not necessary to remove the discoloration marks on the piston valves and cylinder head These marks are normal and will not affect engine operation Remove the loose deposits from around the top ring land area using compressed air or a soft bristle brush WARNING To prevent eye injury always wear eye protection when using compressed air TR
92. ower cylinder shield screw 10 24 also used to attach fuel solenoid ground wire 1 4 20 Fig 4 Remove Cylinder Shield CONTROL BRACKET 6 Remove No 2 cylinder shield 1 4 20 SCREW 7 Remove valve covers and discard gaskets 8 Remove rocker arms and push rods Fig 7 Note Mark push rods so that they may be reassembled in their original position Intake valve push rods are aluminum 9 Remove cylinder heads and discard gaskets Fig 8 Fig 8 Remove Cylinder Head DISASSEMBLE CYLINDER HEAD 1 Remove valves Fig 10 Note Place a shop rag or short section of rubber fuel line under valves inside combustion chamber to hold valve in place while compressing spring Thread rocker arm support screw into cylinder head a few turns and compress spring with valve spring compressor Tool 19347 Remove the following a Valve spring retainer locks b Valve spring retainer c Valve spring d IN and EX valve 2 Remove and discard intake valve stem seals Fig 11 Cylinder Head Cylinder Head Gasket Valve Spring Retainer Locks Valve Spring Retainer Valve Spring Valve Intake Valve Stem Seal Valve Guide 1 2 3 4 5 6 7 8 Fig 10 Remove Valves Fig 11 Remove Valve Stem Seal 1 Check cylinder head Fig 12 Be sure all gasket material is removed from surfaces before checking Use a gasket scraper if necessary a Inspect cylin
93. r rhet Rr Rua 1 RESIZING 2 Cylinder Finish RR RR RR RE IRR vows 3 Cleaning 3 AREE 3 BEARINGS Check Mag Bearing 3 Remove Mag Bearing 1 3 Install Mag Bearing onus os 4 Check Cam Bearings lt iss lt icveosctindiwassierwss es 4 Check PTO Bearings Senne eters REI 4 Install gt lt gt 5 525 5 ees 5 HONING FIXTURE 5 5 5 250555 beeen see EE EFE FER rend 5 Check cylinder for cracks stripped threads broken fins Check cylinder bores for damage or scoring 1 Check cylinder head mounting surface for distortion with a straight edge Fig 1 If mounting surfaces are distorted more than 004 0 1 mm the cylinder must be replaced 2 Check cylinder bores for wear using telescoping gauge Tool 19404 and dial caliper Tool 19199 CENTER Standard Bore Size BOTTOM Model 405770 2 969 2 970 75 41 75 43 mm 4 Model 445770 3 119 3 120 79 22 79 25 mm MEASURE AT SIX POINTS
94. r to all of the internal components of the engine unless it is completely removed NOTE When cylinder and crankcase have been thoroughly cleaned use a clean white rag or napkin and wipe the cylinder bore If honing grit is present it will appear as a gray residue on rag If any honing grit is evident re wash and rinse entire cylinder and crankcase and check again When there is no trace of honing grit on rag the cylinder is properly cleaned Then oil cylinder bore to prevent rusting BEARINGS Check Mag Bearing Check DU magneto bearing for damage Check for wear using plug gauge Tool 19219 Fig 5 Try gauge at several locations If plug gauge is not available see reject dimension below Reject Dimension 1 383 35 12 mm Replace bearing if damaged or worn 1 383 35 12 MM Fig 5 Check Mag Bearing Remove Mag Bearing Insert bushing driver Tool 19226 into bearing from oil seal side Place a reference mark on driver to indicate proper depth of bushing when installing new bushing ini ada 1 Place cylinder on cylinder support Tool 19227 with large opening facing DU bearing Fig 6 2 Press out bearing with bushing driver Tool 19226 Fig 6 Remove Mag Bearing Install Mag Bearing 1 Place cylinder on cylinder support Tool 19227 with large opening facing bearing Fig 7 2 Align oil hole in DU bearing with oil hole in cylinder 3 Press in new bearing to correct depth with bushing driv er Tool 19226
95. rd voltage drop across the diode s If the voltage drop is less than 0 7 volts the meter will Beep once as well as display the voltage drop A continuous tone indicates continuity shorted diode An incomplete circuit open diode will be displayed as OL Charging Circuit Red Wire RO N Insert RED test lead into receptacle in meter Insert BLACK test lead into receptacle in meter Rotate selector to or nl Diode Test position Attach BLACK test lead clip to point red wire Fig 17 It may be necessary to pierce wire with a pin as shown Insert RED test lead probe into harness connector a If meter Beeps once diode is OK b If meter makes a continuous tone diode is defec tive shorted Replace harness c If meter displays OL proceed to step 6 Reverse test leads a If meter Beeps once diode is installed back wards Replace harness b If meter still displays OL diode is defective open Replace harness BLACK LEAD RED WIRE Fig 17 Diode Testing Charging Circuit Lighting Circuit White Wire 1 Insert RED test lead into V receptacle in meter 2 Insert BLACK test lead into receptacle in meter 3 4 Attach RED test lead clip to point A white wire Rotate selector to n Diode Test position Fig 18 It may be necessary to pierce wire with a pi
96. rless and deadly poison DO NOT remove fuel tank nor fill fuel tank Gm while engine is hot or running DO NOT refuel indoors or in an unventilated area Allow en gine to cool 2 minutes before refueling DO NOT place hands or feet near moving or rotating parts DO NOT store spill or use gasoline near an open flame nor near an appliance like a stove furnace or water heater that uses a pilot light or can create a spark DO NOT refuel indoors or in an unventilated area DO NOT operate or tip engine equipment at such a severe angle that causes gasoline spillage DO NOT operate engine if gasoline is spilled or when smell of gasoline is present or other explosive conditions exist Move equipment away from spill and avoid any ignition until gasoline has evaporated DO NOT transport engine with fuel in tank or fuel shut off valve open DO NOT choke carburetor to stop engine especially in an enclosed vehicle Whenever possible gradually reduce engine speed before stopping DO NOT tamper with governor springs links or other parts to increase engine speed Run engine at speed set for equip ment manufacturer DO NOT check for spark with spark plug removed Use an approved tester DO NOT run engine without blower housing or other safety shields removed when doing repairs DO NOT crank engine with spark plug removed If engine is flooded place throttle in FAST and crank until engine star
97. rmature Fig 12 NOTE This allows the brush retainer to remain assembled to commutator for inspection of brush to commutator contact 4 Remove end cap and brush retainer with brushes Replace end cap if bushing is worn or damaged Inspect Armature Commutator The armature commutator may be cleaned with fine sandpaper DO NOT use emery cloth Commutator may be machined to no less than 1 230 31 24 mm Fig 13 Slots between commutator bars should be cleaned with a hack saw blade after cleaning or machining Fig 13 The slots can also be cleaned using an aerosol carburetor cleaner or compressed air The armature should be checked for shorts with a growler Inspect Brushes The brushes should be checked for proper seating weak brush springs dirt oil or corrosion Brush spring pressure should be strong enough to ensure good brush contact with armature Check to be sure brushes are not sticking in their holders Minimum brush dimension is 1 4 6 mm Fig 14 ASSEMBLE STARTER MOTOR 1 Assemble brushes in their proper holders Note Brush retainers may made using Part No 26634 control wire as shown in Fig 15 2 Assemble brush retainer to commutator and remove brush retainers a Assemble end cap to armature shaft Fig 13 Inspect Commutator NORMAL LENGTH 1 4 6 MM OR LESS REPLACE Fig 14 Inspect Brushes NEGATIVE BRUSHE USHES POSITIVE BRUSHES MAKE FROM 26634 CONTROL WIRE Fig
98. s Manual Microfiche MS 6255 or Sales Manual MS 4052 Standard and Reject Dimensions Description Standard Dimension Reject Dimension Cylinder Bore Model 405777 2 969 2 970 75 41 75 44 mm 2 973 75 51 mm Model 445777 3 119 3 120 79 22 79 25 mm 3 1235 79 33 mm Qutot round All BER RE 0015 0 04 mm Main Bearing Magneto 1 379 1 3805 35 02 35 06 mm 1 383 35 12 mm Cam Bearing Magneto 6255 626 15 88 15 90 mm 6275 15 93 mm Cylinder Head Guides 727222222 R2 335109 9 05 240 6 09 mm 285 5 233 5 92 mm Sump Main Bearing PTO 1 6268 1 6275 41 32 41 34 mm 1 629 41 37 mm Cam Bearing PTO 6255 626 15 88 15 90 mm 6275 15 93 mm Crankshaft Crankpin 1 4982 1 499 38 05 38 07 mm 1 4965 38 01 mm Magneto Journal 1 3776 1 3784 34 99 35 01 mm 1 376 34 95 mm PTO Journal 1 6241 1 6249 41 25 41 27 mm 1 623 41 22 mm Cam Shaft JOUrTidlS 624 625 15 85 15 87 mm 623 15 82 Lobes 1 228 1 231 31 19 31 26 1 225 31 15 Exhaust 1 226 1 229 31 14 31 21 1 223 31 06 mm Connecting Rod Crankpin Bearing 1 500 1 5006 38 10 38 11 mm 1 5015 38 13 mm
99. s are required when making governor adjustments Fig 21 1 Tachometer Tool 19200 or 19389 2 Tang bender Tool 19480 Start and run engine for approximately 5 minutes to allow engine to warm up Fig 20 Adjust Governor Tach DIGITAL TACH amp HOURMETER TANG BENDER Fig 21 Governor Adjustment Tools Governed Idle Adjustment Perform adjustments exactly in order shown 1 Move equipment control lever to SLOW position 2 Hold throttle lever against idle speed adjustment screw and adjust idle speed to 1200 RPM Fig 22 Re lease throttle lever 3 Bend governed idle tang to obtain 1750 RPM Fig 23 4 With engine running at governed idle RPM bend throttle restrictor tang so that tang just contacts gover nor lever Fig 24 Adjust Top No Load Speed Refer to Service Engine Sales Microfiche MS 6225 or Service Engine Sales Manual MS 4052 for Top No Load RPM by engine model and type number 1 Move equipment control to FAST position and check RPM a Bend tang to obtain correct RPM Fig 25 Note Governor spring tension adjustment must not exceed 200 RPM or the governor spring must be replaced IDLE SPEED SCREW CARBURETOR THROTTLE TANG BENDER SES Fig 25 Adjusting Top No Load Speed Section 5 Cylinder Head and Valves Section Contents Page REMOVE CYLINDER HEAD
100. s felt Then pull cord rapidly to avoid kickback and prevent hand or arm injury 4 WEAR suitable eye protection safety glasses goggles or face shield when performing repair procedures X PREVENT ACCIDENTAL STARTING by removing spark plug wire from spark plug when servicing engine or equipment Dis connect negative wire from battery terminal if equipped with electric starting system X REMOVE blower housing periodically and clean engine Keep cylinder fins and governor parts free of dirt grass and other debris which can affect engine speed USE fresh gasoline Stale fuel can gum carburetor and cause leakage X CHECK fuel lines and fittings frequently for cracks or leaks Replace if necessary X USE ONLY Genuine Briggs amp Stratton Parts or their equiva lent The use of replacement parts which are not of equivalent quality may damage the engine A WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm BRIGGS amp STRATTON NUMERICAL NUMBER SYSTEM All Briggs amp Stratton engines have a unique numerical designation system Each engine is identified by a Model Type and Code number Example Model Type Code 405777 0125 01 99052115 This chart explains the numerical model designation system It is possible to determine most of the important mechanical features of the engine by merely knowing the model number Her
101. sitive terminal to positive post FIRST to pre vent sparks from accidental grounding Tighten con nectors securely 4 Install protective cover over positive battery terminal ends 5 Connect negative terminal to negative battery terminal Tighten connectors securely ALTERNATOR ANTI AFTERFIRE STOP CN SOLENOID SWITCH KEY SWITCH DC OUTPUT SOLENOID TAB TERMINAL STARTER 22 7 TERMINAL SOLENOID LIGHT BATTERY SWITCH TERMINAL STARTER LIGHTS 12 VOLT MOTOR BATTERY Fig 27 Typical 12 Wiring Diagram Checking Battery Physical check clean if necessary a Corrosion b Dirt c Terminal and clamps secure good conditions 2 Bring battery to full charge CHECK ALL CELLS AF TER CHARGING USE TEMPERATURE COMPENSATED HYDROMETER REPLACE IF READINGS ARE BELOW 1 225 OR IF CELLS VARY BY MORE THAN 50 Fig 28 Checking 12 V Battery Cells Lead Acid Wet Cell With Fill Caps DO NOT EXCEED CHARGE RATE OF 1 10 AMPERE FOR EVERY AMPERE OF BATTERY RATING Consult battery manufacturer for charging recommendations Overcharging may cause battery failure a Use a taper charger automatically reduces charge rate b Fill battery cells with distilled water or tap water unless maintenance free type after charging for batteries that have been in service NOTE If bat tery gets hot to the touch or is spitting acid gas sing excessively unplug charger periodically 3 With ba
102. ssemble Governor And Choke Link SPACER ASSEMBLE CARBURETOR TO INTAKE MAN IFOLD 1 Connect choke link to choke lever and assemble carbu retor and spacer to intake manifold with new gaskets a Use Torx socket Tool 19455 and torque studs to 65 in Ibs 7 0 Nm 2 Assemble air horn to carburetor with new gasket a Torque nuts to 45 in lbs 5 0 Nm INSTALL INTAKE MANIFOLD AND CARBURETOR 1 Connect wiring at solenoid 2 Connect governor link to governor lever 3 Assemble intake manifold and carburetor to engine with new gaskets a Torque screws to 80 in lbs 9 0 Nm b Connect breather tube to air horn SOLENOID Fig 22 Install Intake Manifold And Carburetor 4 Connect fuel line to carburetor Install clamp with tabs facing to sides or down 5 Install blower housing a Torque screws to 80 in lbs 9 0 Nm 6 Install rotating screen a Torque screws to 20 in Ibs 2 0 Nm Assemble air cleaner ADJUST GOVERNOR A WARNING IF carburetor and manifold are re moved static governor adjustment should be checked Misadjustment could result in engine overspeeding which could cause engine damage property damage or personal injury Static Governor Adjustment 1 Loosen governor lever nut Rotate governor control swivel counter clockwise as far as it will go wide open throttle and hold in this position 2 Rotate governor shaft clockwise as far it will go Fig 24 a Torque governor nut
103. st washer 4 Remove governor shaft from sump Fig 9 a Remove lower E ring b Rotate governor paddle clockwise and slide gov ernor shaft out of bushing c Remove and discard oil seal Fig 9 Remove Governor Shaft 5 The following tools are required to remove the governor shaft bushing Fig 10 a 3 8 drive 5 8 socket b 1 4 flat washer 1 4 20 screw and nut from 19165 flywheel pull er d 94349 flat washer Assemble tools as shown a Tighten nut until bushing is removed Fig 11 Check Governor Gear And Governor Gear Shaft 1 Check governor gear for burrs or nicks Fig 12 2 Check flyweights for damage or wear 3 Check governor cup and thrust washer for damage or wear 4 Check governor gear shaft and bearings for damage or wear Replace as required Install Governor Shaft Bushing Lubricate new bushing and governor shaft with engine oil 1 Assemble governor shaft to sump to act as a pilot for bushing Do not install lower E ring 2 Using Tool 19129 press in bushing until it bottoms Fig 13 3 Install lower E ring a Install new oil seal Governor shaft must rotate freely 19129 Fig 13 Install Governor Shaft Bushing Reassemble 1 Lubricate thrust washer governor gear and governor with engine oil and assemble to shaft Fig 14 GOVERNOR 2 Install sump with new gasket Fig 15 a Torque screws in sequence shown to 200 in Ibs 23 0 Nm
104. sulated handle Attach ignition tester Tool 19368 between the spark plug lead and each spark plug Fig 8 19368 TESTER SPARK PLUG Fig 8 Start and run engine running at top no load speed and note spark at ignition testers If the spark is equal at both ignition testers the problem is not ignition related A spark miss will be readily apparent Now note RPM of engine Ground out one cylinder with screwdriver by contacting alligator clip on ignition tester and a good ground on engine Fig 9 Note RPM loss Then ground out the other spark plug and note the RPM loss If the difference between the two cylinders does not exceed 75 RPM the amount of work the two cylinders are doing should be considered equal SPARK PLUG LEAD SPARK PLUG GROUND WITH SCREW DRIVER Fig 9 Cylinder Balance Test Things Which Affect Both Cylinders 1 Carburetion 2 Crankcase vacuum 3 Ignition timing a A partially sheared flywheel key will effect ignition timing and engine performance If the RPM loss is greater than 75 RPM this indicates that the cylinder with the least RPM loss is the weakest of the two cylinders Look to that cylinder for a problem See Example Example Engine RPM Both Cylinders 3400 RPM Engine RPM 1 Cylinder Grounded 3300 RPM Engine RPM 2 Cylinder Grounded 3100 RPM Conclusion 1 cylinder is weakest of the two cylinders Things Which Affect One Cylinder 1 Spark plug a Afouled spark plug may
105. sure lubrication system with an oil filter The gear driven oil pump draws oil from a screened oil pickup in the sump and pumps the oil through the oil filter The filtered oil flows through oil galleries in the sump and is distributed to the main bearings connecting rod bearings and camshaft bearings Engine oil pressure will vary with oil viscosity ambient air temperature differences operating temperatures and engine load Follow the oil recommendation on page 1 of this section Oil Pressure 70 F 21 C 15 50 psi 1 0 3 5 Bar A pressure relief valve limits the maximum oil pressure in the system An optional oil pressure switch is available The switch may be used to activate a warning device if oil pressure drops below approximately 5 psi 0 07 Bar The warning device and all wiring is supplied by the equipment manufacturer CHANGE OIL Change oil and filter after first 8 hours of operation Thereafter change oil and filter every 50 hours of operation Change oil and filter more often if engine is operated in dusty or dirty conditions or if engine is operated under heavy loads or high ambient air temperatures Remove oil drain plug and drain oil while engine is still warm Fig 1 Install and torque drain plug to 125 in 108 14 0 Nm Remove oil fill cap and refill with oil of recommended grade and viscosity See page 1 Oil Capacity 4 0 pints 1 9 liters with filter 3 3 4 pints 1 8 liters without filter Fill
106. t Checking Cam Checking Crankshaft Inspect crankshaft threads and keyways for damage or wear If threads or keyways are damaged or worn replace crankshaft Check journals for scoring If journals are scored replace crankshaft Check journals for wear See crankshaft reject sizes Crankshaft Reject Sizes Model PTO Mag Crankpin Series Journal Journal Journal 1 623 1 376 1 4965 405770 41 22 34 95 38 01 Check oil galleries for blockage or obstructions Check timing gear for damaged teeth Timing gear is replaceable See illustrated parts list Crankshaft crankpin may re ground for 020 undersize connecting rods Fig 2 See illustrated parts list for part number See crankshaft grinding dimensions Crankshaft Grinding Dimensions Dima 1 4782 1 479 170 180 1 4435 1 4465 37 54 37 56 mm 4 32 4 57 mm 36 66 36 74 mm Checking Cam Shaft Inspect gear teeth lobes and journals for wear and nicks Fig 3 Check oil galleries for blockage or obstructions Camshaft journal and lobe reject sizes are shown below Replace cam gear if not to specification Camshaft Reject Size Journals Intake Exhaust Mag amp PTO Lobes lobes 623 1 225 1 223 15 82 31 15 31 06 9905 OIL GALLERIES CRANKPIN MAG JOURNAL TIMING GEAR TEETH P T O JOURNAL THREADS AND KEY
107. t Hegulator HecliliBE 11 Testing Regulator Rectifier 10 Amp System 11 Testing Regulator Rectifier 16 Amp System 11 Regulator Rectifier With Charge Indicator 12 eee 14 EXTA Ra RR A E I RR ICA UC 14 Checking Battery tenses sense 15 SPECIFICATION TABLES Table No 1 Alternator Identification 2 Table No 2 Flywheel Identification 4 9905 The alternator systems installed on Briggs amp Stratton Intek OHV Twin Cylinder Engines can easily be identified by the color of the stator output wires and the connector Table No 1 provides a means of identifying the various alternator systems Note All output figures are rated at 3600 RPM TABLE NO 1 Alternator Stator Output Connector Alternator Output Test Type Wire s Color Color at 3600 RPM Page 6 Dual Red 5 Regulated Black Green 5 Amp b Regulated Black Green 9 Amp Regulated 2 Black Yellow 10 Amp Regulated 2 Black Yellow 16 Amp 14 Volts AC Lights Unregulated 2 4 Amps DC Charging Unregulated 2 4 Amps
108. ternator output Fig 7 NOTE Large magnet flywheels cannot be used with the AC only DC only Dual Circuit and Tri Circuit alternator systems The following list is provided to aid you in diagnosing problems with alternator systems TROUBLESHOOTING COMPLAINT POSSIBLE CAUSES Battery not charging Engine RPM too low Inline fuse blown if equipped Defective battery Loose pinched or corroded battery ground leads Loose pinched or corroded battery charge leads Open shorted or grounded wires between output connector and battery Defective diode open or shorted Defective or improperly grounded regulator rectifier Diode installed incorrectly reversed Damaged battery shorted battery cells Excessive current draw from accessories Low magnetic flux or damaged alternator magnets Battery in state of Severe battery vibration missing or broken tie down straps overcharge Battery rate of charge not matched to alternator output Damaged battery shorted battery cells Defective regulator One OHM resistor shorted or grounded Tri Circuit system only Headlamps not working Inline fuse blown if equipped Defective headlamps Loose or corroded wires Open shorted or grounded wires between output connector and headlamps Light switch defective Defective diode Tri Circuit system open or shorted white output lead side Low magnetic flux or damaged alternator magnets Electri
109. to 130 in lbs 15 0 Nm 3 Install throttle and choke control cables and check for proper operation Dynamic Governor Adjustment ALL ADJUSTMENTS MUST BE MADE WITH AIR CLEAN ER ASSEMBLY INSTALLED The following tools are required when making governor adjustments Fig 25 1 Tachometer Tool 19200 or 19389 2 Tang bender Tool 19480 Start and run engine for approximately 5 minutes to allow engine to warm up Fig 24 Adjust Governor Tiny TACHOMETER Tach DIGITAL TACH amp HOURMETER TANG BENDER Fig 25 Governor Adjustment Tools Governed Idle Adjustment Perform adjustments exactly in order shown 1 Move equipment control lever to SLOW position 2 Hold throttle lever against idle speed adjustment screw IDLE SPEED and adjust idle speed to 1200 RPM Fig 26 Release SCREW throttle lever CARBURETOR THROTTLE 3 Bend governed idle tang to obtain 1750 RPM Fig 27 WO EN IDLE TANG 4 With engine running at governed idle RPM bend throttle restrictor tang so that tang just contacts gover nor lever Fig 28 Adjust Top No Load Speed Refer to Service Engine Sales Microfiche MS 6225 or Service Engine Sales Manual MS 4052 for Top No Load RPM by engine model and type number 1 Move equipment control to FAST position and check RPM a Bend tang to obtain correct RPM Fig 29 Note Governor spring tension adjustment must not exceed 200 RPM or the governor spring
110. to FULL mark on dipstick Fig 2 DO NOT OVERFILL Overfilling sump can cause a smoking or overheating condition due oil foaming CHANGE OIL FILTER Change oil filter every 100 hours of operation or every season Before installing new filter lightly oil filter gasket with fresh clean engine oil Note Hand tighten 1 2 turn after gasket contacts mounting surface OIL DRAIN PLUG Fig 2 Oil Fill Fig 3 Replacing Oil Filter OIL FILL TUBE AND DIPSTICK The oil fill tube and the dipstick are equipped with an O ring for proper sealing Fig 4 Note leak at the seal between the tube and sump or at the seal at the upper end of the dipstick can result in a loss of crankcase vacuum and a discharge of oil or smoke through the muffler CHECK PRESSURE SWITCH Use Digital multimeter Tool 19464 Set meter to test for continuity Remove pressure switch for testing Connect one continu ity tester lead to the switch terminal and the other tester lead to the metal body of the switch Fig 5 The tester should indicate continuity when no pressure is applied to the switch The switch should open no continuity when approximately 4 5 PSI 0 3 Bar is applied Replace the switch if test results are not to specification CHECK OIL PRESSURE Oil level must be between the LOW and FULL mark on dipstick If oil level is low check for leaks and add to FULL mark
111. ts DO NOT strike flywheel with a hammer or hard object as this may cause flywheel to shatter in operation To remove fly wheel use Briggs amp Stratton approved tools and proceed ures only DO NOT operate engine without a muffler Inspect periodi cally and replace if worn or leaking If engine is equipped with muffler deflector inspect periodically and replace if nec essary Replacement parts must be same as on original equipment DO NOT operate engine with an accumulation of grass leaves or other combustible material in muffler area DO NOT use this engine on any forest covered brush cov ered or grass covered unimproved land unless a spark ar rester is installed on muffler The spark arrester must be maintained in working order by the owner and or operator In the State of California the above is required by law Sec tion 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on feder al lands DO NOT touch hot muffler cylinder or fins which can cause burns DO NOT start engine with air cleaner or air cleaner cover re moved or cover over carburetor air intake if Sno Gard en gine DO NOT attempt to start engine with cutting blade loose or removed Blade must be tight otherwise a kickback may occur Prior to work read and understand the section s of this manual that pertain to the job Follow all safety warnings PULL starter cord slowly until resistance i
112. ts If grounded leads are not visible re place the stator Fig 14 Testing Diode NOTE Service replacement diode harnessers are avail able Use Resin Core solder when installing new harness Use shrink tubing or tape all connections DO NOT USE CRIMP CONNECTORS AC Output Test 1 Insert RED test lead into receptacle in meter 2 Insert BLACK test lead into receptacle in meter 3 Rotate selector toV AC volts position 4 Attach RED test lead clip to AC output terminal Fig 15 BLACK TEST CLIP TO GOOD GROUND SURFACE Fig 15 Testing AC Output 5 Attach BLACK test lead clip to engine ground 6 With engine running at 3600 RPM output should be no less than 14 volts AC 7 If no output or low output is found replace stator TRI CIRCUIT ALTERNATOR The tri circuit alternator provides alternating current through a single output lead and connector to a wiring harness containing two diodes One diode rectifies the AC current to 5 amps negative DC for lights The second diode rectifies the AC current to 5 amps positive DC for battery charging and external loads such as an electric clutch NOTE Some equipment manufacturers supply the diodes as an integral part of the equipment wiring harness Some equipment manufacturers use a 1 OHM 20 WATT resistor placed in series with
113. ttery fully charged check specific gravity read ings unless maintenance free type of each cell with a Battery Hydrometer and record readings Fig 28 All readings should be above 1 250 compensating for temperature If specific gravity readings varied 50 or if ALL cells read less than 1 225 replace battery 15 Section 8 Lubrication System Section Contents Page DESCRIPTION 2 2 22522 ee 2 CHANGE OIL EEN E bse ER IU i url eee eee 2 CHANGE OIL FILTER 2 OIL FILL TUBE AND DIPSTICK 3 CHECK PRESSURE SWITCH 3 CHECK OIL PRESSURE 3 CRANKCASE BREATHER Check Breather kine ene Sere 4 Install ikke eee 4 DISASSEMBLE OIL PUMP 5 ASSEMBLE OIL PUMP 5 50 30 EET E 40 20 10 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE Use a high quality detergent oil classified For Service SE or higher Use no special additives with recommended oils 9905 1 DESCRIPTION Briggs amp Stratton Intek OHV V Twins use a full pres
114. ttery voltage is below 12 volts The charging indicator light should light when the key switch is in the ON position engine not running With engine running the charging indicator light should go out indicating that the charging circuit is operating providing that battery voltage is above 12 volts The charge indicator light and all wiring is supplied by the equipment manufacturer See typical wiring diagram page 13 12 DC charging output values and test procedures are the same as those listed for the 10 amp or 16 amp system RED WIRE AND RAISED RIB INDICATES gt DC OUTPUT BLUE WIRE CHARGING INDICATOR WHITE OUTPUT CONNECTOR Fig 24 493219 Regulator Rectifier TYPICAL 16 AMP REGULATED ALTERNATOR WIRING DIAGRAM 6 POLE SWITCH WITH CHARGE INDICATOR LIGHT CHARGE INDICATOR LIGHT gt ALTERNATOR ANTI AFTERFIRE STOP SOLENOID SWITCH AC OUTPUT WIRES BLUE WIRE REGULATOR 0 4 N RAISED RIB HEADLIGHT SWITCH RED WIRE SOLENOID TAB DC OUTPUT TERMINAL BATTERY STARTER TERMINAL TERMINAL STARTER MOTOR TET Function To Ground used only with insulated panel Switch Position Continuity To Carburetor Solenoid 1 OFF To Stop Switch Terminal On Engine To Solenoid tab terminal To Battery battery terminal on solenoid i TERMINAL 1 GROUNDED INTERNALLY TO KEY SWITCH CASE To Alternator DC Output 13 Testing
115. uled Install a new spark plug before proceeding If miss continues problem may be carburetion or compression See Check Carburetion Check Compression Also see Cylinder Balance Test SPARK PLUG LEAD SPARK PLUG GROUND WITH SCREW DRIVER Fig 7 Checking For Fouled Plugs Check Carburetion Before making a carburetion check be sure the fuel tank has an ample supply of fresh clean gasoline Be sure that the shutoff valve if equipped is open and fuel flows freely through the fuel line before starting engine Inspect and adjust the idle needle valve Check to see that the choke closes completely If engine will not start remove and inspect the spark plugs If plugs are wet look for Overchoking Plugged air cleaner Excessively rich fuel mixture Water in fuel Float needle valve stuck open If plug is dry look for Inoperative anti afterfire solenoid Gummy or dirty carburetor fuel line or tank Float needle valve stuck shut Inoperative fuel pump Leaking carburetor mounting gaskets A simple check to determine if the fuel is getting to the combustion chamber through the carburetor is to remove either spark plug and pour a small quantity of gasoline through the spark plug hole Replace the plug If the engine fires a few times and then stops look for the same conditions as for a dry plug Check Compression Briggs amp Stratton does not publish any compression pressures as it is extremely difficult to obtain

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