Briggs & Stratton 402500 User Manual

REPLACES FORM MS−5762−11/18/2005

Illustrated Parts List

Model Series

402500

TYPE NUMBERS

0025 through 0365.

TABLE OF CONTENTS

Air Cleaner 5. . . . . . . . . . . . . . . . . . . . . . . . .

Alternator 7. . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Housing 5. . . . . . . . . . . . . . . . . . . . .

Camshaft 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Carburetor 4. . . . . . . . . . . . . . . . . . . . . . . . . .

Controls 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft 2. . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head 3. . . . . . . . . . . . . . . . . . . . . .

Electric Starter 6. . . . . . . . . . . . . . . . . . . . . .

Engine Sump 2. . . . . . . . . . . . . . . . . . . . . . .

Flywheel 6. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Supply 4. . . . . . . . . . . . . . . . . . . . . . . . .

Gasket Set − Engine 4. . . . . . . . . . . . . . . . .

Gasket Set − Valve 4. . . . . . . . . . . . . . . . . .

Governor Spring 6. . . . . . . . . . . . . . . . . . . .

Ignition 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake Manifold 3. . . . . . . . . . . . . . . . . . . . .

Kit − Carburetor Overhaul 4. . . . . . . . . . . .

Lubrication 2. . . . . . . . . . . . . . . . . . . . . . . . .

Piston, Rings, Connecting Rod 2. . . . . . .

Valves 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FORM MS−5762−06/20/2006

FILE IN SECT. 2 OF SERVICE MANUAL

402500

PRINTED IN U.S.A.

All rights reserved. No part of this material may be reproduced or transmitted,
in any form or by any means, electronic or mechanical, including photocopying,
recording or by any information storage and retrieval system, without permission
in writing from Briggs & Stratton Corporation.

COPYRIGHT by BRIGGS & STRATTON CORPORATION

402500

1

2

3

847

525

524

718

718

10

8

11

252

9

250

25

523

842

287

4

1017

15

691

12

552

1024

20

1035

22

710

1280

415

1058 OPERATOR’S MANUAL

1330 REPAIR MANUAL

16A

146

741

26

29

28

27

27

29

32

46

32

24

16

146

741

965

943

750

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−2 Assemblies include all parts shown in frames. 06/20/2006

2

402500

13

5

42

798

1100

383

35

1029

36

1022

635

192

883

337

5A

33

1023

1022

7

34

868

1023A

1022

51E

33

883

212

45

654

53

1026

1026A

914

34

868

51E

50

51E

7

122A

51

51

51E

1022

1029

192

36

35

1100

42

798

54

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−3 Assemblies include all parts shown in frames. 06/20/2006

3

402500

118E

125C

141A

947

276A

117E

51

51D

108A

231

633A

105

98

133B

104

975B

1127A

127

137A

276A

131A

987A

130A

135B

137A

240

95

121C CARBURETOR OVERHAUL KIT

51

104

105

977C CARBURETOR GASKET SET

51

3

51D

137A

51D

358B ENGINE GASKET SET

51

51D

51E

276A

633A

987A

51E

51E

187B

187D

601

51

601

7

628

788

918

385

601A

1095 VALVE GASKET SET

51E

868

1022

51D

387

883

12

7

9

524

691

842

868

883

943

20

1022

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−4 Assemblies include all parts shown in frames. 06/20/2006

4

304

402500

968B

467A

1036 EMISSIONS LABEL

445

967

573

431

51D

405A

703

305

305A

447

865

865A

447A

865B

447A

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−5 Assemblies include all parts shown in frames. 06/20/2006

5

402500

74

73

668

1070

332

75

616

552

552A

742
404

552A

691

271

213

216

265

267

219

615

209

227

505

278

211

265

267

562

1005

23

363

695726
165

269

268

222

270

220

309

510

783

513

1051

310

188

801

801

544

803

697

1090

579

797

802

311

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−6 Assemblies include all parts shown in frames. 06/20/2006

6

474C

877C

878C

DUAL

CIRCUIT

402500

1059

NOTE: All stators use a No. mounting screw.
NOTE: The proper flywheel part number and/or the alternator magnet size will

determine the alternator type or output. See repair instruction manual
for additional information.

1119

789B

789A

1119

334

333

851

635

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−7 Assemblies include all parts shown in frames. 06/20/2006

7

402500

REF. PART REF. PART REF. PART

NO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

1 699751 Cylinder Assembly
2 499585 Kit−Bushing/Seal

(Magneto Side)

3 K391086s Seal−Oil

(Magneto Side)

4 699747 Sump−Engine
5 792299 Head−Cylinder

(Cylinder #1)

5A 792300 Head−Cylinder

(Cylinder #2)

7 K∆690962 Gasket−Cylinder Head
8 792185 Breather Assembly
9 K690937 Gasket−Breather

10 691108 Screw

(Breather Assembly)

11 792184 Tube−Breather
12 K697227 Gasket−Crankcase
13 791130 Screw

(Cylinder Head)

15 691680 Plug−Oil Drain

(3/8” Standard)

16 699700 Crankshaft

(Used After Code Date

04010800).

16A 699701 Crankshaft

(Used Before Code
Date 04010900).

20 K690947 Seal−Oil

(PTO Side)

22 694966 Screw

(Crankcase Cover/
Sump)

23 691054 Flywheel
24 222698s Key−Flywheel

(.020” Oversize)

25 499588 Piston Assembly

(Standard)

−−−−−−− Note −−−−−
499590 Piston

Assembly
(.020” Oversize)

26 499604 Ring Set

(Standard)

−−−−−−− Note −−−−−
499606 Ring Set

(.020” Oversize)

27 690975 Lock−Piston Pin
28 690229 Pin−Piston

(Standard)

29 699699 Rod−Connecting

(Used After Code Date

04010800).

−−−−−−− Note −−−−−

(Used Before Code
Date 04010900).
(For Replacement Rod
See Ref 16A)

32 690976 Screw

(Connecting Rod)

33 499596 Valve−Exhaust
34 792200 Valve−Intake
35 694865 Spring−Valve

(Intake)

36 694865 Spring−Valve

(Exhaust)

42 499586 Keeper−Valve
45 690977 Tappet−Valve
46 790562 Camshaft

50A 699801 Manifold−Intake

51KD

z∆699803Gasket−Intake

51DKDz∆699800Gasket−Intake

z∆690949Gasket−Intake

51EKD

53 690951 Stud

(Carburetor)

54 699816 Screw

(Intake Manifold)
(Used After Code Date

04110400).

−−−−−−− Note −−−−−
695240 Screw

(Intake Manifold)
(Used Before Code
Date 04110500).

73 494439 Screen−Rotating
74 698425 Screw

(Rotating Screen)

75 691056 Washer

(Flywheel)

95 690718 Screw

98 699721 Kit−Idle Speed
104 D694918 Pin−Float Hinge
105 D698537 Valve−Float Needle

108A 699808 Valve−Choke

117E 791406 Jet−Main

(Standard)

118E 699820 Jet−Main

(High Altitude)

121C 699814 Kit−Carburetor

Overhaul

122A 699802 Spacer−Carburetor
125C 699807 Carburetor

127 698810 Plug−Welch
130A 699809 Valve−Throttle
131A 699812 Kit−Throttle Shaft
133B 694914 Float−Carburetor
135B 792022 Tube−Fuel Transfer
137A D698781 Gasket−Float Bowl
141A 699811 Kit−Choke Shaft

146 690979 Key−Timing

165 693148 Nut

(Ring Gear)

187B 791872 Line−Fuel

(Formed Hose)

187D 791744 Line−Fuel

(Formed)(Cut to
Required Length)

188 691003 Screw

(Control Bracket)

192 690083 Adjuster−Rocker Arm

209 692909 Spring−Governor

(Yellow)

211 691019 Spring−Governed Idle

212 699805 Link−Throttle
212B 792265 Link−Throttle

213 691021 Bracket−Choke

Control

216 691022 Link−Choke

219 698231 Gear−Governor

220 690412 Washer

(Governor Gear)

222 698761 Bracket−Control

227 792492 Lever−Governor

Control

231 690718 Screw(Choke Valve)

(Choke Valve)

240 691035 Filter−Fuel

250 690957 Retainer−Breather

252 690956 Collector−Oil

265 691024 Clamp−Casing

267 695134 Screw (Casing Clamp)

268 691025 Casing−Control Wire

(Cut to Required
Length)

K Included in Engine Gasket Set−Ref. No.358B.
D Included in Carburetor Overhaul Kit−Ref. No. 121C.

z Included in Carburetor Gasket Set−Ref. No. 977C.

∆ Included in Valve Gasket Set−Ref. No 1095.

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−8 Assemblies include all parts shown in frames. 06/20/2006

8

402500

REF. PART REF. PART REF. PART

NO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

269 691026 Wire−Control

(Cut to Required
Length)

270 691027 Nut

(Control Wire Casing)

271 691028 Lever−Control

276A D695410 Washer−Sealing

278 792651 Washer

(Governor Control
Lever)

287 691108 Screw

(Dipstick Tube)

304 790688 Housing−Blower

(Black)

305 691005 Screw

(Blower Housing)

305A 698336 Screw

(Blower Housing)

309 497595 Motor−Starter
310 690323 Bolt

(Starter Motor)

311 497608 Brush Set
332 691059 Nut

(Flywheel)

333 691060 Armature−Magneto
334 691061 Screw

(Magneto Armature)

337 491055s Plug−Spark

358B 699823 Gasket Set−Engine

363 19203 Flywheel Puller
383 19374s Wrench−Spark Plug
385 691108 Screw

(Fuel Pump)

387 808656 Pump−Fuel
404 690442 Washer

(Governor Crank)

405A 697820 Screw

(Back Plate)
(Mounting)

415 690283 Plug
431 699806 Elbow−Intake
445 499486s Filter−Air Cleaner

Cartridge

447 691003 Screw

(Air Guide Cover)

447A 691108 Screw

(Air Guide Cover)

467A 691008 Screw

(Air Filter Cover)

474C 696459 Alternator

(Dual Circuit)

505 691029 Nut

(Governor Control
Lever)

510 696541 Drive−Starter
513 692024 Clutch−Drive
523 691036 Dipstick
524 K691032 Seal−Dipstick Tube
525 691037 Tube−Dipstick
544 Armature−Starter

(Service with 497595
Starter Motor)

552 690552 Bushing−Governor

Crank

552A 690553 Bushing−Governor

Crank

562 690311 Bolt

(Governor Control
Lever)

573 790444 Plate−Back
579 691029 Nut

(Starter Cable)

601 791850 Clamp−Hose

(Green)

601A 691038 Clamp−Hose

(Black)

615 698290 Shaft−Governor

Retainer

616 691045 Crank−Governor

(Intake Manifold)

628 691108 Screw

(Fuel Pump Bracket)

633A D695414 Seal−Choke/Throttle

Shaft

635 66538s Boot−Spark Plug
654 690958 Nut

(Carburetor)

668 691215 Spacer
691 K690657 Seal−Governor Shaft
695 693149 Screw

(Ring Gear)

697 690372 Screw

(Drive Cap)

703 691010 Clip
710 697474 Cover−Oil Filter
718 690959 Pin−Locating

726 499612 Gear−Ring

741 690980 Gear−Timing

742 690328 Retainer−E Ring

750 696999 Screw

(Oil Pump Cover)

783 695708 Gear−Pinion

788 691039 Bracket−Fuel Pump
789A 790544 Harness−Wiring
789B 698330 Harness−Wiring

(6 Pin Customer
Conversion)

797 693167 Nut

(Brush Retainer)

798 697890 Screw

(Rocker Arm)

801 691283 Cap−Drive

802 691286 Cap−End

803 Housing−Starter

(Service with 497595
Starter Motor)

842 K691031 Seal−O Ring

(Dipstick)

847 499602 Dipstick/Tube

Assembly

851 493880s Terminal−Spark Plug

865 691012 Cover−Air Guide

(Cylinder #1)

865A 691014 Cover−Air Guide

(Cylinder #2)

865B 691015 Cover−Air Guide

(Valley)

868 K∆690968 Seal−Valve
877C 393456 Wire/Connector−

Alternator
(Dual Circuit)

878C 398661 Harness−Alternator

(Dual Circuit)

883 K

∆690970 Gasket−Exhaust

914 691127 Screw

(Rocker Cover)

918 694000 Hose−Vacuum

943 K690589 Seal−O Ring

(Oil Pump Cover)

947 699728 Solenoid−Fuel

965 499613 Cover−Oil Pump

967 273638s Filter−Pre Cleaner
968B 790095 Cover−Air Cleaner

K Included in Engine Gasket Set−Ref. No.358B.
D Included in Carburetor Overhaul Kit−Ref. No. 121C.

z Included in Carburetor Gasket Set−Ref. No. 977C.

∆ Included in Valve Gasket Set−Ref. No 1095.

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−9 Assemblies include all parts shown in frames. 06/20/2006

9

402500

REF. PART REF. PART REF. PART

NO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

975B 699502 Bowl−Float
977C 699815 Gasket Set−Carburetor
987A D699813 Seal−Throttle Shaft

1005 499603 Fan−Flywheel

(Used After Code Date

04071900).

−−−−−−− Note −−−−−
790698 Fan−Flywheel

(Used Before Code
Date 04072000).

1017 690770 Screen−Oil Pump
1022 K∆690971 Gasket−Rocker Cover

1023 499599 Cover−Rocker Arm

(Cylinder #1)

1023A 499600 Cover−Rocker Arm

(Cylinder #2)

1024 499054 Pump−Oil
1026 690981 Rod−Push

(Steel)

1026A 690982 Rod−Push

(Aluminum)

1029 690972 Arm−Rocker
1035 691042 Shaft−Pump
1036 Label−Emissions

(Available from an
Authorized Briggs and
Stratton Service
Dealer.)

1051 691265 Ring−Retaining
1058 276245 Operator’s Manual
1059 698516 Kit−Screw/Washer
1070 690372 Screw

(Fan Retainer)

1090 691293 Retainer−Brush
1095 699822 Gasket Set−Valve
1100 791959 Pivot−Rocker Arm

1119 691183 Screw

(Alternator)

1127A 695407 Screw

(Float Bowl)

1280 697475 Seal−O Ring

(Oil Filter Cover)

1330 273521 Manual−Repair

K Included in Engine Gasket Set−Ref. No.358B.
D Included in Carburetor Overhaul Kit−Ref. No. 121C.

z Included in Carburetor Gasket Set−Ref. No. 977C.

∆ Included in Valve Gasket Set−Ref. No 1095.

Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.

5762−10 Assemblies include all parts shown in frames. 06/20/2006

10