Briggs & Stratton CE8069, 270962, 273521, 276535, 271172 User Manual

Repair Manuals for other Briggs & Stratton Engines:

273521 Twin Cylinder OHV Air-Cooled Engines 271172 Twin Cylinder L-Head Air-Cooled Engines 270962 Single Cylinder L-Head Air-Cooled Engines 276535 Two-Cycle Snow Engines CE8069 Out of Production Engines (1919-1981)

Briggs & Stratton

Single Cylinder OHV

Air-Cooled Engines

Quality Starts With A

Master Service Technician

www.ThePowerPortal.com (Dealers)

BRIGGSandSTRATTON.COM (Consumers)

SINGLE CYLINDER OHV AIR-COOLED ENGINES

Part No. 276781-8/09

BRIGGS&STRATTON

CORPORATION

POST OFFICE BOX 702 MILWAUKEE, WI 53201 USA

8/09

FORWARD

This manual was written to assist engine technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton engines. It assumes that persons using this manual have been properly trained in and are familiar with the servicing procedures for these products, including the proper use of required tools and safety equipment and the application of appropriate safety practices. Persons untrained or unfamiliar with these procedures or products should not attempt to perform such work.

Proper maintenance and repair is important to safe, reliable operation of all engines and engine-driven systems. The troubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate for the Briggs & Stratton engines described herein. Alternative methods or procedures may pose risk to personal safety and the safety and/or reliability of the engine and are not endorsed or recommended by Briggs & Stratton.

All information, illustrations, and specifications contained in this manual were based on the data available at the time of publication. Briggs & Stratton Corporation reserves the right to change, alter, or otherwise improve the product or the product manuals at any time without prior notice.

Briggs & Stratton offers two complementary publications to enhance understanding of engine technology, maintenance, and repair. (Neither publication, however, is a substitution for a recognized training program for engine technicians.)

• For consumers, Small Engine Care & Repair (p/n 274041) provides a comprehensive overview of how small air-cooled engines work, basic troubleshooting, and step-by-step maintenance procedures.

• For engine technicians and consumers alike, an in-depth study of engine theory and operation can be found in the textbook Small Engines (p/n CE8020).

Both publications can be purchased at BRIGGSandSTRATTON.COM or through a local Authorized Briggs & Stratton Service Dealer.

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

This Engine Repair Manual includes the following

Engine Models:

• MODEL 110000 HORIZONTAL SERIES

• MODEL 120000 HORIZONTAL SERIES

• MODEL 150000 HORIZONTAL SERIES

• MODEL 200000 HORIZONTAL SERIES

• MODEL 210000 HORIZONTAL SERIES

• MODELS 97700 & 99700 VERTICAL SERIES

• MODEL 110000 VERTICAL SERIES

• MODEL 120000 VERTICAL SERIES

• MODEL 210000 VERTICAL SERIES

• MODEL 280000 VERTICAL SERIES

• MODEL 310000 VERTICAL SERIES

• MODEL 330000 VERTICAL SERIES

SECTION 1 - Safety, Maintenance and Adjustments

SECTION 2 - Troubleshooting

SECTION 3 - Exhaust Systems

SECTION 4 - Fuel Systems and Carburetion

SECTION 5 - Governor Systems

SECTION 6 - Cylinder Heads and Valves

SECTION 7 - Starters

SECTION 8 - Lubrication Systems

SECTION 9 - Cylinders, Covers and Sumps

SECTION 10 - Crankshafts, Camshafts, Balancing Systems, and Gear Reductions

SECTION 11 - Pistons, Rings and Connecting Rods

SECTION 12 - Engine Specifications

THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE, ECONOMICAL AND RELIABLE

SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS

ENGINE SAFETY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - 7

ENGINE MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

FUEL AND OIL RECOMMENDATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

MAINTENANCE CHART - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

FLYWHEEL BRAKE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

COMBUSTION CHAMBER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

AIR FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

SNOW HOOD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

OIL AND OIL FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

SPARK PLUG - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

ENGINE ADJUSTMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16

ADJUST REMOTE CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

GOVERNOR ADJUSTMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

ADJUST VALVE CLEARANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

ENGINE SAFETY

This repair manual contains safety information that is designed to:

• Make you aware of hazards associated with engines.

• Inform you of the risk of injury associated with those hazards.

• Tell you how to avoid or reduce the risk of injury.

Signal Words in Safety Messages

The safety alert symbol ( ) is used to identify safety information about hazards that can result in personal injury.

A signal word ( is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.

DANGER, WARNING, or CAUTION)

DANGER indicates a hazard which, if not

avoided, will result in death or serious injury.

WARNING indicates a hazard which, if

not avoided, could result in death or serious injury.

CAUTION indicates a hazard which, if

not avoided, could result in minor or moderate injury.

NOTICE indicates a situation that could

result in damage to the product.

and cause leakage, flow restrictions, or other failures.

• Check fuel lines and fittings frequently for cracks or leaks and replace if necessary.

WAR NING

Before attempting to service this equipment, read and understand this manual and the operating instructions of the engine and the equipment it powers.

Failure to follow instructions could result in property damage, serious injury (including paralysis) or even death.

Hazard Symbols and Meanings

Prior to work, read and understand the section(s) of this manual that pertain to the job. Follow all safety warnings.

• Wear suitable eye protection.

• When servicing engines or equipment, prevent accidental starting by disconnecting spark plug wire from the spark plug(s) and disconnect negative battery cable.

• Periodically clean engine. Keep governor parts free of dirt, grass, and other debris which can affect engine speed and cooling.

• Always use fresh gasoline. Stale fuel can cause gum deposits in the carburetor

WARNING

WAR NING

Briggs & Stratton does not approve or authorize the use of these engines on 3-wheel All Terrain Vehicles (ATV’s), motor bikes, fun/recreational go-karts, aircraft products, or vehicles intended for use in competitive events. Use of these engines in such applications could result in property damage, serious injury (including paralysis), or even death.

WARNING

The engine exhaust from this product contains chemicals known the State of California to cause cancer, birth defects, and other reproductive harm.

WARNING

Gasoline and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.

When adding fuel:

• Turn engine OFF and let engine cool for at least 2 minutes before removing the fuel cap.

• Fill fuel tank outdoors or in a well-ventilated area.

• Do not overfill fuel tank. To allow for expansion of the gasoline, do not fill above the bottom of the fuel tank neck.

• Keep gasoline away from sparks, open flames, pilot lights, heat and other ignition sources.

• Check fuel lines, tank, cap, and fittings frequently for cracks or leaks. Replace if necessary.

• If fuel spills, wait until it evaporates before starting engine.

When starting engine:

• Make sure spark plug, muffler, fuel cap, and air cleaner are in place.

• Do not crank engine with spark plug removed.

• If fuel spills, wait until it evaporates before starting engine.

• If engine floods, set choke (if equipped) to OPEN/RUN position. Place throttle (if equipped) in FAST and crank until engine starts.

When operating equipment:

• Do not tip engine or equipment at an angle which would cause fuel to spill.

• Do not choke carburetor to stop engine.

• Never start or run the engine with the air cleaner assembly (if equipped) or the air filter (if equipped) removed.

When changing oil:

• If you drain the oil from the top oil fill tube, the fuel tank must be empty or fuel can leak out and result in a fire or explosion.

When transporting equipment:

• Transport with fuel tank empty or with fuel shut-off valve set to OFF.

When storing gasoline or equipment with fuel in the tank:

• Store away from furnaces, stoves, water heaters, or other appliances that have a pilot light or other ignition source because they can ignite gasoline vapors.

Running engines produce heat. Engine parts, especially mufflers, become extremely hot. Severe thermal burns can occur on contact. Combustible debris, such as leaves, grass, brush, etc. can catch fire.

• Allow muffler, engine cylinder fins, and radiator to cool before touching.

• Remove accumulated debris from muffler area and cylinder fins.

• It is a violation of California Public Resource Code, Section 4442, to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other States and Federal jurisdictions may have similar laws. Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine.

WAR NING

Unintentional sparking can result in fire or electrical shock. Unintentional start-up can result in entanglement, traumatic amputation, or severe lacerations.

Before performing adjustments or repairs:

• Disconnect spark plug wire and keep it away from spark plug.

• Disconnect the negative (-) battery terminal.

When testing for spark:

• Use approved spark plug tester.

• Do not check for spark with spark plug removed.

WAR NING

Engines give off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause nausea, fainting, or death.

• Start and run engine outdoors.

• Do not start or run engine in an enclosed area, even if doors and windows are open.

WARNING

WAR NING

Starting engine creates sparking. Sparking can ignite nearby flammable gases. Explosion and fire could result.

• If there is a natural or LP gas leak in the area, do not start engine.

• Do not use pressurized starting fluids because vapors are flammable.

WARNING

Rotating parts can contact or entangle hands, feet, hair, clothing, or accessories. Traumatic amputation or severe lacerations can result.

• Operate equipment with guards in place.

• Keep hands and feet away from rotating parts.

• Tie up long hair and remove jewelry.

• Do not wear loose-fitting clothing, dangling drawstrings, or items that could become entangled in the equipment.

WARNING

Charging batteries produce hydrogen gas. Do not store or charge a battery near an open flame or device that utilizes a pilot light or can create a spark.

Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go. Broken bones, fractures, bruises, or sprains could result.

• When starting engine, pull the starter cord slowly until resistance is felt and then pull rapidly to avoid kickback.

• Remove all external equipment/engine loads before starting engine.

• Direct-coupled equipment components, such as but not limited to blades, impellers, pulleys, and sprockets, must be securely attached.

WAR NING

Prolonged or repeated contact with used motor oil could cause injury.

• Used motor oil has been shown to cause skin cancer in certain laboratory animals.

• Thoroughly wash exposed areas with soap and water.

WARNING

Kerosene and its vapors are extremely flammable and should be handled with the same precautions as gasoline.

WARNING

Damaged, worn, or loose fuel components can leak fuel. Explosion or fire could result.

• All fuel components should be in good condition and properly maintained.

• Repairs should only be made with factory approved parts.

• Repair work should be done by a qualified technician.

• Flexible supply lines should be checked regularly to make sure they are in good condition.

B RI GG S & ST RA TT ON

NUMERICAL IDENTIFICATION SYSTEM

This chart explains the unique Briggs & Stratton numerical model designation system. It is possible to determine most of the important mechanical features of the engine by merely knowing the model number. Here is how it works:

A. The first one or two digits indicate the approximate CUBIC INCH DISPLACEMENT. B. The first digit after the displacement indicates the BASIC DESIGN SERIES, relating to

cylinder construction, ignition, general configuration, etc. C. The second digit after the displacement indicates ORIENTATION OF CRANKSHAFT. D. The third digit after the displacement indicates TYPE OF BEARINGS, and whether or

not the engine is equipped with REDUCTION GEAR or AUXILIARY DRIVE. E. The last digit indicates the TYPE OF STARTER.

YOUR KEY TO THE WORLD’S FINEST ENGINES

BRIGGS & STRATTON MODEL NUMBERING SYSTEM

FIRST DIGIT

AFTER DISPLACEMENT

A B C D E

CUBIC INCH

DISPLACEMENT

2 5 6 8 9 10 11 12 13 15 16 18 19 20 21 22 23 24 25 28 29 30 31 32 35 38 40 42 43 44 46 47 49 52 54 58 61

EXAMPLE - To identify Model 303447:

30 3 4 4 7

30 Cubic Inch Design Series 3 Horizontal Shaft Ball Bearing

TYPE 1234–01, The type number identifies the engines mechanical parts, color of paint, decals, governed speed, and Original Equipment Manufacturer.

CODE

01061201, The code is the manufacturing date and is read as follows:

YEAR MONTH DAY ASSEMBLY LINE AND MANUFACTURING PLANT

01 06 12 01

BASIC

DESIGN SERIES

0 1 2 3 4 5 6 7 8 9

A to Z

SECOND DIGIT

AFTER DISPLACEMENT

CRANKSHAFT ORIENTATION

0 to 4 - Horizontal Shaft

5 to 9 - Vertical Shaft A to G - Horizontal Shaft H to Z - Vertical Shaft

THIRD DIGIT

AFTER DISPLACEMENT

PTO BEARING, REDUCTION GEAR, AUXILIARY DRIVE,

LUBRICATION

0 - Plain Bearing/DU

Non–Flange Mount

1 - Plain Bearing

Flange Mounting

2 - Sleeve Bearing

Flange Mounting Splash Lube

3 - Ball Bearing

Flange Mounting Splash Lube

4 - Ball Bearing

Flange Mounting Pressure Lubrication

5 - Plain Bearing

Gear Reduction (6 to 1) CCW Rotation Flange Mounting

6 - Ball Bearing

Gear Reduction (2 to 1) CCW Rotation

7 - Plain Bearing

Pressure Lubrication

8 - Plain Bearing

Auxiliary Drive (PTO) Perpendicular to Crankshaft

9 - Plain Bearing

Auxiliary Drive Parallel to Crankshaft

A - Plain Bearing

Pressure Lubrication Without Oil Filter

Flange Mounting

Pressure Lubrication

FOURTH DIGIT

AFTER DISPLACEMENT

TYPE OF STARTER

0 - Without Starter 1 - Rope Starter 2 - Rewind Starter 3 - Electric Starter

Only 110 or 230 Volt Gear Drive

4 - Electric Starter/

110 or 230 Volt Gear Drive with Alternator

5 - Electric Starter

Only 12 or 24 Volt

Gear Drive 6 - Alternator Only 7 - Electric Starter

12 or 24 Volt

Gear Drive with

Alternator 8 - Vertical Pull

Starter or

Side Pull Starter 9 - Mechanical

Starter A - Electric Starter

12 or 24 Volt

Gear Drive with

Alternator and

Inverter

Electric Starter

12 or 24 Volt Gear Drive

with Alternator

Revised 12/08

ENGINE MAINTENANCE

Fuel and Oil Recommendations

Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.

• A minimum of 87 octane / 87 AKI (90 RON).

• Gasoline with up to 10% ethanol (gasahol) or up to 15% MTBE (methyl tertiary butyl ether) is acceptable.

• NOTICE: Do not use unapproved gasoline, such as E85. Do not mix oil in gasoline or modify the engine to run on alternate fuels. This will damage the engine components and void the engine warranty.

To protect the fuel system from gum formation, mix a fuel stabilizer into the fuel. All fuel is not the same. If starting or performance problems occur, change fuel providers or change brands. This engine is certified to operate on gasoline. The emissions control system for this engine is EM (Engine Modifications).

High Altitude

At altitudes over 5,000 feet (1524 meters), a minimum 85 octane / 85 AKI (89 RON) gasoline is acceptable. To remain emissions compliant, high altitude adjustment is required. Operation without this adjustment will cause decreased performance, increased fuel consumption, and increased emissions.

Operation of the engine at altitudes below 2,500 feet (762 meters) with the high altitude kit is not recommended.

Oil must meet these requirements:

• Briggs & Stratton Warranty Certified oils are recommended for best performance.

• Other high-quality detergent oils are acceptable if classified for service SF, SG, SH, SJ or higher.

• Do not use special additives.

Outdoor temperatures determine the proper oil viscosity for the engine. Use the chart (Figure 1) to select the best viscosity for the outdoor temperature range expected.

Figure 1

Fresh Start

Some engines are equipped with a Fresh Start fuel cap. The Fresh Start fuel cap is designed to hold a cartridge (sold separately) that contains fuel stabilizer.

® Fuel Cap

Maintenance Chart

Flywheel Brake

First 5 Hours

• Change oil

Every 8 Hours or Daily

• Check engine oil level

• Clean area around muffler and controls

• Clean finger guard

Every 25 Hours or Annually

• Clean air filter*

• Clean pre-cleaner*

Every 50 Hours or Annually

• Change engine oil

• Check muffler and spark arrester

Annually

• Replace air filter

• Replace pre-cleaner

• Replace spark plug

• Replace fuel filter

• Clean air cooling system*

* In dusty conditions or when airborne debris is present, clean more often.

Model Series 97700, 99700, 110000, 120000 Vertical Shaft

The flywheel brake is part of the safety control system required for some applications. While running at FAST speed position, the flywheel brake MUST stop the engine within three seconds, when the operator releases the equipment safety control.

Test Brake Torque

1. Disconnect spark plug wire.

2. Unscrew and/or pry off static guard (A, Figure 2).

3. Unscrew and remove fuel tank (B).

Figure 2

4. Remove dipstick and oil fill tube (A, Figure 3).

5. Unscrew and remove blower housing/ rewind assembly (B).

Figure 3

6. Using a torque wrench and socket to fit the flywheel nut, turn flywheel clockwise with brake engaged. While turning at a steady rate, torque reading should be 26 lb.-in. (3 Nm) or higher.

7. If reading is low, check thickness of brake pad. Replace brake assembly if thickness is less than 0.09” (2.28mm).

8. If brake pad thickness is acceptable, adjust control cable to position pad closer to flywheel when safety control is in RUN position.

9. Replace brake assembly if correct adjustment cannot be made.

Inspect Brake and Switches

1. Disconnect spring from brake anchor (A, Figure 4).

2. Disconnect stop switch wire from stop switch (B). If engine is equipped with an electric starter, disconnect both wires from the starter interlock switch (C).

3. Remove two screws (D) from brake bracket and remove bracket.

Figure 4

4. Inspect brake pad on brake lever. Replace brake assembly if thickness is less than

0.09” (2.28mm).

5. Test stop switch as described in Section 2.

6. Test electric starter interlock switch as described in Section 2.

Assemble Flywheel Brake

1. Install brake assembly on cylinder and torque mounting screws to values listed in Section 12 - Engine Specifications.

2. Install stop switch wire and bend end of

wire 90°. Install wires on interlock switch, if equipped.

3. Install brake spring.

4. Actuate brake system to ensure proper movement, then test brake torque as previously described.

5. Install blower housing/rewind assembly, install dipstick tube and dipstick, and install fuel tank and static guard. Torque all screws to values listed in Section 12 Engine Specifications.

Combustion Chamber

Remove combustion chamber deposits every 500 hours or whenever the cylinder head is removed.

With the piston at Top Dead Center (TDC), scrape deposits from top of piston and upper bore with a plastic scraper.

Remove the loosened deposits from around the top ring land area using compressed air or a shop vacuum and a soft bristle brush.

NOTICE: Use care to prevent debris from entering push rod or oil return cavities in cylinder. Do not damage bore, top of piston, cylinder head, or cylinder head gasket surfaces.

It is not necessary to remove the discoloration marks on the piston, valves, and/or cylinder head. These marks are normal and will not affect engine operation.

Air Filter

A correctly serviced air filter protects internal engine parts from airborne dirt and dust. Poor filter maintenance will allow dirt and dust to be drawn into the engine, causing wear to the intake system and contamination of the oil. Dirt in the oil forms an abrasive mixture which wears down moving parts.

NOTE: Snow engines do not have an air cleaner assembly. Please refer to Snow Hood Maintenance for disassembly procedures

2. Gently tap air filter cartridge on a hard surface to loosen debris. Replace cartridge if very dirty.

3. Wash foam filters and pre-cleaners in warm, soapy water, then rinse and allow to air dry. Saturate foam filters in clean engine oil, then squeeze out access oil. DO NOT OIL PRE-CLEANERS.

4. Drain and clean oil bath reservoirs, then re-fill with clean engine oil.

5. Reassemble the air cleaner system.

Figures 5 through 16 illustrate the various air cleaner systems found on Briggs & Stratton single-cylinder OHV engines.

Figure 5

WARNING

Gasoline and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.

• Never start or run the engine with the air cleaner assembly or the air filter removed.

NOTE: Do not use pressurized air or solvents to clean the filter. Pressurized air can damage the filter and solvents will dissolve the filter.

1. Disassemble air cleaner system.

Figure 6

Figure 7

Figure 8

Figure 10

Figure 11

Figure 9

Figure 12

Figure 13

Figure 14

Snow Hood

NOTE: Snow engines do not have an air cleaner

assembly. Instead, a 1-piece or 2-piece snow hood is installed to protect the carburetor area, retain heat to resist carburetor icing, and provide a mounting surface for engine controls.

Remove

1. Remove choke knob (A, Figure 15 and Figure 16).

2. Remove fasteners and hood (B).

3. Disconnect stop switch wire (C) and primer hose (D).

Figure 15

Figure 16

Inspection

1. Check hood for cracks or worn mounting holes. Replace if necessary.

2. Check primer hose for brittleness or leaks and check stop switch and wire for damage. Replace parts as necessary.

Install

1. Connect stop switch wire (C, Figure 15) and primer hose (D).

2. Install hood and fasteners (B).

3. Install choke knob (A) with tab under knob fitting into slot of hood. Actuate the choke knob to check for proper movement.

Oil and Oil Filter

Spark Plug

WARNING

Gasoline and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.

• If you drain the oil from the top oil fill tube, the fuel tank must be empty or fuel can leak out and result in a fire or explosion.

• To empty the fuel tank, run the engine until it stops from lack of fuel.

Change oil after the first 5 hours of operation. After that, change oil after every 50 hours of operation. Change oil more often if engine is operated in dirty or dusty conditions, under heavy loads, or in high ambient temperatures.

1. Remove oil drain plug from side or bottom of engine and drain oil while the engine is still warm.

2. Install drain plug.

3. Remove oil filter, if equipped.

• Clean surface of filter mounting adapter.

• Apply light coat of clean engine oil to new

filter gasket.

4. Screw new filter on by hand until gasket contacts filter mounting adapter. Then tighten an additional 1/2 to 3/4 turn.

5. Fill crankcase with the correct amount of new oil.

6. Start engine and run at idle for a minute or so.

7. Shut engine off and wait for oil to settle back into the cylinder.

8. Check dipstick. If necessary, add more oil slowly to bring level to FULL mark on dipstick.

Spark plugs should be replaced every year.

NOTICE

Spark plugs have different thread “reach” and heat ranges. When changing a spark plug, use only the specified replacement, otherwise engine damage could occur.

NOTE: In some areas, local law requires using

resistor spark plugs to suppress radio frequency interference.

1. Disconnect spark plug wire.

2. Remove and inspect spark plug for wear and damage. Replace spark plug if electrodes are burned away, or the porcelain is cracked.

3. Do not blast clean spark plugs. Clean by scraping or wire brushing, and then washing in a commercial solvent.

4. Using a wire gage, check and set the gap (A, Figure 15) per Section 12 Specifications.

Figure 17

NOTICE

Do not overfill. Overfilling can cause seals to fail, smoke from the exhaust, or overheating due to oil foaming.

9. Replace oil fill cap and dipstick.

10. Start and run engine. Check for oil leaks.

5. Re-install spark plug and torque to values listed in Section 12 - Specifications.

6. Connect spark plug wire.

Cooling System

WARNING

Running engines produce heat. Severe burns can occur on contact.

• Allow muffler, engine cylinder fins, and radiator to cool before touching.

• Remove accumulated combustibles from muffler area and cylinder area.

Dirt or debris can restrict air flow and cause the engine to overheat, resulting in poor performance and reduced engine life. Continued operation with a clogged cooling system can cause severe overheating and possible engine damage. Clean these areas yearly or more often when dust or airborne debris is present (Figures 18, 19, 20).

NOTICE: Do not use water to clean the engine. Water could contaminate the fuel system. Use a brush or dry cloth to clean the engine.

Figure 19 - Rotating Screen

Figure 20 - Ducting & Cylinder Fins

Figure 18 - Static Screen

ENGINE ADJUSTMENTS

Remote Control Wire Travel

The remote control wire should measure 2.125” (54 mm) when extended outside the casing (Figure 21). After installation, the travel of the remote control wire must be at least 1.375” (35 mm) to properly actuate the choke (on Choke-AMatic® systems) and the ignition stop switch (if equipped).

Figure 21

Remote Controls

Horizontal Models 110000, 120000, 150000

1. Loosen casing clamp screw (A, Figure 22).

2. Move throttle lever to fast position.

3. Move casing in direction of arrow until slack is removed.

4. Tighten casing clamp screw.

Figure 22

Vertical Models 97700, 99700

1. Loosen casing clamp screw (A, Figure 23) on intake elbow assembly.

Figure 23

2. Move equipment speed control lever (B) to FAST position.

3. Move control wire and casing at governor bracket to align hole (C) in carburetor control lever with hole in carburetor control bracket.

4. Tighten casing screw.

Vertical Models 110000, 120000 with Primer Carburetors

1. Loosen casing clamp screw (A, Figure 24, Figure 25).

2. Move throttle lever to fast position.

3. Move casing in direction of arrow until slack is removed.

4. Tighten casing clamp screw.

Figure 24

Figure 25

Vertical Models Series 110000, 120000 with Choke-A-Matic® Carburetors

1. Loosen casing clamp screw (A, Figure 26).

2. Move throttle lever to fast position.

3. Move casing in direction of arrow until casing stops moving and choke lever (B) moves to full choke position.

Figure 26

4. Tighten casing clamp screw.

Horizontal and Vertical Models 200000, 210000, 280000, 310000, 330000

1. L oosen casing cl amp screw (C, Figure 27).

2. Set throttle control to FAST position.

3. Move governor control rack (D) until holes are aligned (B) between control lever (A) and the control bracket.

4. Tighten casing clamp screw.

Figure 27

Governor Adjustments

A complete governor system adjustment includes a static adjustment, engine warm-up, idle and/or governed idle adjustment, and top noload adjustment. Be sure to complete all steps.

Static Adjustment

1. Loosen screw holding governor lever to governor crank (A, Figure 28) or (C, Figure 29).

2. Rotate throttle linkage from idle position to wide open throttle. Note direction of rotation of the governor arm attached to the throttle linkage.

3. While holding linkage at wide open throttle, use the appropriate tool to rotate the governor shaft (B, Figure 29) until it stops in the direction noted in Step 2.

4. Tighten screw holding governor lever to governor crank per Section 12 - Engine Specifications.

5. Before starting engine, manually actuate throttle linkage to check for binding.

Top No Load Adjustment Vertical Models 97700, 99700

1. Place throttle (A, Figure 30 and 31) in FAST position and insert a 1/8” (3.2 mm) rod (B) through holes in carburetor control bracket and lever.

Figure 30

Figure 28

Figure 29

Figure 31

2. Start engine and measure RPM using Tachometer #19200 or #19389. Adjust Top No Load RPM by turning screw (C).

3. Remove 1/8” (3.2 mm) rod.

NOTE: Correct Top No Load RPM for each model-type-trim can be found in the engine replacement data on Briggs & Stratton websites.

Top No Load Adjustment Vertical Models 110000, 120000, 150000 with Primer Carburetors

1. Start engine and run until it reaches operating temperature.

2. Place throttle in FAST position.

3. Using Tachometer #19200 or #19389, and Tang Bender #19229 or #19352, bend Top No Load spring tang to obtain correct Top No Load RPM (Figure 32).

NOTE: Correct Top No Load RPM for each model-type-trim can be found in the engine replacement data on Briggs & Stratton websites.

Figure 32

3. Hold throttle lever against idle speed screw and, using Tachometer #19200 or #19389, adjust to 1500 RPM. Release throttle lever.

4. Using Tang Bender #19229 or 19352 bend governed idle spring tang to obtain 1750 RPM (Figure 34).

5. Remove 1/8” rod.

Figure 34

6. Move throttle lever to FAST position. Hole in lever will line up with hole in governor control bracket (Figure 35). Insert a 1/8” rod through holes to lock lever in this position.

Idle and Top No Load Adjustment Vertical Models 110000, 120000, 150000 with ChokeA-Matic® Carburetors

1. Start engine and run until it reaches operating temperature.

2. Place throttle in SLOW position. Hole in lever will line up with hole in governor control bracket (Figure 33). Insert a 1/8” rod through holes to lock lever in this position.

Figure 35

7. Using Tang Bender, bend Top No Load spring tang to obtain correct Top No Load RPM.

NOTE: Correct Top No Load RPM for each model-type-trim can be found in the engine replacement data on Briggs & Stratton websites.

Figure 33

Idle and Top No Load Adjustment Horizontal and Vertical Models 200000, 210000

1. Start engine and run until it reaches operating temperature.

2. Place throttle in SLOW position.

3. Hold throttle lever against idle speed screw, and, using Tachometer #19200 or #19389, adjust screw to obtain 1300 RPM. Release throttle lever.

4. Using Tang Bender #19229 or #19352, bend governed idle spring tang to obtain 1750 RPM (Figure 36).

Figure 36

5. Place throttle in FAST position.

6. Adjust screw to obtain correct Top No Load RPM (Figure 37).

Idle and Top No Load Adjustment Vertical Models 280000, 310000, 330000

All carburetor mixture adjustments should be made before adjusting governor speeds.

1. Start engine and run until it reaches operating temperature.

2. Place control lever in idle position.

3. Hold throttle in closed position with finger, adjusting idle speed screw to 1200 RPM.

4. Release throttle.

5. Set control to 1750 RPM and bend tang (A, Figure 38) until it contacts remote control slide (B).

6. Using Tang Bender #19229 or 19352, bend spring tang to obtain the correct Top No Load RPM.

NOTE: Correct Top No Load RPM for each model-type-trim can be found in the engine replacement data on Briggs & Stratton websites.

Figure 37

NOTE: Correct Top No Load RPM for each model-type-trim can be found in the engine replacement data on Briggs & Stratton websites.

Figure 38

Initial Adjustment (All Models)

1. Install idle speed screws and spring. Install idle mixture screw and spring.

2. Turn idle mixture screw in until it just bottoms.

3. Then back out screw 1-1/4” turn. This will permit the engine to start.

Final Adjustment (All Models)

1. Install complete air cleaner before starting engine. Start and run engine for five minutes at 1/2 throttle to bring engine up to operating temperature.

2. Move equipment speed control to idle position.

3. Turn idle screw to obtain 1750 RPM minimum.

4. Then turn idle mixture screw clockwise slowly until engine begins to slow.

5. Then turn screw opposite direction until engine just begins to slow.

6. Then turn screw back to midpoint (Figure

39).

Figure 39

7. Install limiter cap (if equipped) on idle mixture screw (Figure 40).

Adjust Valve Clearance

All Models - Except Vertical Models 110000, 120000 Early Production

NOTE: Check valve clearance while the engine

is cold.

1. Turn crankshaft counterclockwise until piston is at top dead center on the compression stroke. This prevents the compression release from holding the valves open.

2. Insert a narrow screwdriver or rod into the spark plug hole as a gauge, then slowly turn crankshaft counterclockwise until the piston has moved down the bore by 1/4” (6mm).

3. Using a feeler gauge (A, Figure 41), adjust rocker nut to obtain the clearance as listed in Section 12 - Engine Specifications.

4. Hold rocker nut and tighten the rocker ball setscrew (B) to the torque valve shown in Section 12 - Engine Specifications.

5. Check clearance again and re-adjust, if necessary.

6. Repeat for other valve.

NOTE: On some models, the nut and setscrew are positioned above the push rod ends.

Figure 41

Figure 40

8. Move equipment speed control from idle to high speed position.

9. Engine should accelerate smoothly. If it doesn’t, open idle mixture screw 1/8 turn open.

Vertical Models 110000, 120000 Early Production

1. Using a feeler gauge (A, Figure 42) adjust the locking hex nut (B) to obtain the correct clearance as listed in Section 12 Engine Specifications.

2. Repeat for other valve.

Figure 42

- OR -

1. Loosen jam nut (A, Figure 43) at base of rocker arm stud. Then, using a feeler gauge (B), turn rocker arm screw (C) to obtain the correct clearance as listed in Section 12 - Engine Specifications.

2. Hold the screw and tighten the jam nut to value shown in Section 12 - Engine Specifications.

3. Check clearance again and re-adjust, if necessary.

Figure 43

SECTION 2 - TROUBLESHOOTING

SYSTEMS CHECK- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25

CHECK IGNITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

CHECK CARBURETION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

CHECK COMPRESSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

ELECTRICAL SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28

EQUIPMENT USED FOR TESTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

ALTERNATOR SYSTEM DIAGNOSIS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

ALTERNATOR IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30

FLYWHEEL IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

TESTING ALTERNATOR OUTPUT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

.5-AMP DC ONLY ALTERNATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

3-AMP DC ONLY ALTERNATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

14-VOLT AC ONLY ALTERNATOR- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34

DUAL CIRCUIT ALTERNATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

TRI-CIRCUIT ALTERNATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36

5 & 9 AMP DC REGULATED ALTERNATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38

10 & 16 AMP DC REGULATED ALTERNATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

20 AMP DC REGULATED ALTERNATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

ELECTRIC STARTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -43

SYSTEM 3® AND SYSTEM 4®- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

12 VOLT DC STARTER MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

120 VOLT AC STARTER MOTOR- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

BATTERIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47

BATTERY AND CABLE RECOMMENDATIONS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

BATTERY INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

CHARGING BATTERY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

TESTING BATTERY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48

EQUIPMENT AFFECTING ENGINE OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49

OIL GARD SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

ENGINE WILL NOT START - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

ENGINE STARTS AND RUNS WITH LOW OIL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50

SYSTEMS CHECK

Most complaints concerning engine operation can be classified as one or a combination of the following:

• Will not start

• Hard starting

• Lack of power

• Runs rough

• Vibration

• Overheating

• High oil consumption

The source of most of these symptoms can be determined by performing a systems check in the following order:

1. Ignition

2. Carburetion

3. Compression

This check-up can usually be done in a matter of minutes. It is the quickest and surest method of determining the cause of failure.

NOTE: What appears to be an engine malfunction may be a fault of the powered equipment rather than the engine. If the equipment is suspect, see Equipment Affecting Engine Operation.

Figure 1

Engine Running

If engine runs but misses during operation, a quick check to determine whether the ignition is at fault can be made by installing Ignition Tester #19368 between the spark plug lead and spark plug (Figure 2). If spark is good but engine misses, install a new spark plug.

1) Check Ignition

Engine Stopped

With spark plug installed, attach Ignition Tester #19368 to spark plug lead and ground the other end of the tester (Figure 1). Pull the starter rope or activate the electric starter (if equipped). If spark jumps the tester gap, you may assume the ignition system is functioning satisfactorily.

Figure 2

If spark does not occur, look for:

• Improperly operating interlock system

• Shorted equipment or engine stop switch wire

• Incorrect armature air gap

• Armature failure

2) Check Carburetion

Before making a carburetion check, be sure the fuel tank has an ample supply of fresh, clean gasoline.

Be sure the shutoff valve, if equipped, is open and fuel flows freely through the fuel line. If fuel fails to flow or is slow, check for plugged fuel cap vent, fuel line restriction or plugged fuel filter.

Be sure throttle and choke controls are properly adjusted.

If engine cranks but will not start, remove and

inspect the spark plug. If plug is wet, look for:

• Over choking

• Excessively rich fuel mixture

• Water in fuel

• Float needle valve stuck open

• Plugged air cleaner

• Fouled spark plug

If plug is dry, look for:

• Leaking carburetor or intake manifold gaskets

• Gummy or dirty carburetor, fuel filter, fuel lines or fuel tank

• Float needle valve stuck closed

• Inoperative fuel pump (if equipped)

• Inoperative fuel shut off solenoid (if equipped)

A simple check to determine if the fuel is getting to the combustion chamber through the carburetor is to remove the 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.

Solenoid Plunger Test NOTE: The solenoid requires a minimum of 9

Volts DC to function.

1. Remove the fuel shut off solenoid from the carburetor.

2. Place a jumper wire on either terminal of a 9 Volt battery and on one of the pins of the solenoid connector.

3. Place another jumper wire on the other pin in the solenoid connector and on the other terminal on the battery (Figure 3).

Figure 3

• Plunger should retract freely, or with very

light fingertip pressure.

• When battery connection is removed,

plunger should extend.

• Replace solenoid if plunger sticks or

does not move.

Solenoid Wiring Test

1. Set multimeter to DC Volts position.

2. With key switch OFF, disconnect solenoid wiring connector (A, Figure 4).

3. Attach meter test leads (B) to pins inside wiring connector.

Testing Fuel Shut Off Solenoid

The fuel shut off solenoid is controlled by the equipment ignition switch. With the switch OFF, the solenoid plunger closes, stopping the fuel flow at the fixed main jet. With the switch in the ON and START positions, the solenoid plunger opens, allowing normal fuel flow. If operating properly, the solenoid will click when the switch is turned ON and OFF.

If solenoid does not click, the problem could be the equipment wiring, engine wiring or the solenoid. To determine which is the problem, perform the following tests in the order shown.

Figure 4

4. Turn key switch ON. Meter should display battery voltage.

If meter does not display battery voltage, the problem is with the solenoid wiring, equipment wire harness, or the keyswitch. Repair or replace as required.

3) Check Compression

Use Leakdown Tester #19545 to check the sealing capabilities of the compression components.

Follow the instructions provided with the tester to perform the leakdown test.

NOTE: Any air leaks at the connections or fittings of the tester will affect the accuracy of the test.

Listen for air leaking from the cylinder head gasket, carburetor, exhaust system, and the crankcase breather tube.

• Air flowing between the cylinder and

cylinder head indicates that the cylinder head gasket is leaking.

• Air flowing from the carburetor indicates

air is leaking past the intake valve and seat.

• Air flowing from the exhaust system

indicates air is leaking past the exhaust valve and seat.

• Air flowing from the crankcase breather

tube or high oil fill dipstick tube indicates air is leaking past the piston rings.

Possible Causes for Poor Compression:

• Loose cylinder head bolts

• Blown head gasket

• Burned valves, valve seats and/or loose

valve seats

• Insufficient tappet clearance

• Warped cylinder head

• Warped valve stems

• Worn bore and/or rings

• Broken connecting rod

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