BRIGGS & STRATTON Micro Engine Repair Manual

0 (0)

Micro Engine

Repair Manual

TABLE OF CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1

DISASSEMBLY AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2

SECTION CONTENTS

1	Section 1

General Information

In The Interest Of Safety

Briggs & Stratton Numerical Identification System Engine Identification

Fuel and Oil Recommendations Gasoline

Lubrication

Maintenance Check Oil Change Oil Air Cleaner

Breather Check Valve

Replace Spark Plug Cooling System Troubleshooting Systematic Check Check Ignition Check Carburetion Check Compression

Equipment Affecting Engine Operation Hard Starting, Kickback or Will Not Start Vibration

Power Loss

2	Section 2

Disassembly and Repair

General Information

Rewind Assembly

Inspect Starter Rope

Remove Blower Housing – Direct Drive Engine

Replace Starter Rope

Install Blower Housing – Direct Drive Engine

Remove Blower Housing – Clutch Drive Engine

Install Blower Housing – Clutch Drive Engine

Ignition Coil

Remove Coil

Install Coil

Adjust Air Gap

Flywheel

Remove Flywheel – Direct Drive Engine

Install Flywheel – Direct Drive Engine

Remove Flywheel – Clutch Drive Engine

Install Flywheel – Clutch Drive Engine

Fuel Tank

Remove Fuel Tank

Install Fuel Tank

Cylinder Head

Remove Cylinder Head

Install Cylinder Head

Muffler

Replace Muffler

Carburetor

Remove Carburetor

Install Carburetor

Idle Speed Adjustment

Section 1

General Information

Section Contents

Page

IN THE INTEREST OF SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FUEL AND OIL RECOMMENDATIONS (Gasoline, Lubrication) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Check Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Change Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replace Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Systematic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Check Ignition (With Engine Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Check Ignition (Engine Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Check Carburetion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Check Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Equipment Affecting Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hard Starting, Kickback or Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

The Briggs & Stratton engine is made of the finest material in a state-of-the-art manufacturing facility. Please understand that Briggs & 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 & Stratton does not necessarily know the application 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.

You should also understand that there are equipment applications for which Briggs & Stratton does not approve the use of its engines. Briggs & Stratton engines are not to be used on vehicles with less than 4 wheels. This includes motor bikes, aircraft products and All Terrain Vehicles. Moreover, Briggs & Stratton does not approve of its engines being used in competitive events. FOR THAT REASON, BRIGGS & 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.

IN THE INTEREST OF SAFETY

The safety alert symbol () is used to identify

safety information about hazards that can result in personal injury.

A signal word (DANGER, WARNING or CAUTION) 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 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, might result in minor or moderate injury.

CAUTION, when used without the alert symbol, indicates a situation that could result in damage to the engine.

HAZARD SYMBOLS AND MEANINGS

Fire	Explosion	Moving
		Parts

Toxic Fumes	Hot	Kickback Shock
	Surface

4Prior to work, read and understand the section(s) of this manual that pertain to the job. Follow all safety warnings.

4WEAR suitable eye protection (safety glasses, goggles or face shield when performing repair procedures).

4PREVENT ACCIDENTAL STARTING by removing spark plug wire from spark plug when servicing engine or equipment.

4PERIODICALLY clean engine. Keep carburetor parts free of dirt, grass and other debris which can affect engine speed.

4USE fresh gasoline. Stale fuel can gum carburetor and cause leakage.

4CHECK fuel lines and fittings frequently for cracks or leaks. Replace if necessary.

WARNING:

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or 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 at least 2 minutes before removing gas cap.

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

•Do not overfill fuel tank. Fill tank to approximately 1-1/2 inches below top of neck to allow for fuel expansion.

•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.

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 to OPEN/RUN position, place throttle in FAST and crank until engine starts.

WHEN OPERATING EQUIPMENT

•Do not tip engine or equipment at angle which causes gasoline to spill.

•Do not choke carburetor to stop engine.

WHEN STORING GASOLINE OR EQUIPMENT WITH FUEL IN TANK

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

WARNING

Unintentional sparking can result in fire or electric shock.

Unintentional start-up can result in entanglement, traumatic amputation, or laceration.

BEFORE PERFORMING ADJUSTMENTS OR REPAIRS

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

WHEN TESTING FOR SPARK

•Use approved spark plug tester.

•Do not check for spark with spark plug removed.

WARNING

Starting engine creates sparking.

Sparking can ignite nearby flammable gases. Explosion and fire could result.

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

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

WARNING

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 enclosed area, even if doors or windows are open.

WARNING

Running engines produce heat. Engine parts, especially muffler, 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 and fins to cool before touching.

•Remove accumulated combustibles from muffler area and cylinder area.

•Install and maintain in working order a spark arrester before using equipment on forest-covered, grass-covered, brush-covered unimproved land. The state of California requires this (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal land.

WARNING

Rotating parts can contact or entangle hands, feet, hair, clothing, or accessories.

Traumatic amputation or severe laceration 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 caught.

WARNING

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 cord slowly until resistance is felt, then pull rapidly.

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

YOUR KEY TO THE WORLD’S FINEST ENGINES

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.

BRIGGS & STRATTON MODEL NUMBERING SYSTEM

	FIRST DIGIT	SECOND DIGIT
	AFTER DISPLACEMENT	AFTER DISPLACEMENT
A	B	C
CUBIC INCH	BASIC	CRANKSHAFT
DISPLACEMENT	DESIGN SERIES	ORIENTATION
36	0	0 to 4 - Horizontal Shaft
38	1	5 to 9 - Vertical Shaft
39	2	5 to 9 - Vertical Shaft
39	2	A to G - Horizontal Shaft
10	3	A to G - Horizontal Shaft
10	3	H to Z - Vertical Shaft
11	4	H to Z - Vertical Shaft
11	4
12	5
13	6
16	7
18	8
19	9
20	A to Z

THIRD DIGIT

AFTER DISPLACEMENT

PTO BEARING,

REDUCTION GEAR,

AUXILIARY DRIVE,

LUBRICATION

0- Plain Bearing/DU NonBFlange 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- Plain 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

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

EXAMPLE - To identify Model 303447:

30	3	4	4	7
30 Cubic Inch	Design Series 3	Horizontal Shaft	Ball Bearing	Electric Starter
			Flange Mounting	12 or 24 Volt Gear Drive
			Pressure Lubrication	with Alternator

TYPE 1234B01, 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
Revised 5/03

ENGINE IDENTIFICATION

2	1	6	7	8
2
				9
3		5

	11
4	12
	12

1.	Carburetor	8.	Fuel return hose		13
2.	Stop switch	9.	Fuel intake hose		13
2.	Stop switch	9.	Fuel intake hose
3.	Rope handle	10.	Primer bulb
4.	Fuel fill	11.	Engine Model	Type	Code
5.	Air cleaner		xxxxxx	xxxx	xxxxxxxx
6.	Choke lever	12.	Oil fill / dipstick
7.	Spark plug	13.	Fuel tank

FUEL AND OIL RECOMMENDATIONS

Gasoline

These engines are certified to operate on unleaded gasoline. Use clean, fresh, regular unleaded gasoline with a minimum of 85 octane. Do not mix oil with gasoline. Fresh fuel prevents gum from forming in fuel system or on essential carburetor parts. Purchase fuel in quantity that can be used within 30 days to assure fuel freshness. We recommend the use of Briggs & Stratton Gasoline Additive. (See your Authorized Briggs & Stratton Service Dealer for Part No. 5041 or the single-use pouch.)

In countries other than U.S.A., leaded gasoline may be used if it is commercially available and unleaded is unavailable.

NOTE: Some fuels, called oxygenated or reformulated gasolines, are gasoline blended with alcohols or ethers. Excessive amounts of these blends can damage the fuel system or cause performance problems. Do not use gasoline containing Methanol. If any undesirable operating symptoms occur, use gasoline with a lower percentage of alcohol or ether.

Lubrication

Oil has four purposes. It cools, cleans, seals and lubricates. During normal operation, small particles 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.

Oil Recommendations

Use a high quality detergent oil classified “For Service SF, SG, SH, SJ” or higher. Briggs & Stratton strongly recommends the use of synthetic oil such as Briggs & Stratton (#100030C) or equivalent. If synthetic oil is not available, Briggs & Stratton nonsynthetic 30 weight oil is an acceptable substitute. No special additives should be used with recommended oils.

Do not mix oil with gasoline.

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