Briggs & Stratton 273521 manual

Briggs & Stratton SINGLE CYLINDER OHV AIR-COOLED ENGINES 8/09 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) Repair Manuals for other Briggs & Stratton Engines: Single Cylind[...]

FORWARD This manual was written t o assist engine tech nicians and service perso nnel with the repair and maintenance procedur es for Briggs & Stratton engine s. It assumes that persons using this manu al have been properly train ed in and are familiar with the servicing proc edures for these pro ducts, including the proper use of r equired too[...]

6 This Engine Repair Manual includes the following Engine Models: • MODEL 1 1 0 0 0 0 HORIZONT AL SERIES • MODEL 1 20 0 0 0 HORIZONT AL SERIES • MODEL 1 50 0 0 0 HORIZONT AL SERIES • M O D E L 2 00000 H O R I ZO N T A L S E R IE S • MODEL 21 0 0 0 0 HORIZONT AL SERIES • MODELS 9770 0 & 99 70 0 VERTIC AL SERIES • MODEL 1 1 00 0 0 V[...]

7 1 2 3 4 5 6 8 9 10 11 12 SECTION 1 - Safety, Main tenance and Adjustments SECTION 2 - Troubleshooting SECTION 3 - Exhaust Systems SECTION 5 - Governor Systems SECTION 6 - Cylinde r Heads and Valves SECTION 7 - Starters SECTION 8 - Lubrication Systems SECTION 9 - Cylinders , Covers and Sumps SECTION 10 - Crankshafts, Cams hafts, Balancin g Systems[...]

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

3 1 1 SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS ENGINE SAFETY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - 7 ENGINE MAINTENANCE - - - - - - - - - - - - - - -[...]

4 1 1 ENGINE SAFETY This repair manual contains safety information that is designed to: • Make you a ware of hazar ds asso ciated with engines . • Inform you of the risk of injury associated with those hazar ds. • T ell you how to a void or reduce the r isk of injur y . Signal Words in Safety Messages The safety alert symbol ( ) is used to id[...]

5 1 1 W ARNING Briggs & Str att on does not approv e or autho- riz e the use of these eng ines on 3-wheel All T errain V ehicles (A TV’ s), motor bikes , fun/rec- reational go-karts, aircr a f t products, or vehi- cles intended f or use in competitive e vents. Use of these engines in such applications could result in propert y damage, serious[...]

6 1 1 W ARNING Starting engi ne creates sparking. Sparking ca n ignite near by flamma ble gases. Explos ion and f ire co uld r esult. • If there is a natural or LP gas leak in t he area, do not start engine. • Do not use pr essuriz ed star ting fluids beca use vapor s are flamma ble . W ARNING Rotating parts can contact or entangle hands, feet,[...]

7 1 1 B R I G G S & S T R A T T O N NUMERICAL IDENTIFICATION SYSTEM YOUR KEY TO THE WORLD’S FINEST ENGINES This chart explains the unique Briggs & Stratton num erical model desig nation sys tem. It is possible to determ ine most of the important mechanical fea tures of the engine by mere ly knowing the model number. Here is how it works: [...]

8 1 1 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 t o 1 0% ethanol (gasahol) or up to 1 5% MTBE (methyl tertiar y butyl ether) is acceptable. • NO TICE: Do not use unapprov ed gasoline , such as E85. Do no[...]

9 1 1 Maintenance Chart * In dusty conditions or when airborne debris is present, clean more often. Flywheel Brake 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 thre[...]

10 1 1 Figure 3 6. Using a torque wrench a nd socket to fit the flywheel nut, turn flyw heel 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 thick[...]

1 1 1 1 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 t op 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 [...]

12 1 1 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12[...]

1 3 1 1 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[...]

14 1 1 Oil and Oil Filter Change oil after the first 5 hours of operation. After that, change oil after every 50 hours of operation. Change oil more often if eng ine is operated in dirty or dusty conditions, under heavy loads, or in high ambient temperatures. 1. Remove oil drain pl ug from side or bottom of engine and drain oil while the engine is [...]

1 5 1 1 Cooling System 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 syste m can cause severe overheating and possible engine damage. Clean these areas yearly or more o ften when dust or airborne debr is is present (Figures 18,[...]

16 1 1 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 tra vel of the remote control wire must be at least 1.375” (35 mm) to properly actuate the choke (on Choke-A- Matic® systems) and the ignition stop switch (if equipped)[...]

1 7 1 1 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® Carburet ors 1. Lo[...]

18 1 1 Governor Adjustments A complete governor system adjustment includes a static adjustment, engine warm-up, idle and/or governed idle adjustmen t, and top no- load adjustment. Be sure to comple te all steps. Static Adjustment 1. Loosen screw holding governor lever to governor crank ( A , Figure 28) or ( C , Figure 29). 2. Rotate throttle linkag[...]

1 9 1 1 Top No Load Adjustmen t 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 #1 9389, and Tang Bender #19229 or #19352, bend Top No Load spring tang to obtain correct Top No Load RPM (Figure 32). NOTE: [...]

20 1 1 Idle and Top No Load Ad justment 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 Bend[...]

2 1 1 1 2. Move equipment speed control to idle position. 3. Turn idle screw to obtain 1750 RPM minimum. 4. Then turn idle mi xture 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[...]

22 1 1 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 ),[...]

2 3 2 2 SECTION 2 - TROUBLESHOOTING SYSTEMS CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 CHECK IGNITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 CHECK CARBURETION -[...]

24 2 2 OIL GARD SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE WILL NOT START - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE STARTS AND RUNS WITH LOW OIL - - - [...]

2 5 2 2 SYSTEMS CHECK Most complaints concerning engine operation can be classified as one or a combination of th e following: • Will not star t • Hard star ting • 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 foll[...]

26 2 2 2) Check Carburetion Before making a carburetion check, be sure the fuel tank has an ample supply of fre sh, 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 fu el filter. Be sure th[...]

2 7 2 2 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 keys witch. Repair or replace as required. 3) Check Compression Use Leakdown Tester #19545 to check the sealing capabilities of the compression components. Follow the[...]

28 2 2 ELECTRICAL SYSTEMS Equipment Used for Testing Digital Multimeter A digital multimeter is recommended for all electrical testing of Briggs & Stratton engines. The meter can be used to r ead volts, ohms, amperes, and t o test diodes. The Fluke® Digital Multimeter #1 9464 and the UNI-T® Digital Multimeter #1 9 581 are a vailable from y ou[...]

2 9 2 2 Alternator System Diagnosis Complaint Possible Causes Battery Not Chargi ng • Engin e RPM too low . • Inline fuse “b lown ” (if equipped) • Def ectiv e or damaged batt er y (shor tened bat tery cells) • Loose, pin ched, or corr oded bat tery ground le ads or charge leads • Open, shorted, or gr ounded wir es bet ween output con[...]

30 2 2 Alternator Identificat ion The alternator systems installed on Briggs & Stratton OHV Engines can eas ily be identified b y the color of the stator output wires and the connector. *Alternator output is determined by the size of the flywheel alternator magnets. Alternator Type Stat or Out put Wir e(s) Color Connector Color Al ter nator Out[...]

3 1 2 2 1. 0.5 Amp DC Only (Figure 8) • Unregulated • Output at 2800 RPM • .5 Amps DC for char ging bat ter y • One blac k lead ( A ) from st ator • White connector ( B ) output lead Figure 8 2. 14 Volt AC Only (Figure 9) • 1 4 V olts AC f or lighting circuit • One blac k lead from stator ( A ) • White connector ( B ) output lead ?[...]

32 2 2 Figure 12 6. 5/9 Amp DC (Figure 13) • 5 or 9 Amp DC based on size of flywheel magnet • 5 - 9 Amps DC regulated f or charging bat ter y • One blac k lead from stator ( A ) • Green connect or ( B ) • Y ellow lead ( C ) to r egulator -rectif ier ( F ) • One lead ( D ) from regulat or -rectifi er with red connector ( E ) Figure 13 7.[...]

3 3 2 2 Flywheel Identification OHV single cylinder flyw heels have a single ring of magnets which provide the magnetic field for the various alternator systems, except Model Series 97700, 99700, 121600, 126000 which use the magneto magnet. There are two sizes of flywheel magnets. The size of the magnet determines alternator output. The following t[...]

34 2 2 5. Attach BLACK test lead clip to positive ( + ) battery terminal. NOTE: Negative ( - ) battery terminal must be grounded. Figure 17 6. With engine running at 3600 RPM, output should be between 2 to 4 Amps DC. • Output will v ar y with bat ter y voltage . If bat ter y voltage is at its maximum, output will be appr oximately 2 Amps. 7. If n[...]

3 5 2 2 Test Alternator Output 1. Insert RED test lead ( A , Figure 19) into the V Ω receptacle in the meter. 2. Insert BLACK test lead ( B ) into COM receptacle. 3. Rotate selector to AC Volts position. 4. Attach RED test lead clip to AC output terminal ( C ). 5. Attach BLACK test lead clip to engine ground. Figure 19 6. With engine running at 36[...]

36 2 2 Figure 21 6. With the engine running at 3600 RPM, output should be between 2 - 4 Amps DC. NOTE: The output will vary with th e battery voltage. At maximum battery voltage the output will be approximately 2 Amps. 7. If NO or LOW output is found, test diode. Test Diode In the Diode Test position, the meter will display forward voltage drop acr[...]

3 7 2 2 resistor is bypassed allowing full output to the battery and clutch. The battery is not used for the lights, so lights are available even if the ba ttery is disconnected or removed. Current for the lights is available when the engine is running. The output varies, so the brightness of the lights changes with engine speed. Test Alternator Ou[...]

38 2 2 2. Insert BLACK test lead ( B ) into the COM receptacle in the meter. 3. Attach RED test lead clip to ( D ) of the WHITE wire ( C ). (It may be necessary to pierce wire with a pin as shown.) 4. Insert BLACK test lead ( B ) into harness connector. Figure 25 • If meter “Beeps” once , diode is OK. • If meter mak es a continuous tone, di[...]

3 9 2 2 1. Connect stator wire harness to regulator- rectifier. 2. Insert RED test lead into 10 Amp receptacle in meter. 3. Insert BLACK test lead into COM receptacle in meter. 4. Rotate selector to DC Amps position. 5. Attach RED test lead clip ( A , Figure 27) to RED DC output terminal on regulator- rectifier. 6. Attach BLACK test lead clip ( B )[...]

40 2 2 NOTICE: Connect test leads BEFORE starting the engine. Be sure connections are secure. If a test lead vibrates loose while engine is running, the regulator-rectifier may be damaged. Use the DC Shunt #19468 ( D , Figure 29) to avoid blowing the fuse in the test meter when testing the DC output of the 16 Amp system. The DC Shunt must be instal[...]

4 1 2 2 20 Amp DC Regulated Alternator The 20 Amp regulated alternator system provides AC current through two output leads to the regulator-rectifier. The regulator-rectifier converts the AC current to DC, an d regulates current to the battery. The charging rate will vary with engine RPM and temperature. Test Alternator Output 1. Temporarily discon[...]

42 2 2 Figure 32 5. Rotate selector to DC volts position. 6. With the engine running at 3600 rpm, the output should be 3-20 amps. 7. If no or low output is found, be sure that the regulator-rectifier is grounded properly and all equipment connections are clean and secure. If there is still no or low output, replace the regulator-rectifier.[...]

4 3 2 2 ELECTRIC STARTERS Before assuming an electric starter requires service, check the engine for freedom of rotation by removing the spark plug and turning the crankshaft over by hand. Any belt, clutch, or other parasitic load will affect the starter cranking performance, so ensure their effects are minimized. The following list is gi ven to ai[...]

44 2 2 Figure 34 If the pinion gear sticks, clean the helix and gear with a mild solvent and compressed air. If the pinion continues to stick, replace the entire starter drive assembly. NOTE: Do not oil the pinion gear or helix. The starter motor clutch is designed to prevent damage from shock loads such as engine backfire. If clutch slip s while c[...]

4 5 2 2 Test Interlock Switch Wiring 1. Disconnect interlock switch wires from spade terminals on switch and at starter motor connection. 2. Set meter to Ohms position. 3. Connect one meter test lead to the end of one wire connector and other test lead to the opposite connector in the same wire (Figure 37). Meter should read low or no resistance. F[...]

46 2 2 Figure 38 5. Activate starter motor and note readings of meter and tachometer.Take reading after meter stabilizes (approximately 2-3 seconds). 6. A starter motor in good condition will be between the following specs: • 6500 RPM (minimum) and 35 Amps (maximum) -OR- • 5000 RPM (minimum) and 20 Amps (maximum) -OR- • 7000 RPM (minimum) and[...]

4 7 2 2 BATTERIES A 12 Volt, lead acid, wet cell battery is required to operate starter motors on Briggs & Stratton OHV single cylinder engi nes. This type is available as a wet charge or dry charge battery. The wet charged maintenance-free ba ttery is filled with electrolyte and sealed at the time production. The level of electrolyte cannot be[...]

48 2 2 Figure 40 Testing Battery Set the digital multimeter to DC volts position. Test the battery while installed in the equipment. 1. Disconnect wire from spark plug and ground ignition using Ignition Tester #19368. 2. Attach RED meter test clip to positive ( + ) battery terminal. Attach BLACK meter test lead to negative ( - ) battery terminal. 3[...]

4 9 2 2 EQUIPMENT AFFECTING ENGINE OPERATION Frequently, what appears to be a problem with engine operation, such as hard starting or vibration, may be the fault of the equipment rather than the engine itself. Below are some common symptoms and potential equipment- related sources. Hard Starting or Will Not Start 1. Check for a loose drive belt or [...]

50 2 2 On/Off Switch Light Does Not Flash 1. Check engine oil level. If low, add oil to bring to FULL mark on dipstick. 2. Try to start engine while shading ON/OFF switch light from bright light such as sunlight. If light does not flash, replace switch. If new switch still does not flash, go to next step. 3. Check wiring of ON/OFF switch. Wire from[...]

5 1 3 3 SECTION 3 - EXHAUST SYSTEMS SPARK ARRESTORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 2 MUFFLER SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52 HORIZONTAL MODELS 1100 00, 120000, 150000[...]

52 3 3 Some engines are equipped with exha ust systems (mufflers, brackets, and hardware) supplied by the OEM. Contact the OEM for muffler service information. Exhaust systems covered in this section are those supplied by Briggs & Stratton. Spark Arresters Remove spark arrester ( A , Figure 1) for cleaning and inspection monthly or every 50 hou[...]

5 3 3 3 Figure 3 3. Remove screws ( A , Figure 4) holding upper muffler bracket to lower muffler bracket. Figure 4 4. Unscrew muffler from exhaust elbow and pipe assembly. 5. Remove and disassemble elbow and pipe assembly, if required. Inspect Exhaust System All exhaust system components must be inspected whenever the exhaust system is disassembled[...]

54 3 3 Figure 7 Horizontal Models 200000, 210000 Shown is a typical muffler application (Figure 8). Figure 8 Remove Guard and Muffler 1. Remove screws ( A , Figure 9) holding muffler guard to muffler. 2. Remove screw holding muffler guard to control bracket. Remove muffler guard and set aside. Figure 9 3. Remove muffler support screws ( A , Figure [...]

5 5 3 3 Figure 11 Inspect Exhaust System All exhaust system components must be inspected whenever the exhaust system is disassembled. Check muffler mounting bracket and/or muffler adapters fo r cracked welds or breakage. Check muffler fo r split seams, loose internal parts, or crac ked welds. Replace any damaged parts with new OEM parts. Never rein[...]

56 3 3 Figure 14 3. Remove muffler support screws ( A , Figure 15). Figure 15 4. Remove the exhaust pipe screws, muffler assembly, and gaskets. Discard gaskets. Inspect Exhaust System All exhaust system components must be inspected whenever the exhaust system is disassembled. Check muffler mounting bracket and/or muffler adapters fo r cracked welds[...]

5 7 3 3 2. Remove screws holding muffler guard ( A , Figure 18). Remove guard and set aside. Figure 18 3. Remove dipstick and oil fill tube ( A , Figure 19). 4. Remove blower housing and rewind starter ( B ). Figure 19 5. Remove screws ( A , Figure 20) holding exhaust pipe flange to cylinder head. 6. Remove sc rew ( B ) holding muffler bracket to c[...]

58 3 3 7. Install blower housing and rewind starter. 8. Install oil fill tube and dipstick. 9. Lightly coat muffler guard mounting screws with Valve Guide Lubricant #93963. 10. Place muffler guard over muffler and start screws ( A , B , C , Figure 22). Torque to values listed in Section 12 - Engine Specifications. Figure 22 Vertical Models 210000, [...]

5 9 3 3 Install Muffler 1. Lightly coat muffler adapter screws with Valve Guide Lubricant #93963. 2. Install new gasket and adapter. Install screws ( A , Figure 25) and torqu e to values listed in Section 12 - Engine Specifications. Figure 25 3. Install muffler supports and start but do not tighten screws ( A , B , C , Figure 26). 4. Slide muffler [...]

60 3 3 Vertical Models 280000, 310000, 330000 with Bolt-On Muffler Shown is a typical muffler application (Figure 27). Figure 27 Remove Muffler 1. Remove muffler support screw ( C , Figure 28). 2. Bend back tabs ( A ) on screw lock and remove mounting screws ( B ), muffler, and gasket. Discard screw lock and gasket. 3. Remove adapter screws, adapte[...]

6 1 4 4 SECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62 FUEL PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63 FUEL FILTER - - - [...]

62 4 4 FUEL SYSTEMS NOTE: Replace air cleaner gaskets and mounting gaskets whenever carburetor is removed for servic e. NOTE: Do not insert a screw in the end of the fuel hose to stop fuel flow. Screw threads will loosen rubber particles which will get into the carburetor. NOTE: Before servicing the carburetor, turn the fuel shutoff valve to the OF[...]

6 3 4 4 Fuel Pump The fuel pump, mounted near the blo wer housing and the air cleaner cover, allows remote fuel tank installations on some engines. The pump is operated by vacuum pulses from the engine. NOTE: The fuel pump itself is not serviceable. If the pump does not operate after inspection an d proper installation, replace the pump. Removal 1.[...]

64 4 4 Fuel Filter Some engines are equipped with a fuel filter (Figure 3) mounted in-line between the fuel ta nk and the carburetor. Replace the filter annually or whenever fuel system service is performed. Figure 3 1. Drain the fuel tank or close the fuel shut- off valve, if equipped. 2. Slide the clamps away from the fuel filter. Twist and pull [...]

6 5 4 4 Installation 1. Install tank support to tank. Slip fuel hose under governor link and spark plug wire through hole in support as tank is installed. Torque screws to values listed in Section 12 - Engine Specifications. 2. Assemble shut-off valve and fuel filter, if equipped, to fuel hose. 3. Install hose assembly to tank fitting and carbureto[...]

66 4 4 5. If necessary, remove two nuts from bracket and slide bracket off cylinder head studs. Inspection 1. Clean gummy or dirty fuel tanks with Briggs & Stratton Carburetor Cleaner #100041 or #100042, or equivalent. 2. Inspect fuel tank for: • Corrosion • Leaks • Brok en mo unting brack ets 3. Check fuel cap and filler neck for: • P [...]

6 7 4 4 CARBURETION Carburetor Identification • Figur e 6 - LMS, Models 97700, 99700, 1 1 00 00, 120000, 1 50000 V er tical and Horiz ontal Shaft • Figur e 7 - ReadyStar t®, Models 1 10000, 1 20000 V er tical Shaft • Figur e 8, Figure 9 - LMT , Models 200000, 21 0000, 280000, 31 0000, 330000 V er tical and Horiz o ntal Shaf t • Figur e 10 [...]

68 4 4 Figure 11 NOTE: Consult the Illustrated Parts List to obtain the appropriate carburet or overhaul kit before reassembling the carburetor. NOTE: Many early carburetors had adjustable needle valves to compens ate for high altitude conditions. Later carbur etors use replaceable main jets to compensate for various high altitude ranges. See the a[...]

6 9 4 4 Figure 13 Figure 14 4. Remove two carburetor mounting screws. 5. Pull carburetor away from the control bracket assembly and rotate it to disengage the governor link from the grommet on top of the throttle shaft lever. NOTE: On early production models, the mounting screws also retained the control bracket. Reinstall these screws to retain th[...]

70 4 4 Inspect and Clean Carburetor Co mponents 1. Inspect openings in the carburetor body for evidence of wear or damage. If found, replace the entire carburetor assembly. 2. Inspect the choke shaft, choke valve, throttle shaft, and throttle valve for evidence of wear or damage. Replace parts as necessary. 3. Using Carb/Choke Cleaner #100041 or #1[...]

7 1 4 4 Figure 20 6. Install new inlet needle ( E , Figure 21) on float ( D ), then position float in carburetor body. Secure with new hinge pin ( C ) an d center the pin between the float bosses. NOTE: On Model 97700, install the flat disc ( B ) and main jet ( A ). Figure 21 7. Place new bowl gasket on carburetor body and install fuel bowl. Place [...]

72 4 4 Figure 24 6. Connect fuel hose to carburetor and secure with clamp. 7. Using new gasket, install air cleaner assembly to carburetor per Section 1. Ensure breather hose is properly installed on the breather tube. 8. Adjust carburetor, if applicable, per Section 1. LMS Carburetor Horizontal Models 110000, 120000, 150000 The exact type of LMS c[...]

7 3 4 4 the governor link from the grom met on top of the throttle shaft lever ( B ). Dis card gasket. Disassemble Carburetor 1. Remove the fixed main jet (bowl nut) and fiber washer, then remove the fuel bowl and the bowl gasket from the carburetor body. Discard the fiber washer and the gasket. 2. Remove the float hinge pin ( C , Figure 27), float[...]

74 4 4 edge of the plug with a non-h ardening sealant. Figure 29 2. Install new foam seal ( B , Figure 30) on choke shaft ( E ), then slide shaft into carburetor body ( C ). Rot ate shaft clockwise ( A ), and insert choke va lve into slot until centered, with dimples ( D ) positioned as shown. Actuate the choke shaft to check for proper movement. F[...]

7 5 4 4 7. Place new bowl gasket on carburetor body and install fuel bowl. Place new fiber washer on fixed main jet (bowl nut) and install. Torque to values listed in Section 12 - Engine Specifications. Install Carburetor NOTE: Always replace air cleaner gaskets and carburetor mounting gaskets any time the carburetor has been removed for service. 1[...]

76 4 4 5. Remove gasket ( A , Figure 36), spacer, and o-ring between control bracket and carburetor ( B ). Figure 36 Disassemble Carburetor 1. Remove the fixed main jet (bowl nut) ( A , Figure 37) and fiber washer ( B ), then remove the fuel bowl ( C ) and the bowl gasket ( D ) from the carburetor body. Discard the fiber washer and the gasket. 2. R[...]

7 7 4 4 3. Place new gasket ( A , Figure 39), spacer, and new o-ring between control bracket ( B ) and carburetor ( C ). 4. Position carburetor on control bracket and install screws. Torque to value listed in Section 12 - Engine Specifications. NOTE: Use new screws or apply Loctite® to original scr ews to pr ev ent loosening from vibration. Figure[...]

78 4 4 Remove Carburetor 1. Disconnect wire(s) from the carburetor solenoid. Two styles of solenoids have been used (Figure 42). Figure 42 2. Remove air cleaner assembly per Section 1. Discard the gasket. 3. Move clamp and disconnect hose from carburetor. 4. Remove two carburetor screws or nuts while holding carburetor. 5. Carefully rotate carburet[...]

7 9 4 4 open position, then pull choke va lve out of choke shaft. Remove choke shaft, return spring (when used ), and foam seal. Discard seal. - OR - If carburetor is equipped with a metal choke shaft, rotate choke shaft to closed position. Remove two choke valve screws and choke valve. Remove choke shaft, return spring and foam seal. Discard seal.[...]

80 4 4 Figure 48 - OR - 3. If carburetor is equipped with a plastic choke shaft, • Install new f oam seal and retur n spring on choke shaf t ( C , F igure 49) with straight end of spring ag ainst choke shaf t lev er ( B ). • Inser t choke shaf t assembly into carburet or body and engage large end of return spring on anchor pin or boss ( A ). Li[...]

8 1 4 4 8. Install emulsion tube using Carburetor Screwdriver #19280 until tube seats ( A , Figure 52). Figure 52 9. Place new bowl gasket on carburetor body and install fuel bowl. Place new wa sher on solenoid and install. 10. After installing emulsion tube, use compressed air to blow out any chips or debris that may have been loosened while insta[...]

82 4 4 Nikki Carburetor Vertical Models 280000, 310000, 330000 Remove Carburetor 1. Disconnect the wire from the carburetor solenoid ( E , Figure 55). 2. Remove air cleaner assembly per Section 1. Discard gasket. 3. Move clamp and disconnect fuel hose from carburetor. 4. Remove two carburetor screws or nuts while holding the carburetor. 5. Carefull[...]

8 3 4 4 Figure 58 6. If equipped, remove the idle mixture screw with spring ( A , Figure 59) and the idle speed screw with spring ( B ). Figure 59 7. Rotate the throttle shaft to the closed position (Figure 60). Remove two screws ( A ) and the throttle plate. Figure 60 8. Pull the throttle shaft from the carburetor body. Discard foam seals. 9. Rota[...]

84 4 4 • Choke shaf t and choke val ve • Throt tle shaft and thr ottle v alve • All passages, openings, and the inside and outside of the carbur etor body NOTE: Do not soak non-metallic components, such as floats, o-rings, s eals, or diaphragms, in carb/choke cleaner or they will be damaged. 4. If any passages remain plugged after cleaning, r[...]

8 5 4 4 NOTE: The holes in the throttle plate a re offset. If the throttle plate is installed incorrectly, if will not close. 9. If equipped, install idle mixture screw with spring and the idle speed scre w with spring. Turn each screw until the head of the screw touches the spring. 10. Insert new inlet needle ( B ) into the slot on the float ( A ,[...]

86 4 4 Figure 71 4. Hook choke link ( C ) into hole in choke lever. 5. Position carburetor on manifold and install screws or nuts by hand. 6. Actuate choke and throttle linkages to ensure proper movement, then tighten screws per values li sted in Section 12 - Engine Specifications. 7. Attach fuel hose to carburetor and secure with hose clamp. 8. Us[...]

8 7 5 5 SECTION 5 - GOVERNOR SYSTEMS LINKAGE AND SPRING ORIENTATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88 GOVERNED RPM LIMITS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 9 GOVERNOR SERVICE- - - - - - - - - - - - - - - - - - - - [...]

88 5 5 GOVERNOR SYSTEMS Linkage and Spring Orientation NOTE: Be sure to note hole position of linkage before removing. • Figur e 1 - Horizontal Shaf t Models 1 1 00 00, 1 20000, 1 50000, 200000, 21 0000. • Figur e 2 - V er tical Shaft Model 97700 • Figur e 3 - V er tical Shaft Model 99700 • Figur e 4 - V er tical Shaft Models 1 1 0000, 1 20[...]

8 9 5 5 Figure 6 Figure 7 Figure 8 Governed RPM Limits To comply with specified top governed speed limits, Briggs & Stratton supplies engines with an adjustable top speed limit, which the e quipment manufacturers set to their own specifications. Top governed speed should be checked with a tachometer when the engine is operating on a completely [...]

90 5 5 Figure 10 Inspect Governor 1. Check governor gear assembly for worn weight pins, worn or damaged governor cup, and chipped or damaged teeth. 2. If wear or damage is found, remove the governor gear by carefully prying it off the spindle with two flat-bladed screw drivers ( A , Figure 11). Discard the washer at the base of the spindle. Figure [...]

9 1 5 5 Vertical Models 97700, 99700, 110000, 120000, 210000, 280000, 310000, 330000 The mechanical governor is part of the oil slinger assembly ( A , Figure 13) attached to the camshaft. The governor crank is mounted in the cylinder assembly. Figure 13 Disassemble 1. Drain oil from engine. 2. Loosen governor lever nut ( A , Figure 14, Figure 15). [...]

92 5 5 6. Place seal protector in oil seal and slide sump over crankshaft until it seats. NOTE: It may be necessary to rotate cranksha ft and cam gear to get oil pump (if equipped) to engage oil pump drive slot in cam gear. 7. Install sump screws in order shown in Figure 16 and Figure 17. Torqu e to values listed in Section 12 - Engine Specificatio[...]

9 3 6 6 SECTION 6 - CYLINDER HEAD AND VALVES SERVICE CYLINDER HEAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -9 4 HORIZONTAL AND VERTICAL MODEL S 97700, 99700, 11000 0, 120000, 150000 - - - - - - - - - - - - - - - - - - - - - - 94 SERVICE CYLINDER HEAD - - - - - - - - - - - - - - - - -[...]

94 6 6 CYLINDER HEADS AND VALVES Before the cylinder head can be removed, other external parts must be removed, such as the air cleaner, fuel tank, oil fill tube, blower housing, muffler, carburetor, cont rol bracket assembly, and intake manifold. Remove Cylinder Head Horizontal and Vert ical Models 97700, 99700, 110000, 120000, 150000 1. Remove fo[...]

9 5 6 6 Figure 6 3. Remove push rods one at a time, marking the location and orientation of each for proper installation later. 4. Using a plastic scraping tool, carefully clean all traces of head gasket from the head and cylinder mating surfaces. Disassemble Cylinder Head 1. Loosen rocker arm screws and/or lock nuts ( A , Figure 7 and 8), and remo[...]

96 6 6 2. If head passes visual inspection, use Plug Gauge #19122 to check valve guides for wear. If gauge enters the guide 1/4” (6.4 mm) or more, replace the guide (models 97700, 99700) or replace the entire head (models 110000, 120000, 150000). If plug gauge is not available, see Section 12 - Engine Specifications for the valve guide reject dim[...]

9 7 6 6 Figure 13 4. Support valve si de of cylinder head on clean shop rags. Plac e valve springs and valve spring retainers over valve stems. Using thumbs, press against each retainer until it securely locks into groove in valve stem (Figure 14). Figure 14 Install Cylinder Head 1. Coat threads of all cylinder head screws with Valve Guide Lubrican[...]

98 6 6 Figure 18 NOTE: Do not torque each screw in one step as it may result in a warped cylinder head. Step- torque all screws to approximately 1/3 of final torque value, then to 2/3 final torque value, then finish at final torque value. 3. Install push r od guide and rocker arm studs (models 97700, 99700). Torque studs to values listed in Section[...]

9 9 6 6 Remove Cylinder Head Models 200000, 210000, 280000, 310000, 330000 1. Remove four screws from rocker cover, then remove cover and gasket ( A , Figure 20). Figure 20 2. Remove cylinder head screws, then remove head and gasket from cylinder. 3. Remove push rods one at a time, marking the location and orientation of each for proper installatio[...]

100 6 6 mm) or more, replace the entire head. If plug gauge is not available, see Section 12 - Engine Specifications for the valve guide reject dimension. 3. If guides are replaced, or the original guides still meet specif ications, use Finish Reamer #19066 and Reamer Guide #19191 to ensure proper sizing and to clean out the guides. Thoroughly clea[...]

101 6 6 Figure 26 Figure 27 Figure 28 NOTE: Do not torque each screw in one step as it may result in a warped cylinder head. Step- torque all screws to approximately 1/3 of final torque value, then to 2/3 final torque value, then finish at final torque values. 3. Install rocker arm studs. Torque to values listed in Section 12 - Engine Specification[...]

102 6 6[...]

103 7 7 SECTION 7 - STARTERS REWIND STARTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104 REMOVE BLOWER HOUSING / STARTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 04 HORIZONTAL MODELS 1100 00, 120000, 150000, 2000[...]

104 7 7 REWIND STARTERS On some engines, the rewind starters are attached to the blower housing with screws and can be quickly removed. Other starters are riveted or spot welded to the blower housing and must be drilled to remove, following the procedures below. For installation, screws and nuts are avai lable separately from the Illustrated Parts [...]

105 7 7 Figure 4 5. Carefully drill through all rivet heads and remove rewind starter. Do not allow drill bit to cut into the holes in the starter housing. NOTE: Do not attempt to drill out the rivets while the blower is still on the engine. The rivets are made of steel and the shavings will collect on the flywheel magnets. Vertical Models 110000, [...]

106 7 7 Figure 8 6. Carefully drill through all rivet heads and remove rewind starter. Do not allow drill bit to cut into the holes in the starter housing. NOTE: Do not attempt to drill out the rivets while the blower is still on the engine. The rivets are made of steel and the shavings will collect on the flywheel magnets. Vertical Model 280000 1.[...]

107 7 7 Inspect Rewind Starter Parts NOTE: Do not remove the spring from the pulley. Both parts are serviced only as an assembly. 1. Inspect the pulley for wear, cracks, rough edges, or burrs in the rope groove and look for wear in the center hole. If wear or damage is found, replace the pulley and spring asse mbly. 2. Inspect the spring for broken[...]

108 7 7 Vertical Models 97700, 99700 1. Install the screws to the blower housing ( D , Figure 11), torquing screws to values listed in Section 12 - Engine Specifications. 2. Install the oil fill tube and dipstick ( C ). Figure 11 3. Install the screws to the finger guard ( A , Figure 12) and the fuel tank ( B ), torquing screws to values listed in [...]

109 7 7 5. Fill fuel tank or open fuel shut-off valve. Connect fuel hose to carburetor and connect spark plug wire. Figure 16 Vertical Model 280000 1. For installation, screws and nuts a re available separately from the Illustrated Parts List and are included with complete replacement starters. 2. Attach blower housing with screws (Figure 8) and to[...]

110 7 7 2. Wipe off any excess oil from the top of the ratchet, then place the ratchet on the housing. 3. Install the retainer cover and seal over the ratchet and press into housing until fully closed. Install retaining screws (if used). 4. Place one drop of clean engine oil on top of crankshaft pilot, then install clutch on crankshaft. Using the S[...]

111 7 7 Remove Starter Drive and Clutch 1. Remove E-ring ( A , Figure 20). 2. Remove three screws ( B ) holding gear cover. 3. Lift clutch assemb ly and gears from shaft. Figure 21 Install Starter Drive and Clutch 1. Slip pinion ( A , Figure 21) on motor shaft. 2. Add approximately 3/4 ounce of Briggs & Stratton Grease #100059 under drive gear [...]

112 7 7 Figure 24 2. Remove retainer ( A , Figure 24), return spring ( B ), fla t washer ( C ), wave washer ( D ), pinion gear ( E ), and starter clutch ( F ). Figure 25 Assemble Starter Motor Drive - C-Ring Retainer 1. Place clutch on starter shaft ( A , Figure 25). Rotate clutch until it drops into place ( B ). Figure 26 2. Install pinion gear ( [...]

113 7 7 Figure 28 4. Place new C-ring over chamfered end of shaft. 5. Align one of the slots ( G , Figure 28) of C- Ring Installer #19435 with open end of C- ring ( H ). 6. Press on tool until C-ring snaps into groove in shaft. 7. Manually actuate pinion gear on helix to ensure proper movement. Figure 29 Disassemble Starter Drive - Roll Pin Retaine[...]

114 7 7 Assemble Starter Drive - Roll Pin Retainer 1. Place clutch ( E , Figure 31) on starter shaft and rotate clutch until it drops into place. Figure 32 2. Install pinion gear ( D ) with beveled edge of teeth up. 3. Place washer ( C ) and retainer ( B ) on starter shaft. 4. Press new roll pin ( A ) through retainer slot and starter shaft hole un[...]

115 8 8 SECTION 8 - LUBRICATION SYSTEMS EXTENDED OIL FILL AND DIPSTICK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 BREATHERS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 HORIZONTAL MODELS 1100 00, 120000, 150000,[...]

116 8 8 EXTENDED OIL FILL AND DIPSTICK Horizontal Models 110000, 120000, 150000, 200000, 210000 These models use a plastic extended oil fill tube and a quarter-turn dipstick. The oil fill tube screws into the crankcase cover. Vertical Models 90000, 110000, 120000, 210000, 280000, 310000, 330000 These models use a plastic extended oil fill tube and [...]

117 8 8 Figure 2 Check Breather 1. Check for movement of the disc valve in the breather assembly. If disc is stuck or binding, replace the brea ther assembly. 2. Visually inspect the assembly for warping, wear, or damage. If these conditions are found, replace the breather assembly. 3. Inspect oil drain-back holes ( C , Figure 3) to make sure they [...]

118 8 8 NOTE: Do not apply fo rce to the wire gauge! The disc valve is retained by an inte rnal bracket which will be distorted if pressure is applied to disc. Figure 4 Install Breather 1. Place new gasket and breather asse mbly on cylinder. Torque to screws to values listed in Section 12 - Engine Specifications. 2. Securely insert breather tube in[...]

119 8 8 Install Breather 1. Install reed with the metal tab facing outside of the engine, as shown in Figure 8. Torque screw to va lues listed in Section 12 - Engine Specifications. 2. Place new gasket or sealant on cylinder. Install breather cover and torque screws to values listed in Section 12 - Engine Specifications. 3. Securely install breathe[...]

120 8 8 Oil Slinger with Pressure Filtrat ion Vertical Models 120000, 210000, 280000, 310000, 330000 Some of these models are equipped with a gerotor pump that draws oil from the sump, pumps it through the oil filter, and back to the sump (Figure 11). The gerotor pump is driven by the cam gear. The slinger splashes oil throughout the crankcase. NOT[...]

121 8 8 Figure 15 2. Carefully remove inner ( C ) and outer rotors ( D ). NOTICE: Depending on Model Series, inner rotor may include the drive shaft or the drive shaft may be a separate part. Remove shaft, when it is a separate part. Remove Pump Screen Three types of oil pum p screens have been used on models 280000, 310000, 330000. Early oil pump [...]

122 8 8 Inspect Oil Pump Parts 1. Inspect surfaces of outer and inner rotors, pump housing, cover, and shaft for wear and scoring. Replace parts if nece ssary. 2. Inspect pump housing and passages for debris. Clean as required. 3. Inspect screen for clogging or damag e. Replace as necessary. Install Screen and Gerotor Pump 1. Install pump screen un[...]

123 8 8 Figure 24 Inspect 1. Check adapter for cracks or damage to the sump and filter mounting surfaces. Replace adapter if necessary. 2. Clean all oil passages in adapter and in sump. Install 1. Using new gasket, place adapter on sump and install screws. Torque screws to values listed in Section 12 - Engine Specifications. 2. Apply a thin film of[...]

124 8 8 Figure 26 Figure 27 There are two types of Oil Gard syst ems in use: • Start Sense • Run Sense Identification Start Sense is designed to prevent the engine from starting if the oil level is too low. It will not start an engine that is already running. Run Sense will stop a running engine if the oil level runs below the ADD level on the [...]

125 9 9 SECTION 9 - CYLINDERS , COVERS AND SUMPS CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126 INSPECT CYLINDER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126 RECO[...]

126 9 9 CYLINDER Inspect Cylinder 1. Visually check cyli nder for cracks, stripp ed threads, and bore damage. • If cracks ar e found, replace the cylinder . • Stripped thr eads can sometimes be repair ed using a helicoil, but if multiple holes hav e thread damage, replace the cylinder . • Bore damage, if not se ver e, may be corrected b y rec[...]

127 9 9 Cleaning Cylinder 1. Wash the cylinder thoroughly in a solvent such as kerosene or other commercial solvent. 2. Wash cylinder again using a stiff brush with soap and hot water. 3. Rinse cylinder thor oughly with hot running water. 4. Repeat washing and rinsing until all traces of honing grit are gone. NOTE: Honing grit is hi ghly abrasive a[...]

128 9 9 replace the affected cylinder, crankcase cover, or sump (Figure 6). NOTE: Standard and reject sizes for the main bearings are shown in Section 12 - Engine Specifications. Figure 6 Replace Bearings Replace DU ™ Bearings 1. Select tools needed from Figure 7 and Figure 8. Figure 7 Figure 8 2. Remove and discard oil seal for bearing to be rep[...]

129 9 9 Figure 10 5. Place cylinder or cover/sump on cylinder support ( B , Figure 11) with large opening facing bearing. 6. Align oil holes in bearing with oil holes in cylinder or cover/sump, then press in new bearing to correct depth with bushing driver ( A ). Figure 11 7. Stake bearing into notch ( A , Figure 12) with 1/8” round pin punch to [...]

130 9 9 Figure 13 3. Assemble washer ( C , Figure 14) to puller screw ( D ) and insert through large end of removal driver ( B ). Place open end of support ( A ) against ball b earing. 4. Insert screw with washer and driver through ball bearing and thread into support. Continue tigh tening screw until ball bearing is removed. Figure 14 5. Lubricate[...]

131 9 9 4. Insert screw, with washer and driver through the ball bearing and thread into support. Continue tigh tening screw until ball bearing is removed. Figure 16 5. Lubricate outside diameter of new ball bearing. Place ball bearing on support ( A , Figure 17). 6. Insert small end of installation driver ( B ) in oil seal bore. Assemble washer ( [...]

132 9 9 Figure 19 NOTE: Always install new oil seals when engine is reassembled or w hen replacing bearings. Always use the correct s eal protector to prevent damaging the oil seal during installation. COVERS AND SUMPS Installation 1. Select correct seal protector for Kit #19356, to protect oil seal when installing cover or sump. 2. Make sure mecha[...]

133 9 9 Figure 22 Figure 23 Figure 24[...]

134 9 9[...]

135 10 10 SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING SYSTEMS, AND GEAR REDUCTIONS CRANKSHAFTS AND CAMSHAF TS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136 REMOVE CRANKSHAFT AND CAMSHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 36 INSPE[...]

136 10 10 CRANKSHAFTS AND CAMSHAFTS Remove Crankshaft and Camshaft 1. Drain oil from engine and all fuel from fuel tank. Drain oil from gear reduction unit (if equipped) and remove from engine ( A , Figure 1). 2. Remove blower housing/rewind assembly and flywheel/fan assembly. 3. Remove burrs and clean crankshaft, then remove crankcase cover or sum[...]

137 10 10 Figure 4 Figure 5 2. Using a dial caliper, measure the journal diameters and cam lobes. Compare results to values listed in Section 12 - Engine Specifications . If wear exceeds the reject dimensions, replace the camshaft. Install Crankshaft and Camshaft 1. Lubricate the cylinder bearing/oil se al with engine oil. 2. Install intake and exh[...]

138 10 10 Install Crankcase Cover or Sump 1. Using a new gasket install crankcase cover or sump using seal protectors. Do not force cover or sump on cylinder. NOTE: It may be nece ssary to rotate crankshaft to get oil pump (if equipped) to engage d rive slot in camshaft. For horizontal crankshafts, it may be necessary to rotate idler gear to mesh w[...]

139 10 10 Check and Adjust Crankshaft End Play When crankcase cover or sump is installed with a standard gasket, end play should match values listed in Section 12 - Engine Specifications. If end play is less than specified, remove cover or sump and install an additional gasket. Do not use more than two gaskets. If end play is more than specified, r[...]

140 10 10 GEAR REDUCTION Disassemble Gear Reduction 1. Note orientation of gear reduction assembly on engine. Place an oil collection pan beneath the assembly. 2. Remove oil vent plug ( C , Figure 17) and set aside. 3. Loosen four cap screws ( D ) that secur e the gear case cover assembly. Pull cover ( A ) away from gear case ( B ) and allow oil to[...]

141 10 10 Figure 20 7. Install pinion gear on crankshaft. 8. Slide drive shaft as sembly into gear case bearing and rotate to engage crankshaft pinion gear. 9. Place new gasket on gear case assembly. 10. Slide cover over drive shaft until seated on new gasket. NOTE: Vent plug hole must be positioned at top. 11. Install four cover screws ( A , F igu[...]

142 10 10 AUXILIARY PTO Some models of the vertical shaft 110000 and 120000 engines were equipped with an auxiliary PTO shaft. The auxiliary PTO shaft ( E , Figure 23) extends through the side of the sump, perpendicular to the crankshaft. Rotation ca n be either clockwise or count erclockwise, as vie wed from the end of the shaft. The oil slinger ([...]

143 10 10 COUNTERBALANCE SYSTEMS Two styles of counterbalance systems are used on Vertical crankshaft engines. Models 280000 and 310000 (built before July 2001) have the Synchro-Balance® system. Models 280000 and 310000 built July 2001 and later, and all models 210000 and 330000 have the AVS® sy stem. Both sy s tems use a counterweight that oscil[...]

144 10 10 Assemble 1. Lubricate all beari ng surfaces with clean engine oil. 2. Slide magneto-side counterweight ( A , Figure 28) on flywheel end of crankshaft. 3. Place crankshaft and counterweight in a vise with soft jaws or shop rags to protect magneto journal. 4. Slip link ( C ) over dowel pin ( D ) with rounded edge ( E ) up. Fit dowel pin int[...]

145 10 10 AVS® Balance S ystem Remove 1. Remove blower housing, flywheel, cylinder head, and sump. Discard gaskets. 2. Remove connecting rod and piston assembly. 3. Remove crankshaft and counterweight assembly. Disassemble 1. Remove the crankshaft gear ( F , Figure 30) from the crankshaft ( A ). If the gear is tight, pry it off using two screwdriv[...]

146 10 10[...]

147 9 11 SECTION 11 - PISTONS, RINGS AND CONNECTING RODS REMOVE PISTON AND CONNECTING ROD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148 DISASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148 INSPECT - - - - - - - - - - - - - - [...]

148 9 11 PISTONS, RINGS, & CONNECTING RODS Remove Piston and Connecting Rod 1. Carefully remove any carbon or ridge at top of cylinder bore to prevent ring breakage. 2. Remove rod bolts and connecting rod cap ( A , Figure 1). 3. Push piston and rod assembly out through top of cylinder bore. Figure 1 Disassemble 1. Rotate pin retainer until one [...]

149 9 11 Engine Specificati ons. If clearance is greater than shown the piston must be replaced. Figure 4 Check Ring End Gap It is recommended that the entire ring set be replaced when servicing the piston and/or cylinder bore. However, the origina l rings can be re-used if they are not damaged and are checked as follows: 1. Clean all carbon from t[...]

150 9 11 NOTE: For Vertical Model 120000 ONLY, install piston with notch or arrow ( A , Figure 8) facing away from “MAG” on the rod. When installed in engine, the notch will face the PTO. Figure 8 3. Install a pin retainer into groove on open side of piston pin bore. Ensure retainers are firmly seated in grooves. 4. Using Piston Ring Expander #[...]

151 12 SECTION 12 - ENGINE SPECIFICATIONS MODEL 110000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 152 MODEL 120000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 154 MODEL 150000 HORIZONTAL SERIES- - - - - - - - - - - - - - - [...]

152 12 MODEL 110000 HO RIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance – Exhaust .009 - .011 in. (.23 - .28 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Ai[...]

153 12 REJECT DIMENSION S STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5008 in. (12.72 mm) .5040 in. (12.80 mm) Bore Diameter 2.688 in. (68.28 mm) 2.692 in. (68.38 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in. (6.32 mm) .267 in. (6.78 mm) Intake Valve Ste[...]

154 12 MODEL 120000 HO RIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance – Exhaust .009 - .011 in. (.23 - .28 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Ai[...]

155 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (12.72 mm) .5040 in. (12.80 mm) Bore Diameter 2.970 in. (75.44 mm) 2.974 in. (75.54 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in. (6.32 mm) .267 in. (6.78 mm) Intake Valve St[...]

156 12 MODEL 150000 HO RIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance – Exhaust .009 - .011 in. (.23 - .28 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Ai[...]

157 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (12.72 mm) .5040 in. (12.80 mm) Bore Diameter 2.970 in. (75.44 mm) 2.974 in. (75.54 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in. (6.32 mm) .267 in. (6.78 mm) Intake Valve St[...]

158 12 MODEL 200000 HO RIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance – Exhaust .004 - .006 in. (.10 - .15 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Ai[...]

159 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 2.688 in. (65.10 mm) 2.691 in. (68.33 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in. (6.32 mm) .267 in. (6.78 mm) Intake Valve Ste[...]

160 12 MODEL 210000 HO RIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance – Exhaust .004 - .006 in. (.10 - .15 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Ai[...]

161 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing 1.1825 in. (30.03 mm) 1.184 in. (30.07 mm) Camshaft Bearing .5011 in. (12.72 mm) .5040 in. (12.80 mm) Bore Diameter 3.300 in. (83.82 mm) 3.304 in. (83.92 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .236 in. (5.99 mm) .240 in. (6.10 mm) Intake Valve[...]

162 12 MODELS 97700 & 99700 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .006 - .012 in. (.15 - .30 mm) Crankshaft End Play .002 - .034 in. (.05 - .86 mm) Spark Plug Gap .030 in. (.76 mm) Alternator Air Gap .010 in. (.25 mm) Valve Clearance – Intake .005 - .007 in. (.13 - .18 mm) Valve Clearance – Exhaust .005 - .007 in. (.13 - .1[...]

163 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .625 in. (15.88 mm) .622 in. (15.80 mm) Bore Diameter 2.563 in. (65.10 mm) 2.567 in. (65.20 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in. (6.32 mm) .267 in. (6.78 mm) Intake Valve Stem[...]

164 12 MODEL 110000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .034 in. (.05 - .86 mm) Spark Plug Gap .03 0 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance – Exhaust .005 - .007 in. (.13 - .18 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Air [...]

165 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (12.72 mm) .504 in. (12.80 mm) Bore Diameter 2.688 in. (68.28 mm) 2.692 in. (68.38 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in. (6.32 mm) .267 in. (6.78 mm) Intake Valve Ste[...]

166 12 MODEL 120000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .034 in. (.05 - .86 mm) Spark Plug Gap .02 0 in. (.50 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance – Exhaust .005 - .007 in. (.13 - .18 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Air [...]

167 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (12.72 mm) .504 in. (12.80 mm) Bore Diameter 2.688 in. (68.28 mm) 2.692 in. (68.38 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in. (6.32 mm) .267 in. (6.78 mm) Intake Valve Ste[...]

168 12 MODEL 210000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .034 in. (.05 - .86 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance – Exhaust .005 - .007 in. (.13 - .18 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Air C[...]

169 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing 1.3795 in. (35.04 mm) 1.383 in. (35.13 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 3.437 in. (87.30 mm) 3.441 in. (87.40 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .237 in. (6.02 mm) .240 in. (6.10 mm) Intake Valve [...]

170 12 MODEL 280000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .023 in. (.05 - .58 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance – Exhaust .005 - .007 in. (.13 - .18 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Air C[...]

171 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing 1.3795 in. (35.04 mm) 1.383 in. (35.13 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 3.437 in. (87.30 mm) 3.441 in. (87.40 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .237 in. (6.02 mm) .240 in. (6.10 mm) Intake Valve [...]

172 12 MODEL 310000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .023 in. (.05 - .58 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance – Exhaust .005 - .007 in. (.13 - .18 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Air C[...]

173 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing 1.3795 in. (35.04 mm) 1.383 in. (35.13 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 3.563 in. (90.50 mm) 3.567 in. (90.60 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .237 in. (6.02 mm) .240 in. (6.10 mm) Intake Valve [...]

174 12 MODEL 330000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .008 - .012 in. (.20 - .30 mm) Crankshaft End Play .002 - .020 in. (.05 - .51 mm) Spark Plug Gap .03 0 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance – Exhaust .003 - .005 in. (.08 - .13 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Air [...]

175 12 REJECT DIMENSION S STANDARD SIZE REJECT S IZE CYLINDER Main Bearing 1.6248 in. (41.27 mm) 1.629 in. (41.38 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 3.701 in. (94.01 mm) 3.705 in. (94.11 mm) Bore Out-Of-Round N/A .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .237 in. (6.02 mm) .240 in. (6.10 mm) Intake Valve [...]

176 12[...]