Specifications

ManualsBrandsBriggs & Stratton ManualsAutomobile Parts250000

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

IGNITION Section 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETION Section 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GOVERNOR CONTROLS, CARBURETOR LINKAGE

& FLYWHEEL BRAKES Section 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GOVERNORS Section 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSION Section 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTERS & CHARGING SYSTEMS Section 7. . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION Section 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PISTONS, RINGS, RODS Section 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFTS, CAM GEARS, GEAR REDUCTIONS &

AUXILIARY DRIVES Section 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDERS & BEARINGS Section 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYNCHRO-BALANCE & OSCILLATING COUNTER BALANCE Section 12. . .

TABLE OF CONTENTS

270962 - Single Cylinder L-Head

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Summary of content (338 pages)

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270962 - Single Cylinder L-Head To go to the beginning of each section, click below. To go back to Table of Contents, click on "Bookmark" to the left TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1 IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 CARBURETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHECK COMMON SPECIFICATIONS FOR CHART ALL SINGLE CYLINDER “L” HEAD ENGINE MODELS CRANKSHAFT TORQUE SPECIFICATIONS BASIC MODEL SERIES OIL CAPACITY Fl. Ozs.J ARMATURE AIR GAP INCHES FLYWHEEL NUT CYLINDER HEAD FT. LBS. IN. LBS. CONN. ROD IN. LBS.
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CHECK COMMON SPECIFICATIONS FOR CHART ALL SINGLE CYLINDER “L” HEAD ENGINE MODELS CRANKSHAFT TORQUE SPECIFICATIONS BASIC MODEL SERIES OIL CAPACITY Fl. Ozs.J ARMATURE AIR GAP INCHES FLYWHEEL NUT CYLINDER HEAD FT. LBS. IN. LBS. CONN. ROD IN. LBS.
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English to Metric Conversion Table Fraction 1/64 Decimal 0.0156 mm 0.3969 1/32 3/64 0.0312 0.0469 1/16 IV 0.7938 1.1906 Fraction 33/64 17/32 35/64 Decimal 0.5156 0.5312 05469 mm 13.0969 13.4938 13.8906 0.0625 1.5875 9/16 0.5625 14.2875 5/64 3/32 7/64 0.0781 0.0938 0.1094 1.9844 2.3812 2.7781 37/64 19/32 39/64 0.5781 0.5938 0.6094 14.6844 15.0812 15.4781 1/8 0.1250 3.1750 5/8 0.6250 15.8750 9/64 5/32 11/64 0.1406 0.1562 0.1719 3.5719 3.9688 4.3656 41/64 21/32 43/64 0.6406 0.
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Drill Size – Decimal Equivalent In Inches 60 .040 39 .0995 20 .161 1 .228 Q .332 59 .041 38 .1015 19 .166 A .234 R .339 58 .042 37 .104 18 .1695 15/64 .2344 11/32 .3438 57 .043 36 .1065 11/64 .1719 B .238 S .348 56 .0465 7/64 .1094 17 .173 C .242 T .358 55 .052 35 .110 16 .177 D .246 23/64 .3594 54 .055 34 .111 15 .180 E, 1/4 .250 U .368 53 .0595 33 .113 14 .182 F .257 3/8 .375 1/16 .0625 32 .116 13 .185 G .261 V .377 52 .
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1 SECTION 1 General Information Section Contents Page SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AIR CLEANER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Cartridge Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 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.
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1 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.
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1 WARNING WARNING Engines give off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause nausea, fainting or death. Rotating parts can contact or entangle hands, feet, hair, clothing, or accessories. Traumatic amputation or severe laceration can result. • Start and run engine outdoors. • Do not start or run engine in enclosed area, even if doors or windows are open. WARNING • Operate equipment with guards in place. • Keep hands and feet away from rotating parts.
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1 LUBRICATION Gasoline Engines FUEL RECOMMENDATIONS These engines are certified to operate on unleaded gasoline. Use clean, fresh, regular unleaded gasoline with a minimum of 77 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.
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1 CHANGE OIL after first 5 hours of operation. Thereafter, change oil monthly or every 50 hours of operation. Change oil more often if engine is operated under heavy load or in high ambient air temperatures. During normal operation, partially burned gasoline, small particles of metal from the cylinder walls, pistons, bearings, combustion deposits, and dust particles from the air will gradually contaminate the oil.
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1 Fig. 4: Model Series 110000, 120000, 130000 1 1 Fig. 4 CLEAN COOLING SYSTEM Grass particles, chaff or dirt can clog the air cooling system. Continued operation with a clogged coolingsystem can cause severe overheating and possible engine damage. Figures 5, (vertical crankshaft model), and 6, (horizontal crankshaft model) show the blower housing removed and areas to be cleaned (1). This should be a regular maintenance operation, performed yearly or every 100 hours, whichever comes first.
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1 AIR CLEANER IDENTIFICATION Refer to Figs. 7 through 16 to determine air cleaner type and service procedures. 1 2 CARTRIDGE TYPE (Fig. 7) 3 (with or without Oil-Foam pre-cleaner or non-oiled pre-cleaner) Remove and Install 1. Remove wing nut or loosen screw (6) .Remove cover (5). 2. Carefully remove cartridge (3) to prevent dirt entry into carburetor. 4 3. Replace grommet if torn or damaged. 6 4. Clean or replace cartridge (3) as described on page 11. 5 7 Fig. 7 5.
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1 DUAL ELEMENT AIR CLEANERS Flat Cartridge (Figs. 9, 10) Remove and Install (Typical) 1. Loosen screw(s) (7) and remove cover (6). Tilt to remove covers with tabs (3) and slots (4), Fig. 9. 2. Carefully remove cartridge (2) and foam precleaner (1) if equipped. 3. Clean pre-cleaner (1) as described on page 11. 4. Install cartridge and foam pre-cleaner. If precleaner has lip, note orientation during disassembly and re-assemble accordingly. 5. Close cover (6) and fasten screw(s) (7) securely.
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1 Remove and Install Air Cleaner, Vertical Crankshaft (Typical, Fig. 13) 1 1. Lift latch (1) on narrow end of air cleaner cover (2) and remove cover. 2. Remove Oil-Foam (3) from air cleaner body. 3. Clean as described on page 11. 4. Place Oil-Foam element (3) in air cleaner body (5) making sure lip (4) of element extends over all edges of air cleaner body to form a seal. 5. Insert slot (7) on cover into tabs (6) on air cleaner body and press down to snap cover shut.
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1 CLEANING AIR CLEANER CARTRIDGE OIL-FOAMR ELEMENTS When to Clean CARTRIDGE only, Clean every 25 hours or once a season, whichever comes first. More often in dusty conditions. CARTRIDGE with dry or oiled foam pre-cleaner, pre-cleaner every 25 hours and cartridge every 100 hours. More often in dusty conditions. OIL-FOAM ELEMENT Clean and re-oil Oil-Foam element every 25 hours or at three month intervals under normal conditions.
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1 TUNE-UP PROCEDURE A “Tune-Up,” as listed below, would normally be performed on relatively new engines brought in for minor difficulties. Performing these steps will either assure that the engine is functioning properly or will point out necessary repairs. These steps are also covered in the Overhaul Procedure and will normally be performed as a part of the complete overhaul. STEP NO. 1. Remove spark plug lead from spark plug. 2. Remove air cleaner. 3. Check oil level and drain.
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1 CHECK-UP Check Ignition Most complaints concerning engine operation can be classified as one or a combination of the following: 1. Will not start 2. Hard starting 3. Kicks back when starting 4. Lack of power 5. Vibration 6. Erratic operation 7. Overheating 8. High oil consumption When the cause of malfunction is not readily apparent, perform a check of the compression, ignition and carburetion systems. This check-up, performed in a systematic manner, can usually be done in a matter of minutes.
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1 Check Carburetion CHECK-UP. cont’d Hard Starting, Kickback, or Will Not Start Before making a carburetion check, be sure the fuel tank has an ample supply of fresh, clean gasoline. On gravity feed (Flo-Jet) models, see that the shut-off valve is open and fuel flows freely through the fuel line. On all models, inspect and adjust the mixture needles per specification. Check to see that the choke closes completely. If engine will not start, remove and inspect the spark plug. If plug is wet, look for: 1.
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1 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.
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2 SECTION 2 Ignition Section Contents Page FLYWHEELS Remove Except Model Series 80000 (with cast iron flywheel), 100700, 100200, 100900, 130000, and 280000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Iron Flywheel, Model Series 80000, 100200, 100900, 110000, 130000 . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Flywheel Key, Keyway and Crankshaft Keyway . . . . . . . . . . . . . . . . . . .
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2 BRIGGS & STRATTON IGNITION SYSTEM 1. Magnetron ignition, a self-contained transistor module (2), ignition armature, (1) and flywheel (3), Fig. 1. Inset: current style 1 2 3 Fig. 1 CHECK IGNITION 1 .008” (0.2 mm) 2 WARNING Unintentional sparking can result in fire or electric shock. • Use approved spark plug tester. • DO NOT check for spark with spark plug removed. .166” (4.2 mm) 1.
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2 SPARK PLUGS Spark Plug Service Gap spark plug to .030” (0.76 mm) gap (1), Fig. 4. Replace spark plug if electrodes are burned away or porcelain is cracked. DO NOT USE ABRASIVE CLEANING MACHINES. 1 NOTE: In some areas, local law requires the use of a resistor spark plug to suppress ignition signals. If originally equipped with a resistor spark plug, use the same type of spark plug for replacement. Fig.
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2 Remove Flywheel NOTE: For Aluminum Series engines: 80000 (with cast iron flywheel), 100200, 100900, 110000 and 130000, and also for kerosene Model Series 135400, 13K400, see text. 2 3 1 1. See Table No. 1, page 15 for correct flywheel puller. 2. Use flywheel nut to protect crankshaft threads and for puller to bear against, Fig. 7. 3. Thread flywheel nut (1) onto crankshaft until top of nut is flush with crankshaft threads or slightly above end of threads. Fig.
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2 5. Use flywheel nut (1) to protect crankshaft threads and for puller to bear on, Fig. 10. 19203 6. Tighten both puller screws equally until flywheel is loose. 1 NOTE: If puller screws on Tool #19203, Flywheel Puller, are too short, use two head bolts from Model Series 280000, Part #93723. Fig. 10 INSPECT – FLYWHEEL KEY, FLYWHEEL AND CRANKSHAFT KEYWAYS Inspect flywheel key for partial or complete shearing. If damaged, replace. Inspect flywheel and crankshaft keyways for damage.
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2 MAGNETRONr IGNITION SYSTEM 1 Identification Magnetron has been produced in two versions, composite Type I (Inset A), Type II (Inset B), and replaceable module (2), Fig. 11. 1 NOTE: Magnetron ignition armatures used on Model Series 120000, 280000 do not have a visible trigger pole (3) and do not have a Mylar spacer (1), Fig. 11. A 1 2 3 B Fig. 11 Remove Magnetronr Ignition Armatures Disconnect Stop Switch Wire Removal of the flywheel is not required to remove Magnetron ignition armatures. 1.
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2 Install Module on Ignition Armature Install the module with the retainer on the side of the armature with small rivet ends (1), Fig. 14. 1 2 Ignition armature ground wire (2), Fig. 14. Ignition armature primary wire (3), Fig. 14. 3 Fig. 14 Install Stop Switch and Ignition Armature Primary Wire 1. Remove all insulating material from ends of wires to ensure good contact. 2. Use a 3/16 inch (4.
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2 Timing Magnetronr Ignition Armature Model Series 32K400 1 2 Position ignition armature bracket so mounting screws are to the far left in the ignition armature bracket slots. Tighten screws. INSTALL IGNITION ARMATURES Pneumatic (Fig. 18) and Mechanical (Fig. 19) 3 1. Install ignition armature and air vane or air guide (3), when used. The mounting holes of the ignition armature are slotted. 2. Push ignition armature away from flywheel (4) as far as possible and tighten one mounting screw (1).
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2 Stationary Stop Switch Location Stationary stop switches are located on fuel tank brackets, governor control brackets, cylinder head brackets, System 2 and System 4 band brake control brackets, and brake shoe on Model Series 100700, 120000. Typical installation, Fig. 22. 2 1 Stop switch assembly (1), slot in bracket (2), insert stop switch into slot (3), push down until it snaps into place (4), stop switch in position (5). Reverse steps to remove. 5 4 3 Fig.
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2 Stationary Stop Switch, Electrical Check 1 1. Push down on wire retainer and remove stop switch wire. On System 2, System 3 and System 4 engines, the band brake control cover (2) must be removed, Figs. 26 and 27. If battery (5) is mounted on the engine, it must be removed from the battery holder before the cover can be removed. On series 100700 engines, the flywheel must be removed before the stop switch can be tested. Spark plug wire holding tab (3) Spark plug (4) Fig. 26 3 2 4 Fig. 26 1 2 2.
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2 NOTE: On System 2 and System 4 engines operate safety control (operator presence control) to move control lever away from stop switch (4), Figs. 24, 28 and 29. 4 4. With control lever in run position, meter should show no continuity (high ohms reading). 5. Move control lever or release safety control to move control lever to stop position. 6. Meter should show continuity (low ohms reading). 7.
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2 5. METAL KEY SWITCH – FIVE OR SIX TERMINALS: Meter must indicate continuity between terminals as noted in keyswitch positions as shown in Fig. 32. 6. SWITCH WITH PLASTIC KEY: Meter should indicate no continuity with key pushed in, and continuity with key pulled out. Switch Position 1. OFF 2. RUN 3. START Continuity 1+3+6 2+5+6 2+4+5 OFF 1+3+6 Fig. 32 B – Terminal Positions: Terminal 1 grounded to switch case. Meter must also indicate continuity between terminal 1 and switch case.
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2 Check Stop Switch Wire Continuity To test, first place control lever or safety control in run position. 1. Use a Digital Multimeter, set meter to ohms (Ω) and connect one test lead to ground (unpainted bracket or engine surface). 2. Hold other test lead against stop switch tang, Fig. 33, while moving stop switch wire up and down. DO NOT pull on stop switch wire. 3. Meter should read less than 1 ohm or more than 0.3 ohms during stop switch wire movement. 4.
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2 Fig 36: Model Series 100700 System 2r Fig. 36 Fig. 37: Model Series 120000 System 2r Fig. 37 NOTE: SPECIFICATION TABLES BEGIN ON PAGE 15 OF THIS SECTION.
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2 SPECIFICATION TABLES TABLE NO. 1 SPECIFICATIONS FOR ALL POPULAR ENGINE MODELS 1. Spark plug gap: .030” IGNITION ARMATURE TWO LEG TWO-LEG AIR GAP THREE LEG THREE-LEG AIR GAP FLYWHEEL PULLER TOOL NO. NO 60000, 80000 .006”-.010” .012”-.016 ” 19069 19167 or 19372 55 Ft. Lbs.♦ (75 Nm) 90000, 9K400, 10A900, 10B900, 10C900, 110000, 120000 .006”-.010” 19069 19167 or 19372 55 Ft. Lbs.♦ (75 Nm) 100700 .006”-.010” 19069 19310 or 19372 55 Ft. Lbs.♦ (75 Nm) 100200, 100900, 130000, 135400, 13K400 .
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3 SECTION 3 Carburetion Section Contents Page IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 4, 5 FLO-JET CARBURETORS LMS Types Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Section Contents, Cont’d. TANK MOUNT CARBURETORS, VERTICAL CRANKSHAFT, CONT’D Pulsa-Jet Cont’d Choke-A-Matic Cont’d Adjust Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Adjust Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Vacu-Jet All-Temperature/Automatic Choke or Automatic Choke . . .
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3 CARBURETOR IDENTIFICATION Several styles of carburetors are used on Briggs & Stratton engines. Compare carburetor to be repaired with the following illustrations for identification. Refer to section index for location of service and repair information. FLO-JET CARBURETORS LMS Small Two Piece LMT Medium Two Piece Small One Piece Large Two Piece Large One Piece Cross-Over NOTE: SPECIFICATION TABLES BEGIN ON PAGE 63 OF THIS SECTION.
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3 TANK MOUNTED CARBURETORS, VERTICAL CRANKSHAFT: Fig. A – Pulsa-Prime: Primer bulb (1) Fig. B – Pulsa-Jet All Temperature/Automatic Choke: Large breather opening (1), Choke link cover (2) Fig. C – Pulsa-Jet Automatic Choke: Small breather opening (1), Choke link cover (2) Fig. D – Pulsa-Jet Choke-A-Matic: Choke-A-Matic lever Fig. E – Vacu-Jet All Temperature/Automatic Choke: Large breather opening (1), Choke link cover (2) Fig.
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3 TANK MOUNTED CARBURETORS, VERTICAL CRANKSHAFT Fig. G – Pulsa-Jet Choke-A-Matic: Choke-A-Matic lever. 1 Fig. G TANK MOUNTED CARBURETORS, HORIZONTAL CRANKSHAFT Fig. A: Air cleaner post (1), Welch plug (2), Idle mixture adjustment needle or fixed pilot jet (3) Fig. B: Pulsa-Jet with Rotary Choke – Rotary choke (1) Fig. C: Pulsa-Jet, Slide Choke: Fuel pump cover (1), Slide choke (2) Fig. D: Vacu-Jet, Slide Choke 1 2 3 1 Fig. A Fig. B 1 2 Fig. C Fig.
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3 BEFORE REMOVAL OF CARBURETOR WARNING Gasoline and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. • • When removing the fuel hose from the carburetor on a machine without a fuel shut off, drain any fuel from the tank first. Do not thread a a bolt or cap screw in the removed hose end. Screw threads will damage the hose ID and rubber particles will enter the fuel system.
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3 TANK MOUNTED CARBURETORS – VERTICAL CRANKSHAFT ENGINES Pulsa-Prime Model Series 9B900, 9C900, 9D900, 93900, 95900, 96900, 10A900, 10B900, 10C900 Remove Carburetor and Tank Assembly (Figs. 1 & 2) 1. Remove fuel tank mounting bolts (1), Fig. 1. 1 Fig. 1 2. Slip carburetor and fuel tank assembly off fuel intake tube (3). 3. Turn assembly to free throttle link from throttle lever (1). 1 2 3 4.
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3 Install Primer, Disassemble Carburetor 1. Slide jet screen off carburetor body. Fixed main jet is not a service part. 2. Press in from both sides of primer bulb cavity to release retainer tabs (inset 4). 3. Pry retainer out and remove primer bulb from primer seat groove (3). 4. Remove primer seat using a crochet hook or other type of hook. Ball (2) and spring (1) will fall out, Fig. 4. 5. Remove intake tube “O” ring from carburetor. NOTE: Do not stretch, bend or compress primer spring.
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3 Assemble Carburetor 1. Place primer spring and ball in primer valve bore. 2. Press primer seat into bore with groove on seat facing out, Fig. 4. 3. Insert primer bulb into retainer and moisten inside diameter of primer bulb. 4. Press into primer cavity lining up locking tabs with locking slot in cavity. 5. Press until both tabs are seated in locking slots. Install Fuel Pick-Up Tube (Fig. 7) 1 Insert pick-up tube (1) in carburetor body. Place screen squarely on a hard surface.
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3 Pulsa-Jet Carburetors Model Series 92900, 94900, 110900, 112900, 113900, 114900 Vacu-Jet Carburetors Model Series 92500, 93500, 94500, 95500 1 2 NOTE: Pulsa-Jet and Vacu-Jet carburetors for vertical crankshaft models are combined in this section. Issues specific to individual models or types will be noted in the text and corresponding illustrations. Carburetor Types (Fig. 10) 3 There are three basic types of Pulsa-Jet and Vacu-Jet carburetors used on above series engines.
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3 Automatic Choke Operation (Fig. 13) A diaphragm under the carburetor (3) is connected to choke shaft by a link (2), Fig. 13. A calibrated spring under diaphragm holds choke plate (1) closed when engine is not running. When running, vacuum created during intake stroke is routed to the bottom of the diaphragm, through a calibrated passage, opening choke against spring pressure.
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3 If engine on a mower with a high-inertia disc type cutter blade becomes hard starting when engine is warm, a leaner carburetor mixture may be required. See following note: NOTE: A heavy, high-inertia disc type cutter blade rotates for a longer period of time, after governor control is placed in “STOP” position. During this “coasting” period, engine continues to induct fuel-air mixture, even when choke is open. If carburetor mixture is too rich, warm engine may flood and become hard starting.
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3 NOTE: Model Series 113900 Type #2999 has a stud (at lower rear of fuel tank) and a mounting screw (at top of fuel tank between carburetor and fuel cap). 1 2 3. Slip carburetor over notch in cylinder shield (4) and away from intake manifold (5), and seal (3), Fig. 16. Rotate carburetor and tank assembly to disconnect governor link (2) from throttle lever (1). 3 NOTE: On some models, it may be necessary to remove blower housing. 4 5 Fig.
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3 Disassemble Pulsa-Jet, Vacu-Jet Carburetors Remove Needle Valve Assembly NOTE: Metering holes in carburetor body (1) should be cleaned with solvent and compressed air only, Fig. 18. Typical “O” ring (2), early “O” ring (inset 3), Fig. 18. 2 3 1 Fig. 18 DO NOT ALTER SIZE OF HOLES Inspect mixture adjustment needle (1), Fig. 19, and replace if bent (2), or grooved (3). 2 1 3 Fig. 19 Screw-In Type (Fig. 20) 1 1. Remove and discard “O” ring. 2.
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3 Remove Throttle Plate and Shaft Throttle shaft, Fig. 22, is removed by backing out idle speed adjusting screw and removing the throttle plate screw (3). After removal of plate, throttle shaft may be lifted out. Throttle (1), throttle plate (2), pencil (4). 1 4 2 3 Fig. 22 Remove Fuel Pick-Up Tubes Zinc Carburetors Model Series 92000, 110900, 111900, 112900, 113900 (except Type #2999), 114900, 130900, 131900, 132900 Short nylon fuel pipes (1) are threaded into carburetor body.
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3 Screw-in Type Model Series 92500, 93500, 94500, 95500 1 NOTE: Vacu-Jet carburetors have a metal ferrule (1) and check ball (3) in nylon fuel pick-up tube (2). To function properly, screen (4) must be clean and check ball free. Replace tube if screen is clogged or check ball is not free, Fig. 26. 2 3 4 Fig. 26 Breather and Intake Manifold (Fig.
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3 Remove Nylon Choke Plate and Shaft Choke-A-Matic or Manual Choke Model Series 92000, 92500, 93500, 94500, 95500, 100900, 113900 (Type #2999), 130900, 131900, 132900 3 4 1. To remove choke parts, disconnect choke return spring (2) (when used), from lever (1) Fig. 30. 2. Pull nylon choke shaft (4) sideways to separate choke shaft from choke plate. 1 2 NOTE: If choke plate is heat-sealed to choke shaft, loosen by sliding sharp pointed tool (3) along edge of shaft. Fig.
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3 Check Tank Top Machined surface on top of fuel tank must be flat in order for diaphragm to provide an adequate seal between carburetor and tank. If surface is not flat, it is possible for gasoline to enter vacuum chamber and into carburetor by passing between tank and diaphragm. 1 2 Flatness can be checked with a straight edge (1) and feeler gauge (2), as shown in Fig. 32. A .002” (.05 mm) feeler gauge should not enter between straight edge and machined surface, when checking at shaded areas shown.
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3 Install Pressed-In Type Fuel Pick-Up Tube (Vacu-Jet) Insert pick-up tube in carburetor body. Place pick-up tube screen squarely on a hard surface. Push firmly on carburetor with palm of hand. Pick-up tube may snap into place with considerable force, Fig. 35. Fig. 35 Install Throttle Shaft and Plate (Fig. 36) 4 Insert throttle shaft (1), place throttle plate (2) on flat side of shaft and secure with throttle plate screw (3), Fig. 36. Pencil (4). 1 2 3 Fig. 36 Assemble Automatic Choke (Fig. 37) 1.
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3 Assemble Bimetal Spring After cleaning, repairing and assembling of other carburetor parts, bimetal spring and shaft assembly may be installed. 45° 1 2 3 A 1. Place choke plate (1) in choke (closed) position. 2. Position notch of shaft assembly so that free end of spring loop will be within shaded area of cavity (5), Fig. 39. Fig. 39 – A: Spring position when ambient temperature is 80-120° Farenheit (27-49° Celsius). 5 2 45° 4 Fig.
PAGE 59
3 Assemble Carburetor to Fuel Tank Pulsa-Jet (except Model Series 113900, Type #2999), and Vacu-Jet (except Choke-A-Matic) 1 2 1. Place “O”-ring (1) in groove in throttle bore, (VacuJet) Fig. 42. Cross section (2), new “O” ring (3), Fig. 42. 3 Fig. 42 2. Holding carburetor body upside down, place diaphragm on body while guiding choke link thru link hole for link. Be sure that pump spring and cap (1) are in fuel pump well, (Pulsa-Jet) Fig. 43. 1 Fig. 43 3.
PAGE 60
3 6. Close choke plate (1). Insert choke link (3) into choke shaft (2) as shown, Fig. 45. 6 1 5 7. Install rubber elbow and assemble carburetor to fuel tank including pre-loading automatic choke diaphragm, see below. 4 3 2 Fig. 45 Pre-Load Diaphragm 1. Move choke plate to an over center position as shown in Fig. 46. 2. Hold choke while tightening carburetor mounting screws in a staggered sequence. NOTE: Opening choke to an over center position places diaphragm in a pre-loaded condition. 3.
PAGE 61
3 Assemble Vacu-Jet Choke-A-Matic Carburetor to Fuel Tank 1 1. Place new tank mounting gasket on tank top. 2. Lower carburetor onto tank top. 3. Install two mounting screws and tighten. 2 Install Needle Valve Assembly, Screw-in Type (Fig. 48) 1. Install needle valve seat (1) being sure not to cause burrs in slot. 2. Insert needle valve into threaded nut assembly. Turn clockwise 1–2 turns. 3. Install needle valve assembly (2), Fig. 48. Fig.
PAGE 62
3 Pulsa-Jet, Vacu-Jet, Choke-A-Matic Model Series 92000 2 1 3 1. Put a light film of oil on “O” ring in throttle bore. 2. With governor link (3) hooked to governor blade (1), connect link to throttle (4) and slip carburetor into place. 4 3. Align carburetor with intake tube and breather tube grommet. 4. Hold choke lever (5) as shown in Fig. 51, so it does not catch on control plate. 5 5. Do not distort “O” ring when fitting carburetor to intake tube. 6 Fig. 51 6. Install mounting bolts. Fig.
PAGE 63
3 Adjust Choke-A-Matic Model Series 92000 A B Choke-A-Matic is standard on Model Series 92900 (type nos. lower than 0500), and Series 92500 (type nos. lower than 600) engines. Remote control must be of type in which control wire moves 2-1/8” (54 mm) (A) out of casing when control lever is moved from “STOP” position (2) to “CHOKE” or “START” position (1) A minimum travel of 1–3/8” (35 mm) (B) is required when remote control is mounted, Fig. 54. 2 1 Fig. 54 1.
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3 Initial Adjustment 1 2 1. Using tool #19263 (4), turn needle valve (5) clockwise until the needle lightly contacts the seat. 3 2. Then open 1-1/2 turns. This initial adjustment will permit engine to be started and warmed up before making final adjustment. 4 Final Adjustment 1. Place governor speed control (6) lever in “FAST” position. 2. Using tool (4), turn needle valve (5) in until engine misses (clockwise – lean mixture) then turn needle valve out (counterclockwise) 3/8 turn, Fig. 57. 6 5 Fig.
PAGE 65
3 Adjustable Pulsa-Jet Carburetors with Choke-A-Matic, Manual or Remote Choke Model Series 60000, 80000, 90000, 100000, 110000, 130000 1 These Pulsa-Jet carburetors all have a combined idle and main jet adjustment needle, integral fuel pump and have either manual rotary (2) or slide choke in manual (3), remote or Choke-A-Matic (1), Fig. 59. 2 3 Fig. 59 Model Series 91200, 92200, 94200 (Fig. 60) 1. Remove air cleaner assembly. 2. Move throttle (top) lever to idle position.
PAGE 66
3 Remove Fuel Tank from Carburetor (Fig. 62) 1 1. Remove remaining screws holding fuel tank onto carburetor. (Install [1] first). 2. Remove screw holding fuel tank bracket to cylinder base. 3. Separate fuel tank from carburetor and remove fuel tank gasket (2) and discard. 4. Disconnect governor linkage and spring from carburetor. Remove Carburetor (Pulsa-Jet and Vacu-Jet) 2 1.
PAGE 67
3 ÉÉÉ ÉÉÉ ÇÇ ÇÇ ÇÇ ÉÉÉ ÇÇ ÉÉÉ ÉÉÉ Pulsa-Jet 1. Remove idle mixture needle and spring. 1 NOTE: Low emissions carburetors use a pilot jet instead of an idle mixture needle and spring. Remove pilot jet. 2. Snap out choke plate and remove choke shaft. 3. Remove filter screen from well, when used. 4. With a modified 1/4 inch (3.9 mm) pin punch, remove welch plug(s) (1) from carburetor body, Fig. 65. DO NOT remove fixed jet. Fig. 65 Remove Needle Valve and Seat 1. Remove needle valve (1) to inspect. 2 2.
PAGE 68
3 Remove Fuel Pick-Up Tube Pulsa-Jet 1 1. To remove screen housing or nylon pipe from brass pipe, slide retaining clip (2) up onto brass pick-up tube (1). 2. Cut end of nylon tube where tube connects to brass tube and remove tube. 3. Slide off old retaining clip and discard, Fig. 68. 2 NOTE: Do not remove brass pipe. Fig. 68 Remove Fuel Pick-Up Tube Vacu-Jet 1 Nylon fuel pick-up tubes are removed and replaced with a 6 point 9/16” (1) socket, Fig. 69.
PAGE 69
3 Disassemble Choke-A-Matic Linkage Slide Choke, (Except Model Series 100900, 130900, 131900, 132900) 2 3 1 1. To remove choke link (2), remove speed adjustment lever (3) and stop switch insulator plate (4). 4 2. Remove speed adjustment lever from choke link. 6 3. Then pull out choke link through hole in choke slide (6), Fig. 72.
PAGE 70
3 High Altitude Compensation (Pulsa-Jet) NOTE: If engine is operated at high altitudes, performance may decrease. If poor performance is experienced remove main air bleed jet (1), Fig. 75. 1 NOTE: For low emission carburetors (type numbers ending in A1 through A9 or E1 through E9) use the following procedure: 1. Remove end welch plug. Fig. 75 2. Using a #3-48 UNC tap, tap into main air bleed jet, Fig. 75. 3. Clamp square end of tap in vise and turn carburetor body clockwise to pull air bleed jet. 4.
PAGE 71
3 PULSA-JET LOW EMISSION CARBURETORS: (Engines with type numbers 1 4 2 ending in A1 through A9 or E1 through E9): 1. Install choke shaft as shown in Fig. 78. 2. Install pilot jet until it seats firmly. 5 3 Fig. 78 Assemble Choke-A-Maticr Linkage Rotary Choke (Pulsa-Jet) 1 3 2 1. Insert “Z” bend of Choke-A-Matic linkage (1) into same hole (6) as return spring (2). 2. Slide washer on the end of linkage and then slide Choke-A-Matic lever onto shaft (3). 3.
PAGE 72
3 Manual Choke 1 Note: Bottom tooth of choke shaft (1) should engage top tooth on manual choke lever (2), Fig. 82. 2 Fig. 82 Install Spiral When inserting spiral, top must be flush to 1/32” (.8 mm) below carburetor flange (1), and spiral parallel with fuel tank mounting surface, Fig. 83. 1 Fig. 83 Install Throttle Shaft and Plate Cast Throttle Shaft 1 1 1. If Pulsa-Jet carburetor body had a throttle shaft seal, install new seal with sealing lip up. 2 4 2.
PAGE 73
3 Vacu-Jet 1. Place new dust seal on throttle shaft and install in carburetor body. 6 4 2. Install throttle plate in carburetor body and install screws. 3 1 Install Choke Shaft and Plate (Pulsa-Jet) 1. Place metal washer (2) next to choke lever and then foam washer (1). 2. Insert shaft assembly in carburetor body with stop against remote control boss (3). 3. Insert choke plate in shaft with hole up (6) and indentations towards large welch plug (7), Fig. 86.
PAGE 74
3 Install Carburetor and Fuel Tank Rotary Choke (Pulsa-Jet) 1 1. Connect governor linkage to carburetor linkage and using Tool #19305, Offset Screwdriver, Tool #19391, Torx Wrench, or open end wrench (2), install two screws (1) holding carburetor to engine, Fig. 89. 3 2. Install screw to bottom of fuel tank bracket (3). 2 Fig. 89 Choke-A-Maticr with Slide Choke (Pulsa-Jet) 1. Install carburetor and tank as one assembly. 1 2. Hook throttle link (1) into carburetor throttle and governor blade. 3.
PAGE 75
3 Vacu-Jet 1. Place new carburetor to cylinder gasket on carburetor and install carburetor on cylinder with two mounting screws. 2. Place new carburetor to fuel tank gasket on fuel tank and lift tank up against bottom of carburetor. Install two screws in carburetor and fuel tank. Choke-A-Maticr Linkage Adjust Choke-A-Maticr Linkage Slide Choke The following covers Choke-A-Matic parts installed as a part of carburetor assembly. See Section 4 for Choke-A-Matic remote controls. 1.
PAGE 76
3 Final Adjustment 1. Start and run engine at half throttle for five minutes to bring engine up to operating temperature. smooth operation point until engine runs unevenly (counterclockwise – rich mixture). 2. Place governor speed control lever in “FAST” position. 4. Turn needle valve to midpoint between rich and lean so engine runs smoothly. 3. Turn needle valve in until engine misses (clockwise – lean mixture) then turn it out past Final Adjustment, except Low Emissions Carburetors 1.
PAGE 77
3 LMS FLO-JET CARBURETORS (LMS, LMT) 6 NOTE: LMS and LMT Flo-Jet carburetors are combined in this section. Issues specific to individual models or types will be noted in the text and corresponding illustrations.
PAGE 78
3 Disassemble Carburetor NOTE: Low emission carburetors do not have an idle mixture needle valve and spring. 1. Remove main jet/fuel bowl nut and fiber washer. 2. Remove float bowl and bowl gasket from carburetor. ÉÉ ÉÉÇÇ ÇÇ ÇÇ ÉÉ ÉÉ NOTE: On Model Series 120000 engines bowl nut may incorporate the fixed main jet. 1 3. Remove float hinge pin, float, and inlet valve (4). 4. Remove idle mixture screw with spring (6) and idle speed screw with spring (8). (Remove mixture screw limiter cap, if so equipped.
PAGE 79
3 Remove Fuel Inlet Seat LMS, LMT Flo-Jet Carburetors were manufactured with two basic types of fuel inlet seats. One type featured a replaceable Viton seat used with a metaltipped float needle. The other type featured a pressedin metal seat used with a Viton-tipped float needle. 1 To remove the replaceable Viton seat, use a small crochet hook (or similar tool), and hook/lift out the old seat. Some carburetor models equipped with a Viton seat also have a serviceable metal pressed-in seat beneath.
PAGE 80
3 NOTE: Some Low Emission LMT carburetors have pressed in pilot jets (1) that are not removable. DO NOT remove the pressed in style pilot jet, Fig. 103. 1 Fig. 103 Remove Emulsion Tube (LMT) Using Tool #19280, Carburetor Screwdriver, remove main carburetor emulsion tube (1), Fig. 104. 1 Inspect Carburetor Inspect all components for wear, damage, cracks, or plugged openings. Replace components if any of the above conditions exist. Use only compressed air and solvents to clear plugged openings.
PAGE 81
3 Assemble Carburetor Install Welch Plug 1. Install welch plug(s) (1) with pin punch (2) slightly smaller than outside diameter of plug. 1 2 2. Press in until plug is flat. DO NOT cave in plug. 3. After plug is installed, seal outside edge of plug with fingernail polish or non-hardening sealant, Fig. 107. Fig.
PAGE 82
3 Install Choke Shaft and Plate LMS Models (Return Spring on Lever) 1 2 1. Install choke shaft (1) and felt washer (2). 2. Rotate choke shaft lever as shown in Fig. 110. 3. Insert choke plate in slot of choke shaft until valve is centered on choke shaft with dimples (3) toward main air jet (4). 4 3 Fig. 110 (Return Spring on Shaft) 1. Install choke shaft, return spring (1), and felt washer (3). 1 2. Rotate choke shaft counterclockwise until arm on shaft is approximately 90° to carburetor bore.
PAGE 83
3 LMT Models (Plastic Choke Shaft and Plate) 2 1 3 1. Insert spring inside large foam seal and slide seal and spring onto choke shaft with straight end of spring up toward choke shaft lever (3). 2. Insert choke shaft into carburetor body until hook of spring hooks on spring anchor (1). 4 3. Lift choke shaft and lever up slightly and turn counterclockwise until stop on lever (2) clears spring anchor (1) and push shaft down, Fig. 113. 6 4.
PAGE 84
3 Install Emulsion Tube 1. Install emulsion tube (1) using Tool #19280, Carburetor Screwdriver, until emulsion tube seats, Fig. 116. Float (2), hinge pin (3), Fig. 116. 1 2. After installing emulsion tube, use compressed air to blow out any chips or debris that may have been loosened while installing emulsion tube. Install Inlet Needle and Float 3 2 1. Insert inlet needle on float and install assembly on carburetor body. 2. Insert float hinge pin and center pin. Float height is non-adjustable. Fig.
PAGE 85
3 NOTE: On Choke-A-Matic carburetors install spring on choke shaft as shown in Fig. 110. 5. Install air cleaner cartridge, Pre-Cleaner (optional) and cover making sure that three tabs engage three slots in back plate. Install Choke-A-Maticr Link (LMT) Horizontal Control Plate 1 1. Insert “Z” bend of link (2) in outer hole of choke lever from bottom of lever (4). 2. Slide “U” bend of link (1) into slot on governor control bracket and place carburetor on intake elbow. 2 3 3. Torque studs(3) to 65 in.
PAGE 86
3 3. Turn idle speed screw to obtain 1750 RPM minimum. 4. Turn idle mixture screw clockwise slowly until engine just begins to slow. 1 5. Then turn screw opposite direction until engine just begins to slow. 6. Turn screw back to midpoint. 7. Install limiter cap (1) at midpoint position, when used, Fig. 121. 8. Move equipment speed control from idle to high speed position. 9. Engine should accelerate smoothly. Fig. 121 10. If the engine stumbles or hesitates, open idle mixture needle screw 1/8 turn.
PAGE 87
3 The large One-Piece Flo-Jet carburetor is similar to the small One-Piece Flo-Jet. The main difference is that the main jet needle valve (1) is below fuel bowl, Fig. 123. 2 Repair procedures for small and large One-Piece Flo-Jet carburetors are similar except for location of adjusting needles. 3 1 Fig. 123 TWO-PIECE FLO-JET (SMALL, MEDIUM AND LARGE) 2 3 Figs. 124, 125, and 126 illustrate the three sizes of Two-Piece Flo-Jets used on Briggs & Stratton engines. 4 Fig.
PAGE 88
3 CROSS-OVER FLO-JET HORIZONTAL CRANKSHAFT ENGINES 1 2 3 The cross-over Flo-Jet carburetor is used on Model Series 253400, 255400 engines and is a float type carburetor with idle circuit and main jet adjustment needles. This carburetor also has an integral fuel pump. All adjustments can be made from top of carburetor, Figs. 127 and 128. 4 Fig. 127 Main jet needle valve (1) Idle needle valve (2) Idle speed adjustment (3) Throttle lever (4) 5 Fig. 127 Disassemble Cross-Over Flo-Jet (Fig. 128) Fig.
PAGE 89
3 5. Small one-piece Flo-Jet (A): Use Tool #19280, Carburetor Screwdriver, to remove emulsion tube (3), Fig. 130 A. 1 1 Fig. 130 Main jet needle (1) Venturi (2) Emulsion tube (3) 2 3 3 A 2 B Fig. 130 Large One-Piece Flo-Jet 1. Remove idle circuit needle valve (1), Fig. 131. 9 2. Remove main jet needle valve assembly (4) from float bowl and remove fuel bowl. 1 8 3. Use Tool #19280, Carburetor Screwdriver, to remove emulsion tube (5), then remove jet from top of carburetor. 4.
PAGE 90
3 Disassemble Two-Piece Flo-Jet 1. Remove idle circuit needle valve (2). 2. On early small model, loosen main jet needle valve packing nut (6, 7). Remove packing nut and main jet needle valve together. On all current models, remove main jet needle valve assembly. 3. Remove emulsion tube (8) with Tool #19280, Carburetor Screwdriver. Use of Tool #19280 will help to prevent damage to threads in lower carburetor body.
PAGE 91
3 Throttle Shaft, Plate and Bushings (Typical) Excessive wear of the throttle shaft and/or throttle shaft bushings can contribute to poor engine performance. 1 Check Throttle Shaft and Bushings for Wear 1. Wear between throttle shaft and bushings should not exceed .010” (.25 mm). 2. Check wear by placing a short iron bar on upper carburetor body as shown in Fig. 136. Fig. 136 3. Measure distance between bar and shaft with feeler gauge (1) while holding shaft down and then holding shaft up. 4.
PAGE 92
3 Replace Inlet Seat, Pressed In Type NOTE: Flo-Jet Carburetors were manufactured with two basic types of fuel inlet seats. One type featured a replaceable Viton seat used with a metal-tipped float needle. The other type featured a pressed-in metal seat used with a Viton-tipped float needle. To remove the replaceable Viton, use a small crochet hook (or similar tool) to hook/lift out the old seat. Some carburetor models equipped with a Viton seat also have a serviceable metal pressed-in seat beneath.
PAGE 93
3 Install Float 1. Install inlet needle to float as shown, Fig. 141. Open end of hook on spring must face away from venturi. 2. Install float and inlet needle assembly and center float hinge pin on two on hinge pin bosses. Fig. 141 Check Float Level 1 1. With body gasket in place on upper body and inlet needle and float installed, float (2) should be parallel to body mounting surface as shown in (1), Fig. 142. 2. If not, bend tang on float (4) with needle nose pliers (3) until surfaces are parallel.
PAGE 94
3 5. Fasten upper and lower bodies together with mounting screws. ÈÈÈ ÈÈ ÈÈÈ ÈÈ ÈÈÈ ÈÈ ÈÈÈ È ÈÈÈ ÈÈÍÍÍ ÈÈÈ ÍÍ ÍÍÍÍÍ ÍÍÍÍ ÍÍ ÍÍ ÍÍ Í ÍÍÍÍÍ ÍÍÍÍ ÍÍ ÍÍ ÍÍ Í ÍÍÍÍÍ ÍÍÍÍ ÍÍ ÍÍÍÍÍÍÍÍÍÍ ÍÍ ÍÍ ÍÍÍÍÍ ÍÍÍÍ ÍÍ ÍÍÍÍÍÍÍÍÍÍ ÇÇ ÍÍÇ ÍÍÍÍÍÍÍÍÍÍ ÇÇ Ç ÍÍÍÍÍÍÍÍÍÍ ÇÇ ÍÍ ÍÍÍÍÍÍÍÍÍÍÍÍ 1 11 6. Screw in emulsion tube (8) with Tool #19280, Carburetor Screwdriver, being careful that emulsion tube tip enters recess in upper body, Fig. 143. Tighten emulsion tube securely. 2 3 10 4 9 8 7 6 5 Fig.
PAGE 95
3 Adjust Carburetor – All Initial Adjustment 1. Turn both idle (1) and main jet needle (2) valves clockwise until they just contact seat, Fig. 147. 2. Turn both needle valves 1-1/2 turns counterclockwise. These settings will allow engine to start. Final adjustment should be made when engine is running and has warmed up. Fig. 147 Idle speed adjusting screw (3) Throttle lever (4) Choke lever (5) 2 1 3 4 5 Fig. 147 Final Adjustment – All (Typical) 1.
PAGE 96
3 Idling Device and Throttle Control (Two-Piece Flo-Jet) A manual friction control (Fig. 149 – A) may be used to limit throttle movement to any pre-set position. It is commonly used for two purposes: 1. To return throttle to a “no-load” position on a pump, generator, etc. 2. For cold weather starting on governed idle engines. Throttle can easily be kept in a “near closed” position while starting, which is most favorable for cold weather starts, Fig. 149 – B. Fig.
PAGE 97
3 Fuel Pumps (Crankcase Vacuum Operated) Some models are factory or field equipped with fuel pumps operated by crankcase vacuum. Fuel pumps may be mounted on the blower housing, Fig. 151, directly on carburetor, Fig. 152, or on a mounting bracket, Fig. 153. Crankcase vacuum is obtained by a fitting on crankcase cover, Fig. 154, a fitting on dipstick tube, Fig. 153, a hollow bolt and fitting, Fig. 154, or from crankcase breather valve, Fig. 152.
PAGE 98
3 ÇÇ ÉÉÉ ÇÇÇÇ ÇÇÉÉÉÇÇÇÇ ÇÇ ÇÇÇÇ ÉÉÉ É ÇÇ ÇÇÇÇ ÉÉÉ É ÇÇÉÉÉÇÇÇÇ ÇÇÇÇ ÉÉÉ ÇÇ Â ÇÇÇÇ ÉÉÉ ÇÇ Â ÇÇÇÇ ÉÉÉÇÇ ÇÇ ÇÇÇÇ ÉÉÉ ÇÇ ÇÇ É ÇÇÇÇ ÉÉÉÉ ÇÇ ÇÇ ÇÇÇÇ ÇÇ ÇÇ ÉÉÉÉ ÉÉÉ ÇÇÇÇ ÇÇ ÇÇ ÉÉÉÉ ÉÉÉ ÇÇÇÇ ÉÉÉÉÇÇ ÇÇ ÉÉÉ ÇÇÇÇ ÇÇ ÉÉÉ ÉÉ ÇÇÇÇ ÇÇ ÉÉ ÇÇÇÇ ÉÉÉ ÇÇÉÉÉÇÇÇÇ É ÇÇÇÇ ÉÉÉ ÇÇ ÇÇÇÇ ÉÉÉ ÇÇ Â ÇÇÇÇ ÉÉÉ ÇÇ Â ÇÇÇÇ ÉÉÉ ÇÇ Â ÇÇ ÇÇÇÇ ÉÉÉ ÇÇ ÇÇ É ÇÇÇÇ ÉÉÉ ÇÇ ÇÇ É ÇÇÇÇ ÉÉÉÇÇ ÇÇ ÉÉÉÉ ÉÉÉ ÇÇÇÇ ÇÇ ÇÇ ÉÉÉÉ ÉÉÉ ÇÇÇÇ ÉÉÉÉÇÇ Operation Typical operation of a fuel pump is illustrated in Figs. 155, 156, and 157.
PAGE 99
3 Service Plastic Body Pump, Disassemble Fuel Pump 1. Remove two screws holding pump to blower housing. 2 1 2. Disconnect vacuum (2), fuel inlet (3) and fuel outlet (1) hoses from pump, Fig. 158. 3. Remove three screws holding pump together, Fig. 158. 4. Remove metal pump cover. 5. Remove and discard pump gasket and damping diaphragm. 3 4 6. Remove pump body, diaphragm spring and spring cup. Fig. 158 7. Remove pump diaphragm from pump base. Inspect Fuel Pump 1.
PAGE 100
3 KEROSENE ENGINES NOTE: Kerosene engines are designed to start on petrol and run on kerosene. Stop kerosene engines by turning the kerosene shut-off to the “off” position to let the engine run out of fuel. 2 1 Starting Procedures, Model Series 9K4000, 135400, 13K400 and 19K400 Fig. 159 – To start Model Series 9K4000, 135400, 13K400 and 19K400, set the choke to the start position. Prime the engine with petrol by depressing the primer bulb (1) five times. Start and run the engine.
PAGE 101
3 SPECIFICATION TABLES DIAPHRAGM SPRING LENGTH Minimum Length Maximum Length None 15/16” (23.8 mm) 1” (25.4 mm) Red 1–1/8” (28.6 mm) 1–7/32” (30.9 mm) Blue 1–5/16” (33.3 mm) 1–3/8” (35 mm) Green 1–7/64” (28.2 mm) 1–3/8” (35 mm) Color TABLE NO.
PAGE 102
3 TABLE NO. 4 DIAPHRAGM SPRINGS WHERE USED BY COLOR Model Series Carburetor Type 90000 Vacu-Jet All Temperature, Automatic Choke Not Colored Standard GREEN See Service Bulletin #533 Vacu-Jet Automatic Choke Not Colored Standard GREEN See Service Bulletin #533 NOTE: Service Bulletin #533 covered installation of choke plate and choke spring (GREEN) (part #396227) to eliminate problems with hot starting.
PAGE 103
3 TABLE NO. 5, (CONT’D.) Carburetor Identification # Model Series 127700 LMS-24 127800 LMS-24 128700 LMS-24 128800 LMS-24 129800 LMS-24 130700 LMS-9 LMS-19 131700 TABLE NO. 6 (CONT’D.) 93400 12B800 LMS-9 LMS-19 MAIN JET HIGH ALTITUDE CHART (CHANGE MAIN JET) TABLE NO. 6 Model Series Carburetor LMS or I.D.
PAGE 104
3 TABLE NO. 6 (CONT’D.) Model Series Carburetor LMS or I.D. # Standard Jet # or Letter TABLE NO. 6 (CONT’D.
PAGE 105
3 TABLE NO. 6 (CONT’D.) Model Series Carburetor LMS or I.D. # Standard Jet # or Letter TABLE NO. 6 (CONT’D.
PAGE 106
3 TABLE NO. 6 (CONT’D.) Model Series 122800 Carburetor LMS or I.D. # Standard Jet # or Letter TABLE NO. 6 (CONT’D.
PAGE 107
3 TABLE NO. 6 (CONT’D.) Model Series Carburetor LMS or I.D.
PAGE 108
3 TABLE NO. 6 (CONT’D.) Model Series Carburetor LMS or I.D. # High Altitude Jet # or Letter Model Series Carburetor LMS or I.D. # LMS-25 LMS-25 LMS-35 LMS-35 LMS-40 LMS-40 LMS-41 129700 Standard Jet # or Letter TABLE NO. 6 (CONT’D.
PAGE 109
4 SECTION 4 Gov. Controls, Carb. Linkage & Flywheel Brakes Section Contents Page GOVERNOR CONTROL BRACKET IDENTIFICATION Horizontal Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Vertical Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BAND BRAKE CONTROLS Disassemble . . . . . . .
PAGE 110
4 GOVERNOR CONTROL BRACKET IDENTIFICATION Horizontal Crankshaft Fig. 1 – 170400, 190400, 195400, 220400, 221400, 251400, 252400 with Swivel Control before Date Code 83121600 Fig. 4 – 253400, 255400 Fig. 2 – 170400, 171400, 190400, 194400, 195400, 221400, 222400, 252400, 254400 with Rack & Pinion Control after Date Code 83121500, except 253400, 255400 Fig. 5 – 230000, 240000, 300000, 320000 Fig.
PAGE 111
4 GOVERNOR CONTROL BRACKET IDENTIFICATION, (CONT’D) Vertical Crankshaft Fig. 6 – 194700, 195700, 196700, 254700, 257700, 258700, 259700, 28A700, 28B700, 28C700, 28D700, 28E700, 28M700, 282700, 283700, 285700, 286700, 288700, 289700 with Horizontal Rack & Pinion control for Briggs & Stratton/Walbro LMT Carburetors Fig.
PAGE 112
4 REMOTE CONTROLS In general, there are three types of remote controls: remote governor control, remote throttle control, and Choke-A-Matic control. See the carburetor section and following pages for specific control assemblies and installation hook-up by engine model. REMOTE GOVERNOR CONTROL The remote governor control regulates the engine speed by changing the governor spring tension, thus allowing the governor to control the carburetor throttle at all times and maintain any desired speed.
PAGE 113
4 GOVERNOR BRACKETS, LINKAGES, AND CONTROLS The following drawings of governor controls (Figs. 14 through 49 and 61 through 136) are to show how governor links and springs are to be installed on carburetors. For governor control adjustments, see Section 5, GOVERNORS. Figs. 14–22 below show Models 60100, 61100, 80100, 81100 Horizontal Crankshaft. “A” indicates movement of cable or linkage to increase speed, “B” to decrease speed. 1 A 2 Fig. 14 Pull out rod (1) to increase speed.
PAGE 114
4 Bell crank (1) and remote control lever (2) move in directions shown to increase (A) or decrease (B) speed, Fig. 19. 1 A B 2 Fig. 19 Closed choke position (1) Stop switch in “run” position (2) Stop switch in “stop” position (3), inset Fig. 20 1 2 3 Fig. 20 Idle adjustment screw (1) Spring hooked in this hole (2) Speed adjusting screw – turn in to increase speed (3) Needle valve adjustment (4) Fig. 21 1 2 3 4 Fig.
PAGE 115
4 Turn thumbscrew (1) counterclockwise as shown to increase speed, spring hooked in #4 hole (2), Fig. 23. 1 2 Fig. 23 Pull out rod (1) to increase speed (A), governor spring in this hole (2) in speed adjusting lever, Fig. 24. 1 2 A B Fig. 24 Turn in speed adjustment screw (2) to increase speed, needle valve (3), idle adjustment screw (1), Fig. 25. 1 2 3 Fig. 25 Inset shows spring attachments, Fig. 26. Fig.
PAGE 116
4 Choke position closed (1), Inset shows spring attachment to stop switch, Fig. 27. 1 Fig. 27 Model Series 83400 Horizontal Crankshaft Turn speed adjusting screw (1) clockwise to increase, counterclockwise to decrease, Fig. 28. 1 Fig. 28 Model Series 80200, 82200, 90200 Horizontal Crankshaft, Air Vane Governor Standard controls, Fig. 29. Fig. 29 Manual choke, top mount remote control, Fig. 30. Fig.
PAGE 117
4 Manual choke, manual friction throttle, Fig. 31. Fig. 31 Manual choke, remote control, governed idle. Fig. 32. Fig. 32 Choke-A-Matic , Fig. 33. Fig. 33 Manual choke, bottom mount remote control, Fig. 34. Fig.
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4 Model Series 60300, 60400, 61300, 80300, 80400, 81400 Horizontal Crankshaft A 1 A A 1 Fig. 35 Fig. 36 Turn governor screw as shown to increase speed. Top speed limit device (1). A Fig. 37 Fig. 38 Turn governor screw as shown to increase speed. Move remote control lever as shown to increase speed. Swivel screw, (1). B A B A Fig. 39 Turn governor screw as shown to increase (A) or decrease (B) speed. 10 B Fig. 40 Move throttle cable as shown to increase (A) or decrease (B) speed.
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4 Model Series 91200, 92200, 94200 Horizontal Crankshaft with date codes ending in A1 through A9 or E1 through E9 Fig. 41 Fig. 42 Fig. 43 Fig. 41 – Manual Friction Fig. 42 – Remote Control Fig. 44 Fig. 43 – Fixed Adjustable Model Series 93400 Horizontal Crankshaft A Fig. 45 Fig. 44 – Vehicle Control Model Series 133400 Horizontal Crankshaft A Fig. 46 Fig. 45 – Move lever (A) as indicated to increase speed.
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4 Model Series 80000, 91200, 110000, 130000 Horizontal Crankshaft, Mechanical Governor Fig. 47 – Standard Controls Fig. 48 – Manual Choke, Manual Friction Fig. 49 – Choke-A-Maticr Fig. 50 – Manual Choke, Remote Controls A B Fig. 51 – Manual Choke, Remote Control, Governed Idle Fig. 53 – Vehicle Controls, Throttle Return 12 Fig.
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4 Model Series 100200, 130200 Horizontal Crankshaft Manual friction governor control. Pull knob up as indicated (A) to increase speed, Fig. 54. A Fig. 54 Remote control with governor, Fig. 55. Fig. 55 Standard governor control. Turn thumbscrew clockwise as indicated (A) to increase speed. Inset: remote control cable moves as indicated to increase speed (A) Fig. 56. A A Fig.
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4 Choke-A-Matic remote control mounted on top of engine showing casing clamp (1), (inset A), and direction cable moves to close choke. Choke-A-Matic remote control (inset B) showing stop switch (2) direction to choke, (3), and movement of linkage to close choke, (4), Fig. 57. A 1 4 B 2 3 Fig. 57 Pull throttle control knob up to run (1), push down to stop (2), Fig. 58. 1 2 Fig. 58 Place lever (4) in choke detent (5).
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4 Model Series 176400, 19B400, 19E400, 19F400, 19G400, 192400, 196400, 197400 with Bell Crank Controls and One Spring, Horizontal Crankshaft Model Series 176400, 19B400, 19E400, 19F400, 19G400, 192400, 196400, 197400 with Bell Crank Controls and Two Springs, Horizontal Crankshaft Fig. 61 Fig. 62 Model Series 226400, 250400, 256400 Horizontal Crankshaft Control, One Spring Model Series 226400, 250400, 256400 Horizontal Crankshaft Control, Two Springs Fig. 63 Fig.
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4 Adjust Choke-A-Matic as shown (A), to increase speed, Fig. 65. A Fig. 65 Adjust remote control cable as shown (A), to increase speed, Fig. 66. A Fig. 66 Adjust Manual Friction as shown (A), to increase speed, Fig. 67. A Fig. 67 Turn fixed adjustable as shown – (A) to increase speed, (B) to decrease speed, Fig. 68. B A Fig.
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4 Model Series 170400, 190400, 195400, 220400, 221400, 251400, 252400 Horizontal Crankshaft with Swivel Lever Control before Date Code 83121600 Adjust Choke-A-Matic linkage and cable as shown (A), to increase speed, Fig. 69. A A Fig. 69 Adjust cable or turn knob as shown (A) to increase speed. Manual friction (1), fixed adjustable (2), remote control (3), Fig. 70. A A A 1 2 3 Fig. 70 Adjust as shown (A) to increase speed. Manual friction (1), fixed adjustable (2), remote control (3), Fig. 71.
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4 Thumb Nut Adjustment 1 Remove thumb nut and upper elastic stop nut (2), Figs. 76 and 77. Replace thumb nut and adjust to desired operating speed. (See Figs. 74-79). Do not change the position of the lower elastic stop nut. It provides protection against overspeeding. 1 Governed Idle All engines in Model Series 243400, 300400, 320400, and some 233400 engines use two governor springs (4), Fig. 78. The shorter spring keeps the engine on governor, even at idle speed.
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4 Model Series 220000, 250000 Horizontal Crankshaft with Rack & Pinion Control after Date code 83121500, Except 253400, 255400 1 B A A Fig. 80 Fig. 81 Fig. 80 – Choke-A-Matic Fig. 81 – Remote Control Choke (1) B A A Fig. 82 Fig. 83 Fig. 82 – Manual Friction Fig. 83 – Fixed Adjustable Figs. 80 – 83: Move as shown (A) to increase speed, (B) to decrease speed.
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4 Model Series 253400, 255400 Horizontal Crankshaft A A Fig. 84 Fig. 85 1 A Fig. 86 Fig. 87 – Fixed speed screw (1) Figs. 84 – 87: Move as shown (A) to increase speed, (B) to decrease speed.
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4 Model Series 90000 Vertical Crankshaft – “A” indicates “FAST” position, “B” indicates “STOP” position A B B A Fig. 88 Fig. 89 Fig. 90 Fig. 91 Model Series 9B900, 9C900, 98900, 10A900, 10B900, 10C900 Vertical Crankshaft, Dual Spring 1 2 1 1 2 Fig. 92 – Manual Friction Fig. 93 – Remote Control Fig. 94 – Fixed Adjustable Model Series 9B900, 9C900, 98900, 10A900, 10B900, 10C900 Vertical Crankshaft, Single Spring 1 2 1 1 2 Fig. 95 – Manual Friction Fig. 96 – Remote Control Fig.
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4 Model Series 120000 Vertical Crankshaft A Fig. 98 “A” indicates increase speed, “B” indicates decrease speed. Model Series 90700, 110700, 112700 Vertical Crankshaft Model Series 91700, 111700, 114700 Vertical Crankshaft B A B Fig. 99 22 Fig.
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4 Model Series 130700, 131700, 132700 Vertical Crankshaft – “A” shows speed increase, “B” shows decrease. B B A A Fig. 101 Fig. 102 Model Series 100900, 130900 Vertical Crankshaft 2 1 Throttle lever (1) Choke lever (2) Choke and throttle remote control casings (3) Casing screws (4) Fig. 103 3 4 Fig. 103 Choke closed (1) Lever in choke (2) Lever in stop(3) Stop switch (4) Blade (5) Fig. 104 1 4 5 3 2 Fig. 104 Place control in choke detent (1).
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4 Model Series 170700, 190700, 191700, 192700, 193700, 220700, 252700, 253700, 280000 Vertical Crankshaft with Rack & Pinion Control Except Model 286700 Move as shown (A) to increase speed, Fig. 107. A Fig. 106 24 Fig.
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4 Model Series 194700, 195700, 254700, 257700, 283700, 286700 Vertical Crankshaft With Horizontal Control Rack & Pinion Control A 1 A Fig. 108 Move as shown (A) to increase speed. Slide control (1), Fig. 109. Fig. 109 Model Series 194700, 195700, 196700, 254700, 257700, 283700, 286700 Vertical Crankshaft With Vertical Rack & Pinion Control A A A Move as shown (A) to increase speed, Figs. 110-111. Fig. 110 Fig.
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4 Model Series 170700, 171700, 190700, 191700 Vertical Crankshaft with Swivel Lever Control A A A Fig. 112 Fig. 113 A A Fig. 114 A Fig. 115 Move as shown (A) to increase speed, Figs. 112-115.
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4 BAND BRAKE CONTROLS Model Series 92000, 93000, 94000, 95000, 110000 System 3 and 4 engines are equipped with the band brake feature, Fig. 116. The band brake MUST STOP the engine (cutter blade) within three seconds after operator releases equipment safety control, Fig. 117. If stopping time exceeds three seconds with equipment speed control set in “FAST” position, remove blower housing (3), and brake cover (2), and examine following for adjustment, alignment, or damage: a. Band brake worn or damaged.
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4 REMOVE BAND BRAKE 1. Remove blower housing and rotating screen, Fig. 116. 3 2. On current style band brake brackets, release brake spring (1) and lift band brake (2) up off both stationary and moving posts (3), Fig. 119. .030”(.76 mm) 3. On early style brake brackets, use tang bender tool #19229 (1) to bend control lever tang (2) to clear band brake loop, then release brake spring tension and remove band brake (4), Fig. 120. 4. Replace band brake if brake material is damaged or worn to less than .
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4 5. With brake spring installed, apply pressure to the control bracket ONLY. Move it until gauge link tension is JUST eliminated. 6. Hold control bracket in this position while torquing screws to 30 in. lbs. (3 Nm). 7. Remove gauge. NOTE: Some manufacturers install a cable clamp bracket using a pop rivet in the control bracket cable clamp screw hole. Place bayonet end of gauge in control lever and rotate control lever sufficiently to install other end of gauge into pop rivet hole. Adjust as noted above.
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4 6. Tighten cable clamp screw securely. 7. Conduct Stop Switch and Stop Switch Wire Tests described in Section 2, Ignition. 8. Install brake control bracket cover and tighten screws. 9. Place battery in holder and tighten screws. 10. After engine is installed on equipment, connect battery wires to connector and place wire on spark plug. 11. Re-test stopping time.
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4 3. Remove blower housing and rewind starter (3, 2), Fig. 127. 3 2 1 Fig. 127 4. Disconnect spring (2) from brake anchor (3), Fig. 128. 1 2 5. Disconnect stop switch wire (1) from stop switch. NOTE: If engine is equipped with electric starter, disconnect both wires (4) from starter interlock switch (5). Remove two screws from brake bracket (6) and remove bracket. 3 7 6 5 4 Fig. 128 Inspect Flywheel Brake and Switches 1. Inspect brake lining on brake lever.
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PAGE 141
5 SECTION 5 Governors Section Contents SAFETY Page Governed Speed Limits, All Model Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MECHANICAL GOVERNORS HORIZONTAL CRANKSHAFT Disassemble Model Series 60000, 80000, with governor lever and shaft mounted on crankcase cover . . . . . . . . . . . . . . . 8 Model Series 80000, 83400, 93400, 100200, 130000, 170000, 190000, 220000, 250000, with governor crank in cylinder . . . . . . . . .
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5 Section Contents, Cont’d. HORIZONTAL CRANKSHAFT, (Cont’d) Page Model Series 80000, 83400, 93400, 100200, 130000, 170000, 190000, 220000, 250000, with governor crank mounted in cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Governor Shaft Bushing, Replace Model Series 80000, 83400, 100200, 100900, 130000, 170000, 190000, 220000, 250000 . . . . . . . . . 21 Model Series 230000, 240000, 300000, 320000 . . . . . . . . . . . . . . . . . . . . . . . .
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5 TOP NO LOAD GOVERNED SPEED LIMITS To comply with specified top governed speed limits, Briggs & Stratton supplies manufacturers with engines using either calibrated governor springs or an adjustable top no load speed. Both methods will regulate top governed speed when the engine is operated on a rigid test stand. However, the design of the cutter blade, deck, etc., can affect engine speeds.
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5 PNEUMATIC GOVERNOR SYSTEMS (FIGS. 1, 2) 1 Adjust Top No Load Speed, Model Series 80000, 90000 Pneumatic Governor with Control Panel 1. Run engine until it reaches operating temperature or for about 5 minutes. 2. Set control lever or remote controls to fast position with engine running. 3. Adjust governed idle by turning stop nut (3) and idle speed screw (2), Fig. 2. Turn stop nut clockwise (A) to increase speed, counterclockwise (B) to decrease. Fig. 1 2 4.
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5 Adjust Top No Load Speed Pneumatic Governor, Dual Spring Control Model Series 9B900, 9C900, 98900, 10A900, 10B900, 10C900. 2 3 Single Spring Control Model Series 9B900, 9C900, 93900, 95900, 96900, 98900, 10A900, 10B900, 10C900 1. Run engine until it reaches operating temperature or for about 5 minutes. 2. Move governor lever (1) to “Fast Position.” Hole in lever (2) will line up with hole in governor control bracket (4). Insert 1/8” rod (3) through both holes to lock lever position, Figs. 5, 6.
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5 Replace Governor Spring Model Series 90000, 110000 1 2 The governor springs used on engine Model Series 90000, 110000 are made with double end loops for a secure attachment and proper governor regulation. Springs with double end loops are easily removed and installed by following the procedure shown below. Fig. 8 CAUTION: DO NOT use a needle-nosed pliers or the end loops of the governor spring will be deformed.
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5 MECHANICAL GOVERNOR SYSTEM HORIZONTAL CRANKSHAFT (Fig. 11, typical) A 1 1 1. Fig. “A” shows engine not running, throttle open (1), spring compressed (2), and counterweights closed (3). Turning thumbscrew as shown (A) increases speed. 2. Fig. “B” shows engine running, throttle closing (1), spring stretching (2), and counterweights opening (3). 2 3 2 3 A B Fig.
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5 Assemble Horizontal Crankshaft 3 On horizontal crankshaft models, the governor rides on a short stationary shaft and is retained by the governor shaft, with which it comes in contact after the crankcase cover is secured in place. 1 2 1. Press governor cup (2), Fig. 13, against crankcase cover to seat retaining ring on shaft, prior to installing crankcase cover. 4 5 6 NOTE: It is suggested that the assembly of the crankcase cover be made with the crankshaft in a horizontal position. Fig. 14 2.
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5 Assemble 4 8 1. Push governor shaft (2) into crankcase cover, with threaded end in. 2 2. Assemble small washer on the inner end of the shaft, then screw shaft into governor follower (4) by turning shaft counterclockwise. 3. Tighten securely. Turn shaft until follower (4) points down as illustrated, Fig. 16. 9 1 4. Place washer on outside end of shaft. 5. Install roll pin (3). The leading end of the pin should just go through the shaft so pin protrudes from only one side of shaft. Fig. 16 6.
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5 Governor Spring Location Note: Consult Engine Sales Manual, MS-4052 or Service Engine Sales Manual Microfiche at the end of each manual to determine specified RPM for engine, EXCEPT FOR GENERATOR ENGINES. See text for Top No Load Speed and Governed Idle adjustments according to engine model and application. Model Series 93400 See Table 4, Specifications, Page 28, and place governor spring in holes 1 through 6, Fig. 18, to attain required RPM. Fig.
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5 Single & Dual Spring Model Series 176400, 19B400, 19C400, 19E400, 19F400, 19G400, 192400, 196400, 226400, 250400, 256400 See Table No. 6, Specifications, Page 28, and place governor spring in holes 1 through 12, Fig. 20, to attain required RPM. Generator Engines Model Series 93400 Place governor spring in governor lever hole number 2 for 50 Cycle (3000 RPM) or hole number 3 for 60 Cycle (3600 RPM) generators. DO NOT USE HOLE LOCATIONS SHOWN IN TABLE NO 4, SPECIFICATIONS, Page 28.
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5 Adjust Top No Load Speed Single Spring Model Series 93400, 133400, 176400, 192400, 196400, 250400, 256400 1. Run engine at half throttle for five minutes to bring engine to operating temperature. 2. Move speed control lever to maximum RPM position. 3. If tab on lever (1) is touching head of TOP NO LOAD RPM adjusting screw (2), back out screw until tab no longer touches screw when control lever is in maximum RPM position, Fig. 22. 1 2 Fig. 22 4. First adjustment: bend spring anchor tang (1), Fig.
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5 Adjust Governed Idle Model Series 93400 (Fig. 24) Single Spring Model Series 133400, (Fig. 25A) Model Series 176400, 192400, 196400, 226400, 256400 (Fig. 25B) B 1. If governed idle is specified, move speed control down until engine is at minimum RPM and adjust carburetor idle speed screw to 1600 RPM. A NOTE: See Section 3 for proper idle speed adjusting procedure for small or large Briggs & Stratton/Walbro carburetors. 4 Fig. 24 2. Move speed control lever to obtain 1800 RPM.
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5 Adjust Dual Spring Governor (Figs. 26, 27) Model Series 176400, 19B400, 19C400, 19E400, 19F400, 19G400, 192400, 196400, 197400, 226400, 250400, 256400 2 1 NOTE: On dual spring system, governed idle must be set before setting TOP NO LOAD RPM. Adjust Governed Idle (Figs. 26, 27) 8 1. Run engine at half throttle for five minutes to bring to operating temperature. 7 6 2. Move speed control lever (1) down to idle speed position until there is slack on main governor spring (2). 3.
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5 3. Use Tool #19229, Tang Bending Tool, to bend spring anchor tang to obtain the proper TOP NO LOAD RPM, Fig. 29. For engines using Top Speed Limit Screws, adjust tang to 4000 RPM. Top Speed Limit screw must be removed while adjusting tang. Choke-A-Matic top speed range is 3700 to 4000 RPM with standard spring. (Top speed limit screw cannot be used.) B NOTE: Refer to Figs. 29 and 30 to identify the type of control. Then refer to Table No. 2, Page 28 (Fig. 29) or Table No. 3, Page 28 (Fig.
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5 Adjusting Top No Load Speed Generator Applications 1. Run engine at half throttle for five minutes to bring to operating temperature. 2. Move speed control lever to maximum RPM position. 3. If tab on lever is touching head of TOP NO LOAD RPM adjusting screw (2), back out screw until tab no longer touches screw when control lever is in maximum RPM position, Fig. 23. 4. Bend spring anchor tang (1) using Tang BenderTool #19229 (4), to 3300 for 50 cycle or 3800 for 60 cycle. 5.
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5 Governed Idle (Non-Generator) 1. Turn carburetor idle speed adjusting screw to obtain 1600 RPM while holding throttle lever against screw. 2. Release throttle lever. 3. Align holes in control bracket and inside lever with 1/8” (3.18 mm) diameter rod. Governor speed control lever of equipment should be in “IDLE” position, Fig. 34. 4. Adjust if necessary. Bend spring tang to obtain 1750 RPM. 5. Remove 1/8” (3.18 mm) diameter rod. A B Fig.
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5 Cast Iron Model Series 230000, 240000, 300000, 320000 (Fig. 37) Disassemble 1 1. Remove engine base. 2. Loosen governor lever bolt and nut. 3. Remove governor lever from governor crank assembly. 2 4. Remove cotter pin and washer from governor crank (3). 3 5. Remove any paint or burrs from governor crank. 4 6. Remove governor crank. NOTE: Current production engines have a spacer (2) on the governor crank (3). Earlier production engines have a long bushing without spacer. Fig. 37 7.
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5 Remote Control Operation 1 Adjust lower stop nut to obtain specified TOP NO LOAD RPM. Adjust Governed Idle 2 First make final carburetor mixture adjustments. Then place remote control in idle position. Hold throttle shaft in closed position and adjust idle screw (2) to 1000 RPM. Release the throttle. With remote control in idle position, adjust upper elastic stop nut (1) to 1200 RPM, Fig. 39. 6 5 4 3 2 1 MECHANICAL GOVERNOR SYSTEM VERTICAL CRANKSHAFT Model Series 100900, 130000, 170000 Fig.
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5 Fig. 41 – Model Series 170000, 190000, 220000, 250000, 280000, Typical Throttle (1) Link (2) Governor bracket (3) Governor spring (4) Cam gear (5) Cup (6) Governor gear (7) Governor shaft (8) Governor lever (9) Carburetor (10) 1 2 3 4 5 10 9 8 7 6 Fig. 41 Fig. 42 – Vertical Shaft Governor and Oil Slinger Assembly, Typical Governor crank (1) Governor cup (2) Crankshaft (3) Spring washer (4) Cam gear (5) Governor slinger (6) 2 1 3 4 5 6 Fig.
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5 NOTE: Model Series 100900, 130700, 130900, 131900 and 132900 use spring washer as shown in Fig. 42. On Model Series 130700, 130900, 131700 and 132900 equipped with right angle auxiliary drive power take-off, the spring washer is not to be used. 3. Complete installation of remaining governor linkages and carburetor. NOTE: If governor shaft bushing is replaced, it must be finish reamed with Tool #19333, Finish Reamer, for 1/4” (6.35 mm) governor crank or with Tool #19058, Finish Reamer, for 3/16” (4.
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5 Replace Governor Shaft Bushing 1 1. Press old governor shaft bushing (5), Fig. 45, out of cylinder. 2 2. Press new bushing into cylinder until bushing is 1/16” (1.57 mm) above outside surface of cylinder. 3. Ream bushing using Tool #19058, Finish Reamer, using suitable lubricant. 4. Place new gasket(s) same thickness as original gasket(s) on cylinder. 3 Assemble 4 6 1. Install governor crank from inside cylinder. 5 2.
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5 4. Turn crank until paddle (1) contacts governor cup on oil slinger (2), Fig. 49. 5. Place new gasket(s) same thickness as original gasket(s) on cylinder. 6. Insert Tool #19356, Orange Seal Protector, into seal of oil sump and install oil sump on cylinder. 7. Place non-hardening sealant such as Permatex II, on screw (1) that enters the breather chamber, Fig. 50, and install sump screws. 8. Torque screws to 85 in. lbs. (10 Nm). Remove seal protector. 2 1 Fig.
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5 Install Governor Spring Model Series 94500, 94900, 95500, 113900, 114900 (Early Style) 1 3 2 4 1. Hold governor spring with open end of small loop down (1). 2. Hook large loop in throttle link loop as shown in (2), Fig. 53, and pull loop toward throttle lever until end of spring loop snaps on. 3. Hook small loop (3) in throttle control lever (4) as shown in Fig. 54. Fig. 53 Fig.
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5 Adjust Top No Load Speed Swivel Vertical Rack and Pinion Control Bracket Horizontal Rack and Pinion Control Bracket Model Series 100900, 130700, 130900, 131900, 132900, 170000, 190000, 220000, 250000, 280000 1 2 A A 1. Set control lever to maximum speed position, with engine running. 2. Use Tool #19229, Tang Bending Tool, to bend spring anchor tang to obtain the proper TOP NO LOAD RPM, Fig. 57, swivel and vertical rack and pinion control brackets or Fig. 58, horizontal rack and pinion control bracket.
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5 Adjust Governed Idle Rack and Pinion Control Horizontal Slide, Vertical Slide 1. To adjust, first make final carburetor mixture adjustments. 2. Then place remote control in idle position. 3. Hold throttle shaft in closed position with finger, adjusting idle speed screw to 1200 RPM (Horizontal Slide), 1550 RPM (Vertical Slide). 4. Release throttle. 5. Set remote control to 1750 RPM and bend tang (1) until it contacts remote control slide, Fig.
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5 Adjust Spring Loaded Screw Type Following steps 1 through 4 above, turn screw (1) until it contacts remote control lever. See Fig. 65. 1 Fig. 65 Adjust Governed Idle Stop 1. Set remote control to 1750 RPM. 2. Loosen governed idle stop and place against remote control lever, Fig. 66. 3. Tighten governed idle stop. Fig. 66 NOTE: SPECIFICATION TABLES BEGIN ON PAGE 28 OF THIS SECTION.
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5 SPECIFICATION TABLES TABLE NO. 1 TABLE NO. 4 Hole Location, Model Series 93400 Blade Length Maximum Rotational RPM RPM Range Hole No. Date Codes 18” (457 mm) 3800 2800 – 3000 2 – 19” (483 mm) 3100 – 3500 3 – 3600 3600 – 3900 4 – 20” (508 mm) 3400 5 After 94111300 6 21” (533 mm) 3250 Before 94111400 22” (559 mm) 3100 23” (584 mm) 2950 24” (610 mm) 2800 25” (635 mm) 2700 TABLE NO. 2 Setting Top No Load Speed 4000 – 4200 TABLE NO.
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5 TABLE NO. 7 Setting Top No Load Speed Top Speed Limit Screw Position No. 1 Position with governor tang set to 4000 RPM No. 1 Position with governor tang set to 3500 RPM No. 2 Position with governor tang set to 4000 RPM Model Series 194700, 195700, 196700, 254700, 257700, 283700, 286700 194700, 195700, 196700, 254700, 257700, 283700, 286700 194700, 195700, 196700, 254700, 257700, 283700, 286700 No Load Top Speed Range 3300 TABLE NO.
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5 TABLE NO.
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6 SECTION 6 Compression Section Contents Page COMPRESSION TEST Tool #19413, Cylinder Leak Down Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CYLINDER HEADS Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6 Compression Test Install Leak Down Tester Tool #19413 2 1. Run engine for approximately 5 minutes to allow engine to reach operating temperature. 1 3 NOTE: If engine is cold or cannot be started, compression components are not at normal operating temperatures and gauge readings may be lower. 2. Remove spark plug from engine. Remove air cleaner and disconnect crankcase breather tube from air cleaner base (if equipped). Remove spacers (2) from 1” diameter crankshafts. Fig. 1 3.
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6 9. Complete test by performing steps 10 through 11. 10. Listen for air leaking from cylinder head gasket, carburetor, exhaust system and either crankcase breather or high oil fill dipstick tube. a. Air flowing between cylinder and cylinder head indicates that cylinder head gasket is leaking. b. Air flowing from carburetor indicates air is leaking past intake valve and seat. c. Air flowing from crankcase breather tube or high oil fill dipstick tube indicates air is leaking past piston rings. d.
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6 1. Use Valve Spring Compressor, Tool #19063, (see [1], Figs. 6, 7), adjusting jaws until they just touch the top and bottom of the valve chamber. Push the compressor in until the upper jaw slips over the upper end of the spring, Figs. 6, 7. Apply grease where shown (6). Inset, Fig. 6 – Cup (2), Spring (3), Collar (4), Valve (5). 2 3 1 4 2. Tighten the jaws to compress the spring. 3. Remove collars (4) or retainers, Fig. 6, pull pins (3) with needle nose pliers (2), Fig. 7, and lift out valve.
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6 Check and Adjust Tappet Clearance NOTE: Check valve clearances while engine is cold. 1. Place valves in their correct guides in cylinder. 2. Turn crankshaft (counterclockwise as viewed from PTO) until piston comes to top dead center, compression stroke. Both valves should be closed. 3. Check clearance of intake and exhaust valves to tappets with feeler gauge, Table No. 7, page 13. Self-Lock Retainers Fig. 9, Illus. C 1.
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6 VALVE GUIDES 5 4 1 Service 1/4” (6.40 mm) Valve Guides Model Series 60000, 80000, 90000, 100000, 110000, 120000, 130000 3 If flat end of Valve Guide Plug Gauge, Tool #19122 (1), can be inserted into valve guide a distance of 5/16” (7.92 mm), Fig. 10, A, the valve guide is worn and should be rebushed. 2 Rebush Worn Aluminum Guides 1. Place pilot of Tool #19064, Counterbore Reamer (2), in valve guide. A B C 6 1 2.
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6 3. Remove tap and flush chips out of bushing. 1 4. Assemble Tool #19272, Puller Nut (2), Tool #19271, Puller Screw (1), and Tool #19270 Puller Washer (3), Fig. 12. 2 5. Thread puller screw into tapped bushing until screw bottoms in tapped hole. 3 6. Back off screw 1/8 to 1/4 turn and place a drop of engine oil on threads of puller screw. 7. Hold puller screw stationary and turn puller nut down on washer until bushing is removed. 8. Use Table No. 3, page 11 to select correct service bushing. 9.
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6 6. Position bushing in counterbored guide. Press bushing with Tool #19204, Bushing Driver, until bushing is flush with top of guide. 7. Finish ream bushing with Tool #19233, Finish Reamer, using kerosene or equivalent to lubricate reamer. 8. Before removing reamer, flush all chips away. 9. Flush all chips and remove reamer as in step 5. Replace Brass or Sintered Valve Guides 1. Lubricate Tool #19264, 9 mm Tap, and bushing with engine oil or kerosene.
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6 Remove Valve Seat Insert 1 1. Use Tool #19138, Valve Seat Puller, as shown in Fig. 14, and select the proper puller nut (2). See Table No. 5, page 12. 1/32” (.80 MM) 2. Be sure the puller body (1) does not rest on the valve seat insert, Fig. 14. 3. Turn the 5/16” bolt with a wrench until insert (3) is pulled out of the cylinder. 2 NOTE: On aluminum alloy cylinder models, it may be necessary to grind the puller nut until the edge is 1/32” (.
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6 Counterbore Cylinder for Intake Valve Seat Installation Cast Iron Cylinder Models Cast iron cylinder models must be counterbored to allow installation of the intake valve seat insert. 1. Select proper seat insert, cutter shank, counterbore cutter, pilot and driver according to Table 6. 1 2. Insert pilot (1) in intake valve guide, Fig. 17. NOTE: The Model Series 320000 intake valve seat is part of the cylinder. There is no replacement valve seat. Fig. 17 3.
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6 SPECIFICATION TABLES TABLE NO. 1 Results TABLE NO. 3 Guide Bushing Identification Reading is Green. A small amount of air is leaking from head gasket. Replace head gasket, then re-test. Reading is Green Minimum air leakage. Look for other problems that are not compression related. Reading is Green/Red or Red, and all the air is leaking from one component. Look for a possible problem with that component. Reading is Red, and air is leaking from several components.
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6 TABLE NO. 5 Valve Seat Inserts INTAKE STANDARD EXHAUST STANDARD EXHAUST COBALITEt INSERT* PULLER ASSEMBLY 60000, 80000 210879• ♦ 211172• 211291 210452 19138 19140 Ex. 19182 In. 90000, 110000 210879• 211172• 211291 210452 19138 19140 Ex. 19182 In. 100200, 100900, 130000 211787 211172 263094 19138 19182 Ex. 19139 In. 120000 213512 213513 None None None 170000, 190000 211661 211661 213316G 19138 19141 220000, 250000, 280000 261463 211661 213316 19138 19141 Ex.
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6 BASIC MODEL SERIES TABLE NO. 6 Valve Seat Insert and Counterbore Tools COUNTERCUTTER & SHANK BORE DRIVER PILOT CUTTER INSERT DRIVER ALUMINUM CYLINDER 60000, 80000 NONE NOT USED 19126 19136 90000 NONE NOT USED 19126 19136 100000, 130000 NONE NOT USED 19126 19136 170000, 190000 NONE NOT USED 19127 19136 230000, 240000 19131 19129 19127 19136 300000, 320000 NONE NOT USED 19127 19136 CAST IRON CYLINDER TABLE NO.
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6 TABLE NO.
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6 TABLE NO.
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6 TABLE NO.
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6 TABLE NO.
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6 TABLE NO. 12 TO CONVERT FROM COBALITEt EXHAUST VALVE (WITH KEYHOLE ROTATOR) TO COBALITEt EXHAUST VALVE (WITHOUT ROTATOR) REMOVE ADD Model Rotator Retainer Spring Pin Retainer Spring Pin Series 491442 Not Used 262750 Not Used 224450 26478 Not Used 60000G 80000G 90000G 491442 Not Used 262750 Not Used 224450 26478 Not Used 110000G 491442 Not Used 262750 Not Used 224450 26478 Not Used 100200G 100900G 130000G G Some standard with Cobalite exhaust valve and seat with Rotator.
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7 SECTION 7A Rewind Starters Section Contents Page All Except Model Series 100700, 120000 Rope Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Spring Remove, Install, Wind . . . . . . . . . . . . . . . . . .
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7 Rewind starter identification Various rewind starter assemblies are illustrated below and on the next page. 1 Fig. 1: Old Style 8 9 7 2 Model Series 60000, 80000, 90000, 100200, 100900 and 110000 3 Fig. 2: Model Series 60000, 80000, 90000, 100200, 100900 and 110000 5 4 Blower housing (1) Unused tang (2) Rewind housing (3) Old-style rewind spring (4) Current style rewind spring (5) Rewind starter grip (6) Nylon bumper (7) Twisted tang (8) Pulley (9) (Figs. 1 and 2) 6 Fig.
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7 Fig. 5: Current Model Series 90000, 10B900, 10C900, 1 120000 with Plastic Pawls 6 2 Starter housing (1) Pulley and spring assembly (2) Rope (3) Rewind starter grip (4) Plastic pawls (5) Retainer (6) 3 5 4 Fig. 5 Fig. 6: Model Series 130000, 170000, 190000, 220000, 250000 and 280000 1 Blower housing (1) Rewind starter grip (2) Rewind spring (3) Rewind housing (4) Tension spring and hub (5) (not used on Model Series 130000) Unused pulley tang (6) Pulley tang (7) Pulley (8) Fig. 6 Fig.
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7 Remove Rope or Spring Models Not Otherwise Specified 2 CAUTION ALWAYS wear Safety Glasses performing any rewind starter repair. 1 3 while 1. Pull starter rope out as far as it will go. 2. While holding pulley and starter housing, pull pulley end of rope out and untie or cut knot at end of rope. 1/16”(1.6 mm) D 3. With rope removed, grasp outer end of rewind spring (1) with pliers, Fig. 6, and pull out of housing as far as possible. 4.
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7 Fig. 11: Bumper tang (1) Hole in pulley (2) Guide lug (3) Eyelet (4) 4 1 3 2 Fig. 11 Fig. 12: Rope eyelet (1) Hole in pulley (2) 1 2 Fig. 12 Install Rope A rope inserter tool may be made by using a piece of music wire or spring wire 1/16” diameter, and flattening the end (2) as shown in Fig. 13. 1. Inspect rope. Replace if frayed. 6” (152.4 mm) 2 1/8” (3.2 mm) 4. If re-using old rope, burn ends of rope with a match. 5.
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7 Current Style without Guide Lug Tie a knot in rope and pull tight. Manipulate knot with needlenose pliers (2) so it can be pulled down into knot cavity (1), Fig. 15. 1 2 Fig. 15 Replace Rewind Assembly (For Engines 5 HP & Up) 3/16” (4.8 mm) 1. If original starter housing is spot welded to blower housing, drill out spot welds using a 3/16” (4.8 mm) diameter drill. ONLY drill deeply enough to loosen spot welds. 2. Locate replacement rewind assembly in desired position and drill mounting holes. 3.
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7 Starter Clutch (Sealed, Fig. 18) Seal (1) Ratchet (2) Clutch housing (3) Retainer cover (4) Six balls (5) 1 4 ÍÍÍ 2 5 3 Fig. 18 1. If necessary, the sealed clutch can be disassembled by using a screwdriver or wedge to pry the retainer cover from the housing, as shown in Fig. 19. 2. Place one drop of a synthetic type engine oil on end of crankshaft before replacing clutch assembly on crankshaft. 3. Tighten clutch to torque noted on specification sheet for your model engine. CAUTION Fig.
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7 Model Series 100700 Starter Disassemble To remove the starter, it may be necessary to remove or raise the fuel tank. 1 1. Loosen starter mounting screw (1) and remove starter, Fig. 22. Fig. 22 2. Pull rope out as far as it will go and while holding pulley and cover, remove rope from pulley. 3. Then slowly relieve spring tension by releasing cover or pulley. 2 4. Remove and save decal. 5. Remove cover screw (1) by turning screw clockwise (2): left hand thread. 6. Remove screw and washer, Fig. 23.
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7 9. With a pair of needle nose pliers grasp spring as close to spring hook on outside edge of pulley and lift out spring, Fig. 25. 10. While gripping spring with pliers, slowly relieve spring tension. Fig. 25 11. Remove plastic washers (1), steel washer (3), pulley and gear (2) from starter shaft, (Fig. 26). 1 Inspect Inspect pulley for cracks, sharp edges and nicks. Inspect gear for broken or cracked teeth. Inspect washers for cracks and sharp edges. Inspect spring for kinks, cracks and nicks.
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7 NOTE: Service springs are held in a retainer (1). For ease of assembly, outer hook (2) of spring should be against end of retainer, Fig. 29. If not, rotate spring until hook is against retainer. 1 2 Fig. 29 7. Place spring and retainer on pulley with hook over spring notch (1) in pulley, Fig. 30. 8. Push spring down into pulley. 9. When reusing original spring, straighten spring. Hook outer end of spring in spring notch and wind spring into pulley. 10. Place a dab of grease in pulley. 11.
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7 17. Turn gear and pulley back 1/2 to 1-1/2 turns until rope knot pocket is in line with cover opening. 18. Insert unknotted end on rope thru rope pocket (1) and pull rope thru until knot is seated in rope pocket, Fig. 33. 19. While holding pulley and cover assembly, tie a slip knot in rope and slowly let rope wind into pulley. 20. Install starter assembly on engine with “O” or “Arrow” pointing at rope eyelet. 21. Torque starter mounting screw to 80 in. lbs. (9 Nm). 1 22.
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7 Inspect Housing, Pulley and Spring 1. Inspect pulley for wear, cracks, rough edges or burrs in pulley groove and wear on center hole. 2 3 1 2. Replace if damaged or worn. 3. Inspect spring for broken ends, kinks and burrs. Replace if damaged. CAUTION ALWAYS wear Safety Glasses performing any rewind starter repair. while • Pulley and spring is serviced as an assembly. • DO NOT REMOVE SPRING FROM PULLEY.
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7 Wind Spring & Install Rope B 1. Turn pulley counterclockwise (B) until spring is wound tightly, Fig. 39. 2. Then rotate pulley CLOCKWISE (A) until rope hole in pulley is in line with starter housing eyelet (1) and hold pulley, Fig. 39. 1 A 2 3. Insert unknotted end of rope through knot cavity and rope hole (2) in pulley. 4. Thread end of rope through starter housing eyelet and pull rope until knot is in rope cavity. 3 4 Fig. 39 5.
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7 Remove Rope 1 1. Pull starter rope out as far as it will go. 2. While holding the pulley and starter housing, pull pulley end of rope out and untie knot at end of rope. 3. Remove rope and handle from starter. 4. Slowly release pulley to release spring tension. 5. Support blower housing on Tool #19227, Cylinder Support (2), and drive out center pin with 5/16” (7.9 mm) dia. pin punch (1), Fig. 42. 2 NOTE: On some models it may be necessary to remove the label before center pin can be removed. Fig.
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7 Inspect starter housing for wear or burrs at rope eyelet (1), center pivot post (2), and at inner spring retainer (3), Fig. 45. Replace if worn. 2 3 Assemble Starter Housing and Pulley 1. Note location of free end of spring in pulley assembly (2) and location of spring retainer (1) in starter housing, Fig. 46. 2. Line up free end of spring with spring retainer in housing and assembly pulley in housing. 1 3. Rotate pulley counterclockwise until spring engages retainer. Fig. 45 4.
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7 VERTICAL PULL STARTER Vertical pull starters have been made in two versions: standard, Fig. 48, and alternate, Fig. 49. NOTE: Before removing alternate style starter, measure length of rope from starter housing to rope handle at equipment handle bar. Fig. 48 Fig. 49 DISASSEMBLE Remove Rope or Spring 1. Before servicing starter, all tension must be removed from rope and spring. CAUTION DO NOT pull rope with the pulley cover removed, unless the spring is detached from spring anchor. 2.
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7 4. Note the warning on the plastic cover, then use a screwdriver as shown in Fig. 51 to remove the cover. 5. Remove anchor bolt (1) and anchor (2), Fig. 52. 6. Inspect starter spring for kinks or damaged ends. Replace if damaged, carefully removing it from the housing, and installing new spring per assembly text. Fig. 51 7. Otherwise, replace cover to keep spring in housing. 2 8. Remove rope guide and note position of link before removing assembly from housing, Fig. 53. 1 Fig. 52 9.
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7 14. Assemble end of link loop (1) toward gear on link assembly (2). Clean all dirty or oily parts and check link for proper friction. Link should move gear to both extremes of its travel. If not, replace link assembly, Fig. 56. 1 2 Fig. 56 NOTE: To repair vertical pull starters with INTERLOCK SYSTEM, follow equipment manufacturers’ interlock repair procedure. Assemble Install Spring 1. Place pulley and gear assembly in starter housing. 2.
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7 8. Pull knot into insert pocket and snap insert (1) into grip (2), Fig. 61. NOTE: On alternate style starter, measure rope from handle end to guide on starter, the same distance as before it was removed from engine. Tie a slip knot in the rope at this point. DO NOT INSTALL HANDLE AND INSERT AT THIS TIME. 1 2 Fig. 61 9. Rotate pulley in a counterclockwise direction until rope is fully retrieved, Fig. 62. 10. Remove cover from pulley. 11.
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7 TABLE No. 1 Rewind Starter Rope Length Model Series 20 Rewind Position Rope Size Starter Pawls Length Inches Meters 90100 ALL #6 Plastic 67 1.7 90200 ALL #4 Metal 88–5/8 2.25 91200 ALL #4 Plastic 88–5/8 2.25 92200 6 o’clock #4 Metal 100 2.54 93200 9 o’clock #4 Metal 68 1.7 93400 9 o’clock #4 Metal 68 1.7 9B900 ALL #4 Metal or Plastic 88–5/8 2.25 9D900 ALL #4 Metal 88–5/8 2.25 98900 ALL #6 Plastic 67 1.7 10A900 ALL #4 Metal 88–5/8 2.
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7 SECTION 7B Electric Starter Systems Section Contents Page BATTERIES, GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7 Section Contents, Cont’d. Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Test 12 volt Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 120 Volt Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7 EQUIPMENT AND TOOLS TO TEST STARTER MOTORS Digital Multimeter (DMM) Available from Briggs & Stratton. Order Tool #19464. The meter may be used to read volts, ohms or amperes, and test diodes (rectifiers), Fig. 1. Volt, Ohm, Ammeter (VOA Meter) Not shown. Similar usage as DMM. Fig. 1 DC Shunt Use with Digital Multimeter. The DC Shunt may be used to read starter motor current draw on 12 volt starter motors. Order as Tool #19359, Fig. 2. Fig. 2 AC Shunt Use with Digital Multimeter.
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7 Test Fixture 1 A starter motor test fixture may be made of steel 1/4” (6.0 mm) thick as shown in Fig. 5. Extra hole for mounting starter brackets (1), two 3/8” (9.5 mm) holes for starter mounting bracket (2), two #7 tap holes for 1/4–20 NC screws for mounting B&S #19200 Tachometer (3), Fig. 5. A known good 6 volt or 12 volt battery is required when testing 6 or 12 volt starting systems. 3/8” (9.5 mm) 2 2–1/4” (57.0 mm) 4” (100.0 mm) #7 1/4–20 NC 3 3–1/2” (89.0 mm) 3–1/2” (89.0 mm) 1” (25.
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7 WARNING Batteries produce hydrogen, an explosive gas. DO NOT store, charge or use a battery near an open flame or devices which utilize a pilot light or can create a spark. Batteries contain corrosive fluids and toxic materials and should be handled with care. • Do not puncture, disassemble, mutilate or incinerate. • As with all rechargeable batteries, explosive gases could be vented during charge or discharge. Use in a well ventilated area, away from sources of ignition.
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7 Installation: 1. Before installing battery, connect all equipment to be operated. 2. Place battery in holder with a flat base. Tighten hold down device evenly until snug. DO NOT overtighten. 3. Connect positive cable first to prevent accidental grounding. Tighten connectors securely. 4. Connect negative cable to negative battery terminal. Tighten connectors securely. 5. Use DMM (#19464) or VOA Meter. 6. Attach RED meter test clip to positive (+) battery terminal. 7.
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7 STARTER ELECTRICAL INFORMATION AND TEST PROCEDURES, BY SYSTEM 1 5 6 Note: Interpreting Starter Motor Test Results, All Systems (Typical) 1. RPM below minimum and higher than normal amps. System 3, System 2 3 4 (+) (–) 4 Briggs & Stratton System 3 and System 4 consist of a starter motor (4), starter switch and/or starter solenoid (5), wiring harness, (wire #6 goes to engine alternator), 6 or 12 volt battery (rechargeable) (3), alternator, and separate trickle type battery charger (2).
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7 5. Place red wire (4) from Harness Wire Terminal #396392 on one resistor lead and use alligator clip on RED test lead wire from meter to hold it in place. 6. Place black wire (5) from Harness Wire Terminal on resistor lead opposite from red wires and use alligator clip on BLACK test lead wire from meter to hold it in place. WARNING NOTE: A meter reading of 4.5 volts DC or less after charging and retest indicates a failed battery cell. Replace battery.
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7 Starter Switch Test 1. Set DMM or VOA meter to “Diode Test” position. In ths position the meter will emit a continuous tone, indicating continuity (complete circuit). No continuity (incomplete circuit) is displayed as “OL” and no tone will be heard. B A 1 2. Set meter to Ohms position and set selector to Rx1 scale, when required. 3. Zero the meter. 4. Test switch as shown in Fig. 12. With switch lever in “RUN” (A) or “STOP” (brake) (B) position, there should be NO continuity. Fig. 12 5.
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7 Test Interlock Switch Wiring Model Series 120000 2 1 1. Disconnect interlock switch wires from spade terminals on switch and at starter motor connector. 3 2. Set meter to read Ω ohms. 4 3. Connect one meter test lead to end of one wire inside connector and other test lead to second connector terminal for the same wire. Light should be on or meter should read low or no resistance. Wiggle wire inside connector. Light should stay constant or meter should not change value.
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7 1. Connect the starter motor, battery and meter as shown in Fig. 17. 2. Activate the starter motor and note readings of meter (Amps DC) and tachometer (RPM). If the motor does not perform satisfactorily, see Interpreting Starter Motor Test Results on page 7, Fig. 17. 1 3 Fig. 17: Optional starter switch (1) Test fixture from P.
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7 Briggs & Stratton Starter Motors “L” 120 Volt AC; 12 Volt DC with Housings 3–1/16” (78.0 mm) to 4–9/16” (115.9 mm) long Model Series 170000, 190000, 220000, 240000, 250000, 280000 and 320000 See Figs. 19 and 20, and Tables No. 6 and 7, Specifications, for motor identification and performance standards. Motor identification code shown (1), Fig. 20. Fig. 19 “L” 1 Fig. 20 12 Volt DC Starter Motor Test Starter Motor Tools, Procedure DMM (#19464) and Tool #19359, DC Shunt.
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7 Tools, Procedure DMM (#19464) with AC Shunt, Tool #19358. Tachometer capable of reading 10,000 RPM. See Table No. 8, Specifications, for maximum allowable amperage. WARNING Unintentional sparking can result in fire or electric shock. • The following test procedure must be used to avoid any accidental shock hazard to the service technician. 1. Set meter to AC amps position. 2. Insert leads into meter and plug starter motor cord into AC shunt, Fig. 21. 1 2 5 3 4 Fig. 21 3.
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7 Testing Rectifier Control Assembly Briggs & Stratton 120 Volt Starter Motor 6 7 The AC control assembly housing contains a spring loaded starter button, cord assembly and rectifier. It is equipped with a three wire grounded receptacle. Fig. 22. 5 4 1 2 3 Fig. 22 Disassemble Control Assembly WARNING Unintentional sparking can result in fire or electric shock. • Disconnect extension cord from AC outlet and control assembly before disassembling. 1.
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7 Test Rectifier (Shorts or Opens) 1. Remove all wires from rectifier before checking. 2. Use DMM (#19464) or VOA Meter. 3. Set meter to “Diode Test.” 4. Using test leads, place RED test lead and BLACK test lead on rectifier terminals in sequence shown in Fig. 24, and TABLE NO. 8, Specifications. 5. If test results differ from those shown, the rectifier is defective and must be replaced. “D” “A” “C” “B” Fig. 24 Test Rectifier (Grounded) 1. Leave DMM in Diode Test position. 2.
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7 Test Switch 1. Test switch assembly using the DMM, with meter in “Diode Test” position. 2. Attach meter test leads to switch terminals, Fig. 27. 3. Meter should display “OL,” indicating no continuity. 4. When button (1) is depressed, the meter should make a continuous tone, indicating continuity. Meter should indicate continuity only when button is depressed. When re-assembling switch, position starter button and return spring as noted in Fig. 22. 1 Fig.
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7 1. Set the meter to read (DC AMPS). 2. Connect the starter motor, battery and meter as Shown in Fig. 28. Optional starter switch (1) Black lead (2) Red lead (3) DC shunt to negative terminal (4) 12 volt battery (5) Test fixture (6) from P. 4. 1 2 3 4 WARNING Unintentional sparking can result in fire or electric shock. • After servicing, the 120 volt starter motor should be Hi-Pot tested by an electric motor repair shop before reinstalling on engine to determine if a shock hazard exists. 5 6 Fig.
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7 5. Depress starter switch. When meter reading stabilizes (approximately 3 seconds), amperage should not exceed the specification shown. CAUTION: If amperage is higher than specification shown, immediately stop the test! An amperage reading higher than number in chart indicates a shorted starter motor, which could be dangerous. 6. If amperage is within specification, check RPM of starter motor.
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7 Replace Flywheel Ring Gear (Typical, all systems) Briggs & Stratton starter motors use either an aluminum or plastic ring gear on the flywheel. American Bosch – Mitsubishi Gear Drive starters use a steel flywheel ring gear with a steel starter pinion gear. Make sure that you get the correct parts for your starter model. 1 2 WARNING Flying objects can cause personal injury or property damage. 3 • Do not strike flywheel with a hard object or metal tool as this may cause flywheel to shatter in operation.
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7 Disassemble, Inspect and Clean Starter Motor 1. Examine Fig. 33, Exploded View disassembly. prior to 2. Remove the starter cover (1), nylon spur gear retainer (2), and the nylon spur gear (4). 3. Remove the three screws (5) holding the starter gear cover (6) and remove the cover. 1 4. Lift the clutch assembly– (gasket [7], felt washer [8], and drive gear [9]) – and the pinion gear (11) off their respective shafts. Fig.
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7 5. Remove both starter motor thru bolts (1), Fig. 34, and separate end cap (2) from housing. 2 1 Fig. 34 6. Push motor armature out through bottom of starter housing (3), taking care to slide rubber mounted terminal (1) out of motor housing (3) along with end cap (2), Fig. 35. Armature shaft (4) 2 1 3 4 Fig. 35 7. Before removing armature from end cap, check brushes (1) for freedom of movement. If brushes stick in their retainers, repair before reassembly, Fig. 36. 8.
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7 Assemble Starter Motor – Armature to End Cap Assembly, Fig. 37 A Lightly lubricate bearings with a #20 oil and reassemble in the following manner. 1. Insert brush springs and brushes in holders as far as possible, and hold them in position with brush retainers (1), Fig. 37. B .176” (4.47 mm) 4 5 2. Place thrust washers on armature shaft in sequence shown, Inset “A”: felt washer (4), steel washer (6), and add gray plastic washers (5) to obtain dimension shown in Fig. 37, Inset “B” (System 3, 4).
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7 14. Tap end cap edge (1) lightly using a soft hammer to align the bearings, Fig. 40. 1 15. Replace nylon spur gear and retainer assembly, and tighten retainer screws securely. Do not lubricate helix except with dry silicone spray. 16. Install starter cover and torque screws to 25 in. lbs. (3 Nm). 17. Install starter motor on engine. Torque rear starter mounting screw (5/16”-18) to 140 in. lbs. (16 Nm). Torque front mounting screw (1/4”-20) to 90 in. lbs. (10 Nm). Fig.
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7 Disassemble Starter Motor A 1. Remove thru bolts. Note position of match marks and thru bolts. They must be reassembled in same position. 2. Remove drive-head end and inspect bushing for wear. Replace drive-head end mounting bracket if worn. B 3. Press (“A”) the armature and commutator end cap against a work surface (1) while sliding housing upward (“B”) off the armature. This allows the armature to remain in the end cap (2) for inspection of brush/armature contact, Fig. 43. 4.
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7 Assemble Starter Motor ÎÎÎÎ ÎÎÎÎ ÎÎÎÎ ÎÎÎÎ ÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎÎ 1 Lightly lubricate bearings with #20 oil and reassemble in the following manner. 1. Insert brush springs and brushes (1), Fig. 46, in holders as far as possible, and hold them in this position with brush retainers, Figs. 6, 46. 2. Slide motor housing over armature with the notch toward commutator end cap. 3. Match notch in housing with boss on brush end cap.
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7 12 Volt DC & 120 Volt AC Gear Drive Starter Motor, Steel Drive Pinion, Exploded View Fig. 48 15 1 2 Model Series 130000 16 3 This system uses either a 12v DC or 120v AC starter motor. They are covered together in this section. Study Fig. 48 prior to starter motor disassembly.
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7 1. Remove thru bolts (1), Fig. 50, then remove end head. 1 Fig. 50 2. Remove armature and end cap (2) by pushing up on armature shaft (A) as shown in Fig. 51. 2 1 3. Clean all residue from the armature, end cap, end head, etc. 4. Do not soak bearings, motor housing or armature in a solvent solution. 5. The armature commutator may be cleaned with a fine sand paper or commutator paper. Do not use emery cloth, as emery will embed in the commutator, causing rapid brush wear. 6.
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7 Assemble Starter Motor Lightly lubricate the bearings with #20 oil prior to reassembly. 1. Insert the brushes in their respective holders. Brush retainers, which can be made from scrap piece of rewind starter spring, Figs. 6 and 53, should be used during assembly. 1 Fig. 53 2. Support armature shaft and slide it slowly into housing (1), Fig. 54 (Typ). 3. Insert rubber mounted terminal into housing. 4. Place thrust washer on motor PTO shaft. 1 5. Install end head and thru bolts. 6.
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7 Briggs & Stratton Starter Motors 12 Volt DC; 120 Volt AC with Housings 3–1/16” (78.0 mm) to 4–9/16” (115.9 mm) long Model Series 170000, 190000, 220000, 240000, 250000, 280000 and 320000 See Figs. 19 and 20, and Table No. 6, Specifications, for motor identification. Fig. 56 Snap ring (1) Retainer (2) Spring (3) Pinion gear (4) Spring washers (6) Washer (7) Drive end head (8) Armature (9) Housing (10) Thru bolts (11) End cap (13) Study exploded view, Fig. 55 (Roll Pin Type), or Fig.
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7 Starter Motor Drive, C-Ring Retainer Type Disassemble 1. Remove C-ring retainer using Tool# 19436, C-Ring Retainer Removal Tool, Fig. 57. Place counterbored side of tool over retainer and align drive pins with open end of C-ring. Place palm of hand over tool. Push down on tool to compress spring washer while turning screw clockwise. Continue turning screw until C-ring retainer pops off. Discard old C-ring. 1 2 WARNING Flying objects can cause personal injury or property damage.
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7 2. Install starter gear with beveled side of teeth up (1), Fig. 60. Then install return spring (2) making sure spring is in recess of starter gear (3). 2 1 3 Fig. 60 3. Place spring washer (2) with concave side up, then place flat washer (1) on starter clutch spline, Fig. 61. 1 2 Fig. 61 4. Install NEW C-ring retainer into groove using Tool #19435, C-Ring Retainer Installer (2), Fig. 62. Place C-ring retainer over chamfered end of shaft.
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7 Starter Motor Drive, Roll Pin Retainer Style Disassemble 1. Place retainer (2) in “V” block (1) as shown in Fig. 63. 2. Drive the roll pin out with a hammer and 1/8” (3.0 mm) diameter punch (3) to remove the retainer. 3 2 1 Fig. 63 NOTE: Some starter drive assemblies utilize a gear return spring. Two styles of returns have been used. Current style, Fig. 64 and early style, Fig. 65. 1 The current style is removed after removing the roll pin (1).
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7 Assemble 5 4 1. Assemble pinion gear with beveled edge on the gear (1) up as shown in Fig. 66. 3 2 2. Assemble cup (2) and spring (3) on gear if original assembly was so equipped, and fit retainer (4) on shaft. 1 3. Drive new roll pin (5) through retainer slot and armature shaft hole. The roll pin should be centered in shaft within 1/32” (.8 mm). Assemble with new roll pin only. Fig. 66 4. If the original assembly is equipped with a spring cap assembly, assemble cap as follows: 5.
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7 5. While holding brush holder and armature, remove bearing end cap (1) from armature, Fig. 69. 6. Remove brush holder from armature commutator. 7. Do Not soak bearings, housing or armature in solvent. 8. The armature commutator may be cleaned with a fine sand paper such as flint or commutator paper. Do Not use emery cloth, as emery will embed in the commutator causing rapid brush wear. ÎÎ ÎÎ ÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎ 9. The commutator may also be machined with a diamond cutting tool to no less than 1.
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7 Assemble Starter Motor C-Ring Retainer Type Lightly lubricate the bearings with #20 oil prior to reassembly. 1. Place brushes in their slots and hold brushes with brush retainers, Figs. 6, 71. 2. Place armature commutator in brush holder and remove brush retainers. 3. Align and install bearing end plate on armature commutator journal. ÎÎÎ ÎÎÎ ÎÎÎ ÎÎÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎÎÎÎ 1 2 Fig. 71 4. Slide motor housing over armature with the notch toward brush holder, Fig. 72. 1 4 2 3 Fig.
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7 6. Place drive end cap on starter housing making sure that mark on cap (1) lines up with housing seam (2), Fig. 74. 1 7. Install through bolts in starter. 8. Use starter clutch to rotate armature and check for binding. Correct if necessary. 2 9. Install starter drive as previously described. Fig. 74 10. Install starter on engine and start mounting screws(1). While holding starter against locating lugs on cylinder (2), Fig. 75, torque mounting screws to 140 in. lbs. (16 Nm). Wire clip (3) 2 2 11.
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7 3. Hold down the armature “A” and commutator end cap against a work surface (1) while sliding housing up “B” off the armature. This allows the armature to remain in the end cap for inspection of brush to armature contact, Fig. 77 (Typ). A Remove Armature from Brush End Cap B 1. Clean all residue from the armature, end cap, motor support, etc. Do Not soak bearings, housing or armature in solvent. 2. The commutator may be cleaned with a fine sand paper such as flint or commutator paper.
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7 Assemble Housing All Except 4–1/2” (111.0 mm), 4–9/16” (115.9 mm) Housings 1. Slide motor housing over armature with the notch toward commutator end cap. 2. Match alignment marks, Fig. 76. 3. Use care to prevent damage to magnets in motor housing during assembly. 4. Assemble spacers and drive head end bracket, again aligning match marks. 5. Assemble thru bolts and washers. 6. Torque thru bolts, 45 to 55 in. lbs. (5 to 6 Nm) for 1/4-20 thru bolts and 40 to 45 in. lbs. (4 to 5 Nm) for 10-24 thru bolts.
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7 Armature assembly (5) Brushes (6) End cap commutator (7) Pinion gear (8) Helix (9) Armature shaft (10) Drive cap (11) Thrust washer (12) End cap (13) Rectifier assembly (14) American Bosch – Mitsubishi Gear Drive Starter Motors 120 Volt AC, 12 Volt DC Model Series 170000, 190000 See exploded views, Fig. 81, before disassembly. Thru bolts (1) Drive assembly (2) Drive end cap (3) Housing (4) 4 5 1 7 3 2 6 1 8 12 4 9 10 13 11 14 Fig. 81 Disassemble Starter Motor Drive Exploded Views – Fig.
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7 Assemble Starter Motor Drive, Fig. 82 1 1. Reverse disassembly procedure for assembling. When assembling helix to shaft, the spline (1) must face threaded end of shaft, Fig. 82. 2. Torque lock nut to 170 in. lbs. (19 Nm) This torque has an effect on pinion travel, so proper torque should be maintained. Fig. 82 Disassemble Starter Motor Fig. 83A – Typical Fig. 83B – American Bosch 12 Bolt Starting Motor 2 1. Remove the lockwasher, nuts and thru bolts (1), Fig. 83.
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7 SPECIFICATION TABLES TABLE NO. 1 System 3 System 4, 6 & 12 Volt Specifications System Minimum Maximum Voltage Motor RPM Amps 800 6 1400 12 18 (Disregard surge current) 9 (Disregard surge current) TABLE NO. 2 12 Volt DC Starter Specifications Nylon Pinion Maximum Minimum Amps RPM 5250 14 (Disregard surge current) TABLE NO. 3 12 Volt Specifications Steel Pinion Maximum Minimum Amps Motor RPM 5600 6 (Disregard surge current) TABLE NO.
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7 Starter Motor Identification TABLE NO. 9 12 Volt Starter Motor Performance Chart Voltage Minimum Required Motor RPM American Bosch SME-12A-8 6V ± 0.1 5000 American Bosch SMH-12A-11 12V ± 0.3 4800 American Bosch 01965-23-MO-30-SM 12V ± 0.3 5500 Mitsubishi MMO-4FL MMO-5ML MOO1TO2271 6V ± 0.1 6700 Starter Motor Identification TABLE NO.
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7 SECTION 7C Alternators Section Contents Page ALTERNATORS Table No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Identification, System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 AC Only Voltage Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7 Section Contents, Cont’d. Adjust (Current Style) Stator Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adjust (Early Style) Stator Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tri-Circuit Test AC Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7 Briggs & Stratton Alternator Systems Single Cylinder Engine Models The alternator systems used on Briggs & Stratton single cylinder engines can be identified by the color of the output wire and connector. Table No. 1, lists the various alternator system, engine model applications. Test procedures are listed by page number, reference illustrations by Fig. number. TABLE NO. 1 Basic Model Series 90000 110000 System 3 System 4 Fig. 1 p.
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7 IDENTIFICATION 3 Figs. 1 through 12 illustrate the different types of alternator systems discussed in this section. 2 1 SYSTEM DESCRIPTIONS System 3r and 4r Alternator The DC alternator operates as an integral part of the engine, separate from the starting and ignition systems. It provides DC charging current to a 6 or 12 volt battery. 4 • .5 Amps DC+ charging for battery • One BLACK lead (1) from stator (3) • Full wave rectifier (2) Two styles of stator have been used.
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7 1.2 AMP ALTERNATOR Used on Model Series 130000 After Date Code 91032400 (Fig. 4) 5 1 The 1.2 amp DC alternator provides current for charging a 12 volt battery. A 12 ampere hour battery is suggested for warm temperature operation and a 24 ampere hour for cold service. 3 • 1.2 amps DC+ for charging battery • One BLACK lead (1) from stator (3) • RED connector output lead (5) Fig. 4 1-1/2 AMP ALTERNATOR Used on Model Series 130000 Before Date Code 91032500 (Fig.
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7 AC Only Alternator (Fig. 7) 3 The AC alternator provides current for headlights only. Current for the lights is available only while the engine is running. Output depends upon engine speed. 12 volt lights with a total rating of 60 to 100 watts may be used. With lights rated at 70 watts, the voltage rises from 8 volts at 2400 RPM to 14 volts at 3600 RPM, so headlight brightness changes with engine speed.
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7 Quad Circuit Alternator (Fig. 10) 1 The quad circuit alternator system provides AC current through two output leads to the regulator-rectifier. The regulator-rectifier converts AC current to DC and provides unregulated current (5 amps DC–) for lighting and regulated current (5 amps DC+) for charging the battery. The charging rate will vary with engine RPM and temperature. 5 3 7 2 3 NOTE: The quad circuit and 10-16 amp regulated system use the same stator.
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7 TROUBLESHOOTING 1. Battery Not Charging a. Engine RPM too low b. Defective battery c. Loose or corroded battery ground leads d. Open, shorted or grounded wires between output connector and battery e. Defective diode (open or shorted) f. Defective or improperly grounded regulator-rectifier g. Diode installed incorrectly (reversed) h. Excessive current draw from accessories i. Low magnetic flux or damaged alternator magnets 2. Battery In State Of Overcharge a.
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7 DC Shunt The DMM will withstand DC input of 10 to 20 Amps for up to 30 seconds. When checking DC output on 16 Amp regulated system, use the DC shunt, Tool #19359, Fig. 14, to avoid blowing fuse in meter. Tachometer Digital tachometer, Briggs & Stratton Tool #19389, Fig. 15. Fig. 14 IMPORTANT NOTE: Check battery polarity. Negative (–) side of battery should be grounded to engine or frame; positive (+) side of battery to starter motor and alternator charge lead.
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7 6. With engine running at specified RPM, output should be as listed in Table No. 2, Specifications. 7. If low or no output, check stator air gap, when applicable. See Table No. 2, Specifications. 8. If stator air gap is within specification and there is low or no output, replace stator. Test AC Voltage Output Procedures are common to all systems with exceptions noted below. Temporarily disconnect stator wire harness from regulator-rectifier. (5 & 9 amp Regulated Alternator) 1.
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7 Stator Air Gap Adjustment (Typical) See Table No. 2, Specifications, if applicable. 1. Rotate flywheel until magnets are away from stator. 2. Loosen both stator mounting nuts and move stator away from flywheel and tighten one nut. 3. Place a .006” (.17 mm) or .010” (.25 mm) thick gauge (7), depending on application, between stator and flywheel. 4. Turn flywheel until magnets are under stator. Loosen nut and let stator be pulled against flywheel magnet. 7 5. Torque mounting nuts to 25 in. lbs. (3 Nm).
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7 Rectifier (Diode) Test Note: In the Diode Test position, the DMM will display the forward voltage drop across the diode(s) in the rectifier. If the voltage drop is less than 0.7 volts, the meter will “Beep” once as well as display the voltage drop. A continuous tone indicates continuity (shorted diode). An incomplete circuit (open diode) will be displayed as “OL.” 1-1/2 Amp Alternator Used on Model Series 130000 Before Date Code 91032500 1. Insert RED test lead (1) into meter. receptacle in 2.
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7 DC Only Alternator Test Test procedures for both systems are identical. 1. Insert RED test lead (1) into meter. receptacle in 2. Insert BLACK test lead (2) into COM receptacle in meter. 3. Rotate selector to (Diode Test) position. 4. Attach RED test lead clip to point “A” and Black test lead clip to point “B,” Fig. 25 (DC Only), Fig. 26 (Dual Circuit). (It may be necessary to pierce the red (3) wire with a pin as shown.) a. If meter “Beeps” once, diode is OK. b.
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7 5. Lighting Circuit (White Wire B–) Attach RED test lead (1) clip to point “A,” Fig. 28. (It may be necessary to pierce white wire (4) with a pin as shown.) Insert BLACK test lead (2) probe into harness connector. a. If meter “Beeps” once, diode is OK. b. If meter makes a continuous tone, diode is defective (shorted). Replace. c. If meter displays “OL,” proceed to step 6. 6. Reverse test leads. a. If meter “Beeps” once, diode is installed backwards. b.
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7 Test Lighting Circuit (DC–) 4 The black wire from the regulator-rectifier provides 5 amps (-) DC and is used only for lighting. If the headlights do not operate, first check bulbs, wiring and/or light switch. To test lighting circuit requires a 1 OHM 20 Watt resistor (4, available from an electrical supply house) and a test harness (5, made from 393362) shown in Fig. 30. 5 Fig. 30 1. Insert RED test lead (1) into 10 A receptacle in meter. 2. Inset BLACK test lead (2) into COM receptacle in meter. 3.
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7 4. Attach RED test lead clip to DC output terminal on the red output connector on the regulator-rectifier (3), Fig. 32. 5. Attach BLACK test lead clip to positive (+) battery terminal. 6. With the engine running at 3600 RPM. The output should be: * 3-5 Amps – 5 Amp System * 3-9 Amps – 9 Amp System * Depending upon battery voltage. A fully charged battery will show less amperage. 7. If no output or low output is found, replace the regulator-rectifier. 2 3 1 Fig.
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7 16 Amp System To avoid blowing fuse in meter when testing DC output of 16 Amp system the DC Shunt, Tool #19359 (3) is required. 1 2 The DC Shunt must be installed on the – (negative) terminal of the battery, Fig. 34. All connections must be clean and secure. 1. Install shunt on negative battery terminal. 2. Insert RED test lead (1) into receptacle in meter and connect to RED post terminal on shunt, Fig. 34. 3.
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7 Suggested Wiring Diagrams Components for typical starting systems are listed below: 1. 12 Volt Battery 2. Starter Motor 3. Solenoid 4. Ignition Switch 5. Upper Stator 6. Lower Stator 7. Anti-Afterfire Solenoid 8. Ammeter 9. Diode 10. Oil Gard Float 11. Oil Gard Module 12. Ignition Armature 13. Spark Plug 14. Alternator 15. Regulator Rectifier 16. Wire – Black/White Tracer 17. Wire – Yellow/Green Tracer 18. Wire – Red/White Tracer 19. Wire – Black 20. Wire – Yellow 21. Wire – Red 22. Wire – Green 23.
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7 SPECIFICATIONS The following wiring diagrams are recommended ways of wiring either five (5) or six (6) terminal ignition switches supplied by Briggs & Stratton. 7 9 4 26 14 25 + 8 27 3 10 1 2 Fig. 36 7 9 4 26 - 25 + 3 8 27 10 1 2 Fig.
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7 7 14 4 26 25 + 15 3 8 27 28 2 1 Fig. 38 7 14 4 26 25 + 15 3 8 27 28 1 Fig.
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7 7 14 4 26 25 + 15 3 8 27 28 2 1 Fig. 40 29 14 7 4 25 30 - 15 3 26 + 8 27 28 1 2 Fig.
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7 7 14 4 26 + 26 - - 8 27 3 28 + 32 2 1 31 Fig. 42 14 7 33 8 26 4 - 28 26 27 + + 3 32 31 1 Fig.
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7 14 7 33 8 4 26 - 28 25 27 + + 3 32 31 1 2 Fig.
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7 TABLE NO. 2 TABLE NO. 3 Alternator DC Output and Stator Air Gap (Where Applicable) Alternator AC Output System 3r and 4r Alternator AC Only Alternator and Dual Circuit Alternator Output: No less than .5 amp DC @2800 RPM. Stator Air Gap: .010” (.25 mm), (current style only). 1/2 Amp Alternator Output: No less than 14 volts AC @3600 RPM. Tri-Circuit Alternator Model Series 121700 – 124700 Output: No less than .5 amp DC @2800 RPM. Stator Air Gap: .006” – .008” (.15 – .
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8 SECTION 8 Lubrication Section Contents Page BREATHER Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 EXTENDED OIL FILL AND DIPSTICKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GEAR REDUCTIONS Check Oil, Aluminum Engines 6 to 1 Gear Reduction, Model Series 60000, 80000, 100200, 130000 . . . .
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8 Oil capacities are listed in the OIL CAPACITY CHART, Specifications, Page 8 of this section. NOTE: Always refill to full mark on dipstick. GEAR REDUCTION UNITS Change Oil, Aluminum Engines (6 to 1 Gear Reduction Models) Model Series 60000, 80000, 100200, 130000 1 2 Every one hundred (100) hours of operation: 1. Remove oil level plug (3) and oil fill plug (1), Fig. 1. 2. Loosen four screws holding gear case cover to drain oil. 3. Retighten cover screws to 85 in. lbs. (10 Nm) torque. 3 4.
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8 EXTENDED OIL FILL TUBE AND DIPSTICK 1. When installing the extended oil fill tube (1) and dipstick assembly, the tube must be installed so the “O” ring seal (2) is firmly compressed. 1 2. Push the tube downward toward the sump, then tighten blower housing screw, securing the tube and bracket. 3. When the cap and dipstick assembly is fully seated, it seals the upper end of the tube, Fig. 4.
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8 LUBRICATION SYSTEMS A Splash Lubrication Aluminum Alloy and Cast Iron Engines In this system the dipper, attached to the connecting rod, dips into the engine oil during rotation, splashing oil on all moving parts. There is no oil pump. Install connecting rod and dipper by engine model series as shown in Section 9. 5 Typical styles of dipper (5) are shown in Figures 7 – 11 Fig. 7, Aluminum Model Series 60000 Fig. 7 Fig.
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8 Slinger Lubrication, Oil Slinger Aluminum Alloy Engines The oil slinger (2) is driven by the cam gear (1) and splashes oil on all moving engine parts. 1 1 2 2 Early style slingers, Fig. 12. Illus. 1, using a die cast bracket assembly have a steel bushing between the slinger and the bracket. Replace bracket on which the oil slinger rides if worn to a diameter of .490” (12.4 mm) or less. Replace steel bushing if worn. Current style oil slingers, Fig. 12. Illus. 2 and Fig.
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8 Principles of Operation, Spark Gap Type This Oil Gard system uses an oil level sensor with a spark gap connected to a high tension lead from the ignition armature (1). When oil is the correct level, the spark gap (2) is filled with oil and a spark will not jump the gap.
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8 I E B F J C H A G 30 DEGREES D Fig. 17 The table below lists possible problems with the probable cause and cure. Refer to Fig. 17.
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8 OIL CAPACITY CHART Basic Model Series Capacity Ounces (Liters) Vertical Crankshaft Aluminum Cylinders 60000, 80000, 90000, 10A900, 10B900, 10C900, 100700, 110000, 120000 100900, 130000 170000, 190000 220000, 250000, 280000 21 (.6) 28 (.8) 36 (1.1) 48 (1.4) Horizontal Crankshaft Aluminum Cylinders 60000, 80000, 90000, 100200, 130000 170000, 190000 220000, 250000 21 (.6) 44 (1.3) 40 (1.2) Horizontal Crankshaft Cast Iron Cylinders 230000, 240000, 300000, 320000 8 64 (1.
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9 SECTION 9 Pistons – Rings – Rods Section Contents Page PISTONS Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Piston Ring Land Wear . . . . . . . . . . . . . . . . . . . . . . . . . . .
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9 Remove Piston and Connecting Rod 1. Bend down rod bolt lock (1), when used, Fig. 1. Connecting rods without rod bolt locks use one or two thin washers, or washer-head bolts. On connecting rods with dippers held by both connecting rod bolts, no washers or rod bolt locks are used. 2 1 2. Remove connecting rod cap (2). 3. Remove any carbon or ridge at top of cylinder bore to prevent ring breakage on cast iron sleeves or cast iron cylinders.
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9 Remove Piston Rings Remove piston rings using Piston Ring Expander Tool, #19340, Fig. 4. NOTE: Some oil control rings consist of two thin steel rails and a spring expander. These steel rails cannot be removed with Piston Ring Expander, Tool #19340. Grasp one end of the steel rail and wind the rail from the oil ring groove into the next ring groove. Repeat as necessary to remove from piston. Fig. 4 Check Piston If cylinder is to be resized, a new oversized piston assembly will be used.
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9 Piston Without Notch on Head 1. Install one pin lock in piston pin bore groove. (If bore is grooved for two locks.) 1 2. Place rod inside piston and slide piston pin into piston from side opposite lock or piston pin stop then through piston and rod until pin seats on lock or stop. Install (remaining) pin lock. Piston With Notch on Head The notch on the piston faces the magneto side of the engine. 1. On pistons except Model Series 300000, 320000, install one pin lock in bore groove opposite notch (1).
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9 Typical piston ring cross section for cast iron sleeve and cast iron bore engines, Fig. 10. NOTE: Some compression rings have an identifying dot on the top of the ring. Always install ring(s) with dot facing top of piston. NOTE: On oil rings that use two thin steel rails and spring expander, install expander first. Twist one steel rail at a time down from one ring groove to the next and onto the expander. Fig.
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9 3. Place piston assembly (5) and compressor upside down on bench and push piston down until head of piston is even with edge of compressor (6), Fig. 13. 7 8 5 4. Tighten compressor with wrench (7) until piston cannot be turned in compressor. 5. Then loosen compressor until piston can be turned with slight resistance. Do not attempt to install piston and ring assembly without ring compressor. 6 Install Piston Assembly (Without Notch On Head) Fig. 13 1.
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9 7. Torque bolts with Torque Wrench, Tool #19197 or 19393, to specifications listed in Table No. 4, Page 8. B NOTE: Some Model Series 280000 engine connecting rods using two different size connecting rod bolts. A A. FIRST torque 3/8” hex connecting rod screw to 160 in. lbs. (18 Nm). B. NEXT torque 1/2” hex connecting rod screw to 260 in. lbs. (23 Nm), Fig. 19. Fig. 19 8.
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9 SPECIFICATION TABLES TABLE NO. 1 Ring End Gap Reject Size TABLE NO. 3 Piston Pin Reject Sizes Compression Rings Inches (mm) Oil Ring Inches (mm) Aluminum Cylinder Bores .035 (.89) .045 (1.14) Cast Iron Cylinder Bores .030 (.76) .035 (.89) TABLE NO. 2 Connecting Rod Reject Size Piston Pin O.D. Pin Bore I.D. Aluminum Cylinder Inches (mm) Inches (mm) 60000, 80000, 90000,100700, 110000, 120000 with small pin before Date Code 970113XX .489 (12.42) .491 (12.
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10 SECTION 10 Crankshafts, Cam Gears, Gear Reductions & Auxiliary Drives Section Contents CRANKSHAFTS Page Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Reject Sizes, Table No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Check . . . . . . . . . . . . . . . . . . . . .
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10 Section Contents, Cont’d. AUXILIARY DRIVES Without Clutch, Model Series 92580, 92980, 94580, 94980, 110980, 111980, 121780, 122780, 124780, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 With Clutch, Model Series 110980 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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10 Camshaft Drive Gear Removal Cast Iron Engines Except Model Series 300000 and 320000 1 2 1. Use a long, blunt punch (1) to drive the cam gear shaft (4) and plug (5) out from the PTO side (2) toward the flywheel side (3), Fig. 3. Do not burr or peen end of shaft while driving out. 2. Hold camshaft drive gear while removing punch to avoid damage to the gear. 3 4 5 Fig. 3 Model Series 300400, 320400 1. Remove short bolt (1) and Belleville washer (2) from PTO drive gear (3), Fig. 4. 2.
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10 CHECK CRANKSHAFT All Engines Fig. 7 shows various crankshaft locations to be checked. Table No. 1, Specifications, shows reject sizes for those dimensions. Inspect the gear teeth (1) for wear or damage. Measure the PTO end journal (2), crankpin journal (3) and magneto end journal (4). Inspect the crankshaft plunger flat or keyway (5). Discard the crankshaft if the flat or keyway are damaged. Inspect the threads (6) for wear or damage.
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10 Model Series 111200, 111900 1 This cam gear has a mechanical compression release on the exhaust cam lobe plus Easy-Spin (1). In the starting position, the actuator cam (3) moves the rocker cam (2) so it will open the exhaust valve at the same time as the Easy-Spin lobe opens the intake valve. When the engine starts, the actuator cam moves down and the exhaust valve operates normally. 2 3 1. To check, move actuator cam to the running position, Fig. 9. 2. Push rocker cam against the actuator cam.
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10 2. Place crankshaft in soft jawed vise with bearing side up. When bearing is sufficiently heated, it will slip over the crankshaft bearing journal. 3. Grasp bearing (2) with the shield down and slip on the crankshaft bearing journal (1), Fig. 12. 1 2 4. The bearing will tighten on the shaft as it cools. DO NOT QUENCH. NOTE: Bearing shield faces crankshaft crankpin. Fig. 12 INSTALL CRANKSHAFT AND CAM GEAR 3 Aluminum Cylinders – Plain Bearing 1. Install valve tappets. 2.
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10 Torque Crankcase Cover or Sump All Aluminum Model Series 1 Torque crankcase cover or sump to specifications listed in Table No. 6, Page 27, Specifications. NOTE: On Model Series 100900, 130700, 131700, and 130900 a spring washer (3) is used on cam gear (2) as shown in Fig. 15. Model Series 130780, 130980, 131780, and 132980 do not use a spring washer. 3 2 Fig. 15 INSTALL CRANKSHAFT AND CAM GEAR Cast Iron Cylinders Plain Bearing 1. Assemble tappets in cylinder and insert cam gear. 2.
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10 Ball Bearing Model Series 300000, 320000 1. Install breaker plunger (2, when used) and tappets (1). 2. Insert cam gear from PTO side of cylinder (3), Fig. 18. 3. Slide cam gear shaft (4) through PTO side and into cam gear, Fig. 19. 1 2 4. Install magneto side cam gear bearing on cylinder. 3 5. Torque bearing screws to 90 in. lbs. (10 Nm). Fig. 18 6. Install long cam gear bolt (5) 5–1/2” (140.00 mm) finger tight to prevent loss of camshaft, Fig. 20.
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10 Install Bearing Supports Model Series 230000, 240000, 300000, 320000 2 1 Install bearing supports with new gaskets. Torque PTO side bearing support (2) bolts to 190 in. lbs. (21 Nm) and flywheel side bearing support (1) bolts to 90 in. lbs. (10 Nm), Fig. 22. Crankshaft End Play All Model Series Crankshaft end play is .002” – .008” (.05 mm – .20 mm) on all models except as listed in Table No. 5, Page 27. Specifications. Procedures for adjusting end play differ according to engine type. See Text. Fig.
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10 Aluminum Cylinders – PTO Ball Bearing End play is adjusted the same way as on plain bearing engines. If thrust washer is required, it is used on the magneto end of the crankshaft. 1 NOTE: Thrust washers cannot be used on engine with two ball bearings. Replace worn parts. Model Series 230000, 240000 Plain and Ball Bearing Fig. 24 With one .020” (.51 mm) thick gasket and magneto bearing support in place, use a feeler gauge (1) to measure end play. End play should be .002 – .008” (.05 – .20 mm), Fig.
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10 Remove Output Gear-PTO Shaft Assembly and Gear Case Assembly 1 4 1. Remove shaft assembly (2) from gear case (4). 2. Bend down two screw locks (1, if equipped), and remove two long cap screws (3). 2 3 3. Remove two short cap screws and lock washers (5). 4. Slide gear case off engine, Fig. 27. 5 1 Fig. 27 Inspect Output Gear-PTO Shaft, Gear Case and Cover Assemblies Inspect seals for cracks, tears, or hardening. Inspect crankshaft pinion gear and drive gear for worn, cracked, or chipped teeth.
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10 NOTE: Standard bearing housing position is 9 O’Clock (A), in relation to the engine crankshaft (7). Optional positions are 12 O’Clock (B), 3 O’Clock (C) and 6 O’Clock (D). 12. Slide cover and seal protector on to gear case and drive shaft until cover is seated on new gasket. Remove seal protector. B 7 C A 13. Torque cover screws (8) to 90 in. lbs. (10 Nm), Fig. 31. D Fig. 30 8 Fig. 31 Fill Gear Case with Lubricant 1 1. Remove oil level plug (2) and vent plug (1). 2.
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10 Disassemble and Drain Gear Reduction Counterclockwise Rotation (CCR) Model Series 170000, 190000, 220000, 230000, 240000, 1 1. Remove oil vent plug (1, if equipped). 2. Remove drain plug (3) from bottom of cover assembly (2). 3. After gear case is drained, loosen and remove four cap screws and cover, Fig. 33. 2 3 Fig. 33 Remove Drive Shaft and Gear Case Assembly 1 1. Note position of gear case assembly, Fig. 36. 2. Remove drive shaft assembly (2) from gear case. 3.
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10 ASSEMBLE 1 Install Seals and Gear Case Assembly 1. Install seal with sealing lip (1) towards engine side of gear case (2) or cover (3) until seal is flush with surface of case (when used) or cover, Fig. 35. 2 1 NOTE: The housing must be installed in the same position as when removed. NOTE: Standard bearing housing position is 9 O’Clock (A), in relation to the engine crankshaft (4). Optional positions are 12 O’Clock (B), 3 O’Clock (C) and 6 O’Clock (D), Fig. 36. 3 Fig. 35 – Installing Seals B 2.
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10 12. Torque cover screws (8) to 190 in. lbs. (21 Nm), Fig. 38. 8 9 Fig. 38 Fill Gear Case with Lubricant (Fig. 39) 1. Install drain plug (2) in bottom of gear case (if equipped). Torque to 65 in. lbs. (7 Nm). 1 2. Remove oil level plug (3). 3. Fill gear case just to the point of overflowing at the lower hole with the proper oil. See Section 8, Lubrication. 4. Install oil level plug in lower hole (if equipped). Torque to 90 in. lbs. (10 Nm). 5. Install vent plug (1) in top hole, (if equipped).
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10 Remove Drive Gear – PTO Shaft Assembly and Gear Case 3 Remove four cap screws (5) and lock washers. Slide gear case (3) and drive shaft assembly (4) off engine, Fig. 41. Remove Bearings Bearing cup in gear case cover is a slip fit, while bearing cup may be either a slip or press fit in gear case. When removing bearing cups take note of which cup has shims. Remove roller bearing by pressing the shaft and gear assembly out of the bearing with an arbor press. Do not reuse bearings.
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10 Install Gear Case Assembly B Install gear case in same position as when removed from engine, Fig. 44. Torque screws with lock washers to 140 in. lbs. (16 Nm). 3 NOTE: Standard bearing housing position is 9 O’Clock (A), in relation to the engine crankshaft (3). Optional positions are 12 O’Clock (B), 3 O’Clock (C) and 6 O’Clock (D), Fig. 44. C A D Fig. 44 Install Gear Case Cover Assembly 1. Place bearing cup in bearing cup counterbore of gear case cover without shims. 2.
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10 NOTE: If a dial indicator is not available, use a sprocket or pulley (3) and feeler gauge (4) to check end play as shown in Fig. 47. 3 7. Remove gear case cover assembly and drive shaft (if shims were behind bearing cup in gear case assembly). Shims are available in .003” (.08 mm) and .010” (.25 mm) thicknesses. 4 8. Use as many shims as needed to equal total end play plus .002” (.05 mm) to .005” (.13 mm). 9.
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10 4. Slide gear and shaft (3) sideways to expose head of sump mounting screw. 1 5. Use 7/16” socket to remove sump screw (4). 6. Remove remaining screws and remove sump. NOTE: Use care when driving out roll pin (2) to prevent damage to threads. Replace gasket (7) when installing cover (6), Fig. 51. Put non-hardening sealant on cover screws (5) . 2 5 7 6 Fig. 51 Remove Sump and Auxiliary PTO Drive Shaft, Model Series 120000 1 1. Remove all rust and burrs from crankshaft before removing sump. 2.
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10 3. Slide drive shaft and gear over to expose head of cap screw. Cap screw can be removed with 7/16” socket. 4. Remove remaining screws and remove sump. Inspect Clutch Operation 1. Push on spring tang (3), Fig. 54, turning spring and clutch sleeve in a counterclockwise direction. 2. Spring and sleeve should rotate approximately 1/8 turn. Worm gear should not rotate in the same direction. 3 3. With clutch released, worm gear should rotate freely in both directions. Fig.
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10 5. Slide clutch spring down, Fig. 57 and lift out upper spring tab (3) to remove spring. Cam gear, oil slinger and clutch drive hub are serviced as an assembly. Inspect Parts Inspect for worn, broken or burred parts. Replace as required. 3 Fig. 57 Assemble Cam Gear – Current Design 1. Assemble clutch spring as shown in Fig. 58. 2. Align hole in clutch sleeve (4) with tab or spring and slide on. 4 Fig. 58 – Assemble Clutch Spring 3. Depress spring tab, if required.
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10 Remove Control Lever Shaft 1 1. Remove “E” ring (1) from groove in shaft (2), Fig. 60. 2. Slide control lever and shaft (3) out slowly until lever clears boss on sump. 3 3. Slowly release spring tension and then remove shaft, spring and “O” ring seal. 4. Inspect shaft assembly for loose lever, worn or broken parts. Replace as needed. 2 Fig. 60 Assemble Control Lever and Shaft Assembly 1 1. Install return spring (1) on shaft and lever assembly (3) as shown in Fig. 61. 2.
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10 7. Install “E” ring. Leg of spring (5) may need to be pushed against sump, Fig. 63. 5 Fig. 63 Cylinder Clip Washer When replacing clip washer in cylinder, be sure flat on clip washer (1) is in line with flat on cam bearing boss and spring tabs are on both sides of cam bearing web (2), Fig. 64. 1 1 2 Fig. 64 NOTE: SPECIFICATION TABLES BEGIN ON PAGE 24 OF THIS SECTION.
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10 SPECIFICATION TABLES TABLE NO. 1 – CRANKSHAFT REJECT SIZES MODEL SERIES PTO JOURNAL CRANKPIN JOURNAL MAGNETO JOURNAL Inches (Millimeters) Inches (Millimeters) Inches (Millimeters) 60000 .873 (22.17) .870 (22.10) .873 (22.17) 80000*, 90200, 92000*, 93000*, 94000, 95000, 96000 .873 (22.17) .996 (25.30) .873 (22.17) 110700*, 110900*, 111900* .873 (22.17) .996 (25.30) .873 (22.17) 100200, 100900, 130000 .998 (25.35) .996 (25.30) .873 (22.
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10 TABLE NO. 2, .020” (.51 mm) UNDERSIZE CONNECTING ROD CRANKPIN GRINDING DIMENSIONS CRANKSHAFT MODEL SERIES Crankpin Dia. Fillet Radius Crankshaft Throw 80000, 90000 .9788/.9783” (24.862/24.849 mm) .130/.110” (3.30/2.79 mm) 1.0100/.990” (25.654/25.146 mm) 100200, 100900 .9788/.9783” (24.862/24.849 mm) .088/.070” (2.24/1.78 mm) 1.0645/1.0605” (27.038/26.937 mm) 100700, 110000 .9788/.9783” (24.862/24.849 mm) .130/.110” (3.30/2.79 mm) .9750/.9650” (24.765/24.
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10 TABLE NO. 3 – CAM GEAR REJECT SIZES MODEL SERIES CAM GEAR JOURNAL CAM LOBE ALUMINUM CYLINDER Inches (mm) Inches (mm) 60000, 80000* .498 (12.65) .883 (22.43) or See Note Below 82500, 82900, 92000, 93000, 94000, 95000, 96000 .498 (12.65) .883 (22.43) 90200, 100700, 120000 .498 (12.65) See Note Below .436 Mag. .498 P.T.O. (11.07 Mag. 12.65 P.T.O.) .870 (22.10) 100200, 100900, 130000 .498 (12.65) .950 (24.13) 170000, 190000 .498 (12.65) .977 (24.82) 220000, 250000, 280000 .498 (12.
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10 TABLE NO. 4 Seal Protectors Tool # Color 19334/1 White 19334/2 19334/3 19334/4 19334/5 TABLE NO. 6 Crankcase Cover or Sump Torque Crankshaft Journal Size .787 (19.99 mm) Red .875 (22.23 mm) Blue .984 (24.99 mm) Orange 1.000 (25.40 mm) Brown 1.062 (26.97 mm) 19334/6 Green 1.181 (30.00 mm) 19334/7 Yellow 1.378 (35.00 mm) 19356/8 Purple 1.317 (33.45 mm) 19356/9 Black 1.503 (38.18 mm) Model Series Torque In. Lbs.
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11 SECTION 11 Cylinders & Bearings Section Contents Page CYLINDERS Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Resizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Standard Bore Size Aluminum Cylinders . . . . . . . . . . . . . . . . . . .
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11 INSPECTION All Models 1 Always inspect the cylinder after engine disassembly. Visual inspection will show cracks, stripped bolt holes, broken fins or cylinder wall damage. 2 3 Use Telescoping Gauge (4), Tool #19404, shown in the middle (2) position, Fig. 1, with a dial caliper, or use an inside micrometer to measure bore size at right angles to cylinder bore. TABLE NO. 1, Specifications, lists the standard bore sizes. 4 Measure the cylinder bore at right angles at each of three locations.
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11 Set Up For Honing 1 1. Clean cylinder at top and bottom to remove burrs and pieces of base or head gaskets. 4 5 2. Fasten cylinder to a heavy iron bracket or use honing plate (2), Fig. 2, Illustration A. Some cylinders require shims (3). 6 3. Use a level to align drill press spindle with bore (1). 4. Oil surface of drill press table liberally. Set plate and cylinder on drill press table. (Do not anchor to drill press table.) If using portable drill, set plate and cylinder on floor.
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11 5. As cutting tension decreases, stop hone and tighten adjusting knob. 6. Check cylinder bore frequently after cooling, with an accurate micrometer. NOTE: On cast iron cylinders, change to finishing stones when within .001” (.04 mm) of desired size. 1 ÉÉ ÉÉ É É ALWAYS HONE .010” (.38 mm), .020” (.51 mm), OR .030” (.76 mm) ABOVE THE STANDARD DIMENSIONS IN TABLE NO. 1. Fig. 3 Cylinder Finish The finish on a resized or reconditioned cylinder should have a 45 degree (1) crosshatch appearance, Fig. 3.
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11 Check Cam Gear Bearing Check cam gear bearing using Tool #19164, Plug Gauge (2), as shown, Fig. 5. If 1/4” (6 mm) or more of gauge enters bearing bore, bearing is worn beyond reject, and the cylinder, sump or crankcase cover must be replaced. 2 NOTE: On Model Series 111200, 112200, 111900, 112900, Tool #19164, Plug Gauge is used on the sump or crankcase cover cam gear bearing. Reject size for cylinder cam gear bearing is .443” (11.00 mm) or larger.
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11 5. Insert reamer guide bushing (7) to bearing to be repaired (10). 2 6. Tighten wing nut (3) to compress valve springs (2). Repair Procedure 1 1. Place reamer guide bushing (3) in oil seal bore of bearing to be repaired. The reamer guide bushing and pilot guide bushing (1) will center the counterbore reamer, even if the bearings are worn. 3 Fig. 7 2.
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11 5. Press in new bushing keeping notch in line with notch in cylinder or crankcase cover until outer edge of new bushing is flush with outer end of reamed out bushing. 6. If notch does not line up, bushing can be pressed into recess of cylinder support and reinstalled. 6 5 On Model Series 171700, 191700, 193700, 195700, 196700 magneto bushing notch (6) should be in line with oil hole (5). Oil hole should be open after installation, Fig. 11. 7.
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11 Install DU Bushing, Cylinder or Crankcase Cover 1 1. Place DU bearing on cylinder or cover bearing with oil hole in cylinder or cover bearing. If cover bearing does not have oil hole, place split (when present) of bearing (1) as shown in Fig. 13. Fig. 13 2. With suitable driver (2), press bearing (1) as shown to dimension shown in TABLE NO. 3. If no dimension is given for Model Series, press bushing until flush with seal surface, Fig. 14.
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11 Cylinder or crankcase cover, Model Series 190000, 220000, 250000, 280000, Fig. 17. 1 1 Fig. 17 Sump, Model Series 220000, 250000, 280000, Fig. 18. 1 Fig. 18 REPLACE OIL SEAL The oil seal (1) is assembled with the sharp edge of the rubber toward the inside of the engine. Lubricate inside diameter of oil seals with engine oil before assembling engine. Most oil seals are pressed in (Illustration A), flush with the hub (2).
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11 SPECIFICATION TABLES TABLE NO. 1 Model Series Standard Bore Size Diameter TABLE NO. 2 Cylinder Bearing Reject Size Chart Model Series Magneto Bearing PTO Bearing Min. Inches (Min. mm) Aluminum Cylinder Inches (mm) Inches (mm) Aluminum Cylinder Max. Inches (Max. mm) 60000, 80000* .878 (22.30) .878 (22.30) 60000 after Ser. #5810030 2.3750 (60.33) 2.3740 (60.30) 90000*, 9K400 .878 (22.30) .878 (22.30) 80000 2.3750 (60.33) 2.3740 (60.30) 100700, 120000 .878 (22.30) 1.065 (27.
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11 TABLE NO. 4 Seal Protectors Tool #1 19334/1 19334/2 19334/3 19334/4 Color White Red Blue Orange Crankshaft Journal Size .787” (19.98 mm) TABLE NO. 5 Crankcase Cover or Sump Torque Model Series Torque In. Lbs. (Torque Nm) 60000, 80000, 90000, 9K400, 120000 85 (10) 100200, 100900 .984” (24.99 mm) 120 (14) 100700, 110000 1.000” (25.
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11 TABLE NO. 6 Magneto Bearing Repair Tool Chart Reamer Pilot CounterBushing Guide Guide bore Driver Bushing Bushing Reamer Mag.
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11 TABLE NO. 7 PTO Bearing Repair Tool Chart Reamer Pilot CounterBushing Guide Guide bore Driver Bushing Bushing Reamer Mag.
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12 SECTION 12 Synchro-Balance and Oscillating Counter Balance Section Contents Page Synchro-Balance  Operation of Synchro-Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation of Oscillating Counter Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Series 170000, 190000, 250000, 280000, Vertical Crankshaft Disassemble . . . . . . . . . . .
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12 ASSEMBLE AND TIME ROTATING SYNCHRO-BALANCE, HORIZONTAL CRANKSHAFT CAST IRON ENGINES 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. • On some Model Series 326400 engines, the Synchro-Balance cover did not have the balance gear and bearing. DO NOT ATTEMPT TO START THESE ENGINES until balance gear and bearing are reinstalled to prevent kickback when starting. 1 2 3 1.
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12 Time Counterweight 1. Remove the timing hole screw (5) from flywheel cover (1) or PTO cover (2), Fig. 5. 1 2 2. Insert a short piece of 1/8” (3 mm) rod (3) through timing hole in cover and into machining hole in counterweight, Fig. 5. The rod holds the counterweight in the proper position while cover is installed on engine. 3 NOTE: One of the screws holding the breather can also be used, instead of 1/8” (3 mm) rods. 3.
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12 Time Counterweights Gears 1. Remove two small screws (1) from cover. 2. Insert 1/8” (3 mm) diameter locating pins (3) through screw hole and into timing hole provided in counterweights (2), Fig. 7. NOTE: Breather screws and extended dipstick tube screw may be used in place of locating pins. 1 3. With piston at TOP DEAD CENTER, install the crankcase cover assembly and cover gasket. 4. Remove the locating pins or screws. 2 5.
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12 6. Remove PTO side weight (4), dowel pin(s) (5), link (7) and spacer(s) (8) (when used). 6 4 7. Remove crankshaft from magneto side counterweight (6), Fig. 10. 8. Open lock tab (when used) (9) and remove screw(s) from counterweight. NOTE: Newer assemblies contain only one screw, one dowel pin and are not equipped with spacers and lock. 5 9 7 8 Fig. 10 Inspect Counterbalance System Check counterweight bearings and crankshaft eccentrics for wear as listed in Table No. 1, Page 6, Specifications.
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12 7. If woodruff key was removed, re-install in crankshaft. Slide crankshaft gear onto crankshaft with chamfer toward eccentric. If gear is tight, heat gear to expand it before installing. 8. Lay cylinder on its side with cylinder head to the left. Use Seal Protector Kit, Tool #19334 or #19356 in magneto crankshaft seal. 9. Place crankshaft and counterweight assembly into cylinder. Start magneto journal into magneto bearing. 10. Align link with crankcase link pin and push assembly into place, Fig. 12. 11.