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VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine MODEL 473100 2 CYLINDER LIQUID COOLED ENGINE COMMERCIAL POWER MANUAL NUMBER: 275429
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine SAFETY INFORMATION The Briggs & Stratton engine is made of the finest material in a state-of-the-art manufacturing facility. Please understand that Briggs & Stratton sells engines to original equipment manufacturers. It also sells to others in the distribution chain who may sell to the ultimate consumer, an equipment manufacturer, another distributor or a dealer.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Table Of Contents MODEL 473100 2 CYLINDER LIQUID COOLED ENGINE COMMERCIAL POWER ......................................... 1 SAFETY INFORMATION ....................................... 2 IN THE INTEREST OF SAFETY ...................... 2 SECTION 1 GENERAL INFORMATION .................................... 3 ENGINE IDENTIFICATION .............................. 4 MAINTENANCE SCHEDULE ........................... 5 FUEL AND OIL RECOMENDATIONS ..............
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Table Of Contents REPLACING PINION GEAR ASSEMBLY ...... 47 CARBURETOR INSPECTION AND REPAIR . 51 SECTION 5 ENGINE ASSEMBLY ............................................ 57 SECTION 6 FINAL ADJUSTMENTS AND SPECIFICATIONS ................................................ 71 GENERAL INFORMATION ............................ 71 REMOTE GOVERNOR CONTROLS .............. 71 INSTALL CRANKSHAFT ................................ 57 CARBURETOR ADJUSTMENT ................
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 1 - General Information SECTION 1 GENERAL INFORMATION BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM This chart explains the unique Briggs & Stratton numerical model designation system. It is possible to determine most of the important mechanical features of the engine by merely knowing the model number. Here is how it works: • A. The first one or two digits indicate the approximate CUBIC INCH DISPLACEMENT. • B.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 1 - General Information ENGINE IDENTIFICATION Oil Fill Cap Fuel Pump Dipstick Muffler (If Equipped) Spark Plug Choke Control 12V Electric Starter Throttle Control (2 Possible Locations) Oil Drain Plug Radiator Reservoir (If Equipped) Fan Belt (If Equipped) Oil Filter Fuel Filter Oil Drip Tray (Igf Equipped) Radiator Drain Plug (If Equipped) Oil Pressure Switch Radiator Screen & Handle (If Equipped) Engine Model Label Radiator & Ra
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 1 - General Information MAINTENANCE SCHEDULE Daily Check Oil Level X Check For Oil Leaks X 50 Hours 100 Hours Change Oil X* Change Oil Filter X* 250 Hours 600 Hours Yearly Check Coolant Change Coolant X X*** X Check Fan Belt X** Clean Air Filter X** Replace Air Filter Check Valve Clearance X Check Battery Electrolyte X Change Spark Plugs X Change Fuel Filter Clean Spark arrestor X X Change oil after first 50 hours of use,
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 1 - General Information FUEL AND OIL RECOMENDATIONS Gasoline Use clean, fresh, unleaded gasoline. Leaded gasoline may be used if unleaded is not available. A minimum of 85 octane is recommended. The use of unleaded gasoline results in fewer combustion deposits and longer valve life. We do not recommend the use of gasoline that contains alcohol, such as gasohol.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 1 - General Information CHANGING OIL AND OIL FILTER 9. Replace oil fill cap and dipstick. 10. Start and run engine to check for oil leaks. Change oil and filter after first fifty (50) hours of operation. Thereafter, change oil and filter every one hundred (100) hours of operation. Change oil more often if engine is operated in dirty or dusty conditions or if engine is operated under heavy loads or in high ambient air temperatures.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 1 - General Information Normal coolant temperature gauge (if equipped) should read between 175° and 195° F (80° and 90° C) when engine is running. If coolant temperature rises above 220° F (105° C), the temperature light (if equipped) will illuminate. Idle engine down for a while. Then stop engine. Once engine is cooled, check coolant level, fan belt tension and clogged radiator fins. 1. Loosen bolt and bolt . 2.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 1 - General Information bore to wear quickly. As the rings and cylinder bore become worn, these abrasive particles enter the crankcase and contaminate the oil, forming an abrasive mixture which will cause wear on all of the internal moving parts. Clean cartridge every 100 hours. To clean cartridge, gently tap on end with handle of screwdriver. Replace cartridge every 600 hours. Clean and replace more often under dusty conditions.
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VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting SECTION 2 TROUBLESHOOTING 3. If starter cranks, there is a problem with the key switch or wiring. GENERAL INFORMATION Most complaints concerning engine operation can be classified as one or a combination of the following: 1. Will not start 2. Hard Starting 3. Lack of power 4. Runs Rough 5. Vibration 6. Overheating 7. High Oil Consumption Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting STARTER CURRENT DRAW TEST 5. A fully charged 12 volt battery. Testing Starter IMPORTANT: When making the starter current draw test make sure that all parasitic load is removed from the engine and that engine has the correct viscosity oil. Engine temperature should be at least 70°F (21°C). Make sure battery and solenoid connections are clean and tight. NOTE: Battery voltage must not be below 11.7 volts.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting NO LOAD STARTER CURRENT DRAW TEST 3. Attach negative battery cable ground such as drive housing. Remove starter motor. 4. Attach positive battery cable terminal on solenoid. To hold starter securely while testing, clamp starter mounting bracket in a vise. DO NOT clamp starter housing in a vise or field windings or magnets may be damaged.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting Check Ignition (With Engine Starter) Check Ignition (Engine Running) With spark plugs installed, attach a #19368 ignition tester to each spark plug lead and ground the other end of the tester as shown in Fig.12. Activate the electric starter. If spark jumps the tester gaps, you may assume the ignition system is functioning satisfactorily.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting DIODE FAILURE DIAGNOSTIC TABLE Ground Wire Harness Diode Diode OFF ON Fig. 14 If miss continues: The problem may be carburetion or compression related. See Check Carburetion and/or Cylinder Balance Test and Cylinder Leakdown Test. Troubleshooting Ground Wire Harness The ground wire harness contains two diodes.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting If meter “Beeps” once, diode is OK. If plugs are dry, look for: If meter makes a continuous tone, diode is defective (shorted). Replace ground harness. 1. Leaking carburetor or intake manifold mounting gaskets If meter displays “OL,” diode is defective (open). Replace ground harness. 2. Gummy or dirty carburetor, fuel filter, fuel lines or fuel tank 6. Now, repeat test for #1 cylinder. Results must be the same. 3.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting Testing Equipment Wiring 4. If solenoid does not “click”, it is defective. Replace. 1. With keyswitch in OFF position, disconnect solenoid wire (GRAY WIRE) from engine wiring harness connector (WHITE WIRE). 2. Insert red meter test lead into equipment side of wiring harness connector (WHITE WIRE) , Fig. 17. 3. Attach black test lead to a good ground . 4. Turn keyswitch to ON position. a.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting CYLINDER BALANCE TEST If the engine is hard starting, runs rough, misses or lacks power, perform a cylinder balance test to determine whether both cylinders are operating to their full potential. Tools Required 1. Tachometer, Tool #19200 or 19389 2. Two #19368 Ignition Testers 3. Screwdriver with insulated handle Attach ignition tester, Tool #19368 between the spark plug lead and each spark plug, Fig. 20. Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting there will be no RPM loss. When the other cylinder is grounded out the engine will stop. NOTE: A twin cylinder engine will run well on one cylinder as long as the power required for the application does not exceed the power produced by the one cylinder. CYLINDER LEAKDOWN TEST An accurate method of checking the sealing capability of the compression components is by using the cylinder leakdown tester Tool# 19545.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting 5. Pull the regulator adjustment knob out and turn knob counterclockwise as far as it will go, Fig. 23. Make sure air outlet valve is closed. 9. Listen for air leaking from the cylinder head gasket, carburetor, exhaust system and the crankcase breather tube. NOTE: If a high flow of air is leaking from the exhaust and carburetor, make sure the piston is at TDC on the compression stroke. a.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting 11. Disconnect outlet hose from tester before removing from spark plug hole. a. Coolant level must be no more than 1 in. (.25 mm) below bottom of filler neck. 12. Repeat test for other cylinder. The variation between the two cylinders should be less than 20%. If the difference is greater than 20%, check the cylinder with the lower reading. Possible Causes for Poor Compression: 1. Loose cylinder head bolts 2.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting 5. Remove thermostat from water and allow it to cool. a. Thermostat should close fully. Fig. 26 The water pump seal is replaceable. See Section 4. Fig. 27 If system does not maintain pressure and no leaks are evident externally, there may be an internal leak such as a blown head gasket, warped cylinder head or cylinder block.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting CHECK OIL PRESSURE 1. Oil level must be between the LOW and FULL mark on dipstick. If oil level is low, check for leaks and add to FULL mark. 2. Remove pressure switch. 3. Install oil pressure gauge, Fig. 29. 4. Start and run engine for approximately 5 minutes. 5. Check oil pressure at 3000 RPM. Oil Pressure - @ 70°F (21°C): 10 ~ 50 psi (0.7 ~ 3.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting CAUTION: Attach meter test leads to AC output 4. Attach RED test lead probe to DC output terminal in white connector (red wire), Fig.31. terminals in white connector (yellow wires) BEFORE STARTING ENGINE. If stator is grounded (defective), and meter test leads contact center DC output pin in white connector (red wire), arcing may occur which may damage wiring. 4.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting 4. Rotate selector to position. Fig. 32 5. With the engine running at 3600 RPM, the output should be: * 3 - 20 Amps - 20 Amp System * Depending upon battery voltage and/or current draw on system. 6. If no or low output is found, be sure that regulatorrectifier is grounded properly and all equipment connections are clean and secure. If there is still no or low output, replace the regulator-rectifier.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 2 - Troubleshooting 3. With battery fully charged, check specific gravity readings of each cell with a Battery Hydrometer and record readings, Fig. 33. All readings should be above 1.250 (compensating for temperature). If specific gravity readings varied . 50 or if all cells read less than 1.225, replace battery. 50 Amp. Hr.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 3 - Engine Disassembly SECTION 3 ENGINE DISASSEMBLY 2. Disconnect by-pass hose at thermostat housing. GENERAL INFORMATION 1. Disconnect battery cables at battery. 2. Disconnect throttle and choke cables. 3. Drain oil and remove oil filter. 4. Drain radiator. REMOVE MUFFLER 1. Remove muffler bracket screws manifold screws , Fig. 34. , and exhaust Fig. 35 3. Remove upper and lower radiator mounting nuts and washers. 4.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 3 - Engine Disassembly DISCONNECT FUEL LINES 3. Remove flywheel housing , Fig. 39. 1. Disconnect fuel line from pump to carburetor , fuel pump pulse line at valve cover , and fuel inlet line at fuel filter , Fig. 37. Fig. 39 4. Loosen fan belt and disconnect regulator- rectifier. 5. Remove fan, Fig. 40. Fig. 37 REMOVE FAN ASSEMBLY 1. Remove lower fan shroud screws and upper fan bracket screws at intake manifold , Fig. 38. 2.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 3 - Engine Disassembly 6. Remove fan adjustment bracket , Fig. 41. REMOVE CARBURETOR 1. Remove air cleaner assembly. 2. Disconnect throttle link and spring at carburetor , Fig. 43. Fig. 41 7. Remove fan brackets , Fig. 42. Fig. 43 3. Remove governor lever and disconnect governor springs, Fig. 44. Fig. 42 Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 3 - Engine Disassembly 4. Remove governor control bracket and disconnect governor link , Fig. 45. 10. Remove air cleaner elbow screws , Fig. 47, and separate carburetor from intake elbow and air cleaner elbow. Fig. 45 Fig. 47 5. Disconnect fuel shut off solenoid wire and remove ground wire. 6. Disconnect breather tube at air cleaner elbow Fig. 46. 7. Remove intake elbow screws . REMOVE STARTER , 1. Remove two screws 48.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 3 - Engine Disassembly 2. Remove fan belt pulley . Fig. 49 3. Place flywheel strap wrench, Tool #19433 around flywheel. 4. Loosen flywheel nut, Fig. 50. 6. Tighten puller nuts equally until flywheel loosens, Fig. 51. Fig. 51 WARNING: DO NOT strike flywheel with a hard object or a metal tool as this may cause flywheel to shatter in operation. Always use approved removal tools. REMOVE INTAKE MANIFOLD 1. Remove thermostat cover 52. 2.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 3 - Engine Disassembly REMOVE CYLINDER HEADS 3. Remove breather, Fig. 53. 1. Remove valve covers. 2. Remove rocker arms 55. and pushrods , Fig. NOTE: Mark pushrods so that they can be reassembled in their original position. Fig. 53 REMOVE ALTERNATOR 1. Remove alternator harness clamp alternator , Fig. 54. and Fig. 55 3. Unscrew 5 head bolts and remove cylinder heads, Fig. 56. Fig. 54 Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 3 - Engine Disassembly REMOVE CRANKCASE COVER 1. Remove water pump cover 2. Remove water pump impeller 4. Remove oil pump screws Fig. 59. and oil pump , , Fig. 57. . Fig. 59 Fig. 57 5. Remove governor gear Fig. 60. and thrust washer , 3. Remove crankcase cover, Fig. 58. Fig. 60 Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 3 - Engine Disassembly REMOVE CAMSHAFT 2. Repeat for other cylinder. 1. Rotate crankshaft and camshaft until timing marks align, then remove camshaft and tappets, Fig. 61. Fig. 62 3. Remove crankshaft. 4. Remove governor shaft, Fig. 63. Fig. 61 REMOVE PISTONS, RODS, CRANKSHAFT NOTE: Remove any carbon or ridge at the top of cylinder bores to prevent breaking rings when removing piston and connecting rod assemblies. 1. Remove No.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul SECTION 4 ENGINE OVERHAUL b. If cylinder bore is worn more than .003” (0.076 mm) or more than .0015” (0.038 mm) out of round, it must be resized. TOP CHECK CYLINDER CENTER Check cylinder for cracks or stripped threads. Check cylinder bores for damage or scoring. BOTTOM MEASURE AT SIX POINTS 1. Check cylinder head mounting surface for distortion with a straight edge, Fig. 64.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul Honing is done with a variable speed 1/2”, portable drill and a honing fixture. A suitable honing fixture can be made from a 2” X 8” X 16” block of wood. Use three or four crankcase cover mounting screws and fasten cylinder to the honing fixture. Clamp honing fixture and cylinder securely in a vise at a convenient work height. Place hone drive shaft in chuck of portable drill and tighten.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul specification. Be careful not to hone oversize or it will be necessary to resize the cylinder. BEARINGS NOTE: To produce the proper cross hatch finish Check Mag Bearing use a drill speed of approximately 200 RPM and 40-60 strokes per minute. Lubricate hone liberally to prevent build up on finishing stones. Check magneto bearing for wear or damage, Fig. 68. Reject Dimension: 1.7765” - (45.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul Check PTO Bearing Check PTO bearing for wear or damage, Fig. 70. Reject Dimension: 1.7765” (45.12 mm) If PTO bearing is worn or damaged, the crankcase cover must be replaced. Fig. 71 Check Camshaft Inspect gear teeth, lobes and journals for wear and nicks. Camshaft journal and lobe reject sizes are shown below. Replace cam gear if not to specification. Fig. 70 CRANKSHAFT Camshaft Reject Sizes: Journals: (Mag & PTO) .
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul necessary to check pistons and rings since a new oversized piston assembly will be used. Disassemble Piston and Connecting Rod 1. Remove piston top and center rings using ring expander, Tool #19340, Fig. 73. a. Remove top oil scraper ring, then bottom scraper ring. b. Remove expander.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul Fig. 76 Fig. 78 3. Check piston pin bore, Fig. 77. 2. Check connecting rod bearings, Fig. 79. Replace if greater than .828” (21.03 mm). NOTE: If crankpin bearing is scored or worn the connecting rod must be replaced. Connecting Rod Reject Sizes: Crankpin Bearing 1.658” (42.11 mm) Piston Pin Bearing .8285” (21.04 mm) CRANKPIN BEARING Fig. 77 Check Piston Pin And Connecting Rod 1. Check piston pin, Fig. 78.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul CYLINDER HEAD INSPECTION AND REPAIR Disassemble Cylinder Head 1. Place a shop rag or short section of rubber fuel line under valves inside combustion chamber to hold valve in place while compressing spring. 2. Thread rocker arm support screw into cylinder head a few turns and compress spring with valve spring compressor, Tool #19347, Fig. 80. Remove the following: a. Valve spring retainer locks b. Valve spring retainers c.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul Remove Valve Guide 1. Press out old valve guide using bushing driver, , Fig. 84. Tool #19367 Fig. 84 Install Valve Guide 1. Press in new valve guide using bushing driver, , Fig. 85. Tool #19416 a. Press in until tool bottoms on valve guide bushing boss. b. Turn reamer clockwise through entire guide. c. Keep turning reamer clockwise when removing reamer. d. Flush out all chips. Fig. 86 Reface Valves And Seats 1.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul a. Use a 605 cutter to narrow seat from bottom and a 155 cutter to narrow seat from top, Fig. 88. NOTE: If valve seat is loose or cracked, replace cylinder head. Assemble Cylinder Head 1. Use valve guide driver, Tool #19416 and install new intake valve stem seals, Fig. 90. a. Oil inner surface and lip of valve stem seal. b. Press seal on to valve guide bushing until it bottoms. 1-16”-3/64” (0.8 MM TO 1.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 3. Place a shop rag or short section of rubber fuel line under valves inside combustion chamber to hold valve in place while compressing spring. 2. Remove oil pick-up tube and screen assembly . a. Discard O-ring. 4. Install springs and valve spring retainers over valve stems. Inspect Oil Pump 5. Temporarily, install rocker arm support screws in cylinder head. Inspect pump drive gear for obvious wear or chipped teeth.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul a. Torque screw to 70 in. lbs. (8.0 Nm). REPLACING WATER PUMP SEAL The water pump seal may be replaced without removing the crankcase cover from the engine. The water pump housing and water pump impeller must be removed. If any evidence of coolant is observed in the oil, this indicates that the oil seal behind the water pump seal is leaking. To replace the oil seal, the crankcase cover must be removed.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 3. Then, carefully drive stud and puller nut the rest of the way through seal. Installing Water Pump Seal 1. Press or drive in new water pump seal until it bottoms with a 32 mm 12 point socket, Fig 100. Fig. 98 4. Center the puller and stud in water pump seal and then rotate puller and stud 90°. 5. Assemble support driver , pilot nut , washer , and nut to puller stud and center assembly over water pump seal. 6.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 4. Engage flats on plunger with fork in drive lever and assemble solenoid to starter, Fig. 102. a. Torque nuts to 70 in. lbs. (8.0 Nm). 5. Install field coil wire and nut. a. Torque nut to 90 in. lbs. (10.0 Nm). Fig. 103 4. Remove starter housing from drive end cap. Fig. 102 REPLACING PINION GEAR ASSEMBLY Pinion gear replacement requires complete starter motor disassembly.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 5. Remove armature and pinion gear with drive lever from drive end cap, Fig. 105. Fig. 105 6. Remove spacer from armature shaft. 7. Use a 14 mm deep socket and drive retainer from C-ring, Fig. 106. 8. Remove and discard C-ring and retainer. Always use a new C-ring and retainer. 9. Remove pinion gear and clutch assembly, Fig. 107. Fig. 107 Clean and inspect helix. If helix is damaged, replace starter.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul Inspect Brushes 3. Attach either test lead to starter housing, Fig. 111. Minimum brush dimension is 1/4” (6.0 mm). If brushes are worn less than specification, replace the starter housing, Fig. 109. 4. Contact first one, then other brush with other test lead as shown. a. Meter should make continuous tone (continuity). b. If meter does not make a tone, (no continuity) replace starter housing. 1/4” (6.0MM) Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul NOTE: Lip on spacer must face bearing in drive end cap. 3. Assemble starter housing to drive housing, aligning notch 115. NOTCH TAB Fig. 113 Fig. 115 Assemble Starter 1. Assemble drive lever to pinion and install armature and drive lever into drive housing, Fig. 114. 4. Install brush holder, inserting tabs on brush holder into slots in starter housing, Fig. 116.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 6. Compress springs with needle nose pliers and insert spring behind brushes. 10. Install solenoid. Fig. 117 7. Install brush retainer plate. 8. Assemble rubber seal to starter housing, Fig. 118. a. Be sure notch in rubber seal is inserted over tab on housing. BRUSH RETAINER Fig. 119 CARBURETOR INSPECTION AND REPAIR Disassemble Carburetor 1. Remove fuel shut off solenoid with washer. NOTCH TAB 2.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 3. Remove fixed main jets . 6. Remove idle mixture screws and springs, Fig. 123. NOTE: Carburetor is equipped with a different size fixed main jet for each cylinder, Fig. 121. The carburetor is marked “L” (#1 cylinder) and “R” (#2 cylinder). 4. Remove pilot jets . Fig. 123 7. Remove welch plugs, Fig. 124. Fig. 121 5. Remove float and inlet valve, Fig. 122. Fig. 124 8.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 9. Remove throttle shaft, spacer and seal, Fig. 125. #100041 or 100042) to clean carburetor parts and body. 4. When cleaning non-metallic parts (plastic, nylon, MinlonE, etc.), do not leave in commercial carburetor cleaner more than 15 minutes. CAUTION: Parts containing rubber, such as seals, O-rings, inlet needles, seats or pump diaphragms should never be placed in commercial carburetor cleaner.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 2. Inspect throttle shaft and choke shaft for wear, Fig. 128. Make sure bushing hole is circular and there is no wear. Replace if worn. IMPORTANT: Install one throttle plate at a time. Check throttle shaft for freedom of operation before installing other throttle plate. NOTE: Use LOCTITE) 222® on screw threads and torque to 6 in. lbs. (0.7 Nm). Fig. 128 Assemble Carburetor When assembling carburetor, use new seals and gaskets.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 4 - Engine Overhaul 6. Install idle mixture screws and springs. DO NOT tighten screws at this time, Fig. 132. 8. Assemble inlet valve to float and install float assembly, Fig. 134. DO NOT install limiter caps at this time. Fig. 134 Fig. 132 7. Install main jets and pilot jets, Fig 133. “L” or #1 cylinder is equipped with #114 main jet . “R” or #2 cylinder is equipped with #118 main jet . Both pilot jets are #48. Fig. 133 9.
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VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly SECTION 5 ENGINE ASSEMBLY Lubricate parts with engine oil and assemble #2 piston and connecting rod, Fig. 138. 1. Offset casting mark on piston must face flywheel side. INSTALL CRANKSHAFT 1. Lubricate mag. bearing and lips of oil seal with engine oil and install crankshaft. 2. Lubricate and install new governor shaft oil seal in cylinder. Then lubricate and install governor shaft , Fig. 136. 2.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly INSTALL PISTON AND CONNECTING ROD NOTE: Install #1 piston and connecting rod first. 1. Oil piston rings, piston skirt, and compress rings with ring compressor Tool #19070. a. Place piston and ring compressor upside down on bench with projections on compressor facing up, Fig. 140. b. Tighten ring compressor evenly until rings are fully compressed. c.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly INSTALL CAMSHAFT 3. Check crankshaft end play. End Play: .004” - .011” (0.09 - 0.26 mm) Lubricate tappets, camshaft journals and lobes with engine oil. Assemble timing gear to crankshaft. 1. Install tappets. 2. Align timing marks on camshaft and crankshaft timing gear and install camshaft, Fig. 143. 3. Install new O-rings in cylinder. Fig. 143 INSTALL GOVERNOR GEAR 1.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly 5. Install water pump cover with new gasket. Torque in sequence shown to 90 in. lbs. (10.0 Nm), Fig. 147. INSTALL STARTER Install starter and solenoid assembly, Fig. 149. Torque screws to 140 in. lbs. (16.0 Nm). Fig. 147 6. Install breather with new gasket, Fig. 148. Torque screws to 35 in. lbs. (4.0 Nm). Fig. 149 INSTALL ALTERNATOR 1. Install alternator. Route wires behind mounting boss as shown, Fig. 150.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly INSTALL FLYWHEEL 4. Insert push rods into recess in tappets. 1. Clean flywheel and crankshaft taper. Remove all oil, dirt or grease. 2. Assemble flywheel to crankshaft and align keyways. 3. Insert flywheel key into keyways. 4. Place flywheel strap wrench, Tool #19433 around outer rim of flywheel, Fig. 151. Torque flywheel nut to 150 ft. lbs. (203 Nm). 5. Install fan pulley. Torque to 140 in. lbs. (16.0 Nm). Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly ADJUST VALVE CLEARANCE 1. Set No. 1 cylinder at 1/4” (6 mm) past TDC, compression stroke. a. Adjust valves and check. Valve Clearance (Cold) IN and EX .008” (0.2 mm) b. Torque lock nut and adjusting screw to 70 in. lbs. (8.0 Nm), Fig. 154. 2. Repeat for No. 2 cylinder. 3. Install valve covers with new gaskets. Torque screws to 70 in. lbs. (8.0 Nm). Fig. 155 1. Rotate flywheel until magnet is under armature laminations. .
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly INSTALL FAN ASSEMBLY b. Torque pivot screw to 125 in. lbs. (14.0 Nm). 1. Install fan brackets, Fig. 157. Torque screws to 150 in. lbs. (17.0 Nm). NOTE: Take care not to pinch wires between fan brackets and cylinder. 2. Assemble fan belt to upper fan pulley. Fig. 158 6. Install fan, Fig. 159. Torque screws to 70 in. lbs. (8.0 Nm). Fig. 157 3.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly 8. Connect regulator-rectifier to alternator. 2. Assemble governor link to governor bracket and install governor control bracket, Fig. 162. Torque screws to 70 in. lbs. (8.0 Nm). Fig. 160 INSTALL INTAKE MANIFOLD 1. Install intake manifold with new gaskets, Fig. 161. Torque screws to 90 in. lbs. (10.0 Nm). Fig. 162 INSTALL CARBURETOR AND INTAKE ELBOW ASSEMBLY Assemble choke link to choke control lever, Fig. 163. Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly 1. Assemble air cleaner elbow and carburetor to intake elbow with new gaskets, Fig. 164. Torque screws to 90 in. lbs. (10.0 Nm). Fig. 164 2. Assemble choke link to choke lever and install carburetor and intake elbow assembly, Fig. 165. Torque screws to 90 in. lbs. (10.0 Nm). 5. Assemble governor link to governor control bracket and install governor control bracket, Fig. 166. Torque screws to 70 in. lbs. (8.0 Nm). Fig. 166 6.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly Do Not tighten governor lever nut at this time. Static Governor Adjustment 1. With governor lever nut loose, rotate governor control swivel clockwise as far as it will go (wide open throttle) and hold in this position, Fig. 170. 2. Rotate governor shaft counter-clockwise as far it will go. Torque governor nut to 70 in. lbs. (8.0 Nm). Fig. 168 9. Assemble throttle link and spring to throttle lever on carburetor, Fig. 169. Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly INSTALL RADIATOR 3. Install fuel line from pump to carburetor , and fuel pump pulse line at valve cover , Fig. 174. 1. Install fan shroud assembly, Fig. 172. Torque screws to 140 in. lbs. (16. 0 Nm). Maintain a 1/8” (3 mm) gap between the shroud and the radiator to prevent wear from vibration. Fig. 174 Fig. 172 4. Install thermostat and thermostat housing with new gasket, Fig. 175. Torque screws to 70 in. lbs. (8.0 Nm). 2.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly • The inside band of the mounting bracket has locating tabs that fit into notches in the air cleaner housing. screw, Fig. 178. Torque front screw to 90 in. lbs. (10 Nm). This allows the air cleaner housing to be rotated in a number of positions in case of clearance concerns in certain equipment applications. Fig. 178 Fig. 176 1.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly 8. Install air cleaner cover with arrows facing up, Fig. 180. Fig. 180 Refer to Section 6 for final adjustment procedures.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 5 - Engine Assembly Page 70
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications SECTION 6 FINAL ADJUSTMENTS AND SPECIFICATIONS GENERAL INFORMATION Governed Idle VanguardE liquid cooled OHV Twin cylinder engines are equipped with a governed idle system, Fig. 182. A throttle restrictor permits the engine to maintain engine speed when a load is applied with the equipment control in the SLOW position.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications 4. Tighten casing clamp screw. CARBURETOR ADJUSTMENT The VanguardE liquid cooled OHV Twin cylinder carburetor fuel mixture adjustment procedure is unique. Perform adjustments exactly in the sequence shown. Initial Adjustment 1. Turn idle mixture screw for #1 cylinder clockwise until it just seats. DO NOT FORCE. 2. Then turn screw counter-clockwise 3/4 turn, Fig 186. 3. Repeat for #2 cylinder.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications The following tools are required when making carburetor adjustments. 1. An accurate tachometer, such as Tool #19389 2. Tang bender, Tool #19480 7. Release throttle lever. Note RPM. . . Fig. 188 Fig. 187 Start engine and run it for approximately 5 minutes to allow engine to reach operating temperature. 8. If necessary, use tang bending Tool, #19480, and bend governed idle tang to obtain 1850 RPM, Fig. 189.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications b. Repeat for other idle mixture valve. 13. Bend tang with Tool #19480 to obtain 3600 RPM, Fig. 192. Fig. 190 10. With equipment control lever in “SLOW” position and engine running at governed idle RPM, use tang bender, Tool #19480, and bend throttle restrictor tang so that tang just contacts governor lever, Fig. 191. Fig.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications MODEL 473100 SPECIFICATIONS Common Specifications ARMATURE AIR GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..005” - .007” (0.13 - 0.18 MM) BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.190” (81.02 MM) CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..004” - .011” (0.
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications Standard And Reject Dimensions DESCRIPTION STANDARD DIMENSION REJECT DIMENSION CYLINDER CYLINDER BORE . . . . . . . . . . . . . . . . OUT OF ROUND . . . . . . . . . . . . . . . . MAIN BEARING (MAGNETO) . . . . . . . . CAM BEARING (MAGNETO) . . . . . . . . 3.190” (81.02 MM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................... 1.775” (45.09 MM) . . . . . . . .
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications ENGINE HARNESS Page 77
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications Page 78
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications Page 79
VanguardTM Twin-Cylinder OHV Liquid-Cooled Engine Section 6 - Final Adjustments & Specifications Page 80
