Briggs & Stratton 273521, 271172, 270962, CE8069, 276535 manual

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Contents Quality Starts With A Master Service Technician Briggs & ledooStrattonSingle Cylinder OHV Air-CooledEngines Repair Manuals for otherAll rights reserved FORWARDCopyright 2009 Briggs & Stratton Corporation Engine Models This Engine Repair Manual includes the followingSECTION 2 - Troubleshooting 1 2 3 4 5 6 7 8 9 10 11 12SECTION 1 - Safety, Maintenance and Adjustments Page SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS Hazard Symbols and Meanings ENGINE SAFETYSignal Words in Safety Messages When testing for spark Before performing adjustments or repairsExplosion and fire could result YOUR KEY TO THE WORLD’S FINEST ENGINES BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEMBRIGGS & STRATTON MODEL NUMBERING SYSTEM Fuel and Oil Recommendations ENGINE MAINTENANCEFuel must meet these requirements High AltitudeEvery 8 Hours or Daily Maintenance Chart First 5 HoursEvery 25 Hours or Annually Every 50 Hours or AnnuallyAssemble Flywheel Brake Inspect Brake and SwitchesAir Filter Combustion ChamberFigure Figure Figure Figure Figure FigureSnow Hood InstallRemove InspectionSpark Plug Oil and Oil FilterNOTICE NOTICECooling System Remote Controls ENGINE ADJUSTMENTSRemote Control Wire Travel Horizontal Models 110000, 120000,2.Move throttle lever to fast position Top No Load Adjustment Vertical Models 97700, Governor AdjustmentsStatic Adjustment 2.Place throttle in FAST position Final Adjustment All Models Initial Adjustment All ModelsAdjust Valve Clearance Vertical Models 110000, 120000 Early Production SECTION 2 - TROUBLESHOOTING OIL GARD SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE WILL NOT START - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE STARTS AND RUNS WITH LOW OIL 1 Check Ignition SYSTEMS CHECKEngine Stopped Engine RunningSolenoid Wiring Test Testing Fuel Shut Off Solenoid2 Check Carburetion Solenoid Plunger TestPossible Causes for Poor Compression 3 Check CompressionEquipment Used for Testing ELECTRICAL SYSTEMSDigital Multimeter DC ShuntPossible Causes Alternator System DiagnosisComplaint Alternator Identification 2.14 Volt AC Only Figure 1.0.5 Amp DC Only Figure3.3 Amp DC Only Figure 4.Dual Circuit Figure8.20 Amp DC Figure 6.5/9 Amp DC Figure7.10/16 Amp DC Figure Flywheel Identification Testing Alternator Output5 Amp DC Only Alternator 3-AmpDC Only AlternatorTest Diode 14-VoltAC AlternatorTest Alternator Output Dual Circuit AlternatorTest Alternator Output-AC Test Alternator Output-DCTest Diode Tri-CircuitAlternatorLighting Circuit Test WHITE Wire Charging Circuit Test RED WireTest Alternator Output Test DiodeTest Regulator-Rectifier 5 & 9 Amp DC Regulated AlternatorTest Alternator Output Test Alternator Output 10 & 16 Amp DC Regulated Alternatorreceptacle Test Regulator - Rectifier2.Install shunt to negative -battery terminal 20 Amp DC Regulated Alternator DC Output Charging Wire TestNOTICE Test Alternator Output5.Rotate selector to DC volts position FigureModel Series 97700, 99700, 110000, ELECTRIC STARTERSSYSTEM 3, SYSTEM Test Starter Motor Test Interlock SwitchTest Starter Motor Test Interlock Switch Wiring12 Volt DC Starter Motor Test Solenoid 120-VoltAC Starter MotorModel Series 120000, 150000, 200000, Battery and Cable Recommendations BATTERIESBattery Installation Charging BatteryTesting Battery OIL GARD SYSTEMS EQUIPMENT AFFECTING ENGINE OPERATIONHard Starting or Will Not Start Engine Won’t StopEngine Starts and Runs With Low Oil On/Off Switch Light Does Not FlashSECTION 3 - EXHAUST SYSTEMS Spark Arresters MUFFLER SERVICEHorizontal Models 110000, 120000, Remove Guard and MufflerInspect Exhaust System Never reinstall broken or damaged componentsInstall Muffler and Guard Shown is a typical muffler application Figure Horizontal Models 200000,Remove Guard and Muffler 3.Remove muffler support screws A, FigureInstall Muffler and Guard Never reinstall broken or damaged componentsInspect Exhaust System All exhaust system components must be inspected whenever the exhaust system is disassembled. Check muffler mounting bracket and/or muffler adapters for cracked welds or breakage. Check muffler for split seams, loose internal parts, or cracked welds. Replace any damaged parts with new OEM partsInstall Muffler and Guard Never reinstall broken or damaged componentsVertical Models 97700, 99700, 110000, Inspect Exhaust SystemInstall Muffler and Guard Never reinstall broken or damagedInspect Exhaust System componentsInspect Exhaust System Never reinstall broken or damaged componentsRemove Muffler Install Muffler Install Muffler Never reinstall broken or damaged componentsShown is a typical muffler application Figure Remove MufflerSECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS Fuel Pump InstallationRemoval InspectionFuel Tanks and Shut-offValves Fuel FilterHorizontal Models 110000, 120000, 150000, 200000, RemovalInstallation InstallationVertical Models 97700, 99700, 110000, Vertical Model2.Inspect fuel tank for •Corrosion •Leaks InstallationInspection Carburetor Identification CARBURETIONRemove Carburetor Carburetor Service LMS CarburetorVertical Models 97700, 99700, 110000, Disassemble Carburetor Assemble Carburetor Inspect and Clean Carburetor ComponentsInstall Carburetor Remove Carburetor LMS Carburetor Horizontal Models 110000, 120000,Disassemble Carburetor Inspect and Clean Carburetor Components•Passages in the fixed main jet bowl nut Assemble Carburetoredge of the plug with a non-hardeningsealant Remove Carburetor Install CarburetorReadyStart Carburetor Vertical Model Assemble Carburetor Inspect and Clean CarburetorDisassemble Carburetor LMT Carburetor Disassemble Carburetor Remove Carburetor3.Move clamp and disconnect hose from carburetor Assemble Carburetor Inspect and Clean CarburetorPage bracket.4 Install CarburetorDisassemble Carburetor Nikki Carburetor Vertical Models 280000, 310000,Remove Carburetor 11.Remove the main jet and seal Inspect and Clean CarburetorAssemble Carburetor •Choke shaft and choke valveInstall Carburetor 12.Install new o-ringon fuel transfer tube EVertical Model 310000 Gaseous Fuel Nikki LP/NG MixerSECTION 5 - GOVERNOR SYSTEMS Linkage and Spring Orientation GOVERNOR SYSTEMSGoverned RPM Limits Governor ServiceHorizontal Models 110000, 120000, 150000, 200000, DisassembleAssemble Inspect GovernorAssemble Governor DisassembleInspect Governor 8. Adjust governor system per Section SECTION 6 - CYLINDER HEAD AND VALVES Remove Cylinder Head CYLINDER HEADS AND VALVESInspection Disassemble Cylinder HeadAssemble Cylinder Head Install Cylinder Head NOTE: Do not torque each screw in one step as it may result in a warped cylinder head. Step- torque all screws to approximately 1/3 of final torque value, then to 2/3 final torque value, then finish at final torque value Models 200000, 210000, 280000, 310000, Remove Cylinder HeadDisassemble Cylinder Head InspectionAssemble Cylinder Head mm or more, replace the entire head. If plug gauge is not available, see Section 12 - Engine Specifications for the valve guide reject dimensionInstall Cylinder Head 4.Install push rods through guides and into same positions as removed. Ensure rods are seated in valve tappets. Place valve stem caps if used on valve stems Figure Page SECTION 7 - STARTERS Remove Blower Housing / Rewind Starter REWIND STARTERSHorizontal Models 110000, 120000, 150000, 200000, Vertical Models 97700,Vertical Models 110000, Disassemble Rewind Starter Service Rewind StarterVertical Model Assemble Rewind Starter Inspect Rewind Starter PartsVertical Models 110000, 2.Install the oil fill tube and dipstick CVertical Models 97700, Vertical Model Service Starter ClutchDisassemble Starter Clutch Inspect Clutch PartsReplace Ring Gear ELECTRIC STARTERSSystem 3, System Check Starter Drive and Clutch12 Volt Starters Install Starter Drive and ClutchRemove Starter Drive and Clutch Check Starter Drive and ClutchAssemble Starter Motor Drive - C-Ring Retainer Disassemble Starter Drive - Roll Pin Retainer Assemble Starter Drive - Roll Pin Retainer 120-VoltStartersSECTION 8 - LUBRICATION SYSTEMS BREATHERS EXTENDED OIL FILL AND DIPSTICKInstall Breather Horizontal Models 110000, 120000,Install Breather 3.Inspect oil drain-backholes C, Figure 3 to make sure they are open. Clean as neededCheck Breather Remove Breather8Current Production Install BreatherRemove Breather Check BreatherInstall Breather LUBRICATION SYSTEMSOil Dipper Lubrication Oil Slinger LubricationOil Slinger with Pressure Filtration Oil Pump ServicePressure Lubrication Vertical Models 120000, 210000, 280000, 310000,Remove Pump Screen Oil Filter and Adapters Remove Install Screen and Gerotor PumpInspect Oil Pump Parts Install Oil Pressure SwitchTest Oil Pressure Switch Oil Gard SystemsLead Wire Colors Lead Wire ColorsTroubleshooting IdentificationSECTION 9 - CYLINDERS, COVERS AND SUMPS Inspect Cylinder CYLINDERReconditioning Bore Resizing BoreCleaning Cylinder MAIN BEARINGSCheck Bearings Check Plain BearingsReplace DU Bearings Replace BearingsMagneto Bearing Tools PTO Bearing ToolsReplace Ball Bearing Horizontal Models 120000, Replace Ball Bearing Horizontal Models 200000, Bearing Installation ToolsBearing Removal Tools Tool/PartReplace Ball Bearing All Vertical Models Installation COVERS AND SUMPSFigure Figure FigurePage SYSTEMS, AND GEAR REDUCTIONS SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCINGRemove Crankshaft and Camshaft CRANKSHAFTS AND CAMSHAFTSInspect Check CrankshaftInstall Crankshaft and Camshaft Install Crankcase Cover or Sump Check and Adjust Crankshaft End Play Disassemble Gear Reduction GEAR REDUCTIONAssemble Gear Reduction Inspect Gear Reduction PartsFill Gear Case with Lubricant Inspection AUXILIARY PTORemove Auxiliary PTO Drive Shaft Assemble Auxiliary PTO Drive ShaftSynchro-BalanceSystem COUNTERBALANCE SYSTEMSDisassemble Remove Counterbalance SystemAssemble InstallAVS Balance System InstallRemove DisassemblePage SECTION 11 - PISTONS, RINGS AND CONNECTING RODS Remove Piston and Connecting Rod PISTONS, RINGS, & CONNECTING RODSDisassemble InspectCheck Ring End Gap Check Connecting RodAssemble Install Piston and Connecting Rod SECTION 12 - ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS MODEL 110000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 120000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing ENGINE SPECIFICATIONS MODEL 150000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 200000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing ENGINE SPECIFICATIONS MODEL 210000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing ENGINE SPECIFICATIONS MODELS 97700 & 99700 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 110000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 120000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 210000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 280000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing ENGINE SPECIFICATIONS MODEL 310000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing ENGINE SPECIFICATIONS MODEL 330000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing

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