Contents
Quality Starts With A Master Service Technician
Briggs & ledooStratton
Single Cylinder OHV Air-CooledEngines
Repair Manuals for other
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Copyright 2009 Briggs & Stratton Corporation
All rights reserved
Engine Models
This Engine Repair Manual includes the following
1 2 3 4 5 6 7 8 9 10 11 12
SECTION 1 - Safety, Maintenance and Adjustments
SECTION 2 - Troubleshooting
Page
SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS
ENGINE SAFETY
Signal Words in Safety Messages
Hazard Symbols and Meanings
When testing for spark
Before performing adjustments or repairs
Explosion and fire could result
BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM
BRIGGS & STRATTON MODEL NUMBERING SYSTEM
YOUR KEY TO THE WORLD’S FINEST ENGINES
Fuel and Oil Recommendations
ENGINE MAINTENANCE
Fuel must meet these requirements
High Altitude
Every 8 Hours or Daily
Maintenance Chart First 5 Hours
Every 25 Hours or Annually
Every 50 Hours or Annually
Assemble Flywheel Brake
Inspect Brake and Switches
Air Filter
Combustion Chamber
Figure Figure Figure
Figure Figure Figure
Snow Hood
Install
Remove
Inspection
Spark Plug
Oil and Oil Filter
NOTICE
NOTICE
Cooling System
Remote Controls
ENGINE ADJUSTMENTS
Remote Control Wire Travel
Horizontal Models 110000, 120000,
2.Move throttle lever to fast position
Governor Adjustments
Static Adjustment
Top No Load Adjustment Vertical Models 97700,
2.Place throttle in FAST position
Final Adjustment All Models
Initial Adjustment All Models
Adjust 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 CHECK
Engine Stopped
Engine Running
Solenoid Wiring Test
Testing Fuel Shut Off Solenoid
2 Check Carburetion
Solenoid Plunger Test
Possible Causes for Poor Compression
3 Check Compression
Equipment Used for Testing
ELECTRICAL SYSTEMS
Digital Multimeter
DC Shunt
Alternator System Diagnosis
Complaint
Possible Causes
Alternator Identification
2.14 Volt AC Only Figure
1.0.5 Amp DC Only Figure
3.3 Amp DC Only Figure
4.Dual Circuit Figure
6.5/9 Amp DC Figure
7.10/16 Amp DC Figure
8.20 Amp DC Figure
Flywheel Identification
Testing Alternator Output
5 Amp DC Only Alternator
3-AmpDC Only Alternator
Test Diode
14-VoltAC Alternator
Test Alternator Output
Dual Circuit Alternator
Test Alternator Output-AC
Test Alternator Output-DC
Test Diode
Tri-CircuitAlternator
Lighting Circuit Test WHITE Wire
Charging Circuit Test RED Wire
Test Alternator Output
Test Diode
5 & 9 Amp DC Regulated Alternator
Test Alternator Output
Test Regulator-Rectifier
Test Alternator Output
10 & 16 Amp DC Regulated Alternator
receptacle
Test Regulator - Rectifier
2.Install shunt to negative -battery terminal
20 Amp DC Regulated Alternator
DC Output Charging Wire Test
NOTICE
Test Alternator Output
5.Rotate selector to DC volts position
Figure
ELECTRIC STARTERS
SYSTEM 3, SYSTEM
Model Series 97700, 99700, 110000,
Test Starter Motor
Test Interlock Switch
Test Interlock Switch Wiring
12 Volt DC Starter Motor
Test Starter Motor
120-VoltAC Starter Motor
Model Series 120000, 150000, 200000,
Test Solenoid
Battery and Cable Recommendations
BATTERIES
Battery Installation
Charging Battery
Testing Battery
OIL GARD SYSTEMS
EQUIPMENT AFFECTING ENGINE OPERATION
Hard Starting or Will Not Start
Engine Won’t Stop
Engine Starts and Runs With Low Oil
On/Off Switch Light Does Not Flash
SECTION 3 - EXHAUST SYSTEMS
Spark Arresters
MUFFLER SERVICE
Horizontal Models 110000, 120000,
Remove Guard and Muffler
Never reinstall broken or damaged components
Install Muffler and Guard
Inspect Exhaust System
Shown is a typical muffler application Figure
Horizontal Models 200000,
Remove Guard and Muffler
3.Remove muffler support screws A, Figure
Install Muffler and Guard
Never reinstall broken or damaged components
Inspect 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 parts
Install Muffler and Guard
Never reinstall broken or damaged components
Vertical Models 97700, 99700, 110000,
Inspect Exhaust System
Install Muffler and Guard
Never reinstall broken or damaged
Inspect Exhaust System
components
Never reinstall broken or damaged components
Remove Muffler
Inspect Exhaust System
Install Muffler
Install Muffler
Never reinstall broken or damaged components
Shown is a typical muffler application Figure
Remove Muffler
SECTION 4 - FUEL SYSTEMS AND CARBURETION
FUEL SYSTEMS
Fuel Pump
Installation
Removal
Inspection
Fuel Tanks and Shut-offValves
Fuel Filter
Horizontal Models 110000, 120000, 150000, 200000,
Removal
Installation
Installation
Vertical Models 97700, 99700, 110000,
Vertical Model
Installation
Inspection
2.Inspect fuel tank for •Corrosion •Leaks
Carburetor Identification
CARBURETION
Carburetor Service LMS Carburetor
Vertical Models 97700, 99700, 110000,
Remove Carburetor
Disassemble Carburetor
Assemble Carburetor
Inspect and Clean Carburetor Components
Install 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 Carburetor
edge of the plug with a non-hardeningsealant
Install Carburetor
ReadyStart Carburetor Vertical Model
Remove Carburetor
Inspect and Clean Carburetor
Disassemble Carburetor
Assemble Carburetor
LMT Carburetor
Remove Carburetor
3.Move clamp and disconnect hose from carburetor
Disassemble Carburetor
Assemble Carburetor
Inspect and Clean Carburetor
Page
bracket.4
Install Carburetor
Nikki Carburetor Vertical Models 280000, 310000,
Remove Carburetor
Disassemble Carburetor
11.Remove the main jet and seal
Inspect and Clean Carburetor
Assemble Carburetor
•Choke shaft and choke valve
Install Carburetor
12.Install new o-ringon fuel transfer tube E
Vertical Model 310000 Gaseous Fuel
Nikki LP/NG Mixer
SECTION 5 - GOVERNOR SYSTEMS
Linkage and Spring Orientation
GOVERNOR SYSTEMS
Governed RPM Limits
Governor Service
Horizontal Models 110000, 120000, 150000, 200000,
Disassemble
Assemble
Inspect Governor
Disassemble
Inspect Governor
Assemble Governor
8. Adjust governor system per Section
SECTION 6 - CYLINDER HEAD AND VALVES
Remove Cylinder Head
CYLINDER HEADS AND VALVES
Inspection
Disassemble Cylinder Head
Assemble 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 Head
Disassemble Cylinder Head
Inspection
mm or more, replace the entire head. If plug gauge is not available, see Section 12 - Engine Specifications for the valve guide reject dimension
Install Cylinder Head
Assemble 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 STARTERS
Horizontal Models 110000, 120000, 150000, 200000,
Vertical Models 97700,
Vertical Models 110000,
Service Rewind Starter
Vertical Model
Disassemble Rewind Starter
Assemble Rewind Starter
Inspect Rewind Starter Parts
2.Install the oil fill tube and dipstick C
Vertical Models 97700,
Vertical Models 110000,
Vertical Model
Service Starter Clutch
Disassemble Starter Clutch
Inspect Clutch Parts
Replace Ring Gear
ELECTRIC STARTERS
System 3, System
Check Starter Drive and Clutch
12 Volt Starters
Install Starter Drive and Clutch
Remove Starter Drive and Clutch
Check Starter Drive and Clutch
Assemble Starter Motor Drive - C-Ring Retainer
Disassemble Starter Drive - Roll Pin Retainer
Assemble Starter Drive - Roll Pin Retainer
120-VoltStarters
SECTION 8 - LUBRICATION SYSTEMS
BREATHERS
EXTENDED OIL FILL AND DIPSTICK
Install Breather
Horizontal Models 110000, 120000,
Install Breather
3.Inspect oil drain-backholes C, Figure 3 to make sure they are open. Clean as needed
Check Breather
Remove Breather
8Current Production
Install Breather
Remove Breather
Check Breather
Install Breather
LUBRICATION SYSTEMS
Oil Dipper Lubrication
Oil Slinger Lubrication
Oil Slinger with Pressure Filtration
Oil Pump Service
Pressure Lubrication
Vertical Models 120000, 210000, 280000, 310000,
Remove Pump Screen
Install Screen and Gerotor Pump
Inspect Oil Pump Parts
Oil Filter and Adapters Remove
Install
Oil Pressure Switch
Test Oil Pressure Switch
Oil Gard Systems
Lead Wire Colors
Lead Wire Colors
Troubleshooting
Identification
SECTION 9 - CYLINDERS, COVERS AND SUMPS
Inspect Cylinder
CYLINDER
Reconditioning Bore
Resizing Bore
Cleaning Cylinder
MAIN BEARINGS
Check Bearings
Check Plain Bearings
Replace DU Bearings
Replace Bearings
Magneto Bearing Tools
PTO Bearing Tools
Replace Ball Bearing Horizontal Models 120000,
Replace Ball Bearing Horizontal Models 200000,
Bearing Installation Tools
Bearing Removal Tools
Tool/Part
Replace Ball Bearing All Vertical Models
Installation
COVERS AND SUMPS
Figure
Figure Figure
Page
SYSTEMS, AND GEAR REDUCTIONS
SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING
Remove Crankshaft and Camshaft
CRANKSHAFTS AND CAMSHAFTS
Inspect
Check Crankshaft
Install Crankshaft and Camshaft
Install Crankcase Cover or Sump
Check and Adjust Crankshaft End Play
Disassemble Gear Reduction
GEAR REDUCTION
Assemble Gear Reduction
Inspect Gear Reduction Parts
Fill Gear Case with Lubricant
Inspection
AUXILIARY PTO
Remove Auxiliary PTO Drive Shaft
Assemble Auxiliary PTO Drive Shaft
Synchro-BalanceSystem
COUNTERBALANCE SYSTEMS
Disassemble
Remove Counterbalance System
Assemble
Install
AVS Balance System
Install
Remove
Disassemble
Page
SECTION 11 - PISTONS, RINGS AND CONNECTING RODS
Remove Piston and Connecting Rod
PISTONS, RINGS, & CONNECTING RODS
Disassemble
Inspect
Check Connecting Rod
Assemble
Check Ring End Gap
Install Piston and Connecting Rod
SECTION 12 - ENGINE SPECIFICATIONS
ENGINE SPECIFICATIONS
MODEL 110000 HORIZONTAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
REJECT DIMENSIONS
ENGINE SPECIFICATIONS
MODEL 120000 HORIZONTAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
Main Bearing
ENGINE SPECIFICATIONS
MODEL 150000 HORIZONTAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
REJECT DIMENSIONS
ENGINE SPECIFICATIONS
MODEL 200000 HORIZONTAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
Main Bearing
ENGINE SPECIFICATIONS
MODEL 210000 HORIZONTAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
Main Bearing
ENGINE SPECIFICATIONS
MODELS 97700 & 99700 VERTICAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
REJECT DIMENSIONS
ENGINE SPECIFICATIONS
MODEL 110000 VERTICAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
REJECT DIMENSIONS
ENGINE SPECIFICATIONS
MODEL 120000 VERTICAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
REJECT DIMENSIONS
ENGINE SPECIFICATIONS
MODEL 210000 VERTICAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
REJECT DIMENSIONS
ENGINE SPECIFICATIONS
MODEL 280000 VERTICAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
Main Bearing
ENGINE SPECIFICATIONS
MODEL 310000 VERTICAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
Main Bearing
ENGINE SPECIFICATIONS
MODEL 330000 VERTICAL SERIES
FASTENER TORQUE SPECIFICATIONS
TORQUE
Main Bearing