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