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

Models: 273521 276535 CE8069 270962 271172

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

Contents

Quality Starts With A Master Service Technician Briggs & ledooStrattonSingle Cylinder OHV Air-CooledEngines Repair Manuals for otherFORWARD Copyright 2009 Briggs & Stratton CorporationAll rights reserved Engine Models This Engine Repair Manual includes the following1 2 3 4 5 6 7 8 9 10 11 12 SECTION 1 - Safety, Maintenance and AdjustmentsSECTION 2 - Troubleshooting Page SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS ENGINE SAFETY Signal Words in Safety MessagesHazard Symbols and Meanings When testing for spark Before performing adjustments or repairsExplosion and fire could result BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM BRIGGS & STRATTON MODEL NUMBERING SYSTEMYOUR KEY TO THE WORLD’S FINEST ENGINES 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 Governor Adjustments Static AdjustmentTop No Load Adjustment Vertical Models 97700, 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 ShuntAlternator System Diagnosis ComplaintPossible Causes Alternator Identification 2.14 Volt AC Only Figure 1.0.5 Amp DC Only Figure3.3 Amp DC Only Figure 4.Dual Circuit Figure6.5/9 Amp DC Figure 7.10/16 Amp DC Figure8.20 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 Diode5 & 9 Amp DC Regulated Alternator Test Alternator OutputTest Regulator-Rectifier 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 FigureELECTRIC STARTERS SYSTEM 3, SYSTEMModel Series 97700, 99700, 110000, Test Starter Motor Test Interlock SwitchTest Interlock Switch Wiring 12 Volt DC Starter MotorTest Starter Motor 120-VoltAC Starter Motor Model Series 120000, 150000, 200000,Test Solenoid 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 MufflerNever reinstall broken or damaged components Install Muffler and GuardInspect Exhaust System 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 componentsNever reinstall broken or damaged components Remove MufflerInspect Exhaust System 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 ModelInstallation Inspection2.Inspect fuel tank for •Corrosion •Leaks Carburetor Identification CARBURETIONCarburetor Service LMS Carburetor Vertical Models 97700, 99700, 110000,Remove Carburetor 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 Install Carburetor ReadyStart Carburetor Vertical ModelRemove Carburetor Inspect and Clean Carburetor Disassemble CarburetorAssemble Carburetor LMT Carburetor Remove Carburetor 3.Move clamp and disconnect hose from carburetorDisassemble Carburetor Assemble Carburetor Inspect and Clean CarburetorPage bracket.4 Install CarburetorNikki Carburetor Vertical Models 280000, 310000, Remove CarburetorDisassemble 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 GovernorDisassemble Inspect GovernorAssemble 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 Inspectionmm 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 HeadAssemble 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, Service Rewind Starter Vertical ModelDisassemble Rewind Starter Assemble Rewind Starter Inspect Rewind Starter Parts2.Install the oil fill tube and dipstick C Vertical Models 97700,Vertical Models 110000, 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 Install Screen and Gerotor Pump Inspect Oil Pump PartsOil Filter and Adapters Remove 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 Connecting Rod AssembleCheck Ring End Gap 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