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

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

Contents

Quality Starts With A Master Service Technician Briggs & ledooStrattonSingle Cylinder OHV Air-CooledEngines Repair Manuals for other All rights reserved FORWARDCopyright 2009 Briggs & Stratton Corporation Engine Models This Engine Repair Manual includes the following SECTION 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 repairs Explosion 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 Altitude Every 8 Hours or Daily Maintenance Chart First 5 HoursEvery 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 InstallRemove Inspection Spark Plug Oil and Oil FilterNOTICE NOTICE Cooling 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 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 CHECKEngine Stopped Engine Running Solenoid Wiring Test Testing Fuel Shut Off Solenoid2 Check Carburetion Solenoid Plunger Test Possible Causes for Poor Compression 3 Check Compression Equipment Used for Testing ELECTRICAL SYSTEMSDigital Multimeter DC Shunt Possible 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 Figure 8.20 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 Alternator Test Diode 14-VoltAC Alternator Test Alternator Output Dual Circuit AlternatorTest Alternator Output-AC Test Alternator Output-DC Test Diode Tri-CircuitAlternator Lighting Circuit Test WHITE Wire Charging Circuit Test RED WireTest Alternator Output Test Diode Test Regulator-Rectifier 5 & 9 Amp DC Regulated AlternatorTest Alternator Output Test Alternator Output 10 & 16 Amp DC Regulated Alternatorreceptacle Test Regulator - Rectifier 2.Install shunt to negative -battery terminal 20 Amp DC Regulated Alternator DC Output Charging Wire TestNOTICE Test Alternator Output 5.Rotate selector to DC volts position Figure Model Series 97700, 99700, 110000, ELECTRIC STARTERSSYSTEM 3, SYSTEM Test Starter Motor Test Interlock Switch Test 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 Battery Testing Battery OIL GARD SYSTEMS EQUIPMENT AFFECTING ENGINE OPERATIONHard 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 SERVICEHorizontal Models 110000, 120000, Remove Guard and Muffler Inspect 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, Figure Install 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 parts Install Muffler and Guard Never reinstall broken or damaged componentsVertical Models 97700, 99700, 110000, Inspect Exhaust System Install Muffler and Guard Never reinstall broken or damagedInspect Exhaust System components Inspect 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 Muffler SECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS Fuel Pump InstallationRemoval Inspection Fuel Tanks and Shut-offValves Fuel FilterHorizontal Models 110000, 120000, 150000, 200000, Removal Installation InstallationVertical Models 97700, 99700, 110000, Vertical Model 2.Inspect fuel tank for •Corrosion •Leaks InstallationInspection Carburetor Identification CARBURETION Remove Carburetor Carburetor Service LMS CarburetorVertical Models 97700, 99700, 110000, 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 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 Carburetor Disassemble Carburetor Nikki Carburetor Vertical Models 280000, 310000,Remove 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 ServiceHorizontal Models 110000, 120000, 150000, 200000, Disassemble Assemble Inspect Governor Assemble Governor DisassembleInspect 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 HeadDisassemble 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 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 Parts Vertical Models 110000, 2.Install the oil fill tube and dipstick CVertical Models 97700, Vertical Model Service Starter ClutchDisassemble Starter Clutch Inspect Clutch Parts Replace Ring Gear ELECTRIC STARTERSSystem 3, System Check Starter Drive and Clutch 12 Volt Starters Install Starter Drive and ClutchRemove 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 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 Breather 8Current Production Install BreatherRemove Breather Check Breather Install Breather LUBRICATION SYSTEMSOil Dipper Lubrication Oil Slinger Lubrication Oil 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 Systems Lead Wire Colors Lead Wire ColorsTroubleshooting Identification SECTION 9 - CYLINDERS, COVERS AND SUMPS Inspect Cylinder CYLINDERReconditioning Bore Resizing Bore Cleaning Cylinder MAIN BEARINGSCheck Bearings Check Plain Bearings Replace DU Bearings Replace BearingsMagneto Bearing Tools PTO Bearing Tools Replace Ball Bearing Horizontal Models 120000, Replace Ball Bearing Horizontal Models 200000, Bearing Installation ToolsBearing Removal Tools Tool/Part Replace Ball Bearing All Vertical Models Installation COVERS AND SUMPS Figure Figure FigurePage SYSTEMS, AND GEAR REDUCTIONS SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING Remove Crankshaft and Camshaft CRANKSHAFTS AND CAMSHAFTSInspect Check Crankshaft Install Crankshaft and Camshaft Install Crankcase Cover or Sump Check and Adjust Crankshaft End Play Disassemble Gear Reduction GEAR REDUCTIONAssemble Gear Reduction Inspect Gear Reduction Parts Fill Gear Case with Lubricant Inspection AUXILIARY PTORemove Auxiliary PTO Drive Shaft Assemble Auxiliary PTO Drive Shaft Synchro-BalanceSystem COUNTERBALANCE SYSTEMSDisassemble Remove Counterbalance System Assemble Install AVS Balance System InstallRemove DisassemblePage SECTION 11 - PISTONS, RINGS AND CONNECTING RODS Remove Piston and Connecting Rod PISTONS, RINGS, & CONNECTING RODSDisassemble Inspect Check Ring End Gap Check Connecting RodAssemble Install Piston and Connecting Rod SECTION 12 - ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS MODEL 110000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 120000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing ENGINE SPECIFICATIONS MODEL 150000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 200000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing ENGINE SPECIFICATIONS MODEL 210000 HORIZONTAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing ENGINE SPECIFICATIONS MODELS 97700 & 99700 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 110000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 120000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 210000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE REJECT DIMENSIONS ENGINE SPECIFICATIONS MODEL 280000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing ENGINE SPECIFICATIONS MODEL 310000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing ENGINE SPECIFICATIONS MODEL 330000 VERTICAL SERIESFASTENER TORQUE SPECIFICATIONS TORQUE Main Bearing