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

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

Contents

Repair Manuals for other Briggs & ledooStrattonQuality Starts With A Master Service Technician Single Cylinder OHV Air-CooledEngines 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 High Altitude ENGINE MAINTENANCEFuel and Oil Recommendations Fuel must meet these requirements Every 50 Hours or Annually Maintenance Chart First 5 HoursEvery 8 Hours or Daily Every 25 Hours or Annually Assemble Flywheel Brake Inspect Brake and Switches Air Filter Combustion Chamber Figure Figure Figure Figure Figure Figure Inspection InstallSnow Hood Remove NOTICE Oil and Oil FilterSpark Plug NOTICE Cooling System Horizontal Models 110000, 120000, ENGINE ADJUSTMENTSRemote Controls Remote Control Wire Travel 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 Engine Running SYSTEMS CHECK1 Check Ignition Engine Stopped Solenoid Plunger Test Testing Fuel Shut Off SolenoidSolenoid Wiring Test 2 Check Carburetion Possible Causes for Poor Compression 3 Check Compression DC Shunt ELECTRICAL SYSTEMSEquipment Used for Testing Digital Multimeter Possible Causes Alternator System DiagnosisComplaint Alternator Identification 4.Dual Circuit Figure 1.0.5 Amp DC Only Figure2.14 Volt AC Only Figure 3.3 Amp DC Only Figure 8.20 Amp DC Figure 6.5/9 Amp DC Figure7.10/16 Amp DC Figure 3-AmpDC Only Alternator Testing Alternator OutputFlywheel Identification 5 Amp DC Only Alternator Test Diode 14-VoltAC Alternator Test Alternator Output-DC Dual Circuit AlternatorTest Alternator Output Test Alternator Output-AC Test Diode Tri-CircuitAlternator Test Diode Charging Circuit Test RED WireLighting Circuit Test WHITE Wire Test Alternator Output Test Regulator-Rectifier 5 & 9 Amp DC Regulated AlternatorTest Alternator Output Test Regulator - Rectifier 10 & 16 Amp DC Regulated AlternatorTest Alternator Output receptacle 2.Install shunt to negative -battery terminal Test Alternator Output DC Output Charging Wire Test20 Amp DC Regulated Alternator NOTICE 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, Charging Battery BATTERIESBattery and Cable Recommendations Battery Installation Testing Battery Engine Won’t Stop EQUIPMENT AFFECTING ENGINE OPERATIONOIL GARD SYSTEMS Hard Starting or Will Not Start Engine Starts and Runs With Low Oil On/Off Switch Light Does Not Flash SECTION 3 - EXHAUST SYSTEMS Remove Guard and Muffler MUFFLER SERVICESpark Arresters Horizontal Models 110000, 120000, Inspect Exhaust System Never reinstall broken or damaged componentsInstall Muffler and Guard 3.Remove muffler support screws A, Figure Horizontal Models 200000,Shown is a typical muffler application Figure Remove Guard and Muffler 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 componentsInstall Muffler and Guard Inspect Exhaust System Inspect Exhaust System Never reinstall broken or damaged componentsInstall Muffler and Guard Vertical Models 97700, 99700, 110000, components Never reinstall broken or damagedInstall Muffler and Guard Inspect Exhaust System Inspect Exhaust System Never reinstall broken or damaged componentsRemove Muffler Install Muffler Remove Muffler Never reinstall broken or damaged componentsInstall Muffler Shown is a typical muffler application Figure SECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS Inspection InstallationFuel Pump Removal Removal Fuel FilterFuel Tanks and Shut-offValves Horizontal Models 110000, 120000, 150000, 200000, Vertical Model InstallationInstallation Vertical Models 97700, 99700, 110000, 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, Assemble Carburetor Inspect and Clean Carburetor ComponentsDisassemble Carburetor •Passages in the fixed main jet bowl nut 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 Disassemble Governor ServiceGoverned RPM Limits Horizontal Models 110000, 120000, 150000, 200000, 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 Inspection Remove Cylinder HeadModels 200000, 210000, 280000, 310000, Disassemble Cylinder Head 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 Vertical Models 97700, REWIND STARTERSRemove Blower Housing / Rewind Starter Horizontal Models 110000, 120000, 150000, 200000, 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, Inspect Clutch Parts Service Starter ClutchVertical Model Disassemble Starter Clutch Check Starter Drive and Clutch ELECTRIC STARTERSReplace Ring Gear System 3, System Check Starter Drive and Clutch Install Starter Drive and Clutch12 Volt Starters Remove 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 Horizontal Models 110000, 120000, EXTENDED OIL FILL AND DIPSTICKBREATHERS Install Breather Remove Breather 3.Inspect oil drain-backholes C, Figure 3 to make sure they are open. Clean as neededInstall Breather Check Breather Check Breather Install Breather8Current Production Remove Breather Oil Slinger Lubrication LUBRICATION SYSTEMSInstall Breather Oil Dipper Lubrication Vertical Models 120000, 210000, 280000, 310000, Oil Pump ServiceOil Slinger with Pressure Filtration Pressure Lubrication Remove Pump Screen Oil Filter and Adapters Remove Install Screen and Gerotor PumpInspect Oil Pump Parts Oil Gard Systems Oil Pressure SwitchInstall Test Oil Pressure Switch Identification Lead Wire ColorsLead Wire Colors Troubleshooting SECTION 9 - CYLINDERS, COVERS AND SUMPS Resizing Bore CYLINDERInspect Cylinder Reconditioning Bore Check Plain Bearings MAIN BEARINGSCleaning Cylinder Check Bearings PTO Bearing Tools Replace BearingsReplace DU Bearings Magneto Bearing Tools Replace Ball Bearing Horizontal Models 120000, Tool/Part Bearing Installation ToolsReplace Ball Bearing Horizontal Models 200000, Bearing Removal Tools Replace Ball Bearing All Vertical Models Installation COVERS AND SUMPS Figure Figure FigurePage SYSTEMS, AND GEAR REDUCTIONS SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING Check Crankshaft CRANKSHAFTS AND CAMSHAFTSRemove Crankshaft and Camshaft Inspect Install Crankshaft and Camshaft Install Crankcase Cover or Sump Check and Adjust Crankshaft End Play Inspect Gear Reduction Parts GEAR REDUCTIONDisassemble Gear Reduction Assemble Gear Reduction Fill Gear Case with Lubricant Assemble Auxiliary PTO Drive Shaft AUXILIARY PTOInspection Remove Auxiliary PTO Drive Shaft Remove Counterbalance System COUNTERBALANCE SYSTEMSSynchro-BalanceSystem Disassemble Assemble Install Disassemble InstallAVS Balance System RemovePage SECTION 11 - PISTONS, RINGS AND CONNECTING RODS Inspect PISTONS, RINGS, & CONNECTING RODSRemove Piston and Connecting Rod Disassemble Check Ring End Gap Check Connecting RodAssemble Install Piston and Connecting Rod SECTION 12 - ENGINE SPECIFICATIONS TORQUE MODEL 110000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS REJECT DIMENSIONS TORQUE MODEL 120000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS Main Bearing TORQUE MODEL 150000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS REJECT DIMENSIONS TORQUE MODEL 200000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS Main Bearing TORQUE MODEL 210000 HORIZONTAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS Main Bearing TORQUE MODELS 97700 & 99700 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS REJECT DIMENSIONS TORQUE MODEL 110000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS REJECT DIMENSIONS TORQUE MODEL 120000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS REJECT DIMENSIONS TORQUE MODEL 210000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS REJECT DIMENSIONS TORQUE MODEL 280000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS Main Bearing TORQUE MODEL 310000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS Main Bearing TORQUE MODEL 330000 VERTICAL SERIESENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS Main Bearing