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Briggs & Stratton CE8069, 271172, 270962, 276535 Forward, Copyright 2009 Briggs & Stratton Corporation, All rights reserved

Contents

Single Cylinder OHV Air-CooledEngines Briggs & ledooStrattonQuality Starts With A Master Service Technician Repair Manuals for other All rights reserved FORWARDCopyright 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 12SECTION 1 - Safety, Maintenance and Adjustments Page SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS Hazard Symbols and Meanings ENGINE SAFETYSignal 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 SYSTEMBRIGGS & STRATTON MODEL NUMBERING SYSTEM Fuel must meet these requirements ENGINE MAINTENANCEFuel and Oil Recommendations High Altitude Every 25 Hours or Annually Maintenance Chart First 5 HoursEvery 8 Hours or Daily Every 50 Hours or Annually Inspect Brake and Switches Assemble Flywheel Brake Combustion Chamber Air Filter Figure Figure Figure Figure Figure Figure Remove InstallSnow Hood Inspection NOTICE Oil and Oil FilterSpark Plug NOTICE Cooling System Remote Control Wire Travel ENGINE ADJUSTMENTSRemote Controls 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 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 Engine Stopped SYSTEMS CHECK1 Check Ignition Engine Running 2 Check Carburetion Testing Fuel Shut Off SolenoidSolenoid Wiring Test Solenoid Plunger Test 3 Check Compression Possible Causes for Poor Compression Digital Multimeter ELECTRICAL SYSTEMSEquipment Used for Testing DC Shunt Possible Causes Alternator System DiagnosisComplaint Alternator Identification 3.3 Amp DC Only Figure 1.0.5 Amp DC Only Figure2.14 Volt AC Only Figure 4.Dual Circuit Figure 8.20 Amp DC Figure 6.5/9 Amp DC Figure7.10/16 Amp DC Figure 5 Amp DC Only Alternator Testing Alternator OutputFlywheel Identification 3-AmpDC Only Alternator 14-VoltAC Alternator Test Diode Test Alternator Output-AC Dual Circuit AlternatorTest Alternator Output Test Alternator Output-DC Tri-CircuitAlternator Test Diode Test Alternator Output Charging Circuit Test RED WireLighting Circuit Test WHITE Wire Test Diode Test Regulator-Rectifier 5 & 9 Amp DC Regulated AlternatorTest Alternator Output receptacle 10 & 16 Amp DC Regulated AlternatorTest Alternator Output Test Regulator - Rectifier 2.Install shunt to negative -battery terminal NOTICE DC Output Charging Wire Test20 Amp DC Regulated Alternator Test Alternator Output Figure 5.Rotate selector to DC volts position Model Series 97700, 99700, 110000, ELECTRIC STARTERSSYSTEM 3, SYSTEM Test Interlock Switch Test Starter Motor Test Starter Motor Test Interlock Switch Wiring12 Volt DC Starter Motor Test Solenoid 120-VoltAC Starter MotorModel Series 120000, 150000, 200000, Battery Installation BATTERIESBattery and Cable Recommendations Charging Battery Testing Battery Hard Starting or Will Not Start EQUIPMENT AFFECTING ENGINE OPERATIONOIL GARD SYSTEMS Engine Won’t Stop On/Off Switch Light Does Not Flash Engine Starts and Runs With Low Oil SECTION 3 - EXHAUST SYSTEMS Horizontal Models 110000, 120000, MUFFLER SERVICESpark Arresters Remove Guard and Muffler Inspect Exhaust System Never reinstall broken or damaged componentsInstall Muffler and Guard Remove Guard and Muffler Horizontal Models 200000,Shown is a typical muffler application Figure 3.Remove muffler support screws A, Figure Inspect Exhaust System Never reinstall broken or damaged componentsInstall Muffler and Guard 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 Vertical Models 97700, 99700, 110000, Never reinstall broken or damaged componentsInstall Muffler and Guard Inspect Exhaust System Inspect Exhaust System Never reinstall broken or damagedInstall Muffler and Guard components Inspect Exhaust System Never reinstall broken or damaged componentsRemove Muffler Install Muffler Shown is a typical muffler application Figure Never reinstall broken or damaged componentsInstall Muffler Remove Muffler SECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS Removal InstallationFuel Pump Inspection Horizontal Models 110000, 120000, 150000, 200000, Fuel FilterFuel Tanks and Shut-offValves Removal Vertical Models 97700, 99700, 110000, InstallationInstallation Vertical Model 2.Inspect fuel tank for •Corrosion •Leaks InstallationInspection CARBURETION Carburetor Identification Remove Carburetor Carburetor Service LMS CarburetorVertical Models 97700, 99700, 110000, Disassemble Carburetor Inspect and Clean Carburetor Components Assemble Carburetor Install Carburetor LMS Carburetor Horizontal Models 110000, 120000, Remove Carburetor •Passages in the fixed main jet bowl nut Inspect and Clean Carburetor ComponentsDisassemble Carburetor 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 Inspect and Clean Carburetor Assemble CarburetorPage 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 Horizontal Models 110000, 120000, 150000, 200000, Governor ServiceGoverned RPM Limits Disassemble Inspect Governor Assemble Assemble Governor DisassembleInspect 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 Disassemble Cylinder Head Remove Cylinder HeadModels 200000, 210000, 280000, 310000, 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 Horizontal Models 110000, 120000, 150000, 200000, REWIND STARTERSRemove Blower Housing / Rewind Starter Vertical Models 97700, Vertical Models 110000, Disassemble Rewind Starter Service Rewind StarterVertical Model Inspect Rewind Starter Parts Assemble Rewind Starter Vertical Models 110000, 2.Install the oil fill tube and dipstick CVertical Models 97700, Disassemble Starter Clutch Service Starter ClutchVertical Model Inspect Clutch Parts System 3, System ELECTRIC STARTERSReplace Ring Gear Check Starter Drive and Clutch Remove Starter Drive and Clutch Install Starter Drive and Clutch12 Volt Starters 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 Install Breather EXTENDED OIL FILL AND DIPSTICKBREATHERS Horizontal Models 110000, 120000, Check Breather 3.Inspect oil drain-backholes C, Figure 3 to make sure they are open. Clean as neededInstall Breather Remove Breather Remove Breather Install Breather8Current Production Check Breather Oil Dipper Lubrication LUBRICATION SYSTEMSInstall Breather Oil Slinger Lubrication Pressure Lubrication Oil Pump ServiceOil Slinger with Pressure Filtration Vertical Models 120000, 210000, 280000, 310000, Remove Pump Screen Oil Filter and Adapters Remove Install Screen and Gerotor PumpInspect Oil Pump Parts Test Oil Pressure Switch Oil Pressure SwitchInstall Oil Gard Systems Troubleshooting Lead Wire ColorsLead Wire Colors Identification SECTION 9 - CYLINDERS, COVERS AND SUMPS Reconditioning Bore CYLINDERInspect Cylinder Resizing Bore Check Bearings MAIN BEARINGSCleaning Cylinder Check Plain Bearings Magneto Bearing Tools Replace BearingsReplace DU Bearings PTO Bearing Tools Replace Ball Bearing Horizontal Models 120000, Bearing Removal Tools Bearing Installation ToolsReplace Ball Bearing Horizontal Models 200000, Tool/Part Replace Ball Bearing All Vertical Models COVERS AND SUMPS Installation Figure Figure FigurePage SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING SYSTEMS, AND GEAR REDUCTIONS Inspect CRANKSHAFTS AND CAMSHAFTSRemove Crankshaft and Camshaft Check Crankshaft Install Crankshaft and Camshaft Install Crankcase Cover or Sump Check and Adjust Crankshaft End Play Assemble Gear Reduction GEAR REDUCTIONDisassemble Gear Reduction Inspect Gear Reduction Parts Fill Gear Case with Lubricant Remove Auxiliary PTO Drive Shaft AUXILIARY PTOInspection Assemble Auxiliary PTO Drive Shaft Disassemble COUNTERBALANCE SYSTEMSSynchro-BalanceSystem Remove Counterbalance System Install Assemble Remove InstallAVS Balance System DisassemblePage SECTION 11 - PISTONS, RINGS AND CONNECTING RODS Disassemble PISTONS, RINGS, & CONNECTING RODSRemove Piston and Connecting Rod Inspect Check Ring End Gap Check Connecting RodAssemble Install Piston and Connecting Rod SECTION 12 - ENGINE SPECIFICATIONS FASTENER TORQUE SPECIFICATIONS MODEL 110000 HORIZONTAL SERIESENGINE SPECIFICATIONS TORQUE REJECT DIMENSIONS FASTENER TORQUE SPECIFICATIONS MODEL 120000 HORIZONTAL SERIESENGINE SPECIFICATIONS TORQUE Main Bearing FASTENER TORQUE SPECIFICATIONS MODEL 150000 HORIZONTAL SERIESENGINE SPECIFICATIONS TORQUE REJECT DIMENSIONS FASTENER TORQUE SPECIFICATIONS MODEL 200000 HORIZONTAL SERIESENGINE SPECIFICATIONS TORQUE Main Bearing FASTENER TORQUE SPECIFICATIONS MODEL 210000 HORIZONTAL SERIESENGINE SPECIFICATIONS TORQUE Main Bearing FASTENER TORQUE SPECIFICATIONS MODELS 97700 & 99700 VERTICAL SERIESENGINE SPECIFICATIONS TORQUE REJECT DIMENSIONS FASTENER TORQUE SPECIFICATIONS MODEL 110000 VERTICAL SERIESENGINE SPECIFICATIONS TORQUE REJECT DIMENSIONS FASTENER TORQUE SPECIFICATIONS MODEL 120000 VERTICAL SERIESENGINE SPECIFICATIONS TORQUE REJECT DIMENSIONS FASTENER TORQUE SPECIFICATIONS MODEL 210000 VERTICAL SERIESENGINE SPECIFICATIONS TORQUE REJECT DIMENSIONS FASTENER TORQUE SPECIFICATIONS MODEL 280000 VERTICAL SERIESENGINE SPECIFICATIONS TORQUE Main Bearing FASTENER TORQUE SPECIFICATIONS MODEL 310000 VERTICAL SERIESENGINE SPECIFICATIONS TORQUE Main Bearing FASTENER TORQUE SPECIFICATIONS MODEL 330000 VERTICAL SERIESENGINE SPECIFICATIONS TORQUE Main Bearing