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Briggs & Stratton 273521, 271172 1 2 3 4 5 6 7 8 9 10 11 12, Safety, Maintenance and Adjustments

Models: 273521 276535 CE8069 270962 271172

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SECTION 1 - Safety, Maintenance and Adjustments

SECTION 1 - Safety, Maintenance and Adjustments

SECTION 2 - Troubleshooting

SECTION 3 - Exhaust Systems

SECTION 4 - Fuel Systems and Carburetion

SECTION 5 - Governor Systems

SECTION 6 - Cylinder Heads and Valves

SECTION 7 - Starters

SECTION 8 - Lubrication Systems

SECTION 9 - Cylinders, Covers and Sumps

SECTION 10 - Crankshafts, Camshafts, Balancing Systems, and Gear Reductions

SECTION 11 - Pistons, Rings and Connecting Rods

SECTION 12 - Engine Specifications

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Briggs & Stratton 273521, 271172, 270962 1 2 3 4 5 6 7 8 9 10 11 12, Safety, Maintenance and Adjustments, Troubleshooting

Contents

Briggs & ledooStratton Quality Starts With A Master Service TechnicianSingle Cylinder OHV Air-CooledEngines Repair Manuals for otherCopyright 2009 Briggs & Stratton Corporation FORWARDAll rights reserved This Engine Repair Manual includes the following Engine ModelsSECTION 1 - Safety, Maintenance and Adjustments 1 2 3 4 5 6 7 8 9 10 11 12SECTION 2 - Troubleshooting Page SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS Signal Words in Safety Messages ENGINE SAFETYHazard Symbols and Meanings Before performing adjustments or repairs When testing for sparkExplosion and fire could result BRIGGS & STRATTON MODEL NUMBERING SYSTEM BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEMYOUR KEY TO THE WORLD’S FINEST ENGINES ENGINE MAINTENANCE Fuel and Oil RecommendationsFuel must meet these requirements High AltitudeMaintenance Chart First 5 Hours Every 8 Hours or DailyEvery 25 Hours or Annually Every 50 Hours or AnnuallyInspect Brake and Switches Assemble Flywheel BrakeCombustion Chamber Air FilterFigure Figure Figure Figure Figure FigureInstall Snow HoodRemove InspectionOil and Oil Filter Spark PlugNOTICE NOTICECooling System ENGINE ADJUSTMENTS Remote ControlsRemote Control Wire Travel Horizontal Models 110000, 120000,2.Move throttle lever to fast position Static Adjustment Governor AdjustmentsTop No Load Adjustment Vertical Models 97700, 2.Place throttle in FAST position Initial Adjustment All Models Final 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SYSTEMS CHECK 1 Check IgnitionEngine Stopped Engine RunningTesting Fuel Shut Off Solenoid Solenoid Wiring Test2 Check Carburetion Solenoid Plunger Test3 Check Compression Possible Causes for Poor CompressionELECTRICAL SYSTEMS Equipment Used for TestingDigital Multimeter DC ShuntComplaint Alternator System DiagnosisPossible Causes Alternator Identification 1.0.5 Amp DC Only Figure 2.14 Volt AC Only Figure3.3 Amp DC Only Figure 4.Dual Circuit Figure7.10/16 Amp DC Figure 6.5/9 Amp DC Figure8.20 Amp DC Figure Testing Alternator Output Flywheel Identification5 Amp DC Only Alternator 3-AmpDC Only Alternator14-VoltAC Alternator Test DiodeDual Circuit Alternator Test Alternator OutputTest Alternator Output-AC Test Alternator Output-DCTri-CircuitAlternator Test DiodeCharging Circuit Test RED Wire Lighting Circuit Test WHITE WireTest Alternator Output Test DiodeTest Alternator Output 5 & 9 Amp DC Regulated AlternatorTest Regulator-Rectifier 10 & 16 Amp DC Regulated Alternator Test Alternator Outputreceptacle Test Regulator - Rectifier2.Install shunt to negative -battery terminal DC Output Charging Wire Test 20 Amp DC Regulated AlternatorNOTICE Test Alternator OutputFigure 5.Rotate selector to DC volts positionSYSTEM 3, SYSTEM ELECTRIC STARTERSModel Series 97700, 99700, 110000, Test Interlock Switch Test Starter Motor12 Volt DC Starter Motor Test Interlock Switch WiringTest Starter Motor Model Series 120000, 150000, 200000, 120-VoltAC Starter MotorTest Solenoid BATTERIES Battery and Cable RecommendationsBattery Installation Charging BatteryTesting Battery EQUIPMENT AFFECTING ENGINE OPERATION OIL GARD SYSTEMSHard Starting or Will Not Start Engine Won’t StopOn/Off Switch Light Does Not Flash Engine Starts and Runs With Low OilSECTION 3 - EXHAUST SYSTEMS MUFFLER SERVICE Spark ArrestersHorizontal Models 110000, 120000, Remove Guard and MufflerInstall Muffler and Guard Never reinstall broken or damaged componentsInspect Exhaust System Horizontal Models 200000, Shown is a typical muffler application FigureRemove Guard and Muffler 3.Remove muffler support screws A, FigureNever reinstall broken or damaged components Install Muffler and GuardInspect 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 partsNever reinstall broken or damaged components Install Muffler and GuardVertical Models 97700, 99700, 110000, Inspect Exhaust SystemNever reinstall broken or damaged Install Muffler and GuardInspect Exhaust System componentsRemove Muffler Never reinstall broken or damaged componentsInspect Exhaust System Install Muffler Never reinstall broken or damaged components Install MufflerShown is a typical muffler application Figure Remove MufflerSECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS Installation Fuel PumpRemoval InspectionFuel Filter Fuel Tanks and Shut-offValvesHorizontal Models 110000, 120000, 150000, 200000, RemovalInstallation InstallationVertical Models 97700, 99700, 110000, Vertical ModelInspection Installation2.Inspect fuel tank for •Corrosion •Leaks CARBURETION Carburetor IdentificationVertical Models 97700, 99700, 110000, Carburetor Service LMS CarburetorRemove Carburetor Disassemble Carburetor Inspect and Clean Carburetor Components Assemble CarburetorInstall Carburetor LMS Carburetor Horizontal Models 110000, 120000, Remove CarburetorInspect and Clean Carburetor Components Disassemble Carburetor•Passages in the fixed main jet bowl nut Assemble Carburetoredge of the plug with a non-hardeningsealant ReadyStart Carburetor Vertical Model Install CarburetorRemove Carburetor Disassemble Carburetor Inspect and Clean CarburetorAssemble Carburetor LMT Carburetor 3.Move clamp and disconnect hose from carburetor Remove CarburetorDisassemble Carburetor Inspect and Clean Carburetor Assemble CarburetorPage Install Carburetor bracket.4Remove Carburetor Nikki Carburetor Vertical Models 280000, 310000,Disassemble Carburetor Inspect and Clean Carburetor 11.Remove the main jet and seal•Choke shaft and choke valve Assemble Carburetor12.Install new o-ringon fuel transfer tube E Install CarburetorNikki LP/NG Mixer Vertical Model 310000 Gaseous FuelSECTION 5 - GOVERNOR SYSTEMS GOVERNOR SYSTEMS Linkage and Spring OrientationGovernor Service Governed RPM LimitsHorizontal Models 110000, 120000, 150000, 200000, DisassembleInspect Governor AssembleInspect Governor DisassembleAssemble Governor 8. Adjust governor system per Section SECTION 6 - CYLINDER HEAD AND VALVES CYLINDER HEADS AND VALVES Remove Cylinder HeadDisassemble Cylinder Head InspectionAssemble 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 InspectionInstall 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 dimensionAssemble 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 StarterHorizontal Models 110000, 120000, 150000, 200000, Vertical Models 97700,Vertical Models 110000, Vertical Model Service Rewind StarterDisassemble Rewind Starter Inspect Rewind Starter Parts Assemble Rewind StarterVertical Models 97700, 2.Install the oil fill tube and dipstick CVertical Models 110000, Service Starter Clutch Vertical ModelDisassemble Starter Clutch Inspect Clutch PartsELECTRIC STARTERS Replace Ring GearSystem 3, System Check Starter Drive and ClutchInstall Starter Drive and Clutch 12 Volt StartersRemove Starter Drive and Clutch Check Starter Drive and ClutchAssemble Starter Motor Drive - C-Ring Retainer Disassemble Starter Drive - Roll Pin Retainer 120-VoltStarters Assemble Starter Drive - Roll Pin RetainerSECTION 8 - LUBRICATION SYSTEMS EXTENDED OIL FILL AND DIPSTICK BREATHERSInstall Breather Horizontal Models 110000, 120000,3.Inspect oil drain-backholes C, Figure 3 to make sure they are open. Clean as needed Install BreatherCheck Breather Remove BreatherInstall Breather 8Current ProductionRemove Breather Check BreatherLUBRICATION SYSTEMS Install BreatherOil Dipper Lubrication Oil Slinger LubricationOil Pump Service Oil Slinger with Pressure FiltrationPressure Lubrication Vertical Models 120000, 210000, 280000, 310000,Remove Pump Screen Inspect Oil Pump Parts Install Screen and Gerotor PumpOil Filter and Adapters Remove Oil Pressure Switch InstallTest Oil Pressure Switch Oil Gard SystemsLead Wire Colors Lead Wire ColorsTroubleshooting IdentificationSECTION 9 - CYLINDERS, COVERS AND SUMPS CYLINDER Inspect CylinderReconditioning Bore Resizing BoreMAIN BEARINGS Cleaning CylinderCheck Bearings Check Plain BearingsReplace Bearings Replace DU BearingsMagneto Bearing Tools PTO Bearing ToolsReplace Ball Bearing Horizontal Models 120000, Bearing Installation Tools Replace Ball Bearing Horizontal Models 200000,Bearing Removal Tools Tool/PartReplace Ball Bearing All Vertical Models COVERS AND SUMPS InstallationFigure Figure FigurePage SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING SYSTEMS, AND GEAR REDUCTIONSCRANKSHAFTS AND CAMSHAFTS Remove Crankshaft and CamshaftInspect Check CrankshaftInstall Crankshaft and Camshaft Install Crankcase Cover or Sump Check and Adjust Crankshaft End Play GEAR REDUCTION Disassemble Gear ReductionAssemble Gear Reduction Inspect Gear Reduction PartsFill Gear Case with Lubricant AUXILIARY PTO InspectionRemove Auxiliary PTO Drive Shaft Assemble Auxiliary PTO Drive ShaftCOUNTERBALANCE SYSTEMS Synchro-BalanceSystemDisassemble Remove Counterbalance SystemInstall AssembleInstall AVS Balance SystemRemove DisassemblePage SECTION 11 - PISTONS, RINGS AND CONNECTING RODS PISTONS, RINGS, & CONNECTING RODS Remove Piston and Connecting RodDisassemble InspectAssemble Check Connecting RodCheck Ring End Gap Install Piston and Connecting Rod SECTION 12 - ENGINE SPECIFICATIONS MODEL 110000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS MODEL 120000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing MODEL 150000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS MODEL 200000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing MODEL 210000 HORIZONTAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing MODELS 97700 & 99700 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS MODEL 110000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS MODEL 120000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS MODEL 210000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEREJECT DIMENSIONS MODEL 280000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing MODEL 310000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing MODEL 330000 VERTICAL SERIES ENGINE SPECIFICATIONSFASTENER TORQUE SPECIFICATIONS TORQUEMain Bearing