Briggs & Stratton 276781 Instruction Manual
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Briggs & Stratton 276781 Instruction Manual

Single cylinder ohv air-cooled engines
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Briggs & Stratton Engines:
273521 Twin Cylinder OHV Air-Cooled Engines
271172 Twin Cylinder L-Head Air-Cooled Engines
270962 Single Cylinder L-Head Air-Cooled Engines
276535 Two-Cycle Snow Engines
CE8069 Out of Production Engines (1919-1981)
Quality Starts With A
Master Service Technician
www.thePowerPortal.com (Dealers)
bRiGGsandstRattoN.coM (consumers)
BRIGGS&STRATTON
coRPoRatioN
Part No. 276781-8/09
Post office box 702
Milwaukee, wi 53201 usa
©2009 Briggs & Stratton Corporation
8/09
Single Cylinder OHV
Air-Cooled Engines

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Summary of Contents for Briggs & Stratton 276781

  • Page 1 Single Cylinder OHV CE8069 Out of Production Engines (1919-1981) Air-Cooled Engines Quality Starts With A Master Service Technician www.thePowerPortal.com (Dealers) bRiGGsandstRattoN.coM (consumers) BRIGGS&STRATTON Post office box 702 Milwaukee, wi 53201 usa coRPoRatioN ©2009 Briggs & Stratton Corporation Part No. 276781-8/09 8/09...
  • Page 2 FORWARD This manual was written to assist engine technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton engines. It assumes that persons using this manual have been properly trained in and are familiar with the servicing procedures for these products, including the proper use of required tools and safety equipment and the application of appropriate safety practices.
  • Page 3 This Engine Repair Manual includes the following Engine Models: MODEL 110000 HORIZONTAL SERIES • • MODEL 120000 HORIZONTAL SERIES • MODEL 150000 HORIZONTAL SERIES • MODEL 200000 HORIZONTAL SERIES • MODEL 210000 HORIZONTAL SERIES • MODELS 97700 & 99700 VERTICAL SERIES •...

  • Page 4: Table Of Contents

    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...
  • Page 5 THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE, ECONOMICAL AND RELIABLE...
  • Page 6 SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS ENGINE SAFETY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 BRIGGS &...

  • Page 7: Engine Safety

    ENGINE SAFETY This repair manual contains safety information and cause leakage, flow restrictions, or that is designed to: other failures. • Make you aware of hazards associated • Check fuel lines and fittings frequently for with engines. cracks or leaks and replace if necessary. •...
  • Page 8 WARNING WARNING Briggs & Stratton does not approve or autho- Running engines produce heat. Engine parts, especially mufflers, become rize the use of these engines on 3-wheel All extremely hot. Terrain Vehicles (ATV’s), motor bikes, fun/rec- Severe thermal burns can occur on reational go-karts, aircraft products, or vehi- contact.
  • Page 9 WARNING WARNING Starting engine creates sparking. Rapid retraction of starter cord (kick- Sparking can ignite nearby flammable back) will pull hand and arm toward gases. engine faster than you can let go. Explosion and fire could result. Broken bones, fractures, bruises, or •...

  • Page 10: Briggs & Stratton Numerical Identification System

    BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM YOUR KEY TO THE WORLD’S FINEST ENGINES This chart explains the unique Briggs & Stratton numerical model designation system. It is possible to determine most of the important mechanical features of the engine by merely knowing the model number. Here is how it works: The first one or two digits indicate the approximate CUBIC INCH DISPLACEMENT.

  • Page 11: Engine Maintenance

    ENGINE MAINTENANCE Fuel and Oil Recommendations Oil must meet these requirements: Fuel must meet these requirements: • Briggs & Stratton Warranty Certified oils • Clean, fresh, unleaded gasoline. are recommended for best performance. • A minimum of 87 octane / 87 AKI •...

  • Page 12: Maintenance Chart

    Maintenance Chart Flywheel Brake Model Series 97700, 99700, 110000, 120000 First 5 Hours Vertical Shaft • Change oil The flywheel brake is part of the safety control system required for some applications. While Every 8 Hours or Daily running at FAST speed position, the flywheel •...

  • Page 13: Section 12 - Engine Specifications

    Figure 3 Figure 4 6. Using a torque wrench and socket to fit the flywheel nut, turn flywheel clockwise with 4. Inspect brake pad on brake lever. Replace brake engaged. While turning at a steady brake assembly if thickness is less than rate, torque reading should be 26 lb.-in.

  • Page 14: Combustion Chamber

    Combustion Chamber 2. Gently tap air filter cartridge on a hard surface to loosen debris. Replace Remove combustion chamber deposits every cartridge if very dirty. 500 hours or whenever the cylinder head is 3. Wash foam filters and pre-cleaners in removed.
  • Page 15 Figure 10 Figure 7 Figure 11 Figure 8 Figure 12 Figure 9...

  • Page 16: Snow Hood

    Figure 15 Figure 13 Figure 16 Inspection 1. Check hood for cracks or worn mounting holes. Replace if necessary. 2. Check primer hose for brittleness or leaks and check stop switch and wire for Figure 14 damage. Replace parts as necessary. Install 1.

  • Page 17: Oil And Oil Filter

    Oil and Oil Filter Spark Plug Spark plugs should be replaced every year. WARNING Gasoline and its vapors are extremely flammable and explosive. NOTICE Fire or explosion can cause severe burns or death. Spark plugs have different thread “reach” and heat ranges. When changing a spark •...

  • Page 18: Cooling System

    Cooling System WARNING Running engines produce heat. Severe burns can occur on contact. • Allow muffler, engine cylinder fins, and radiator to cool before touching. • Remove accumulated combustibles from muf- fler area and cylinder area. Figure 19 - Rotating Screen Dirt or debris can restrict air flow and cause the engine to overheat, resulting in poor performance and reduced engine life.

  • Page 19: Engine Adjustments

    ENGINE ADJUSTMENTS Remote Control Wire Travel The remote control wire should measure 2.125” (54 mm) when extended outside the casing (Figure 21). After installation, the travel of the remote control wire must be at least 1.375” (35 mm) to properly actuate the choke (on Choke-A- Matic®...
  • Page 20 Vertical Models 110000, 120000 with Primer Carburetors 1. Loosen casing clamp screw (A, Figure 24, Figure 25). 2. Move throttle lever to fast position. 3. Move casing in direction of arrow until slack is removed. 4. Tighten casing clamp screw. Figure 26 4.

  • Page 21: Governor Adjustments

    Governor Adjustments Top No Load Adjustment Vertical Models 97700, 99700 A complete governor system adjustment 1. Place throttle (A, Figure 30 and 31) in includes a static adjustment, engine warm-up, FAST position and insert a 1/8” (3.2 mm) idle and/or governed idle adjustment, and top no- rod (B) through holes in carburetor control load adjustment.
  • Page 22 Top No Load Adjustment Vertical Models 3. Hold throttle lever against idle speed 110000, 120000, 150000 with Primer screw and, using Tachometer #19200 or Carburetors #19389, adjust to 1500 RPM. Release 1. Start engine and run until it reaches throttle lever. operating temperature.
  • Page 23 Idle and Top No Load Adjustment Horizontal Idle and Top No Load Adjustment Vertical and Vertical Models 200000, 210000 Models 280000, 310000, 330000 All carburetor mixture adjustments should be 1. Start engine and run until it reaches made before adjusting governor speeds. operating temperature.

  • Page 24: Adjust Valve Clearance

    2. Move equipment speed control to idle Adjust Valve Clearance position. All Models - Except Vertical Models 110000, 3. Turn idle screw to obtain 1750 RPM 120000 Early Production minimum. 4. Then turn idle mixture screw clockwise NOTE: Check valve clearance while the engine slowly until engine begins to slow.
  • Page 25 Vertical Models 110000, 120000 Early Production 1. Using a feeler gauge (A, Figure 42) adjust the locking hex nut (B) to obtain the correct clearance as listed in Section 12 - Engine Specifications. 2. Repeat for other valve. Figure 42 - OR - 1.

  • Page 26: Section 2 - Troubleshooting

    SECTION 2 - TROUBLESHOOTING SYSTEMS CHECK- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25 CHECK IGNITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 CHECK CARBURETION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 CHECK COMPRESSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27...
  • Page 27 OIL GARD SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE WILL NOT START - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE STARTS AND RUNS WITH LOW OIL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50...

  • Page 28: Systems Check

    SYSTEMS CHECK Most complaints concerning engine operation can be classified as one or a combination of the following: • Will not start • Hard starting • Lack of power • Runs rough • Vibration • Overheating • High oil consumption The source of most of these symptoms can be determined by performing a systems check in the following order:...

  • Page 29: Check Carburetion

    2) Check Carburetion Solenoid Plunger Test NOTE: The solenoid requires a minimum of 9 Before making a carburetion check, be sure the Volts DC to function. fuel tank has an ample supply of fresh, clean 1. Remove the fuel shut off solenoid from the gasoline.

  • Page 30: Check Compression

    4. Turn key switch ON. Meter should display battery voltage. If meter does not display battery voltage, the problem is with the solenoid wiring, equipment wire harness, or the keyswitch. Repair or replace as required. 3) Check Compression Use Leakdown Tester #19545 to check the sealing capabilities of the compression components.

  • Page 31: Electrical Systems

    ELECTRICAL SYSTEMS Equipment Used for Testing Digital Multimeter A digital multimeter is recommended for all electrical testing of Briggs & Stratton engines. The meter can be used to read volts, ohms, amperes, and to test diodes. The Fluke® Digital Multimeter #19464 and the UNI-T®...

  • Page 32: Alternator System Diagnosis

    Alternator System Diagnosis Complaint Possible Causes Battery Not • Engine RPM too low. Charging • Inline fuse “blown” (if equipped) • Defective or damaged battery (shortened battery cells) • Loose, pinched, or corroded battery ground leads or charge leads • Open, shorted, or grounded wires between output connector and battery •...

  • Page 33: Alternator Identification

    Alternator Identification The alternator systems installed on Briggs & Stratton OHV Engines can easily be identified by the color of the stator output wires and the connector. Alternator Stator Connector Alternator Output Figure Type Output Color (at 3600 RPM *) * Unless Noted Wire(s) Color...
  • Page 34 1. 0.5 Amp DC Only (Figure 8) • Unregulated • Output at 2800 RPM • .5 Amps DC for charging battery • One black lead (A) from stator • White connector (B) output lead Figure 10 4. Dual Circuit (Figure 11) •...
  • Page 35 • One red lead (B) from regulator-rectifier to red connector output lead (A) • 10 and 16 Amp systems use the same stator, color coding and regulator-rectifier • Alternator output is determined by the flywheel alternator magnet size Figure 12 Figure 14 6.

  • Page 36: Flywheel Identification

    Flywheel Identification 1. Insert RED test lead into 10 Amp receptacle in meter. OHV single cylinder flywheels have a single ring 2. Insert BLACK test lead into COM of magnets which provide the magnetic field for receptacle in meter. the various alternator systems, except Model Series 97700, 99700, 121600, 126000 which use 3.

  • Page 37: 14-Volt Ac Only Alternator

    5. Attach BLACK test lead clip to positive (+) battery terminal. NOTE: Negative (-) battery terminal must be grounded. Figure 18 • If meter “Beeps” once, diode is OK. Figure 17 • If meter makes a continuous tone, diode is defective (shorted). 6.

  • Page 38: Dual Circuit Alternator

    Test Alternator Output Test Alternator Output-AC 1. Insert RED test lead (A, Figure 19) into 1. Insert RED test lead (A, Figure 20) into the V Ω receptacle in the meter. the V Ω receptacle in the meter. 2. Insert BLACK test lead (B) into COM 2.

  • Page 39: Tri-Circuit Alternator

    Figure 22 Figure 21 • If meter “Beeps” once, diode is OK. 6. With the engine running at 3600 RPM, • If meter makes a continuous tone, diode output should be between 2 - 4 Amps DC. is defective (shorted). NOTE: The output will vary with the battery •...
  • Page 40 resistor is bypassed allowing full output to the “Beep” once as well as display voltage drop. A battery and clutch. continuous tone indicates continuity (shorted diode). An incomplete circuit (open diode) will be The battery is not used for the lights, so lights are displayed as “OL.”...

  • Page 41: 5 & 9 Amp Dc Regulated Alternator

    2. Insert BLACK test lead (B) into the COM Test Alternator Output receptacle in the meter. 1. Temporarily disconnect stator wire harness from the regulator-rectifier. 3. Attach RED test lead clip to (D) of the WHITE wire (C). (It may be necessary to 2.

  • Page 42: 10 & 16 Amp Dc Regulated Alternator

    1. Connect stator wire harness to regulator- The stator and regulator-rectifier are the same rectifier. for the 10 and 16 Amp systems. The system output is determined by the flywheel magnet 2. Insert RED test lead into 10 Amp size. receptacle in meter.
  • Page 43 NOTICE: Connect test leads BEFORE starting and all connections are clean and secure. the engine. Be sure connections are secure. If a If there is still NO or LOW output, replace test lead vibrates loose while engine is running, the regulator-rectifier. the regulator-rectifier may be damaged.

  • Page 44: 20 Amp Dc Regulated Alternator

    20 Amp DC Regulated Alternator DC Output Charging Wire Test A simple test can be used to test the DC output The 20 Amp regulated alternator system charging wire circuit. If a wiring problem exists, it provides AC current through two output leads to can be corrected before testing the regulator- the regulator-rectifier.
  • Page 45 Figure 32 5. Rotate selector to DC volts position. 6. With the engine running at 3600 rpm, the output should be 3-20 amps. 7. If no or low output is found, be sure that the regulator-rectifier is grounded properly and all equipment connections are clean and secure.

  • Page 46: Electric Starters

    ELECTRIC STARTERS Before assuming an electric starter requires 4. Starter Motor Blows Fuses - (120 Volt service, check the engine for freedom of rotation Starter Motor Only) by removing the spark plug and turning the • Parasitic load crankshaft over by hand. Any belt, clutch, or •...
  • Page 47 Figure 34 If the pinion gear sticks, clean the helix and gear with a mild solvent and compressed air. If the Figure 35 pinion continues to stick, replace the entire starter drive assembly. 4. Using Tachometer #19200 (F), spin the NOTE: Do not oil the pinion gear or helix.

  • Page 48: 12 Volt Dc Starter Motor

    Test Interlock Switch Wiring 12 Volt DC Starter Motor 1. Disconnect interlock switch wires from Model Series 120000, 150000, 200000, spade terminals on switch and at starter 210000, 280000, 310000, 330000 motor connection. These starter motors were produced in three 2.

  • Page 49: Volt Ac Starter Motor

    3. Disconnect wire from tab terminal on solenoid. 4. Insert RED test lead into the V Ω receptacle in the meter and insert BLACK test lead into COM receptacle in the meter. 5. Set meter to Diode position. 6. Attach one meter test lead to each stud terminal (B,C) on solenoid.

  • Page 50: Batteries

    BATTERIES A 12 Volt, lead acid, wet cell battery is required to operate starter motors on Briggs & Stratton OHV single cylinder engines. This type is WARNING available as a wet charge or dry charge battery. The wet charged maintenance-free battery is Battery posts, terminals, and related filled with electrolyte and sealed at the time accessories contain lead and lead...

  • Page 51: Testing Battery

    Figure 40 Testing Battery Set the digital multimeter to DC volts position. Test the battery while installed in the equipment. 1. Disconnect wire from spark plug and ground ignition using Ignition Tester #19368. 2. Attach RED meter test clip to positive (+) battery terminal.

  • Page 52: Equipment Affecting Engine Operation

    EQUIPMENT AFFECTING ENGINE OPERATION OIL GARD SYSTEMS Frequently, what appears to be a problem with engine operation, such as hard starting or vibration, may be the fault of the equipment Engine Will Not Start, On/Off Switch Light rather than the engine itself. Below are some Flashes common symptoms and potential equipment- 1.
  • Page 53 On/Off Switch Light Does Not Flash 1. Check engine oil level. If low, add oil to bring to FULL mark on dipstick. 2. Try to start engine while shading ON/OFF switch light from bright light such as sunlight. If light does not flash, replace switch.
  • Page 54 SECTION 3 - EXHAUST SYSTEMS SPARK ARRESTORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52 MUFFLER SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52 HORIZONTAL MODELS 110000, 120000, 150000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52 HORIZONTAL MODELS 200000, 210000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54...

  • Page 55: Spark Arrestors

    Some engines are equipped with exhaust systems (mufflers, brackets, and hardware) supplied by the OEM. Contact the OEM for muffler service information. Exhaust systems covered in this section are those supplied by Briggs & Stratton. WARNING Replacement parts must be the same and installed in the same position as the original parts or fire could result.
  • Page 56 Install Muffler and Guard 1. Coat threads of pipe with Valve Guide Lubricant #93963. Thread pipe into cylinder head exhaust port (A, Figure 5). 2. Coat exposed threads of elbow with Valve Guide Lubricant #93963. Install elbow (B) on pipe (C) and tighten securely with outlet straight out from cylinder head.

  • Page 57: Horizontal Models 200000, 210000

    Figure 7 Figure 9 3. Remove muffler support screws (A, Figure 10). Horizontal Models 200000, 210000 Shown is a typical muffler application (Figure 8). Figure 8 Remove Guard and Muffler 1. Remove screws (A, Figure 9) holding muffler guard to muffler. 2.

  • Page 58: Horizontal Models 120000, 150000, 200000, 210000 (Snow Engines)

    Horizontal Models 120000, 150000, 200000, 210000 (Snow Series) Shown are typical muffler applications (Figure 12 and Figure 13). Figure 11 Inspect 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 Figure 12 breakage.

  • Page 59: Vertical Models 97700, 99700, 110000, 120000

    3. Install screws at exhaust pipe and torque to values listed in Section 12 - Engine Specifications. 4. Install muffler support screws and torque to values listed in Section 12 - Engine Specifications. 5. Lightly coat muffler guard mounting screws with Valve Guide Lubricant #93963.
  • Page 60 2. Remove screws holding muffler guard (A, Figure 18). Remove guard and set aside. Figure 20 Inspect Exhaust System Figure 18 All exhaust system components must be inspected whenever the exhaust system is 3. Remove dipstick and oil fill tube disassembled.

  • Page 61: Vertical Models 210000, 280000, 310000, 330000 (Clamped Muffler)

    7. Install blower housing and rewind starter. 3. Remove adapter screws, adapter, and gaskets. Discard gaskets. 8. Install oil fill tube and dipstick. 9. Lightly coat muffler guard mounting screws with Valve Guide Lubricant #93963. 10. Place muffler guard over muffler and start screws (A, B, C, Figure 22).
  • Page 62 Install Muffler 1. Lightly coat muffler adapter screws with Valve Guide Lubricant #93963. 2. Install new gasket and adapter. Install screws (A, Figure 25) and torque to values listed in Section 12 - Engine Specifications. Figure 25 3. Install muffler supports and start but do not tighten screws (A, B, C, Figure 26).

  • Page 63: Vertical Models 280000, 310000, 330000 (Bolt-On Muffler)

    Vertical Models 280000, 310000, Install Muffler 1. Lightly coat muffler adapter screws with 330000 with Bolt-On Muffler Valve Guide Lubricant #93963. Shown is a typical muffler application 2. Install new gasket and adapter. Install (Figure 27). screws (A, Figure 29) and torque to values listed in Section 12 - Engine Specifications.
  • Page 64 SECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -62 FUEL PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63 FUEL FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64 FUEL TANKS AND SHUTOFF VALVES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64...

  • Page 65: Fuel Systems

    FUEL SYSTEMS WARNING WARNING Never start or operate engine with air Gasoline and its vapors are extremely cleaner removed, fire can result. flammable and explosive. Fire or explosion can cause severe burns or death. When adding fuel: WARNING • Turn engine OFF and let engine cool for at least 2 minutes before removing the fuel cap.

  • Page 66: Fuel Pump

    Fuel Pump The fuel pump, mounted near the blower housing and the air cleaner cover, allows remote fuel tank installations on some engines. The pump is operated by vacuum pulses from the engine. NOTE: The fuel pump itself is not serviceable. If the pump does not operate after inspection and proper installation, replace the pump.

  • Page 67: Fuel Filter

    Fuel Filter Some engines are equipped with a fuel filter (Figure 3) mounted in-line between the fuel tank and the carburetor. Replace the filter annually or whenever fuel system service is performed. Figure 4 4. Release hose clamp and disconnect fuel hose from carburetor fitting.

  • Page 68: Vertical Models 97700, 99700, 110000, 120000

    Installation Inspection 1. Install tank support to tank. Slip fuel hose 1. Clean gummy or dirty fuel tanks with under governor link and spark plug wire Briggs & Stratton Carburetor Cleaner through hole in support as tank is #100041 or #100042, or equivalent. installed.
  • Page 69 5. If necessary, remove two nuts from bracket and slide bracket off cylinder head studs. Inspection 1. Clean gummy or dirty fuel tanks with Briggs & Stratton Carburetor Cleaner #100041 or #100042, or equivalent. 2. Inspect fuel tank for: • Corrosion •...

  • Page 70: Carburetion

    CARBURETION Carburetor Identification • Figure 6 - LMS, Models 97700, 99700, 110000, 120000, 150000 Vertical and Horizontal Shaft • Figure 7 - ReadyStart®, Models 110000, 120000 Vertical Shaft • Figure 8, Figure 9 - LMT, Models 200000, 210000, 280000, 310000, 330000 Vertical and Horizontal Shaft •...

  • Page 71: Carburetor Service

    Carburetor Service LMS Carburetor Vertical Models 97700, 99700, 110000, 120000 The exact type of LMS carburetor can be identified by a number stamped on the edge of the mounting flange (A, Figure 12). These carburetors have a fixed high-speed main jet and a non-adjustable idle mixture (except on early production models), and are available in manual/ remote choke or Choke-a-Matic...
  • Page 72 Discard the hinge pin, inlet needle, and seat. NOTE: On Model 97700, remove the main jet (A) and float disc (B) before removing the hinge pin, float, and needle. Figure 13 Figure 15 3. Remove idle speed screw with spring (B, Figure 16).
  • Page 73 Inspect and Clean Carburetor Components 2. Install new foam seal (B, Figure 18) on choke shaft (E), then slide shaft into 1. Inspect openings in the carburetor body carburetor body (C). Rotate shaft for evidence of wear or damage. If found, clockwise (A), and insert choke valve into replace the entire carburetor assembly.
  • Page 74 3. Place new gaskets or o-rings between control bracket (D, Figure 22), adapter (if equipped), and carburetor. 4. Position carburetor on control bracket or adapter and install screws (C). Torque to value listed in Section 12 - Engine Specifications. Figure 20 6.

  • Page 75: Lms (110000, 120000, 150000 Horizontals)

    Figure 25 Figure 24 Remove Carburetor 6. Connect fuel hose to carburetor and secure with clamp. 7. Using new gasket, install air cleaner WARNING assembly to carburetor per Section 1. Ensure breather hose is properly installed Before servicing the carburetor or other fuel on the breather tube.
  • Page 76 the governor link from the grommet on top of the throttle shaft lever (B). Discard gasket. Disassemble Carburetor 1. Remove the fixed main jet (bowl nut) and fiber washer, then remove the fuel bowl and the bowl gasket from the carburetor body.
  • Page 77 edge of the plug with a non-hardening sealant. Figure 31 Figure 29 4. Install idle speed screw with spring, if equipped. 2. Install new foam seal (B, Figure 30) on 5. Using Bushing Driver #19057 choke shaft (E), then slide shaft into (A, Figure 32), install new needle seat with carburetor body (C).

  • Page 78: Readystart (120000 Vertical)

    7. Place new bowl gasket on carburetor body ReadyStart® Carburetor and install fuel bowl. Place new fiber Vertical Model 120000 washer on fixed main jet (bowl nut) and install. Torque to values listed in Section 12 - Engine Specifications. This carburetor utilizes a thermostatically controlled choke system, requiring no primer or Install Carburetor manual choking when starting.
  • Page 79 5. Remove gasket (A, Figure 36), spacer, NOTE: Do not disassemble the carburetor body and o-ring between control bracket and or linkages. carburetor (B). Inspect and Clean Carburetor 1. Inspect openings in the carburetor body for evidence of wear or damage. If found, replace the entire carburetor assembly.

  • Page 80: Lmt (200000, 210000, 280000, 310000, 330000 Vertical And Horizontal)

    3. Place new gasket (A, Figure 39), spacer, LMT Carburetor and new o-ring between control bracket Horizontal and Vertical Models (B) and carburetor (C). 200000, 210000, 280000, 310000, 4. Position carburetor on control bracket and 330000 install screws. Torque to value listed in Section 12 - Engine Specifications.
  • Page 81 Remove Carburetor 1. Disconnect wire(s) from the carburetor solenoid. Two styles of solenoids have been used (Figure 42). Figure 44 3. Remove float hinge pin, float, and inlet needle. Discard the hinge pin and inlet Figure 42 needle. 2. Remove air cleaner assembly per 4.
  • Page 82 open position, then pull choke valve out of NOTE: Do not soak non-metallic components, choke shaft. Remove choke shaft, return such as floats, o-rings, seals, or diaphragms, in spring (when used), and foam seal. carb/choke cleaner or they will be damaged. Discard seal.
  • Page 83 4. Install new throttle shaft seal (C, Figure 50) with sealing lip down in carburetor body until top of seal is flush with top of carburetor (D). Install new foam seal (B) on throttle shaft, then slide shaft into carburetor body. Rotate shaft until flat is facing out.
  • Page 84 8. Install emulsion tube using Carburetor Screwdriver #19280 until tube seats (A, Figure 52). Figure 53 3. Hook choke link into outer hole of choke Figure 52 shaft from underneath. Slide other end of choke link into slot in governor control 9.

  • Page 85: Nikki (280000, 310000, 330000 Vertical)

    Nikki Carburetor Disassemble Carburetor 1. Remove fuel bowl screws (A, Figure 56). Vertical Models 280000, 310000, Remove the fuel bowl (B) from the 330000 carburetor body. WARNING Before servicing the carburetor or other fuel system components, drain all fuel from the tank and turn OFF the fuel valve (if equipped).
  • Page 86 Figure 58 Figure 61 6. If equipped, remove the idle mixture screw with spring (A, Figure 59) and the idle 10. Remove the choke shaft, return spring, speed screw with spring (B). and foam seal. Discard spring and seal. 11. Remove the main jet and seal. NOTE: Do not attempt to remove the pilot jets, which are pressed in and not serviceable.
  • Page 87 • Choke shaft and choke valve • Throttle shaft and throttle valve • All passages, openings, and the inside and outside of the carburetor body NOTE: Do not soak non-metallic components, such as floats, o-rings, seals, or diaphragms, in carb/choke cleaner or they will be damaged. 4.
  • Page 88 NOTE: The holes in the throttle plate are offset. If the throttle plate is installed incorrectly, if will not close. 9. If equipped, install idle mixture screw with spring and the idle speed screw with spring. Turn each screw until the head of the screw touches the spring.

  • Page 89: Nikki Lp/Ng Mixer (Gaseous Fueled Vertical Shaft)

    Figure 71 4. Hook choke link (C) into hole in choke lever. 5. Position carburetor on manifold and install screws or nuts by hand. 6. Actuate choke and throttle linkages to ensure proper movement, then tighten screws per values listed in Section 12 - Engine Specifications.

  • Page 90: Section 5 - Governor Systems

    SECTION 5 - GOVERNOR SYSTEMS LINKAGE AND SPRING ORIENTATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -88 GOVERNED RPM LIMITS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -89 GOVERNOR SERVICE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -89 HORIZONTAL MODELS 110000, 120000, 150000, 200000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89...
  • Page 91 GOVERNOR SYSTEMS Linkage and Spring Orientation NOTE: Be sure to note hole position of linkage before removing. • Figure 1 - Horizontal Shaft Models 110000, 120000, 150000, 200000, 210000. • Figure 2 - Vertical Shaft Model 97700 • Figure 3 - Vertical Shaft Model 99700 •...
  • Page 92 If a governor spring must be replaced, consult the appropriate Illustrated Parts List for the correct part number. After a new governor spring is installed, check the engine top governed speed with an accurate tachometer, as noted above, and adjust as required.
  • Page 93 2. Slide the governor lever on crank and finger-tighten bolt and nut until crank turns with a slight resistance. 3. Rotate crank until paddle is aligned with cup on governor gear assembly. 4. Install new crankcase cover gasket(s) of same thickness as originally removed from cylinder.
  • Page 94 Vertical Models 97700, 99700, 110000, 120000, 210000, 280000, 310000, 330000 The mechanical governor is part of the oil slinger assembly (A, Figure 13) attached to the camshaft. The governor crank is mounted in the cylinder assembly. Figure 15 3. Slide lever (B) off governor crank (C) and disconnect from governor link (D).
  • Page 95 6. Place seal protector in oil seal and slide sump over crankshaft until it seats. NOTE: It may be necessary to rotate crankshaft and cam gear to get oil pump (if equipped) to engage oil pump drive slot in cam gear. 7.

  • Page 96: Section 6 - Cylinder Heads And Valves

    SECTION 6 - CYLINDER HEAD AND VALVES SERVICE CYLINDER HEAD- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -94 HORIZONTAL AND VERTICAL MODELS 97700, 99700, 110000, 120000, 150000 - - - - - - - - - - - - - - - - - - - - - - 94 SERVICE CYLINDER HEAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -99 HORIZONTAL AND VERTICAL MODELS 200000, 210000, 280000, 310000, 330000 - - - - - - - - - - - - - - - - - - - - - 99...
  • Page 97 CYLINDER HEADS AND VALVES Before the cylinder head can be removed, other external parts must be removed, such as the air cleaner, fuel tank, oil fill tube, blower housing, muffler, carburetor, control bracket assembly, and intake manifold. Remove Cylinder Head Horizontal and Vertical Models 97700, 99700, 110000, 120000, 150000 1.
  • Page 98 Figure 6 Figure 8 3. Remove push rods one at a time, marking the location and orientation of each for 2. Remove valve stem caps (A, Figure 9) (if proper installation later. used), the rocker arm studs, and the push rod guide (models 97700, 99700).
  • Page 99 2. If head passes visual inspection, use Plug 4. Inspect valves for wear or damage. Gauge #19122 to check valve guides for Replace if necessary. wear. If gauge enters the guide 1/4” (6.4 NOTE: Valve faces can be resurfaced on a mm) or more, replace the guide (models commercially available valve grinder.
  • Page 100 Figure 13 Figure 15 4. Support valve side of cylinder head on clean shop rags. Place valve springs and valve spring retainers over valve stems. Using thumbs, press against each retainer until it securely locks into groove in valve stem (Figure 14). Figure 16 Figure 14 Install Cylinder Head...
  • Page 101 Figure 18 NOTE: Do not torque each screw in one step as Figure 19 it may result in a warped cylinder head. Step- torque all screws to approximately 1/3 of final 7. Rotate crankshaft at least twice to ensure torque value, then to 2/3 final torque value, then proper movement of the push rods and finish at final torque value.
  • Page 102 Remove Cylinder Head Models 200000, 210000, 280000, 310000, 330000 1. Remove four screws from rocker cover, then remove cover and gasket (A, Figure 20). Figure 21 2. Remove the rocker arm studs. 3. Using thumbs, press down on each valve spring retainer and disengage retainer (A, Figure 22) from valve stem (B).
  • Page 103 mm) or more, replace the entire head. If 3. Lightly coat valve stems with Valve Guide plug gauge is not available, see Section Lubricant #93963. then insert valves into 12 - Engine Specifications for the valve cylinder head. Do not get lubricant on guide reject dimension.
  • Page 104 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 29). Figure 26 Figure 29 5. Place rocker arms and rocker balls on rocker arm studs.
  • Page 106 SECTION 7 - STARTERS REWIND STARTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 REMOVE BLOWER HOUSING / STARTER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 HORIZONTAL MODELS 110000, 120000, 150000, 200000, 210000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 VERTICAL MODELS 97700, 99700- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104...

  • Page 107: Rewind Starters

    REWIND STARTERS On some engines, the rewind starters are attached to the blower housing with screws and can be quickly removed. Other starters are riveted or spot welded to the blower housing and must be drilled to remove, following the procedures below. For installation, screws and nuts are available separately from the Illustrated Parts List and are included with complete replacement starters.

  • Page 108: Vertical Models 110000, 120000

    Figure 6 Figure 4 4. Remove screws (D, Figure 7) and screw 5. Carefully drill through all rivet heads and and spacer (E), then remove tank from remove rewind starter. Do not allow drill bit engine. to cut into the holes in the starter housing. NOTE: Do not attempt to drill out the rivets while the blower is still on the engine.

  • Page 109: Vertical Model 280000

    5. If rewind starter is riveted, carefully drill through all rivet heads and remove rewind starter. Do not allow drill bit to cut into holes in the starter housing. NOTE: Do not attempt to drill out the rivets while the blower is still on the engine. The rivets are made of steel and the shavings will collect on the flywheel magnets.

  • Page 110: Install Blower Housing / Starter

    Inspect Rewind Starter Parts an overhand knot in end of rope, then pull rope until knot is seated in pulley. Trim excess rope if necessary. NOTE: Do not remove the spring from the pulley. Both parts are serviced only as an assembly. 6.

  • Page 111: Vertical Models 97700, 99700

    Vertical Models 97700, 99700 1. Install the screws to the blower housing (D, Figure 11), torquing screws to values listed in Section 12 - Engine Specifications. 2. Install the oil fill tube and dipstick (C). Figure 13 2. Install screws (D, Figure 14) and spacer (E), then install tank from engine.

  • Page 112: Vertical Model 280000

    5. Fill fuel tank or open fuel shut-off valve. Service Starter Clutch Connect fuel hose to carburetor and connect spark plug wire. Some Vertical model 280000s utilized a sealed starter clutch on the rewind starters. The starter clutch assembly consists of a seal (A, Figure 18), ratchet (B), clutch housing (C), retainer cover (D), and 6 ball bearings (E).

  • Page 113: Electric Starters

    2. Wipe off any excess oil from the top of the ratchet, then place the ratchet on the housing. 3. Install the retainer cover and seal over the ratchet and press into housing until fully closed. Install retaining screws (if used). 4.

  • Page 114: 12 Volt Starters

    Remove Starter Drive and Clutch 12 Volt Starters 1. Remove E-ring (A, Figure 20). Check Starter Drive and Clutch 2. Remove three screws (B) holding gear When starter switch is activated, pinion gear cover. should engage the ring gear and crank engine. 3.
  • Page 115 Figure 24 2. Remove retainer (A, Figure 24), return Figure 26 spring (B), flat washer (C), wave washer (D), pinion gear (E), and starter clutch (F). 2. Install pinion gear (C, Figure 26) with beveled edge of teeth up. Install return spring (D) into recess of pinion gear.
  • Page 116 Figure 30 Figure 28 4. Place new C-ring over chamfered end of shaft. 5. Align one of the slots (G, Figure 28) of C- Ring Installer #19435 with open end of C- ring (H). 6. Press on tool until C-ring snaps into groove in shaft.

  • Page 117: Volt Starters

    Assemble Starter Drive - Roll Pin Retainer 1. Place clutch (E, Figure 31) on starter shaft and rotate clutch until it drops into place. Figure 32 2. Install pinion gear (D) with beveled edge of teeth up. 3. Place washer (C) and retainer (B) on starter shaft.
  • Page 118 SECTION 8 - LUBRICATION SYSTEMS EXTENDED OIL FILL AND DIPSTICK- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -116 BREATHERS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -116 HORIZONTAL MODELS 110000, 120000, 150000, 200000, 210000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -116 VERTICAL MODELS 97700, 99700, 110000, 120000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -116...

  • Page 119: Extended Oil Fill And Dipstick

    EXTENDED OIL FILL AND DIPSTICK Horizontal Models 110000, 120000, 150000, Vertical Models 90000, 110000, 120000, 200000, 210000 210000, 280000, 310000, 330000 These models use a plastic extended oil fill tube These models use a plastic extended oil fill tube and a quarter-turn dipstick. The oil fill tube and a quarter-turn, dipstick.

  • Page 120: Vertical Models 280000, 310000

    Figure 3 Figure 2 Install Breather Check Breather 1. Install new breather passage gasket and 1. Check for movement of the disc valve in breather passage cover on top of cylinder. the breather assembly. If disc is stuck or Torque four screws to values listed in binding, replace the breather assembly.

  • Page 121: Vertical Models 210000, 280000, 310000, 330000

    NOTE: Do not apply force to the wire gauge! The date code 070719xx) or clean off sealant disc valve is retained by an internal bracket (after date code 070718xx). which will be distorted if pressure is applied to disc. Figure 6 Check Breather 1.

  • Page 122: Lubrication Systems

    Install Breather values listed in Section 12 - Engine Specifications. 1. Install reed with the metal tab facing outside of the engine, as shown in Figure 3. Securely install breather tube in breather 8. Torque screw to values listed in Section cover.

  • Page 123: Oil Slinger With Pressure Filtration

    Oil Slinger with Pressure Filtration Vertical Models 280000, 310000, 330000 On some of these models the gerotor pump Vertical Models 120000, 210000, 280000, draws oil from the sump and pumps it through 310000, 330000 the oil filter, then directly to the PTO bearing in Some of these models are equipped with a the sump (Figure 14).
  • Page 124 Figure 15 Figure 17 2. Carefully remove inner (C) and outer Current oil pump screen must be driven out from rotors (D). inside the sump (Figure 18). NOTICE: Depending on Model Series, inner rotor may include the drive shaft or the drive shaft may be a separate part.

  • Page 125: Oil Filter And Adapters

    Inspect Oil Pump Parts 1. Inspect surfaces of outer and inner rotors, pump housing, cover, and shaft for wear and scoring. Replace parts if necessary. 2. Inspect pump housing and passages for debris. Clean as required. 3. Inspect screen for clogging or damage. Replace as necessary.

  • Page 126: Oil Pressure Switch

    Figure 24 Inspect 1. Check adapter for cracks or damage to Figure 25 the sump and filter mounting surfaces. Test Oil Pressure Switch Replace adapter if necessary. 1. Unscrew the switch to remove it for 2. Clean all oil passages in adapter and in testing.
  • Page 127 The engine can be restarted, but will only run briefly. Type of Lead Wire Colors Starter Rewind Gray/Black White/Gray Electric Gray/Black White/Gray Troubleshooting In engines equipped with a Start Sense system, Figure 26 if the engine will not start, check oil level and bring level to FULL.
  • Page 128 SECTION 9 - CYLINDERS, COVERS AND SUMPS CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126 INSPECT CYLINDER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126 RECONDITIONING BORE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126 RESIZING BORE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126...

  • Page 129: Cylinder

    CYLINDER Inspect Cylinder Compare measurements to the standard cylinder bore sizes provided in Section 12 - Engine 1. Visually check cylinder for cracks, stripped Specifications. threads, and bore damage. If the cylinder bore is more than 0.003” (0.08 • If cracks are found, replace the cylinder. mm) oversize, or 0.0015”...

  • Page 130: Clean Cylinder

    Cleaning Cylinder When cylinder and crankcase have been thoroughly cleaned, use a clean white rag to 1. Wash the cylinder thoroughly in a solvent wipe the cylinder bore. If honing grit is still such as kerosene or other commercial present, it will appear as a grey residue on the solvent.

  • Page 131: Replace Bearings

    replace the affected cylinder, crankcase cover, PTO Bearing Tools or sump (Figure 6). Model Bushing Cylinder NOTE: Standard and reject sizes for the main Series Driver Support bearings are shown in Section 12 - Engine 110000 Replace Crankcase Cover Specifications. 120000 or Sump 150000...
  • Page 132 Figure 12 Figure 10 5. Place cylinder or cover/sump on cylinder Replace Ball Bearing support (B, Figure 11) with large opening Horizontal Models 120000, 150000 facing bearing. 1. Select tools needed from charts below. 6. Align oil holes in bearing with oil holes in cylinder or cover/sump, then press in new bearing to correct depth with bushing driver (A).
  • Page 133 Figure 13 3. Assemble washer (C, Figure 14) to puller screw (D) and insert through large end of Figure 15 removal driver (B). Place open end of support (A) against ball bearing. NOTE: Always install new oil seals when engine is reassembled or when replacing bearings.
  • Page 134 4. Insert screw, with washer and driver through the ball bearing and thread into Bearing Removal Tools support. Continue tightening screw until Tool/Part Tool/Part # ball bearing is removed. Description Washer 690582 Puller Screw 19318 Removal Driver 19401 Removal Support 19454 Bearing Installation Tools Tool/Part...

  • Page 135: Covers And Sumps

    NOTE: Always install new oil seals when engine is reassembled or when replacing bearings. Always use the correct seal protector to prevent damaging the oil seal during installation. Figure 19 COVERS AND SUMPS Installation 1. Select correct seal protector for Kit #19356, to protect oil seal when installing cover or sump.
  • Page 136 Figure 22 Figure 23 Figure 24...
  • Page 138 SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING SYSTEMS, AND GEAR REDUCTIONS CRANKSHAFTS AND CAMSHAFTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -136 REMOVE CRANKSHAFT AND CAMSHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -136 INSPECT CRANKSHAFT AND CAMSHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -136 INSTALL CRANKSHAFT AND CAMSHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -137...

  • Page 139: Crankshafts And Camshafts

    CRANKSHAFTS AND CAMSHAFTS Remove Crankshaft and Camshaft 6. Rotate crankshaft to place piston at Top Dead Center (TDC). 1. Drain oil from engine and all fuel from fuel 7. Remove connecting rod cap, then slide out tank. Drain oil from gear reduction unit (if crankshaft.

  • Page 140: Install Crankshaft And Camshaft

    7. On horizontal crankshaft engines, make sure the paddle on the governor shaft (B, Figure 6) is rotated in line with the governor cup inside the crankcase cover. 8. On vertical crankshaft engines, assemble governor gear/oil slinger (B, Figures 7 and 8) to camshaft.

  • Page 141: Install Crankcase Cover Or Sump

    Install Crankcase Cover or Sump 1. Using a new gasket install crankcase cover or sump using seal protectors. Do not force cover or sump on cylinder. NOTE: It may be necessary to rotate crankshaft to get oil pump (if equipped) to engage drive slot in camshaft.

  • Page 142: Check And Adjust Crankshaft End Play

    Check and Adjust Crankshaft End Play When crankcase cover or sump is installed with a standard gasket, end play should match values listed in Section 12 - Engine Specifications. If end play is less than specified, remove cover or sump and install an additional gasket. Do not use more than two gaskets.

  • Page 143: Gear Reduction

    GEAR REDUCTION Disassemble Gear Reduction Inspect Gear Reduction Parts 1. Note orientation of gear reduction 1. Inspect seals for cracks, tears, or assembly on engine. Place an oil hardening. Replace seals if necessary. collection pan beneath the assembly. 2. Inspect crankshaft pinion gear and drive 2.

  • Page 144: Fill Gear Case

    Fill Gear Case with Lubricant 1. Remove oil level plug (C, Figure 22) and vent plug (A). 2. Fill gear case with SAE oil: • Above 40°F (10°C) use 80w90 for Horizontal Models 120000, 150000. • Above 40°F (10°C) use 30w for Horizontal Models 200000, 210000.

  • Page 145: Auxiliary Pto

    AUXILIARY PTO Some models of the vertical shaft 110000 and 120000 engines were equipped with an auxiliary PTO shaft. The auxiliary PTO shaft (E, Figure 23) extends through the side of the sump, perpendicular to the crankshaft. Rotation can be either clockwise or counterclockwise, as viewed from the end of the shaft.

  • Page 146: Counterbalance Systems

    COUNTERBALANCE SYSTEMS Two styles of counterbalance systems are used Disassemble on Vertical crankshaft engines. 1. Remove crankshaft gear (A, Figure 26). Models 280000 and 310000 (built before July NOTE: If gear is tight, pry it off using two 2001) have the Synchro-Balance® system. screwdrivers being careful not to damage gear.
  • Page 147 Assemble 1. Lubricate all bearing surfaces with clean engine oil. 2. Slide magneto-side counterweight (A, Figure 28) on flywheel end of crankshaft. 3. Place crankshaft and counterweight in a vise with soft jaws or shop rags to protect magneto journal. 4.

  • Page 148: Avs® Balance System

    AVS® Balance System 3. Measure the crankshaft eccentric diameters and compare to the values Remove shown in Section 12 - Engine 1. Remove blower housing, flywheel, Specifications. cylinder head, and sump. Discard gaskets. 4. If crankshaft eccentrics are worn, scored, 2.
  • Page 150 SECTION 11 - PISTONS, RINGS AND CONNECTING RODS REMOVE PISTON AND CONNECTING ROD- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -148 DISASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -148 INSPECT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -148 ASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -149...
  • Page 151 PISTONS, RINGS, & CONNECTING RODS Remove Piston and Connecting Rod 4. Using Piston Ring Expander #19340 (Figure 3), remove rings one at a time. 1. Carefully remove any carbon or ridge at Note the order and orientation of the rings top of cylinder bore to prevent ring before removal.
  • Page 152 Engine Specifications. If clearance is Check Connecting Rod greater than shown the piston must be If the crankpin bearing (A, Figure 6) or the piston replaced. pin bearing (B) is scored, the rod must be replaced. 1. Reinstall rod cap and bolts on rod. 2.
  • Page 153 NOTE: For Vertical Model 120000 ONLY, install piston with notch or arrow (A, Figure 8) facing away from “MAG” on the rod. When installed in engine, the notch will face the PTO. Figure 9 4. Fit connecting rod bearing on crankpin journal, then install rod cap with match Figure 8 marks aligned.
  • Page 154 SECTION 12 - ENGINE SPECIFICATIONS MODEL 110000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -152 MODEL 120000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -154 MODEL 150000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -156 MODEL 200000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -158...

  • Page 155: Model 110000 Horizontal Series

    MODEL 110000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance –...
  • Page 156 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5008 in. (12.72 mm) .5040 in. (12.80 mm) Bore Diameter 2.688 in. (68.28 mm) 2.692 in. (68.38 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in.

  • Page 157: Model 120000 Horizontal Series

    MODEL 120000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance –...
  • Page 158 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (12.72 mm) .5040 in. (12.80 mm) Bore Diameter 2.970 in. (75.44 mm) 2.974 in. (75.54 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in.

  • Page 159: Model 150000 Horizontal Series

    MODEL 150000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance –...
  • Page 160 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (12.72 mm) .5040 in. (12.80 mm) Bore Diameter 2.970 in. (75.44 mm) 2.974 in. (75.54 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in.

  • Page 161: Model 200000 Horizontal Series

    MODEL 200000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance –...
  • Page 162 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 2.688 in. (65.10 mm) 2.691 in. (68.33 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in.

  • Page 163: Model 210000 Horizontal Series

    MODEL 210000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .028 in. (.05 - .71 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm) Valve Clearance –...
  • Page 164 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing 1.1825 in. (30.03 mm) 1.184 in. (30.07 mm) Camshaft Bearing .5011 in. (12.72 mm) .5040 in. (12.80 mm) Bore Diameter 3.300 in. (83.82 mm) 3.304 in. (83.92 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .236 in.

  • Page 165: Models 97700 & 99700 Vertical Series

    MODELS 97700 & 99700 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .006 - .012 in. (.15 - .30 mm) Crankshaft End Play .002 - .034 in. (.05 - .86 mm) Spark Plug Gap .030 in. (.76 mm) Alternator Air Gap .010 in.
  • Page 166 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .625 in. (15.88 mm) .622 in. (15.80 mm) Bore Diameter 2.563 in. (65.10 mm) 2.567 in. (65.20 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in.

  • Page 167: Model 110000 Vertical Series

    MODEL 110000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .034 in. (.05 - .86 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance –...
  • Page 168 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (12.72 mm) .504 in. (12.80 mm) Bore Diameter 2.688 in. (68.28 mm) 2.692 in. (68.38 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in.

  • Page 169: Model 120000 Vertical Series

    MODEL 120000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .034 in. (.05 - .86 mm) Spark Plug Gap .020 in. (.50 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance –...
  • Page 170 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Camshaft Bearing .5011 in. (12.72 mm) .504 in. (12.80 mm) Bore Diameter 2.688 in. (68.28 mm) 2.692 in. (68.38 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .249 in.

  • Page 171: Model 210000 Vertical Series

    MODEL 210000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .034 in. (.05 - .86 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance –...
  • Page 172 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing 1.3795 in. (35.04 mm) 1.383 in. (35.13 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 3.437 in. (87.30 mm) 3.441 in. (87.40 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .237 in.

  • Page 173: Model 280000 Vertical Series

    MODEL 280000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .023 in. (.05 - .58 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance –...
  • Page 174 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing 1.3795 in. (35.04 mm) 1.383 in. (35.13 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 3.437 in. (87.30 mm) 3.441 in. (87.40 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .237 in.

  • Page 175: Model 310000 Vertical Series

    MODEL 310000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .010 - .014 in. (.25 - .36 mm) Crankshaft End Play .002 - .023 in. (.05 - .58 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance –...
  • Page 176 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing 1.3795 in. (35.04 mm) 1.383 in. (35.13 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 3.563 in. (90.50 mm) 3.567 in. (90.60 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .237 in.

  • Page 177: Model 330000 Vertical Series

    MODEL 330000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap .008 - .012 in. (.20 - .30 mm) Crankshaft End Play .002 - .020 in. (.05 - .51 mm) Spark Plug Gap .030 in. (.76 mm) Valve Clearance – Intake .003 - .005 in. (.08 - .13 mm) Valve Clearance –...
  • Page 178 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing 1.6248 in. (41.27 mm) 1.629 in. (41.38 mm) Camshaft Bearing .5011 in. (15.88 mm) .504 in. (12.80 mm) Bore Diameter 3.701 in. (94.01 mm) 3.705 in. (94.11 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .237 in.

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