Briggs & Stratton Vanguard 05000 Manual
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Briggs & Stratton Vanguard 05000 Manual

Single cylinder ohv air-cooled engines
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Other Briggs & Stratton
Commercial Power Repair Manuals:
272147 - Vanguard Single Cylinder OHV Air-Cooled Engines
272144 - Vanguard Twin Cylinder OHV Air-Cooled Engines
275429 - Vanguard Twin Cylinder OHV Liquid-Cooled Engines
MS-0750 - Vanguard 3-Cylinder OHV Liquid-Cooled Gasoline Engines
MS-1055 - Vanguard 3-Cylinder OHV Liquid-Cooled Diesel Engines
Quality Starts With A
Master Service Technician
BRIGGS&STRATTON
CORPORATION
Part No. 272147-1/07
POST OFFICE BOX 702
MILWAUKEE, WI 53201 USA
BRIGGSandSTRATTON.COM
©2007 Briggs & Stratton Corporation
Vanguard Single Cylinder
OHV Air-Cooled Engines
1/07
™

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Summary of Contents for Briggs & Stratton Vanguard 05000

  • Page 1 Other Briggs & Stratton Commercial Power Repair Manuals: 272147 - Vanguard Single Cylinder OHV Air-Cooled Engines 272144 - Vanguard Twin Cylinder OHV Air-Cooled Engines 275429 - Vanguard Twin Cylinder OHV Liquid-Cooled Engines MS-0750 - Vanguard 3-Cylinder OHV Liquid-Cooled Gasoline Engines Vanguard Single Cylinder ™...
  • Page 2 SECTION 1- Safety, Maintenance & Adjustments SECTION 2 -Troubleshooting SECTION 3 - Engine Disassembly SECTION 4 - Exhaust Systems SECTION 5 - Fuel Systems & Carburetion SECTION 6 - Governor Systems SECTION 7- Cylinder Heads & Valves SECTION 8 - Starters SECTION 9 - Lubrication Systems SECTION 10 - Cylinders, Covers &...

  • Page 3: Section 2 -Troubleshooting

    FORWARD This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufactured by Briggs &...

  • Page 4: Table Of Contents

    SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS ENGINE SAFETY ................. 5 In The I nterest Of Safety ............. 5 The Safety Alert Symbol ............... 5 Additional Precautions................8 BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM..9 ENGINE MAINTENANCE..............10 Fuel and Oil Recommendations............10 Changing Oil..................

  • Page 6: Engine Safety

    ENGINE SAFETY The Safety Alert Symbol The safety alert symbol ( ) is used to identify safety information about hazards that can result In The Interest Of Safety in personal injury. This repair manual contains safety information A signal word ( , or DANGER WARNING...
  • Page 7 HAZARD SYMBOLS AND WARNING MEANINGS Gasoline and its vapors are extremely Explosion Fire Shock flammable and explosive. Fire or explosion can cause severe burns or death. When adding fuel: Goggles Chemical Explosive • Turn engine OFF and let engine cool at Burns Pressure least 2 minutes before filling or refilling.
  • Page 8 DANGER DANGER Engines give off carbon mono xide, an Running engines produce heat. odorless, colorless, poison gas. Temperature of muffler and surrounding Breathing carbon monoxide can cause areas can exceed 150°F (65°C). Severe nausea, fainting or death . • burns can occur on contact. Start and run engine outdoors.

  • Page 9: Additional Precautions

    WARNING Charging batteries produces hydrogen gas. Do not store or charge and battery near an open flame or devices that utilize a pilot light or can create a spark. WARNING Kerosene and its vapors are extremely flammable and should be handle d with t he same precautions as gasoline.

  • Page 10: Briggs & Stratton Numerical Identification System

    BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM...

  • Page 11: Engine Maintenance

    ENGINE MAINTENANCE minutes to circulate the stabilizer throughout the system. The engine and fuel can then be stored for up to 24 months. Fuel and Oil Recommendations If gasoline has not been treated with a fuel stabilize r prior to storage, it must be draine d fr om the engine into an approved container.

  • Page 12: Changing Oil

    1. Park equipment so engine is level. 2. Remove oil drain plug ([A] Fig. 2). • Drain oil while engine is still warm. 3. Install drain plug. Torque to value listed SEE SECTION 14- ENGINE SPECIFICATIONS. 4. Remove oil filter ([C] Fig. 3), if equipped. •...

  • Page 13: Maintenance Schedule

    MAINTENANCE SCHEDULE W A R N I N G Unintentiona l spa rking can result in fire or electric shock. Unin tentiona l sta rt-up can re sult in entanglem ent, traum atic amp utation or severe lacerations. Before perform ing adjustme nts or repairs: •...

  • Page 14: Air Cleaner Service

    Air Cleaner Service Remove Air Cleaner Assembly 1. Follow steps 1 through 3 listed previously. 2. Remove screws and nuts holding air CAUTION : Never operate an engine with the air cleaner base (F) to carburetor and/or cleaner assembly or air cleaner cartri dge control bracket.
  • Page 15 Fig. 9 Fig. 7 Fig. 8 Fig. 10...

  • Page 16: In-Line Fuel Filter Service

    Install Air Cleaner Assembly ENGINE ADJUSTMENTS 1. Connect breather tube to back side of air cleaner base. Armature Air Gap Adjustments 2. Position base (with new gasket) on carburetor. 1. Rotate flywheel until magnets are away from armature. NOTE: Use new screws with sealant band or 2.

  • Page 17: Control Adjustments

    5. Turn idle mixture screw back to midpoint and release the speed control lever. 6. Install limiter cap (if equipped) using knockout pin (#19135) Fig. 14 Fig. 12 NOTE: (138400) Does not have an idle adjustment screw. Fig. 15 7. Move speed control from SLOW FAST If the engine does not accelerate smoothly:...
  • Page 18 Choke-A-Matic® Throttle Control (161400, 104700, 260700, 261700) (104700, 161400, 260700, 261700, Refer to Figures 16 and 17 that show your 28Q700) engine. Choke control cables are often provided by the 1. Loosen casing clamp screw (A). original equipment manufacturer. Please refer to 2.

  • Page 19: Cooling System Maintenance

    Clean the static screen ([A] Fig. 21) Fig. 19 Fig. 21 Clean the ducting (B) and cylinder fins ([C] Fig. 22), yearly or every of operatio n. Clean 100 hours more often when dust or airborne debris is present. Fig. 20 Cooling System Maintenance CAUTION : Keep engine parts clean to reduce...

  • Page 20: Flywheel Brake Adjustments (104700)

    Flywheel Brake Adjustments (104700) DANGER The flywhe el brake system is part of a safety control mechanism required by some equipment applications. When the operator releases an equip ment control (bail) with the engine running Engines give off carbon monoxide, an at the selection, the flywheel brake must FAST...
  • Page 21 Static Governor Adjustment (161400, 104700, 260700, 261700, 28Q700) 1. Loosen nut holding governor lever ([A] Fig. 25) to governor crank. 2. Rotate throttle linkage from idle to wide open throttle. Note the direction of rotation of the governor arm attached to the throttle linkage.
  • Page 22 3. With the carburetor idle speed screw (A), adjust RPM to 1200 RPM 4. With governed idle screw ([B] Fig. 30), adjust RPM to 1400 RPM Fig. 27 Fig. 28 Fig. 30 NOTE: (050000, 118400, 28Q700) Do not Governed Idle Speed Adjustments have a Governed Idle Speed adjustment.
  • Page 23 Governed Idle RPM Adjustments 5. Remove rod ([C] Fig. 33 th rough Fig. 35). (161400, 260700, 261700) #19480 or #19229 Fig. 31 Install all linkages and springs and be sure that all carburetor adjustments have been made before performing any of the run ning governor adjustments.
  • Page 24 • Some units may have remote throttles furnished by the OEM. 1. Move throttle to FA ST 2. Align holes in the governor control lever gear (A) and governor control plate ([B] Fig. 37 or Fig. 38). 3. Insert 0.125 in. (3.2 mm) diameter rod ([ C] Fig.
  • Page 25 Top No Load RPM, Fixed Speed Top No Load RPM, Fixed Speed Adjustable Adjustable (161400 - Generators) (161400 - No Generators) 1. Turn the speed regulator nut ([A] Fig. 41) until the desired top no load speed is achieved. Fig. 39 1.

  • Page 26: Electro-Magnetic Idle Down Adjustments

    clarity)use the tang bender ([A] Fig. 42) to obtain proper pre-load speed. 5. use the tang bender ([A] Fig. 42) to obtain proper pre-load speed. 6. As soon as pre-load RPM is set, move throttle to IDLE 7. Stop engine. 8.

  • Page 27: Spark Plug Maintenance

    3. With the engine running, apply 12VDC to Use a wire gauge ([A] Fig. 45) to set the spark white connector with the blue plug gap. wires([C]Fig. 44). Extended governor will Set spark plug gap at listed value. be pulled against head of idle down bolt. ([C]Fig.

  • Page 28: Combustion Chamber Deposits

    7. Tighten the jamb nut without moving the adjustment screw Fig. 46, 47, 49, 49. Fig. 46 8. Rotate the crankshaft through a few revolutions and recheck the clearance. Fig. 49 Combustion Chamber Deposits Remove combustion chamber deposits every 500 hours or whenever cylinder head is removed.
  • Page 30 SECTION 2 - TROUBLESHOOTING GENERAL INFORMATION ................31 SYSTEMATIC ENGINE CHECKS..............31 IGNITION SYSTEM..................32 Spark Test ........................32 Spark Miss Test......................32 CARBURETION ..................... 32 COMPRESSION .................... 33 Compression Test ....................33 ELECTRICAL TEST EQUIPMENT ..............35 Digital Multimeters & Settings ..................35 AC Volts.
  • Page 31 ELECTRICAL COMPONENT TESTS ............Diode Test ........................45 Anti-Afterfire Solenoid Test ..................46 Batteries ........................4 7 Installing A Battery ....................47 Charge Indicator Test....................47 Stop Switch Test...................... 48 Rocker Switch Test (085400, 115400, 117400, 138400, 161400, 185400, 235400, 245400) ......................4 9 KEY &...

  • Page 32: General Information

    GENERAL INFORMATION Vibration 1. Bent cutter blades 2. Loose spindles and couplings Most complaints concerning engine operation 3. Bent/broken deck or weldments can be classified as one or more of the following: 4. Bent crankshaft 1. Will not start 5. Loose equipment mounting bolts 2.

  • Page 33: Ignition System

    IGNITION SYSTEM Operate starter and be sure the RPM is 350 or more. Observe tester gap in window of tester. Spark Test If spark jumps tester gap: • Ignition is good. If spark does not jump tester gap: WARNING • Check the ignition coil. Spark Miss Test Prevent accidental starting.

  • Page 34: Compression

    Compression Test Dry plug symptoms: • Leaking carburetor mounting gaskets 1. Run engine for 5 minutes allowing engine to reach operating temperature. • Gummy or dir ty carburetor, fuel line or tank NOTE : If engine is cold or cannot be started, air •...

  • Page 35: Section 4 - Exhaust Systems

    NOTE NOTE : The crankshaft must be held with the : Any air lea ks at the connections or piston at top dead center to seal the combustion fittings of the tester will affect the accuracy of the chamber and eliminate any chance of rotation. If test.

  • Page 36: Electrical Test Equipment

    11. When te st is complete, close air valve. DC Volts Then, pull out knob and turn counterclockwise as far as it will go to Insert the BLACK test lead release pressure in combustion cha mber. into the COM receptacle of ∼...

  • Page 37: Diode Test

    DC Shunt Diode Test When checking DC output on systems over 10 Amps, use a digital multimeter with the DC Shunt Insert the BLACK test lead Fig.12) to avoid blowing a fuse in the 19468] into the COM receptacle of ∼...
  • Page 38 2. Test diode(s). Test in the following sequence: 1. Set meter to DC Output test. See Figure 2. Attach RED test lead clip to DC output terminal connector ([A] Fig. 14). Fig. 15 If meter beeps once: • Diode is OK. If meter makes a continuous tone : •...

  • Page 39: Ac Alternator

    AC Only Alternator 1.2 Amp Unregulated Alternator The AC alternator provides current for headlights The 1.2 amp DC alternator provides current for only. Current for lights is available when the charging a 12 volt battery. The alternator has a engine is running. Use 12 volt lights with a total RED connector (A) and BLACK wire ([B] Fig.

  • Page 40: Amp Regulated Alternator

    4 Amp Regulated Alternator The electrical system must be connected to a charged 12 volt battery to test alternator output. 1. Disconnect battery ground cable from battery negative (-) terminal. 2. Set meter. See Figure 11. 3. Place DC Shunt # on negative 19468 battery post.

  • Page 41: 10 Amp Regulated Alternator

    Fig. 20 Fig. 21 3. Attach BLACK test lead clip to engine 3. Attach BLACK test lead clip to positive (+) ground. battery terminal. AC output should be no less than 40VAC @3600 4. Start Engine. RPM. Output should be 3 – 9 Amps @ 3600 RPM. is found: no or low output •...

  • Page 42: 10 & 16 Amp Regulated Alternator

    If there is continuity: • Reconnect the RED wire with BLACK stripes to regulator/rectifier. 11. Connect multimeter test leads to the two wires not connected to regulator/rectifier. There should be continuity If there is no continuity: • Replace stator. If there is continuity: •...
  • Page 43 Regulator-Rectifie r Test In order to avoid blowing the fuse in the meter, DC shunt tool is required when testing #19359 the 10 & 16 Amp systems. The DC shunt must Fig. 23 be installed on the negative (-) terminal of the battery.

  • Page 44: Dual Circuit Alternator

    Dual Circuit Alternator The bump on the connector indicates the DC output terminal. The dual circuit alternator provides DC for battery charging and AC for the headlights. The battery is not used for the lights, so lights are available if battery is disconn ected or removed. The current from the DC side of the alternator is unregulated and rated at 3 amps.

  • Page 45: Tri-Circuit Alternator

    If meter still displays Output should be no less than 14 volts AC @ 3600 RPM. • Diode is open. If no or low output is found: • Replace the diode. • Replace stator. 4. If diode tests OK, check sta tor for bare wires or other obvious defects.

  • Page 46: Electrical Component Tests

    Test in the following sequence: 1. Set meter. See Figure 5. 2. Attach RED test lead clip to green output terminal ([F] Fig. 31). Fig. 32 Fig. 31 Charging Circuit Test (Red Wire) 3. Attach BLACK test lead clip to engine 1.

  • Page 47: Anti-Afterfire Solenoid Test

    Anti-Afterfire Solenoid Test The anti-afterfire solenoid is controlled by the equipment key switch. With the switch , the solenoid plunger closes, stopping fuel flow through the fixed main jet. With the switch in the posi tions, the solenoid plunger START opens, allowing normal fuel flow.

  • Page 48: Batteries

    Plunger ([A] Fig. 34) should retract freely. When battery connections is removed, plunger should return. Replace solenoid if plunger sticks or doesn’t move. Batteries Handling Instructions Batteries contain corrosive fluid s and toxic materials. Handle with care. • Keep batteries away from children. •...

  • Page 49: Stop Switch Test

    Meter should display or more when If control lever does not contact stop switch 9 volts cranking engine. tang: If less than 9 volts: • Check control cable for adjustment or binding. Bend tang as required or • Replace battery. replace worn parts as needed.

  • Page 50: Rocker Switch Test (085400, 115400, 117400, 138400, 161400, 185400, 235400, 245400)

    Fig. 40 3. Move safety control to . The brake pad lever tab must not con tact the switch tang. 4. Adjust control as necessary or per OEM instructio ns. Fig. 39 8. Move stop switch wire(s) ([A] Fig. 39). Continuity should remain constant.

  • Page 51: Key & Interlock Switches

    2. Operate rocker switch and observe meter If control lever does not contact stop switch readings. tang: 3. The meter should show maximum or very • Check control cable for adjustment or low resistance as the switch is moved binding. Adjust as required or replace back and forth.

  • Page 52: Troubleshooting Six-Terminal Key Switch

    There should be between the terminals shown in Fig. 45.There must be continuity continuity as listed in the table. Replace switch if the re is no between terminals #1, #3, # 6 and the key continuity or continuity exists where it should not. switch case when key switch is OFF.

  • Page 53: Oil Pressure Switch Test

    2. Connect one tester lead to the switch terminal and the other tester lead to the metal body of the switch, Fig. 49. Fig. 47 Fig. 49 There should be continuity when no pressure is applied to the switch. 3. Connect the probe end of the switch to a low pressu re source ([A] Fig.

  • Page 54: Oil Gard® Low-Oil Protection Systems

    1. Oil level must be between the The system may have a module with four wires mark on dipstick. or two w ires FULL (BLUE, BLACK, WHITE and RED) (BLACK, BLACK) 2. Remove pressure switch or 1/8 in. NPTF plug in oil filter adapter. Preliminary Low Oil Checks: 3.

  • Page 55: Troubleshooting Oil Gard® 4-Wire System

    • Check the ignition switch ([H] Fig. 51). If the wire is go od: • Replace the float sensor in the cylinder ([F] Fig. 52). Symptom: Engine will no t start • Disconnect wire at ([C and D] Fig. 52) and start engine.

  • Page 56: Troubleshooting Oil Gard® (161400)

    Troubleshooting Oil Gard® (161400) Fig. 53 Problem Letter Cause Remedy No Spark - Light Flashes Low Oil In Cylinder Refill With Oil Excessive Angle Of Operation Reduce Angle of Operation Worn Oil Gard® Switch Replace Switch No Spark - Light Does Not Wiring Harness Grounded Repair Or Replace Wiring Harness Flash - Correct Amount of...

  • Page 57: Starter Motors

    STARTER MOTORS Check Starter Motor Wiring (138400, 185400, 235400, 245400) Check Starter Motor Drive Required Equipment: (All Models) Multimeter set to DC Volts. 1. When the starter motor is activated, the pinion gear should rise, engage the 1. Charge the battery if the voltage is low. flywheel ring gear and crank the engine.

  • Page 58: Test Key Switch & Solenoid (138400, 185400, 235400, 245400)

    Test Key Switch & Solenoid If continuity is present: (138400, 185400, 235400, 245400) • Proceed to step 4. Required Equipment: If not: Set meter. See Figure 8. • Replace key switch. 1. Turn the key switch 4. Reconnect the connector from the starter 2.

  • Page 59: Check Starter Motor (104700, 161400, 260700, 261700)

    2. Connect starter motor (A), starter switch Remove starter motor from engine. (B), DC shu nt (C) on negative battery 1. Set multimeter to 300mv. See Figure 7. terminal (D) and meter ([E] Fig. 60). 2. Connect starter switch (D) to starter motor (E), battery (C), BLACK lead (G), RED lead (H), shunt (B) and multimeter ([A] Fig.
  • Page 60 SECTION 3 - ENGINE DISASSEMBLY GENE RAL DISASSEMBLY STEPS ............... 61 Blower Housing Removal ( 050000, 085400, 0 86400, 1 15400, 1 17400, 118400, 185400 ) ........................61 Blower Housing Removal (138400, 235400, 245400) ..........61 Blower Housing Removal (104700) ................. 61 Blower Housing Removal (161400) .................
  • Page 61 BREATHER SYSTEMS ................. Breather System (050000, 085400, 086400, 115400, 117400, 118400, 138400, 185400, 235400, 245400) ....................6 7 Remove/Replace Breather System (10470 0) ........................67 Breather System (16140 0) ........................68 Breather System (26070 0, 261700) ....................6 9 Breather System (28Q700) ......................... 70 ELECTRIC STARTER MOTORS ..............

  • Page 62: General Disassembly Steps

    Blower Housing Removal GENERAL DISASSEMBLY STEPS (138400, 235400, 245400) The sequence of actions required to NOTE : Disconnect the wires ([A] Fig. 2) for the disassemble the outer components of an engine voltage regulator and key switch (if installed). vary from model to model. As a general rule, it is most efficient to remove only those items that prevent access to a system or part.

  • Page 63: Blower Housing Removal (161400)

    Blower Housing Removal Blower Housing Removal (161400) (28Q700) 1. Remove the five screws ([A] Fig. 4) that 1. Remove the oil cap and dipstick secure the blower housing to the engine assembly. block. 2. Remove the four screws (A) that secure the rotating screen.

  • Page 64: Control Brackets

    7. Remove the two screws that hold the rear housing mounting bracket ([B] Fig. 8). Fig. 9 Fig. 8 NOTE : Leave the cotter pin ([C] Fig. 9) in the 8. Remove inner blower housing and set governor shaft to prevent it from falling into the aside.

  • Page 65: Control Bracke T Removal (161400)

    Control Bracket Removal 3. Remove the screws holding the control bracket ([A] Fig. 11). (260700, 261700) NOTE : For better access to the control bracket, remove the oil filter adapter first. SEE SECTION 3- OIL FILTER ADAPTER. 1. Remove the links and springs from the governor lever ([A] Fig.

  • Page 66: Control Bracket Removal (28Q700)

    Control Bracket Removal ENGINE BAFFLES (28Q700) Engine Baffle Removal NOTE : Part of the control bracket assembly must be removed in order to remove the (05000, 085400, 086400, 115400, carburetor. SEE SECTION 5- REMOVING 117400, 118400, 138400, 185400, CARBURETOR. 235400, 245400) The engine baffles for the models listed above To remove remaining control bracket consist of stamped sheet metal parts (A) that...

  • Page 67: En Gine Baffle Rem Oval (161400)

    Engine Baffle Removal (161400) NOTE : The l ower baffle still has one mounting The main cylinder baffle is removed with the bolt that will be removed when the flywheel is engine control bracket. SEE SECTION 3- removed. SEE SECTION 3- FLYWHEEL CONTROL BRACKET REMOVAL..

  • Page 68: Breather Systems

    BREATHER SYSTEMS Briggs & Stratton engines use a breather valve to maintain and control a pulsating vacuum in the cylinder or sump. The vacuum helps to control oil leakage past piston rings, valve guides, oil seals, governor lever shaft and gaskets. The breather valve is a fiber disc or reed that closes on the piston's up stroke and opens on the piston's down stroke.

  • Page 69: Breather System (16140 0)

    Breather System 2. Remove breather cover ([A] Fig. 24) from top of cylinder. (161400) 1. Remove four screws that hold valve cover NOTE: Fiber disc valve cannot be checked with (A) and gaske t (B). gauge. 2. Remove valve cover. Breather assembly (C) and gaske t ([D] Fig.
  • Page 70 3. Install screws. Torque screws to listed CAUTION : Do not force the gauge. The fiber value. SEE SECTION 14- ENGINE disc valve is held in place by a retainer that will SPECIFICATIONS. distort if pressure is applied to the disc. Breather System (260700, 261700) NOTE: (260700, 261700)

  • Page 71: Breather System (28Q700)

    2. Remove two screws holding breather. Remove breather and gasket and discard gasket. 3. A 0.045 in. (1.14 MM.) wire gauge (A) should not enter the space between the fiber disc valve (B) and the body (C). The breather holes ([D] Fig. 34) must be open. 4.

  • Page 72: Electric Starter Motors

    Electric Starter Removal ELECTRIC STARTER MOTORS (104700, 260700, 261700, 28Q700) 1. Remove the two bolts that secure starter Electric Starter Removal to cylinder ([A] Fig. 37 , 38,39). (138400, 235400, 245400) 1. Remove negative battery cable. 2. Disconnect the wire from the key switch. 3.

  • Page 73: Magnetron® Ignition Systems

    Ignition System Removal 41) or other strap wrench or socket-type flywheel holder, determined above. (050000, 085400, 086400, 115400, 3. Turn the flywheel nut CCW with a 1/2 in. 117400, 118400, 235400, 245400, breaker bar (B) and socket to remove. 161400, 104700, 260700, 261700, 28Q700) 1.

  • Page 74: Flywheel Removal (10470 0)

    Flywheel Removal (104700) 1. Disconnect the tension spring on the flywheel brake from its anchor ([A] Fig.45). Fig. 43 Fig. 45 2. Remove the flywheel nut with a strap wrench and a 1in. socket. 3. Using tool , remove flywheel and #19203 drive key.

  • Page 75: Oil Filter Adapters

    4. Install tool as shown ( [A] Fig. 47) #19203 and tighten the nuts evenly until the flywheel comes free of the crankshaft. Fig. 49 2. Use a new gasket and reposition adapter. Fig. 47 3. Torque screws to listed value as shown in Fig.
  • Page 76 SECTION 4 - EXHAUST SYSTEMS GENERAL INFORMATION ................Inspecting Exhaust Systems..................77 REMOVE/INSTALL EXHAUST SYSTEM (050000, 085400, 115400, 117400, 118400, 138400, 185400, 235400, 245400) ........REMOVE/INSTALL EXHAUST SYSTEM (104700) ........REMOVE/INSTALL EXHAUST SYSTEM (161400) ........REMOVE/INSTALL EXHAUST SYSTEM (260700, 261700) ......REMOVE/INSTALL EXHAUST SYSTEM (28Q700) ........

  • Page 78: General Information

    GENERAL INFORMATION To meet the various requirements of the original equipment manufacturers (OEMs), some engines are shipped without exhaust systems. Exhaust systems for these engines are serviced and supplied by the OEM. Contact the original equipment manufacturer for speci fic service information on non-Briggs &...

  • Page 79: Remove/Install Exhaust System (050000, 085400, 115400, 117400, 118400, 138400, 185400, 235400, 245400)

    REMOVE/INSTALL EXHAUST SYSTEM (050000, 085400, 115400, 117400, 1 18400, 138400, 1 85400, 235400, 245400) A typical muffler installation for the models listed above is shown in (Fig. 2). Fig. 4 2. Remove two muffler nuts ([A] Fig. 5). Fig. 2 To remove the muffler assembly: 1.

  • Page 80: Remove/Install Exhaust System (104700)

    4. Check for proper alignment and any 4. Remove backplate and gasket. SEE interference issues. SECTION 3-ENGINE DISASSEMBLY. 5. Torque muffler nuts to listed values. 5. Take off the two screws (A) that hold the exhaust elbow shield ([B] Fig. 8) and 6.

  • Page 81: Remove/Install Exhaust System (161400)

    To install the 104700 muffler system: REMOVE/INSTALL EXHAUST SYSTEM (161400) NOTE : U se valve lubricant on all (#93963) exhaust system threads to prevent galling of the threads and ease future disassembly. 1. Position new gasket, exhaust elbow and screws ([A] Fig. 10). 2.
  • Page 82 3. Take the muffler guard bracket ([A] Fig. To install muffler to model 161400: 13) off of the muffler. 1. Assemble the lower portion of the exhaust manifold (with its gasket) and two bolts ([A] Fig. 16) to the muffler and finger- tighten.

  • Page 83: Remove/Install Exhaust System (260700, 261700)

    When all components are properly aligned; REMOVE/INSTALL EXHAUST 4. Torque manifold bolts ([A] Fig. 18) to listed SYSTEM values. SEE SECTION 14- ENGINE (260700, 261700) SPECIFICATIONS. 5. Torque bracket bolts ([B] Fig. 18) to listed values.SEE SECTION 14- ENGINE SPECIFICATIONS. 6.
  • Page 84 that secure the exhaust elbow cover (Fig. 22). Fig. 22 5. With the clamp loose, work the muffler Fig. 24 free of manifold. 6. Slide exhaust elbow cover free of exhaust 10. Inspect the exhaust system components. manifold. SEE SECTION 4- EXHAUST SYSTEMS. To install muffler assembly: NOTE : If further engine disassembly is required:...

  • Page 85: Remove/Install Exhaust System (28Q700)

    3. Place exhaust manifold elbow on gasket 11. Torque muffler clamp screw and nut to in heat shield and install mounting bolts. listed values.SEE SECTION 14- ENGINE ([A] Fig. 26) SPECIFICATIONS. 12. Torque lower bracke t bolts to listed values. SEE SECTION 14- ENGINE SPECIFICATIONS.
  • Page 86 5. Remove muffler adapter screws ([A] Fig. 6. Bend tabs ([A] Fig. 32) to secure the bolts. 30). ™ A T-40 TORQUX bit is required. Briggs & Stratton “TORQUX STAR BITS.” (#19442) Fig. 32 Fig. 30 6. Inspect the exhaust system components. SEE SECTION 4- EXHAUST SYSTEMS.
  • Page 88 SECTION 5 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEM CLEANING AND INSPECTION..........……….. FUEL TANKS, FITTINGS AND LINES ............……….. Fuel System (050000, 118400)................………...90 Fuel System (085400, 115400, 117400, 138400, 185400, 235400, 245400) ..………...90 Fuel System (104700) ....................………...93 Fuel System (161400) ....................………...94 Fuel System (260700, 261700)................………...96 Fuel System (28Q700).....................………...97 CARBURETOR SERVICE PROCEDURES (0500 00, 085400, 086400,...

  • Page 90: Fuel System Cleaning And Inspection

    WARNING FUEL SYSTEM CLEANING AND INSPECTION Gasoline and its vapors are extremely flammable and explosive. CAUTION: Do not use carburetor cleaner on Fire or explosion can cause severe burns or non-metallic parts. Use carburetor cleaner only death. after removing plastic and rubber parts. When adding fuel: •...

  • Page 91: Fuel Tanks, Fittings And Lines

    FUEL TANKS, FITTINGS AND 6. Remove tank mounting bolts.Keep hoses with tank. LIN ES 7. Open hose clamp and remove hose from tank outlet fitting and set aside. Fuel System (050000, 118400) 8. Remove shut-off valve and bracket if Removal necessary.
  • Page 92 3. Open carburetor bowl drain screw and 12. Release clamp and disconnect hose drain remaining fuel into appropriate from tank outlet fitting. Set aside. container. 13. Release clamp and disconnect hose at 4. Close bowl drain screw. carburetor fitting. 5. If equipped with metal key switch cover 14.
  • Page 93 Fig. 6 Fig. 8 3. Slide carburetor from its mounting studs and disconnect governor link ([A] Fig. 7) Inspect Fuel System. SEE SECTION 5- FUEL and anti-backlash spring ([B] Fig. 7) when SYSTEM CLEANING AND INSPECTION. carburetor is free. Installation 4.

  • Page 94: Fuel System (104700)

    11. Torque screws and nuts to values listed. 12. Position trim plate and install short screw on left side and long screw on right side. 13. Install separate control cover (if equipped) and torque screws to values listed. 14. Install throttle control kno b. 15.

  • Page 95: Fuel System (161400)

    8. Install tank using long screw next to brake assembly and short screws underneath. 9. Torque screws to values listed. 10. Position brake assembly cover and install phillips screws to values listed. 11. Install hose assembly to tank fitting and carburetor fitting with new clamps.
  • Page 96 10. Remove bo lts ([A] Fig. 15) that secure Inspect Fuel System. SEE SECTION 5- FUEL shut-off valve. SYSTEMS AND CARBURETION. Installation For torque values: SEE SECTION 14- ENGINE SPECIFICATIONS. 1. Install the carburetor assembly as shown in (Fig. 17). Fig.

  • Page 97: Fuel System (260700, 261700)

    9. Fit left end of trim plate into slot in air 6. Loosen screw at hose clamp, if equipped, cleaner base. on control bracket. 10. Start screws in holes along trim plate. 7. Remove pump screws and remove pump and hose assembly from engine. 11.

  • Page 98: Fuel System (28Q700)

    2. Disconnect the clamps at the carburetor fitting ([A] Fig. 21) and the crankcase ([B] Fig. 21). 3. Remove the bolts ([C] Fig. 21) that secure the pump to its mounting bracket. Fig. 20 2. While sliding carburetor on its mounting studs, install the governor link and anti- backlash spring (Refer back to Fig.
  • Page 99 Fig. 25 2. Install air intake manifold and torque bolts to values listed. Fig. 23 3. Slip mounting bolts through carburetor 9. Whi le removing the carburetor, disconnect and connect governor lever with its anti- the governor link with anti-backlash spring backlash spring and the choke link.

  • Page 100: Carburetor Service Procedures

    CARBURETOR SERVICE Disasse mbly 1. Remove float bowl mounting screw (A), PROCEDURES washer (B) and float bowl ([C] Fig. 27). (050000, 085400, 086400, 115400, 117400, 1 18400, 104700, 1 61400, 185400, 260700, 261700) Some engines were built using both Nikki and Walbro carburetors.
  • Page 101 Fig. 31 9. Remove screws (A) holding choke pl ate Fig. 29 ([B] Fig. 32) and remove. The float hinge pin ([A] Fig. 30) is a wedge fit. 5. Tap the small end of the pin (B) with a center punch until it is loo se. 6.
  • Page 102 Fig. 35 To clean carburetor: SEE SECTION 5- FUEL SYSTEMS AND Fig. 33 CARBURETION. not ending in NOTE: Engines with type numbers A1 or E1 have removable idle and main air jets. Remove jets ([A] Fig. 34 ) with carburetor jet (#19280) screwdriver Assembly...
  • Page 103 7. Install choke shaft ([A] Fig. 39) into carburetor. NOTE : Make sure the choke shaft retainer stop (B) is between the carburetor body stop (C) and the detent spring ([D] Fig. 39) in order to install the choke plate next. Fig.
  • Page 104 Fig. 41 Fig. 43 CAUTION: Emulsion tube ([A] fig. 42) must be installed before main jet (B) or damage to th e 15. Install spring (A) to groove in fuel needle threads of the emulsion tube will result. valve ([B] Fig. 44). 9.
  • Page 105 hinge (C) and both hinge pin posts ([D] 21. Install float bowl gasket ([A] Fig. 48) to Fig. 46). carburetor body groove. 22. Make sure the gasket does not twist or kink. Fig. 48 Fig. 46 23. Position bowl drain ([A] Fig. 49 ) as shown.

  • Page 106: Carburetor Service - Mikuni (104700)

    Type Numbers Not Ending In A1Or E1 Model Standard High Standard Hi g h Seri es Altitude Pilot Altitude Main Jet Main Jet Pilot Jet 085400 71.3 67. 5 42.5 115400** 72.5 42.5 115400* 72.5 42.5 37.5 117400 81.3 78. 8 42.5 41.3 185400**...
  • Page 107 3. Push float hinge pin (A) out of th e hinge After Date Code 90042833 posts (B). Remove float (C) and needle Remove the fixed main jet. Remove the main assembly ([D] Fig. 53). emulsion tube with Carburetor Jet Screwdriver, 4.
  • Page 108 11. Remove air jets (if removable) on either Assembly side of the choke plate opening with Use new seals and gaskets when assembling 19280 Carburetor Jet Screwdriver # carburetor. 12. Note the p osition of the throttle plate. 1. Install throttle shaft seal ([B] Fig. 59) to 13.
  • Page 109 Fig. 62 Fig. 60 8. Connect one spring end ([A] Fig. 61) to the carburetor body (B), the other end (C) 9. Place choke plate ([A] Fig. 63) on choke to the choke lever ([D] Fig. 61) to hold shaft with stamped number (B) tow ard the choke plate open.
  • Page 110 Fig. 64 15. Slide fuel need le valve assembly (A) on to tab (B) of float ([C] Fig. 65). Fig. 66 17. Insert the float hinge pin (A) through the float hinge and both hinge pin posts ([B] Fig. 67). Center the hinge pin in the hinge pin posts.

  • Page 111: Carburetor Service - Mikuni

    Fig. 70 Identifying Main Jets (104700) Fig. 68 Model Series Standard Jet High Altitude Jet If not parallel: Before 92.5 • Replace the fuel inlet valve, float and 90091033 hinge pin. After 107.5 102.5 90090933 19. Install the emulsion tube (A) and then the main jet ([B] Fig.
  • Page 112 Fig. 73 4. Remove the pin, float and inlet needle Fig. 71 assembly. Disasse mbly Remove fixed main jet from end of 1. Remove the float bowl mounting screw fuel pick up tube first, Fig. 74, then (C), washer (B) and float bowl ([A] Fig. remove the emulsion tube ([A] Fig.
  • Page 113 Fig. 75 6. Remove pilot jet ([A] Fig. 76) with 19062 Fig. 77 screwdriver # 9. Unhook the choke shaft spring. 10. Remove choke plate screws ([A] Fig.78). 11. Remove choke plate (B), shaft (C), spring (D), washers (if used),se al (E), bushings (F) Fig.
  • Page 114 15. Remove and inspect the bushing ([F] Fig. 80). Replace if worn or damaged. Remove or install jets ([A] Fig. 79) with (#19280) carburetor jet screwdriver Fig. 80 To clean carburetor: SEE SECTION 5- FUEL SYSTEMS AND Fig. 79 CARBURETION. Inspect the idle mixture screw.
  • Page 115 spring should hold the choke plate open Fig. 84. Fig. 81 5. Lay the throttle plate (A) on the shaft with the stamped numbers (B) to the left. Install two screws ([C] Fig. 82). Fig. 84 10. Place choke plate (A) on choke shaft with stamped nu mber(s) (B) facing opposite the fuel inlet (C).
  • Page 116 Fig. 88 15. Slide fuel need le valve assembly (A) on to tab (B) of float ([C] Fig. 89). Fig. 86 Place emulsion tube in fuel pick up first, then install fixed main jet ([A] Fig. 87) 13. Install the emulsion tube (B) with jet #19062 screwdriver , (C) and install the...
  • Page 117 Fig. 92 22. Install idle mixture screw ( D) and spring Fig. 93. Turn screw in until it just seats. Do not tighten. Fig. 90 1-1/2 turns 23. Back screw off 18. Turn the carburetor body upside down. 24. Install limiter ([E] Fig. 93), if used. The floa t (A) should be parallel to the float bowl mounting surface ([B] Fig.

  • Page 118: Carburetor Service - Mikuni (260700, 261700)

    Identifying Main Jets (161400) Model Series Standard Jet High Altitude Jet Before 92.5 90091033 After 107.5 102.5 90090933 Fig. 94 These carburetors are equipped with two styles of choke shafts: • Plastic shaft with snap-in choke plate • Metal shaft with screw-mounted choke plate.
  • Page 119 Disasse mble 1. Remove fuel bowl mounting screw (C) and washer (B). Remove the fuel bowl ([A] Fig. 95). Fig. 95 2. Remove float bowl gasket ([A] Fig. 96). Fig. 97 5. Remove the main jet (A) from the fuel pick-up tube.
  • Page 120 Fig. 101 11. Remove the air jets located on either side of the choke plate opening with # 19280 carburetor jet screwdriver 12. Note the position of the throttle plate for reinstallation. 13. Remove the throttle shaft screws ([B] Fig. 99 Fig.
  • Page 121 shaft. Secure with two screws ([ G] Fig. 105). Fig. 103 15. Using carburetor nozzle screwdriver # 19280 , remove main carburetor emulsion tube ([A] Fig. 104). Fig. 105 1. Install throttle shaft seal (A) to carburetor body. Install seal with grooved side out. 2.

  • Page 122: Carburetor Service Procedures

    CARBURETOR SERVICE PROCEDURES (138400) Carburetor Service - Nikki (138400) CAUTION: Do not use wires, drills or other devices to clean out metering holes or passages. NOTE : Use compressed air at a moderate Fig. 107 pressure setting (5-7 PSI). Blow in both directions to clean out all openings and 6.
  • Page 123 (D) and float bowl screw washer ([B] Fig. 109). Fig. 109 Fig. 111 2. Remove float hinge pin (A), ca rburetor 6. Remove screw ([A] Fig. 112). float (B) and float needle valve ([C] Fig. 7. Remove, throttle plate (B), throttle shaft 110).
  • Page 124 Fig. 113 9. Remove idle speed screw ([A] Fig. 114). Fig. 115 TO CLEAN CARBURETOR: SEE SECTION 5- FUEL SYSTEMS AND CARBURETION. Assemble 1. Install pilot jet ([A] Fig. 116). Fig. 114 10. Remove pilot jet ([A] Fig. 115). Fig. 116 2.
  • Page 125 (C) on choke lever detents ([D] Fig. 117). Rotate shaft closed. 3. Place choke plate (E) on choke shaft (B), secure with screw ([F] Fig. 117). Fig. 119 NOTE: For correct main jet and pilot jet identification and selection. 10. Insert the inlet needle (A) into the slot on Fig.

  • Page 126: Carburetor Service Procedures (235400, 245400, 28Q700)

    12. Place new float bowl gasket (A) in NOTE : Use compressed air at a moderate carburetor body groove, Fig. 119. pressure setting (5-7 PSI). Blow in both directions to clean out all openings and 13. Place float bowl (B) on carburetor with passages.
  • Page 127 Fig. 126 15. Remove float hinge pin (A), float ([B] Fig. 127), and inlet needle. Float hinge pin is a drive fit and one end of the pin has two flats. Fig. 124 16. Tap the end opposite the flats with a center pun ch ([C] Fig.
  • Page 128 throttle lever should be to the left of the idle speed screw. 9. Rotate the throttle shaft CW until the idle stop is against the idle speed screw. 10. Place the throttle plate (L) on to the throttle shaft with the numbers (M) facing into the carburetor, on the right.

  • Page 129: Carburetor Service - Nikki (28Q700)

    2. Place a new bowl gasket on the carburetor body. 3. Place the bowl on the carburetor. Install the float bowl screw. 4. Torque the screw to values listed. Identifying Main Jets (235400, 245400, 28Q700) High Altitude Model Series Standard Jet Fig.
  • Page 130 9. Remove two screws (A) and throttle plate (B) and pull the throttle shaft ([C] Fig. 136) from the carburetor body. Fig. 133 6. Remove the float base gasket ([M] Fig. 134) from the carburetor body. Fig. 136 10. Remove the idle mixture screw with spring (D) and the idle speed screw with spring ([E] Fig.
  • Page 131 Assembly 1. If separated, place the throttle return spring ([A] Fig. 140) inside the large foam seal (B). 2. Slide the seal and spring on to the choke shaft (C) with the top of the spring (D) contacting the choke shaft lever ([E] Fig.140).
  • Page 132 The dimples position the choke plate on the shaft. Fig. 144 12. Install idle mixture screw ( O) with spring and the idle speed screw ([P] Fig. 145) Fig. 142 with spring . 13. Turn each screw until the head of the 8.
  • Page 133 20. Insert the spring ([Y] Fig. 150) to the bottom of the float assembly. Fig. 146 Fig. 149 18. Place gasket (U) on carburetor body ([V] 21. Place the fuel bowl (A) on the carburetor Fig. 147). base ([B] Fig. 150). 22.
  • Page 134 SECTION 6 - GOVERNOR SYSTEMS MECHANICAL GOVERNOR SYSTEMS............Governor System Operation (Typical) ..............135 Governed Speed (RPM) Limits ................136 GOVERNOR COMPONENTS (050000, 118400) .......... Governor Component Removal ................136 Governor Component Inspection ................137 Governor Component Installation ................138 GOVERNOR COMPONENTS (085400, 086400, 115400, 117400, 138400, 185400, 235400, 245400) ................

  • Page 136: Mechanical Governor Systems

    MECHANICAL GOVERNOR series of interconnecting linkages and springs ([D] Fig. 3). SYSTEMS Governor System Operation (Typical) A governor system operates by transmitting engine RPM through a pair of flyweights (A) th at retract and extend a sliding cup ([B] Fig. 1). Fig.

  • Page 137: Governed Speed (Rpm) Limits

    Governed Speed (RPM) Limits 2. While holding governor shaft (B), loosen nut (A) as shown in Fig. 4. In order to comply with specific top governed speed limits, Briggs & Stratton supplies equipment manufacturers (OEM)s with engines that have adjustable top speed limits. These limits are set to OEM specifications.

  • Page 138: Governor Component Inspection

    11. Tap the shaft through the cylinder housing with a small punch or equivalent (Fig. 8). Fig. 6 6. Remove cylinder cover. See SECTION 10- CYLINDERS, COVERS AND SUMPS. 7. Rotate the engine crankshaft so the counter weight ([J] Fig. 7) is in position shown.

  • Page 139: Governor Component Installation

    Governor Component Installation 5. Install E-clip ([A] Fig. 11) on governor crank and push crank up through cylinder 1. Make sure the flyweights, spool and gear housing and install thrust washer. Make move freely. sure the paddle of the governor shaft rests 2.

  • Page 140: Governor Component Removal

    13. Ensure that you can feel the governor 4. Rotate crankshaft ([I] Fig. 14) as crank paddle make contact with the necessary for adequate clearance to governor cup on governor gear. remove governor crank (F). 14. While holding the paddle against the governor cup, tighten the upper locknut.

  • Page 141: Governor Component Inspection

    10. Remove thrust washer. Fig. 16 Governor Component Inspection See SECTION 6- GOVERNOR SYSTEMS. Fig. 18 Governor Gear Shaft - Remove and Governor Component Installation Replace 1. Place thrust washer on governor gear 1. Press governor gear shaft (K) out of shaft.

  • Page 142: Governor Components (104700, 161400, 260700, 261700, 28Q700)

    9. Install lower nut (C) on governor crank (F) with serrations UP until nut bottoms on threads of the crank. Tighten nut (left hand threads), Fig. 19. 10. Place governor lever (B), on governor crank (F). 11. Install top nut ([A] Fig. 19) with serratio ns down on l ever.

  • Page 143: Governor Component Inspection

    5. Inspect bushing for burrs or foreign materi al. f35p15 Fig. 22 5. Remove spring clip ([A] Fig. 23). Fig. 24 6. Push governor crank down through If discrepancies are found: cylinder and out of bearing. • Replace the go vernor gear as a complete 7.

  • Page 144: Governor Component Installation

    4. Thoroughly clean away all chips and cutting debris. Fig. 27 Fig. 25 Governor Component Installation 1. Press in new seal. 2. Slide governor crank ([A] Fig. 26) up through the bushing and position as shown in the appropriate illustration. CAUTION Ensure that governor crank is in the position illustrated.
  • Page 145 4. Install governor gear. Ensure that counterweights ([A] Fig. 30) move freely without binding. Fig. 30 5. Install cylinder cover or sump. See SECTION 10- CYLINDERS, COVERS AND SUMPS. NOTE: (161432 Type 0080-01) When assembling governor lever assembly (A), ensure that tab on strike plate ([B] Fig.
  • Page 146 SECTION 7 - CYLINDER HEADS AND VALVES ROCKER ARM ASSEMBLIES ............... Remove Rocker Arm Assembly (050000, 118400)..........147 Remove Rocker Arms (085400, 086400, 115400, 117400, 138400, 185400) ..147 Remove Rocker Arm Assembly (235400, 245400)..........147 Remove Rocker Arms (104700, 161400, 260700, 261700, 28Q700) .....148 CYLINDER HEAD REMOVAL................
  • Page 147 CYLINDER HEAD ASSEMBLY ..............Install Push Rod Guides and Studs (085400, 104700, 115400, 117400, 118400, 28Q700) .........................1 53 Installing Valve Springs & Retainers (050000, 235400, 245400) ......154 Install Valve Springs And Retainers (104700, 28Q700) ....................155 Install Valve Springs And Retainers (085400, 115400, 117400, 138400, 185400) ............155 Install Valve Springs And Retainers (161400, 260700, 261700) ..................

  • Page 148: Rocker Arm Assemblies

    Remove Rocker Arms ROCKER ARM ASSEMBLIES (085400, 086400, 115400, 117400, 138400, 185400) Remove Rocker Arm Assembly 1. Remove the jamb nut (A) from the rocker (050000, 118400) arm stud. 1. Remove the four bolts ([A] Fig. 1) that 2. Remove the rocker arm pivot (B) from the mount the rocker arm assembly to the studs and remove the rocker arms ([C] cylinder head.

  • Page 149: Remove Rocker Arms (104700, 161400, 260700, 261700, 28Q700)

    6. Remove valve adjusting screw and nut 4. Remove rocker arm studs (D) and push ([F] Fig. 4) from rocker arm. rod guides ([E] Fig. 5), if equipped. Fig. 5 Fig. 4 Remove Rocker Arms (104700, 161400, 260700, 261700, CYLINDER HEAD REMOVAL 28Q700) 1.

  • Page 150: Remove Cylinder Head (104700, 161400, 260700, 261700)

    3. Make note of an y discrepancies and discard old head gaske t. Remove Cylinder Head (104700, 161400, 260700, 261700) 1. Remove head bolts ([A, B, C & D] Fig.7) and cylinder head. NOTE : Engines manufactured before 940501xx were equipped with sealing washers under cylinder head bolts (A) and ([C] Fig.

  • Page 151: Valves

    Remove Valves VALVES (085400, 086400, 115400, 117400, 138400, 185400, 161400, 260700, Remove Valves 261700, 28Q700) (050000, 086400, 118400, 104700) 1. Place cylinder head on a solid and flat 1. Place cylinder head on a solid and flat work surface. work surface. 2.

  • Page 152: Inspect Cylinder Head Components

    INSPECT CYLINDER HEAD 3. If an area is questionable, use a feeler gauge to measure the amount of COMPONENTS distortion as shown in Fig. 13. Inspect Push Rods (All Models) Check pushrods for straightness as shown in Fig. 11. Fig. 11 Replace if bent.

  • Page 153: Inspect Va Lve Stem / Valve Guide Tolerance (All Models)

    Inspect Valve Stem / Valve Guide Reface Valves and Seats (All Models) Tolerance (All Models) Valve faces can be resurfaced using a commercially available valve grinding tool. 1. Measure the valve stem at the locations Briggs & Stratton does not recommend this illustrated in ([A &...

  • Page 154: Cylinder Head Assembly

    4. Replace valve seat if dimension ([B] Fig. 16) is less than 1/64” (.4mm). Fig. 16 Replace broken, distorted, or worn valve springs. Fig. 18 2. Coat rocker arm stud threads with Loctite #242 sealant. 3. Install rocker arm studs. CYLINDER HEAD ASSEMBLY •...

  • Page 155: 28Q700)

    Two piece valve stem seals were used on early Be sure Valve Guide Lubricant is not on #93963 production intake valves (28Q700), Fig. 19. valve face, valve seat, or exposed end of valve stem. • Gasket seal or washer is used on intake valve only, (085400, 115400, 117400, 118400, 185400, 235400, 245400, 28Q700).

  • Page 156: Install Valve Springs And Retainers

    Make sure the keeper is completely seated in the 3. Place retainer on spring. Use Valve Spring groove of the valve stem. Compressor, to press #19347 ([A] Fig. 24) on retainer and compress spring. • Repeat this process for the remaining valve.
  • Page 157 • Fig. 31 ( 138400) Torque cylinder he ads in three steps: For example: For final torque of 220 lb-in. (25 Nm) • First step 75 lb-in. (9 Nm) • Second step 150 lb-in. (17 Nm) • Final step 220 lb-in. (25 Nm) CAUTION : Do not tighten any screw to the final torque before all screws have been tightened to...

  • Page 158: Install Rocker Arms

    INSTALL ROCKER ARMS Install Push Rods & Rocker Arms (104700, 161400, 260700, 261700, 28Q700) 1. Install push rods (A) through push rod guide. Make sure push rods are seated in valve tappets ([B] Fig. 32). Fig. 30 Fig. 32 2. Remove all lubri cant from end of valve stems.

  • Page 159: Install Push Rods & Rocker Arms (235400, 245400)

    Install Push Rods & Rocker Arms 6. Tighten the jamb nut without moving the adjustment screw. (235400, 245400) 1. Install push rods. Be sure each push rod is seated in its tappet. 2. Place rocker arm shaft assembly on cylinder head making sure that push rod sockets engage valve adjusting screws.
  • Page 160 5. Adjust as required. Fig. 36 6. When valves are adjusted, hold rocker nut and tighten rocker ball screw or nut to torque listed. 7. Recheck clearance and adjust, if required.
  • Page 162 SECTION 8 - STARTERS REWIND STARTERS………………………............ Remove Rewind Starter Housings (Typical) ............163 Install Rope And Handle Assembly................1 66 Disassemble Rewind Starter (161400, 235400, 245400) ........166 Inspect Rewind Starter (161400, 235400, 245400) ..........167 Assemble Rewind Starter (161400, 235400, 245400) ..........167 Disassemble Rewind Starter With Metal Pawls (104700) ........168 Inspect Rewind Starter With Metal Pawls (104700)..........

  • Page 164: Rewind Starters

    Install Rope And Handle Assembly REWIND STARTERS Handles With Inserts Remove Rewind Starter Housings NOTE : Some units do not use an insert in the (Typical) handle. 1. To determine proper length of starter rope, 1. Remove four screws (A) holding rewind see SECTION 14- ENGINE starter housing ([B] Fig.
  • Page 165 Disassemble Rewind Starter 9. Wiggle pulley until spring comes free of its anchor. (115400, 117400, 118400, 138400, 10. Carefully lift out pulley and spri ng 185400, 260700, 261700) assembly, (Fig. 5). WARNING NOTE : Do not remove spring from pulley. Pulley and spring are serviced as an assembly.
  • Page 166 4. Position springs (A) over posts (B) in pulley. Install pawls ([C] Fig. 9). Assemble Rewind Starter (115400, 117400, 118400, 138400, 185400, 260700, 261700) 1. Lay starter housing flat on work bench. 2. Position pulley and coil spring assembly (A) over center pivot post ([B] Fig. 7) in starter housing.

  • Page 167: Disassemble Rewind Starter (161400, 235400, 245400)

    Disassemble Rewind Starter (161400, 10. Lift out pulley. The starter spring cup (D) will normally remain in starter housing ([E] 235400, 245400) Fig. 12). 1. Pull starter rope out as far as it will go. 2. Lock pulley to prevent it from retracting in starter housing.

  • Page 168: Inspect Rewind Starter (161400, 235400, 245400)

    Inspect Rewind Starter (161400, Assemble Rewind Starter (161400, 235400, 245400) 235400, 245400) 1. Inspect starter pulley for cracks, rough 1. Place spring and cup in pulley, with outer edges, wear or bu rrs in pulley groove (A), end of spring (A) between two wide wear on spring cup lugs (B) and center spaced lugs (B) in pulley and spring cup hole ([C] Fig.

  • Page 169: Disassemble Rewind Starter With Metal Pawls (104700)

    8. Insert rope through housing and hole in pulley. 9. Secure rope to pulley with overhand knot. 10. Remove pu lley lock and allow spring to slowly retract rope into rewind starter assembly. 11. Install handle. See SECTION 8- Fig. 3. Fig.

  • Page 170: Inspect Rewind Starter With Metal Pawls (104700)

    9. Remove brake spring (C). 10. Rotate pulley and spring assembly ([D] Fig. 22) until pulley feels free. 11. Lift out pulley and spring assembly. NOTE : Pulley and spring with retainer are serviced as an assembly. Do not remove spring retainer fr om pulley.

  • Page 171: Disassemble Rewind Starter (28Q700)

    4. Install pawls (A), pawl springs (B), and 9. Insert rope through housing and hole in brake spring ([C] Fig. 26). pulley. 10. Secure rope to pulley with overhand knot. See SECTION 8- FIG. 3. 11. Remove pu lley lock and allow spring to slowly retract rope into rewind starter assembly.

  • Page 172: Assemble Rewind Starter (28Q700)

    Assemble Rewind Starter (28Q700) 8. Install rope. 1. Straighten spring to allow easier installation and restore tension. 2. Oil spring. 3. Insert either end of spring into blower housing slot and hook into pulley (A). 4. Place a dab of grease (B) on steel pul ley. 5.

  • Page 173: Ring Gear Replacement

    Fig. 34 Fig. 33 NOTE: Some engines are equipped with an OEM supplied electric starter. Contact the OEM Test Starter Drive and Clutch for service information and adjustment When the starter is activa ted, the pinion gear procedures. should engage the ring gear and crank the engine.

  • Page 174: Starter Drive (104700, 161400, 260700, 261700)

    Starter Drive CAUTION: Do not oil pinion gear on clutch helix. (104700, 161400, 260700, 261700) 3. Wash the parts in solvent. Disassemble Starter Drive (Roll Pin Retainer) 1. Place starter drive retainer on support Assemble Starter Drive block and drive out rol l pin ([A] Fig. 36) to remove starter drive.

  • Page 175: Starter Drive (235400, 245400)

    Starter Drive (235400, 245400) Disassemble Starter Drive (Snap Ring Retainer) 1. Remove dust cover (A). 2. Push down on upper spring retainer (B) to expose snap ring ([C] Fig. 39) on shaft. Fig. 38 Inspect Starter Drive 1. Inspect the pinion gear and clutch ([D] Fig. 38) for damaged teeth.

  • Page 176: Starter Drive (28Q700)

    Starter Drive (28Q700) 6. Remove upper spring retainer (B), return spring (G), lower retainer (H), pinion gear (I), and starter clutch ([J] Fig. 39). Inspect Starter Drive 1. Inspect the pinion gear (I) for damaged teeth. Some pinion gears use a rubber bottom as part of the clutch.
  • Page 177 Inspect Starter Drive 1. Inspect the pinion gear ([E] Fig. 42) for damaged teeth. Some pinion gears use a rubber bottom as part of the clutch. If clutch rubber inside pinion gear is worn or damaged, pinion gear will slip when starter is engaged.
  • Page 178 SECTION 9 - LUBRICATION SYSTEMS SYSTEM TYPES……………………………............ Oil Dipper (050000, 085400, 086400, 115400, 117400, 138400, 185400, 235400, 245400) ......................179 Oil Dipper (161400) ....................179 Oil Slinger (28Q700) ....................179 Pressure Lubrication (104700, 260700, 261700).............1 80 Pressure Filtration ....................180 OIL PUMP SERVICE ..................Oil Pump &...

  • Page 180: System Types

    SYSTEM TYPES For information regarding external breather systems: See SECTION 3- ENGINE DISASSEMBLY. Briggs & Stratton OHV engines use four lubrication systems. 1. Oil Dipper f23p11 2. Oil Slinger 3. Pressure Filtration 4. Pressure Lubrication Fig. 2 Oil Dipper (050000, 085400, 086400, Oil Slinger (28Q700) 115400, 117400, 138400, 185400, The oil slinger (A) i s driven by the camshaft ([B]...

  • Page 181: Pressure Lubrication (104700, 260700, 261700)

    Pressure Lubrication (104700, Pressure Filtration 260700, 261700) Fig. 6 OIL PUMP SERVICE Oil Pump & Screen Removal/ Installation (104700, 260700, 261700) Fig. 4 The oil pump can be accessed from the outside of the sump. Oil Pump Removal/Installation (104700) 1. Remove the three screws that hold the oil pump cover to the sump.
  • Page 182 2. Lift the pump rotor and its drive shaft from 2. Remove snap ring ([A] Fig. 10) retaining the sump ([A] Fig. 8). inner rotor to shaft. f32p15 Fig. 8 Fig. 10 3. Remove the outer oil pump rotor ([A] Fig.9).

  • Page 183: Oil Pump & Screen Removal/Installation (28Q700)

    Oil Screen Removal/Installation (104700) Fig. 14).Press screen into position as shown. The oil pump screen is located inside the sump. Remove sump from cylinder to clean or replace the screen. 1. Remove two screen retaining screws ([A] Fig. 12). Clean or replace as needed. Fig.
  • Page 184 Slide screen out from its cavity. Clean and/or Oil Pump Removal/Installation (28Q700) replace. All three oil pump configurations can be removed from the outside of the sump. With slight variations of the O-ring channel and design of Current oil pump screen (After date code the pump cover, the removal and installation requires the sump be removed from...

  • Page 185: Oil Gard® System

    After Date Code 98063000 (28Q700) Before 94110700 (28Q700) 1. Install new O-ring ([A] Fig. 21) in channel 1. Install O-ring ([A] Fig. 23) to groove in in sump. sum p. 2. Place pump cover on oil pump cavity, and install three screws. 3.

  • Page 186: Oil Gard

    Low oil will cause contact between the cylinder OIL GARD® (161400) housing and a shaft attached to a float. The sensor assembly is show n with the shaft ([A] Fig. For Troubleshooting information: 24) grounding against the cylinder housing. See SECTION 2- TROUBLESHOOTING, pg.55. Oil Gard®...
  • Page 187 Disassemble Oil Gard® System (161400) Inspect Oil Gard® System (16140 0) 1. Disconne ct wire (A) from float assembly 1. Inspect float assembly for cracks in terminal and remove mounting screws housing and float. ([B] Fig. 28). 2. Check Oil Gard® switch operation by connecting a continuity tester to the wire terminal and ground clip.
  • Page 188 SECTION 10 - CYLINDERS, COVERS AND SUMPS REMOVING COVERS AND SUMPS ............. Removal: (All Models) ....................1 89 Crankshaft Seals (All Models)..................189 BEARINGS ..................... Camshaft Bearings (All Models)................189 Ball Bearing Service (050000) ................. 190 Ball Bearing Service (085400, 086400) ..............1 90 Ball Bearing Service (115400, 117400, 118400) .............192 Ball Bearing Service Counter-Balance (185400) .............195 Ball Bearing Service (235400, 245400) ..............1 96...

  • Page 190: Removing Covers And Sumps

    REMOVING COVERS AND SUMPS Crankshaft Seals (All Models) Removal: (All Models) Oil seals are a press fit in cylinder and sump covers. Before removing a cover or sump from engine, remove rust, paint, or burrs from the PTO end of Oil Seal Removal (All Models) the crankshaft.

  • Page 191: Ball Bearing Service (050000)

    Ball Bearing Service (085400, 086400) Use the following plug gauges to check cam bearings: Removal: Magneto-Side Ball Bearing • 161400 - Gauge #19383 Bearing Removal Tools: (Refer to Fig. 4) • 104700 - Gauge (Magneto-Side) #19164 • Puller Screw ([A] #19318) •...
  • Page 192 Installation: Magneto-Side Ball Bearing 4. Insert puller screw (A) with adapter/driver (C) into bearing and thread into bushing Bearing Installation Tools: (Refer to Fig. 5). (D). • Adapter/Driver ([A] #19397) • Driver ([B] #19320) • Washer ([C] #225136) • Puller Screw ([D] #19318) •...

  • Page 193: Ball Bearing Service (115400, 117400, 118400)

    5. Tighten screw until bearing is seated. Installation: Magneto-Side Ball Bearing Bearing Installation Tools: (Refer to Fig. 9) • Support ([A] #19394) • Washer ([B] #225136) • Puller Screw ([C) #19318) • Pilot ([D] #19396) 1. Lubricate outside of ball bearing. 2.
  • Page 194 5. Insert puller screw (B) w ith driver (C) 6. Tighten until ball bearing is seated. through ball bearing and thread into support (D). Removal: PTO-Side Ball Bearing (With 6:1 Gear Reduction) Bearing Removal Tools: (Refer to Fig. 12). • Puller Nut ([A] #19139) •...
  • Page 195 2. Using arbor press and tool Installation: Magneto-Side Ball Bearing ([A] #19320) Bearing Installation Tools: (Refer to Fig. 15) • Washer ([A] #225136) • Puller Screw ([B] #19318) • Pilot ([C] #19396) • Support ([D] #19394) 1. Lubricate outside of bearing. 2.

  • Page 196: Ball Bearing Service Counter-Balance (185400)

    Ball Bearing Service Counter-Balance (185400) Removal: Counter-Balance Ball Bearing Bearing Removal Tools: (Refer to Fig. 18) • Puller Nut ([A] #19406) • Puller Stand-Off ([B] #19408) Fig. 16 • Nut-Hex ([C] #92278) • Screw-Hex ([D] #94373) 1. Remove nut-hex (C) and screw-he x (D) Installation: PTO-Side Ball Bearing from flywheel puller (#19069)

  • Page 197: Ball Bearing Service (235400, 245400)

    Installation: Counter-Balance Ball Bearing 2. Assemble washer (A) to puller screw (B) and insert through large end of driver (C). Bearing Installation Tool: (Refer to Fig. 19) 3. Place open side of support (D) against ball • Driver ([A] #19320) bearin g.

  • Page 198: Du & Ball Bearing Service (161400)

    2. Remove oil seal. 3. Assemble washer (A) to puller screw (B) and insert through large end of driver. 4. Assemble second washer (A) over puller screw (B) up against driver (C). Fig. 23 2. Install shim(s) -if used. 3. Assemble washer (A) to puller screw (C). 4.

  • Page 199: Aluminum Bearing Service (104700)

    Installation: Magneto-Side DU Bearing Removal: PTO Ball Bearing 1. Place cylinder on cylinder support tool 1. Remove oil seal . (#19351) 2. Support the cylinder cover on arbor press 2. Position new bushing against counter- and press out bearing using bushing (A) bored bearing with the oil hole aligned driver .

  • Page 200: Du™ & Ball Bearing Service (28Q700)

    If measurement exceeds specified • Place split of bearing seam ([A] Fig. 30) dimension: as shown. • Replace cylinder and/or sump. Aluminum Bearing Service (260700, 261700) Measure magneto-side be aring and PTO beari ng with plug gauge or compare (#19378) measurements with reject size dimension.

  • Page 201: Installing Covers And Sumps

    Installation: Cylinders and Covers PTO-Side Ball Bearing And Sumps (All Models) If the measurement obtained from the sump cover bearing exceeds limitations: Make sure the mating surfaces of the cylinder and cover or sump are clean. • Replace sump. 1. Place the gasket ([A] Fig. 33) on the mating surface of the cylinder.
  • Page 202 Fig. 37 Fig. 34 Fig. 38 Fig. 35 Fig. 39 Fig. 36...

  • Page 203: Crankshaft End Play

    CRANKSHAFT END PLAY When cylinder cover or sump is installed with a standard gasket, end play should be as listed in SECTION 14- ENGINE SPECIFICATIONS. Always measure end play with a standard gasket in place. If end play is less than listed: •...

  • Page 204: Cylinder Bores

    Resizing Cylinder Bores CYLINDER BORES A cylinder bore may be resized to 0.020 in. (0.51 mm) over the standard size shown in the engine Inspect the cylinder whenever the engine has specifications. See SECTION 14- ENGINE been disassembled. Look for cracks, stripped SPECIFICATIONS.
  • Page 205 Fig. 46 If using hand drill to hone: • Clamp the cylinder and honing fixture in a vise at a convenient working height. If using drill press: • Oil the surface of the drill press table liberally. Set (do not anchor) the honing fixture/plate (A) and cyl inder on dril l press table.([B] Fig.

  • Page 206: Finishing And Cleaning Cylinder

    travel area, (D) use this area to guide hone to Honing grit is abrasive and will cause rapid wear straighten cylinder bore, Fig. 47. to internal components of the engine unless it is completely removed. The entire cylinder must be 10.
  • Page 208 SECTION 11 - CRANKSHAFTS, CAMSHAFTS, BALANCING SYSTEMS, GEAR REDUCTIONS CRANKSHAFT & CA MSHAFT REMOVAL (050000, 085400, 086400, 117400, 138400, 185400, 235400, 245400, 161400, 104700, 260700, 261700) ......................Inspecting Camshaft (All Models) ................213 Inspecting Crankshaft....................2 14 BALANCING SYSTEMS ..................215 Rotating Counterweight System (161400, 185400, 235400, 245400)..... 215 Oscillating Counterweight System (260700, 261700)..........

  • Page 210: Inspecting Camshaft (All Models)

    8. Remove the piston. See SECTION 12- PISTONS, RINGS AND CONNECTING RODS. CRANKSHAFT & CAMSHAFT 9. Remove crankshaft(Fig. 2). REMOVAL (050000, 085400, 086400, 117400, 138400, 1 85400, 235400, 2 45400, 161400, 1 04700, 260700, 2 61700) 1. Drain oil from cylinder/sump. 2.

  • Page 211: Inspecting Crankshaft

    If any discrepancies are found: • Replace complete camshaft assembly. Inspecting Compression Release (050000, 085400, 115400, 117400, 118400, 138400, 185400, 235400, 245400) Inspecting Valve Tappets (All Models) When inspe cting the compression release Inspect valve tappets for wear on the tappet mechanism, ensure that all parts move freely.

  • Page 212: Balancing Systems

    For reject size dimensi ons, see SECTION 14- ENGINE SPECIFICATIONS. BALANCING SYSTEMS Rotating Counterweight System (161400, 185400, 235400, 245400) This system uses a geared counterweight (A) that rotates opposite the crankshaft counterweight (B), Fig. 8. Fig. 9 Installation Refer to Fig. 10. 1.

  • Page 213: Oscillating Counterweight System (260700, 261700)

    Oscillating Counterweight System 6. Remove connector link ([I] Fig. 13). (260700, 261700) Removal/Disassembly 1. Remove cylinder cover. See SECTION 10- CYLINDERS, COVERS AND SUMPS. 2. Turn crankshaft to align timing mark on gear (A) with timing mark on camshaft (B). 3.

  • Page 214: Synchro-Balance® System (28Q700)

    Synchro-Balance® System (28Q700) 3. Install counterweight assembly into cylinder and slide link (N) on to crankshaft This system uses a link and counterweight that eccentric ([O] Fig. 14). oscillates opposite the piston Fig. 16. Fig. 16 Fig. 14 Removal/Inspection Synchro-Balance® 4.
  • Page 215 5. Install screw ([B] Fig. 19). Torque to listed value. Fig. 18 9. Measure counterweight bearings and crankshaft eccentrics and compare to reject dimensions. See SECTION 14- ENGINE SPECIFICATIONS. If counterweight bearings are discolored, scored or worn beyond tolerances: • Counterweights must be replaced as a Fig.

  • Page 216: Gear Reductions

    The housing can be installed in four positions (A, B, C, D) relative to the crankshaft ([E] Fig. 21). Fig. 20 Fig. 21 10. Install connecting rod and piston with lubrication hole in rod toward magneto side. This will expose rod assembly Remove Gear Reduction Housing (115400, marks.
  • Page 217 gear teeth for wear, pitting or scoring. 8. Replace crankshaft oil seal and cork Replace if necessary gasket ([H] Fig. 25). 5. Inspect crankshaft gear teeth ([F] Fig. 23) for wear, pitting or scoring. Replace if necessary. Fig. 25 Fig. 23 Assemble Gear Reduction Housing 6.
  • Page 218 Install Gear Reduction Housing 5. Insert seal protector (E) in seal of cover. (115400, 118400) Install cover ([F] Fig. 29) to gear case. 1. Install new cork gasket on housing, and place housing against cylinder cover in original position, Fig. 27. Fig.

  • Page 220: Mounting Positions (115400, 118400)

    SECTION 12 - PISTONS, RINGS AND CONNECTING RODS REMOVE PISTON AND CONNECTING ROD..........Piston Removal ......................2 21 Piston Ring Removal....................221 Piston Pin Removal....................222 INSPECT PISTON ..................Measure Piston Pin Bore ..................222 Measure Ring Groove Clearance................222 Measure Piston Ring End Gap................. 223 INSPECT CONNECTING ROD..

  • Page 222: Remove Piston And Connecting Rod

    4. Remove the piston. (Fig. 2). Be careful no t to damage the surface of the cylinder bo re with the connecting rod. REMOVE PISTON AND CONNECTING ROD Piston Removal For related engine information: See SECTION 3- ENGINE DISASSEMBLY. 1. Clean carbon deposits or any ridge buildup from top of cylinder bore to prevent ring breakage.

  • Page 223: Piston Pin Removal

    Piston Pin Removal INSPECT PISTON 1. Remove snap ring ([A] Fig. 4) from both sides of piston( if equipped). Inspect piston for scuffing or galling of the piston skirt. Discoloration of the piston is not cause for rejection Measure Piston Pin Bore Always look for "out-of-round"...

  • Page 224: Measure Piston Ring End Gap

    Replace piston if rej ect dimensions are exceeded. See SECTION 14- ENGINE SPECIFICATIONS. Measure Piston Ring End Gap 1. Insert the top ring into the cylinder about an inch below the surface of the head ([A] Fig. 8). 2. Measu re gap with feeler gauge ([B] Fig. 8) Fig.

  • Page 225: Ring Installations

    not have offset piston pin bores and can be marks on the first and second ring. Install them assembled to the connecting rod in either facing up. direction. 6. Oil the piston pin. 7. Insert pin from the side opposite the shoulder stop or the first installed lock.

  • Page 226: Piston Installation (Typical)

    3. Install the top ring ([D] Fig. 14). 2. Install the center ring (C). 3. Install the top ring ([D] Fig. 16). Fig. 14 Fig. 16 Ring Installation (161400) Note the shape of each ring and be careful to PISTON INSTALLATION (TYPICAL) install them in their proper position.

  • Page 227: Install Connecting Rod Caps

    8. Set piston and compressor assembly ([A] Fig. 21) on cylinder. Be careful not to scratch the surface of the bore with the connecting rod. 9. Push the piston down through the ring compressor and into the cylinder (B) until piston is in cylinder bore ([C] Fig.
  • Page 228 Fig. 23 NOTE: (28Q700) The notch in the connecting rod cap (A) must engage the tab on the connecting rod ([B] Fig. 24). Fig. 24 2. Install the rod bolts, dipper an d washers (if equipped) and torque as listed. See SECTION 14- ENGINE SPECIFICATIONS.

  • Page 230: Section 13 - Final Engine Assembly

    SECTION 13 - FINAL ENGINE ASSEMBLY GENERAL INFORMATION ................231 MODEL 050000....................231 Models 085400, 086400, 115400, 117400, 118400, 13840 0, 185400, 235400, 245400 ..................... 234 MODEL 104700....................236 MODEL 161400....................238 MODELS 260700, 261700 ................240 MODEL 28Q700..................... 242...

  • Page 232: General Information

    GENERAL INFORMATION 2. Check to make sure the small steel bushing ([A] Fig. 2) is installed in the intake side baffle. Install baffle as shown This engine assembly section assumes you have in Fig. 2. inspected all the items listed in the "Reject Dimensions"...
  • Page 233 4. Install flywheel, woodruff key and position flywheel on crankshaft (Fig. 4). Fig. 6 Fig. 4 7. Torque the flywheel nut to value listed in SECTION 14- ENGINE 5. Position the starter cup (A) on top of the SPECIFICATIONS. blower fan (B) by aligning the two drive 8.
  • Page 234 9. Install the cylinder shield (Fig. 8). 11. Install grounding lead ([A] Fig. 10) as shown. Fig. 8 Fig. 10 10. Set the blower housing in position and check that no wires are pinched. Position 12. Assemble shield ([A] Fig. 11) as shown. spark plug lead in the contour created for it ([A] Fig.

  • Page 235: Models 085400, 086400, 115400, 117400, 118400, 13840 0, 185400, 235400, 245400

    14. Refer to Fig. 12 and install components MODELS 085400, 086400, 115400, as shown. 117400, 1 18400, 138400, 1 85400, 235400, 245400 NOTE : The 185400 was used as a general representation of the following models; 085400, 086400, 115400, 117400, 118400, 138400, 235400, 245400.
  • Page 236 5. Install the upper (A) and lower ([B] Fig. 11. Connect fuel hose ([C] Fig. 18) to 16) cylinder shields. carburetor. Fig. 16 Fig. 18 12. Install air cleaner base ([A] Fig. 19). 6. Install the blower housing. Make sure the engine turns over with the starter rope.

  • Page 237: Model 104700

    14. Mount the Oil Gard® module ([A] Fig. 21) 3. Place large carburetor gasket-adapter ([A] as shown and connect wires to the stop Fig. 24). switch. Fig. 24 Fig. 21 4. With the governor lever in position, loosely 15. Install the breather tube (A) and route the install both control brackets ([A &...
  • Page 238 8. Route the alternator wire (D) and the carburetor assembly ([C] Fig. 28) on ignition coil wire (E) as shown in Fig. 27. mounting studs. Fig. 28 15. Install blower housing and valve cover. 16. Install muffler assembly. See SECTION 4- EXHAUST SYSTEMS.

  • Page 239: Model 161400

    MODEL 161400 4. Position the fan to allow for the magnet to fit in the fan cut-out ([A] Fig. 31). 1. Install the cylinder baffle using the upper head bolts (A) and one lower mounting screw ([B] Fig. 29). Make sure to torque head bolts to listed values.
  • Page 240 8. Connect the other end of the governor link 11. Torque carburetor mounting bolts ([D] and spring to throttle lever ([D] Fig. 33) Fig. 35) to values listed. See SECTION and temporarily install carburetor. 14- ENGINE SPECIFICATIONS. Fig. 33 9. Route the spark plug wire (A) and the governor links as shown and install the Fig.

  • Page 241: Models 260700, 261700

    17. Connect breather hose and install air 2. Install the control bracket (Fig. 39). filter housing (A) and trim ([B] Fig. 37). Fig. 39 Fig. 37 3. Connect the main governor spring ([A] 18. Install air filter and cover. Fig. 40). MODELS 260700, 261700 1.
  • Page 242 6. Install the ignition coil harness to the 11. Install the fan retainer, flywheel nut and ground term inal (A) and route the starter cup. Torque to listed values. harness ([B] Fig. 42) as shown. Fig. 44 Fig. 42 12. Install the ignition coil and set the air gap. 7.

  • Page 243: Model 28Q700

    14. Install the governor links as sho wn in Fig. 21. Install blower housing. Fig. 48 Fig. 46 15. Install the air cleaner manifold and attach breather hose. Torque nuts to listed MODEL 28Q700 values. See SECTION 14- ENGINE SPECIFICATIONS. 16.
  • Page 244 4. Install flywheel with fan, fan retainer and 7. Install governor link with spring (A) and flywheel nut. Torque nut ([A] Fig. 50) as connect choke arm ([B] Fig. 52) as shown to values listed in section 14. shown. Fig. 50 Fig.
  • Page 245 9. Install inner blower housing with brackets ([A] Fig. 54) as shown. Fig. 54 10. Install the oil-fill tube. 11. Install the outer blower housing on brackets (Refer to Fig. 54). 12. Install grill to top of flywheel fan. 13. Install bracket for the fuel pump (A). Install pump (B) and connect fuel lines ([C] Fig.

  • Page 246: Section 14 - Engine Specifications & Reference Tables

    SECTION 14 - ENGINE SPECIFICATIONS & REFERENCE TABLES MODEL 050000 ................... 247 Engine S pecifications .................. 247 Fastener Torque S pecifications..............247 Reject Dimensions..................248 MODELS 085400 & 086400 ................ 250 Engine S pecifications .................. 250 Fastener Torque S pecifications..............250 Reject Dimensions..................
  • Page 247 MODELS 235400 & 245400 ................ 265 Engine Specifications .................. 265 Fastener Torque S pecifications..............265 Reject Dimensions..................266 MODEL 161400................... 268 Engine Specifications .................. 268 Fastener Torque S pecifications..............268 Reject Dimensions..................269 MODEL 104700................... 271 Engine Specifications .................. 271 Fastener Torque S pecifications..............

  • Page 248: Model 050000

    MODEL 050000 Engine Specifications (050000) Armature Air Gap .012 -.020 in. (.30 -.50 mm) Bolt Circle (1) 3.625 in. (92.08 mm) Bore 2.047 in. (52.0 mm) Crankshaft End Play .002 -.006 in. (.05 -.15 mm) Displacement 4.88 cu. in. (80 cc) Fuel Tank Capacity 1.7 qt.

  • Page 249: Reject Dimensions

    Fastener Torque Specifications (050000) Tool Size Torque Oil Guard Float Switch 10 mm 45 lb-in. (5 Nm) Rewind Retainer Screw Phillips 70 lb-in. (8 Nm) Rewind Starter 10 mm 45 lb-in. (5 Nm) Rocker Arm Assembly 10 mm 45 lb-in. (5 Nm) Rocker Ball Set Screw or Nut 10 mm 45 lb-in.
  • Page 250 Reject Dimensions (050000) Standard Size Reject Size Connecting Rod (050000) Crank Pin Bearing .9059 in. (23.01 mm) .9071 in. (23.04 mm) Piston Pin Bearing .5516 in. (14.01 mm) .5528 in. (14.04 mm) Piston (050000) Piston Pin Diameter .5512 in. (14.00 mm) .5496 in.

  • Page 251: Models 085400 & 086400

    MODELS 085400 AND 086400 Engine Specifications (085400 & 086400) Armature Air Gap .012 -.020 in. (.30 -.50 mm) Bolt Circle (1) 3.625 in. (92.08 mm) Bore 2.441 in. (62.0 mm) Crankshaft End Play .001 -.008 in. (.03 -.20 mm) Displacement 7.69 cu.

  • Page 252: Reject Dimensions

    Reject Dimensions (085400 & 086400) Standard Size Reject Size Cylinder (085400 & 086400) Magneto Bearing Ball Camshaft Bearing .5909 in. (15.01 m m) .5917 in. (15.03 m m) Bore Diameter 2.441 in. (62.00 m m) 2.442 in. (62.03 m m) Bore Out-Of-Round .0015 in.
  • Page 253 Reject Dimensions (085400 & 086400) Standard Size Reject Size Piston (085400 & 086400) Piston Pin Diameter .5512 in. (14.00 m m) .5504 in. (13.98 m m) Piston Pine Bore .5516 in. (14.01 m m) .5524 in. (14.03 m m) Ring End Gap (Top) .006-.014 in.

  • Page 254: Models 115400 & 117400

    MODELS 115400 AND 117400 Engine Specifications (115400 & 11740 0) Armature Air Gap .012 -.020 in. (.30 -.50 mm) Bolt Circle (1) 3.625 in. (92.08 mm) Bore 2.677 in. (68.0 mm) Crankshaft End Play .001 -.008 in. (.03 -.20 mm) Displacement 11.05 cu.

  • Page 255: Reject Dimensions

    Fastener Torque Specifications (115400 & 117400) Tool Size Torque Rewind Retainer Screw Phillips 70 lb-in. (8 Nm) Rewind Starter 10 mm 45 lb-in. (5 Nm) Rocker Arm Piv ot 14 mm Rocker Arm St ud 12 mm 175 lb-in. (20 Nm) Rocker Ball Set Screw or Nut 10 mm 35 lb-in.
  • Page 256 Reject Dimensions (115400 & 117400) Standard Size Reject Size Camshaft (115400 & 117400) Mag-Side J ournal .5905 in. (15.00 m m) .5898 in. (14.98 m m) PTO-Side J ournal .5905 in. (15.00 m m) .5898 in. (14.98 m m) Intake lobes 1.1102 in.

  • Page 257: Model 118400

    MODEL 118400 Engine Specifications (118400) Armature Air Gap .012 -.020 in. (.30 -.50 mm) Bolt Circle (1) 3.625 in. (92.08 mm) Bolt Circle (2) 4.5 in. (114.3 mm) Bore 2.677 in. (68.0 mm) Crankshaft End Play .002 -.006 in. (.05 -.15 mm) Displacement 11.05 cu.

  • Page 258: Reject Dimensions

    Reject Dimensions (118400) Standard Size Reject Size Cylinder (118400) Magneto Bearing Ball Camshaft Bearing .5909 in. (15.01 m m) .5917 in. (15.03 m m) Bore Diameter 2.677 in. (68.00 m m) 2.678 in. (68.07 m m) Bore Out-Of-Round .0015 in. (.04 m m) Cylinder Head (118400) Standard Size Reject Size...
  • Page 259 Reject Dimensions (118400) Standard Size Reject Size Connecting Rod (118400) Crank Pin Bearing 1.1815 in. (30.01 mm) 1.1827 in. (30.04 mm) Piston Pin Bearing .6303 in. (16.01 mm) .6315 in. (16.04 mm) Piston (118400) Piston Pin Diameter .6299 in. (16.00 mm) .6283 in.

  • Page 260: Model 138400

    MODEL 138400 Engine Specifications (138400) Armature Air Gap .012 -.020 in. (.30 -.50 mm) Bolt Circle (1) 3.937 in. (100 mm) Bolt Circle (2) 5.0 in. (127 mm) Bolt Circle (3) 6.5 in. (165.1 mm) Bore 2.835 in. (72.0 mm) Crankshaft End Play .002 -.025 in.

  • Page 261: Reject Dimensions

    Fastener Torque Specifications (138400) Tool Size Torque Rocker Arm Pivot 14 mm Rocker Arm Stud 12 mm 175 lb-in. (20 Nm) Rocker Ball Set Screw or Nut 10 mm 35 lb-in. (4 Nm) Spark Plug 5/8 in. 180 lb-in. (20 Nm) Starter Contactor 10 mm 45 lb-in.
  • Page 262 Reject Dimensions (138400) Standard Size Reject Size Camshaft (138400) Mag-Side Journal .5905 in. (15.00 mm) .5898 in. (14.98 mm) PTO-Side Journal .5905 in. (15.00 mm) .5898 in. (14.98 mm) Intake lobes 1.1476 in. (29.15 mm) 1.1083 in. (28.15 mm) Exhaust lobes 1.1476 in.

  • Page 263: Model 18544

    MODEL 185400 Engine Specifications (185400) Armature Air Gap .012 -.020 in. (.30 -.50 mm) Bolt Circle (1) 3.937 in. (100 mm) Bolt Circle (2) 6.5 in. (165.1 mm) Bore 3.150 in. (80.0 mm) Crankshaft End Play .001 -.008 in. (.02 -.20 mm) Displacement 18.06 cu.

  • Page 264: Reject Dimensions

    Fastener Torque Specifications (185400) Tool Size Torque Rewind Retainer Screw Phillips 70 lb-in. (8 Nm) Rewind Starter 10 mm 55 lb-in. (6 Nm) Rocker Arm Pivot 14 mm Rocker Arm Shaft 12 mm 175 lb-in. (20 Nm) Rocker Ball Set Screw or Nut 10 mm 35 lb-in.
  • Page 265 Reject Dimensions (185400) Standard Size Reject Size Camshaft (185400) Mag-Side Journal .5905 in. (15.00 mm) .5898 in. (14.98 mm) PTO-Side Journal .5905 in. (15.00 mm) .5898 in. (14.98 mm) Intake lobes 1.2657 in. (32.15 mm) 1.2402 in. (31.50 mm) Exhaust lobes 1.2657 in.

  • Page 266: Models 235400 & 245400

    MODELS 235400 AND 245400 Engine Specifications (235400 & 245400) Armature Air Gap .012 -.020 (.30 -.50 mm) Bolt Circle (1) 5.0 in. (127 mm) Bolt Circle (2) 6.5 in. (165.1 mm) Bolt Circle (3) 7.75 in. (197 mm) Bore 3.504 in. (89.0 mm) Crankshaft End Play .001 -.008 in.

  • Page 267: Reject Dimensions

    Fastener Torque Specifications (235400 & 245400) Tool Size Torque Rocker Arm Shaft 10 mm 85 lb-in. (10 Nm) Rocker Ball Set Screw or Nut 12 mm 35 lb-in. (4 Nm) Spark Plug 5/8 in. 180 lb-in. (20 Nm) Starter Contactor 8 mm 35 lb-in.
  • Page 268 Reject Dimensions (235400 & 245400) Stand ard Size Reject Size Camshaft (235400 & 245400) Mag-Side Journal .5905 in. (15.00 mm) .5898 in. (14.98 mm) PTO-Side Journal .5905 in. (15.00 mm) .5898 in. (14.98 mm) Intake lobes 1.2894 in. (32.75 mm) 1.2598 in.

  • Page 269: Model 161400

    MODEL 161400 Engine Specifications (161400) Armature Air Gap .008 -.012 in. (. 20 -.30 mm) Bolt Circle (1) 5.0 in. (127 mm) Bolt Circle (2) 6.5 in. (165.1 mm) Bore 3.0 in. (76.2 mm) Crankshaft End Play .002 -.025 in. (. 05 -.64 mm) Displacement 16.48 cu.

  • Page 270: Reject Dimensions

    Fastener Torque Specifications (161400) Tool Size Torque Intake Manifold 8 mm 55 lb-in. (6 Nm) Muffler 8 mm 45 lb-in. (5 Nm) Muffler Brac ket 8 mm 45 lb-in. ((5 Nm) Muffler Guard 1/4 in. & 8 mm 30 lb-in. (30 Nm) Oil Drain Plug 3/8 in.
  • Page 271 Reject Dimensions (161400) Standard Size Reject Size Cylinder Cover (161400) PTO Bearing Ball Camshaft Bearing .6255 in. (15.89 m m) .6275 in. (15.94 m m) Counterweight Bearing .6255 in. (15.98 m m) .6275 in. (15.94 m m) Crankshaft (161400) Crank Pin Journal 1.43 in.

  • Page 272: Model 104700

    MODEL 104700 Engine Specifications (104700) Armature Air Gap .008-.012 in. (.20-.30 mm) Bolt Circle (1) 8.0 in. (203.2 mm) Bore 2.561 in. (65.06 mm) Crankshaft End Play .002-.020 in. (.05-.51 mm) Displacement 10 cu. in. (164 cc) Fuel Tank Capacity 1.5 qt.

  • Page 273: Reject Dimensions

    Fastener Torque Specifications (104700) Tool Size Torque Oil Pump Cover 8 mm 55 ln-in. (6 Nm) Oil Pump Screen 7 mm 35 lb-in. (4 Nm) Rewind Retainer Screw Phillips 70 lb-in. (8 Nm) Rewind Starter 8 mm 55 lb-in. (6 Nm) Rocker Arm Stud 10 mm 85 lb-in.
  • Page 274 Reject Dimensions (104700) Standard Size Reject Size Camshaft (104700) Mag-Side J ournal .5 in. (12.7 m m) .498 in. (12.65 m m) PTO-Side J ournal .6890 in. (17.5 m m) .6871 in. (17.45 m m) Intake lobes 1.136 in. (28.85 m m) Exhaust lobes 1.136 in.

  • Page 275: Models 260700 & 261700

    MODELS 260700 & 261700 Engine Specifications (260700 & 26170 0) Armature Air Gap .008 -.012 in. (.20 -.30 mm) Bolt Circle (1) 10.0 in. (254 mm) Bore 3.437 in. (87.29 mm) Crankshaft End Play .002 -.020 in. (.05 -.51 mm) Displacement 26.55 cu.

  • Page 276: Reject Dimensions

    Fastener Torque Specifications (260700 & 261700) Tool Size Torque Oil Drain Plug 7/16 in. Square 125 lb-in. (14 Nm) Oil Fill Tube 8 mm 20 lb-in. (2 Nm) Oil Filter Adapter 10 mm 140 lb-in. (16 Nm) Oil Pressure Switch 1 1/16 in.
  • Page 277 Reject Dimens ions (260700 & 2617 00) Standard Size Reject Size Sump Cover (260700 & 261700) PTO Bearing 1.625 in. (41.28 mm) 1.628 in. (41.35 mm) Camshaft Bearing .6255 in. (15.89 mm) .6280 in. (15.95 mm) Counterweight Pivot Shaft .5 in. (12.7 mm) .498 in.

  • Page 278: Model 28Q700

    MODEL 28Q700 Engine Specifications (28Q700) Armature Air Gap .010 -. 014 in. (. 25 -.36 m m) Bolt Circle (1) 10.0 in. (254 mm) Bore 3.437 in. (87.29 m m) Crankshaft End Play .002 -. 023 in. (. 05 -.58 m m) Displacement 28.37 cu.

  • Page 279: Reject Dimensions

    Fastener Torque Specifications (28Q700) Tool Size Torque Oil Drain Plug 7/16 in. Square 125 lb-in. (14 Nm) Oil Fill T ube 1/4 in. 20 lb-in. (2 Nm) Oil Filter Adapter 1/2 in. or T-40 125 lb-in. (14N m) Oil Pressure Switch 1 1/16 in.
  • Page 280 Reject Dimensions (28Q700) Standard Size Reject Size Crankshaft (28Q700) Crank Pin Journal (Before 98070xx) 1.2489 in. (31.72 mm) 1.2478 in. (31.69 mm) Crank Pin Journal (After 98070xx) 1.4986 in. (38.06 mm) 1.4975 in. (38.04 mm) Mag-Side Journal 1.3780 in. (34.99 mm) 1.3761 in.

This manual is also suitable for:

Vanguard 086400Vanguard 118400Vanguard 085400Vanguard 138400Vanguard 18544Vanguard 235400 ... Show all

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