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REPAIR MANUAL
Vanguard
BIG BLOCK
®
Diagnostic and Repair
M540000/M610000

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Summary of Contents for Vanguard BIG BLOCK M540000

  • Page 1 REPAIR MANUAL Vanguard BIG BLOCK ™ ® Diagnostic and Repair M540000/M610000...
  • Page 2 Foreword This manual was written to assist engine technicians and service personnel with the maintenance and repair procedures for Briggs & Stratton® engines. It assumes that persons using this manual have been properly trained and are familiar with the service procedures for these products, including the proper use of required tools and the application of appropriate safety practices.
  • Page 3 Engine Models Covered This engine repair manual includes the following engine models: • MODEL 540000 • MODEL 610000 NOTE: Some models have limited service parts. Review the Illustrated Parts List for part availability before conducting any service work. NOTE: Many of the images in this document are representative of the Horizontal-shaft EFI-ETC engine. While other engines models may appear somewhat different, unless indicated otherwise, the procedures are the same.
  • Page 4 How To Use This Manual Besides describing the service maintenance tasks and the intervals at which they are to be performed, three basic levels of service are presented in this manual: troubleshooting problems with the engine, engine top end service, and engine bottom end service.
  • Page 5 SECTION 1 - SAFETY AND GENERAL INFORMATION SECTION 2 - MAINTENANCE SECTION 3 - TROUBLESHOOTING AND SPECIAL TOOLS SECTION 4 - REMOVE EXTERNAL ASSEMBLIES SECTION 5 - DISASSEMBLE ENGINE SECTION 6 - SERVICE ENGINE SUBASSEMBLIES SECTION 7 - ASSEMBLE ENGINE SECTION 8 - INSTALL EXTERNAL ASSEMBLIES SECTION 9 - SPECIFICATIONS vanguardpower.com...
  • Page 6: Table Of Contents

    SECTION 1 - SAFETY AND GENERAL INFORMATION SAFETY INFORMATION ----------------------------------------------------------------------------------------------------------------------------------- 8 Safety Alert Symbol and Signal Words ----------------------------------------------------------------------------------------------------------- 8 Hazard Symbols and Meanings --------------------------------------------------------------------------------------------------------------------- 8 General Safety Messages ---------------------------------------------------------------------------------------------------------------------------- 8 GENERAL INFORMATION -------------------------------------------------------------------------------------------------------------------------------11 Engine Identification ---------------------------------------------------------------------------------------------------------------------------------- 11 Fuel Recommendations ------------------------------------------------------------------------------------------------------------------------------11 Fuel Recommendations - Gaseous Engines --------------------------------------------------------------------------------------------------- 11 Oil Recommendations -------------------------------------------------------------------------------------------------------------------------------- 11 Fuel Storage -------------------------------------------------------------------------------------------------------------------------------------------- 12...
  • Page 7: Safety Information

    SAFETY INFORMATION WARNING  Briggs & Stratton® Engines are not designed for and are not to be used to power: fun-karts; go-karts; Safety Alert Symbol and Signal Words children's, recreational, or sport all-terrain vehicles (ATVs); motorbikes; hovercraft; aircraft products; or vehicles used The safety alert symbol identifies safety information in competitive events not sanctioned by Briggs &...
  • Page 8 • During maintenance if it is necessary to tilt the unit, make sure that the fuel tank, if mounted on the engine, WARNING  is empty and that the spark plug side is up. If the fuel Fuel vapors are flammable and explosive. Fire or tank is not empty, leakage can occur and could result a explosion could result in burns or death.
  • Page 9 WARNING  Accidental engine spark can cause an electric shock, fire or explosion and could result in entanglement, traumatic amputation or laceration. Before you make adjustments or repairs: • Disconnect all spark plug wires and keep them away from the spark plugs. •...
  • Page 10: General Information

    • Gasoline with up to 10% ethanol (gasohol) is permitted. GENERAL INFORMATION NOTICE  Do not use unapproved gasoline, such as E15 and E85. Engine Identification Do not mix oil in gasoline or change the engine to operate See Figure 1. On horizontal shaft engines, the engine model, on alternate fuels.
  • Page 11: Fuel Storage

    Use the chart to select the best viscosity for the outdoor Fuel Storage ® temperature range expected. Vanguard 15W-50 Synthetic Keep the engine level at the correct operating position. Fill the oil gives the best protection in most environments as fuel tank (A, Figure 2) with fuel.
  • Page 12 MAINTENANCE SCHEDULE ---------------------------------------------------------------------------------------------------------------------------- 14 Preliminary Instructions ------------------------------------------------------------------------------------------------------------------------------ 14 Check Engine Oil Level/Change Engine Oil/Replace Oil Filter ----------------------------------------------------------------------------14 Check/Change Engine Oil/Replace Oil Filter on Vanguard® Oil Guard™ System ---------------------------------------------------16 Check Oil Guard Oil Level ---------------------------------------------------------------------------------------------------------------------16 Clean/Replace Air Filter/Safety Filter -------------------------------------------------------------------------------------------------------------17 Clean/Replace Air Filter - Low Profile ----------------------------------------------------------------------------------------------------------- 18...
  • Page 13: Maintenance Schedule

    Change Engine Oil and Replace Oil Filter ÷ Every 600 Hours • Replace Safety Filter * + Engines not equipped with the Vanguard Oil Guard System. ÷ Engines equipped with the Vanguard Oil Guard System. † Clean more often in dusty conditions or when airborne debris is present.
  • Page 14 Install oil drain plug(s) (C1 or C2) and tighten as follows: 10. Install oil filter as follows: A. Verify the oil filter mount flange is clean and dry. Oil Drain Plug B. Lubricate gasket of new oil filter with a thin film of Engine Plug Type Torque...
  • Page 15: Check/Change Engine Oil/Replace Oil Filter On Vanguard Oil Guard System

    Check/Change Engine Oil/Replace Oil Filter on container for disposal. ® ™ Vanguard Oil Guard System Grasp tab and rotate oil filter (C) ¼ turn to unlock. Remove oil filter from filter housing.
  • Page 16: Clean/Replace Air Filter/Safety Filter

    Install dipstick. Gently tap air filter on a hard surface to remove dust, dirt and debris. Carefully brush and/or vacuum air filter as necessary. NOTE: Use of pressurized air or solvents will damage air filter. Carefully inspect air filter, and replace if it cannot be adequately cleaned or if any damage is observed.
  • Page 17: Clean/Replace Air Filter - Low Profile

    Gently tap air filter on a hard surface to loosen dirt and Clean/Replace Air Filter - Low Profile debris. Carefully clean with a soft bristle brush and a portable hand vacuum as necessary. Remove plastic cap (A, Figure 9) to release air filter cover (B).
  • Page 18: Clean/Gap/Replace Spark Plug

    Remove the oxygen sensor (A, Figure 12) from the Clean/Gap/Replace Spark Plug muffler. Take care to avoid damaging the sensor wires. Remove spark plug wire from spark plug terminal. Thoroughly clean area around spark plug to keep dirt and debris out of combustion chamber. Remove spark plug from cylinder head using a 5/8 inch spark plug wrench.
  • Page 19: Check/Adjust Valve Clearance

    Verify that exhaust manifold to cylinder head screws (A, A. While rotating flywheel end of crankshaft by hand Figure 13) are tightened to 195 lb-in (22 Nm). in the direction of engine rotation, watch the rocker arms to determine the action of the valves. After the exhaust valve closes, the intake valve begins to open.
  • Page 20: Idle Speed Adjustment - Mechanical Governor

    Insert feeler gauge between rocker arm and intake valve Adjust the screw to bring the idle speed to the correct stem. Verify that intake valve clearance is 0.004-0.006 RPM based on the specification of the engine. See The inches (0.10-0.15 mm). If adjustment is necessary, see Power Portal for correct idle speed RPM.
  • Page 21: Static Governor Adjustment - Mechanical Governor

    If equipped, remove the fasteners (A, Figure 20)  to Static Governor Adjustment - Mechanical Governor release the debris covers (B) on each side of the engine. Complete the governor static adjustment BEFORE starting or running the engine. Incorrect adjustment may result in engine overspeeding.
  • Page 22 Remove 3 fasteners to release air guide  on starter motor side of engine. From front to back of engine, air guide screws are threaded into the intake manifold (A, Figure 21), back plate (B), and crankcase (C).  NOTE: Removal of the air guide screws may also release other parts, such as the blower housing and wire harness or hose clips.
  • Page 23 SECTION 3 - TROUBLESHOOTING AND SPECIAL TOOLS TROUBLESHOOTING ------------------------------------------------------------------------------------------------------------------------------------- 26 Preliminary Instructions ------------------------------------------------------------------------------------------------------------------------------ 26 Check Ignition System ------------------------------------------------------------------------------------------------------------------------------- 26 Check Fuel System - Carbureted Engine -------------------------------------------------------------------------------------------------------27 Check Fuel System - Fuel-Injected Engine (EFI) ---------------------------------------------------------------------------------------------27 Check Fuel System Pressure - EFI and EFI-ETC -------------------------------------------------------------------------------------- 28 Check Compression Components ---------------------------------------------------------------------------------------------------------------- 29 Compression Test --------------------------------------------------------------------------------------------------------------------------------29 Cylinder Leakdown Test ------------------------------------------------------------------------------------------------------------------------29...
  • Page 24 Test Oil Pressure --------------------------------------------------------------------------------------------------------------------------- 42 Starter Motor ---------------------------------------------------------------------------------------------------------------------------------------42 Conditions Affecting Starter Motor Performance ----------------------------------------------------------------------------------- 42 Troubleshooting - Starter Motor -------------------------------------------------------------------------------------------------------- 43 Starter Motor Solenoid Continuity Test ----------------------------------------------------------------------------------------------- 43 Starter Motor Solenoid Voltage Test -------------------------------------------------------------------------------------------------- 44 Starter Motor Solenoid Load and Current Draw Test ----------------------------------------------------------------------------- 44 SPECIAL TOOLS ------------------------------------------------------------------------------------------------------------------------------------------- 46 Special Tools List --------------------------------------------------------------------------------------------------------------------------------------46 Special Tools Image Chart -------------------------------------------------------------------------------------------------------------------- 47...
  • Page 25: Troubleshooting

    ALWAYS wear safety glasses and gloves while performing TROUBLESHOOTING any maintenance and repair operation. General Complaints Most complaints concerning engine operation include one or more of the following: Check Ignition System • Will not start If the engine cranks but does not start, move to step 2. If •...
  • Page 26: Check Fuel System - Carbureted Engine

    11. See Figure 24. Install free end of spark plug wire onto A wet spark plug may indicate: inline tester prong. Install tester alligator clip onto spark • Over choking plug terminal. • Excessively rich fuel mixture • Water in fuel •...
  • Page 27: Check Fuel System Pressure - Efi And Efi-Etc

    Visually inspect the fuel system, its components, wiring NOTE: A small amount of gasoline may drain from the harness and connectors. Schrader valve when the gauge is removed. Wrap a Perform On-Board Diagnostic (OBD) system check. shop towel around the valve fitting to catch any fuel Refer to applicable EFI Diagnostic Manual.
  • Page 28: Check Compression Components

    Rotate the crankshaft in direction of operation until the Check Compression Components piston is at Top Dead Center (TDC) of the compression stroke on the cylinder being tested. Hold the crankshaft securely in place, with the piston Compression Test at TDC, to minimize the chance of rotation. This can An assessment of the engine's compression components can be done by holding the flywheel nut with a socket and be made with a compression test.
  • Page 29: Cylinder Balance Test

    • from the carburetor indicates air is leaking past the Start the engine and run at top no-load speed. intake valve and valve seat. Note the spark at the ignition tester. • from the exhaust system indicates air is leaking past the If the spark is equal at both ignition testers, the problem exhaust valve and valve seat.
  • Page 30: Check Crankcase Breather

    Apply vacuum or draw air out through breather hose to Check Crankcase Breather verify that air flows freely through valve. Engine Does Not Start If air flow has no resistance when blowing or is restricted under vacuum, the crankcase breather is faulty. Gently blow air into breather hose (A, Figure 27)to verify See SECTION 7 –...
  • Page 31: Troubleshooting Guide - Gasoline Fueled Engines

    Troubleshooting Guide - Gasoline Fueled Engines The troubleshooting guide that follows is designed to outline common problems, potential causes, and repair action related to gasoline-fueled engines. This guide is applicable to both carbureted and fuel-injected engine, with the differences noted within the chart.
  • Page 32 Gasoline-Fueled Engine Troubleshooting Chart Gasoline-Fueled Engine Troubleshooting Chart Problem Potential Cause Action Worn or fouled spark plug Replace spark plug with new and gap to recommended specification Air cleaner plugged Clean or replace air filter. See SECTION 2 - MAINTENANCE - Clean/Replace Air Filter Choke partly closed (carbureted engine) Open choke;...
  • Page 33 Gasoline-Fueled Engine Troubleshooting Chart Gasoline-Fueled Engine Troubleshooting Chart Problem Potential Cause Action Engine lacks power Perform On-Board Diagnostics See applicable EFI Diagnostic and (OBD) test (EFI engines) Repair manual for your engine Choke partially closed (carbureted engines) Open choke fully Carburetor out of adjustment Service carburetor.
  • Page 34: Troubleshooting Guide - Gaseous-Fueled Engines

    Troubleshooting Guide - Gaseous-Fueled Engines The troubleshooting guide that follows is designed to outline common problems, potential causes, and repair action related specifically to gaseous-fueled engines. Troubleshooting of common engine components and systems, such as the ignition system, is listed in the Gasoline-Fueled Troubleshooting Chart.
  • Page 35: Additional Troubleshooting Help

    Gaseous-Fueled Engine Troubleshooting Chart Gaseous-Fueled Engine Troubleshooting Chart Problem Potential Cause Action Debris and contamination on inlet needle of Clean system of debris and regulator contamination. Add fuel filter Regulator not positioned vertically Regulator may only be positioned with the outlet pointing straight up.
  • Page 36: Electrical Systems

    Electrical Systems Alternator System Diagnosis - Alternator The troubleshooting guide that follows is designed to outline common problems, potential causes, and repair action related to the alternator system. This guide is applicable to both carbureted and fuel-injected engines. Alternator System Troubleshooting Alternator System Troubleshooting Problem Potential Cause...
  • Page 37: Testing Alternator Output

    10. With the engine running at 3600 RPM, the output should Testing Alternator Output be between 13.9 and 14.5 VDC. 20 Amp Regulated Alternator 20/50 Amp Regulated Alternator Output Test - 20 Amp Alternator Output Test - 20/50 Amp Alternator Obtain 2 digital multimeters.
  • Page 38: Anti-Afterfire Solenoid - Carbureted Engines

    Turn the key switch to ON. The multimeter should display  NOTE: On engines equipped with "battery-less" charging battery voltage. systems, the output should be between 12.9 and 13.9 VDC. If the meter DOES NOT display battery voltage, the problem exists within the equipment wiring harness. Consult equipment repair manual for testing procedures.
  • Page 39: Test Engine Wiring Harness

    Connect the RED test lead probe to the POSSITVE Observe the multimeter display. The meter should terminal of the battery, and the BLACK test lead probe to red OL if the diode is healthy and working correctly. the NEGATIVE terminal of the battery. If the meter shows values different that the above values, Disconnect BOTH ignition wires from the spark plugs and the diode is defective.  The diode can be either open or...
  • Page 40: Engine Wiring Harness Diagram

    Engine Wiring Harness Diagram EFI and EFI-ETC Engine Refer to the EFI and EFI-ETC Diagnostic Manual that corresponds to your engine for pin-outs and diagnostic troubleshooting of the engine wiring harness. Carbureted and Gaseous Engines Your engine model may be fitted with additional equipment or lack components which may alter the appearance of the wire harness.
  • Page 41: Oil Pressure

    Start the engine. Allow the engine to run for Oil Pressure approximately 5 minutes. Check the oil pressure at 3000 RPM. Oil pressure should read between 10-50 PSI (0.7-3.5 Bar). Test Oil Pressure Switch 2 types of oil pressure switches may be used on your engine, Oil Pressure Troubleshooting Guide depending on the model, trim and type. The first type is a Low Oil Pressure...
  • Page 42: Troubleshooting - Starter Motor

    Troubleshooting - Starter Motor If a starting problem is encountered, check the engine to eliminate it as the cause of the problem. Check the engine for freedom of rotation by removing the spark plugs and turning the crankshaft over slowly by hand. Starter Motor Troubleshooting Starter Motor Troubleshooting Guide Problem...
  • Page 43: Starter Motor Solenoid Voltage Test

    For testing the solenoid output voltage, proceed as Starter Motor Solenoid Voltage Test follows: Prior to conducting this test, make sure the battery is fully Disconnect BOTH ignition wires from the spark plugs. charged and in good condition, see Testing the Battery.  NOTE: On gaseous-fueled standby generator engines, turn This is a 2-part test.
  • Page 44 Crank the engine for 15 seconds and observe the multimeter display. Record results. The observed voltage reading should match the observed reading from the battery load test. If the voltage drop is HIGHER than observed on the battery load test, check cables, wiring and connectors between the solenoid and the battery.
  • Page 45: Special Tools

    10. Valve Adjustment Set (Part No. 19465) SPECIAL TOOLS 11. Tang Adjusting Tool (Part No. 19480) 12. Dial Bore Gauge (Part No. 19487) Special Tools List 13. Leakdown Tester (Part No. 19545) Piston Ring Compressor (Part No. 19070) 14. Master Seat Cutter Kit (Part No. 19547) Flywheel Puller (Part No. 19203) 15.
  • Page 46: Special Tools Image Chart

    Special Tools Image Chart...
  • Page 47 SECTION 4 - REMOVE EXTERNAL ASSEMBLIES REMOVE EXTERNAL ASSEMBLIES ----------------------------------------------------------------------------------------------------------------- 50 Preliminary Instructions ------------------------------------------------------------------------------------------------------------------------------ 50 Relieve Fuel System Pressure - EFI and EFI-ETC ------------------------------------------------------------------------------------- 50 Oil Filter -------------------------------------------------------------------------------------------------------------------------------------------------- 50 Oil Cooler ------------------------------------------------------------------------------------------------------------------------------------------------ 51 Oil Diverter Valve and Drip Tray ------------------------------------------------------------------------------------------------------------------ 51 Oil Pressure Switch ----------------------------------------------------------------------------------------------------------------------------------- 51 Optional Oil Guard System ------------------------------------------------------------------------------------------------------------------------- 52 Air Cleaner Assembly - Cyclonic ------------------------------------------------------------------------------------------------------------------ 53...
  • Page 48 Fuel Rail and Fuel Injectors - EFI ---------------------------------------------------------------------------------------------------------------- 71 Fuel Rail and Fuel Injectors - EFI-ETC ----------------------------------------------------------------------------------------------------------71 T-MAP Sensor - EFI ---------------------------------------------------------------------------------------------------------------------------------- 71 Intake Manifold ----------------------------------------------------------------------------------------------------------------------------------------- 72 Wire Harness - EFI ----------------------------------------------------------------------------------------------------------------------------------- 73 Wire Harness - EFI-ETC ---------------------------------------------------------------------------------------------------------------------------- 74 Wire Harness - Carbureted and Gaseous ------------------------------------------------------------------------------------------------------ 77 Air Block Plate, Valley Air Guides, Speed Control Bracket -------------------------------------------------------------------------------- 78 Governor Arm Bracket ------------------------------------------------------------------------------------------------------------------------------- 79...
  • Page 49: Remove External Assemblies

    Relieve Fuel System Pressure - EFI and EFI-ETC REMOVE EXTERNAL ASSEMBLIES Turn Ignition OFF. Loosen fuel filler cap to relieve fuel tank pressure. Preliminary Instructions Tighten filler cap after loosening. Prior to starting any repair or maintenance operation. Remove access cover. See Engine Covers in this Make sure you are familiar with ALL safety warnings and section.
  • Page 50: Oil Cooler

    If equipped, remove the 2 fasteners (A, Figure 35) that Oil Cooler secure the oil drip tray to the engine block. Remove the drip tray from the engine block and set Remove the fastener (A, Figure 33) to release oil cooler aside.
  • Page 51: Optional Oil Guard System

    10. Disengage blue clip lock and remove crankcase Optional Oil Guard System ventilation hose connector from crankcase fitting. This section describes the procedure for removal of the Oil 11. Disengage green clip lock and remove oil supply Guard System scavenge, supply and vent lines as well as hose connector from crankcase cover fitting farthest from the engine mounted fittings.
  • Page 52: Air Cleaner Assembly - Cyclonic

    Air Cleaner Assembly - Cyclonic Air Cleaner Assembly - Low Profile Loosen band clamp (A, Figure 39) and remove hose Unscrew the air cleaner cover cap (A, Figure 40). from air intake elbow. Remove the air cleaner cover (B). Unscrew the air filter plate knob (C). Remove the air filter plate (D).
  • Page 53: Muffler

    Remove 2 fasteners (H) to release muffler manifolds Muffler from cylinder heads. Disconnect HO sensor connector (A, Figure 41), if  NOTE: Depending on your engine model and trim, the equipped. muffler manifold to cylinder head fastener may be replaced   with studs and nuts. NOTE: If necessary, rotate sensor body hex counter- Remove 2 fasteners (I) to release muffler bracket from clockwise to remove HO...
  • Page 54: Engine Covers

    Disconnect the choke rod from the speed control Engine Covers bracket (A, Figure 43) by releasing the retaining clip and There are 2 engine covers, which are identified here as the removing the rod from the bushing hole. key switch cover and the air intake elbow cover. The key switch cover serves as the housing for the ignition key switch and/or throttle lever, if equipped, and is always fastened to the blower housing.
  • Page 55: Throttle Control

    Remove the "Z" bend of the throttle cable (B) from the Throttle Control hole in the speed control bracket. Depending on your engine's model and trim, a manual detent throttle may be equipped. For engines equipped with  NOTE: The support bracket that houses the throttle control a Cyclonic Air Cleaner assembly, the throttle control may also serves as the air cleaner support bracket.
  • Page 56 On the starter motor side of the engine, remove the 3 fasteners (A, B, C, Figure 48) that secure the cylinder air guide to the engine. Remove the air guide from the engine and set aside.
  • Page 57: Blower Housing

    Blower Housing Voltage Regulator Your engine may be equipped with either a 20 amp or a 20/50 Remove 4 fasteners (A, Figure 49) to release wire guard amp voltage regulator. The 20/50amp voltage regulator has a (B) from coupling nuts. capacitor mounted to a bracket atop the regulator. Disconnect the voltage regulator to stator connector.
  • Page 58: Starter Motor

    Remove the voltage regulator (D, Figure 51 and Figure 52) from the engine and set aside. Remove the 2 starter motor support bracket to engine block nuts (B). Remove the 2 starter motor mounting fasteners (A, Figure 55). Starter Motor Remove starter motor positive terminal nut (A, Figure 53) and remove the wires from the terminal.
  • Page 59: Fuel Filter

    Remove fuel lift pump and set aside. Fuel Filter Squeeze tangs and move hose clamps (A, Figure 56) Fuel Pump - Carbureted Engine away from fuel inlet (B) and outlet (C) fittings. Remove fuel inlet and outlet hoses from fuel filter (E) fittings. Squeeze tangs and move hose clamp on the fuel feed line (A, Figure 58) away from the fuel pump.
  • Page 60 Remove the 2 fasteners (A, Figure 59) that secure the fuel pump to the fuel pump bracket. Remove the fuel pump and set aside.
  • Page 61: Fuel Pump Module

    On a vertical-shaft engine, the fuel pump module to Fuel Pump Module module mounting bracket bolts (A, Figure 61) are accessible at this point. Remove the 3 fuel pump module Disconnect the fuel pump module electrical connector (A, fasteners and set the fuel pump module aside. Figure 60).
  • Page 62: Engine Control Module (Ecm) - Efi

    Remove the 2 fasteners securing the fuel pump module Remove the J1 (GRAY) (C) and J2 (BLACK) (D) harness support bracket to the valley air guides (A, Figure 63). connectors from the ECM by depressing the connector Set mounting bracket aside. tab and pulling away from the ECM.
  • Page 63: Crankshaft Position Sensor (Ckp)

    Crankshaft Position Sensor (CKP) Optional Speed Sensor Disconnect the crankshaft position sensor electrical Remove the 2 speed sensor fasteners (A, Figure connector (A, Figure 65). 66) from the engine back plate mounting. Remove the 2 crankshaft position sensor fasteners (B). Set sensor aside. Remove the sensor wiring (B) from the back plate routing.
  • Page 64: Ignition Coil/Armature - Carbureted And Gaseous

    Ignition Coil/Armature - Carbureted and Gaseous Ignition Coil - EFI and EFI-ETC Starting with the ignition coil/armature for cylinder 1, Disconnect the engine wire harness connector from the remove the 2 fasteners (A, Figure 67) that secure the ignition coil electrical connector (A, Figure 68). ignition coil to the engine block.
  • Page 65: Intake Elbow And Throttle Body Adapter - Efi

    Remove the air cleaner base plate to support bracket Intake Elbow and Throttle Body Adapter - EFI fasteners. On engines equipped with a cyclonic air cleaner, an intake  NOTE: Depending on your engine's trim, the air cleaner base elbow is fitted. Follow the removal steps for the intake elbow. plate may be secured to a support bracket with either 2 or 4 On engines equipped with a low-profile air cleaner, a throttle fasteners.
  • Page 66: Throttle Position Sensor (Tps)

    Remove dead idle screw with spring from throttle body. Throttle Position Sensor (TPS) Mark throttle plate position for ease of installation. Depending on your engine's specification and production date, 2 styles of TPS may be equipped. The late style non- adjustable TPS (A, Figure 73) can be identified by the round fastener holes (B) in the mounting flange.
  • Page 67: Carburetor And Spacers

    Remove the 4 fasteners that secure the carburetor (A, Carburetor and Spacers Figure 75) to the intake elbow. Remove the intake elbow Your engine may be equipped with either a cyclonic air and discard old gasket. cleaner assembly or a low-profile air cleaner assembly. On engines equipped with a low-profile air cleaner, the air cleaner base makes use of 4 studs that secure the intake adaptor, carburetor, spacers and gaskets to the intake...
  • Page 68 Remove the 4 fasteners that secure the air cleaner base to the intake adaptor (A, Figure 76). Remove air cleaner base and discard old gasket. Remove intake adaptor from carburetor. Discard old gasket. Lift the carburetor SLIGHTLY to allow for the disconnection of the throttle rod and spring.
  • Page 69: Anti-Afterfire Solenoid

    On vertical-mounted mixers, remove the spacer from Anti-Afterfire Solenoid the mixer or stepper motor bracket (if equipped). Discard old gasket. See Figure 77. Disconnect the wire harness connector from the anti- afterfire solenoid. Unscrew the anti-afterfire solenoid from the carburetor bowl by turning the solenoid in a counter-clockwise direction.
  • Page 70: Fuel Rail And Fuel Injectors - Efi

    14. On horizontally-mounted mixers, remove the 3 Remove retaining clips and then remove fuel injector fasteners that secure the intake manifold elbow to the caps from fuel injectors. intake manifold. Remove the elbow and insulator spacer Remove fuel injectors from intake manifold bores. from the manifold.
  • Page 71: Intake Manifold

    Intake Manifold Remove the 4 intake manifold fasteners (A, Figure 81). Remove the intake manifold from the cylinder heads. Remove and discard the intake manifold gaskets. Clean the intake manifold and cylinder head mating surfaces of all old gasket material. The mating surfaces need to be clean, dry and free of all contamination and gasket material.
  • Page 72: Wire Harness - Efi

    Disconnect fuel injector connector. Wire Harness - EFI Disconnect ignition coil connector. The instructions for the removal of the wiring harness for Disconnect CKP sensor connector. EFI engines can be used as a stand-alone instruction on an assembled engine OR in conjunction with the disassembly Disconnect IAC connector.
  • Page 73: Wire Harness - Efi-Etc

    12. Disconnect cylinder 1 ignition coil connector (L, Figure Wire Harness - EFI-ETC 85) after removing anchor of rosebud style clip from The instructions for the removal of the wiring harness for EFI- boss at rear of intake manifold. Pull out red secondary ETC engines can be used as a stand-alone instruction on an lock, and then press and hold tab before pulling apart assembled engine OR in conjunction with the disassembly...
  • Page 75 vanguardpower.com...
  • Page 76: Wire Harness - Carbureted And Gaseous

    Disconnect the ignition armature spade connectors (G-H) Wire Harness - Carbureted and Gaseous from the armatures. The instructions for the removal of the wiring harness for carbureted and gaseous engines can be used as a stand-  NOTE: The wiring for the ignition armatures, oil pressure alone instruction on an assembled engine OR in conjunction switch, and grounds may be secured to the intake manifold with the disassembly process of an engine.
  • Page 77: Air Block Plate, Valley Air Guides, Speed Control Bracket

    Remove the 4 valley air guide fasteners (A, Figure 88). Air Block Plate, Valley Air Guides, Speed Control Bracket Remove the 2 valley air block plate mounting fasteners (A, Figure 87).  NOTE: Your engine may be equipped with an air filter support bracket or a speed control bracket.
  • Page 78: Governor Arm Bracket

    If equipped, remove the 2 fasteners that secure the fuel module support bracket to the engine (A, Figure 91).  NOTE: Make a note of the governor arm spring positions for proper reassembly. Check springs for fatigue, and replace if necessary. Loosen the governor arm bracket pinch bolt (A, Figure 93).
  • Page 79 SECTION 5 - DISASSEMBLE ENGINE TOP END DISASSEMBLY ------------------------------------------------------------------------------------------------------------------------------- 81 Preliminary Instructions ------------------------------------------------------------------------------------------------------------------------------ 81 Top End Disassembly -------------------------------------------------------------------------------------------------------------------------------- 81 BOTTOM END DISASSEMBLY -------------------------------------------------------------------------------------------------------------------------83 Flywheel Fan and Flywheel -------------------------------------------------------------------------------------------------------------------------83 Alternator and Guard Plate ------------------------------------------------------------------------------------------------------------------------- 85 Bottom End Disassembly ----------------------------------------------------------------------------------------------------------------------------85 vanguardpower.com...
  • Page 80: Top End Disassembly

    Move piston of first cylinder to Top Dead Center (TDC) of TOP END DISASSEMBLY the compression stroke. Proceed as follows:  NOTE: Disassembly with the valve train loaded can result in Preliminary Instructions bent push rods. Prior to starting any repair or maintenance operation. Make sure you are familiar with ALL safety warnings and A.
  • Page 81 vanguardpower.com...
  • Page 82: Bottom End Disassembly

    Obtain the Strap Wrench (see SECTION 3 - BOTTOM END DISASSEMBLY TROUBLESHOOTING - Special Tool List), correct size socket for flywheel nut, and breaker bar. See Figure 97 and proceed as follows: Flywheel Fan and Flywheel  NOTE: DO NOT use an impact wrench to loosen the See SECTION 4 - REMOVE EXTERNAL ASSEMBLIES flywheel nut.
  • Page 83 Obtain Flywheel Puller (see SECTION 3 - TROUBLESHOOTING - Special Tool List), see Figure 98 and proceed as follows: A. Install flywheel nut until top is flush with end of crankshaft. B. Run hex nut about half way down each of 2 puller screws.
  • Page 84: Alternator And Guard Plate

    Alternator and Guard Plate Bottom End Disassembly Remove the fastener (A, Figure 99) to release the Obtain a Crankcase Cover Puller, and proceed as alternator wire clamp from crankcase. follows: Remove 11 fasteners (1 - 11, Figure 101) from crankcase cover (A). Remove the 4 fasteners and washers (A, Figure 100) to release the alternator (B) from crankcase bosses.
  • Page 85 Place tube A, Figure 102) of puller over crankshaft Remove the 2 o-rings (A, Figure 103) from crankcase seating end of forcing screw (B) at end of crankshaft. flange. Discard the old o-rings. 10. Remove locating pins (B) from crankcase flange and set Back up forcing screw as necessary, so that base (C) aside.
  • Page 86 11. Rotate crankshaft (A, Figure 104) to align timing marks 15. Use a plastic scraper to carefully remove carbon ridge at (see inset image) on crankshaft gear tooth and camshaft top of cylinder bore (A, Figure 105). gear root.  NOTE: Failure to remove carbon ridge can result in piston ring breakage.
  • Page 87 18. Remove connecting rod and piston assembly from • PISTON AND CONNECTING ROD cylinder bore. • FLYWHEEL, CRANKSHAFT AND CAMSHAFT 19. Repeat steps 17-18 on opposite cylinder. • CRANKCASE AND CRANKCASE COVER. 20. Remove crankshaft from crankcase. 21. See the following topics under SECTION 6 - SERVICE ENGINE SUBASSEMBLIES: vanguardpower.com...
  • Page 88 SECTION 6 - SERVICE ENGINE SUBASSEMBLIES PRELIMINARY INSTRUCTIONS ----------------------------------------------------------------------------------------------------------------------- 91 CYLINDER HEAD -------------------------------------------------------------------------------------------------------------------------------------------91 Disassembly ---------------------------------------------------------------------------------------------------------------------------------------------91 Cleaning -------------------------------------------------------------------------------------------------------------------------------------------------- 92 Inspection ------------------------------------------------------------------------------------------------------------------------------------------------ 92 Cylinder Head ------------------------------------------------------------------------------------------------------------------------------------- 92 Valve Guide Inspection ------------------------------------------------------------------------------------------------------------------------- 93 Valve Seat Inspection ---------------------------------------------------------------------------------------------------------------------------93 Valves ----------------------------------------------------------------------------------------------------------------------------------------------- 93 Valve Springs --------------------------------------------------------------------------------------------------------------------------------------97 Valve Spring Retainers/Tapered Keepers Inspection ---------------------------------------------------------------------------------- 97 Tappets, Push Rods, Adjuster Screws, and Rocker Arms ----------------------------------------------------------------------------97 Intake Manifold Studs --------------------------------------------------------------------------------------------------------------------------- 97...
  • Page 89 Oil Pump - Vertical Shaft Engines - Assembly ----------------------------------------------------------------------------------------- 107 Optional Oil Guard System - Disassembly ---------------------------------------------------------------------------------------------- 107 Oil Guard Oil Supply Pump - Removal --------------------------------------------------------------------------------------------- 107 Oil Guard Oil Scavenge Pump - Removal ----------------------------------------------------------------------------------------- 108 Optional Oil Guard System - Assembly -------------------------------------------------------------------------------------------------- 109 Oil Guard Oil Scavenge Pump - Install --------------------------------------------------------------------------------------------- 109 Oil Guard Oil Supply Pump - Install ------------------------------------------------------------------------------------------------- 109 PTO Oil Bearing Seal - Disassembly ----------------------------------------------------------------------------------------------------- 110...
  • Page 90: Preliminary Instructions

    Place tool (B) over head of fulcrum screw engaging small Preliminary Instructions end of slot. Prior to starting any repair or maintenance operation. With prongs of tool on valve spring retainer (C), pivot tool Make sure you are familiar with ALL safety warnings and to compress valve spring (D).
  • Page 91: Cleaning

    15. Repeat steps 1 - 14 to remove valve assemblies from Check the cylinder head to cylinder mating surface for second cylinder head. warpage or distortion. Discard the cylinder head if any low spot is 0.002 inches (0.05 mm) or more. Proceed as follows: Cleaning A.
  • Page 92: Valve Guide Inspection

    To verify cleanliness, lightly hone bore using a suitable valve guide hone and then scrub with a valve guide cleaning brush to remove any dirt or debris. Measure the inside diameter using an inside ball micrometer or plug gauge. Replace the cylinder head if the measurement is 0.240 in (6.106 mm) or more.
  • Page 93 Inspect intake valve face and seat. If only minimal wear is found, lap the valve face and seat as follows: A. Obtain Valve Lapping Compound (see SECTION 9 - SPECIFICATIONS - Engine Fluid and Sealant Specifications). B. Apply lapping compound sparingly around the entire valve face and valve seat.
  • Page 94 H. Remove valve from the cylinder head and thoroughly If the desired results are not observed, obtain a valve clean the valve face and valve seat of any lapping seat cutting tool kit. For engines equipped with 3-angle compound. Use a clean rag dipped in mineral spirits valve seats, see Figure 112, and proceed as follows.
  • Page 95 11. For engines equipped with single-angle valve seats, see Figure 113 and proceed as follows:  NOTE: Carefully read manufacturer's directions for proper assembly and use of valve seat cutting tool. A. Install the proper sized pilot in the intake valve guide.  ...
  • Page 96: Valve Springs

    Valve Springs Intake Manifold Studs Inspect valve springs for broken or discolored coils. Inspect intake manifold studs (A, Figure 114). Replace Replace springs if either of these conditions are found. studs if broken, bent, or if severe thread damage is observed.
  • Page 97 Install exhaust valve assembly as follows: E. To distribute the assembly lube evenly around the valve stem and guide, hand spin the valve as it is A. Lightly lubricate inside diameter new valve stem installed. Work the valve back and forth in the bore seal (A, Figure 115) with clean engine oil.
  • Page 98: Piston And Connecting Rod

    M. Fit the tapered keepers (E) into the valve stem Remove compression ring from the top ring groove. See groove with the tapered side down. For best results, Figure 118. apply a suitable engine assembly lube to the inside of the keepers before installation. Arrange keepers so that the gap is evenly spaced, and release the valve spring compression (F).
  • Page 99: Cleaning

     NOTE: A piston with superficial wear marks, minor Cleaning scratching or mild scoring may continue to be used. Lightly oil, with clean engine oil, a good piston pin and Piston insert it into the piston pin bore to feel for proper fitment. Do not sand blast or glass bead blast piston.
  • Page 100: Connecting Rod

    Measure the piston ring side clearance as follows: Install the connecting rod cap to the connecting rod so that the marks on the connecting rod cap and shank are  NOTE: Worn ring grooves result in high oil consumption aligned (see Figure 122). Start the 2 fasteners by hand, and blow-by of exhaust gases.
  • Page 101: Assembly

    Install new piston pin lock ring into pin bore groove, Assembly so that end of the lock ring is 90° from the pick lock groove. Exercise care to avoid kinking, stretching, or Apply clean engine oil to piston pin, piston pin bosses, distorting lock ring.
  • Page 102 Obtain the Piston Ring Expander (see SECTION 3 - 12. Stagger the ring gaps around the piston. Proceed as TROUBLESHOOTING - Special Tool List). follows: A. Rotate expander spring, so that the gap is positioned  NOTE: Always use the piston ring expander to prevent at the front of the piston (A, Figure 127).
  • Page 103: Flywheel, Crankshaft And Camshaft

    Crankshaft FLYWHEEL, CRANKSHAFT AND CAMSHAFT Carefully remove crankshaft end play shims (A, Figure 129), if present. Count shims as they are removed to be Cleaning sure of installing the correct number when the engine is assembled. Inspect shims for tears, holes, or other Thoroughly clean parts in a non-volatile cleaning solution or solvent.
  • Page 104: Camshaft

    Camshaft CRANKCASE AND CRANKCASE COVER Check camshaft gear (A, Figure 130) for worn, cracked, chipped, or missing teeth. Governor Shaft and Seal - Disassembly If equipped, remove C-clips (A, Figure 131) from top 2 grooves in governor shaft (B) and bottom groove within the crankcase.
  • Page 105: Crankcase Cover

    MAG Bearing Oil Seal - Disassembly Crankcase Cover Using Figure 132 as a reference, remove and discard oil Governor Gear - Disassembly seal from crankcase bearing bore. Exercise care to avoid scratching bearing bore during removal. Remove governor cup (A, Figure 133) from governor shaft (B).
  • Page 106: Oil Pump - Horizontal Shaft Engines - Disassembly

    Remove 4 fasteners (A, Figure 135) to release cover (B) Oil Pump - Horizontal Shaft Engines - Disassembly from crankcase cover (C). The following procedure applies to horizontal shaft engines. Remove 2 fasteners (A Figure 134) to release oil pump (B) from crankcase cover (C) . Remove o-ring (D) from crankcase cover groove.
  • Page 107: Oil Guard Oil Scavenge Pump - Removal

    Remove 4 fasteners (A, Figure 136) to release the oil Remove roll pin (A, Figure 138) from hole in gear shaft. supply pump gerotor cover (B) from crankcase cover (C). Remove o-ring (A, Figure 137) from the crankcase cover groove. Remove crescent ring (B) from the groove on the gear shaft.
  • Page 108: Optional Oil Guard System - Assembly

    Remove 4 fasteners (A, Figure 139) to release oil Remove inner and outer gerotors (B) from gear shaft. scavenge pump gerotor cover (B) from the crankcase Remove oil filter screen (C). cover (C). Remove roll pin (A, Figure 141) from hole in gear shaft. On opposite side of crankcase cover, remove gear shaft assembly from crankcase cover.
  • Page 109: Pto Oil Bearing Seal - Disassembly

    Install the oil supply pump cover onto the crankcase PTO Oil Bearing Seal - Assembly cover. Start by hand the 4 cover fasteners. Tighten to 90 lb-in Apply a thin film of clean engine oil the oil seal bore and (10.2 Nm).
  • Page 110: Starter Motor Solenoid - Assembly

    Remove the stator brush fastener and washer (A, Figure Disconnect the stator brush strap (B) from the solenoid 144). by lifting it up and over the threaded stud. Take care to avoid damaging the brush strap. Remove the solenoid from the starter motor housing. Starter Motor Solenoid - Assembly Apply grease (see SECTION 9 - SPECIFICATIONS - Fluid and Sealant Specifications) with a small brush or...
  • Page 111 Vanguard Model 540000 vanguardpower.com...
  • Page 112 Disassembly - Carburetor - Vanguard Model 540000 the carburetor body. Remove the cover plate and discard the gasket. The Vanguard Model 540000 OHV V-Twin utilizes a fixed jet, Remove the 2 fasteners that secure the choke plate (G) two-barrel, side draft, flo-jet carburetor. Except for idle speed, to the choke shaft (H).
  • Page 113 Vanguard Model 610000 vanguardpower.com...
  • Page 114 Disassembly - Carburetor - Vanguard Model 610000 The Vanguard Model 610000 OHV V-Twin utilizes a fixed jet, two-barrel, side draft, flo-jet carburetor. Except for idle speed, the carburetor is non adjustable. The carburetor incorporates a fuel shut-off (anti-afterfire) solenoid that controls the flow to the fuel metering system.
  • Page 115 Install the 2 float bowl fasteners and tighten until snug. compressed air. Hold main jet assembly up to the light to verify Assembly - Carburetor - Vanguard Model 610000 cleanliness. Verify that all orifices are clean and open. Install new seal and bushings onto throttle shaft (J, Check main jet passageway for discoloration, dirt, Figure 146). Install throttle shaft into carburetor body.
  • Page 116: Mixer - Gaseous Engines

    11. Using a thin profile wrench, install the anti-afterfire MIXER - GASEOUS ENGINES solenoid into the float bowl with new sealing washer. Tighten until snug. 12. Install the float bowl and 4 fasteners (A) onto the Mixer - Gaseous Engines carburetor body.
  • Page 117 SECTION 7 - ASSEMBLE ENGINE PRELIMINARY INSTRUCTIONS ----------------------------------------------------------------------------------------------------------------------119 BOTOM END ASSEMBLY ------------------------------------------------------------------------------------------------------------------------------119 Bottom End Assembly ------------------------------------------------------------------------------------------------------------------------------ 119 Alternator and Guard Plate ------------------------------------------------------------------------------------------------------------------------124 Flywheel Fan and Flywheel ----------------------------------------------------------------------------------------------------------------------- 125 TOP END ASSEMBLY -----------------------------------------------------------------------------------------------------------------------------------126 Top End Assembly ---------------------------------------------------------------------------------------------------------------------------------- 126 Crankcase Breather ----------------------------------------------------------------------------------------------------------------------------128 vanguardpower.com...
  • Page 118: Preliminary Instructions

    10. Start piston/connecting rod assembly into bore of cylinder Preliminary Instructions 1, so that the rod stamp OUT-1 is visible through the  crankcase cover opening (A, Figure 147). Prior to starting any repair or maintenance operation. Make sure you are familiar with ALL safety warnings and procedures as outlined in SECTION 1 - SAFETY AND GENERAL INFORMATION - Safety Information.
  • Page 119 11. See Figure 148. Verify that the locating dot on the piston 12. Obtain the Piston Ring Compressor (see SECTION 3 - crown is on the MAG bearing side. TROUBLESHOOTING - Special Tool List), and proceed as follows: A. Using tool wrench, unwind sleeve of piston ring compressor.
  • Page 120 15. Start piston/connecting rod assembly into cylinder 2 21. Verify that valve tappets are clear of camshaft lobes, and bore, so that the rod stamp OUT-2 is visible through install camshaft into bearing bore aligning timing mark on the crankcase cover opening (B, Figure 150), and the camshaft gear root with timing mark on crankshaft gear locating dot on the piston crown is on the MAG bearing tooth See Figure 151.
  • Page 121 24. Lightly lubricate two new o-rings (A, Figure 152) with 27. See Figure 153. Verify that governor cup is installed on clean engine oil and insert into crankcase flange. Be sure governor gear shaft. that old o-rings are not installed, as stacking old and new o-rings will cause oil leaks.
  • Page 122 29. See Figure 154. Install steel core gasket, if used, or 33. Start 11 fasteners  to secure crankcase cover (A, Figure apply a bead of Silicone Sealant (see SECTION 9 - 155) to crankcase. Proceed as follows: SPECIFICATIONS - Lubricants and Sealants) 0.06-0.10 inches (1.5-2.5 mm) thick to crankcase cover.
  • Page 123: Alternator And Guard Plate

    35. Using Figure 156 as a reference, check crankshaft end Alternator and Guard Plate play as follows: Place the stator (A, Figure 157) on crankcase bosses. Route stator wires around the boss as shown in Figure A. Mount base of dial indicator to crankcase or 158.
  • Page 124: Flywheel Fan And Flywheel

    Install SEMS screw (G) to fasten back plate to crankcase Install flywheel (A, Figure 160) engaging keyway with at location shown. Tighten fastener to 90 lb-in (10.2 Nm). installed key on crankshaft taper. Verify that flywheel fits tightly without wobbling. Flywheel Fan and Flywheel Verify that flywheel and crankshaft tapers are free of grease, oil, dust, and dirt.
  • Page 125: Top End Assembly

    Obtain Strap Wrench (see SECTION 3 - Install 4 blower housing mounting posts (A, Figure 163) TROUBLESHOOTING - Special Tool List), torque into crankcase. Tighten posts to 110 lb-in (12.4 Nm). wrench, and correct size socket. Using Figure 161 as a reference, proceed as follows: See TOP END ASSEMBLY in this section.
  • Page 126 Tighten cylinder head bolts in sequence as shown in Start fasteners (A, Figure 165) to fasten rocker Figure 164: arms (B) and fulcrums (C) to cylinder head. Tighten fasteners to 105 lb-in (11.9 Nm). Insert push rods into cylinder head bores to engage valve tappets.
  • Page 127: Crankcase Breather

    18. Start 4 fasteners to secure valve covers to cylinder Crankcase Breather heads. Alternately tighten fasteners to 70 lb-in (7.9 Nm) using the sequence shown in Figure 167. Check crankcase breather as follows:  NOTE: The engine lifting brackets are secured by the valve A.
  • Page 128 Install the inner baffle (G) with raised edges (J) facing Install O-ring (F) into valve cover groove. Inspect for OUT. dryness, cracking, or cuts. 10. Install the outer baffle (D) into the breather cover with the   three bosses facing out. NOTE: DO NOT forcibly install components. One corner of the breather components have a sharper radius than the 11.
  • Page 129 SECTION 8 - INSTALL EXTERNAL ASSEMBLIES INSTALL EXTERNAL ASSEMBLIES ---------------------------------------------------------------------------------------------------------------- 132 Preliminary Instructions -----------------------------------------------------------------------------------------------------------------------------132 Governor Arm Bracket ------------------------------------------------------------------------------------------------------------------------------132 Air Block Plate, Valley Air Guides, Speed Control Bracket -------------------------------------------------------------------------------132 Wire Harness  - EFI ---------------------------------------------------------------------------------------------------------------------------------- 134 Wire Harness - EFI-ETC ---------------------------------------------------------------------------------------------------------------------------135 Wire Harness - Carburetor and Gaseous ----------------------------------------------------------------------------------------------------- 138 Intake Manifold --------------------------------------------------------------------------------------------------------------------------------------- 139 T-MAP Sensor ...
  • Page 130 Muffler --------------------------------------------------------------------------------------------------------------------------------------------------- 156 Air Cleaner Assembly - Cyclonic ---------------------------------------------------------------------------------------------------------------- 156 Air Cleaner Assembly - Low Profile ------------------------------------------------------------------------------------------------------------ 158 Optional Oil Guard System ------------------------------------------------------------------------------------------------------------------------159 Oil Pressure Switch --------------------------------------------------------------------------------------------------------------------------------- 160 Oil Diverter Valve and Drip Tray ---------------------------------------------------------------------------------------------------------------- 160 Oil Cooler ---------------------------------------------------------------------------------------------------------------------------------------------- 161 Oil Filter -------------------------------------------------------------------------------------------------------------------------------------------------161 Final Instructions ------------------------------------------------------------------------------------------------------------------------------------- 162...
  • Page 131: Section 8 - Install External Assemblies

    Start the 2 air block plate fasteners (A, Figure 170) by INSTALL EXTERNAL ASSEMBLIES hand. Tighten to 18 lb-in (2 Nm). Preliminary Instructions Prior to starting any repair or maintenance operation. Make sure you are familiar with ALL safety warnings and procedures as outlined in SECTION 1 - SAFETY AND GENERAL INFORMATION - Safety Information.
  • Page 132 Start the 4 air guide fasteners by hand (A, Figure 171). If equipped, install the valley component bracket (A, Tighten to 195 lb-in (22 Nm). Figure 174) in the valley of the engine block.  NOTE: Your engine may be equipped with an air filter support bracket or a speed control bracket.
  • Page 133: Wire Harness - Efi

    See section C of Figure 175. Proceed as follows: Wire Harness - EFI Connect TPS connector. The instructions for the installation of the wiring harness for Connect fuel pump module connector. Push in grey EFI engines can be used as a stand-alone instruction for the secondary lock to secure.
  • Page 134: Wire Harness - Efi-Etc

    Running conduit between intake manifold and fuel rail, Wire Harness - EFI-ETC connect cylinder 2 fuel injector connector (P, Figure 176). The instructions for the installation of the wiring harness for Push in white secondary lock. If removed, install fuel EFI and EFI-ETC engines can be used as a stand-alone injector cap screw and tighten to 110 lb-in (12.4 N-m).
  • Page 135 12. Proceed as follows: A. Cylinder 2 (Oil Filter) Side: • Capture wire harness (ignition coil, fuel injector, and ground wire ring terminal conduit) in double- sided clamp (W). Opposite side of clamp captures fuel rail hose. • Start short hex flange screw  (X) to fasten clamp to intake manifold boss.
  • Page 137: Wire Harness - Carburetor And Gaseous

    Secure the anti-afterfire ground ring terminal (C) and the Wire Harness - Carburetor and Gaseous harness ground ring terminal (E) to the engine with the The instructions for the installation of the wiring harness for fastener. Tighten fastener to 18 lb-in (2 Nm). carbureted and gaseous engines can be used as a stand- alone instruction on an assembled engine OR in conjunction  NOTE: The 2 ground wire ring terminals are secured to the...
  • Page 138: Intake Manifold

    Reserve connecting the equipment harness connector (A) until all service and repairs are complete and the engine is safe to run. Install fuel injectors into intake manifold. Intake Manifold Install retaining clips to secure fuel injector caps to fuel Install the intake manifold (A, Figure 179) with new injectors.
  • Page 139: Fuel Rail And Fuel Injectors - Efi-Etc

    Install retaining clips to secure fuel injector caps to fuel Fuel Rail and Fuel Injectors - EFI-ETC injectors. To install fuel rail, proceed as follows:  NOTE: Be sure retaining clips are properly installed. Side slots on clip engage lip on cap, while tab (K) on fuel injector body is captured between prongs (L) on clip.NOTE: Install fuel injectors into intake manifold bores.
  • Page 140 On Horizontal Shaft engines, install the 3 fasteners that Install the new gaskets and spacers between the secure the intake elbow to the intake manifold (B, Figure carburetor and intake manifold (Vertical Shaft engines) 182). Tighten to 90 lb-in (10.2 Nm). or intake elbow (Horizontal Shaft engines). On Horizontal Shaft engines, install the 3 fasteners that secure the intake elbow to the intake manifold (B, Figure 183). Tighten to 90 lb-in (10.2 Nm).
  • Page 141: Anti-Afterfire Solenoid

    10. Connect the fuel vent line to the intake elbow port. On vertically-mounted mixers, install new gaskets and spacer between the mixer or stepper motor bracket (if 11. Connect the valve cover breather hose to the carburetor equipped), using Figure 185 as a reference. port.
  • Page 142: Throttle Position Sensor (Tps) - Late Style

    Using the Diagnostic Tool, select the Dashboard icon in Throttle Position Sensor (TPS) - Late Style the left sidebar to view the Dealer tab. Select the Test Procedures tab in the lower left corner. Install the TPS into the throttle body. Slew the Idle Air Control Position (Steps) to 0 steps.
  • Page 143: Intake Elbow/Throttle Body Adaptor

    Start the 2 fasteners (B, Figure 187) by hand. Tighten to Throttle Body Adaptor Installation 13 lb-in (1.5 Nm). Install the throttle body adaptor with new gasket onto the throttle body. If equipped, install the ECM/Fuse Block mounting bracket to the throttle body adaptor. The throttle body adaptor is secured to the throttle body with 4 fasteners that also secure the low-profile air cleaner base.
  • Page 144: Ignition Coil/Armature - Carbureted And Gaseous

    Install the wire harness connector for the ignition coil on Apply a small amount of threadlocker (see to the intake manifold by sliding the attachment tab onto SPECIFICATIONS - Engine Fluids and Sealant the intake manifold (B, Figure 191). Specifications) to the armature fastener threads. Start the 2 armature fasteners by hand (A-B, Figure 192).
  • Page 145: Optional Speed Sensor

    Apply a small amount of threadlocker (see Optional Speed Sensor SPECIFICATIONS - Engine Fluids and Sealant Specifications) CKP fastener threads. Start the 2 sensor Install the speed sensor onto the engine back plate. Align fasteners (B, Figure 194) by hand. Tighten until the the 2 mounting holes with the threaded back plate holes.
  • Page 146: Fuel Pump Module

    Start by hand the 2 fasteners that secure the ECM to the Start the 3 module fasteners by hand (A, Figure 196). mounting bracket (A, Figure 195). Tighten to 90 lb-in (10.2 Nm). On a horizontal-shaft engine, it may be necessary to secure the fuel pump module to the mounting bracket prior to installation on the engine.
  • Page 147: Fuel Pump - Carbureted

    Start the 3 fasteners by hand. Tighten to 115 lb-in (13 Start the 2 mounting fasteners by hand (A, Figure 199). Nm). Tighten to 90 lb-in (10.2 Nm). Install the fuel feed line (C, Figure 198), from fuel pump module to fuel injectors, by pressing the connector onto the port until it "clicks."...
  • Page 148: Electric Lift Fuel Pump

    Install the fuel outlet hose onto the outlet port of the Start the 2 mounting fasteners by hand (A, Figure 201). pump (B, Figure 200). Press the hose onto the port, Tighten to 90 lb-in (10.2 Nm). squeeze the tangs of the clamp and slide along the hose until it is positioned on top of the outlet port.
  • Page 149: Fuel Filter

    Start the 2 mounting fasteners by hand (A, Figure 203). Fuel Filter Tighten to 140 lb-in (15.8 Nm). The inline fuel filter has 2 ports, an inlet port which receives fuel from the tank and an outlet port which feed fuel to the fuel pump.
  • Page 150: Voltage Regulator

    Connect the ignition switch start wire (B, Figure 205) to  NOTE: The 20 amp alternator has a single 2-wire connector. the starter motor terminal. The 20/50 amp alternator has double 2-wire connectors. Connect the RED voltage regulator wire with ring terminal connector to the positive starter motor terminal (B).
  • Page 151: Blower Housing

    Install the triangular spacer (E, Figure 210) to the fan Blower Housing mounting posts. Install the debris screen (D) atop the triangular spacer. Align the mounting holes of the spacer If removed during disassembly, install by hand the 4 and screen to the threaded holes of the mounting posts. blower housing mounting posts to the engine block and cylinder heads (A, Figure 208). Tighten to 110 lb-in (12.4 Nm).
  • Page 152: Cylinder Air Guides

    Start by hand the 3 fasteners (A, B, C, Figure 212). Cylinder Air Guides Tighten to 90 lb-in (10.2 Nm). On the oil filter side of the engine, install the cylinder air guide to the cylinder head. Align the air guide mounting holes to the threaded holes in the cylinder head.
  • Page 153: Engine Covers

    Insert the "Z" bend of the throttle cable (B, Figure 213) Engine Covers into the hole in the speed control bracket tab. There are 2 engine covers, which are identified here as the key switch cover and the air intake elbow cover. The key switch cover serves as the housing for the ignition key switch and/or throttle lever, if equipped, and is always fastened to the blower housing.
  • Page 154: Intake Elbow Cover

    If equipped with a manual rotary throttle lever, install Intake Elbow Cover the throttle lever (B, Figure 216) with fastener (A) and washer stack (C) to the throttle shaft (D). Tighten to 90 If equipped, connect MIL/tachometer/hourmeter harness lb-in (10.2 Nm). connector to component connector on the back of the cover.
  • Page 155: Muffler

    Apply anti-seize compound to threads of 4 fasteners (H), Muffler and then install to fasten muffler manifolds to cylinder heads. Tighten fasteners to 195 lb-in (22 Nm). If equipped with optional muffler bracket support, proceed as follows:  NOTE: Depending on your engine model and trim, the A.
  • Page 156 Position air cleaner assembly (I) on air cleaner top 18. If equipped, install safety filter into air cleaner base. bracket with the duckbill air valve pointing down. Orient the safety filter so that the open end installs into the base. Engage hook on air cleaner strap (J) with lip on air cleaner top bracket.
  • Page 157: Air Cleaner Assembly - Low Profile

    NOTE: Note that back plate is stamped “Air Filter Side” Air Cleaner Assembly - Low Profile to ensure proper installation. Position throttle body gasket (A, Figure 221) at top of Install 4 fasteners (E) with lock washers (F) to secure throttle body.
  • Page 158: Optional Oil Guard System

    10. Remove foam pre-cleaner (A, Figure 223) from air filter 15. Install foam pre-cleaner onto air filter. (B). 16. Place air filter with foam pre-cleaner onto air cleaner back plate (C). 17. Fit metal retainer plate (D) evenly and snugly into air filter. 18. Install thumb nut (E) onto threaded rod and tighten until snug.
  • Page 159: Oil Pressure Switch

    Install oil scavenge hose fitting and hose as follows: Start by hand the switch (B, Figure 225) into the crankcase. Tighten to 15 lb-in (1.7 Nm). A. Apply a light film of clean engine oil to new o-ring (C) of oil scavenge pump hose fitting (D). Install o-ring onto fitting.
  • Page 160: Oil Cooler

    Rotate hex (B) to install adapter (C) and diverter (D) to Oil Filter crankcase flange. Verify the oil filter mount flange (A, Figure 229) is clean  NOTE: Orient diverter so that the locator tab faces toward and dry. the PTO side crankcase cover side as shown. Tighten adapter to 240 lb-in (27.1 Nm).
  • Page 161: Final Instructions

     NOTE: If equipped with Vanguard Oil Guard System, make Final Instructions sure that the system is properly primed prior to operation. Prior to the operation of the engine after completion of See this section, Optional Oil Guard System step 5. any service and repair procedures, you must obey all Install spark plug wires onto spark plug terminals.
  • Page 162 SECTION 9 - SPECIFICATIONS SPECIFICATIONS -----------------------------------------------------------------------------------------------------------------------------------------164 Engine Specifications - 610000 ------------------------------------------------------------------------------------------------------------------ 164 Engine Specifications - 540000 ------------------------------------------------------------------------------------------------------------------ 164 Engine Parameter Specifications - 540000 and 610000 ---------------------------------------------------------------------------------- 165 Engine Fluid and Sealant Specifications ------------------------------------------------------------------------------------------------------ 165 Torque Specifications ------------------------------------------------------------------------------------------------------------------------------- 166 Standard and Reject Sizes ------------------------------------------------------------------------------------------------------------------------168...
  • Page 163: Specifications

    SPECIFICATIONS Engine Specifications - 610000 ENGINE 6114, 6134-37 6132-3 Fuel Type and System Gasoline - Gaseous - Mixer Gaseous - Mixer Gasoline - EFI-ETC Gasoline - EFI Gasoline - EFI-ETC Carburetor Bore 3.366 in (85.5 mm) Stroke 3.405 in (86.5 mm) Displacement 60.6 ci (993 cc) Compression Ratio...
  • Page 164: Engine Parameter Specifications - 540000 And 610000

    Engine Fluid and Sealant Specifications FLUIDS AND SEALANTS MODEL 540000 MODEL 610000 Engine Oil - Standard to Hot Temperature Operating Vanguard Synthetic 15W-50 Condition Engine Oil - Acceptable Alternate Service Specification Synthetic 5W-30 - Service Class SF, SG, SH, SJ Crankcase Cover Silicone Sealant Briggs &...
  • Page 165: Torque Specifications

    FASTENER TORQUE Torque Specifications Intake Elbow Cover - Cover to Fuel 90 lb-in (10.2 Nm) FASTENER TORQUE Module Bracket Screws Air Block Plate to Crankcase Screw 18 lb-in (2 Nm) Intake Manifold Stud Nut 135 lb-in (15.3 Nm) Air Guide to Intake Manifold Screw 90 lb-in (10.2 Nm) Intake Manifold Stud 45 lb-in (5 Nm)
  • Page 166 FASTENER TORQUE FASTENER TORQUE Starter Solenoid Rotor Brush Strap 87 lb-in (9.8 Nm) Valve Cover Breather Screw - 87 lb-in (9.8 Nm) Large 4 Bolt Design Stud/Plate to Fuse Block Bracket 12 lb-in (1.4 Nm) Wire Guard to Coupling Nut 90 lb-in (10.2 Nm) Throttle Body Collar Studs 95 lb-in (10.7 Nm)
  • Page 167: Standard And Reject Sizes

    Standard and Reject Sizes ITEM STANDARD SIZE REJECT SIZE CRANKCASE/CYLINDER Camshaft Bearing Bore Diameter 0.787-0.788 in (20.0-20.015 mm) 0.799 in (20.30 mm) or more Cylinder Bore Circularity (Out-Of-Round) 0.0003 in (0.007 mm) - Measured in 5 spots at the top, middle and bottom of the cylinder bore Cylinder Bore Diameter - M61 and M54 3.366-3.367 in (85.5-85.525 mm) 3.370 in (85.598 mm) or more...
  • Page 168 BRIGGS & STRATTON CUSTOMER EDUCATION Milwaukee, WI 53201 USA Copyright ©2023. All rights reserved. VANGUARDPOWER.COM 80114787 (Revision A)

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