Briggs & Stratton 115400 Page 6 Manual Download | Manualshive

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ENGINE SAFETY

In The Interest Of Safety

This repair manual contains safety information
that is designed to:

• Make you aware of hazards associated

with engines.

• Inform you of the risk of injury associated

with those hazards.

• Tell you how to avoid or reduce the risk

of injury.

•

The Safety Alert Symbol

The safety alert symbol ( ) is used to identify
safety information about hazards t hat can result
in personal injury.

A signal word (

DANGER

,

WARNING

, or

CAUTION

)

is used with the alert symbol to indicate the
likelihood and the potential severity of injury. In
addition, a hazard symbol may be used to
represent the type of hazard.

DANGER

indicates a h azard which, if

not avoided,

will result in death or

serious injury.

WARNING

indicates a hazard which, if

not avoided,

could result in death or

serious injury.

CAUTION

indicates a hazard which, if

not avoided,

might result in minor or

moderate injury.

CAUTION

:

When this signal word is used

without the alert symbol, it indicates a situation
that could result in damage to the engine.

• Prior to work, read and understand the

section(s) of this manual that pertain to
the job. Follow all safety warnings.

• Wear suitable eye protection.

• When servicing engines or equipment,

prevent accidental starting by removing
the spark plug wire from the spark
plug(s).

• Disconnect negative battery terminal if

the application is equipped with an
electric starting system.

• Peri odically clean en gine. Keep governor

parts free of dirt, grass and other debris
which can affect engine speed and
cooling.

• Always use fresh gasoline. Stale fuel can

cause gum deposits in the carburetor
and cause leakage, flow restrictions or
other failures.

• Check fuel lines and fittings frequent ly for

cracks or leaks and replace if necessary.

WARNING

Before attempting to service this
equipment, read and understand this
manual and the operating instructions of
the equipment it powers.

Failure to

FOLLOW

instructions could result in

DEATH, SERIOUS INJURY

(includi ng

paralysis) or property damage.

WARNING

Briggs & Stratton does not approve or
authorize the use of these engines on 3-
wheel All Terrain Vehicles (ATV’s),
motorbikes, fun/recreational ve hicles for
use in competitive events. Use of these
engines is such applications could result in
property damage, serious injury (including
paralysis), or even death.

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Summary of Contents for 115400

Page 1: ...r OHV Liquid Cooled Engines MS 0750 Vanguard 3 Cylinder OHV Liquid Cooled Gasoline Engines MS 1055 Vanguard 3 Cylinder OHV Liquid Cooled Diesel Engines Other Briggs Stratton Commercial Power Repair Manuals Vanguard Single Cylinder OHV Air Cooled Engines POST OFFICE BOX 702 MILWAUKEE WI 53201 USA BRIGGSandSTRATTON COM 2007 Briggs Stratton Corporation BRIGGS STRATTON CORPORATION Part No 272147 1 07 ...

Page 2: ...ion SECTION 6 Governor Systems SECTION 7 Cylinder Heads Valves SECTION 8 Starters SECTION 9 Lubrication Systems SECTION 10 Cylinders Covers Sumps SECTION 11 Crankshafts Camshafts Balancing Systems Gear Reductions SECTION 12 Pistons Rings Connecting Rods SECTION 13 Final Engine Assembly SECTION 14 Engine Specifications Reference Tables SECTION 4 Exhaust Systems ...

Page 3: ...of every possible hazards and or results of each procedure or method We have not undertaken any such wide evaluation Therefore anyone who uses a procedure or method not described by the manufacturer must first satisfy himself that neither his safety nor the safety of the product will be endangered by the service or operating procedure selected All information illustrations and specifications conta...

Page 4: ...ations 10 Changing Oil 11 MAINTENANCE SCHEDULE 12 Air Cleaner Service 13 In Line Fuel Filter Service 15 ENGINE ADJUSTMENTS 15 Armature Air Gap Adjustments 15 Carburetor Idle Mixture Adjustments 15 Control Adjustments 16 Cooling System Maintenance 18 Flywheel Brake Adjustments 104700 19 Governor Adjustments 19 Electro Magnetic Idle Down Adjustments 25 Spark Plug Maintenance 26 Valve Clearance Adjus...

Page 5: ...4 1 ...

Page 6: ...nderstand the section s of this manual that pertain to the job Follow all safety warnings Wear suitable eye protection When servicing engines or equipment prevent accidental starting by removing the spark plug wire from the spark plug s Disconnect negative battery terminal if the application is equipped with an electric starting system Periodically clean engine Keep governor parts free of dirt gra...

Page 7: ...asoline away from sparks open flames pilot lights heat and other ignition sources Check fuel lines tank cap and fittings frequently for cracks or leaks and replace if necessary When starting engine Make sure spark plug muffler fuel cap and air cleaner are in place Do not crank engine with spark plug removed If fuel spills wait until it evaporates before starting engine If engine floods set choke t...

Page 8: ... plug Disconnect negative battery terminal When testing for spark Use approved spark plug tester Do not check for spark with spark plug removed DANGER Engines give off carbon monoxide an odorless colorless poison gas Breathing carbon monoxide can cause nausea fainting or death Start and run engine outdoors Do not start or run engine in an enclosed area even if doors and windows are open DANGER Sta...

Page 9: ...to blades impellers pulleys and sprockets must be securely attached WARNING All fuel components should be in good condition and properly maintained Repairs should only be made with factory approved parts Repair work should be done by a qualified technician Flexible supply lines should be checked regularly to make sure they are in good condition WARNING Charging batteries produces hydrogen gas Do n...

Page 10: ...9 1 BRIGGS STRATTON NUMERICAL IDENTIFICATION SYSTEM ...

Page 11: ...ge if fuel stabilizer is added according to instructions Run the engine for two minutes to circulate the stabilizer throughout the system The engine and fuel can then be stored for up to 24 months If gasoline has not been treated with a fuel stabilizer prior to storage it must be drainedfrom the engine into an approved container Run the engine until it stops from lack of fuel The use of a fuel sta...

Page 12: ... 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 Clean surface of filter mounting adaptor D Fig 3 Apply light coat of clean engine oil to new filter gasket Fig 3 5 Screw filter on by hand until gasket contacts oil filter mounting adapter Then tighten an additi...

Page 13: ...n 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 Disconnect spark plug s Disconnect neg ative battery cable Use only the correct tools ...

Page 14: ...ne 1 Loosen screws or knobs A holding air cleaner cover in place and remove cover B 2 Carefully clean debris from the base and cover then remove air filter element retaining nut C if equipped 3 Lift off filter element D with the pre cleaner E if so equipped 4 Wash pre cleaner in warm soapy water 5 Rinse and dry thoroughly 6 Saturate pre cleaner in fresh clean engine oil and squeeze out excess Do n...

Page 15: ...14 1 Fig 7 Fig 8 Fig 9 Fig 10 ...

Page 16: ... ENGINE SPECIFICATIONS 5 Turn flywheel Loosen screws and allow the magnets to pull armature against thickness gauge B Fig 11 6 Tighten screws to listed values See on page 255 Carburetor Idle Mixture Adjustments Initial Mixture Adjustment Refer to the figure that shows your engine 1 Turn the idle mixture screw A Fig 12 in until you feel it just make contact with the seat 2 Back the idle mixture scr...

Page 17: ...g 15 7 Move speed control from SLOW to FAST If the engine does not accelerate smoothly Adjust idle mixture screw 1 8 turn CCW 8 Check idle RPM and readjust to specifications if required Control Adjustments Throttle Control 050000 085400 086400 115400 117400 118400 138400 185400 235400 245400 28Q700 The throttle controls on these units are interconnected withthe governor linkage system SEE SECTION ...

Page 18: ... are often provided by the original equipment manufacturer Please refer to the information provided by the OEM when this general description is not sufficient to adjust the choke control 1 Loosen choke control casing clamp screw on engine control panel or governor control bracket 2 Move choke control lever or knob to CHOKE 3 Move choke control casing in the direction that completely closes the cho...

Page 19: ... compressed air may be used Grass particles chaff or dirt can clog the air cooling system especially after prolonged service in very dusty conditions or when cutting dry grass Continued operation with a clogged cooling system can cause severe overheating and possible engine damage Clean the static screen A Fig 21 Fig 21 Clean the ducting B and cylinder fins C Fig 22 yearly or every 100 hours of op...

Page 20: ... the OEM for service procedures on these model types A complete governor system adjustment includes the following 1 A static governor adjustment 2 Engine warm up 3 Idle and or governed idle adjustment 4 Top no load RPM adjustment Install all linkages and springs before performing static governor adjustments Refer to the illustration that matches the governor system on your engine NOTE 050000 08540...

Page 21: ...ever 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 3 Place and hold the throttle in high speed position 4 While holding the throttle plate rotate the governor shaft B Fig 25 until it stops in the direction noted in step 2 5 While holding the governor shaft torque the governor ...

Page 22: ...9 1 Start and run engine at 1 2 throttle for 5 minutes to bring engine to operating temperature 2 Move throttle to SLOW 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 30 NOTE 050000 118400 28Q700 Do not have a Governed Idle Speed adjustment 19200 19389 ...

Page 23: ... Start and run engine at 1 2 throttle for 5 minutes to bring engine to operating temperature 2 Move throttle to SLOW 3 Align holes in the governor control lever gear A and governor control plate B Fig 33 through Fig 35 Insert 0 125 in 3 2 mm diameter rod C 4 Using tang bender tool D bend governed idle speed tang to obtain 1400 RPM 5 Remove rod C Fig 33 through Fig 35 Fig 33 Fig 34 Governed Idle RP...

Page 24: ...ain proper no load RPM Fig 36 Top No Load RPM Adjustments 104700 161400 260700 261700 28Q700 Refer to the figure that shows your model Some units may have remote throttles furnished by the OEM 1 Move throttle to FAST 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 37 or Fig 38 NOTE 104700 Alignment holes o...

Page 25: ...emove rod Top No Load RPM Fixed Speed Adjustable 161400 Generators 1 Turn the speed regulator nut A Fig 41 until the desired top no load speed is achieved Fig 41 Pre Load RPM Fixed Speed Adjustable 161400 Generators 1 Push in and up on speed regulator nut to disengage from notch in control panel 2 Start and run engine at 1 2 throttle for 5 minutes to bring to operating temperature Fig 42 3 Push th...

Page 26: ...nuts A and B Fig 43 Then unscrew nut A until flush with end of bolt 2 Start and run engine at 1 2 throttle for 5 minutes to bring engine up to operating temperature 3 With the engine running apply 12VDC to connector C Extended governor lever D Fig 43 will be pulled against head of idle bolt Fig 43 4 Adjust nut A to obtain 2300 RPM Remove 12VDC from connector 5 Hold nut A and idle down control in p...

Page 27: ...last clean spark plugs Spark plugs should be cleaned by scraping or hand wire brushing and washing in a commercial solvent Use a wire gauge A Fig 45 to set the spark plug gap Set spark plug gap at listed value Fig 45 Torque spark plugs to listed value SEE SECTION 14 ENGINE SPECIFICATIONS Valve Clearance Adjustments Adjust Valve Clearance Valve clearances should always be adjusted on a cold engine ...

Page 28: ...its from top of piston with a plastic scraper or a scotch pad CAUTION Use care to prevent debris from entering push rod or oil return cavities in cylinder Do not damage cylinder top of piston cylinder head and cylinder head gasket surfaces It is not necessary to remove the discoloration marks on the piston valves and or cylinder head These marks are normal and will not affect engine operation Remo...

Page 29: ...28 1 ...

Page 30: ...s Settings 35 AC Volts 35 DC Volts 35 DC Amps over 10 Amps 35 Ohms or Continuity 35 Diode Test 36 AC Amps 36 DC Amps under 10 Amps 36 DC Shunt 36 Tachometers 36 ALTERNATOR OUTPUT TESTS 36 DC Alternator 36 AC Alternator 38 1 2 Amp Unregulated Alternator 38 4 Amp Regulated Alternator 39 9 Amp Regulated Alternator 39 10 Amp Regulated Alternator 40 10 16 Amp Regulated Alternator 41 Dual Circuit Altern...

Page 31: ... Terminal Key Switch 51 LOW OIL PRESSURE SWITCH 51 Oil Pressure Switch Test 52 Oil Pressure Test 52 OIL GARD LOW OIL PROTECTION SYSTEMS 53 Troubleshooting Oil Gard 2 Wire Systems 53 Troubleshooting Oil Gard 4 Wire System 54 Troubleshooting Oil Gard 161400 55 STARTER MOTORS 56 Check Starter Motor Drive All Models 56 Check Starter Motor Wiring 138400 185400 235400 245400 56 Test Key Switch Solenoid ...

Page 32: ...ill not stop 1 Equipment stop switch not functioning 2 Engine ground wire damaged or disconnected Vibration 1 Bent cutter blades 2 Loose spindles and couplings 3 Bent broken deck or weldments 4 Bent crankshaft 5 Loose equipment mounting bolts 6 Damaged or worn belts and pulleys 7 Out of balance impeller Power Loss 1 Bind or drag in equipment 2 Grass build up under deck 3 No lubrication in equipmen...

Page 33: ...g 2 Start and run engine If spark consistently jumps the tester gap but the miss continues The problem is downstream from the tester 1 Check the spark plug 2 Check compression 3 Check fuel system and or carburetion If spark in tester gap is erratic Check ignition coil and associated wiring CARBURETION Before checking the carburetion be sure the fuel tank has an ample supply of fresh clean gasoline...

Page 34: ...utlet gauge remains in the green area However if a single component is displaying more audibleleakage look to that component for a potential problem For example Frequently a slight air leak at the head gasket may not register on the gauge Obviously the head gasket would require replacement as any leak at the head gasket would have an adverse affect on engine performance Compression Test 1 Run engi...

Page 35: ...ead gasket carburetor exhaust system and the cylinder breather tube NOTE If a high flow of air is leaking from the exhaust and carburetor make sure the piston is at TDC on the compression stroke Air flowing between the cylinder and cylinder head indicates that the cylinder head gasket is leaking Air flowing from the carburetor indicates air is leaking past the intake valve and seat Air flowing fro...

Page 36: ...al that applies to your meter for the procedure to check the fuses and general operation The digital multimeter is used for numerous tests which include the following Fig 5 Fig 6 Fig 7 Fig 8 0 1 0 2 0 3 0 O F F C O M VΩ 10 A F U SE D Ω V 3 0 0m V V A A AC Volts Insert the BLACK test lead into the COM receptacle of the multimeter Insert the RED test lead into the VΩ receptacle Set the rotary switch...

Page 37: ...speed to the RPM specified in the test instructions before testing alternator output Perform alternator tests in the following sequence 1 Test alternator output 0 10 20 30 O FF C OM V Ω 10A FUS ED Ω V 30 0m V V A A Diode Test Insert the BLACK test lead into the COM receptacle of the multimeter Insert the RED test lead into the VΩ receptacle Set the rotary switch to This setting also signals contin...

Page 38: ...eter will beep once and display the voltage drop A continuous tone indicates continuity shorted diode An incomplete circuit open diode will be displayed as OL 1 Set meter to Diode Test See Figure 9 2 Attach RED test lead A Fig 15 clip to point B and BLACK test lead C clip to point D Fig 15 It may be necessary to pierce wire with a pin as shown Fig 15 If meter beeps once Diode is OK If meter makes ...

Page 39: ...o engine ground B Fig 16 4 Start engine AC output should be no less than 14 volts 3600 RPM If low or no output is found Replace stator 1 2 Amp Unregulated Alternator The 1 2 amp DC alternator provides current for charging a 12 volt battery The alternator has a RED connector A and BLACK wire B Fig 17 Fig 17 1 Set meter to DC test See Figure 11 2 Attach RED test lead clip to DC output pin C Fig 18 i...

Page 40: ...m repair If there is continuity Reconnect RED wire to regulator rectifier Disconnect wires at E and F Fig 19 Connect multimeter test leads to two wires not connected to regulator rectifier There should be continuity Fig 19 With one test lead still connected to one of the wires check for continuity to ground with the other test lead There should not be continuity If there is continuity Replace stat...

Page 41: ...gure 11 2 Attach RED test lead clip to DC output terminal A Fig 21 on regulator rectifier Fig 21 3 Attach BLACK test lead clip to positive battery terminal 4 Start Engine Output should be 3 9 Amps 3600 RPM 10 AMP Regulated Alternator Model 185400 To test alternator output engine s electrical system must be connected to a fully charged 12 volt battery 1 Adjust governor to 3600 RPM for test 2 Discon...

Page 42: ...ith 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 Check for continuity between GREEN wire and engine ground There should not be continuity If there is continuity to ground Replace stator Readjust governor to original set RPM 10 16 ...

Page 43: ...meter DC shunt tool 19359 is required when testing the 10 16 Amp systems The DC shunt must be installed on the negative terminal of the battery Fig 25 All connections must be clean and tight for correct amperage readings Make sure the stator wire harness is connected to the regulator rectifier Make tests in the following sequence 1 Install shunt on negative battery terminal 2 Set Meter See Figure ...

Page 44: ...e 11 2 Attach RED test lead clip to DC output pin E Fig 27 in the connector F Fig 27 The bump on the connector indicates the DC output terminal Fig 27 3 Attach BLACK test lead clip to positive battery terminal 4 Start engine With a fully charged battery output will be approximately 2 amps DC at 3600 RPM If no or low output is found Test the diode Dual Circuit Diode Test 1 Rotate selector to DIODE ...

Page 45: ...hrough a single output lead and connector B Fig 29 to a wiring harness containing two diodes C One diode rectifies the AC to 5 amps negative DC for lights D The second diode rectifies the AC to 5 amps positive DC for battery charging and external loads E Fig 30 Fig 30 NOTE Some equipment manufacturers supply the diodes as an integral part of the equipment wiring harness A 1 ohm 20 watt resistor su...

Page 46: ...p once as well as display the voltage drop A continuous tone indicates continuity shorted diode An incomplete circuit open diode will be displayed as OL Fig 32 Charging Circuit Test Red Wire 1 Insert RED test lead into VΩ receptacle in meter 2 Insert BLACK test lead into COM receptacle in meter 3 Rotate selector to DIODE TEST position See Figure 9 4 Attach BLACK test lead clip A to point B of the ...

Page 47: ...d is operating properly if it clicks when the switch is turned ON or OFF If solenoid does not click the problem could be the equipment wiring engine wiring or the solenoid Afterfire can also be caused by using the afterfire terminal of the key switch to turn the alternator OFF when the engine is turned OFF The alternator continues to produce voltage and current as long as the engine continues to t...

Page 48: ...ecessary and check for Corrosion Dirt Terminals clamps secure in good condition 2 Bring battery to full charge Use a charger that automatically reduces charge rate Fill battery cells with distilled water after charging for batteries previously in service NOTE If battery gets hot to the touch or is spitting acid gassing unplug charger periodically 3 Set meter to DC Volts See Figure 6 4 Attach RED m...

Page 49: ...switch tang B Fig 37 Fig 37 If control lever does not contact stop switch tang Check control cable for adjustment or binding Bend tang as required or replace worn parts as needed 2 Inspect stop switch mounting to be sure switch is firmly anchored in control bracket Replace switch if it cannot be anchored securely 3 Set meter to test for continuity See Figure 8 4 Move speed control to FAST 5 Discon...

Page 50: ... safety control on equipment to RUN then to STOP The tab on the brake pad lever B Fig 40 must contact the switch tang C Fig 40 Fig 40 3 Move safety control to RUN The brake pad lever tab must not contact the switch tang 4 Adjust control as necessary or per OEM instructions Rocker Switch Test 085400 115400 117400 138400 161400 185400 235400 245400 Two types of rocker switches are used to stop these...

Page 51: ...3 Fig 43 If control lever does not contact stop switch tang Check control cable for adjustment or binding Adjust as required or replace worn parts as needed Be sure the stop switch is firmly anchored in control bracket Replace switch if it cannot be anchored securely Key Interlock Switches Troubleshooting Interlock Switch 104700 1 Disconnect interlock switch wires from spade terminals of switch 2 ...

Page 52: ...rminals with key switch in position shown See number sequence of terminals shown in Fig 45 There must be continuity between terminals 1 3 6 and the key switch case when key switch is OFF Fig 46 4 Disconnect interlock switch wires from spade terminals on switch and at starter motor connector 5 Set multimeter to Ohms See Figure 8 6 Connect one meter test lead to the end of one wire connector Connect...

Page 53: ...he metal body of the switch Fig 49 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 pressure source A Fig 49 The switch should open at approximately 104700 4 to 6 psi 0 28 0 41 bar 260700 261700 7 to 10 psi 0 48 0 69 bar 28Q700 7 to 10 psi 0 48 0 69 bar 4 Replace the switch if test results are not to specification Torque to ...

Page 54: ...d prevents the spark plug from firing When a restart is attempted a light in the ON OFF switch flashes to indicate LOW OIL The Oil Gard protection system consists of An oil float sensor located inside the cylinder An electronic module An ON OFF rocker switch Connecting wires The system may have a module with four wires BLUE BLACK WHITE and RED or two wires BLACK BLACK Preliminary Low Oil Checks En...

Page 55: ... dies Replace the module E and retest If the engine starts and runs Reconnect the wire at A If the engine dies Check continuity in the wire between A and B If there is no continuity Replace the wire If the wire is good Replace the float sensor in the cylinder F Fig 52 Symptom Engine will not start Disconnect wire at C and D Fig 52 and start engine If the engine does not start Check the ignition ar...

Page 56: ...etron Armature Repair Or Replace Wiring Harness Repair Or Replace Wire Replace Armature Spark Present Light Does Not Flash G H C Worn Light Or Harness Oil Gard Switch Wire Not Making Ground To Cylinder Worn Oil Gard Switch Replace Light Adjust Wire Replace Switch Intermittent Spark D or E C H Ground Stop Wire Or Harness Worn Oil Gard Switch Oil Gard Switch Wire Not Making Ground To Cylinder Repair...

Page 57: ...nds on pinion moving freely on helix Fig 55 Fig 55 Check Starter Motor Wiring 138400 185400 235400 245400 Required Equipment Multimeter set to DC Volts 1 Charge the battery if the voltage is low 2 Set meter See Figure 6 3 Disconnect wire from starter terminal A Fig 56 4 Connect BLACK test lead to engine ground or negative battery post B 5 Connect RED test lead to the wire disconnected from the sta...

Page 58: ...e key in the START position and ground B Fig 58 Fig 58 If continuity is present Proceed to step 4 If not Replace key switch 4 Reconnect the connector from the starter switch 5 Test for continuity at the output terminal A of the solenoid with the key in the START position and ground B Fig 59 Fig 59 If continuity is present Replace starter If not Replace solenoid Check Starter Motor 138400 185400 23...

Page 59: ...quivalent A fully charged 12 volt battery C Fig 61 Remove starter motor from engine 1 Set multimeter to 300mv See Figure 7 2 Connect starter switch D to starter motor E battery C BLACK lead G RED lead H shunt B and multimeter A Fig 61 Fig 61 3 Note length of starter motor housing 4 Activate starter motor 5 Note multimeter and tachometer readings A starter motor in good condition will be within spe...

Page 60: ...Housing Removal 28Q700 62 CONTROL BRACKETS 63 Control Bracket Removal 050000 085400 086400 115400 117400 118400 138400 185400 235400 245400 63 Control Bracket Removal 104700 63 Control Bracket Removal 161400 64 Control Bracket Removal 260700 261700 64 Control Bracket Removal 28Q700 65 ENGINE BAFFLES 65 Engine Baffle Removal 05000 085400 086400 115400 117400 118400 138400 185400 235400 245400 65 En...

Page 61: ...l 138400 235400 245400 71 Electric Starter Removal 104700 260700 261700 28Q700 71 MAGNETRON IGNITION SYSTEMS 72 Spark Plug Wires All Models 72 Ignition System Removal 050000 085400 086400 115400 117400 118400 235400 245400 161400 104700 260700 261700 28Q700 72 FLYWHEELS 72 Flywheel Removal 050000 085400 086400 115400 117400 118400 138400 185400 235400 245400 28Q700 72 Flywheel Removal 104700 73 Fl...

Page 62: ...l tanks and associated components for your model SEE SECTION 5 FUEL SYSTEMS AND CARBURETION For information regarding the removal of exhaust systems SEE SECTION 4 EXHAUST SYSTEMS Blower Housing Removal 050000 085400 086400 115400 117400 118400 185400 NOTE 050000 118400 Disconnect the return spring on the governor lever and the wire to the Low Oil Sensing Module Remove the mounting bolts A Fig 1 sh...

Page 63: ...using Removal 28Q700 1 Remove the oil cap and dipstick assembly 2 Remove the four screws A that secure the rotating screen 3 Remove the two mounting bolts B Fig 6 that secure the fuel pump mounting bracket Fig 6 4 Remove the two screws A that secure the top of the outer housing to the inner housing 5 Remove the remaining screws B Fig 7 around the perimeter of the outer blower housing Fig 7 6 Remov...

Page 64: ...nd the governor shaft cotter pin while removing the top or bottom governor lever nut 2 Remove the lower nut B and set aside CAUTION 085400 086400 115400 117400 138400 185400 235400 245400 have left hand threads on the governor shaft Fig 9 NOTE Leave the cotter pin C Fig 9 in the governor shaft to prevent it from falling into the cylinder Control Bracket Removal 104700 Part of the control bracket m...

Page 65: ... bolts hand tight 4 Remove the oil fill tube screw D Fig 12 5 Remove control bracket screws E Fig 12 Fig 12 6 Remove the wire from the Oil Gard terminal and the stop switch Control Bracket Removal 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 13 Fig 13 2 L...

Page 66: ...rom the governor lever Fig 16 3 Set control bracket aside 4 Loosen nut that secures governor lever to governor shaft 5 Remove governor lever and set aside ENGINE BAFFLES Engine Baffle Removal 05000 085400 086400 115400 117400 118400 138400 185400 235400 245400 The engine baffles for the models listed above consist of stamped sheet metal parts A that wrap around the cylinder The larger engines have...

Page 67: ...n A Fig 19 2 Remove the bolts that secure the oil fill tube Fig 19 NOTE The lower baffle still has one mounting bolt that will be removed when the flywheel is removed SEE SECTION 3 FLYWHEEL REMOVAL 3 Remove the bolts that secure the baffle to the cylinder A Fig 20 Fig 20 Engine Baffle Removal 28Q700 1 Remove the two bolts A Fig 21 Fig 21 NOTE The blower housing support baffle plate B Fig 21 must b...

Page 68: ...alve cover and gasket s Fig 22 The breather components are built into the valve cover for the models listed They consist of A a port for the breather hose B a reed and valve assembly inside the cover and C Fig 23 a relief hole to balance cylinder pressures in case the breather assembly sticks or binds Fig 23 To check breather assembly 1 Cover relief hole with thumb 2 Blow into the breather port ho...

Page 69: ...properly Inspect breather tube A Fig 26 for cracks holes and hardening Fig 26 Breather System 161400 1 Remove four screws that hold valve cover A and gasket B 2 Remove valve cover Breather assembly C and gasket D Fig 27 will come off with valve cover Fig 27 3 Separate valve cover from breather assembly 4 Replace the breather if the fiber disc valve is stuck or binding 0 045 in 1 14 MM wire gauge A...

Page 70: ... Replace the entire breather valve assembly Refer to A Fig 30 1 Check the breather valve assembly with a 0 045 in 1 14 MM wire gauge It should not enter the space between the fiber disc and the valve assembly CAUTION Do not force the gauge The fiber disc valve is held in place by a retainer that will distort if pressure is applied to the disc Fig 30 To replace breather valve assembly 1 Install new...

Page 71: ...breather 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 Check as shown in Fig 34 Fig 34 Replace the breather if the fiber disc valve is stuck or binding CAUTION The fiber disc valve is held in place by an internal ...

Page 72: ...witch 3 Remove the nuts A Fig 35 that support the starter motor 4 Remove starter Fig 35 1 Disconnect the wire from the voltage regulator 2 Remove the nuts A Fig 36 that support the starter motor Fig 36 Electric Starter Removal 104700 260700 261700 28Q700 1 Remove the two bolts that secure starter to cylinder A Fig 37 38 39 Fig 37 Fig 38 Fig 39 ...

Page 73: ...33 A Fig 41 or other strap wrench or socket type flywheel holder determined above 3 Turn the flywheel nut CCW with a 1 2 in breaker bar B and socket to remove Fig 41 4 Thread the flywheel nut A on to the crankshaft until top of nut is flush with end of crankshaft threads Fig 42 5 Install Flywheel Puller 19203 B Turn puller screws into flywheel puller holes until puller contacts flywheel nut 6 Tigh...

Page 74: ...45 Fig 45 2 Remove the flywheel nut with a strap wrench and a 1in socket 3 Using tool 19203 remove flywheel and drive key Flywheel Removal 260700 261700 1 Remove the nut and washer and starter cup A Fig 46 Fig 46 2 Remove the second nut and washer B Fig 46 3 Remove the backing plate that secures the fan to the flywheel ...

Page 75: ... flywheel is removed the stator andthe remaining bolt A Fig 48 for the support baffle can be removed Fig 48 OIL FILTER ADAPTERS Remove Replace Oil Filter Adapters 1 Remove oil filters and oil filter adapters as shown below Fig 49 2 Use a new gasket and reposition adapter 3 Torque screws to listed value as shown in Fig 50 Fig 50 Fig 51 ...

Page 76: ... Systems 77 REMOVE INSTALL EXHAUST SYSTEM 050000 085400 115400 117400 118400 138400 185400 235400 245400 78 REMOVE INSTALL EXHAUST SYSTEM 104700 79 REMOVE INSTALL EXHAUST SYSTEM 161400 80 REMOVE INSTALL EXHAUST SYSTEM 260700 261700 82 REMOVE INSTALL EXHAUST SYSTEM 28Q700 84 ...

Page 77: ...76 4 ...

Page 78: ... or damaged components Check for Cracks Broken welds Split muffler seams Loose internal parts Gaskets General wear and fit Inspect the exhaust manifold for damage and signs of leakage at the cylinder and muffler mating surfaces Spark Arrestors Remove spark arrester A Fig 1 for cleaning and inspection monthly or every 50 hours Replace screen if deteriorated or perforated Fig 1 DANGER Running engine...

Page 79: ... Fig 4 if equipped Fig 3 Fig 4 2 Remove two muffler nuts A Fig 5 Fig 5 3 Remove the muffler and exhaust gaskets 4 Inspect the exhaust system SEE SECTION 4 EXHAUST SYSTEMS To install the muffler assembly NOTE Use 93963 valve lubricant on all exhaust system threads to prevent galling of the threads and ease future disassembly 1 Place new exhaust gasket on cylinder head studs 2 Mount muffler 3 Instal...

Page 80: ...ped 2 Bend down locking tabs A on screw lock 3 Remove muffler screws and muffler brace nut B Fig 7 Fig 7 NOTE For access to the exhaust elbow remove the blower housing if necessary 4 Remove backplate and gasket SEE SECTION 3 ENGINE DISASSEMBLY 5 Take off the two screws A that hold the exhaust elbow shield B Fig 8 and remove shield Fig 8 6 Remove the screws A Fig 9 holding the exhaust elbow and set...

Page 81: ... plate and push screws through muffler 5 Place new gasket on mating surface of muffler and insert screws through back plate 6 Position second new gasket on the back plate and fit assembly into place on exhaust elbow 7 Torque muffler mounting screws to listed values SEE SECTION 14 ENGINE SPECIFICATIONS 8 Bend the screw lock tabs against the flat of the muffler mounting screw heads 9 Install muffler...

Page 82: ...d exhaust gaskets Fig 15 6 Inspect the exhaust system components See SECTION 4 EXHAUST SYSTEMS To install muffler to model 161400 1 Assemble the lower portion of the exhaust manifold with its gasket and two bolts A Fig 16 to the muffler and finger tighten Fig 16 2 Secure the muffler manifold assembly and its gasket to the head and finger tighten 3 Make sure the support bracket is under the blower ...

Page 83: ...cure muffler guard A Fig 19 to its bracket with four screws and torque to listed values Fig 19 9 Install carburetor heat shield B Fig 19 with two mounting screws C and torque to listed values REMOVE INSTALL EXHAUST SYSTEM 260700 261700 Fig 20 To remove muffler from model 261700 1 Remove the engine blower housing SEE SECTION 3 ENGINE DISASSEMBLY 2 Remove the two lower bolts A that hold muffler to b...

Page 84: ...w mounting bolts A Fig 24 8 Set exhaust manifold B manifold guard C Fig 24 aside 9 Discard old gaskets Fig 24 10 Inspect the exhaust system components SEE SECTION 4 EXHAUST SYSTEMS To install muffler assembly NOTE Use 93963 valve lubricant on all exhaust system threads to prevent galling of the threads and ease future disassembly 1 Set new exhaust gasket on mating surface of cylinder head A Fig 25...

Page 85: ... A on the exhaust manifold B Fig 27 Fig 27 9 Install support bolts through lower support bracket and finger tighten 10 Make sure the muffler assembly is completely seated on exhaust manifold 11 Torque muffler clamp screw and nut to listed values SEE SECTION 14 ENGINE SPECIFICATIONS 12 Torque lower bracket bolts to listed values SEE SECTION 14 ENGINE SPECIFICATIONS 13 Install mounting screws in exh...

Page 86: ...Q700 NOTE Use 93963 valve lubricant on all exhaust system threads to prevent galling of the threads and ease future disassembly 1 Install muffler adapter with new gasket Fig 31 2 Torque mounting bolts to listed values SEE SECTION 14 ENGINE SPECIFICATIONS 3 Install muffler with new gasket Fig 32 4 Install muffler bracket screw 5 Torgue muffler mounting bolts to listed values 6 Bend tabs A Fig 32 to...

Page 87: ...86 4 ...

Page 88: ...SERVICE PROCEDURES 050000 085400 086400 115400 117400 118400 104700 161400 185400 260700 261700 99 Carburetor Service Mikuni 050000 085400 086400 115400 117400 118400 185400 99 Carburetor Service Mikuni 104700 105 Carburetor Service Mikuni 161400 110 Carburetor Service Mikuni 260700 261700 117 CARBURETOR SERVICE PROCEDURES 138400 121 Carburetor Service Nikki 138400 121 CARBURETOR SERVICE PROCEDURE...

Page 89: ...88 5 ...

Page 90: ...flammable and explosive Fire or explosion can cause severe burns or death When adding fuel Turn engine OFF and let engine cool at least 2 minutes before removing Fill fuel tank outdoors or in a well ventilated area Do not overfill fuel tank Fill tank to approximately 1 1 2 inches below top of neck to allow for fuel expansion Keep gasoline away from sparks open flames pilot lights heat and other ig...

Page 91: ...ve bracket on side of blower housing and torque screws to values listed 2 Install shut off valve and hose on valve bracket Clamp hose to carburetor fitting 3 Install new hose and clamp on tank outlet fitting Connect other end of hose and clamp to shut off valve fitting Route tank hose through retainer on crankcase cover then position tank on engine 4 Start all screws then torque each to values lis...

Page 92: ...nd or nuts from front and rear of tank 11 Lift off tank and hose 12 Release clamp and disconnect hose from tank outlet fitting Set aside 13 Release clamp and disconnect hose at carburetor fitting 14 Remove screw A Fig 5 and remove shut off valve with spacer B Fig 5 15 Drain any remaining fuel into appropriate container 16 Disassemble shut off valve if necessary Removing Governor Linkage Bracket 08...

Page 93: ...n mounting studs 2 Connect governor choke linkages on carburetor and position carburetor on mounting studs 3 Mount governor control bracket s as required and connect links and springs 4 Position shut off valve and hose intoindex hole on blower housing 5 Install spacer and screw and torque to values listed 6 Connect hose with clamp to carburetor fitting 7 Install new hose and clamp on tank outlet f...

Page 94: ...f valve if equipped 2 Release clamp and disconnect fuel hose from carburetor fitting 3 Place hose in appropriate container open shut off valve and allow fuel to completely drain from tank 4 Release clamp and disconnect hose from tank fitting 5 Disassemble shut off valve and filter if equipped from hoses and set aside 6 Remove the two Phillips screws that secure the brake assembly cover A Fig 9 Fig...

Page 95: ...sted 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 12 Add small amount of fuel to tank open shut off valve and check for leaks 13 Start engine and check for leaks again Fuel System 161400 Removal 1 Release clamp and disconnect tank hose at shut off valve A Fig 14 2 Place hose in appropri...

Page 96: ...if necessary Fig 16 Inspect Fuel System SEE SECTION 5 FUEL SYSTEMS AND CARBURETION Installation For torque values SEE SECTION 14 ENGINE SPECIFICATIONS 1 Install the carburetor assembly as shown in Fig 17 Fig 17 Refer to Fig 17 A Carburetor gaskets in these locations B Choke link connected to choke shaft C Governor Lever and anti backlash spring connected to throttle 2 Torque carburetor mounting bo...

Page 97: ... equipped and drain remaining fuel into appropriate container 4 Close bowl drain screw 5 Release clamps and disconnect impulse hose at crankcase fitting B Fig 18 and fuel supply hose at carburetor fitting C Fig 18 Fig 18 6 Loosen screw at hose clamp if equipped on control bracket 7 Remove pump screws and remove pump and hose assembly from engine 8 Disassemble hoses from pump shut off valve and fil...

Page 98: ...if equipped and check for leaks 13 Start engine and check for leaks again Fuel System 28Q700 Removal For this engine series remote fuel tanks were typically installed by the OEM The following procedure does not include removal of the tank from the equipment 1 Release clamp and disconnect tank hose at pump inlet fitting Previously removed 2 Disconnect the clamps at the carburetor fitting A Fig 21 a...

Page 99: ...acklash spring and the choke link 4 Slip carburetor gasket on the bolts install carburetor Torque bolts to values listed 5 Place gasket on studs and mount air cleaner housing on carburetor studs Torque nuts to values listed 6 Install air cleaner housing supporting bolt See B Fig 22 Torque to values listed SEE SECTION 14 ENGINE SPECIFICATIONS 7 Install air filter and cover 8 Install fuel pump to it...

Page 100: ...is carburetor also has a primer bulb port Carburetor Service Mikuni 050000 085400 086400 115400 117400 118400 185400 CAUTION Do not use wires drills or other devices to clean out metering holes or passages Do not use carburetor cleaner on non metallic parts NOTE Use compressed air at a moderate pressure setting 5 7 PSI Blow in both directions to clean out all openings and passages Fig 26 Disassemb...

Page 101: ...ove the float C Fig 30 and inlet needle assembly Fig 30 7 Remove pilot jet A with Screwdriver 19062 8 Pry off the idle mixture valve limiter B if used Remove the idle mixture screw and spring C Fig 31 Fig 31 9 Remove screws A holding choke plate B Fig 32 and remove Fig 32 10 Lift out choke shaft A with upper B and lower C Fig 33 choke shaft bushings ...

Page 102: ...te 12 Lift out throttle shaft and plastic washer C Fig 35 Fig 35 To clean carburetor SEE SECTION 5 FUEL SYSTEMS AND CARBURETION Assembly Use new seals and gaskets when assembling carburetor 1 Install plastic washer B on throttle shaft A 2 Install the throttle shaft in the carburetor body with flat C Fig 36 facing out Fig 36 3 Place the throttle plate A on the throttle shaft B with the stamped numb...

Page 103: ...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 39 NOTE Holes in choke plate are offset from center Be sure to install choke plate with holes properly aligned with holes in choke shaft 8 Place choke plate A on choke shaft B Fig 40 and secure with two screws Fig 40 NOT...

Page 104: ... 107 10 Install pilot jet A Fig 43 11 Install idle mixture screw B Fig 43 and spring 12 Turn mixture screw in until it just makes contact with the seat 13 Back mixture screw off 1 1 2 turns 14 Install limiter C Fig 43 if used Fig 43 15 Install spring A to groove in fuel needle valve B Fig 44 Fig 44 16 Slide fuel needle valve assembly A on tab B of float C Fig 45 Fig 45 17 Place float assembly A Fi...

Page 105: ...el Replace the fuel inlet valve float and hinge pin If still not parallel Replace carburetor 21 Install float bowl gasket A Fig 48 to carburetor body groove 22 Make sure the gasket does not twist or kink Fig 48 23 Position bowl drain A Fig 49 as shown 24 Install float bowl B washer C and mounting screw D to carburetor 25 Tighten screw D Fig 49 securely Fig 49 Identifying Main And Pilot Jets 085400...

Page 106: ...at bowl A Fig 51 Fig 51 2 Remove float bowl gasket A Fig 52 Fig 52 Model Series Standard Main Jet High Altitude Main Jet Standard Pilot Jet High Altitude Pilot Jet 085400 71 3 67 5 42 5 40 115400 75 72 5 45 42 5 115400 75 72 5 42 5 37 5 117400 81 3 78 8 42 5 41 3 185400 93 8 90 40 35 185400 91 3 90 37 5 35 Large Air Cleaner Small Air Cleaner Model Series Standard Main Jet High Altitude Main Jet St...

Page 107: ...he main jet in the carburetor Unscrew the main jet first then the emulsion tube After Date Code 90042833 Remove the fixed main jet Remove the main emulsion tube with Carburetor Jet Screwdriver 19062 6 Pry off the idle mixture valve limiter if used Remove the idle mixturescrew and spring from carburetor body A Fig 55 7 Remove pilot jet B Fig 55 with Jet Screwdriver 19062 Fig 55 8 Remove choke plate...

Page 108: ...d gaskets when assembling carburetor 1 Install throttle shaft seal B Fig 59 to carburetor body A Install seal with grooved side out Fig 59 2 Place throttle shaft retainer C on throttle shaft D Install throttle shaft to carburetor body 3 Rotate throttle shaft until the flat E on the throttle shaft D is facing out 4 Lay the throttle plate F on the shaft with the stamped numbers G to the left Install...

Page 109: ...tor jet screwdriver 19280 Fig 62 9 Place choke plate A Fig 63 on choke shaft with stamped number B toward the fuel inlet nipple C side of the carburetor 10 Secure with two screws D Fig 63 Fig 63 11 Choke should close when shaft is rotated CCW Tighten screws securely 12 Install idle and main air jets if equipped on either side of carburetor air inlet 13 Install pilot jet B Fig 64 Tighten securely 1...

Page 110: ...loat assembly A Fig 66 in carburetor 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 Fig 67 18 Turn the carburetor body upside down The float A should be parallel to the float bowl mounting surface B Fig 68 ...

Page 111: ...crew D to carburetor 22 Tighten screw D Fig 70 securely Fig 70 Identifying Main Jets 104700 Carburetor Service Mikuni 161400 CAUTION Do not use wires drills or other devices to clean out metering holes and passages NOTE Use compressed air at a moderate pressure setting 5 7 PSI Blow in both directions to clean out all openings and passages Model Series Standard Jet High Altitude Jet Before 90091033...

Page 112: ...s two flats B Fig 73 Tap the opposite end of the pin until loose Fig 73 4 Remove the pin float and inlet needle assembly 5 Remove fixed main B jet from end of fuel pick up tube first Fig 74 then remove theemulsion tube A Fig 74 Fig 74 If emulsion tube does not come out with jet Reach into carburetor throat with flat blade screwdriver and gently tap top of stuck emulsion tube until it comes out Fig...

Page 113: ...er A Fig 77 8 Remove the idle mixture screw B Fig 77 Fig 77 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 seal E bushings F Fig 78 Fig 78 NOTE Engines with type numbers not ending in A1 or E1 have removable idle and main air jets ...

Page 114: ...if worn or damaged Fig 80 To clean carburetor SEE SECTION 5 FUEL SYSTEMS AND CARBURETION Inspect the idle mixture screw Replace the screw if the point is bent or there is a groove in the tip of the needle Assembly Use new seals and gaskets when assembling carburetor 1 Install throttle shaft bushing A to carburetor body with grooved side out Fig 81 2 Place washer B and throttle shaft seal C on the ...

Page 115: ...l spring A washer B bushing C and seal D to choke shaft E Fig 83 8 Insert shaft to carburetor body Fig 83 Fig 83 9 Connect the ends of the spring A to the lever B and carburetor body C The spring should hold the choke plate open Fig 84 Fig 84 10 Place choke plate A on choke shaft with stamped number s B facing opposite the fuel inlet C Attach with screws D Fig 85 Fig 85 11 Install pilot jet A Fig ...

Page 116: ... For main jet and pilot jet identification and selection See Identifying Main Jets on page 14 Install spring A to groove in fuel needle valve B Fig 88 Fig 88 15 Slide fuel needle valve assembly A on to tab B of float C Fig 89 Fig 89 16 Place float assembly A in carburetor Fig 90 17 Insert the small end of the float hinge pin B by hand until pin is through the float hinge C and both hinge pin posts...

Page 117: ...the fuel inlet valve float and hinge pin 19 Position bowl drain as shown Fig 92 20 Install float bowl A washer B and mounting screw C Fig 92 to carburetor 21 Tighten screw C securely Fig 92 22 Install idle mixture screw D and spring Fig 93 Turn screw in until it just seats Do not tighten 23 Back screw off 1 1 2 turns 24 Install limiter E Fig 93 if used Fig 93 ...

Page 118: ...oke plate To remove plastic choke shaft and plate 1 Rotate choke shaft to wide open position 2 Pull choke plate out of choke shaft and lever 3 Remove choke shaft and lever return spring when used and foam washer To remove metal choke shaft and plate 1 Rotate choke shaft and lever closed Replacement carburetors may have a spring detent that will hold the choke closed 2 Hold choke closed Remove two ...

Page 119: ... A float B Fig 97 and inlet needle Float hinge pin is a drive fit and one end of the pin has two flats 4 Tap the end opposite the flats with a center punch C Fig 97 until it is loose Fig 97 5 Remove the main jet A from the fuel pick up tube 6 Remove the emulsion tube B Fig 98 with a carburetor jet screwdriver Fig 98 7 Remove the pilot jet A with Screwdriver 19062 Fig 99 ...

Page 120: ...air jets located on either side of the choke plate opening with carburetor jet screwdriver 19280 12 Note the position of the throttle plate for reinstallation 13 Remove the throttle shaft screws B Fig 101 Remove the throttle plate Low emission LMT carburetors with type numbers that end in A1 or E1 have pressed in pilot jets that are not removable Do not remove the pressed in pilot jets A Fig 102 F...

Page 121: ...If thecarburetor has a spring detent guide the detent spring into the slot on the choke shaft lever 6 Place choke plate F on shaft single notch on edge towards fuel inlet Two half moon dimples position the plate on the shaft Secure with two screws G Fig 105 Fig 105 1 Install throttle shaft seal A to carburetor body Install seal with grooved side out 2 Place plastic throttle shaft seal B on throttl...

Page 122: ...UTION Do not use wires drills or other devices to clean out metering holes or passages NOTE Use compressed air at a moderate pressure setting 5 7 PSI Blow in both directions to clean out all openings and passages Fig 108 Disassemble 1 Remove bowl mounting screw A and float bowl C Discard float bowl gasket Model Series Standard Main Jet High Altitude Main Jet Standard Pilot Jet High Altitude Pilot ...

Page 123: ...10 Fig 110 3 Remove main jet first A Fig 111 with a carburetor jet screwdriver 4 Remove carburetor emulsion tube B Fig 111 5 Remove rubber plug C Fig 111 Fig 111 6 Remove screw A Fig 112 7 Remove throttle plate B throttle shaft C and seal D Fig 112 Fig 112 8 Remove screw A choke plate B choke shaft C and choke shaft seal D Fig 113 ...

Page 124: ...0 Remove pilot jet A Fig 115 Fig 115 TO CLEAN CARBURETOR SEE SECTION 5 FUEL SYSTEMS AND CARBURETION Assemble 1 Install pilot jet A Fig 116 Fig 116 2 Place new seal A Fig 117 lip down on the choke shaft B Insert shaft into carburetor while engaging detent spring ...

Page 125: ...ng Turn screw until it touches throttle lever stop 6 Place throttle plate E on throttle shaft with holes over shaft and secure with screw F Fig 118 Fig 118 7 Insert tapered end of rubber plug A in passage 8 Install emulsion tube B 9 Install main jet C Fig 119 Fig 119 NOTE For correct main jet and pilot jet identification and selection 10 Insert the inlet needle A into the slot on the float B Fig 1...

Page 126: ...gh speed main jet with a screw for idle mixture adjustment B and a screw for idle speed adjustment A Fig 123 The different carburetors are identified as LMT1 and up The letters LMT are cast into the body of the carburetor while the identification numbers C are stamped into carburetor mounting flange next to idle mixture screw or above the fuel inlet D Fig 123 Fig 123 Disassembly 1 Remove float bow...

Page 127: ... if used and the foam seal 13 Remove the float bowl 14 Remove the emulsion tube E Fig 126 with Carburetor Jet Screwdriver 19280 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 16 Tap the end opposite the flats with a center punch C Fig 127 until it is loose Fig 127 To clean carburetor SEE SECTION 5 FUEL SYSTEM...

Page 128: ...I on to the throttle shaft K 8 Slide the throttle shaft and seal into the carburetor body The idle stop on the 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 11 Place a drop of Loctite on t...

Page 129: ...ions to clean out all openings and passages Location of the part number A Fig 131 Fig 131 Disassembly 1 Remove fuel bowl screws G and separate fuel bowl H and solenoid E from the carburetor body I Fig 132 Do not lose the spring between the fuel bowl and the float assembly Fig 132 2 Remove the solenoid E from the fuel bowl H Fig 132 3 Remove the float assembly J from the carburetor base I 4 Pull th...

Page 130: ...base tube Press the jet in until it clicks into position Do not force Fig 135 9 Remove two screws A and throttle plate B and pull the throttle shaft C Fig 136 from the carburetor body Fig 136 10 Remove the idle mixture screw with spring D and the idle speed screw with spring E Fig 137 Fig 137 11 Turn the choke plate as shown in Fig 138 12 Pull the choke plate F from the choke shaft G Fig 138 13 Re...

Page 131: ...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 3 Turn the choke shaft ccw while gently pushing it into the carburetor body until the bottom end of the spring A rests on the back of the spring perch F Fig 140 Fig 140 4 Lift the choke shaft up slightly and continue turning ccw until the ...

Page 132: ... it will not close 11 Lay the throttle plate M on the flat of the throttle shaft Install two screws N Fig 144 Fig 144 12 Install idle mixture screw O with spring and the idle speed screw P Fig 145 with spring 13 Turn each screw until the head of the screw touches the spring Fig 145 14 Put the inlet needle Q Fig 146 into the slot on the float R 15 Place the needle and float assembly into the float ...

Page 133: ...the carburetor base as shown 19 Place the float assembly S on the carburetor base V Fig 148 Fig 148 20 Insert the spring Y Fig 150 to the bottom of the float assembly Fig 149 21 Place the fuel bowl A on the carburetor base B Fig 150 22 Fasten with screws C Fig 150 23 Install solenoid D and washer E Fig 150 24 Torque solenoid to values listed Fig 150 Fig 150 ...

Page 134: ...omponent Installation 138 GOVERNOR COMPONENTS 085400 086400 115400 117400 138400 185400 235400 245400 139 Governor Component Removal 139 Governor Component Inspection 140 Governor Gear Shaft Remove and Replace 140 Governor Component Installation 140 GOVERNOR COMPONENTS 104700 161400 260700 261700 28Q700 141 Governor Component Removal 141 Governor Component Inspection 142 Governor Crank Bushing Rep...

Page 135: ...134 6 ...

Page 136: ... by a governor lever C and a series of interconnecting linkages and springs D Fig 3 Fig 3 The purpose of the governor system is to maintain a desired engine speed RPM in spite of the changing loads imposed on the engine When at rest the springs are set to hold the throttle plate open In operation the flyweights cause the throttle plate to close The engine speed at which these two forces balance is...

Page 137: ...aced Consult the appropriate Illustrated Parts List After a new governor spring is installed check engine top governed speed with an accurate tachometer and adjust as required GOVERNOR COMPONENTS 050000 118400 Governor Component Removal NOTE The blower housing flywheel and other components of the engine must be removed to replace the governor gear assembly See SECTION 3 ENGINE DISASSEMBLY Remove g...

Page 138: ...tain 11 Tap the shaft through the cylinder housing with a small punch or equivalent Fig 8 Fig 8 The entire assembly will come free of the housing Governor Component Inspection 1 Inspect the governor gear for wear and chipped or damaged teeth 2 Inspect the governor flyweight assembly for freedom of movement 3 Ensure that the cup is retained throughout the flyweight travel If discrepancies are found...

Page 139: ...haft drive gear 5 Install E clip A Fig 11 on governor crank and push crank up through cylinder housing and install thrust washer Make sure the paddle of the governor shaft rests on the face of the governor cup Fig 11 6 Install the spring clip A Fig 12 as shown Fig 12 7 Install cylinder cover 8 Install lower nut upside down on governor crank until it bottoms on the threads of the shaft 9 Place gove...

Page 140: ...r cover See SECTION 3 ENGINE DISASSEMBLY 3 Remove cylinder cover See SECTION 10 CYLINDERS COVERS AND SUMPS The governor gear H and governor crank F are illustrated in Fig 13 Fig 13 4 Rotate crankshaft I Fig 14 as necessary for adequate clearance to remove governor crank F Fig 14 5 Remove nut A Fig 15 left hand threads and lift off governor lever B 6 Remove nut C left hand threads spring clip D and...

Page 141: ...ust washer on governor gear shaft 2 Place governor gear weights if removed in governor cup and place assembly on governor gear shaft 3 Push assembly down until gear snaps into groove on governor gear shaft 4 Position the crankshaft and other components as required for clearance to install the governor crank 5 Install E ring if equipped in groove on governor crank F Refer to Fig 11 6 Push governor ...

Page 142: ... outer hole P Fig 21 while 50 Hz generators use the inner hole Q on the governor lever B Generator governor spring part numbers are listed in the Illustrated Parts List 14 Reinstall any other components you removed 15 Perform static adjustment See SECTION 1 page 18 GOVERNOR COMPONENTS 104700 161400 260700 261700 28Q700 Governor Component Removal NOTE 161430 type 0199 01 This is equipped with a gov...

Page 143: ...s B for freedom of movement 4 Ensure that cup C is retained throughout the flyweight travel 5 Inspect bushing for burrs or foreign material Fig 24 If discrepancies are found Replacethegovernor gear as a complete assembly If the shaft bushing is damaged or worn Replace bushing Governor Crank Bushing Replacement 1 Remove bushing with a 375 in 9 5 mm rod A Fig 25 by driving downward into the cylinder...

Page 144: ... bushing and position as shown in the appropriate illustration CAUTION Ensure that governor crank is in the position illustrated Fig 26 Fig 27 and Fig 28 If it is not proper governor adjustments cannot be made and will result in over speeding and engine damage Fig 26 Fig 27 Fig 28 3 Install washer and spring clip Install spring clip A Fig 29 as shown Fig 29 f40p16 ...

Page 145: ...YLINDERS COVERS AND SUMPS NOTE 161432 Type 0080 01 When assembling governor lever assembly A ensure that tab on strike plate B Fig 31 is between upper and lower half of lever clamping area Fig 31 6 Re install any components you removed to gain access to the cylinder cover 7 Perform a static adjustment See SECTION 1 SAFETY MAINTENANCE AND ADJUSTMENTS ...

Page 146: ...0 117400 118400 138400 185400 148 Remove Cylinder Head 104700 161400 260700 261700 149 Remove Cylinder Head 28Q700 149 VALVES 150 Remove Valves 050000 086400 118400 104700 150 Remove Valves 085400 086400 115400 117400 138400 185400 161400 260700 261700 28Q700 150 INSPECT CYLINDER HEAD COMPONENTS 151 Inspect Push Rods All Models 151 Inspect Head For Distortion All Models 151 Inspect Valve Guide Inn...

Page 147: ...55 Install Valve Springs And Retainers 085400 115400 117400 138400 185400 155 Install Valve Springs And Retainers 161400 260700 261700 155 INSTALLING CYLINDER HEADS 155 INSTALL ROCKER ARMS 157 Install Push Rods Rocker Arms 104700 161400 260700 261700 28Q700 157 Install Push Rods Rocker Arms 235400 245400 158 ADJUST VALVE CLEARANCE 158 Valve Clearance Typical 158 Valve Clearance 104700 161400 26070...

Page 148: ...the rocker arm stud 2 Remove the rocker arm pivot B from the studs and remove the rocker arms C Fig 2 Fig 2 3 Remove valve stem caps if equipped and push rods D 4 Remove rocker stud E and push rod guide F Fig 2 Remove Rocker Arm Assembly 235400 245400 1 Remove two hex screws A holding rocker arm shaft to cylinder head Fig 3 Fig 3 2 Remove valve stem caps if equipped 3 Remove push rods and label th...

Page 149: ...tical 260700 261700 The intake push rod has center section that is made of aluminum and is hollow 28Q700 The intake push rod is aluminium and hollow Exhaust push rod has a red band of paint for identification 4 Remove rocker arm studs D and push rod guides E Fig 5 if equipped Fig 5 CYLINDER HEAD REMOVAL Remove Cylinder Head 050000 085400 086400 115400 117400 118400 138400 185400 1 Remove four cyli...

Page 150: ...es manufactured before 940501xx were equipped with sealing washers under cylinder head bolts A and C Fig 7 2 Remove and discard head gasket Fig 7 Remove Cylinder Head 28Q700 1 Remove head bolts A Fig 8 and cylinder head 2 Remove and discard head gasket 3 Make note of any discrepancies and discard old head gasket Fig 8 ...

Page 151: ...e remaining valve 7 Remove oil splash guard if equipped and set aside Remove Valves 085400 086400 115400 117400 138400 185400 161400 260700 261700 28Q700 1 Place cylinder head on a solid and flat work surface 2 Bundle a rag under the face of the valve being removed 3 Install rocker arm nuts A Fig 10 and studs in cylinder head Do not tighten 4 Slip end of Valve Spring Compressor 19347 B under nut a...

Page 152: ...equal contact is made in all positions the mating surface is good Fig 12 Fig 12 3 If an area is questionable use a feeler gauge to measure the amount of distortion as shown in Fig 13 Fig 13 For reject dimensions see SECTION 14 ENGINE SPECIFICATIONS If the allowable distortion limit is exceeded Replace the cylinder head and or cylinder block Inspect Valve Guide Inner Diameter All Models For 28Q700 ...

Page 153: ...ool Briggs Stratton does not recommend this practice as a high quality repair procedure Replace damaged or worn valves For specifications relating to the engine you are working on see SECTION 14 ENGINE SPECIFICATIONS 1 Cut valve seats with Neway Valve Seat Cutter Kit 19237 or 19343 A Fig 15 to specifications listed for your engine s exhaust and intake seats Place the proper guide pin in the valve ...

Page 154: ...TOP except 104700 toward Mag side of cylinder head Fig 17 or Fig 17 Fig 18 2 Coat rocker arm stud threads with Loctite 242 sealant 3 Install rocker arm studs Torque studs B Fig 17and Fig 18 to value listed in SECTION 14 ENGINE SPECIFICATIONS NOTE All engines use valve stem seals on the intake valve Valves will stick and damage the valve stem seals if the stems and guides are not free of foreign ma...

Page 155: ... or tap seal down until it bottoms Be sure Valve Guide Lubricant 93963 is not on 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 Installing Valve Springs Retainers 050000 235400 245400 1 Install the oil splash guide in the rocker box if equipped as shown in Fig 21 Fig 21 NOTE The exhaust v...

Page 156: ...r valve stem 2 Thread rocker arm nut on rocker stud with hex nut down 3 Place retainer on spring Use Valve Spring Compressor 19347 A Fig 24 to press on retainer and compress spring Fig 24 4 Compress spring until valve stem extends through valve retainer and groove is above retainer 5 Place both halves of valve keeper in valve stem groove Slowly release tension on valve spring and valve spring keep...

Page 157: ...rst 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 the second step Uneven tightening may warp the cylinder head Fig 25 Fig 26 Fig 27 Fig 28 Fig 29 1 4 2 3 1 3 2 4 4 2 3 1 1 3 5 2 4 1 4 3 2 ...

Page 158: ...R 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 32 2 Remove all lubricant from end of valve stems 3 Place valve caps C Fig 33 when used on end of valve stems 4 Place rocker arms on studs Install rocker arm nuts D and screw while holding rocker arm against valve cap C Fi...

Page 159: ...4 Insert the proper blade of feeler gauge B Fig 35 5 While moving it back and forth carefully tighten the adjustment screw until a slight amount of resistance is felt on the feeler gauge 6 Tighten the jamb nut without moving the adjustment screw Fig 35 7 Rotate the crankshaft through a few revolutions and recheck the clearance 8 Repeat this process until both valves consistently fall within specif...

Page 160: ...159 7 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 161: ...160 7 ...

Page 162: ...00 167 Disassemble Rewind Starter With Metal Pawls 104700 168 Inspect Rewind Starter With Metal Pawls 104700 169 Assemble Rewind Starter With Metal Pawls 104700 169 Disassemble Rewind Starter 28Q700 170 Assemble Rewind Starter 28Q700 171 ELECTRIC STARTERS 171 Ring Gear Replacement 172 Test Starter Drive and Clutch 172 Starter Drive 104700 161400 260700 261700 173 Starter Drive 115400 117400 138400...

Page 163: ...162 8 ...

Page 164: ...se nuts and bolts C Fig 2 as listed in the Illustrated Parts List IPL Install Rope And Handle Assembly Handles With Inserts NOTE Some units do not use an insert in the handle 1 To determine proper length of starter rope see SECTION 14 ENGINE SPECIFICATIONS Cut as necessary 2 Insert rope A through starter handle B and starter handle insert C 3 Tie knot on end of rope leaving approximately 1 2 in 13...

Page 165: ... until spring comes free of its anchor 10 Carefully lift out pulley and spring assembly Fig 5 NOTE Do not remove spring from pulley Pulley and spring are serviced as an assembly Fig 5 Inspect Pulley Assembly 1 Inspect pulley for wear cracks rough edges A or burrs in pulley groove B and wear on center hole C Fig 6 Replace pulley if damaged or worn 2 Inspect spring for broken ends kinks and burrs Re...

Page 166: ... over posts B in pulley Install pawls C Fig 9 Fig 9 5 Install retainer A making sure that slots B in retainer engage tabs C Fig 10 on pulley 6 Hold retainer down compressing pawl springs and install retainer screw Torque screw D to listed value See SECTION 14 ENGINE SPECIFICATIONS 7 While holding retainer rotate pulley to extend and retract pawls If the pawls do not extend and retract remove retai...

Page 167: ...urn pulley end of rope to prevent swelling and unraveling 7 Remove retainer screw A small washer B retainer C brake spring D and large washer E Fig 11 Fig 11 8 Lift out pawls A and pawl springs B 9 Rotate pulley C until it feels free 10 Lift out pulley The starter spring cup D will normally remain in starter housing E Fig 12 Fig 12 11 Remove spring and cup A from starter housing B Fig 13 or pulley...

Page 168: ...g retainer C Fig 15 Replace housing assembly if worn or damaged Fig 15 Assemble Rewind Starter 161400 235400 245400 1 Place spring and cup in pulley with outer end of spring A between two wide spaced lugs B in pulley and spring cup projections C Fig 16 next to the two wide spaced lugs Fig 16 Fig 17 2 Note location of inner spring tab A and location of inner spring anchor B Fig 17 on center post of...

Page 169: ...mbly 11 Install handle See SECTION 8 Fig 3 Disassemble Rewind Starter With Metal Pawls 104700 1 Pull starter rope out as far as it will go 2 Lock pulley to prevent it from retracting in starter housing 3 Extract rope at pulley and cut off knot 4 Remove rope and handle from rewind starter 5 Unlock pulley and slowly release spring tension 6 Inspect rope for frayed and broken strands Replace if worn ...

Page 170: ...loose spring retainer B Fig 23 Fig 23 2 Inspect starter housing A for wear or burrs at starter housing eyelet B center pivot post C and at inner spring retainer D Fig 24 Replace damaged or worn components Fig 24 Assemble Rewind Starter With Metal Pawls 104700 1 Note the location of the free end of the spring in the pulley assembly and of the inner spring retainer A Fig 25 in the starter housing Fi...

Page 171: ...ey with overhand knot See SECTION 8 FIG 3 11 Remove pulley lock and allow spring to slowly retract rope into rewind starter assembly Disassemble Rewind Starter 28Q700 NOTE If problems are encountered with the clutch replace the entire clutch unit Remove starter clutch from crankshaft pilot with tool 19244 1 Cut knot at starter pulley and remove rope 2 Grasp outer end of rewind spring A Fig 28 with...

Page 172: ...tock into center of pulley hub With pulley oriented as in Fig 29 wind the stock and pulley counterclockwise until spring is wound tightly and end of spring seats in tapered hole B Fig 30 Fig 30 7 Back off pulley until pulley hole is aligned A Fig 31 with eyelet in blower housing 8 Install rope Fig 31 9 Insert rope through housing and hole in pulley 10 Secure rope to pulley with overhand knot See S...

Page 173: ... 3 Attach new gear to flywheel using four screws C and lock nuts D Fig 34 provided with gear Fig 34 Test Starter Drive and Clutch When the starter is activated the pinion gear should engage the ring gear and crank the engine Clutch should not slip during engine cranking To check starter drive Inspect helix A and pinion gear B Fig 35 for freedom of operation If damage or binding is noted Replace th...

Page 174: ...embling starter drive Refer to Fig 37 1 Place starter clutch H on armature shaft and rotate clutch until it drops into place 2 Install pinion gear G with beveled edges of pinion gear teeth away from motor 3 Place washer F and clutch retainer E on armature shaft 4 Place spring D spring retainer C and cover B on to clutch retainer 5 Press new roll pin A through retainer slot and armature shaft hole ...

Page 175: ...lithium grease 2 Assemble clutch and pinion gear D on to shaft 3 Install spring C and spring retainer A with open end up 4 Seat the retainer ring in the groove in the shaft 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 39 3 Place two halves of tool 19467 D with hex ends...

Page 176: ...h until it drops into place 4 Assemble lower spring retainer H with open end up 5 Install return spring G and install upper spring retainer B with open end up 6 Place new retainer ring C inside two halves of tool 19467 D and slide tool sleeve down over two halves Fig 41 7 Place tool 19467 over armature and strike tool with hammer L to drive ring into groove 8 Pull up on upper spring retainer B unt...

Page 177: ...A Fig 42 are available as separate service parts from your Briggs Stratton source of supply Assemble Starter Motor Drive Refer to Fig 448 1 Place starter clutch F Fig 42 on starter shaft Turn clutch until it drops into place 2 Grease inside of pinion gear with Lubriplate or equivalent 3 Install the pinion gear with the chamfered teeth up 4 Install return spring D making sure spring is in recess of...

Page 178: ...er 28Q700 179 Pressure Lubrication 104700 260700 261700 180 Pressure Filtration 180 OIL PUMP SERVICE 180 Oil Pump Screen Removal Installation 104700 260700 261700 180 Oil Pump Screen Removal Installation 28Q700 182 OIL GARD SYSTEM 050000 085400 086400 115400 117400 138400 185400 235400 245400 184 Oil Gard System 184 Oil Gard 161400 185 Oil Gard System 161400 185 ...

Page 179: ...178 9 ...

Page 180: ...400 138400 185400 235400 245400 The dipper A Fig 1 is an integral part of the connecting rod cap Replace connecting rod if dipper is damaged or broken Fig 1 Oil Dipper 161400 The dipper A Fig 2 is a separate part held on the connecting rod cap with the connecting rod screws If dipper shows cracks or missing pieces Replace connecting rod or dipper Fig 2 Oil Slinger 28Q700 The oil slinger A is drive...

Page 181: ...l Pump Screen Removal Installation 104700 260700 261700 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 The O ring that seals the cover is held in a channel machined into the sump A Fig 7 Fig 7 ...

Page 182: ...Remove three screws that hold the pump cover and O ring 2 Remove snap ring A Fig 10 retaining inner rotor to shaft Fig 10 3 Carefully remove inner and outer rotors Remove the drive shaft 4 Inspect the O ring channel inner and outer pump rotor and the drive shaft for any signs of wear or damage Replace if any discrepancies are found 5 Oil and install outer A and inner rotor B Fig 11 in pump cavity ...

Page 183: ...or replace the screen 1 Drive out screen Fig 13Do not reuse Fig 13 2 Install oil pump screen with hole A facing away from governor shaft bearing B Fig 14 Press screen into position as shown Fig 14 Oil Pump Screen Removal Installation 28Q700 Screen Removal Installation 28Q700 Three types of oil pump screens were used on these engines Oil pump screens A Before date code 94110700 were mounted inside ...

Page 184: ...00 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 the pump cover the removal and installation procedure is essentially the same All Date Codes 28Q700 1 Remove the pump cover Fig 19 2 Remove the inner rotor and the outer rotor Fig 20 3 Remove O ring and discard 4 Inspect the O ring channel inner and outer pump...

Page 185: ...y Fig 22 3 Install three screws and torque to listed value Before 94110700 28Q700 1 Install O ring A Fig 23 to groove in sump 2 Place pump cover on oil pump cavity and install three screws 3 Torque to listed value Fig 23 OIL GARD SYSTEM 050000 085400 086400 115400 117400 138400 185400 235400 245400 For Troubleshooting information See SECTION 2 TROUBLESHOOTING pg 54 Oil Gard System OIL GARD will st...

Page 186: ...6 or four wire module which is connected to a stop switch Fig 26 OIL GARD 161400 For Troubleshooting information See SECTION 2 TROUBLESHOOTING pg 55 Oil Gard System 161400 When engine runs low on oil the engine will stop and the Oil Gard light will flash The engine will not restart until the correct amount of oil is added This system uses a float to operate a magnetic switch When the oil level is ...

Page 187: ...ousing and float 2 Check Oil Gard switch operation by connecting a continuity tester to the wire terminal and ground clip 3 In the normal upright position the tester should read continuity 4 Turn the float assembly upside down 5 The tester should read no continuity Assemble Oil Gard System 161400 Refer to Fig 29 1 Install serviceable light assembly in control panel 2 Install new gasket A Fig 29 wi...

Page 188: ... Bearing Service Counter Balance 185400 195 Ball Bearing Service 235400 245400 196 DU Ball Bearing Service 161400 197 Aluminum Bearing Service 104700 198 Aluminum Bearing Service 260700 261700 199 DU Ball Bearing Service 28Q700 199 INSTALLING COVERS AND SUMPS 200 Seal Protectors All Models 200 Installation Cylinders and Covers And Sumps All Models 200 Crankshaft End Play 202 CYLINDER BORES 203 Mea...

Page 189: ...188 10 ...

Page 190: ...ee SECTION 12 PISTONS RINGS AND CONNECTING RODS Crankshaft Seals All Models Oil seals are a press fit in cylinder and sump covers Oil Seal Removal All Models Pry the old seal out of its mounting Fig 2 using a screwdriver Fig 2 Install new oil seals whenever engine is disassembled or when replacing bearings Use a seal protector to prevent damage to the oil seal when installing cover or sump BEARING...

Page 191: ... the inner diameter of the bearings are not If bearing replacement is necessary replace both bearings as a set and be sure to order the bearings by individual part number Installation Magneto And PTO Side Ball Bearing Press a new bearing into a housingor cover from the outside in Be sure that the bearing goes into the channel straight and that the bearing is completely seated into its machined ope...

Page 192: ...ools Refer to Fig 6 Puller Screw A 19318 Washer B 225136 Adapter Driver C 19397 Bushing D 19454 1 Remove governor gear 2 Remove oil seal 3 Assemble washer B to puller screw A and insert through adapter driver C 4 Insert puller screw A with adapter driver C into bearing and thread into bushing D Fig 6 5 Tighten until ball bearing comes free of the cover Installation PTO Side Ball Bearing Bearing In...

Page 193: ...efer to Fig 9 Support A 19394 Washer B 225136 Puller Screw C 19318 Pilot D 19396 1 Lubricate outside of ball bearing 2 Place ball bearing on support A 3 Assemble washer B to puller screw C and insert through pilot D 4 Insert puller screw C with small end of pilot D into cylinder and thread into support A Fig 9 5 Tighten screw until ball bearing is seated 6 Install new oil seal Use large end of dri...

Page 194: ...ew B washer A driver C and ball bearing into pilot nut D Fig 11 6 Tighten until ball bearing is seated Removal PTO Side Ball Bearing With 6 1 Gear Reduction Bearing Removal Tools Refer to Fig 12 Puller Nut A 19139 Puller Stud B 19398 Support C 19454 Washer D 225136 Nut E 94814 1 Remove governor gear 2 Assemble puller nut A to puller stud B and insert through ball bearing 3 Place support C over bal...

Page 195: ...n Magneto Side Ball Bearing 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 Place ball bearing on support D 3 Assemble washer A to puller screw B 4 Insert small end of pilot C into seal boss in cylinder 5 Insert puller screw B through pilot C and thread into support D 6 Tighten until ball bearing is seat...

Page 196: ...er 8 Install thrust washer and governor gear Push governor gear and cup on to shaft as far as it will go 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 Nut Hex C 92278 Screw Hex D 94373 1 Remove nut hex C and screw hex D from flywheel puller 19069 2 Place a flat washer with a 1 4 hol...

Page 197: ... D against ball bearing 4 Insert puller screw B with driver C through ball bearing and thread into support D 5 Tighten until bearing comes free of cylinder Installation Magneto Side Ball Bearing Bearing Installation Tools Refer to Fig 21 Washer A 225136 Puller Screw B 19318 Pilot C 19396 Support D 19440 1 Lubricate outside of bearing 2 Place ball bearing on support D 3 Assemble washer A to puller ...

Page 198: ...asher A 225136 Support B 19440 Puller Screw C 19318 Pilot D 19396 1 Lubricate outside of bearing Fig 23 2 Install shim s if used 3 Assemble washer A to puller screw C 4 Insert large end of pilot D into seal boss of cylinder cover 5 Insert puller screw C through pilot D and thread into support B 6 Tighten until bearing is seated 7 Install new oil seal Use large end of driver 19320 and press oil sea...

Page 199: ...ration 7 Install the oil seal Removal PTO Ball Bearing 1 Remove oil seal 2 Support the cylinder cover on arbor press and press out bearing using bushing A driver 19226 Press bearing to theinside of the cover Fig 27 Fig 27 Installation PTO Ball Bearing 1 Lubricate outside surface of bearing and set on inside of cover 2 Using an arbor press and a suitable block press against the outer race of bearin...

Page 200: ...agneto Side DU Bearing 1 Remove oil seal 2 Using cylinder support tool 19351 and bearing driver tool 19350 A Fig 29 press bearing out of cylinder Fig 29 Installation Magneto Side DU Bearing 1 Place DU bearing on cylinder with oil hole in line with oil hole in cylinder bearing If cylinder bearing cavity does not have oil hole Place split of bearing seam A Fig 30 as shown Fig 30 2 Use cylinder suppo...

Page 201: ...r tight NOTE It may be necessary to rotate crankshaft and camshaft toget oil pump when equipped to engage drive slot in camshaft For counter balanced engines it may be necessary to rotate the counterweight shaft to mesh with timing gear when installing cover Do not force cover Make sure mechanical governor gear and oil pump if used is engaged with camshaft For adjustment procedure for crankshaft e...

Page 202: ...201 10 Fig 34 Fig 35 Fig 36 Fig 37 Fig 38 Fig 39 ...

Page 203: ...PECIFICATIONS Always measure end play with a standard gasket in place If end play is less than listed Use additional gasket s between the oil sump and cylinder to get proper end play If end play is more than listed Use Part 220624 shim on magneto end of crankshaft A Fig 43 non pump applications or on PTO end of crankshaft B Fig 44 pump applications Fig 43 Fig 44 ...

Page 204: ... be resized to 0 020 in 0 51 mm over the standard size shown in the engine specifications See SECTION 14 ENGINE SPECIFICATIONS If done accurately the corresponding 0 020 in 0 51mm oversize rings and pistons will fit correctly and maintain proper clearances Cylinders can be resized with a good quality hone set For aluminum bore engines Briggs Stratton Hone Set 19205 For sleeve bore engines Briggs S...

Page 205: ...f cylinder bore 6 Tighten adjusting knob with finger or small screwdriver until stones fit snugly against cylinder wall Do not force 7 Drill press or portable electric drill should operate at 300 to 700 RPM 8 Connect drive shank to hone Be sure that cylinder and hone are centered and aligned with drive shank and drill spindle 9 Lubricate and flush honing stones and cylinder bore frequently with ho...

Page 206: ...d Cleaning Cylinder A reconditioned cylinder should have a 30 to 45 crosshatch finish Fig 48 Fig 48 Correct stones lubrication and drill speed along with rapid movement of hone within the cylinder during the last few strokes will produce this finish To produce the proper cross hatch finish Use a drill speed of approximately 200 RPM 40 60 strokes per minute Honing grit is abrasive and will cause ra...

Page 207: ...206 10 ...

Page 208: ...185400 235400 245400 161400 104700 260700 261700 213 Inspecting Camshaft All Models 213 Inspecting Crankshaft 214 BALANCING SYSTEMS 215 Rotating Counterweight System 161400 185400 235400 245400 215 Oscillating Counterweight System 260700 261700 216 Synchro Balance System 28Q700 217 GEAR REDUCTIONS 219 Mounting Positions 115400 118400 219 ...

Page 209: ...208 11 ...

Page 210: ...nd bearing 3 Remove cylinder cover or sump See SECTION 10 CYLINDERS COVERS AND SUMPS With the cover removed the following components are visible Refer to Fig 1 A Camshaft B Crankshaft C Timing Gear and Key Fig 1 4 Align timing marks and lift out the camshaft A Fig 1 5 Remove the tappets 6 Remove the timing gear and retain woodruff key 7 Remove connecting rod bolts and rod cap 8 Remove the piston S...

Page 211: ... and freedom of movement Fig 5 If any discrepancies are found Replace complete camshaft assembly Inspecting Valve Tappets All Models Inspect valve tappets for wear on the tappet surface Replace if worn or damaged Inspecting Crankshaft Refer to Fig 6 to check wear points on crankshaft 1 Measure the diameters of the PTO journal A crank pin B and mag journal C 2 Check keyways D for wear and spreading...

Page 212: ...nspect the counterweight shaft journals E and gear teeth F Fig 9 Replace shaft if worn beyond tolerances 5 Measure both counterweight bearings 6 Replace the cylinder cover or cylinder if corresponding bearing is beyond tolerances For reject size dimensions see SECTION 14 ENGINE SPECIFICATIONS Fig 9 Installation Refer to Fig 10 1 Turn crankshaft to align timing marks G on cam gear and crankshaft ti...

Page 213: ... out link pin H Fig 13 6 Remove connector link I Fig 13 Fig 13 Inspect Counterweight Assembly 260700 261700 Inspect the following counterweight components for damage or wear Replace parts as necessary Refer to Fig 13 Pivot Shaft Bearing J Pivot Shaft K Link Pin Bore G Link Pin H Connector Link Pin Bearing L Connector Link Eccentric Bearing M Connector Link I For reject dimensions see SECTION 14 EN...

Page 214: ...0 This system uses a link and counterweight that oscillates opposite the piston Fig 16 Fig 16 Removal Inspection Synchro Balance 1 Remove sump cover and cylinder head See SECTION 10 CYLINDERS COVERS AND SUMPS 2 Remove connecting rod cap 3 Remove connecting rod and piston from engine See SECTION 12 PISTONS RINGS AND CONNECTING RODS 4 Remove camshaft and crankshaft with counterweight assembly 5 Remo...

Page 215: ...agneto journal 3 Slip link E over dowel pin D with rounded edge of free end H up 4 Slide PTO side counterweight C on to dowel pin and crankshaft eccentric I 5 Install screw B Fig 19 Torque to listed value Fig 19 NOTE Rotate crankshaft to check for binding If necessary loosen and re torque screw Check again for freedom of rotation 6 Install woodruff key and slide timing gear on to crankshaft with c...

Page 216: ... to 1 turn of the PTO shaft Mounting Positions 115400 118400 The housing can be installed in four positions A B C D relative to the crankshaft E Fig 21 Fig 21 Remove Gear Reduction Housing 115400 118400 1 Remove the drain plug A Drain the oil from the gear housing into an appropriate container 2 Clean PTO shaft with crocus cloth and wipe with a solvent such as kerosene to remove residue It is impo...

Page 217: ...24 to cylinder Bend ears on locking plates away from heads of two screws inside housing Fig 24 7 Remove housing and inspect for bearing wear cracks and warping Replace if necessary 8 Replace crankshaft oil seal and cork gasket H Fig 25 Fig 25 Assemble Gear Reduction Housing Install seals with sealing lip A toward engine side of gear case B or cover C Fig 26 Press until seal is flush with case or c...

Page 218: ...ket D Fig 29 5 Insert seal protector E in seal of cover Install cover F Fig 29 to gear case Fig 29 6 Install cover screws and torque to listed value 7 Check end play of PTO shaft End play limits 0 002 0 030 in 0 05 0 76 mm Filling Reduction Gear Case 115400 118400 1 To fill gear case remove oil level plug A Fig 30 and oil fill vent plug B 2 Fill gear case with SAE 30W 3 Fill gear case just to the ...

Page 219: ...218 11 ...

Page 220: ...n Removal 222 INSPECT PISTON 222 Measure Piston Pin Bore 222 Measure Ring Groove Clearance 222 Measure Piston Ring End Gap 223 INSPECT CONNECTING ROD 223 Inspect Connecting Rod Bearings 223 ASSEMBLE PISTON AND CONNECTING ROD 223 Piston Pin Installation 223 Ring Installations 224 PISTON INSTALLATION TYPICAL 225 Install Connecting Rod Caps 226 ...

Page 221: ...220 12 ...

Page 222: ...e connecting rod cap removed rotate the crankshaft to push the piston to Top Dead Center TDC 4 Remove the piston Fig 2 Be careful not to damage the surface of the cylinder bore with the connecting rod Fig 2 Piston Ring Removal 1 Remove the first two piston rings using Piston Ring Expander 19340 Fig 3 Fig 3 Some oil control rings consist of two thin steel rails and a spring expander The oil control...

Page 223: ...cting rod aside INSPECT PISTON 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 conditions 1 Measure piston pin bore with telescoping gauge and compare reading with reject dimension Fig 6 See SECTION 14 ENGINE SPECIFICATIONS Replace piston if out of round or worn beyond reject dime...

Page 224: ... a telescoping gauge at approximate 120 intervals and record the readings to get an average dimension as shown in Fig 9 3 Replace rod if either measurement exceeds tolerances See SECTION 14 ENGINE SPECIFICATIONS Fig 9 ASSEMBLE PISTON AND CONNECTING ROD Piston Pin Installation 1 Orient the connecting rod and piston as shown in Fig 10 2 Align the letters MAG A if used on the connecting rod with the ...

Page 225: ... ring C 3 Install the top ring D Fig 568 4 Note the shape of each ring and be careful to install them in the proper position Ring Installation 050000 118400 Fig 11 Ring Installation 085400 Note the shape of each ring and be careful to install them in their proper position NOTE The top ring is plated The center ring is phosphate coated black This model has id marks on the first and second ring Inst...

Page 226: ...nstall them in their proper position NOTE Install gap of oil ring expander B 180 degrees from gap in oil control ring A Fig 16 1 Install the oil control ring A and expander B 2 Install the center ring C 3 Install the top ring D Fig 16 Fig 16 PISTON INSTALLATION TYPICAL To prevent excessive oil consumption and or compression blow by stagger the piston ring gaps as illustrated in Fig 17 Fig 17 CAUTI...

Page 227: ...heel side of the engine Fig 20 Fig 20 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 21 CAUTION Do not use excessive force when installing the piston You could damage the side rails of the oil control ...

Page 228: ...per andwashers if equipped and torque as listed See SECTION 14 ENGINE SPECIFICATIONS CAUTION 28Q700 Torque screw closest to the piston first Torque screw farthest from the piston second 3 Rotate crankshaft two revolutions to ensure crank pin and rod are not binding 4 Move connecting rod from side to side to ensure clearance from crank pin sidewalls ...

Page 229: ...228 12 ...

Page 230: ... 13 FINAL ENGINE ASSEMBLY GENERAL INFORMATION 231 MODEL 050000 231 Models 085400 086400 115400 117400 118400 138400 185400 235400 245400 234 MODEL 104700 236 MODEL 161400 238 MODELS 260700 261700 240 MODEL 28Q700 242 ...

Page 231: ...230 13 ...

Page 232: ...or reinstalling troublesome parts Refer to SECTION 1 SAFETY MAINTENANCE AND ADJUSTMENTS for final adjustment and general servicing information seeSECTION 2 TROUBLESHOOTING for procedures designed to isolate and repair specific problems MODEL 050000 1 Secure wire harness A Fig 1 as shown Fig 1 2 Check to make sure the small steel bushing A Fig 2 is installed in the intake side baffle Install baffle...

Page 233: ...by aligning the two drive flanges with the casting depressions Install starter hub if equipped washer C and flywheel nut D Fig 5 Fig 5 6 Place Flywheel Strap Wrench 19433 A Fig 6 around outer rim of flywheel Fig 6 7 Torque the flywheel nut to value listed in SECTION 14 ENGINE SPECIFICATIONS 8 Position the Oil Gard module A Fig 7 as shown Fig 7 ...

Page 234: ... that no wires are pinched Position spark plug lead in the contour created for it A Fig 9 Fig 9 11 Install grounding lead A Fig 10 as shown Fig 10 12 Assemble shield A Fig 11 as shown Fig 11 13 Mount the remaining blower housing bolts and torque to value listed See SECTION 14 ENGINE SPECIFICATIONS ...

Page 235: ... 138400 235400 245400 Those engines that have gear reduction systems are covered in section 11 With minor variations the 185400 is a good outline for the procedures required to assemble the above mentioned engines 1 Make sure the wiring harness is routed and secured as shown in A Fig 14 Fig 14 2 Mount ignition coil B Fig 14 and connect ground wire 3 Mount flywheel A Fig 15 making sure the new wood...

Page 236: ...return spring A carburetor throttle link B and the choke link C to the control bracket D Fig 17 Fig 17 8 Install muffler 9 Install fuel tank 10 Install fuel shut off valve A and support for air filter assembly B 11 Connect fuel hose C Fig 18 to carburetor Fig 18 12 Install air cleaner base A Fig 19 Fig 19 13 Install air filter and cover NOTE Make sure ground wire is mounted as shown in Fig 20 Fig ...

Page 237: ...s MODEL 104700 1 Install electric starter if equipped 2 Position governor lever in position as shown in A Fig 23 Fig 23 3 Place large carburetor gasket adapter A Fig 24 Fig 24 4 With the governor lever in position loosely install both control brackets A B Fig 25 Fig 25 5 Connect governor return spring A Fig 26 Fig 26 6 Position the back plate A Fig 27 and loosely start the mounting screws 7 Mount ...

Page 238: ...hield See SECTION 4 EXHAUST SYSTEMS 12 Install the oil fill tube and torque to listed values 13 Slip the insulator and gasket on the carburetor mounting bolts 14 Connect governor link A and Choke A Matic link B if installed Slide carburetor assembly C Fig 28 on mounting studs Fig 28 15 Install blower housing and valve cover 16 Install muffler assembly See SECTION 4 EXHAUST SYSTEMS 17 Install air f...

Page 239: ...the flywheel woodruff key fan fan retainer starter cup and screen assembly and the flywheel nut 4 Position the fan to allow for the magnet to fit in the fan cut out A Fig 31 Fig 31 5 Install the ignition coil and adjust the air gap 6 Route the ignition harness as shown A and connect wire to ignition coil Torque control bracket screws B Fig 32 to values listed in section 14 Fig 32 7 Connect the mai...

Page 240: ...stall the intake manifold A and the bracket for the fuel shut off valve B Engage the choke control C as shown 11 Torque carburetor mounting bolts D Fig 35 to values listed See SECTION 14 ENGINE SPECIFICATIONS Fig 35 12 Connect fuel line from the shut off valve to thecarburetor and install valve A Fig 36 as shown Fig 36 13 Install the oil fill tube 14 Connect ground wire to Oil Gard sensor 15 Insta...

Page 241: ...nstall air filter and cover MODELS 260700 261700 1 Mount the governor lever A on the governor shaft as shown in Fig 38 Fig 38 2 Install the control bracket Fig 39 Fig 39 3 Connect the main governor spring A Fig 40 Fig 40 4 Connect the idle control spring A Fig 41 Fig 41 5 Install the alternator ...

Page 242: ... See SECTION 14 ENGINE SPECIFICATIONS 9 Install electric starter 10 Install the flywheel with its woodruff key When positioning the fan assembly on the flywheel make sure the cutout for the magnet is properly positioned 11 Install the fan retainer flywheel nut and starter cup Torque to listed values Fig 44 12 Install the ignition coil and set the air gap 13 Install the exhaust system See SECTION 4...

Page 243: ...ig 47 to carburetor and cylinder Fig 47 18 Install oil fill tube 19 Install air cleaner assembly See SECTION 1 SAFETY MAINTENANCE AND ADJUSTMENTS 20 Install oil filter adapter 21 Install blower housing Fig 48 MODEL 28Q700 1 Install flywheel guard A Fig 49 2 Install alternator with the power output wires positioned as shown B Fig 49 3 Install starter motor C with the bracket for the voltage regulat...

Page 244: ...set air gap 6 With coil installed and ground wire connected route wire through small clamp A Fig 51 to grounding terminal on equipment Fig 51 7 Install governor link with spring A and connect choke arm B Fig 52 as shown Fig 52 8 Install air cleaner base to carburetor and torque mounting nuts A Fig 53 to listed values See SECTION 14 ENGINE SPECIFICATIONS Fig 53 ...

Page 245: ...s 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 55 Fig 55 ...

Page 246: ...ons 250 Reject Dimensions 251 MODELS 115400 117400 253 Engine Specifications 253 Fastener Torque Specifications 253 Reject Dimensions 254 MODEL 118400 256 Engine Specifications 256 Fastener Torque Specifications 256 Reject Dimensions 257 MODEL 138400 259 Engine Specifications 259 Fastener Torque Specifications 259 Reject Dimensions 260 MODEL 18544 262 Engine Specifications 262 Fastener Torque Spec...

Page 247: ...stener Torque Specifications 268 Reject Dimensions 269 MODEL 104700 271 Engine Specifications 271 Fastener Torque Specifications 271 Reject Dimensions 272 MODELS 260700 261700 274 Engine Specifications 274 Fastener Torque Specifications 274 Reject Dimensions 275 MODEL 28Q700 277 Engine Specifications 277 Fastener Torque Specifications 277 Reject Dimensions 278 ...

Page 248: ...e 7 mm 30 lb in 3 Nm Blower Housing 10 mm 100 lb in 11 Nm Carburetor Bowl Screw 10 mm 55 lb in 6 Nm Connecting Rod 10 mm 90 lb in 10 Nm Control Bracket 10 mm 45 lb in 5 Nm Control Panel Trim Phillips 30 lb in 3 Nm Cylinder Cover 10 mm 90 lb in 10 Nm Cylinder Head 12 mm 250 lb in 28 Nm Cylinder Shield 10 mm 90 lb in 10 Nm Engine Mounting Plate 10 mm 90 lb in 10 Nm Exhaust Manifold Adapter 12 mm 180...

Page 249: ...A Intake Valve Seat Width 3 64 4 64 in 1 19 1 59 mm N A Intake Valve Stem Diameter 2154 in 5 47 mm 2134 in 5 42 mm Intake Valve Guide 2165 in 5 50 mm 2200 in 5 59 mm Exhaust Valve Seat Angle 45 N A Exhaust Valve Seat Width 3 64 4 64 in 1 19 1 59 mm N A Exhaust Valve Stem Diameter 2154 in 5 47 mm 2134 in 5 42 mm Exhaust Valve Guide 2165 in 5 50 mm 2200 in 5 59 mm Cylinder Cover 050000 PTO Bearing N...

Page 250: ... Pine Bore 5516 in 14 01 mm 5528 in 14 04 mm Ring End Gap Top 006 014 in 15 35 mm 030 in 76 mm Ring End Gap Middle 006 014 in 15 35 mm 030 in 76 mm Ring End Gap Oil Control 008 028 in 20 70 mm 040 in 1 02 mm Ring Land Clearance Top 001 003 in 03 07 mm 008 in 20 mm Ring Land Clearance Middle 001 003 in 03 07 mm 008 in 20 mm Ring Land Clearance Oil Control 001 033 in 03 07 mm 008 in 20 mm Starter Ro...

Page 251: ...using 10 mm 45 lb in 5 Nm Carburetor Bowl Screw 12 mm 85 lb in 10 Nm Connecting Rod 10 mm 90 lb in 10 Nm Control Bracket 10 mm 45 lb in 5 Nm Control Panel Trim 10 mm 45 lb in 5 Nm Cylinder Cover 12 mm 175 lb in 20 Nm Cylinder Head 12 mm 220 lb in 25 Nm Cylinder Shield 10 mm 45 lb in 5 Nm Flywheel Nut 21 mm 44 lb ft 60 Nm Fuel Shut Off Valve 10 mm 70 lb in 8 Nm Fuel Tank 10 mm 90 lb in 10 Nm Govern...

Page 252: ... 1 59 mm N A Exhaust Valve Stem Diameter 2346 in 5 96 mm 2338 in 5 94 mm Exhaust Valve Guide 2368 in 6 02 mm 2378 in 6 04 mm Cylinder Cover 085400 086400 PTO Bearing Ball N A Camshaft Bearing 5909 in 15 01 mm 5917 in 15 03 mm Crankshaft 085400 086400 Crank Pin Journal 1 0236 in 26 00 mm 1 0228 in 25 98 mm Mag Side Journal 7874 in 20 00 mm 7866 in 19 98 mm PTO Side Journal 7874 in 20 00 mm 7866 in ...

Page 253: ... 006 014 in 15 35 mm 040 in 1 0 mm Ring End Gap Middle 006 014 in 15 35 mm 040 in 1 0 mm Ring End Gap Oil Control 008 028 in 35 70 mm 060 in 1 50 mm Ring Land Clearance Top 001 003 in 03 07 mm 008 in 20 mm Ring Land Clearance Middle 001 003 in 03 07 mm 008 in 20 mm Ring Land Clearance Oil Control 001 003 in 03 07 mm 008 in 20 mm Starter Rope 085400 086400 Rope Size 4 3 18 mm N A Rope Length 67 in ...

Page 254: ...30 lb in 3 Nm Blower Housing 10 mm 45 lb in 5 Nm Carburetor Bowl Screw 12 mm 85 lb in 10 Nm Choke Lever Stud Screw 10 mm 45 lb in 5 Nm Connecting Rod 10 mm 90 lb in 10 Nm Control Bracket 10 mm 45 lb in 5 Nm Control Panel Trim 10 mm 45 lb in 5 Nm Cylinder Cover 12 mm 175 lb in 20 Nm Cylinder Head 12 mm 220 lb in 25 Nm Cylinder Shield 10 mm 45 lb in 5 Nm Flywheel Nut 21 mm 44 lb ft 60 Nm Fuel Shut O...

Page 255: ...9 in 15 01 mm 5917 in 15 03 mm Bore Diameter 2 6772 in 68 00 mm 2 6783 in 68 03 mm Bore Out Of Round N A 0015 in 04 mm Cylinder Head 115400 117400 Standard Size Reject Size Intake Valve Seat Angle 45 N A Intake Valve Seat Width 3 64 4 64 in 1 19 1 59 mm N A Intake Valve Stem Diameter 2346 in 5 96 mm 2338 in 5 94 mm Intake Valve Guide 2368 in 6 02 mm 2378 in 6 04 mm Exhaust Valve Seat Angle 45 N A ...

Page 256: ...earing 6303 in 16 01 mm 6311 in 16 03 mm Piston 115400 117400 Piston Pin Diameter 6299 in 16 00 mm 6291 in 15 98 mm Piston Pine Bore 6303 in 16 01 mm 6311 in 16 03 mm Ring End Gap Top 006 004 in 15 35 mm 040 in 1 0 mm Ring End Gap Middle 006 004 in 15 35 mm 040 in 1 0 mm Ring End Gap Oil Control 014 028 in 35 70 mm 060 in 1 50 mm Ring Land Clearance Top 001 003 in 03 07 mm 008 in 20 mm Ring Land C...

Page 257: ...ting Rod 10 mm 90 lb in 10 Nm Control Bracket 10 mm 45 lb in 5 Nm Control Panel Trim 10 mm 45 lb in 5 Nm Cylinder Cover 12 mm 175 lb in 20 Nm Cylinder Head 12 mm 220 lb in 25 Nm Cylinder Shield 10 mm 45 lb in 5 Nm Exhaust Manifold Adapter 12 mm 180 lb in 20 Nm Flywheel Guard 10 mm 45 lb in 5 Nm Flywheel Nut 21 mm 44 lb ft 60 Nm Fuel Shut Off Valve 10 mm 70 lb in 8 Nm Fuel Shut Off Valve Bracket 10...

Page 258: ...xhaust Valve Seat Angle 45 N A Exhaust Valve Seat Width 3 64 4 64 in 1 19 1 59 mm N A Exhaust Valve Stem Diameter 215 in 5 46 mm 213 in 5 41 mm Exhaust Valve Guide 2165 in 5 50 mm 22 in 5 59 mm Cylinder Cover 118400 PTO Bearing Ball N A Camshaft Bearing 5909 in 15 01 mm 5917 in 15 03 mm Crankshaft 118400 Crank Pin Journal 1 1811 in 30 0 mm 1 1795 in 29 96 mm Mag Side Journal 9842 in 25 0 mm 9827 i...

Page 259: ... Pine Bore 6303 in 16 01 mm 6315 in 16 04 mm Ring End Gap Top 006 014 in 15 35 mm 030 in 76 mm Ring End Gap Middle 006 014 in 15 35 mm 030 in 76 mm Ring End Gap Oil Control 008 028 in 20 70 mm 040 in 1 02 mm Ring Land Clearance Top 001 003 in 03 07 mm 008 in 20 mm Ring Land Clearance Middle 001 003 in 03 07 mm 008 in 20 mm Ring Land Clearance Oil Control 001 003 in 03 07 mm 008 in 20 mm Starter Ro...

Page 260: ...rmature 10 mm 30 lb in 3 Nm Blower Housing 10 mm 45 lb in 5 Nm Carburetor Bowl Screw 12 mm 85 lb in 10 Nm Connecting Rod 10 mm 90 lb in 10 Nm Control Bracket 10 mm 45 lb in 5 Nm Control Panel Trim 10 mm 45 lb in 5 Nm Cylinder Cover 12 mm 175 lb in 20 Nm Cylinder Head 12 mm 220 lb in 25 Nm Cylinder Shield 10 mm 45 lb in 5 Nm Flywheel Nut 21 mm 44 lb ft 60 Nm Fuel Shut Off Valve 10 mm 70 lb in 8 Nm ...

Page 261: ...m 5917 in 15 03 mm Bore Diameter 2 8346 in 72 0 mm 2 8358 in 72 03 mm Bore Out Of Round N A 0015 in 04 mm Cylinder Head 138400 Standard Size Reject Size Intake Valve Seat Angle 45 N A Intake Valve Seat Width 3 64 4 64 in 1 19 1 59 mm N A Intake Valve Stem Diameter 2346 in 5 96 mm 2338 in 5 94 mm Intake Valve Guide 2368 in 6 02 mm 2378 in 6 04 mm Exhaust Valve Seat Angle 45 N A Exhaust Valve Seat W...

Page 262: ...ing 6303 in 16 01 mm 6311 in 16 03 mm Piston 138400 Piston Pin Diameter 6299 in 16 00 mm 6291 in 15 98 mm Piston Pine Bore 6303 in 16 01 mm 6311 in 16 03 mm Ring End Gap Top 006 014 in 15 35 mm 040 in 1 0 mm Ring End Gap Middle 006 014 in 15 35 mm 040 in 1 0 mm Ring End Gap Oil Control 014 028 in 35 70 mm 060 in 1 5 mm Ring Land Clearance Top 001 003 in 03 07 mm 008 in 20 mm Ring Land Clearance Mi...

Page 263: ...A Air Cleaner Support Bracket Armature 10 mm 30 lb in 3 Nm Blower Housing 10 mm 45 lb in 5 Nm Carburetor Bowl Screw 12 mm 85 lb in 10 Nm Connecting Rod 10 mm 175 lb in 20 Nm Control Bracket 10 mm 45 lb in 5 Nm Control Panel Trim 10 mm 45 lb in 5 Nm Cylinder Cover 12 mm 175 lb in 20 Nm Cylinder Head 14 mm 310 lb in 35 Nm Cylinder Shield 10 mm 45 lb in 5 Nm Flywheel Nut 21 mm 63 lb ft 85 Nm Fuel Shu...

Page 264: ...ll NA Camshaft Bearing 5909 in 15 01 mm 5917 in 15 03 mm Bore Diameter 3 1496 in 80 0 mm 3 1508 in 80 03 mm Bore Out Of Round N A 0015 in 04 mm Cylinder Head 185400 Standard Size Reject Size Intake Valve Seat Angle 45 N A Intake Valve Seat Width 3 64 4 64 in 1 19 1 59 mm N A Intake Valve Stem Diameter 2346 in 5 96 mm 2338 in 5 94 mm Intake Valve Guide 2368 in 6 02 mm 2378 in 6 04 mm Exhaust Valve ...

Page 265: ...ing 7091 in 18 01 mm 7098 in 18 03 mm Piston 185400 Piston Pin Diameter 7086 in 18 00 mm 7078 in 17 98 mm Piston Pine Bore 7091 in 18 01 mm 7098 in 18 03 mm Ring End Gap Top 006 014 in 15 35 mm 040 in 1 0 mm Ring End Gap Middle 006 014 in 15 35 mm 040 in 1 0 mm Ring End Gap Oil Control 014 028 in 35 70 mm 060 in 1 5 mm Ring Land Clearance Top 001 003 in 03 07 mm 008 in 20 mm Ring Land Clearance Mi...

Page 266: ...upport Bracket 10 mm 45 lb in 5 Nm Armature 10 mm 30 lb in 3 Nm Blower Housing 10 mm 45 lb in 5 Nm Connecting Rod 10 mm 175 lb in 20 Nm Control Bracket 10 mm 45 lb in 5 Nm Control Panel Trim 10 mm 45 lb in 5 Nm Cylinder Cover 12 mm 175 lb in 20 Nm Cylinder Head 14 mm 420 lb in 47 Nm Cylinder Shield 10 mm 45 lb in 5 Nm Fly Wheel Fan Retainer 12 mm 90 lb in 10 Nm Flywheel Nut 21 mm 63 lb ft 85 Nm Fu...

Page 267: ...ing Ball N A Bore Diameter 3 5039 in 89 0 mm 3 5051 in 89 03 mm Bore Out Of Round N A 0015 in 04 mm Cylinder Head 235400 245400 Intake Valve Seat Angle 45 N A Intake Valve Seat Width 3 64 4 64 in 1 19 1 59 mm N A Intake Valve Stem Diameter 2346 in 5 96 mm 2338 in 5 94 mm Intake Valve Guide 2368 in 6 02 mm 2378 in 6 04 mm Exhaust Valve Seat Angle 45 N A Exhaust Valve Seat Width 3 64 4 64 in 1 19 1 ...

Page 268: ...ank Pin Bearing 1 5362 in 39 02 mm 1 5370 in 39 04 mm Piston Pin Bearing 7878 in 20 01 mm 7886 in 20 03 mm Piston 235400 245400 Piston Pin Diameter 7874 in 20 00 mm 7866 in 19 98 mm Piston Pine Bore 7878 in 20 01 mm 7886 in 20 03 mm Ring End Gap Top 006 014 in 15 35 mm 040 in 1 0 mm Ring End Gap Middle 006 014 in 15 35 mm 040 in 1 0 mm Ring End Gap Oil Control 014 028 in 35 70 mm 060 in 1 5 mm Rin...

Page 269: ...32 in 30 ln in 3 Nm Blower Housing 8 mm 45 lb in 5 Nm Connecting Rod 5 16 in 12 Point 185 lb in 21 Nm Control Bracket 10 mm 55 lb in 6 Nm Control Panel Trim 8 mm 45 lb in 5 Nm Cylinder Cover 10 mm 140 lb in 16 Nm Cylinder Head 10 mm 165 lb in 19 Nm Cylinder Shield 8 mm 45 lb in 5 Nm Exhaust Manifold Adaptor 10 mm 140 lb in 16 Nm Exhaust Manifold Heat Shield 7 mm 35 lb in 4 Nm Flywheel Guard 7 mm 3...

Page 270: ...arter Motor Thorough Bolts 8 mm 34 lb in 4 Nm Stator 1 4 in 30 lb in 3 Nm Valve Cover 8 mm 55 lb in 6 Nm Voltage Regulator Rectifier 10 mm 45 lb in 5 Nm Reject Dimensions 161400 Standard Size Reject Size Cylinder 161400 Magneto Bearing 1 5005 in 38 11 mm 1 5015 in 38 14 mm Camshaft Bearing 6255 in 15 89 mm 6275 in 15 94 mm Counterweight Bearing 6255 in 15 89 mm 6275 in 15 94 mm Bore Diameter 3 0 i...

Page 271: ...ounterweight Shaft 161400 Mag Side Journal 6250 in 15 88 mm 6230 in 15 82 mm PTO Side Journal 6250 in 15 88 mm 6230 in 15 82 mm Connecting Rod 161400 Crank Pin Bearing 1 4303 in 36 33 mm 1 4331 in 36 40 mm Piston Pin Bearing 8009 in 20 34 mm 8013 in 20 35 mm Piston 161400 Piston Pin Diameter 8005 in 20 33 mm 80 in 20 32 mm Piston Pin Bore 8009 in 20 34 mm 8013 in 20 35 mm Ring End Gap Top 006 014 ...

Page 272: ... 8 mm 55 lb in 6 Nm Connecting Rod 8 mm 90 lb in 10 Nm Control Bracket 8 mm 45 lb in 5 Nm Throttle Control Bracket 7 mm 35 lb in 4 Nm Sump Cover 10 mm 140 lb in 16 Nm Cylinder Head 13 mm 165 lb in 19 Nm Exhaust Manifold Adaptor 10 mm 140 lb in 16 Nm Exhaust Manifold Heat Shield 7 mm 35 lb in 4 Nm Flywheel Brake Assembly 7 mm 35 lb in 4 Nm Flywheel Brake Cover Phillips 35 lb in 4 Nm Flywheel Guard ...

Page 273: ... mm Camshaft Bearing 5010 in 12 73 mm 5031 in 12 78 mm Bore Diameter 2 561 in 65 06 mm 2 464 in 65 12 mm Bore Out Of Round N A 0015 in 04 mm Cylinder Head 104700 Standard Size Reject Size Intake Valve Seat Angle 45 N A Intake Valve Seat Width 3 64 4 64 in 79 1 19 mm N A Intake Valve Stem Diameter 2354 in 5 98 mm 2346 in 5 96 mm Intake Valve Guide 2380 in 6 05 mm 24 in 6 10 mm Exhaust Valve Seat An...

Page 274: ...on Pin Bearing 5519 in 14 02 mm 5522 in 14 02 mm Piston 104700 Piston Pin Diameter 5515 in 14 01 mm 5511 in 14 0 mm Piston Pine Bore 5519 in 14 02 mm 5522 in 14 02 mm Ring End Gap Top 006 014 in 15 35 mm 030 in 76 mm Ring End Gap Middle 006 014 in 15 35 mm 030 in 76 mm Ring End Gap Oil Control 014 028 in 35 70 mm 065 in 1 65 mm Ring Land Clearance Top 001 003 in 03 07 mm 004 in 10 mm Ring Land Cle...

Page 275: ...wer Housing 8 mm 45 lb in 5 Nm Breather Cover 8 mm 80 lb in 9 Nm Breather Retainer 7 32 in 25 lb in 23 Nm Connecting Rod 5 16 in 12 Point 200 lb in 23 Nm Control Bracket 8 mm 45 lb in 5 Nm Sump Cover 13 mm 250 lb in 28 Nm Cylinder Head 13 mm 225 lb in 25 Nm Cylinder Shield 8 mm 45 lb in 5 Nm Exhaust Manifold Adaptor 10 mm 140 lb in 16 Nm Exhaust Manifold Heat Shield 8 mm 1 4 in 25 lb in 3 Nm Flywh...

Page 276: ...rter Motor Thorough Bolts 8 mm 35 lb in 4 Nm Stator 1 4 in 30 lb in 3 Nm Valve Cover 8 mm 55 lb in 6 Nm Voltage Regulator Rectifier 10 mm 45 lb in 5 Nm Reject Dimensions 260700 261700 Standard Size Reject Size Cylinder 260700 261700 Magneto 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 Bore Diameter 3 436 in 87 29 mm 3 439 in 87 3 mm Bore Out Of Rou...

Page 277: ... 65 1 78 mm Counterweight Assembly 260700 261700 Pivot Shaft Bore 5015 in 12 74 mm 5031 in 12 78 mm Counterweight Pin Bore 6281 in 15 80 mm 6230 in 15 82 mm Link Pin 6205 in 15 76 mm 6189 in 15 72 mm Connector Pin Bore 6221 in 15 80 mm 6230 in 15 82 mm Connector Eccentric Bore 2 862 in 68 12 mm 2 684 in 68 17 mm Connecting Rod 260700 261700 Crank Pin Bearing 1 625 in 41 30 mm 1 627 in 41 33 mm Pis...

Page 278: ...Blower Housing 3 8 in T 20 85 lb in 10 Nm Breather Cover Air Cleaner Base 5 16 in 35 lb in 4 Nm Breather Cover Cylinder 5 16 in 55 lb in 6 Nm Carburetor To Manifold Bolts 5 16 in 65 lb in 7 Nm Connecting Rod After 980630xx 5 16 in 185 lb in 21 Nm Small Bolt Before 980701xx 3 8 in 160 lb in 18 Nm Large Bolt Before 980701xx 1 2 in 260 lb in 29 Nm Control Bracket 5 16 in 45 lb in 5 Nm Counterweight S...

Page 279: ...ge Regulator Rectifier 3 8 in 45 lb in 5 Nm Reject Dimensions 28Q700 Standard Size Reject Size Cylinder 28Q700 Magneto Bearing 1 365 in 34 96 mm 1 3830 in 35 13 mm Camshaft Bearing 5015 in 12 74 mm 5040 in 12 80 mm Link Pin 4900 in 12 45 mm 4885 in 12 41 mm Bore Diameter 3 4365 in 87 29 mm 3 4395 in 87 36 mm Bore Out Of Round N A 0015 in 04 mm Cylinder Head 28Q700 Standard Size Reject Size Intake ...

Page 280: ...4915 in 12 48 mm 4930 in 12 52 mm Link Pin 4900 in 12 45 mm 4885 in 12 41 mm Connecting Rod 28Q700 Crank Pin Bearing Before 980701xx 1 2502 in 31 76 mm 1 2521 in 31 80 mm Crank Pin Bearing After 980701xx 1 5003 in 38 11 mm 1 5020 in 38 15 mm Piston Pin Bearing 8009 in 20 34 mm 8013 in 20 35 mm Piston 28Q700 Piston Pin Diameter 8005 in 20 33 mm 80 in 20 32 mm Piston Pine Bore 8009 in 20 34 mm 8013 ...

Page 281: ...280 14 ...

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