Briggs & Stratton 272144 Repair Manual Download Page 1 | Manualshive

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®

®

BRIGGS & STRATTON CORPORATION

Milwaukee, WI 53201

Part No. 275429-1/04 Printed in U.S.A.

www.briggsandstratton.com

272147 - Single Cylinder OHV Air-Cooled Engines
272144 - Vanguard™ Twin Cylinder OHV Air-Cooled Engines
275429 - Vanguard™ Twin Cylinder OHV Liquid-Cooled Engines
MS-0750 - Vanguard™ 3-Cylinder OHV Liquid-Cooled Gasoline Engines
MS-1055 - Vanguard™ 3-Cylinder OHV Liquid-Cooled Diesel Engines

Quality Starts With A

Master Service Technician

Other Briggs & Stratton
Commercial Power Repair Manuals:

Vanguard Twin Cylinder

OHV Liquid-Cooled Engines

Briggs & Stratton

V

ANGUARD™ TWIN CYLINDER OHV LIQUID-COOLED ENGINES

Part No. 275429-1/04

REPAIR MANUAL

™

275429_2LC_.1875_Spine 3/29/06 11:11 AM Page 1

For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

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Summary of Contents for 272144

Page 1: ...inder OHV Liquid Cooled Gasoline Engines MS 1055 Vanguard 3 Cylinder OHV Liquid Cooled Diesel Engines Quality Starts With A Master Service Technician Other Briggs Stratton Commercial Power Repair Manu...

Page 2: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine MODEL 473100 2 CYLINDER LIQUID COOLED ENGINE COMMERCIAL POWER MANUAL NUMBER 275429...

Page 3: ...paralysis or property damage IN THE INTEREST OF SAFETY The safety alert symbol is used to identify safety information about hazards that can result in personal injury A signal word DANGER WARNING or C...

Page 4: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine...

Page 5: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine...

Page 6: ...PUMP GENERAL INFORMATION 17 CYLINDER BALANCE TEST 18 CYLINDER LEAKDOWN TEST 19 CHECKING COOLING SYSTEM 21 CHECK OIL PRESSURE SWITCH 22 CHECK OIL PRESSURE 23 CHARGING SYSTEM 23 BATTERY INFORMATION 25...

Page 7: ...9 INSTALL CRANKCASE COVER 59 INSTALL STARTER 60 INSTALL ALTERNATOR 60 INSTALL FLYWHEEL 61 INSTALL CYLINDER HEADS 61 INSTALL ROCKER ARMS 61 ADJUST VALVE CLEARANCE 62 INSTALL ARMATURES 62 INSTALL FAN AS...

Page 8: ...ounting Splash Lube Ball Bearing Flange Mounting Pressure Lubrication Plain Bearing Gear Reduction 6 1 CCW Rotation Flange Mounting Plain Bearing Gear Reduction 2 1 CCW Rotation Plain Bearing Pressure...

Page 9: ...n Belt If Equipped Fuel Filter Radiator Drain Plug If Equipped Radiator Screen Handle If Equipped Radiator Radiator Cap If Equipped Air Cleaner If Equipped Fuel Pump Muffler If Equipped Choke Control...

Page 10: ...rborne debris is present Replace air cleaner parts if very dirty If an extended life coolant is used interval may be increased to once every 3000 hours MAINTENANCE SCHEDULE Daily 50 Hours 100 Hours 25...

Page 11: ...ricating qualities Oil Recommendations Use a high quality detergent oil classified For Service SF SG SH SJ or higher Briggs Stratton strongly recommends the use of synthetic oil such as Briggs Stratto...

Page 12: ...o bring oil level to FULL mark on dipstick Do Not Overfill NOTE Overfilling can cause a smoking or overheating condition due oil foaming Fig 2 9 Replace oil fill cap and dipstick 10 Start and run engi...

Page 13: ...not to damage radiator fins CAUTION Engine parts should be kept clean to reduce the risk of overheating and ignition of accumulated debris Fig 3 ADJUST FAN BELT Check condition of fan belt Replace if...

Page 14: ...dge Pressurized air can damage cartridge solvents will dissolve cartridge 1 Unlock clamps and remove cover 2 Remove cartridge from air cleaner body 3 Carefully clean out air cleaner cover 4 Install ca...

Page 15: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine Section 1 General Information Page 10...

Page 16: ...sure battery cables and solenoid connections are clean and tight 3 Check battery voltage from positive battery terminal to battery terminal on solenoid Voltage must not be below 11 7 volts Check Star...

Page 17: ...wire with alligator clips 5 A fully charged 12 volt battery Testing Starter NOTE To prevent engine from starting remove spark plug wires from spark plugs and ground ignition using two Ignition Tester...

Page 18: ...tivate starter by contacting positive battery terminal with other end of jumper wire Fig 11 a Allow 3 seconds for meter reading to stabilize 7 Current draw should not exceed 50 amps DC If amperage dra...

Page 19: ...t armature air gap 5 Armature failure Check Ignition Engine Running If engine runs but misses during operation a quick check to determine if ignition is or is not at fault can be made by installing To...

Page 20: ...the meter will display the forward voltage drop across the diode s If the voltage drop is less than 0 7 volts the meter will Beep once as well as display the voltage drop A continuous tone indicates c...

Page 21: ...fuel pump 5 Inoperative fuel shut off solenoid A simple check to determine if the fuel is getting to the combustion chamber through the carburetor is to remove either spark plug and pour a small quant...

Page 22: ...t transistor battery are required for this test 1 Attach one jumper wire to solenoid wire GRAY WIRE and positive terminal on battery Fig 18 2 Attach second jumper wire to negative terminal on battery...

Page 23: ...note the RPM loss If the difference between the two cylinders does not exceed 75 RPM the amount of work the two cylinders are doing should be considered equal Fig 21 Things Which Affect Both Cylinders...

Page 24: ...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 wou...

Page 25: ...at TDC on the compression stroke a Air flowing between the cylinder and cylinder head indicates that the cylinder head gasket is leaking b Air flowing from the carburetor indicates air is leaking pas...

Page 26: ...ssure Testing Cooling System 1 Remove radiator cap and make sure coolant is at correct level Fig 25 a Coolant level must be no more than 1 in 25 mm below bottom of filler neck Fig 25 2 Install cooling...

Page 27: ...A thermometer capable of reading 212 F 100 C or more is required 1 Check to make sure thermostat valve is fully closed 2 Immerse thermostat in water and heat water gradually Fig 27 3 Note temperature...

Page 28: ...nd regulates current to the battery The charging rate will vary with engine RPM and temperatures The stator regulator rectifier and flywheel are not interchangeable with any other alternator system TR...

Page 29: ...e Fig 31 Fig 31 5 Attach BLACK test lead probe to negative battery terminal 6 Turn equipment key switch to ON position Meter should display battery voltage 7 If meter does not display battery voltage...

Page 30: ...ce Before activating a dry charge battery read and follow the manufacturer s recommended procedure Battery Installation 1 Before installing battery connect all equipment to be operated 2 Place battery...

Page 31: ...enoid and to starter plus ground return to battery negative post 6 AWG 4 ft 1 2 m or less 5 AWG 5 ft 1 5 m or less 4 AWG 6 ft 1 8 m or less EQUIPMENT AFFECTING ENGINE OPERATION Frequently what appears...

Page 32: ...r REMOVE MUFFLER 1 Remove muffler bracket screws and exhaust manifold screws Fig 34 Fig 34 REMOVE RADIATOR 1 Remove upper and lower radiator hoses Fig 35 2 Disconnect by pass hose at thermostat housin...

Page 33: ...tor fuel pump pulse line at valve cover and fuel inlet line at fuel filter Fig 37 Fig 37 REMOVE FAN ASSEMBLY 1 Remove lower fan shroud screws and upper fan bracket screws at intake manifold Fig 38 2 R...

Page 34: ...ly Page 29 6 Remove fan adjustment bracket Fig 41 Fig 41 7 Remove fan brackets Fig 42 Fig 42 REMOVE CARBURETOR 1 Remove air cleaner assembly 2 Disconnect throttle link and spring at carburetor Fig 43...

Page 35: ...e 6 Disconnect breather tube at air cleaner elbow Fig 46 7 Remove intake elbow screws 8 Remove intake elbow and carburetor assembly 9 Disconnect choke link at choke control Fig 46 10 Remove air cleane...

Page 36: ...flywheel nut Fig 50 Fig 50 5 Install flywheel puller Tool 19203 6 Tighten puller nuts equally until flywheel loosens Fig 51 Fig 51 WARNING DO NOT strike flywheel with a hard object or a metal tool as...

Page 37: ...53 REMOVE ALTERNATOR 1 Remove alternator harness clamp and alternator Fig 54 Fig 54 REMOVE CYLINDER HEADS 1 Remove valve covers 2 Remove rocker arms and pushrods Fig 55 NOTE Mark pushrods so that they...

Page 38: ...gine Disassembly Page 33 REMOVE CRANKCASE COVER 1 Remove water pump cover Fig 57 2 Remove water pump impeller Fig 57 3 Remove crankcase cover Fig 58 Fig 58 4 Remove oil pump screws and oil pump Fig 59...

Page 39: ...s to prevent breaking rings when removing piston and connecting rod assemblies 1 Remove No 2 connecting rod cap and push connecting rod and piston assembly out of cylinder Fig 62 NOTE Reassemble cap t...

Page 40: ...ng stones to restore the proper cross hatch angle in the cylinder bores The proper cylinder crosshatch ensures proper lubrication and piston ring break in Refer to Page 3 Cylinder Finish Cross Hatch f...

Page 41: ...ore Fig 66 Lubricate hone frequently to prevent build up on stones As cutting tension decreases stop hone and tighten adjusting knob following hone manufacturer s recommendations Check cylinder bore f...

Page 42: ...one Honing grit is highly abrasive and will cause rapid wear to all of the internal components of the engine unless it is completely removed NOTE When cylinder and crankcase have been thoroughly clean...

Page 43: ...rnals are scored or worn replace crankshaft Fig 71 Check Camshaft Inspect gear teeth lobes and journals for wear and nicks Camshaft journal and lobe reject sizes are shown below Replace cam gear if no...

Page 44: ...g rod Keep pistons and connecting rods together as an assembly Do not mix Fig 74 Check Piston And Rings If the cylinder is not going to be resized and the piston shows no signs of scoring the piston s...

Page 45: ...Rod 1 Check piston pin Fig 78 Fig 78 2 Check connecting rod bearings Fig 79 NOTE If crankpin bearing is scored or worn the connecting rod must be replaced Fig 79 Replace if greater than 828 21 03 mm R...

Page 46: ...Valve springs d IN and EX valves Fig 80 3 Remove and discard valve stem seals Fig 81 Fig 81 Inspect And Repair 1 Check cylinder head Be sure all gasket material is removed from surfaces before checki...

Page 47: ...nisol or kerosene to lubricate reamer b Turn reamer clockwise through entire guide c Keep turning reamer clockwise when removing reamer d Flush out all chips Fig 86 Reface Valves And Seats 1 Measure v...

Page 48: ...4150 NOTE In most instances it is more economical to replace the valves than to reface them Assemble Cylinder Head 1 Use valve guide driver Tool 19416 and install new intake valve stem seals Fig 90 a...

Page 49: ...cker arm screws Fig 92 OIL PUMP Disassemble Oil Pump 1 Remove two screws and oil pump gear baffle Fig 93 Fig 93 2 Remove oil pick up tube and screen assembly a Discard O ring Inspect Oil Pump Inspect...

Page 50: ...emoving the crankcase cover from the engine The water pump housing and water pump impeller must be removed If any evidence of coolant is observed in the oil this indicates that the oil seal behind the...

Page 51: ...6 Hold hex head of puller stud and tighten nut until water pump seal is removed 7 Thoroughly clean seal bearing surfaces Fig 99 Installing Water Pump Seal 1 Press or drive in new water pump seal until...

Page 52: ...starter motor disassembly It is recommended that a complete inspection of all components be performed at that time Disassemble Starter For ease of disassembly and assembly clamp drive end housing in...

Page 53: ...g 107 Clean and inspect helix If helix is damaged replace starter Inspect bearing journals on armature shaft for wear or damage If bearing journals are worn or damaged replace starter NOTE Bearings in...

Page 54: ...test lead as shown a Meter should make continuous tone continuity b If meter does not make a tone no continuity replace starter housing Fig 110 3 Attach either test lead to starter housing Fig 111 4...

Page 55: ...and drive lever into drive housing Fig 114 Fig 114 2 Align tab on drive lever with notch in housing Fig 48 3 Assemble starter housing to drive housing aligning notch 115 Fig 115 4 Install brush holder...

Page 56: ...r housing Fig 118 a Be sure notch in rubber seal is inserted over tab on housing Fig 118 9 Install end cap Fig 119 a Torque through bolts to 70 in lbs 8 0 Nm 10 Install solenoid Fig 119 CARBURETOR INS...

Page 57: ...nd R 2 cylinder 4 Remove pilot jets Fig 121 5 Remove float and inlet valve Fig 122 Fig 122 If idle mixture screws are equipped with adjustment limiter caps use a pliers to remove them before removing...

Page 58: ...aner Part 100041 or 100042 to clean carburetor parts and body 4 When cleaning non metallic parts plastic nylon MinlonE etc do not leave in commercial carburetor cleaner more than 15 minutes CAUTION To...

Page 59: ...nt such as Permatex 2 or nail polish on outside diameter of plug to prevent air leaks Fig 129 3 Install new throttle shaft seal Fig 130 4 Install throttle shaft with spacer IMPORTANT Install one throt...

Page 60: ...133 L or 1 cylinder is equipped with 114 main jet R or 2 cylinder is equipped with 118 main jet Both pilot jets are 48 Fig 133 8 Assemble inlet valve to float and install float assembly Fig 134 Fig 13...

Page 61: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine Section 4 Engine Overhaul Page 56...

Page 62: ...semble 2 piston and connecting rod Fig 138 1 Offset casting mark on piston must face flywheel side 2 OUT 2 on connecting rod must face PTO side opposite notch or casting mark on piston a Install pisto...

Page 63: ...rankshaft until it as at bottom of stroke 3 Install 1 piston with notch or offset casting mark on piston toward flywheel side Fig 141 a Push piston down by hand until connecting rod is seated on crank...

Page 64: ...3 Install new O rings in cylinder Fig 143 INSTALL GOVERNOR GEAR 1 Lubricate thrust washer and assemble to governor gear shaft Fig 144 2 Install governor gear Fig 144 INSTALL CRANKCASE COVER 1 Install...

Page 65: ...ll breather with new gasket Fig 148 Torque screws to 35 in lbs 4 0 Nm Fig 148 INSTALL STARTER Install starter and solenoid assembly Fig 149 Torque screws to 140 in lbs 16 0 Nm Fig 149 INSTALL ALTERNAT...

Page 66: ...0 Nm Fig 151 INSTALL CYLINDER HEADS 1 Install cylinder heads with new gaskets NOTE Arrow on gasket must face flywheel side 2 Lubricate threads of head bolts with Valve Guide Lubricant 93963 NOTE Inst...

Page 67: ...mature away from flywheel as far as possible and tighten one screw to hold armature in place 3 Repeat for second armature NOTE Make sure wires are routed over armature mounting posts Fig 155 1 Rotate...

Page 68: ...fan belt over lower pulley and assemble fan and adjustment bracket to fan brackets Install upper pivot screw Then install adjustment screw 4 Fit torque wrench in the square hole in adjustment bracket...

Page 69: ...NTAKE MANIFOLD 1 Install intake manifold with new gaskets Fig 161 Torque screws to 90 in lbs 10 0 Nm Fig 161 2 Assemble governor link to governor bracket and install governor control bracket Fig 162 T...

Page 70: ...screws to 90 in lbs 10 0 Nm 3 Connect breather tube to air cleaner elbow 4 Connect fuel shut off solenoid wire and install ground wire Fig 165 5 Assemble governor link to governor control bracket and...

Page 71: ...ailure to make the static adjustments first could result in engine overspeeding which may result in engine damage property damage or personal injury Static Governor Adjustment 1 With governor lever nu...

Page 72: ...in lbs 11 0 Nm Torque lower mounting nuts first then upper mounting nuts Fig 173 3 Install fuel line from pump to carburetor and fuel pump pulse line at valve cover Fig 174 Fig 174 4 Install thermost...

Page 73: ...towards air inlet side Fig 177 2 Rotate air cleaner housing so that base of mounting bracket is parallel to air inlet tube Fig 177 3 Assemble air cleaner housing and mounting bracket to engine and ins...

Page 74: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine Section 5 Engine Assembly Page 69 8 Install air cleaner cover with arrows facing up Fig 180 Fig 180 Refer to Section 6 for final adjustment procedures...

Page 75: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine Section 5 Engine Assembly Page 70...

Page 76: ...OLS VanguardE liquid cooled OHV Twin cylinder engines are equipped for remote governor controls Fig 181 Speed Regulation Remote governor controls supplied by equipment manufacturer control engine spee...

Page 77: ...actly in the sequence shown Initial Adjustment 1 Turn idle mixture screw for 1 cylinder clockwise until it just seats DO NOT FORCE 2 Then turn screw counter clockwise 3 4 turn Fig 186 3 Repeat for 2 c...

Page 78: ...ure screw for 1 cylinder clockwise until engine speed just starts to slow lean mixture 4 Then turn idle mixture screw counterclockwise 3 8 turn NOTE It may be necessary to readjust idle speed screw to...

Page 79: ...st contacts governor lever Fig 191 Fig 191 11 Move equipment control to FAST position Engine should accelerate smoothly Readjust idle mixture valve 1 8 turn richer if necessary 12 Move control throttl...

Page 80: ...COVER 200 IN LBS 23 0 NM CYLINDER HEAD 30 FT LBS 40 0 NM EXHAUST MANIFOLD 190 IN LBS 22 0 NM FAN BELT ADJUSTMENT SCREW 110 IN LBS 12 NM FAN BELT PIVOT SCREW 125 IN LBS 14 0 NM FAN BRACKET TO CYLINDER...

Page 81: ...45 09 MM 1 7765 45 12 MM CAM BEARING PTO 788 20 01 MM 790 20 06 MM CRANKSHAFT CRANKPIN 1 654 42 01 MM 1 6525 41 97 MM MAGNETO JOURNAL 1 771 44 99 MM 1 7695 44 94 MM PTO JOURNAL 1 771 44 99 MM 1 7695...

Page 82: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine Section 6 Final Adjustments Specifications Page 77 ENGINE HARNESS...

Page 83: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine Section 6 Final Adjustments Specifications Page 78...

Page 84: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine Section 6 Final Adjustments Specifications Page 79...

Page 85: ...VanguardTM Twin Cylinder OHV Liquid Cooled Engine Section 6 Final Adjustments Specifications Page 80...

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