Vanguard OHV V-Twin User Manual Download

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Section 2

Troubleshooting

Page

ELECTRICAL SYSTEMS

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Alternators

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Alternator System Diagnosis

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Charging System Identification

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Flywheel Magnet Identification

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Equipment Used to Test Alternators

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Testing Alternator Output

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AC Alternator

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DC Alternator

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Dual Circuit Alternator

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Tri-Circuit Alternator

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5 & 9 Amp Regulated Alternator

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10 & 16 Amp Alternator

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20 Amp Regulated Alternator

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Powerlink System

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Anti-Afterfire Solenoid

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Testing Battery

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Testing Engine Wiring Harness

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Oil Pressure

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Panel Kit with Key Switch and Solenoid

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Starter Motor

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Conditions Affecting Starter Motor Performance

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Troubleshooting

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Testing

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Solenoid Test

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Performance Control

Electronic Governor

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Wiring Diagram

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Governor Test

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Replacing Actuator

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EQUIPMENT PROBLEMS AFFECTING ENGINE OPERATION

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GASEOUS-FUELED ENGINES

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Troubleshooting Guide

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Carburetor Adjustment

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LPG-Only Operation

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SYSTEMATIC CHECK

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Ignition

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Carburetion

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Compression

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Summary of Contents for OHV V-Twin

Page 1: ...ion 5 CYLINDER HEADS AND VALVES Section 6 STARTERS Section 7 LUBRICATION SYSTEMS Section 8 CYLINDERS AND CRANKCASE COVERS SUMPS Section 9 CRANKSHAFTS AND CAMSHAFTS Section 10 PISTONS RINGS AND CONNECT...

Page 2: ...351400 380400 351700 380700 14 CHOKE CONTROL ADJUSTMENT 16 COMBUSTION CHAMBER DEPOSITS 16 COOLING SYSTEM CLEANING 16 CRANKCASE OIL 17 FUEL AND OIL RECOMMENDATIONS 7 Fuel Recommendations 7 Oil Recommen...

Page 3: ...n about hazards that 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 h...

Page 4: ...gasoline to spill Do not choke carburetor to stop engine WHEN TRANSPORTING EQUIPMENT Transport with fuel tank EMPTY or with fuel shut off valve OFF WHEN STORING GASOLINE OR EQUIPMENT WITH FUEL IN TANK...

Page 5: ...rest covered grass covered brush covered unimproved land The state of California requires this Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws appl...

Page 6: ...d crank until engine starts DO NOT strike flywheel with a hammer or hard object This could cause the flywheel to shatter in operation Use only Briggs Stratton approved tools and proce dures to remove...

Page 7: ...orizontal Shaft H to Z Vertical Shaft 0 Plain Bearing DU Non Flange Mount 1 Plain Bearing Flange Mounting 2 Sleeve Bearing Flange Mounting Splash Lube 3 Ball Bearing Flange Mounting Splash Lube 4 Ball...

Page 8: ...lter yearly or every 100 hours whichever occurs first Replace filter if dirt or water are present See illustrated parts list for correct fuel filter Gaseous Fuel Engines Many state county and city gov...

Page 9: ...ently to prevent any possible engine damage due to lack of lubrication SAE 30 oil if used in ambient temperatures below 40 F 4 C will result in hard starting and possible engine damage due to inade qu...

Page 10: ...or a check up or repair If the air cleaner shows signs of neglect show it to the customer before cleaning Instruct the customer on proper care to assure long engine life NOTE Replace worn or damaged a...

Page 11: ...paper cartridge in cover with tabs on cartridge 3 in slots of cover Fig 3 8 Reinstall cover assembly on air cleaner body Cyclonic Air Cleaner NOTE The debris valve automatically discharges dust and de...

Page 12: ...re for the other armature CARBURETOR ADJUSTMENTS Models 290000 350000 The Vanguard OHV twin cylinder engine carbure tor fuel mixture adjustment procedure is unique Per form adjustments exactly in the...

Page 13: ...Governed Idle Spring 805454 WHITE Fig 10 4 Turn idle mixture screw slowly CLOCKWISE 1 until engine speed just starts to slow LEAN mixture Fig 11 Fig 11 5 Then turn idle mixture screw COUNTER CLOCKWISE...

Page 14: ...ne should accelerate smoothly Re adjust idle mixture valve 1 8 turn richer if necessary Fig 14 Performance Control Engines NOTE All carburetor adjustments with engine running must be made with the air...

Page 15: ...rizontal crankshaft engines 1 and vertical crankshaft engines 2 are shown in Fig 18 Initial Adjustment 1 Turn idle mixture screw for 1 cylinder CLOCK WISE until it just seats DO NOT FORCE Fig 18 Fig 1...

Page 16: ...overned idle tang LEFT to INCREASE 4 right to DECREASE 5 engine speed to obtain RPM shown a 1750 RPM Governed Idle Spring 805453 RED b 1100 RPM Governed Idle Spring 805454 WHITE NOTE Parts removed for...

Page 17: ...its from entering push rod or oil return cavity in cylinder Take care not to damage cylinder top of piston cylinder head and cylinder head gasket surfaces NOTE Remove only the combustion chamber de po...

Page 18: ...turn CAUTION DO NOT run the engine unless the Easy Clean Access panel is correctly installed Crankcase Oil Change Oil and Filter Drain oil while the engine is still warm See Fig 28 for approximate dra...

Page 19: ...nor lever nut Push on governor lever 1 until throttle is wide open Fig 30 Fig 30 Do not bend governor link or distort governor lever CAUTION 2 Use a screwdriver 2 to rotate governor shaft COUNTERCLOCK...

Page 20: ...moved for clarity Fig 34 Fixed Speed Adjustable Except Generators Governor spring is installed in 1 hole in governor lever 3 Fig 35 Start and run engine for approximately 5 minutes to allow engine to...

Page 21: ...40 2 Loosen and remove fixed speed adjustable control nut spring and retainer 3 Rotate governor control swivel 1 counterclock wise to end of travel Fig 39 4 Install Adjustment Gauge 19385 3 with notch...

Page 22: ...n 1 hole 3 on governor lever Fig 42 NOTE The secondary governor spring must be adjusted BEFORE the engine is started Perform the adjustment in the sequence shown Adjust Secondary Governor Spring 1 Mov...

Page 23: ...ith an oil cooler Fig 46 The oil cooler is mounted on the blower housing Filtered oil is routed through the oil cooler through two oil lines from a special oil filter adapter Forced air from the flywh...

Page 24: ...FAST position in set Fig 48 3 Move control casing and wire until governor control swivel is at end of travel 4 Tighten casing clamp screw Fig 48 FAST SLOW Valve Clearance Adjustment 1 Set No 1 cylind...

Page 25: ...w gaskets 13 Reinstall blower housing 14 Install new oil filter Replace oil and fuel 15 Adjust equipment control and cables if used for correct operation 16 Service air cleaner pre cleaner and cartrid...

Page 26: ...ck end play Replace oil seal 7 Electric starter 8 Flywheel and starter pulley if equipped 9 Armatures adjust air gap 10 Check spark 11 Valves seals springs and retainers 12 Cylinder heads push rods ro...

Page 27: ...1 26...

Page 28: ...r 41 20 Amp Regulated Alternator 43 Powerlink System 45 Anti Afterfire Solenoid 47 Testing Battery 48 Testing Engine Wiring Harness 50 Oil Pressure 53 Panel Kit with Key Switch and Solenoid 53 Starter...

Page 29: ...roduce spark AVOID ELECTRICAL SHOCK WARNING A partially sheared flywheel key will affect ignition timing and engine performance Spark can still occur with a sheared flywheel key A severe shock or kick...

Page 30: ...cleaner If plugs are dry look for 1 Leaking carburetor mounting gaskets 2 Gummy or dirty carburetor fuel line or tank 3 Float needle valve stuck shut 4 Inoperative fuel pump 5 Inoperative anti afterf...

Page 31: ...ct other end to tester 7 While securely holding the flywheel nut with the breaker bar and socket pull the adjustment knob OUT arrow Fig 4 Slowly turn the regula tor adjustment knob 1 CLOCKWISE until t...

Page 32: ...Engine RPM Cylinder 2 Grounded 3100 RPM Conclusion Cylinder 1 is weaker cylinder NOTE A partially sheared flywheel key will affect ignition timing and engine performance Problems Affecting One Cylind...

Page 33: ...missing or broken tie down straps Battery rate of charge not matched to alternator output Damaged battery shorted battery cells Defective regulator One OHM resistor shorted or grounded Tri Circuit sys...

Page 34: ...5 Amps AC Lights Unregulated 35 DC Only Red Red 2 4 Amps DC Charging Unregulated 36 Dual Circuit Red Black White 2 4 Amps DC Charging Unregulated 5 Amps AC Lights Unregulated 37 Tri Circuit Black Gree...

Page 35: ...d 9 A S Regulated 10 A S Regulated 16 A S Regulated 20 A S Equipment Used to Test Alternators Digital Multimeter The Digital Multimeter 19464 Fig 8 is available from your Briggs Stratton source of sup...

Page 36: ...tor provides current for headlights only Current for the lights is available when the engine is running To check use 12 volt lights with a total rating of 60 100 watts Alternator output varies with en...

Page 37: ...ll be approximately 2 amps 7 If NO or LOW output is found test diode Fig 13 Diode Test In the DIODE TEST position the meter will display the forward voltage drop across the diode s If the voltage drop...

Page 38: ...alternator is unregulated and is rated at 3 amps The output rises from 2 amps 2400 RPM to 3 amps 3600 RPM 1 Stator assembly 1 Fig 15 2 RED lead from stator 2 DC output for charging battery 3 BLACK lea...

Page 39: ...ailable Use resin core solder when installing new harness Use shrink tubing or tape all connections DO NOT USE CRIMP CONNECTORS Fig 17 A AC Output Test 1 Insert RED test lead into V receptacle in mete...

Page 40: ...tput is good test the diodes in the wiring harness Fig 20 Diode Test NOTE One diode is for the charging circuit the other diode is for the lighting circuit In the DIODE TEST position the meter will di...

Page 41: ...iode is installed backwards Replace harness b If meter still displays OL diode is open Replace harness NOTE Service replacement diode harnesses are available Fig 22 A 5 9 Amp Regulated Alternator The...

Page 42: ...stator wire harness to regulator rectifier 1 Insert RED test lead into 10A receptacle in meter 2 Insert BLACK test lead into COM receptacle 3 Rotate selector to A DC AMPS position 4 Attach RED test le...

Page 43: ...for amperage output a 12 volt battery with a minimum charge of 5 volts is required There will be no output if battery voltage is below 5 volts CAUTION Connect test leads BEFORE starting engine Be sure...

Page 44: ...e the same as those listed for the 10 amp or 16 amp system Fig 29 20 Amp Regulated Alternator The 20 amp regulated alternator system provides AC current through two output leads to the regulator recti...

Page 45: ...egative battery terminal 6 Turn equipment key switch to ON position Meter should display BATTERY VOLTAGE 7 If meter does not display battery voltage check for blown fuse or broken or shorted wires Reg...

Page 46: ...GED 2 Plug in a trouble light or radio to confirm that electrical power is present 3 Press the GFCI test button 1 to trip the GFCI Fig 34 If the device is still being powered the GFCI is NOT working c...

Page 47: ...key switch ON The meter should display BATTERY VOLTAGE If the meter does not display battery voltage there is a problem with the equipment wiring or the interlock switch Refer to the equipment repair...

Page 48: ...id The anti afterfire solenoid is controlled by the equipment ignition switch With the switch OFF the solenoid plunger closes stopping fuel flow through the fixed main jet With the switch in the ON an...

Page 49: ...e eye open and flush with clear water for AT LEAST 20 minutes Call a physician IMMEDIATELY Batteries give off explosive gasses DO NOT smoke Sparking can ignite nearby flammable gasses resulting in exp...

Page 50: ...that have been in service NOTE If battery gets HOT to the touch or is spitting acid gassing excessively unplug charger periodically 3 Use Digital Multimeter 19464 Set meter to read DC Volts 4 Attach R...

Page 51: ...eplace regulator rectifier Fig 44 Testing Engine Wiring Harness The engine wiring harness consists of a ground wire 1 with a diode 4 for each armature 5 and a sepa rate wire 2 for the carburetor solen...

Page 52: ...isconnect harness at solenoid 2 Insert RED meter test lead 2 into GRAY wire 1 in solenoid connector 3 Attach BLACK test lead to a good ground Fig 47 4 Turn key switch to ON position Meter should displ...

Page 53: ...2 Open Diodes SWITCH ON CAUSE Won t Run No Spark Engine Runs Both Cylinders Engine Runs On 1 Cylinder SWITCH OFF Shuts Off OK DIODE GROUND WIRE HARNESS EQUIPMENT SWITCH DIODE FAILURE DIAGNOSIS DIODE E...

Page 54: ...49 OIL PRESSURE TROUBLESHOOTING GUIDE Engine RPM Too Low Wrong Viscosity or Diluted Oil L Oil Low Oil Level Low Oil Pressure Broken Pressure Relief Spring Pressure Missing Pressure Relief Plunger Wor...

Page 55: ...between terminals with key switch in position shown NOTE The 2 and 5 terminals should show CONTINUITY in both the RUN and START position Switch Position Continuity 1 OFF 1 3 6 2 RUN 2 5 6 3 START 2 4...

Page 56: ...inal 5 Orange To Battery battery terminal on solenoid 6 Red To Regulator Rectifier SOLENOID REGULATOR RECTIFIER ANTI AFTERFIRE SOLENOID STARTER MOTOR 6 5 4 3 2 1 STOP SWITCH 12 VOLT BATTERY WIRES SUPP...

Page 57: ...tch open circuit e Open circuit in starter motor f Brushes sticking etc g Faulty solenoid Starter Motor Spins But Does Not Crank Engine a Sticking pinion gear due to dirt b Damaged pinion or ring gear...

Page 58: ...ery Remove battery cable from stud terminal on solenoid 3 Disconnect YELLOW wire from tab terminal on solenoid 4 Key switch must be in OFF position 5 Insert RED test lead into V receptacle in meter 6...

Page 59: ...ch harness and a throttle actuator The control module is equipped with an idle down circuit for applications requiring that feature By cutting and removing the yellow or red loop wire the control modu...

Page 60: ...pment manufacturers specifications 4 Remove jumper wire from ground Engine should return to top governed speed Fig 54 Static Check To determine whether a governor problem is being caused by the actuat...

Page 61: ...rench when torquing nuts Screws must NOT turn while torquing nuts 2 Assemble governor link to actuator Make sure link snaps into hole in actuator grommet 3 Assemble throttle return spring through slot...

Page 62: ...nked or obstructed fuel hose Remove the kink and or replace the hose No or low fuel in tank Refuel the tank Engine does not accelerate from low speed or high speed or run smoothly when loaded Propane...

Page 63: ...he system Fuel tank is too small especially if the ambient temperature is low Increase the size of the fuel tank to increase the vaporization rate of the fuel Consult with local gas supplier Restricti...

Page 64: ...ne to between 1100 1750 no load RPM Adjust the idle mixture to achieve 1 2 1 CO in the exhaust 4 Return the engine to high speed full load If required readjust the setting to 1 2 1 CO 5 Stop the engin...

Page 65: ...te control assembly for proper adjustment 4 Check interlock system for shorted wires loose or corroded connections or defective modules or switches Engine Will Not Stop 1 Check equipment ignition stop...

Page 66: ...00 69 Remove Blower Housing and Fan 69 Remove Carburetor and Intake Manifold 70 Vertical Crankshaft All Models 70 Horizontal Crankshaft All Models 70 Remove Control Bracket 70 Remove Armatures 70 Remo...

Page 67: ...OWER HOUSING ROTATING SCREEN GOVERNOR LEVER INTAKE MANIFOLD AND CARBURETOR CHOKE BRACKET GOVERNOR CONTROL BRACKET AIR CLEANER SUPPORT EXHAUST MANIFOLD CYLINDER SHIELDS AIR CLEANER BASE VALVE COVERS 3...

Page 68: ...AND CONNECTING ROD ASSEMBLY STARTER MOTOR BREATHER 1 PISTON AND CONNECTING ROD ASSEMBLY CRANKCASE COVER OR SUMP CAMSHAFT AND GOVERNOR SPOOL FLYWHEEL AND FAN 2 CYLINDER HEAD 14 15 16 17 18 19 20 21 22...

Page 69: ...ng nuts 1 4 Remove air cleaner base and breather tube Fig 1 Early style Square cartridge Fig 2 1 Remove air cleaner cover 2 Remove four screws 6 lock washers 4 and flat washers 7 3 Remove air cleaner...

Page 70: ...base and remove air cleaner base 3 Fig 5 Horizontal Crankshaft Models 540000 610000 1 Loosen the clamp 1 for the air inlet hose Fig 6 2 Remove two mounting band screws 2 Re move the air cleaner assemb...

Page 71: ...onnect anti afterfire solenoid wire from equipment switch wire Remove blower housing 1 Remove two screws and choke control bracket 5 Fig 11 2 Disconnect choke link 1 from carburetor 3 Disconnect fuel...

Page 72: ...ove starter hub screw first Then remove flywheel nut 2 Turn the flywheel nut COUNTERCLOCKWISE arrow with a 1 2 breaker bar 4 and a 30 mm socket to remove NOTE Do not remove fan retainer and fan at thi...

Page 73: ...t over the crankshaft as shown Fig 18 5 Place the flywheel puller over the pilot Back out the puller screw 5 until the flange on the puller is flush with the flange on the flywheel Fig 19 6 Align the...

Page 74: ...move push rods NOTE Label push rods for reassembly in the original location Fig 21 Fig 22 3 Remove head bolts 5 6 7 8 and cylinder head Fig 23 Discard cylinder head gasket NOTE Engines manufactured be...

Page 75: ...to prevent breaking rings when removing piston and connecting rod assemblies 1 Remove 2 connecting rod cap 2 Push connecting rod and piston assembly 11 out of 2 cylinder arrow Fig 27 Reassemble cap to...

Page 76: ...0xx 81 Aisan Carburetor Model 610000 109 Mikuni Carburetor Models 290700 303700 350700 before 951001xx 85 Mikuni Carburetor Models 290400 303400 350400 before 950801xx 99 Nikki Carburetor Models 29040...

Page 77: ...m the carburetor Remove the fuel tank 6 Remove air cleaner base Disconnect the breather tube 7 Remove 4 screws 6 and the fuel tank base plate Fig 2 Fig 2 8 If necessary remove 4 screws and 2 PTO side...

Page 78: ...the carburetor Install the fuel tank Torque screws 2 and shoulder bolts 3 PTO side to 140 in lbs 16 Nm Fig 6 Fig 6 6 Connect the fuel shut off valve link Slide the looped end of the link over the knob...

Page 79: ...at 12 30 5 cm maximum lift CAUTION Excessive fuel pressure can result in an over rich carburetor mixture and ultimately cylinder scoring and or other engine damage resulting from gasoline diluting th...

Page 80: ...4 Fuel Shut Off Valve Engines equipped with an optional fuel tank will also have a fuel shut off valve Fig 15 Inspect valve for ease of operation and leakage Replace valve if operation is difficult or...

Page 81: ...e choke control bracket 6 and disconnect link 4 Fig 17 Fig 17 4 Unhook governor link spring 7 from throttle lever Disconnect governor link Fig 18 Fig 18 5 Remove air cleaner elbow support screw 8 Fig...

Page 82: ...hoke shaft clearance must not exceed 0 010 0 25 mm NOTE The inspection in Step 2 is performed after the carburetor has been disassembled 2 Inspect throttle shaft and choke shaft for wear 2 Fig 22 Fig...

Page 83: ...26 Fig 26 7 Use a pliers to remove the idle mixture screw adjustment limiter cap 11 if equipped Fig 27 8 Remove the idle mixture screw 12 Fig 27 11 12 9 The top and bottom edges of the throttle plate...

Page 84: ...Remove and discard all old gaskets seals and sealing material AVOID INJURY Wear suitable protection when using cleaners Follow instructions on container CAUTION 3 Use commercial carburetor cleaning s...

Page 85: ...e NOTE Use LOCTITE 222 on screw threads 8 Install new throttle shaft welch plug Use round punch and tap in plug until it is flat 9 Use sealant on outside diameter of welch plug to prevent leaks 10 Ins...

Page 86: ...own 22 Torque screw or solenoid to 45 in lbs 5 Nm Fig 40 23 24 25 26 27 Mikuni Carburetor Models 290700 303700 350700 Before 951001xx Check Throttle Choke Shaft and Body For Wear NOTE The measurement...

Page 87: ...19061 Fig 44 3 Remove float 5 and inlet needle 6 NOTE Float hinge pin 8 is swaged on one end Drive hinge pin out from side opposite swage Fig 44 4 Remove emulsion tube 10 Fig 45 NOTE If carburetor is...

Page 88: ...choke shaft Wear eye protection Use caution when removing shaft AVOID EYE INJURY Fig 48 20 21 22 23 24 25 Remove Fuel Inlet Body and Seat The fuel inlet body must be removed before the inlet seat can...

Page 89: ...Do not use wire drills or other mechanical devices to clean out metering holes or passages Inspect Carburetor Inspect all parts for wear cracks nicks and burrs Inspect float for leaks Replace damaged...

Page 90: ...t 23 Fig 55 15 Install idle mixture screw 21 and spring 22 NOTE DO NOT tighten screw DO NOT install limiter cap at this time Fig 55 21 22 23 16 Install emulsion tube 24 Fig 56 using Screw driver 19062...

Page 91: ...r shaft clearance exceeds 0 010 0 25 mm when a new shaft is used Disassemble NOTE The carburetors used on vertical crankshaft Models 351700 and 380700 and horizontal crankshaft Models 351400 and 38040...

Page 92: ...l 380400 Left 1 cylinder is equipped with 110 main jet Right 2 cylinder is equipped with 114 main jet Fig 61 4 Remove carburetor lower body screws 9 Lift lower body straight away from upper body Fig 6...

Page 93: ...and discard all old gaskets seals and sealing material AVOID INJURY Wear suitable protection when using cleaners Follow instructions on container CAUTION 3 Use a commercial carburetor cleaner such as...

Page 94: ...choke shaft 8 5 Install choke plate 7 NOTE Check shaft for freedom of operation after installing plate NOTE Use LOCTITE 222 on screw threads 6 Fig 69 6 Assemble inlet needle 11 to float 10 Install fl...

Page 95: ...body gasket 21 Fig 74 Make sure gasket does not twist or kink Fig 74 21 14 Assemble lower body with main jet plugs 23 facing throttle shaft side 24 of carburetor Make sure gasket remains in position...

Page 96: ...is used Disassemble 1 Remove four screws and upper body 1 Fig 78 Do not damage emulsion tube 2 in upper body Fig 78 2 Remove and discard gasket 3 Remove float and inlet needle Fig 79 If idle mixture...

Page 97: ...n Carburetor 1 Disassemble carburetor 2 Remove and discard all old gaskets seals and sealing material AVOID INJURY Wear suitable protection when using cleaners Follow instructions on container CAUTION...

Page 98: ...g 86 6 Install choke plate 3 with vent hole facing bowl vent nipple 4 NOTE Use LOCTITE 222 on screw threads Fig 86 7 Install new throttle shaft seal 6 with sealing lip in Fig 87 8 Install throttle sha...

Page 99: ...er on the float hinge pin 20 2 While holding the float hinge pin down turn the carburetor to a position PAST VERTICAL 21 as shown in Fig 92 This allows the weight of the float to close the inlet needl...

Page 100: ...ed carburetor the end of the nozzle is approximately parallel 4 to the choke shaft The fixed main jet used with a fuel pump system is numbered 110 The fixed main jet used with a gravity system is numb...

Page 101: ...l bowl drain screw 15 and spring Fig 101 14 15 16 10 Mark throttle plate 21 Fig 102 before removing to ensure re reinstallation in the original position Top and bottom edges are beveled Remove screws...

Page 102: ...bly procedure Clean Carburetor 1 Disassemble carburetor 2 Remove and discard all old gaskets seals and sealing material AVOID INJURY Wear suitable protection when using cleaners Follow instructions on...

Page 103: ...Fig 108 8 Assemble spacer 9 onto choke shaft 9 Insert spring and check ball 11 in to spring pocket Compress with a small round punch 10 Push choke shaft into hole until ball engages groove in choke sh...

Page 104: ...allel 25 with carburetor bowl mounting surface If not use a small screw driver to bend tang 26 and lower 27 or raise 28 the float level as shown CAUTION DO NOT press on float to adjust Fig 112 25 26 2...

Page 105: ...win utilizes a fixed jet two barrel side draft flo jet carburetor Except for idle speed the carburetor is non adjustable The carburetor incorporates a fuel shut off anti afterfire solenoid that contro...

Page 106: ...e carburetor has been disassembled 2 Inspect throttle shaft and choke shaft for wear on the shaft bore surfaces 2 Fig 116 Fig 116 Replace either shaft if worn Replace the carburetor if the body is wor...

Page 107: ...nal position Sides of throttle plate are beveled Fig 122 17 16 12 Remove screws throttle plates and throttle shaft with seal Discard seal 17 This completes the carburetor disassembly procedure Clean C...

Page 108: ...ean out metering holes or passages Inspect Carburetor Inspect all parts for wear cracks nicks and burrs Inspect float for leaks Replace damaged parts Assemble Carburetor When assembling carburetor use...

Page 109: ...emble bowl gasket 9 to body 9 Install main jet according to engine model 10 Install the float bowl assembly to the carburetor body 11 Assemble fuel solenoid 13 to float bowl 12 Fig 129 Use a 13 mm thi...

Page 110: ...Information The Vanguardt Model 610000 OHV V Twin utilizes a fixed jet two barrel side draft flo jet carburetor The carburetor incorporates a fuel shut off anti afterfire solenoid that controls fuel...

Page 111: ...tle plate are beveled 9 Remove screws 9 throttle plates and throttle shaft 14 with bushings 16 and seal 17 Discard seal Fig 132 11 12 13 14 15 17 16 18 This completes the carburetor disassembly proced...

Page 112: ...ate at a time Check throttle for freedom of operation before installing other throttle plate Use LOCTITER 222 on screw threads 2 Insert bushings and choke shaft into carburetor body 3 Install choke pl...

Page 113: ...4 112...

Page 114: ...5 LOCKED FOR PRINTING SELECT SECT NEEDED 113 Section 5 Governor Page GENERAL INFORMATION 114 GOVERNOR CONTROLS 114 GOVERNORS 114 All Models Except 540000 610000 114 Models 540000 610000 117...

Page 115: ...ion or remote control have a governed idle system Fig 3 A throttle restrictor maintains the engine speed when a load is applied and the equipment control is in the SLOW position Fig 3 GOVERNOR CONTROL...

Page 116: ...ly on hinge pins 1 Replace camshaft if hinge pins are loose or governor spool does not move freely on journal Fig 7 Remove Governor Shaft 1 Remove cotter pin 3 and collar 2 Discard cotter pin Fig 8 2...

Page 117: ...ing 3 in cylinder Fig 11 2 Insert proper seal protector through oil seal 3 Install crankcase cover or sump with new gasket Torque screws in sequence shown to 150 in lbs 17 Nm Fig 12 4 Reinstall oil fi...

Page 118: ...ove freely on the hinge pins 2 If necessary remove the governor gear 1 from the crankcase cover with two screwdrivers 3 Remove the washer from under the governor gear Fig 15 Inspect Governor Gear 1 Ch...

Page 119: ...t of the bushings 7 3 Replace the oil seal 6 under the washer Replace worn or damaged components NOTE Inspect the crank and the crank bushings If the bushings are damaged or worn replace the cylinder...

Page 120: ...9 Section 6 Cylinder Heads and Valves Page CYLINDER HEAD SERVICE 120 Remove Cylinder Head 120 Disassembly 121 Inspect and Repair 121 Assembly 123 Install Cylinder Head 124 Install Rocker Arms 124 Inst...

Page 121: ...e The redesigned cylinder head gasket and rocker arm assembly will not interchange with previous cylinder heads The new cylinder head may be used on earlier V Twins but only as a complete assembly Ref...

Page 122: ...alve in place while com pressing spring 2 Compress valve spring and retainer with Valve Spring Compressor 3 19347 Fig 7 3 Remove valve spring retainer locks 2 4 Gradually release pressure on the valve...

Page 123: ...Reamer 19444 6 to ream new valve guide Fig 13 a Use Stanisol or kerosene to lubricate reamer b Ream through entire guide c Keep turning reamer CLOCKWISE when removing reamer d Flush out all chips Fig...

Page 124: ...de bushing until it bottoms Fig 17 2 Install valves Fig 18 NOTE Lightly coat valve stems with Valve Guide Lubricant 93963 before installing valves Be sure valve guide lubricant is not on valve face se...

Page 125: ...er arms 3 to cylinder head Fig 21 Torque studs to 100 in lbs 11 Nm Fig 21 Early Style NOTE Rocker shaft support 3 holes are offset Install with holes facing ends of rocker shaft Fig 22 1 Lubricate roc...

Page 126: ...tarter 142 RING GEAR SERVICE 136 STARTER DRIVE SERVICE Except Models 540000 610000 126 C Ring Style 127 Roll Pin Style 127 Steel Pinion Style 128 STARTER MOTOR SERVICE Except Models 540000 610000 128...

Page 127: ...a steel pinion gear and is used only with flywheels equipped with a steel ring gear The flywheel ring gear is NOT replaceable Fig 2 Solenoid Shift The starter motor in Fig 3 uses a solenoid to engage...

Page 128: ...lutch drive 1 to starter shaft Rotate clutch until it drops into place Fig 8 2 Install pinion gear 5 with beveled side of teeth up Then install return spring 4 making sure spring is in recess of start...

Page 129: ...se 2 Assemble clutch and pinion gear to shaft 3 Assemble lower spring retainer with OPEN END UP 4 Install spring 5 Install upper spring retainer with OPEN END UP 6 Compress spring Install NEW retainin...

Page 130: ...be cleaned with fine sandpaper DO NOT use emery cloth The commutator can be machined a diameter of NO LESS THAN 1 230 31 24 mm Slots between commutator bars should be cleaned as shown in Fig 16 A aft...

Page 131: ...ig 20 Assemble End Cap NOTE When all parts have been inspected lightly lubricate bearings in both end caps with 20 oil Radial Flat Coil Brush Spring 1 Assemble armature to brush end cap before install...

Page 132: ...he brush retainer in Fig 23 are 1 7 8 22 mm 2 2 51 mm 3 1 25 mm 4 1 25 mm 5 1 4 6 mm radius 6 2 1 2 64 mm Fig 23 1 Install positive 7 and negative 8 brushes with beveled edge UP in position shown Fig...

Page 133: ...Spin armature to check for binding Correct any binding 6 Install starter drive Fig 28 STARTER MOTOR SERVICE Models 540000 610000 Remove Starter Solenoid 1 Remove nut and field coil wire from stud term...

Page 134: ...3 Remove brush end cap Fig 31 NOTE To prevent losing brush springs do not remove brush retainer 1 until starter housing has been removed from drive end cap Fig 31 Fig 31 4 Remove starter housing from...

Page 135: ...MM Inspect Brushes Minimum brush dimension 1 is 1 4 6 mm If brushes are worn less than specification replace the starter housing Fig 37 Fig 37 Use digital multimeter and check for continuity between...

Page 136: ...5 Assemble spacer to armature shaft Fig 41 NOTE Lip 1 on spacer must face bearing in drive end cap Fig 41 Assemble Starter 1 Assemble drive lever 2 to pinion 1 Install armature and drive lever into d...

Page 137: ...46 8 Install end cap Fig 47 Torque thru bolts to 70 in lbs 8 Nm Fig 47 9 Install solenoid see Starter Solenoid RING GEAR SERVICE NOTE Ring gear is not replaceable on models 540000 610000 1 Mark cente...

Page 138: ...rewind starters Current Style Early Style Fig 49 1 Rewind Starter 2 Air Inlet Slots larger on current starters 3 Retainer nylon on current starters metal on early starters 4 Starter Dogs nylon on cur...

Page 139: ...igure eight knot at one end of rope Fig 52 Fig 52 3 Rotate pulley COUNTERCLOCKWISE arrow six complete turns Fig 53 4 Rotate pulley CLOCKWISE just until rope hole in pulley 2 is in line with starter ho...

Page 140: ...ut dogs 3 and dog springs 4 Fig 56 4 Rotate pulley CLOCKWISE until pulley disengages spring 5 Carefully lift out pulley with spring Fig 57 Fig 57 Inspect Starter Housing and Pulley Inspect pulley for...

Page 141: ...sts in pulley 1 Install dogs 2 Fig 62 Fig 62 2 Install retainer making sure that slots 4 in retainer 6 engage tabs 7 on pulley Fig 63 3 Hold retainer down compressing dog springs and install retainer...

Page 142: ...y for cracks rough edges 1 or burrs in pulley groove wear on spring cup lugs 2 and wear on center hole 3 Fig 67 Replace pulley if damaged or worn Fig 67 Inspect starter housing for wear and sharp edge...

Page 143: ...ly 1 Install dogs 2 and dog springs 1 in pulley Fig 72 Fig 72 2 Place large washer 7 brake spring 6 and retainer 5 on pulley Fig 73 3 Place small washer 4 on shoulder screw 3 Install screw and washer...

Page 144: ...ion 8 Lubrication Systems Page CRANKCASE BREATHER IDENTIFICATION 144 CRANKCASE BREATHER SERVICE 145 Models 290000 300000 350000 3510000 145 Model 380000 146 Models 540000 610000 147 GENERAL INFORMATIO...

Page 145: ...ble The switch may be used to activate a warning device if oil pressure drops below approximately 5 psi 0 3 Bar The warning device and wiring is supplied by the OEM Crankcase Breather Identification V...

Page 146: ...hecking Fiber Disc Breather If the fiber disc valve 3 is stuck or binding the breather assembly 1 must be replaced A 0 045 1 14 mm wire gauge 2 should not enter the space between the fiber disc valve...

Page 147: ...ing surface of reed stop on flat surface use the following drills to check reed stop height Fig 12 5 Use 29 drill as GO gauge 6 Use 24 drill as NO GO gauge Replace reed stop if not to specification Fi...

Page 148: ...er reed valve facing out 3 Install the O ring over the reed valve assembly Use fingertips to seat the O ring into the valve cover 4 Position the outer baffle into the breather cover with the 3 bosses...

Page 149: ...For proper sealing on these models the oil fill cap 5 has an O ring the dipstick has a grommet 6 Fig 18 NOTE The oil dipstick tube 7 is not removeable serviceable on these models If damaged replace t...

Page 150: ...nkcase Covers Sumps Page CYLINDERS 150 Inspect and Measure 150 Resizing Cylinder 150 Finishing 151 Cleaning 151 ENGINE BEARINGS 152 Mag Bearing before 970501xx 152 Mag Bearing after 970430xx 152 PTO B...

Page 151: ...rings and pistons will fit correctly maintaining proper clearances Cylinders should be resized with a good quality hone such as Briggs Stratton Tool 19205 Contact your Briggs Stratton source of suppl...

Page 152: ...osshatch finish necessary for proper lubrication The correct crosshatch angle is approximately 45 1 Fig 4 Recondition the cylinder bores to restore the finish when new piston rings are to be installed...

Page 153: ...earing 5 Press out bearing with bushing driver 1 Fig 7 Install 1 Place cylinder on Cylinder Support 19227 with large opening facing bearing Fig 7 2 Align oil holes in bearing with oil holes in cylinde...

Page 154: ...oles in bearing with oil holes in cylinder 3 Press in new bearing to correct depth with Bushing Driver 19349 3 Fig 11 Fig 11 4 Grind off the taper 5 approximately 1 8 3 mm 4 from one end of new roll p...

Page 155: ...is seated 4 Use Cylinder Support 19227 and press oil seal until flush with crankcase cover Fig 17 PTO Plain Bearing Replace the sump if the PTO bearing is scored or if Plug Gauge 19380 1 enters bearin...

Page 156: ...10 155 Section 10 Crankshafts and Camshafts Page INSPECT CAMSHAFT 156 INSPECT CRANKSHAFT 156 INSPECT FLYWHEEL 157...

Page 157: ...Replace timing gear if teeth are damaged or worn Measure crankpin 5 for wear Fig 1 Crankshaft crankpin may be re ground for 0 020 undersize connecting rods when available See IPL for part number Accur...

Page 158: ...shown in specifications page in Appendix Replace cam gear if not to specification Governor spool 2 must move freely on PTO journal 6 of camshaft Flyweight 12 must move freely on pivot 8 Make sure fly...

Page 159: ...10 158...

Page 160: ...159 Section 11 Pistons Rings and Connecting Rods Page ASSEMBLE PISTON AND CONNECTING ROD 161 ASSEMBLE RINGS TO PISTON 162 DISASSEMBLE 160 GENERAL INFORMATION 160 INSPECT PISTON AND PISTON RINGS 160 I...

Page 161: ...oil control ring coil expander and oil control rings Fig 1 3 Disassemble piston from connecting rod Fig 2 a Remove piston pin locks 2 b Piston pin is a slip fit in piston and connecting rod Keep pist...

Page 162: ...el 540000 0 826 20 98 mm Fig 6 2 Check connecting rod bearings Fig 7 NOTE Undersize 0 020 connecting rods are available for use on a reground crankpin journal on some engines See IPL for availability...

Page 163: ...osite arrow on piston 4 Install piston pin locks with needle nose pliers Fig 9 2 Assemble Piston Rings to Piston Install rings in order shown Fig 10 Use Piston Ring Expander 19340 when installing cent...

Page 164: ...tor Breather Alternator 167 Install Flywheel 167 Flywheel All Models Except POWERLINKE 167 Flywheel POWERLINKE 168 Torque Flywheel Nut 290000 300000 540000 610000 167 Torque Flywheel Nut 350000 380000...

Page 165: ...1 piston with notch or offset casting mark 3 toward the FLYWHEEL SIDE of the engine 4 Fig 3 Push piston down by hand until connecting rod is seated on crankpin NOTE The words OUT 1 5 on 1 connecting r...

Page 166: ...g 6 2 Install oil pump assembly and gear baffle 1 to crankcase Use new O rings 3 under the screws Fig 6 Vertical Crankshaft 1 Make sure the oil pickup screen 3 is clean and in position 2 Place new O r...

Page 167: ...into recess in tappets NOTE All Models except 540000 610000 Exhaust valve push rods are aluminum Models 540000 610000 All push rods are aluminum Fig 10 Install Rocker Arms Current Style 1 Lubricate ro...

Page 168: ...res 3 Install starter motor 3 Torque screws to 140 in lbs 16 Nm 4 Install breather Models 290000 350000 Torque screws to 30 in lbs 3 Nm Fig 15 Install Flywheel All models except Engines with POWERLINK...

Page 169: ...2 and starter hub screw 1 Fig 18 Install Flywheel Engines with PowerLinkt NOTE Before installing flywheel make sure the fly wheel magnets are free of debris WARNING The flywheel magnets are VERY POWE...

Page 170: ...emble governor lever 3 to governor shaft DO NOT tighten nut at this time 4 Install governor control bracket 2 Torque screws to 140 in lbs 16 Nm Install Carburetor and Manifold Vertical Crankshaft Mode...

Page 171: ...equipped with an anti afterfire solenoid route the wire under the intake manifold and through the hole in 1 cylinder shield at this time Fig 25 Fig 26 3 Connect choke link 7 to choke lever and instal...

Page 172: ...ink 6 to carburetor and choke lever and install choke bracket 10 Torque screws to 65 in lbs 7 Nm 6 Install fuel line and clamp Install fuel line at carburetor Rotate fuel line clamp tabs horizontally...

Page 173: ...on retainer 10 Assemble choke link 13 to carburetor and choke lever Install choke bracket 15 Torque screws to 65 in lbs 7 Nm 11 Install air cleaner elbow support Torque screw to 65 in lbs 7 Nm Fig 35...

Page 174: ...reather tube onto breather nipple Install air cleaner base on carburetor mounting studs 3 Install carburetor shield 2 4 Install nuts 3 and screws 1 finger tight 5 Torque nuts and screws to 65 in lbs 7...

Page 175: ...r inlet hose clamp to 30 in lbs 3 4 Nm Fig 43 Fig 43 2 With the outlet tube 7 to the LEFT service cover 3 to the RIGHT install the mounting band 4 NOTE The air cleaner is held in place by the mounting...

Page 176: ...ING Incorrect adjustment could result in engine overspeeding causing engine damage property damage or personal injury Correct speed is found in the Service Engine Sales Manual Microfiche MS 6225 or th...

Page 177: ...12 176...

Page 178: ...000 610000 184 Honing Fixture 186 Starter Motor Support Block 187 Starter Motor Test Bracket 187 Tables 188 Fuel System Identification 188 Carburetor Main Jets 188 Reference Pressures Gaseous Fuel Eng...

Page 179: ...0 2327 5 91 Crankcase Cover Main Bearing 1 3795 1 380 35 04 35 05 1 381 35 07 Cam Bearing 0 7874 0 788 20 0 20 02 0 789 20 04 Crankshaft Crankpin 1 4567 1 458 37 00 37 03 1 455 36 95 Magneto Journal B...

Page 180: ...3 Nm Carburetor to Manifold 65 in lbs 7 Nm Connecting Rod 115 in lbs 13 Nm Crankcase Cover 150 in lbs 17 Nm Cylinder Head 165 in lbs 19 Nm Cylinder Shield 65 in lbs 7 Nm Exhaust Manifold 150 in lbs 1...

Page 181: ...nkcase Cover Main Bearing 1 3795 1 380 35 04 35 05 1 381 35 07 Cam Bearing 0 7874 0 788 20 0 20 02 0 789 20 04 Crankshaft Crankpin 1 4567 1 458 37 00 37 03 1 455 36 95 Magneto Journal Before 9705010 1...

Page 182: ...3 Nm Carburetor to Manifold 65 in lbs 7 Nm Connecting Rod 115 in lbs 13 Nm Crankcase Cover 150 in lbs 17 Nm Cylinder Head 165 in lbs 19 Nm Cylinder Shield 65 in lbs 7 Nm Exhaust Manifold 150 in lbs 1...

Page 183: ...Crankcase Cover Main Bearing 1 3795 1 380 35 04 35 05 1 381 35 07 Cam Bearing 0 7874 0 788 20 0 20 02 0 789 20 04 Crankshaft Crankpin 1 4567 1 458 37 00 37 03 1 455 36 95 Magneto Journal Before 970501...

Page 184: ...3 Nm Carburetor to Manifold 65 in lbs 7 Nm Connecting Rod 115 in lbs 13 Nm Crankcase Cover 150 in lbs 17 Nm Cylinder Head 165 in lbs 19 Nm Cylinder Shield 65 in lbs 7 Nm Exhaust Manifold 150 in lbs 1...

Page 185: ...ntake 0 234 0 235 5 95 5 96 0 233 5 92 Exhaust 0 2338 0 234 5 94 5 95 0 2327 5 91 Crankcase Cover Main Bearing 1 3795 1 380 35 04 35 05 1 381 35 07 Cam Bearing 0 7874 0 788 20 0 20 02 0 789 20 04 Cran...

Page 186: ...in lbs 14 Nm Crankcase Cover 200 in lbs 23 Nm Cylinder Head 350 in lbs 40 Nm Cylinder Shield 90 in lbs 10 Nm Exhaust Manifold 200 in lbs 23 Nm Flywheel 150 ft lbs 203 Nm Flywheel Fan Screws 90 in lbs...

Page 187: ...g Hardware Fasteners Required 4 Crankcase Cover Screws 4 Flat Washers 3 8 9 5 mm I D 10 10 13 32 Thru Hole 4 Material Wood 2 x 10 x 10 51 mm x 254 mm x 254 mm 2 8 9 16 8 5 32 3 3 1 4 254 mm 254 mm 217...

Page 188: ...ons for the test bracket are a 4 101 6 mm b 2 1 4 57 2 mm c 3 1 2 88 9 mm d 2 50 8 mm e 10 254 mm f 1 25 4 mm g 3 1 2 88 9 mm 1 Drill two holes 1 3 8 9 5 mm diameter for mounting starter 2 Use a 7 dri...

Page 189: ...CE PRESSURES FOR GASEOUS FUELED ENGINES Tank Pressure 90 psi minimum Secondary inlet under load 11 inches of water Secondary outlet under load 0 to slight vacuum 1 psi 16 ounces 27 72 inches of water...

Page 190: ...0 0781 16 0 177 O 0 316 47 0 0785 15 0 180 P 0 323 46 0 081 14 0 182 21 64 0 3281 45 0 082 13 0 185 Q 0 332 44 0 086 3 16 0 1875 R 0 339 43 0 089 12 0 189 11 32 0 3438 42 0 0935 11 0 191 S 0 348 3 32...

Page 191: ...45 64 0 7031 17 859 7 32 0 2188 5 558 23 32 0 7188 18 258 15 64 0 2344 5 954 47 64 0 7344 18 654 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 2656 6 746 49 64 0 7656 19 446 9 32 0 2813 7 145 25 32 0 78...

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Vanguard OHV V-Twin, User Manual

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