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Standard and Reject Sizes

ITEM

STANDARD SIZE

REJECT SIZE

CRANKCASE/CYLINDER

Camshaft Bearing Bore Diameter

0.787-0.788 in (20.0-20.015 mm)

0.799 in (20.30 mm) or more

Cylinder Bore Circularity (Out-Of-Round)

0.0003 in (0.007 mm) - Measured in 5 spots at the top, middle and bottom of the cylinder bore

Cylinder Bore Diameter - M61 and M54

3.366-3.367 in (85.5-85.525 mm)

3.370 in (85.598 mm) or more

CYLINDER HEAD
Intake

Valve Seat Angle - 3-Angle Seat

31°, 46°, 60°

Valve Stem Diameter

0.234-0.235 in (5.945-5.960 mm)

0.228 in (5.791 mm) or less

Valve Guide Bore Diameter

0.236-0.237 in (6.006-6.026 mm)

0.240 in (6.106 mm) or more

Exhaust

Valve Seat Angle - 3-Angle Seat

31°, 46°, 60°

Valve Stem Diameter

0.233-0.234 in (5.940-5.955 mm)

0.228 in (5.791 mm) or less

Valve Guide Bore Diameter

0.236-0.237 in (6.006-6.026 mm)

0.240 in (6.106 mm) or more

CRANKCASE COVER

Camshaft Bearing Bore Diameter

0.787-0.788 in (20.0-20.025 mm)

0.799 in (20.30 mm) or more

CRANKSHAFT

Crank Pin Journal Diameter

1.693-1.694 in (43.0-43.02 mm)

1.691 in (42.95 mm) or less

MAG Bearing Journal Diameter

1.771-1.772 in (44.976-45.0 mm)

1.769 in (44.926 mm) or less

PTO Bearing Journal Diameter

1.771-1.772 in (44.976-45.0 mm)

1.769 in (44.926 mm) or less

CAMSHAFT

MAG Bearing Journal Diameter

0.785-0.786 in (19.947-19.960 mm)

0.783 in (19.897 mm) or less

PTO Bearing Journal Diameter

0.785-0.786 in (19.947-19.960 mm)

0.783 in (19.897 mm) or less

CONNECTING ROD

Crank Pin Bearing Bore Diameter

1.695-1.696 in (43.06-43.08 mm)

1.698 in (43.13 mm) or more

Piston Pin Bearing Bore Diameter

0.827-0.828 in (21.014-21.021 mm)

0.830 in (21.071 mm) or more

PISTON

Piston Pin Diameter

0.826-0.827 in (21.0-21.004 mm)

0.826 in (20.970 mm) or less

Piston Pin Bore Diameter

0.827-0.827 in (21.006-21.013 mm)

0.829 in (21.063 mm) or more

Top Compression Ring End Gap

0.008-0.014 in (0.20-0.35 mm)

0.044 in (1.11 mm) or more

Middle Oil Wiper Ring End Gap

0.014-0.022 in (0.35-0.55 mm)

0.052 in (1.31 mm) or more

Bottom Oil Control Ring End Gap

0.008-0.028 in (0.2-0.70 mm)

0.063 in (1.59 mm) or more

Top Compression Ring Side Clearance

0.004-0.005 in (0.09-0.13 mm)

0.012 in (0.31 mm) or more

168

vanguardpower.com

Содержание BIG BLOCK M540000

Страница 1: ...Repair Manual 80114787 Revision A BRIGGS STRATTON CUSTOMER EDUCATION Milwaukee WI 53201 USA Copyright 2023 All rights reserved VANGUARDPOWER COM Vanguard BIG BLOCK Diagnostic and Repair M540000 M61000...

Страница 2: ...the data available at the time of publication Briggs Stratton reserves the right to change alter or otherwise improve the product or the product manuals at any time without prior notice Briggs Stratt...

Страница 3: ...ed service parts Review the Illustrated Parts List for part availability before conducting any service work NOTE Many of the images in this document are representative of the Horizontal shaft EFI ETC...

Страница 4: ...ts see SECTION 5 DISASSEMBLE ENGINE TOP END DISASSEMBLY and then proceed to SECTION 6 SERVICE ENGINE SUBASSEMBLIES CYLINDER HEAD When cylinder head service is complete see SECTION 7 ASSEMBLE ENGINE TO...

Страница 5: ...CTION 3 TROUBLESHOOTING AND SPECIAL TOOLS 3 SECTION 4 REMOVE EXTERNAL ASSEMBLIES 4 SECTION 5 DISASSEMBLE ENGINE 5 SECTION 6 SERVICE ENGINE SUBASSEMBLIES 6 SECTION 7 ASSEMBLE ENGINE 7 SECTION 8 INSTALL...

Страница 6: ...ATION 8 Safety Alert Symbol and Signal Words 8 Hazard Symbols and Meanings 8 General Safety Messages 8 GENERAL INFORMATION 11 Engine Identification 11 Fuel Recommendations 11 Fuel Recommendations Gase...

Страница 7: ...etitive events not sanctioned by Briggs Stratton For information about competitive racing products see www briggsracing com For use with utility and side by side ATVs please contact Briggs Stratton Po...

Страница 8: ...cal switches Do not use a phone in the vicinity Evacuate the area Contact the gas supplier or the fire department WARNING Fuel vapors are flammable and explosive Fire or explosion could result in burn...

Страница 9: ...removed WARNING Rotating parts can entangle hands feet hair clothing or accessories and result in traumatic amputation or laceration Operate equipment with the guards correctly installed Keep hands a...

Страница 10: ...r engines with electronic fuel injection are ECM Engine Control Module MFI Multiport Fuel Injection TBI Throttle Body Fuel Injection and if equipped an O2S Oxygen Sensor High Altitude At altitudes ove...

Страница 11: ...the correct operating position Fill the fuel tank A Figure 2 with fuel For fuel expansion do not fill above the fuel tank neck B Fuel can become stale when kept in a storage container for more than 3...

Страница 12: ...System 16 Check Oil Guard Oil Level 16 Clean Replace Air Filter Safety Filter 17 Clean Replace Air Filter Low Profile 18 Replace Fuel Filter 18 Clean Gap Replace Spark Plug 19 Clean Inspect Muffler 19...

Страница 13: ...rs or every third air filter replacement Preliminary Instructions Prior to starting any repair or maintenance operation Make sure you are familiar with ALL safety warnings and procedures as outlined i...

Страница 14: ...tchet and extension bar tighten oil filter to 75 lb in 8 5 Nm Do not use air tools 5 11 See Figure 3 Slowly pour the recommended type of oil into the valve cover opening See SECTION 1 SAFETY AND GENER...

Страница 15: ...n hose and rotate turn to lock Capture hose in retaining clip 10 Apply light film of clean engine oil to top and bottom o rings of new oil filter 11 Install oil filter into filter housing and rotate t...

Страница 16: ...rized air or solvents will damage air filter 5 Carefully inspect air filter and replace if it cannot be adequately cleaned or if any damage is observed 6 Inspect seal at air cleaner base D for cuts te...

Страница 17: ...o air dry completely 9 Carefully inspect foam pre cleaner and air filter Replace parts if they cannot be adequately cleaned or if any damage is observed 10 Install foam pre cleaner onto air filter 11...

Страница 18: ...l Clean Inspect Muffler 1 Remove spark plug wires from spark plug terminals Secure spark plug wires to prevent contact with spark plug terminal 2 Remove the oxygen sensor A Figure 12 from the muffler...

Страница 19: ...ses so that both valves are closed with the rocker arms loose insert a wooden dowel through the spark plug hole until seated at the top of the piston C Rotate engine in the same direction until the pi...

Страница 20: ...the throttle stop adjustment screw B 16 5 Adjust the screw to bring the idle speed to the correct RPM based on the specification of the engine See The Power Portal for correct idle speed RPM Dependin...

Страница 21: ...se a screwdriver to rotate the governor shaft C COUNTERCLOCKWISE as far as it will go 4 While maintaining the governor shaft position tighten the governor arm bracket pinch bolt to 135 lb in 15 3 Nm C...

Страница 22: ...ubborn accumulations of dirt and other deposits using a plastic putty knife or stiff bristle brush D Apply a light solvent to bristle brush to loosen and remove grit and oily residue if necessary 6 St...

Страница 23: ...36 Electrical Systems 37 Alternator 37 System Diagnosis Alternator 37 Charging System Identification 37 Testing Alternator Output 38 20 Amp Regulated Alternator 38 Output Test 20 Amp Alternator 38 Re...

Страница 24: ...ter Motor Performance 42 Troubleshooting Starter Motor 43 Starter Motor Solenoid Continuity Test 43 Starter Motor Solenoid Voltage Test 44 Starter Motor Solenoid Load and Current Draw Test 44 SPECIAL...

Страница 25: ...gnition 2 Fuel System 3 Compression Preliminary Instructions Prior to starting any repair or maintenance operation Make sure you are familiar with ALL safety warnings and procedures as outlined in SEC...

Страница 26: ...Gummy or dirty carburetor fuel filter fuel lines or fuel tank Carburetor float needle valve stuck closed Inoperative fuel pump if equipped Inoperative fuel shut off solenoid if equipped NOTE To deter...

Страница 27: ...towel around fitting to catch any fuel leakage 10 Install fuel pressure test adapter between fuel rail and fuel pump module 11 Remove protective cap from Schrader valve on fuel pressure test adapter a...

Страница 28: ...g for proper setup steps and testing procedures 1 Obtain engine leakdown tester See Special Tool List 2 Remove spark plug from engine 3 Disconnect the crankcase breather tube 4 Rotate the crankshaft i...

Страница 29: ...speed a Note the spark at the ignition tester If the spark is equal at both ignition testers the problem is not ignition related A spark miss will be readily apparent Repair and retest 4 Connect the t...

Страница 30: ...flow through valve 27 2 Apply vacuum or draw air out through breather hose to verify that air flows freely through valve 3 If air flow has no resistance when blowing or is restricted under vacuum the...

Страница 31: ...epair manual for your engine Fuel line plugged or kinked Clean or replace fuel line Fuel tank suction screen or fuel filter plugged Clean screen or replace fuel filter Water in fuel tank Drain and cle...

Страница 32: ...arburetor or fuel injection system See SECTION 6 SERVICE ENGINE SUBASSEMBLIES Carburetor See EFI Diagnostics Manual Ignition system out of time Check crankshaft flywheel key for wear or damage See SEC...

Страница 33: ...gine load too great Check equipment for damaged components worn bearings or debris buildup Exhaust system leak Check exhaust manifold muffler and all gaskets for leaks Replace as necessary Engine does...

Страница 34: ...lator valve vent ports Low fuel pressure Check the fuel pressure Adjust fuel pressure at the regulator and verify adequate pipe size for the application Plugged fuel filter Replace fuel filter Kinked...

Страница 35: ...ighten fitting replace if damaged Gas leak from fuel line Damaged cracked or worn hose Replace hose Gas leak from regulator Damaged diaphragm in regulator Replace damaged components Additional Trouble...

Страница 36: ...ux or damaged alternator magnets Inspect components Replace if necessary Mismatched battery to alternator output Check equipment operator s manual for correct battery specifications Damaged battery In...

Страница 37: ...utes 10 With the engine running at 3600 RPM the output should be between 13 9 and 14 5 VDC 20 50 Amp Regulated Alternator Output Test 20 50 Amp Alternator 1 Obtain 2 digital multimeters See Special To...

Страница 38: ...ground 6 Turn the key switch to ON The multimeter should display battery voltage If the meter DOES NOT display battery voltage the problem exists within the equipment wiring harness Consult equipment...

Страница 39: ...7 Reverse the meter test lead clips so that the RED test lead clip is attached to the armature connector and the BLACK test lead clip is attached to the engine harness connector a Observe the multimet...

Страница 40: ...re Solenoid or Fuel Cut Off Gray Wire and Brown Wire Connector E Ground Wire Brown Wire Connector F Oil Pressure Switch Green Wire Connector G Ignition Armature Black Wire Connector H Ignition Armatur...

Страница 41: ...ication but the warning light remains ON proceed to oil pressure test Test Oil Pressure The engine oil level must be between the LOW and FULL mark on the dipstick If the oil level is low check for lea...

Страница 42: ...due to dirt Clean pinion gear Damaged pinion or ring gear Replace starter motor or flywheel Starter clutch slipping Replace starter motor Starter Motor Spins But Does Not Crank Engine Reverse rotation...

Страница 43: ...observe the multimeter display 12 The multimeter display should indicate battery voltage If the multimeter display DOES NOT indicate battery voltage the solenoid is faulty Replace starter motor soleno...

Страница 44: ...between the solenoid and the battery 8 Select AMPS on the multimeter or if equipped install the multimeter inductive clamp on the POSSITIVE battery cable 9 Crank the engine for 15 seconds and observe...

Страница 45: ...rt No 19393 9 Strap Wrench Part No 19433 10 Valve Adjustment Set Part No 19465 11 Tang Adjusting Tool Part No 19480 12 Dial Bore Gauge Part No 19487 13 Leakdown Tester Part No 19545 14 Master Seat Cut...

Страница 46: ...Special Tools Image Chart 30 47...

Страница 47: ...uides 56 Blower Housing 58 Voltage Regulator 58 Starter Motor 59 Fuel Filter 60 Electric Lift Fuel Pump 60 Fuel Pump Carbureted Engine 60 Fuel Pump Module 62 Engine Control Module ECM EFI 63 Crankshaf...

Страница 48: ...ail and Fuel Injectors EFI ETC 71 T MAP Sensor EFI 71 Intake Manifold 72 Wire Harness EFI 73 Wire Harness EFI ETC 74 Wire Harness Carbureted and Gaseous 77 Air Block Plate Valley Air Guides Speed Cont...

Страница 49: ...il and oil filter at a proper waste disposal or recycling center Relieve Fuel System Pressure EFI and EFI ETC 1 Turn Ignition OFF 2 Loosen fuel filler cap to relieve fuel tank pressure Tighten filler...

Страница 50: ...e oil cooler to an appropriate disposal container Oil Diverter Valve and Drip Tray 1 Rotate hex A Figure 34 to release adapter B and diverter C from crankcase flange 34 2 Remove o ring D from diverter...

Страница 51: ...k hose connector If connector is a tight fit disengage slots on each end of clip lock from tabs in housing before pushing 7 Disengage red clip lock and remove oil scavenge hose connector from oil tank...

Страница 52: ...release air cleaner bottom bracket from air intake elbow 8 Remove duckbill air valve M on air inlet port of air cleaner cover Look for cuts tears holes or general deterioration Air Cleaner Assembly L...

Страница 53: ...orts from crankcase cover G studs 3 Remove 2 fasteners H to release muffler manifolds from cylinder heads NOTE Depending on your engine model and trim the muffler manifold to cylinder head fastener ma...

Страница 54: ...style throttle level and a push pull choke proceed to step 3 If your engine is equipped with a detent style throttle lever see Throttle Control in this section 3 If your engine is equipped with cover...

Страница 55: ...stener A Figure 46 from the speed control bracket to release the throttle cable 46 3 Remove the Z bend of the throttle cable B from the hole in the speed control bracket NOTE The support bracket that...

Страница 56: ...3 On the starter motor side of the engine remove the 3 fasteners A B C Figure 48 that secure the cylinder air guide to the engine 48 4 Remove the air guide from the engine and set aside 57...

Страница 57: ...voltage regulator has a capacitor mounted to a bracket atop the regulator 1 Disconnect the voltage regulator to stator connector If equipped with a 20 amp regulator see A Figure 51 if equipped with a...

Страница 58: ...pped with a starter motor support bracket Removal of this bracket is required for starter motor removal If equipped proceed to steps 3 and 4 If your engine is NOT equipped with a starter motor support...

Страница 59: ...mps C and move away from fuel inlet and outlet fittings Remove fuel inlet and outlet hoses from the lift pump D NOTE Wrap shop towel around fuel filter fittings to catch any fuel leakage 4 Remove fuel...

Страница 60: ...7 Remove the 2 fasteners A Figure 59 that secure the fuel pump to the fuel pump bracket 59 8 Remove the fuel pump and set aside 61...

Страница 61: ...any fuel spillage 4 Remove the fuel supply line D from the lift pump to the fuel pump module a Squeeze the tangs on the fuel supply line clamp and slide along the hose away from the fuel pump module...

Страница 62: ...ally to the engine 1 Remove the 2 fasteners A Figure 64 and wire harness ground wire B that secure the ECM to the support bracket 2 Remove the J1 GRAY C and J2 BLACK D harness connectors from the ECM...

Страница 63: ...shaft position sensor fasteners B Set sensor aside Optional Speed Sensor 1 Remove the 2 speed sensor fasteners A Figure 66 from the engine back plate mounting 66 2 Remove the sensor wiring B from the...

Страница 64: ...n Coil EFI and EFI ETC 1 Disconnect the engine wire harness connector from the ignition coil electrical connector A Figure 68 68 2 Remove the ignition coil electrical connector B from the intake manif...

Страница 65: ...the throttle body to intake elbow o ring for damage and contamination Replace if necessary Throttle Body Adapter Removal 1 Remove the crankcase breather hose from the valve cover to the throttle body...

Страница 66: ...ines equipped with the late style TPS may also come equipped with a tamper proof TORX idle set screw 73 Throttle Position Sensor TPS Late Style 1 Disconnect the wire harness to TPS electrical connecto...

Страница 67: ...fuel line during removal to catch any residual fuel in the line 4 Disconnect the fuel pump vent line at the intake manifold port by squeezing the tangs of the clamp and sliding the clamp away from th...

Страница 68: ...e the spring Remove the throttle rod from the throttle lever at the carburetor 5 Remove the carburetor from the engine NOTE Place the carburetor in a container or on shop towels to capture any residua...

Страница 69: ...nk rod and spring from the throttle lever Release the link rod clip release the spring and remove the link rod from the throttle lever bushing hole 7 On engines equipped with a Stepper Motor disconnec...

Страница 70: ...ector halves 80 2 Remove 2 fasteners C D to release fuel injector cap flanges from intake manifold 3 Remove retaining clips and then remove fuel injector caps from fuel injectors 4 Remove fuel injecto...

Страница 71: ...take manifold from the cylinder heads 3 Remove and discard the intake manifold gaskets 4 Clean the intake manifold and cylinder head mating surfaces of all old gasket material The mating surfaces need...

Страница 72: ...1 side of engine see B Figure 82 and proceed as follows 1 Disconnect ECM J1 connector 2 Remove fastener to release ECM ground wire ring terminal from ECM fuse block bracket 3 Disconnect fuel injector...

Страница 73: ...removing anchor of rosebud style clip from boss at rear of intake manifold Pull out red secondary lock and then press and hold tab before pulling apart connector halves Remove 2 fasteners to release i...

Страница 74: ...84 75...

Страница 75: ...85 76 vanguardpower com...

Страница 76: ...d D from the solenoid 4 Remove the fastener that secures the anti afterfire ground ring terminal AND harness ground Cand E from the engine and move ground wires aside 5 Disconnect the ignition armatur...

Страница 77: ...the 4 valley air guide fasteners A Figure 88 88 NOTE Your engine may be equipped with an air filter support bracket or a speed control bracket These brackets utilize the valley air guide fasteners to...

Страница 78: ...quire the removal of additional fasteners connecting the valley support bracket to the speed control bracket Governor Arm Bracket 1 Release the high speed A Figure 92 and low speed B governor arm spri...

Страница 79: ...EMBLE ENGINE TOP END DISASSEMBLY 81 Preliminary Instructions 81 Top End Disassembly 81 BOTTOM END DISASSEMBLY 83 Flywheel Fan and Flywheel 83 Alternator and Guard Plate 85 Bottom End Disassembly 85 80...

Страница 80: ...inder head For example on carbureted engines the fuel pump mounting bracket is attached to the cylinder head with the valve cover fasteners Take note of any additional mounting brackets and their orie...

Страница 81: ...94 82 vanguardpower com...

Страница 82: ...ase fan E from flywheel 5 Obtain the Strap Wrench see SECTION 3 TROUBLESHOOTING Special Tool List correct size socket for flywheel nut and breaker bar See Figure 97 and proceed as follows NOTE DO NOT...

Страница 83: ...art puller screws into threaded holes in flywheel Install puller screws into flywheel an equal number of turns until positive engagement is obtained F Move top hex nuts down puller screws until firm c...

Страница 84: ...0 Amp alternator appears visually different to the 20 Amp alternator however the removal process is identical 3 Remove the alternator from the engine and set aside Take care to avoid damage to the alt...

Страница 85: ...cover 6 Install 4 screws with flat washers D to fasten base to cover and alternately tighten in a crosswise pattern until snug 7 Rotate forcing screw in a clockwise direction until cover is free Remov...

Страница 86: ...so that it can be installed in its original location when the engine is assembled 14 Rotate the crankshaft until piston is at the bottom of its stroke 15 Use a plastic scraper to carefully remove carb...

Страница 87: ...19 Repeat steps 17 18 on opposite cylinder 20 Remove crankshaft from crankcase 21 See the following topics under SECTION 6 SERVICE ENGINE SUBASSEMBLIES PISTON AND CONNECTING ROD FLYWHEEL CRANKSHAFT A...

Страница 88: ...ld Studs 97 Assembly 97 PISTON AND CONNECTING ROD 99 Disassembly 99 Cleaning 100 Piston 100 Connecting Rod 100 Inspection 100 Piston and Pin 100 Connecting Rod 101 Assembly 102 FLYWHEEL CRANKSHAFT AND...

Страница 89: ...ssembly 109 Oil Guard Oil Scavenge Pump Install 109 Oil Guard Oil Supply Pump Install 109 PTO Oil Bearing Seal Disassembly 110 PTO Oil Bearing Seal Assembly 110 STARTER MOTOR 110 Starter Motor Solenoi...

Страница 90: ...rew A Figure 107 and tighten until positive thread engagement is obtained 107 5 Place tool B over head of fulcrum screw engaging small end of slot 6 With prongs of tool on valve spring retainer C pivo...

Страница 91: ...appets push rods and rocker arms in a non volatile cleaning solution or solvent Follow up with a thorough wash in hot soapy water Blow dry with low pressure compressed air Inspection Cylinder Head 1 C...

Страница 92: ...ad if the measurement is 0 240 in 6 106 mm or more Valve Seat Inspection 1 Inspect valve seats for cracking chipping or burning Replace cylinder head if any of these conditions are found or if either...

Страница 93: ...ly lubricate the valve guide and valve stem with clean engine oil D From the bottom of the cylinder head insert the valve stem into the valve guide A Figure 111 111 E Push on bottom of valve until it...

Страница 94: ...sized pilot in the intake valve guide NOTE Do not drop the cutter onto the valve seat during installation or removal as the blades may cause seat damage that requires additional cutting NOTE Applying...

Страница 95: ...fast will produce chatter marks that adversely affect sealing integrity Rotate the cutter slowly so that it takes about three seconds to make one complete rotation 113 B Install the 45 base angle cutt...

Страница 96: ...have smooth surfaces but still have concave wear Hold a straight edge across the tappet face Any concave wear found on the tappet faces may also indicate worn camshaft lobes 3 Roll push rods on a flat...

Страница 97: ...om of the cylinder head insert the valve stem into the valve guide E To distribute the assembly lube evenly around the valve stem and guide hand spin the valve as it is installed Work the valve back a...

Страница 98: ...t until time of installation PISTON AND CONNECTING ROD Disassembly 1 Insert small pick into pick lock groove and pull piston pin lock ring out of pin boss groove see Figure 117 Discard lock ring 117 2...

Страница 99: ...h low pressure compressed air 3 Verify that oil holes in connecting rod shank and at top of piston pin bore are clean and open Inspection Piston and Pin 1 Carefully inspect the piston for damage or ex...

Страница 100: ...g or bending 2 Inspect bearing surfaces for scratches or scoring 3 Inspect dipper on connecting rod cap for bending chipping or cracking NOTE Replace connecting rod and cap if any of the above conditi...

Страница 101: ...Do not reuse piston pin lock ring after it has been removed The lock ring may weaken or become distorted during removal causing it to break or dislodge during engine operation 4 Install new piston pi...

Страница 102: ...cessive oil consumption and lower service life on valves and other components 10 Carefully install the compression ring B into the top ring groove so that the single painted mark is to the right of th...

Страница 103: ...fins Crankshaft 1 Carefully remove crankshaft end play shims A Figure 129 if present Count shims as they are removed to be sure of installing the correct number when the engine is assembled Inspect sh...

Страница 104: ...lips 131 2 Remove flat washer C from crankcase boss 3 Remove governor shaft from inside crankcase 4 Using a small pick remove oil seal D from crankcase bore Exercise caution to avoid scratching bore d...

Страница 105: ...til the oil seal is flush to 0 040 in 0 1 0 mm below the bearing bore lip Crankcase Cover Governor Gear Disassembly 1 Remove governor cup A Figure 133 from governor shaft B 133 2 Remove retaining ring...

Страница 106: ...ers A Figure 135 to release cover B from crankcase cover C 135 2 Remove o ring D from crankcase cover groove Discard O ring 3 Remove oil intake filter E from crankcase cover 4 Remove 3 fasteners F to...

Страница 107: ...he gear shaft 4 Remove oil filter screen C 5 Remove roll pin A Figure 138 from hole in gear shaft 138 6 Remove crescent ring B from the groove on the gear shaft 7 Remove thrust washer C from gear shaf...

Страница 108: ...in into the hole in the gear shaft 3 Install the oil filter screen 4 Install the inner and outer gerotors onto the gear shaft 5 Install new o ring into the crankcase cover groove 6 Install the oil pum...

Страница 109: ...val 142 PTO Oil Bearing Seal Assembly 1 Apply a thin film of clean engine oil the oil seal bore and OD of new oil seal 2 Place the oil seal into the bearing bore 3 Place the suitable oil seal driver o...

Страница 110: ...mounting fork of the starter motor 3 Install the stator brush strap B Figure 144 over the lower mounting stud Take care to not damage or break the strap 4 Install the stator brush washer and fastener...

Страница 111: ...Vanguard Model 540000 145 112 vanguardpower com...

Страница 112: ...4 Remove the float hinge pin float D and needle 5 Remove the emulsion tube body fastener and remove the emulsion tube E and gasket Discard old gasket 6 Remove the 3 fasteners that secure the cover pla...

Страница 113: ...Vanguard Model 610000 146 114 vanguardpower com...

Страница 114: ...oat bowl Discard sealing washer 3 Remove the main jets D from the float bowl 4 Remove the float hinge pin float E and needle from the carburetor body 5 Remove the limiter caps and mixture adjustment s...

Страница 115: ...nd circlip to secure the throttle shaft to the carburetor 3 Apply LOCTITE 222 or equivalent on throttle plate fastener threads Install one throttle plate J at a time Check throttle for freedom of oper...

Страница 116: ...Tighten until snug NOTE DO NOT overtighten the anti afterfire solenoid Damage to the main jet and float bowl may occur MIXER GASEOUS ENGINES Mixer Gaseous Engines The mixer on gaseous engines cannot b...

Страница 117: ...E PRELIMINARY INSTRUCTIONS 119 BOTOM END ASSEMBLY 119 Bottom End Assembly 119 Alternator and Guard Plate 124 Flywheel Fan and Flywheel 125 TOP END ASSEMBLY 126 Top End Assembly 126 Crankcase Breather...

Страница 118: ...seal protector sleeve over crankshaft taper NOTE Use black electrical tape if oil seal protector sleeve is not available 6 Carefully install crankshaft into crankcase positioning MAG bearing journal i...

Страница 119: ...eve is still loose enough to be rotated E Gently tap on the top edge of the compressor sleeve to be sure the bottom edge is in full contact with cylinder deck F Apply steady pressure to piston crown t...

Страница 120: ...tappet shafts with clean engine oil 19 Install tappets into tappet bores Be sure to install each tappet in the same bore from which it was removed 20 Lubricate the camshaft MAG bearing journal camshaf...

Страница 121: ...152 25 Lubricate the camshaft PTO bearing journal and camshaft bearing bore in crankcase cover with clean engine oil 26 Apply a thin film of clean engine oil to PTO bearing oil seal lip 27 See Figure...

Страница 122: ...ins 32 Remove oil seal protector sleeve or black electrical tape from crankshaft 33 Start 11 fasteners to secure crankcase cover A Figure 155 to crankcase Proceed as follows 155 NOTE See inset of Figu...

Страница 123: ...s 0 39 1 00 mm if steel core gasket was installed H Repeat the procedure to verify the reading I If end play is not within specification replace the crankcase cover If engine is used in a pump applica...

Страница 124: ...dust and dirt Verify that keyways are clean and completely free of dirt and grit 2 Install key A Figure 159 into keyway on crankshaft taper 159 3 Install flywheel A Figure 160 engaging keyway with ins...

Страница 125: ...this section TOP END ASSEMBLY Top End Assembly 1 Verify that mating surfaces of cylinder and cylinder head are clean and dry Any dust or dirt left on mating surfaces can cause leaks 2 Verify that 2 lo...

Страница 126: ...rods to be sure that ball ends are seated in valve tappet sockets as shown in Figure 166 166 9 Install adjuster screws D Figure 165 and lock nuts E onto rocker arms 10 Tighten adjuster screws to obtai...

Страница 127: ...ark plug terminals at this time 20 See SECTION 8 INSTALL EXTERNAL ASSEMBLIES Crankcase Breather 1 Check crankcase breather as follows A Gently blow air into breather hose A Figure 168 to verify that t...

Страница 128: ...gnment 8 Install the reed valve assembly E into the valve cover H with the reed valve facing out 9 Install O ring F into valve cover groove Inspect for dryness cracking or cuts 10 Install the outer ba...

Страница 129: ...s 142 Throttle Position Sensor TPS Late Style 143 Throttle Position Sensor TPS Early Style 143 Throttle Position Sensor TPS Adjustment 143 Idle Air Control Valve IAC EFI 143 Intake Elbow Throttle Body...

Страница 130: ...Cleaner Assembly Cyclonic 156 Air Cleaner Assembly Low Profile 158 Optional Oil Guard System 159 Oil Pressure Switch 160 Oil Diverter Valve and Drip Tray 160 Oil Cooler 161 Oil Filter 161 Final Instr...

Страница 131: ...t 3 Tighten the governor arm bracket pinch bolt B to 135 lb in 15 3 Nm 4 Attach the 2 governor arm springs in the same position as noted when removed NOTE The 2 governor arm springs attach to the spee...

Страница 132: ...the valley air guide fasteners to attach to the engine See Figure 172 for engines equipped with the low profile air cleaner support bracket and see Figure 173 for engines equipped with the speed cont...

Страница 133: ...A of Figure 175 On cylinder 2 side of engine proceed as follows 1 Install fastener for fuse block cover to ECM fuse block bracket Tighten fastener to 87 lb in 9 8 Nm 2 Connect MAP MAT sensor connector...

Страница 134: ...lb in 10 2 Nm 5 Install Phillips screw to fasten engine ground wire ring terminal T to crankcase boss Tighten screw to 45 lb in 5 Nm 6 Install anchor of fir tree style clip Q Figure 177 capturing MIL...

Страница 135: ...rey secondary lock 15 Start long hex flange screw to fasten fuel pump module bracket and fuse relay block bracket to cylinder 2 head On opposite side start short hex flange screw to fasten fuel pump m...

Страница 136: ...176 137...

Страница 137: ...ire ground ring terminal C and the harness ground ring terminal E to the engine with the fastener Tighten fastener to 18 lb in 2 Nm NOTE The 2 ground wire ring terminals are secured to the engine by t...

Страница 138: ...red secondary connector lock to secure the connector to the sensor Fuel Rail and Fuel Injectors EFI 1 Lightly lubricate fuel injector O rings with clean engine oil 2 Install fuel injectors into intak...

Страница 139: ...nto fuel injectors 4 Install retaining clips to secure fuel injector caps to fuel injectors NOTE Be sure retaining clips are properly installed Side slots on clip engage lip on cap while tab K on fuel...

Страница 140: ...the valve cover breather hose to the carburetor port Low Profile Air Cleaner Equipped Engines 1 Install the new gaskets and spacers between the carburetor and intake manifold Vertical Shaft engines or...

Страница 141: ...and spacer between the mixer or stepper motor bracket if equipped using Figure 185 as a reference 185 7 On engines equipped with the optional Actuator connect the actuator link and spring to the throt...

Страница 142: ...Diagnostic Tool select the Dashboard icon in the left sidebar to view the Dealer tab Select the Test Procedures tab in the lower left corner 4 Slew the Idle Air Control Position Steps to 0 steps 5 Ad...

Страница 143: ...1 Install the throttle body adaptor with new gasket onto the throttle body 2 If equipped install the ECM Fuse Block mounting bracket to the throttle body adaptor 3 The throttle body adaptor is secure...

Страница 144: ...This Side Out You must install the armature in the correct orientation with the label facing the flywheel 2 Apply a small amount of threadlocker see SPECIFICATIONS Engine Fluids and Sealant Specificat...

Страница 145: ...ition Sensor CKP 1 Install the crankshaft position sensor onto the crankcase bosses above the flywheel on the cylinder 1 side of the engine 2 Apply a small amount of threadlocker see SPECIFICATIONS En...

Страница 146: ...module is mounted to the engine in a number of ways based on the trim and engine orientation If your engine is a vertical shaft proceed as follows If your engine is a horizontal shaft engine skip to s...

Страница 147: ...ect the wire harness connector to the fuel pump module connector A Press the harness connector onto the module connector until it clicks Fuel Pump Carbureted 1 Install the fuel pump onto the fuel pump...

Страница 148: ...et port Electric Lift Fuel Pump 1 Install the electric lift pump onto the mounting bracket NOTE The electric lift pump has 2 ports an inlet which receives fuel from the tank and an outlet which suppli...

Страница 149: ...engine is completely assembled and ready to be started See Final Instructions Starter Motor 1 Install the starter motor onto the engine by inserting the starter into the mounting hole Make sure that...

Страница 150: ...th the threaded holes in the engine block 2 Start by hand the 2 mounting fasteners C Figure 206 Tighten to 90 lb in 10 2 Nm 206 3 Connect the stator wire harness connector to the voltage regulator con...

Страница 151: ...ts F Tighten to 90 lb in 10 2 Nm 4 Install the triangular spacer E Figure 210 to the fan mounting posts Install the debris screen D atop the triangular spacer Align the mounting holes of the spacer an...

Страница 152: ...by the air guide mounting fastener Install the wire clamp and make sure that the oil pressure switch wire is routed correctly before torqueing the fastener 3 On the starter motor side of the engine i...

Страница 153: ...fastened to the blower housing The air intake elbow cover has a contoured opening to accommodate the air intake elbow and is variously fastened to other bracketry or components such as the fuel pump...

Страница 154: ...ol bracket by pushing the shaft into the bracket groove until captured 8 Start by hand the 2 cover fasteners and retaining washers A B Figure 217 Tighten to 30 lb in 3 4 Nm 217 Intake Elbow Cover 1 If...

Страница 155: ...nti seize compound to threads of studs and tighten nuts to 195 lb in 22 Nm 4 Install 2 fasteners I to fasten muffler bracket to crankcase Tighten screws to 195 lb in 22 Nm 5 If removed rotate sensor b...

Страница 156: ...r or solvents will damage air filter 15 Carefully inspect air filter and replace if it cannot be adequately cleaned or if any damage is observed 16 Inspect seal in air cleaner base for cuts tears hole...

Страница 157: ...ion 5 Install 4 fasteners E with lock washers F to secure carburetor shield G spacers H back plate throttle body adapter gasket throttle body adapter and throttle body gasket to throttle body Tighten...

Страница 158: ...lace parts if they cannot be adequately cleaned or if any damage is observed 15 Install foam pre cleaner onto air filter 16 Place air filter with foam pre cleaner onto air cleaner back plate C 17 Fit...

Страница 159: ...old and new o rings will result in oil leaks C Install hose fitting into check valve and tighten to 325 lb in 36 7 Nm 5 Prime oil supply pump as follows NOTE Failure to prime oil supply gerotor pump w...

Страница 160: ...he tangs of the hose clamps D Figure 228 and slide clamps along the hose until positioned over the diverter valve oil fittings 228 2 Install 2 fasteners C to secure the oil cooler bottom bracket to th...

Страница 161: ...MAINTENANCE Check Change Engine Oil Replace Oil Filter on Vanguard Oil Guard System NOTE If equipped with Vanguard Oil Guard System make sure that the system is properly primed prior to operation See...

Страница 162: ...ATIONS 164 Engine Specifications 610000 164 Engine Specifications 540000 164 Engine Parameter Specifications 540000 and 610000 165 Engine Fluid and Sealant Specifications 165 Torque Specifications 166...

Страница 163: ...earance Exhaust 0 007 0 009 in 0 18 0 23 mm Crankcase MAG Bearing Oil Seal Depth Flush to 0 040 in 0 1 0 mm Crankcase Cover PTO Bearing Oil Seal Depth 0 040 0 080 in 1 0 2 0 mm Engine Specifications 5...

Страница 164: ...EALANTS MODEL 540000 MODEL 610000 Engine Oil Standard to Hot Temperature Operating Condition Vanguard Synthetic 15W 50 Engine Oil Acceptable Alternate Service Specification Synthetic 5W 30 Service Cla...

Страница 165: ...ver to Air Cleaner Bracket Screws 90 lb in 10 2 Nm FASTENER TORQUE Intake Elbow Cover Cover to Fuel Module Bracket Screws 90 lb in 10 2 Nm Intake Manifold Stud Nut 135 lb in 15 3 Nm Intake Manifold St...

Страница 166: ...lb in 10 2 Nm Valley Air Block Plate to Crankcase 18 lb in 2 Nm Valve Cover Bolt 70 lb in 7 9 Nm Valve Cover Breather Screw Small 2 Bolt Design 43 lb in 4 8 Nm FASTENER TORQUE Valve Cover Breather Sc...

Страница 167: ...meter 1 693 1 694 in 43 0 43 02 mm 1 691 in 42 95 mm or less MAG Bearing Journal Diameter 1 771 1 772 in 44 976 45 0 mm 1 769 in 44 926 mm or less PTO Bearing Journal Diameter 1 771 1 772 in 44 976 45...

Страница 168: ...Repair Manual 80114787 Revision A BRIGGS STRATTON CUSTOMER EDUCATION Milwaukee WI 53201 USA Copyright 2023 All rights reserved VANGUARDPOWER COM Vanguard BIG BLOCK Diagnostic and Repair M540000 M61000...

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