Briggs & Stratton Repair Manuals for other Briggs & Stratton Engines: 273521 Twin Cylinder OHV Air-Cooled Engines 271172 Twin Cylinder L-Head Air-Cooled Engines 270962 Single Cylinder L-Head Air-Cooled Engines 276535 Two-Cycle Snow Engines CE8069 Out of Production Engines (1919-1981) Single Cylinder OHV Air-Cooled Engines Quality Starts With A Master Service Technician www.ThePowerPortal.com (Dealers) BRIGGSandSTRATTON.COM (Consumers) BRIGGS&STRATTON CORPORATION Part No.
FORWARD This manual was written to assist engine technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton engines. It assumes that persons using this manual have been properly trained in and are familiar with the servicing procedures for these products, including the proper use of required tools and safety equipment and the application of appropriate safety practices.
6 This Engine Repair Manual includes the following Engine Models: • MODEL 110000 HORIZONTAL SERIES • MODEL 120000 HORIZONTAL SERIES • MODEL 150000 HORIZONTAL SERIES • MODEL 200000 HORIZONTAL SERIES • MODEL 210000 HORIZONTAL SERIES • MODELS 97700 & 99700 VERTICAL SERIES • MODEL 110000 VERTICAL SERIES • MODEL 120000 VERTICAL SERIES • MODEL 210000 VERTICAL SERIES • MODEL 280000 VERTICAL SERIES • MODEL 310000 VERTICAL SERIES • MODEL 330000 VERTICAL SERIES
SECTION 1 - Safety, Maintenance and Adjustments SECTION 2 - Troubleshooting SECTION 3 - Exhaust Systems SECTION 4 - Fuel Systems and Carburetion SECTION 5 - Governor Systems SECTION 6 - Cylinder Heads and Valves 1 2 3 4 5 6 SECTION 7 - Starters 7 SECTION 8 - Lubrication Systems SECTION 9 - Cylinders, Covers and Sumps 8 9 SECTION 10 - Crankshafts, Camshafts, Balancing Systems, and Gear Reductions 10 SECTION 11 - Pistons, Rings and Connecting Rods 11 SECTION 12 - Engine Specifications 12
THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE, ECONOMICAL AND RELIABLE
SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS ENGINE SAFETY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - 7 ENGINE MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 1 FUEL AND OIL RECOMMENDATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - -
ENGINE SAFETY This repair manual contains safety information that is designed to: • Make you aware of hazards associated with engines. and cause leakage, flow restrictions, or other failures. • Check fuel lines and fittings frequently for cracks or leaks and replace if necessary. • Inform you of the risk of injury associated with those hazards. 1 • Tell you how to avoid or reduce the risk of injury.
WARNING Briggs & Stratton does not approve or authorize the use of these engines on 3-wheel All Terrain Vehicles (ATV’s), motor bikes, fun/recreational go-karts, aircraft products, or vehicles intended for use in competitive events. Use of these engines in such applications could result in property damage, serious injury (including paralysis), or even death.
WARNING • 1 • Starting engine creates sparking. Sparking can ignite nearby flammable gases. Explosion and fire could result. If there is a natural or LP gas leak in the area, do not start engine. Do not use pressurized starting fluids because vapors are flammable. WARNING • • WARNING 1 • • • • Rotating parts can contact or entangle hands, feet, hair, clothing, or accessories. Traumatic amputation or severe lacerations can result. Operate equipment with guards in place.
BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM YOUR KEY TO THE WORLD’S FINEST ENGINES This chart explains the unique Briggs & Stratton numerical model designation system. It is possible to determine most of the important mechanical features of the engine by merely knowing the model number. Here is how it works: A. The first one or two digits indicate the approximate CUBIC INCH DISPLACEMENT. B.
ENGINE MAINTENANCE Fuel and Oil Recommendations Fuel must meet these requirements: • Clean, fresh, unleaded gasoline. • A minimum of 87 octane / 87 AKI (90 RON). 1 • Gasoline with up to 10% ethanol (gasahol) or up to 15% MTBE (methyl tertiary butyl ether) is acceptable. 1 • NOTICE: Do not use unapproved gasoline, such as E85. Do not mix oil in gasoline or modify the engine to run on alternate fuels. This will damage the engine components and void the engine warranty.
Maintenance Chart First 5 Hours • Change oil Every 8 Hours or Daily • Check engine oil level • Clean area around muffler and controls • Clean finger guard Every 25 Hours or Annually Flywheel Brake Model Series 97700, 99700, 110000, 120000 Vertical Shaft The flywheel brake is part of the safety control system required for some applications. While running at FAST speed position, the flywheel brake MUST stop the engine within three seconds, when the operator releases the equipment safety control.
1 1 Figure 3 Figure 4 6. Using a torque wrench and socket to fit the flywheel nut, turn flywheel clockwise with brake engaged. While turning at a steady rate, torque reading should be 26 lb.-in. (3 Nm) or higher. 7. If reading is low, check thickness of brake pad. Replace brake assembly if thickness is less than 0.09” (2.28mm). 8. If brake pad thickness is acceptable, adjust control cable to position pad closer to flywheel when safety control is in RUN position. 9.
Combustion Chamber Remove combustion chamber deposits every 500 hours or whenever the cylinder head is removed. With the piston at Top Dead Center (TDC), scrape deposits from top of piston and upper bore with a plastic scraper. Remove the loosened deposits from around the top ring land area using compressed air or a shop vacuum and a soft bristle brush. NOTICE: Use care to prevent debris from entering push rod or oil return cavities in cylinder.
1 1 Figure 10 Figure 7 Figure 11 Figure 8 Figure 12 Figure 9 12
1 1 Figure 15 Figure 13 Figure 16 Inspection 1. Check hood for cracks or worn mounting holes. Replace if necessary. Figure 14 Snow Hood NOTE: Snow engines do not have an air cleaner assembly. Instead, a 1-piece or 2-piece snow hood is installed to protect the carburetor area, retain heat to resist carburetor icing, and provide a mounting surface for engine controls. 2. Check primer hose for brittleness or leaks and check stop switch and wire for damage. Replace parts as necessary. Install 1.
Oil and Oil Filter WARNING Spark plugs should be replaced every year. Gasoline and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. 1 • 1 Spark Plug • If you drain the oil from the top oil fill tube, the fuel tank must be empty or fuel can leak out and result in a fire or explosion. To empty the fuel tank, run the engine until it stops from lack of fuel. Change oil after the first 5 hours of operation.
Cooling System WARNING Running engines produce heat. Severe burns can occur on contact. • • 1 Allow muffler, engine cylinder fins, and radiator to cool before touching. Remove accumulated combustibles from muffler area and cylinder area. Dirt or debris can restrict air flow and cause the engine to overheat, resulting in poor performance and reduced engine life. Continued operation with a clogged cooling system can cause severe overheating and possible engine damage.
ENGINE ADJUSTMENTS 1 Remote Control Wire Travel The remote control wire should measure 2.125” (54 mm) when extended outside the casing (Figure 21). After installation, the travel of the remote control wire must be at least 1.375” (35 mm) to properly actuate the choke (on Choke-AMatic® systems) and the ignition stop switch (if equipped). 1 Figure 21 Remote Controls Horizontal Models 110000, 120000, 150000 1. Loosen casing clamp screw (A, Figure 22). 2. Move throttle lever to fast position. 3.
Vertical Models 110000, 120000 with Primer Carburetors 1. Loosen casing clamp screw (A, Figure 24, Figure 25). 2. Move throttle lever to fast position. 3. Move casing in direction of arrow until slack is removed. 1 4. Tighten casing clamp screw. 1 Figure 26 4. Tighten casing clamp screw. Horizontal and Vertical Models 200000, 210000, 280000, 310000, 330000 1. Loosen casing clamp screw (C, Figure 27). Figure 24 2. Set throttle control to FAST position. 3.
Governor Adjustments A complete governor system adjustment includes a static adjustment, engine warm-up, idle and/or governed idle adjustment, and top noload adjustment. Be sure to complete all steps. 1 Top No Load Adjustment Vertical Models 97700, 99700 1. Place throttle (A, Figure 30 and 31) in FAST position and insert a 1/8” (3.2 mm) rod (B) through holes in carburetor control bracket and lever. Static Adjustment 1.
Top No Load Adjustment Vertical Models 110000, 120000, 150000 with Primer Carburetors 1. Start engine and run until it reaches operating temperature. 2. Place throttle in FAST position. 3. Using Tachometer #19200 or #19389, and Tang Bender #19229 or #19352, bend Top No Load spring tang to obtain correct Top No Load RPM (Figure 32). NOTE: Correct Top No Load RPM for each model-type-trim can be found in the engine replacement data on Briggs & Stratton websites. 3.
Idle and Top No Load Adjustment Horizontal and Vertical Models 200000, 210000 1. Start engine and run until it reaches operating temperature. 2. Place throttle in SLOW position. 3. Hold throttle lever against idle speed screw, and, using Tachometer #19200 or #19389, adjust screw to obtain 1300 RPM. Release throttle lever. 1 4. Using Tang Bender #19229 or #19352, bend governed idle spring tang to obtain 1750 RPM (Figure 36).
2. Move equipment speed control to idle position. Adjust Valve Clearance 3. Turn idle screw to obtain 1750 RPM minimum. All Models - Except Vertical Models 110000, 120000 Early Production 4. Then turn idle mixture screw clockwise slowly until engine begins to slow. NOTE: Check valve clearance while the engine is cold. 5. Then turn screw opposite direction until engine just begins to slow. 6. Then turn screw back to midpoint (Figure 39). 1.
Vertical Models 110000, 120000 Early Production 1. Using a feeler gauge (A, Figure 42) adjust the locking hex nut (B) to obtain the correct clearance as listed in Section 12 Engine Specifications. 2. Repeat for other valve. 1 1 Figure 42 - OR 1. Loosen jam nut (A, Figure 43) at base of rocker arm stud. Then, using a feeler gauge (B), turn rocker arm screw (C) to obtain the correct clearance as listed in Section 12 - Engine Specifications. 2.
SECTION 2 - TROUBLESHOOTING SYSTEMS CHECK- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25 CHECK IGNITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 CHECK CARBURETION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 CHECK COMPRESSION - - - - - - - - - - - -
OIL GARD SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE WILL NOT START - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49 ENGINE STARTS AND RUNS WITH LOW OIL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50 2 2 24
SYSTEMS CHECK Most complaints concerning engine operation can be classified as one or a combination of the following: • Will not start • Hard starting • Lack of power • Runs rough • Vibration 2 2 • Overheating • High oil consumption The source of most of these symptoms can be determined by performing a systems check in the following order: Figure 1 1. Ignition 2. Carburetion 3. Compression This check-up can usually be done in a matter of minutes.
2) Check Carburetion 2 2 Before making a carburetion check, be sure the fuel tank has an ample supply of fresh, clean gasoline. Be sure the shutoff valve, if equipped, is open and fuel flows freely through the fuel line. If fuel fails to flow or is slow, check for plugged fuel cap vent, fuel line restriction or plugged fuel filter. Be sure throttle and choke controls are properly adjusted. If engine cranks but will not start, remove and inspect the spark plug.
4. Turn key switch ON. Meter should display battery voltage. If meter does not display battery voltage, the problem is with the solenoid wiring, equipment wire harness, or the keyswitch. Repair or replace as required. 3) Check Compression Use Leakdown Tester #19545 to check the sealing capabilities of the compression components. Follow the instructions provided with the tester to perform the leakdown test.
ELECTRICAL SYSTEMS Equipment Used for Testing 2 2 Digital Multimeter A digital multimeter is recommended for all electrical testing of Briggs & Stratton engines. The meter can be used to read volts, ohms, amperes, and to test diodes. The Fluke® Digital Multimeter #19464 and the UNI-T® Digital Multimeter #19581 are available from your Briggs & Stratton source of supply. NOTICE: The digital multimeters are equipped with fuses to prevent damage to the meter if the input limits are exceeded.
Alternator System Diagnosis Complaint Battery Not Charging Battery Overcharged Headlamps Not Working Electric Clutch Not Working (Tri-Circuit Alternator) Possible Causes • Engine RPM too low.
Alternator Identification The alternator systems installed on Briggs & Stratton OHV Engines can easily be identified by the color of the stator output wires and the connector. Alternator Type 2 2 Connector Color Alternator Output (at 3600 RPM *) Figure # DC Only Stator Output Wire(s) Color Black White .
1. 0.5 Amp DC Only (Figure 8) • Unregulated • Output at 2800 RPM • .5 Amps DC for charging battery • One black lead (A) from stator • White connector (B) output lead 2 2 Figure 10 4. Dual Circuit (Figure 11) Figure 8 2. 14 Volt AC Only (Figure 9) • 14 Volts AC for lighting circuit • One black lead from stator (A) • White connector (B) output lead • Unregulated Figure 9 3.
• One red lead (B) from regulator-rectifier to red connector output lead (A) • 10 and 16 Amp systems use the same stator, color coding and regulator-rectifier • Alternator output is determined by the flywheel alternator magnet size 2 2 Figure 12 Figure 14 6. 5/9 Amp DC (Figure 13) 8.
Flywheel Identification OHV single cylinder flywheels have a single ring of magnets which provide the magnetic field for the various alternator systems, except Model Series 97700, 99700, 121600, 126000 which use the magneto magnet. There are two sizes of flywheel magnets. The size of the magnet determines alternator output. The following table identifies the magnet size to be used with a specific alternator system. NOTICE: Do not use large-magnet flywheels with AC-only, DC-only, or Dual Circuit Alternators.
5. Attach BLACK test lead clip to positive (+) battery terminal. NOTE: Negative (-) battery terminal must be grounded. 2 2 Figure 18 Figure 17 6. With engine running at 3600 RPM, output should be between 2 to 4 Amps DC. • Output will vary with battery voltage. If battery voltage is at its maximum, output will be approximately 2 Amps. • If meter “Beeps” once, diode is OK. • If meter makes a continuous tone, diode is defective (shorted). • If meter displays “OL,” proceed to Step 4. 4. Reverse test leads.
Test Alternator Output 1. Insert RED test lead (A, Figure 19) into the V Ω receptacle in the meter. Test Alternator Output-AC 1. Insert RED test lead (A, Figure 20) into the V Ω receptacle in the meter. 2. Insert BLACK test lead (B) into COM receptacle. 2. Insert BLACK test lead (B) into COM receptacle. 3. Rotate selector to AC Volts position. 3. Rotate selector to AC Volts position. 4. Attach RED test lead clip to AC output terminal (C). 4. Attach RED test lead clip to AC output pin (C). 5.
2 2 Figure 21 6. With the engine running at 3600 RPM, output should be between 2 - 4 Amps DC. NOTE: The output will vary with the battery voltage. At maximum battery voltage the output will be approximately 2 Amps. 7. If NO or LOW output is found, test diode. Test Diode In the Diode Test position, the meter will display forward voltage drop across the diode(s). If voltage drop is less than 0.7 volts, meter will “Beep” once as well as display voltage drop.
resistor is bypassed allowing full output to the battery and clutch. The battery is not used for the lights, so lights are available even if the battery is disconnected or removed. Current for the lights is available when the engine is running. The output varies, so the brightness of the lights changes with engine speed. Test Alternator Output 1. Insert RED test lead (A, Figure 23) into the V Ω receptacle in the meter. 2. Insert BLACK test lead (B) into COM receptacle.
2. Insert BLACK test lead (B) into the COM receptacle in the meter. 3. Attach RED test lead clip to (D) of the WHITE wire (C). (It may be necessary to pierce wire with a pin as shown.) 4. Insert BLACK test lead (B) into harness connector. Test Alternator Output 1. Temporarily disconnect stator wire harness from the regulator-rectifier. 2. Insert RED test lead (A, Figure 26) into the V Ω receptacle in the meter. 3. Insert BLACK test lead (B) into COM receptacle. 4. Rotate selector to AC Volts position. 5.
1. Connect stator wire harness to regulatorrectifier. 2. Insert RED test lead into 10 Amp receptacle in meter. 3. Insert BLACK test lead into COM receptacle in meter. 4. Rotate selector to DC Amps position. 5. Attach RED test lead clip (A, Figure 27) to RED DC output terminal on regulatorrectifier. 6. Attach BLACK test lead clip (B) to positive (+) battery terminal. The stator and regulator-rectifier are the same for the 10 and 16 Amp systems. The system output is determined by the flywheel magnet size.
NOTICE: Connect test leads BEFORE starting the engine. Be sure connections are secure. If a test lead vibrates loose while engine is running, the regulator-rectifier may be damaged. and all connections are clean and secure. If there is still NO or LOW output, replace the regulator-rectifier. Use the DC Shunt #19468 (D, Figure 29) to avoid blowing the fuse in the test meter when testing the DC output of the 16 Amp system. The DC Shunt must be installed to the negative (-) terminal of the battery.
20 Amp DC Regulated Alternator The 20 Amp regulated alternator system provides AC current through two output leads to the regulator-rectifier. The regulator-rectifier converts the AC current to DC, and regulates current to the battery. The charging rate will vary with engine RPM and temperature. Test Alternator Output 1. Temporarily disconnect stator wire harness from regulator-rectifier. 2. Insert RED test lead into V Ω receptacle in meter. 3. Insert BLACK test lead into COM receptacle. 4.
2 2 Figure 32 5. Rotate selector to DC volts position. 6. With the engine running at 3600 rpm, the output should be 3-20 amps. 7. If no or low output is found, be sure that the regulator-rectifier is grounded properly and all equipment connections are clean and secure. If there is still no or low output, replace the regulator-rectifier.
ELECTRIC STARTERS Before assuming an electric starter requires service, check the engine for freedom of rotation by removing the spark plug and turning the crankshaft over by hand. Any belt, clutch, or other parasitic load will affect the starter cranking performance, so ensure their effects are minimized. The following list is given to aid in diagnosing problems for 12 Volt and 120 Volt starting systems. 1. Engine Cranks Slowly • Parasitic load affecting performance 4.
2 2 Figure 34 If the pinion gear sticks, clean the helix and gear with a mild solvent and compressed air. If the pinion continues to stick, replace the entire starter drive assembly. NOTE: Do not oil the pinion gear or helix. The starter motor clutch is designed to prevent damage from shock loads such as engine backfire. If clutch slips while cranking, replace the entire starter drive assembly. Test Starter Motor 1. Clamp starter motor test fixture in vise. 2.
Test Interlock Switch Wiring 1. Disconnect interlock switch wires from spade terminals on switch and at starter motor connection. 2. Set meter to Ohms position. 3. Connect one meter test lead to the end of one wire connector and other test lead to the opposite connector in the same wire (Figure 37). Meter should read low or no resistance.
3. Disconnect wire from tab terminal on solenoid. 4. Insert RED test lead into the V Ω receptacle in the meter and insert BLACK test lead into COM receptacle in the meter. 5. Set meter to Diode position. 6. Attach one meter test lead to each stud terminal (B,C) on solenoid. 2 2 Figure 38 5. Activate starter motor and note readings of meter and tachometer.Take reading after meter stabilizes (approximately 2-3 seconds). 6.
BATTERIES A 12 Volt, lead acid, wet cell battery is required to operate starter motors on Briggs & Stratton OHV single cylinder engines. This type is available as a wet charge or dry charge battery. The wet charged maintenance-free battery is filled with electrolyte and sealed at the time production. The level of electrolyte cannot be checked. The dry charge battery requires electrolyte to be added at the time the battery is placed in service.
2 2 Figure 40 Testing Battery Set the digital multimeter to DC volts position. Test the battery while installed in the equipment. 1. Disconnect wire from spark plug and ground ignition using Ignition Tester #19368. 2. Attach RED meter test clip to positive (+) battery terminal. Attach BLACK meter test lead to negative (-) battery terminal. 3. Turn switch to START. Meter should display 9 volts or more while cranking engine. If less than 9 volts, replace battery.
EQUIPMENT AFFECTING ENGINE OPERATION Frequently, what appears to be a problem with engine operation, such as hard starting or vibration, may be the fault of the equipment rather than the engine itself. Below are some common symptoms and potential equipmentrelated sources. Hard Starting or Will Not Start 1. Check for a loose drive belt or a loose blade, which will counteract engine cranking effort. 2. Check for parasitic load; disengage equipment controls before starting. 3.
On/Off Switch Light Does Not Flash 1. Check engine oil level. If low, add oil to bring to FULL mark on dipstick. 2. Try to start engine while shading ON/OFF switch light from bright light such as sunlight. If light does not flash, replace switch. If new switch still does not flash, go to next step. 3. Check wiring of ON/OFF switch. Wire from module with spade terminal should be on “L” terminal. RED ground wire should be on #3 terminal and BLACK wire from ignition armature should be on #2 terminal.
SECTION 3 - EXHAUST SYSTEMS SPARK ARRESTORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52 MUFFLER SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52 HORIZONTAL MODELS 110000, 120000, 150000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52 HORIZONTAL MODELS 200000, 210000 - - - - - - - - - - - - - - - - - - - - - - -
Some engines are equipped with exhaust systems (mufflers, brackets, and hardware) supplied by the OEM. Contact the OEM for muffler service information. Exhaust systems covered in this section are those supplied by Briggs & Stratton. WARNING Replacement parts must be the same and installed in the same position as the original parts or fire could result. 3 3 Spark Arresters WARNING Running engines produce heat. Engine parts, especially mufflers, become extremely hot.
Install Muffler and Guard 1. Coat threads of pipe with Valve Guide Lubricant #93963. Thread pipe into cylinder head exhaust port (A, Figure 5). 2. Coat exposed threads of elbow with Valve Guide Lubricant #93963. Install elbow (B) on pipe (C) and tighten securely with outlet straight out from cylinder head. 3 Figure 3 3 3. Remove screws (A, Figure 4) holding upper muffler bracket to lower muffler bracket. Figure 5 3.
3 Figure 7 3 Figure 9 3. Remove muffler support screws (A, Figure 10). Horizontal Models 200000, 210000 Shown is a typical muffler application (Figure 8). Figure 8 Remove Guard and Muffler 1. Remove screws (A, Figure 9) holding muffler guard to muffler. 2. Remove screw holding muffler guard to control bracket. Remove muffler guard and set aside. Figure 10 4. Remove the exhaust pipe screws, muffler assembly, and gaskets. Discard gaskets (Figure 11).
Horizontal Models 120000, 150000, 200000, 210000 (Snow Series) Shown are typical muffler applications (Figure 12 and Figure 13). 3 Figure 11 Inspect Exhaust System All exhaust system components must be inspected whenever the exhaust system is disassembled. Check muffler mounting bracket and/or muffler adapters for cracked welds or breakage. Check muffler for split seams, loose internal parts, or cracked welds. Replace any damaged parts with new OEM parts. Never reinstall broken or damaged components.
3. Install screws at exhaust pipe and torque to values listed in Section 12 - Engine Specifications. 4. Install muffler support screws and torque to values listed in Section 12 - Engine Specifications. 5. Lightly coat muffler guard mounting screws with Valve Guide Lubricant #93963. 3 Figure 14 6. Place muffler guard over muffler and install screws into control bracket and top of muffler. Torque to values listed in Section 12 - Engine Specifications. 3. Remove muffler support screws (A, Figure 15).
2. Remove screws holding muffler guard (A, Figure 18). Remove guard and set aside. 3 Figure 20 Figure 18 3. Remove dipstick and oil fill tube (A, Figure 19). 4. Remove blower housing and rewind starter (B). Inspect Exhaust System All exhaust system components must be inspected whenever the exhaust system is disassembled. Check muffler mounting bracket and/or muffler adapters for cracked welds or breakage. Check muffler for split seams, loose internal parts, or cracked welds.
7. Install blower housing and rewind starter. 8. Install oil fill tube and dipstick. 3. Remove adapter screws, adapter, and gaskets. Discard gaskets. 9. Lightly coat muffler guard mounting screws with Valve Guide Lubricant #93963. 10. Place muffler guard over muffler and start screws (A, B, C, Figure 22). Torque to values listed in Section 12 - Engine Specifications. 3 3 Figure 22 Vertical Models 210000, 280000, 310000, 330000 with Clamped Muffler Shown is a typical muffler application (Figure 23).
Install Muffler 1. Lightly coat muffler adapter screws with Valve Guide Lubricant #93963. 2. Install new gasket and adapter. Install screws (A, Figure 25) and torque to values listed in Section 12 - Engine Specifications. 3 3 Figure 25 3. Install muffler supports and start but do not tighten screws (A, B, C, Figure 26). 4. Slide muffler and muffler clamp on adapter. 5. Torque muffler support screws (A, B, C) to values listed in Section 12 - Engine Specifications. 6.
Vertical Models 280000, 310000, 330000 with Bolt-On Muffler Shown is a typical muffler application (Figure 27). Install Muffler 1. Lightly coat muffler adapter screws with Valve Guide Lubricant #93963. 2. Install new gasket and adapter. Install screws (A, Figure 29) and torque to values listed in Section 12 - Engine Specifications. 3 3 Figure 27 Remove Muffler 1. Remove muffler support screw (C, Figure 28). 2. Bend back tabs (A) on screw lock and remove mounting screws (B), muffler, and gasket.
SECTION 4 - FUEL SYSTEMS AND CARBURETION FUEL SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -62 FUEL PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63 FUEL FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64 FUEL TANKS AND SHUTOFF VALVES - - - - - - - - -
FUEL SYSTEMS WARNING Gasoline and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. 4 4 When adding fuel: • Turn engine OFF and let engine cool for at least 2 minutes before removing the fuel cap. • Fill fuel tank outdoors or in a well-ventilated area. • Do not overfill fuel tank. To allow for expansion of the gasoline, do not fill above the bottom of the fuel tank neck.
Fuel Pump The fuel pump, mounted near the blower housing and the air cleaner cover, allows remote fuel tank installations on some engines. The pump is operated by vacuum pulses from the engine. NOTE: The fuel pump itself is not serviceable. If the pump does not operate after inspection and proper installation, replace the pump. Removal 1. Close the fuel shut-off valve, if equipped. 4 2. Release clamps and disconnect fuel lines (A, Figures 1 and 2) and vacuum line (B) from the fuel pump (C). 3.
Fuel Filter Some engines are equipped with a fuel filter (Figure 3) mounted in-line between the fuel tank and the carburetor. Replace the filter annually or whenever fuel system service is performed. 4 Figure 4 4. Release hose clamp and disconnect fuel hose from carburetor fitting. 4 Figure 3 1. Drain the fuel tank or close the fuel shutoff valve, if equipped. 2. Slide the clamps away from the fuel filter. Twist and pull the fuel lines off of the fuel filter. Discard filter. 3.
Installation 1. Install tank support to tank. Slip fuel hose under governor link and spark plug wire through hole in support as tank is installed. Torque screws to values listed in Section 12 - Engine Specifications. 2. Assemble shut-off valve and fuel filter, if equipped, to fuel hose. 3. Install hose assembly to tank fitting and carburetor fitting with new clamps. 4. Install control panel/trim plate. Torque screws to values listed in Section 12 Engine Specifications. 5.
5. If necessary, remove two nuts from bracket and slide bracket off cylinder head studs. Inspection 1. Clean gummy or dirty fuel tanks with Briggs & Stratton Carburetor Cleaner #100041 or #100042, or equivalent. 2. Inspect fuel tank for: • Corrosion • Leaks 4 • Broken mounting brackets 3. Check fuel cap and filler neck for: • Proper seals • Vents • Functional quantity gauge (if equipped) 4 4. Check fuel filter for blockage of any kind. 5. Check fuel shut-off valve for proper operation.
CARBURETION Carburetor Identification • Figure 6 - LMS, Models 97700, 99700, 110000, 120000, 150000 Vertical and Horizontal Shaft • Figure 7 - ReadyStart®, Models 110000, 120000 Vertical Shaft • Figure 8, Figure 9 - LMT, Models 200000, 210000, 280000, 310000, 330000 Vertical and Horizontal Shaft 4 • Figure 10 - Nikki, Models 280000, 310000, 330000 Vertical Shaft • Figure 11 - Nikki LP / NG Mixer Gaseous Fueled Vertical Shaft Figure 8 4 Figure 6 Figure 9 Figure 7 Figure 10 67
Carburetor Service LMS Carburetor Vertical Models 97700, 99700, 110000, 120000 The exact type of LMS carburetor can be identified by a number stamped on the edge of the mounting flange (A, Figure 12). These carburetors have a fixed high-speed main jet and a non-adjustable idle mixture (except on early production models), and are available in manual/ remote choke or Choke-a-Matic® versions.
Discard the hinge pin, inlet needle, and seat. NOTE: On Model 97700, remove the main jet (A) and float disc (B) before removing the hinge pin, float, and needle. 4 Figure 13 4 Figure 15 3. Remove idle speed screw with spring (B, Figure 16). Remove limiter cap and idle mixture screw with spring, if equipped. Figure 14 4. Remove two carburetor mounting screws. 5.
Inspect and Clean Carburetor Components 1. Inspect openings in the carburetor body for evidence of wear or damage. If found, replace the entire carburetor assembly. 2. Inspect the choke shaft, choke valve, throttle shaft, and throttle valve for evidence of wear or damage. Replace parts as necessary. 2. Install new foam seal (B, Figure 18) on choke shaft (E), then slide shaft into carburetor body (C).
3. Place new gaskets or o-rings between control bracket (D, Figure 22), adapter (if equipped), and carburetor. 4. Position carburetor on control bracket or adapter and install screws (C). Torque to value listed in Section 12 - Engine Specifications. 4 Figure 20 6. Install new inlet needle (E, Figure 21) on float (D), then position float in carburetor body. Secure with new hinge pin (C) and center the pin between the float bosses. NOTE: On Model 97700, install the flat disc (B) and main jet (A).
4 Figure 25 Figure 24 Remove Carburetor 6. Connect fuel hose to carburetor and secure with clamp. 4 7. Using new gasket, install air cleaner assembly to carburetor per Section 1. Ensure breather hose is properly installed on the breather tube. 8. Adjust carburetor, if applicable, per Section 1. WARNING Before servicing the carburetor or other fuel system components, drain all fuel from the tank and turn OFF the fuel valve (if equipped). Do not attempt to stop fuel flow by plugging the fuel hose. 1.
the governor link from the grommet on top of the throttle shaft lever (B). Discard gasket. Disassemble Carburetor 1. Remove the fixed main jet (bowl nut) and fiber washer, then remove the fuel bowl and the bowl gasket from the carburetor body. Discard the fiber washer and the gasket. 2. Remove the float hinge pin (C, Figure 27), float (A), and inlet needle (B). If the needle has a metal tip, also remove the soft needle seat in the carburetor body. Discard the hinge pin, inlet needle, and seat.
edge of the plug with a non-hardening sealant. 4 Figure 31 Figure 29 2. Install new foam seal (B, Figure 30) on choke shaft (E), then slide shaft into carburetor body (C). Rotate shaft clockwise (A), and insert choke valve into slot until centered, with dimples (D) positioned as shown. Actuate the choke shaft to check for proper movement. 4 4. Install idle speed screw with spring, if equipped. 5.
7. Place new bowl gasket on carburetor body and install fuel bowl. Place new fiber washer on fixed main jet (bowl nut) and install. Torque to values listed in Section 12 - Engine Specifications. Install Carburetor NOTE: Always replace air cleaner gaskets and carburetor mounting gaskets any time the carburetor has been removed for service. 1. Hook z-bend of governor link into grommet on top of the throttle shaft lever.
5. Remove gasket (A, Figure 36), spacer, and o-ring between control bracket and carburetor (B). NOTE: Do not disassemble the carburetor body or linkages. Inspect and Clean Carburetor 1. Inspect openings in the carburetor body for evidence of wear or damage. If found, replace the entire carburetor assembly. 2. Inspect the choke shaft, choke valve, throttle shaft, and throttle valve for evidence of wear or damage. If found, replace the entire carburetor assembly. 4 3.
3. Place new gasket (A, Figure 39), spacer, and new o-ring between control bracket (B) and carburetor (C). 4. Position carburetor on control bracket and install screws. Torque to value listed in Section 12 - Engine Specifications. NOTE: Use new screws or apply Loctite® to original screws to prevent loosening from vibration. LMT Carburetor Horizontal and Vertical Models 200000, 210000, 280000, 310000, 330000 Two versions of this carburetor have been used (Figures 40 and 41).
Remove Carburetor 1. Disconnect wire(s) from the carburetor solenoid. Two styles of solenoids have been used (Figure 42). Figure 44 4 Figure 42 4 3. Remove float hinge pin, float, and inlet needle. Discard the hinge pin and inlet needle. 2. Remove air cleaner assembly per Section 1. Discard the gasket. 4. Screw a 1/4-20 tap into fuel inlet seat 3-4 turns and remove. 3. Move clamp and disconnect hose from carburetor. 5. Place a hex nut (A, Figure 45) and washer (B) on a 1/4-20 screw.
open position, then pull choke valve out of choke shaft. Remove choke shaft, return spring (when used), and foam seal. Discard seal. - OR If carburetor is equipped with a metal choke shaft, rotate choke shaft to closed position. Remove two choke valve screws and choke valve. Remove choke shaft, return spring and foam seal. Discard seal. 11. With a modified pin punch (A, Figure 46) remove welch plug (B) from carburetor body.
4. Install new throttle shaft seal (C, Figure 50) with sealing lip down in carburetor body until top of seal is flush with top of carburetor (D). Install new foam seal (B) on throttle shaft, then slide shaft into carburetor body. Rotate shaft until flat is facing out. Position throttle valve (E) on flat with numbers facing out, then install screws. Actuate the throttle shaft to check for proper movement. 4 Figure 48 4 - OR 3.
8. Install emulsion tube using Carburetor Screwdriver #19280 until tube seats (A, Figure 52). 4 Figure 53 Figure 52 9. Place new bowl gasket on carburetor body and install fuel bowl. Place new washer on solenoid and install. 10. After installing emulsion tube, use compressed air to blow out any chips or debris that may have been loosened while installing tube. NOTE: On Model Series 280000, 310000, 330000, install main jet after installing emulsion tube. 3.
Nikki Carburetor Vertical Models 280000, 310000, 330000 Disassemble Carburetor 1. Remove fuel bowl screws (A, Figure 56). Remove the fuel bowl (B) from the carburetor body. WARNING 4 Before servicing the carburetor or other fuel system components, drain all fuel from the tank and turn OFF the fuel valve (if equipped). Do not attempt to stop the fuel flow by plugging the fuel hose. Remove Carburetor 1. Disconnect the wire from the carburetor solenoid (E, Figure 55). 4 2.
4 Figure 58 6. If equipped, remove the idle mixture screw with spring (A, Figure 59) and the idle speed screw with spring (B). Figure 61 10. Remove the choke shaft, return spring, and foam seal. Discard spring and seal. 11. Remove the main jet and seal. 4 NOTE: Do not attempt to remove the pilot jets, which are pressed in and not serviceable. 12. Remove the welch plug (A, Figure 62) from the carburetor with a modified pin punch. Discard the welch plug. Figure 59 7.
• Choke shaft and choke valve • Throttle shaft and throttle valve • All passages, openings, and the inside and outside of the carburetor body NOTE: Do not soak non-metallic components, such as floats, o-rings, seals, or diaphragms, in carb/choke cleaner or they will be damaged. 4. If any passages remain plugged after cleaning, replace the component or the entire carburetor assembly. 4 4 Assemble Carburetor 1. Install new welch plug with pin punch of slightly smaller diameter than the plug.
NOTE: The holes in the throttle plate are offset. If the throttle plate is installed incorrectly, if will not close. 9. If equipped, install idle mixture screw with spring and the idle speed screw with spring. Turn each screw until the head of the screw touches the spring. 10. Insert new inlet needle (B) into the slot on the float (A, Figure 67). 11. Place the needle and float assembly into the fuel transfer tube. Secure with new hinge pin (C) and center the pin between the float bosses.
4 Figure 71 4. Hook choke link (C) into hole in choke lever. 5. Position carburetor on manifold and install screws or nuts by hand. 4 6. Actuate choke and throttle linkages to ensure proper movement, then tighten screws per values listed in Section 12 Engine Specifications. 7. Attach fuel hose to carburetor and secure with hose clamp. 8. Using new gasket, install air cleaner assembly per Section 1. 9. Connect wires to solenoid (E). 10. Adjust carburetor and/or governor settings per Section 1.
SECTION 5 - GOVERNOR SYSTEMS LINKAGE AND SPRING ORIENTATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -88 GOVERNED RPM LIMITS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -89 GOVERNOR SERVICE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -89 HORIZONTAL MODELS 110000, 120000, 150000, 200000 - - - - - - - - - - - - - - - - - - - - - - -
GOVERNOR SYSTEMS Linkage and Spring Orientation NOTE: Be sure to note hole position of linkage before removing. • Figure 1 - Horizontal Shaft Models 110000, 120000, 150000, 200000, 210000. • Figure 2 - Vertical Shaft Model 97700 • Figure 3 - Vertical Shaft Model 99700 5 • Figure 4 - Vertical Shaft Models 110000, 120000, 210000 (Primer Carburetors). • Figure 5 - Vertical Shaft Models 110000, 120000, 210000 (Choke-A-Matic® Carburetors).
If a governor spring must be replaced, consult the appropriate Illustrated Parts List for the correct part number. After a new governor spring is installed, check the engine top governed speed with an accurate tachometer, as noted above, and adjust as required. Governor Service Figure 6 Horizontal Models 110000, 120000, 150000, 200000, 210000 The mechanical governor is part of the crankcase cover. The governor gear (A, Figure 9) is driven by the crankshaft timing gear (B) through an idler gear (C).
2. Slide the governor lever on crank and finger-tighten bolt and nut until crank turns with a slight resistance. 3. Rotate crank until paddle is aligned with cup on governor gear assembly. 4. Install new crankcase cover gasket(s) of same thickness as originally removed from cylinder. 5. Place seal protector in oil seal and slide cover over crankshaft until it seats. NOTE: It may be necessary to rotate crankshaft to engage idler gear with timing gear. 5 Figure 10 Inspect Governor 1.
Vertical Models 97700, 99700, 110000, 120000, 210000, 280000, 310000, 330000 The mechanical governor is part of the oil slinger assembly (A, Figure 13) attached to the camshaft. The governor crank is mounted in the cylinder assembly. 5 Figure 15 3. Slide lever (B) off governor crank (C) and disconnect from governor link (D). Figure 13 Disassemble 1. Drain oil from engine. 2. Loosen governor lever nut (A, Figure 14, Figure 15). 4. Remove push nut or clip and washer (E) from governor crank.
6. Place seal protector in oil seal and slide sump over crankshaft until it seats. NOTE: It may be necessary to rotate crankshaft and cam gear to get oil pump (if equipped) to engage oil pump drive slot in cam gear. 5 7. Install sump screws in order shown in Figure 16 and Figure 17. Torque to values listed in Section 12 - Engine Specifications. NOTE: The screw at position four or position nine (Figure 16 or Figure 17) was factory coated with sealant.
SECTION 6 - CYLINDER HEAD AND VALVES SERVICE CYLINDER HEAD- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -94 HORIZONTAL AND VERTICAL MODELS 97700, 99700, 110000, 120000, 150000 - - - - - - - - - - - - - - - - - - - - - - 94 SERVICE CYLINDER HEAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -99 HORIZONTAL AND VERTICAL MODELS 200000, 210000, 280000, 310000, 330000 - - - - - - - - - - - - - -
CYLINDER HEADS AND VALVES Before the cylinder head can be removed, other external parts must be removed, such as the air cleaner, fuel tank, oil fill tube, blower housing, muffler, carburetor, control bracket assembly, and intake manifold. Remove Cylinder Head 6 Horizontal and Vertical Models 97700, 99700, 110000, 120000, 150000 1. Remove four screws (A, Figure 1 or 2) from rocker cover, then remove cover and gasket. Figure 3 6 Figure 1 Figure 4 Figure 2 Figure 5 2.
6 Figure 6 3. Remove push rods one at a time, marking the location and orientation of each for proper installation later. 4. Using a plastic scraping tool, carefully clean all traces of head gasket from the head and cylinder mating surfaces. Disassemble Cylinder Head 1. Loosen rocker arm screws and/or lock nuts (A, Figure 7 and 8), and remove from rocker arm studs. Remove rocker arms (B) and rocker balls from studs. Figure 8 2.
6 2. If head passes visual inspection, use Plug Gauge #19122 to check valve guides for wear. If gauge enters the guide 1/4” (6.4 mm) or more, replace the guide (models 97700, 99700) or replace the entire head (models 110000, 120000, 150000). If plug gauge is not available, see Section 12 Engine Specifications for the valve guide reject dimension. NOTE: To replace valve guides (models 97700, 99700), use Valve Guide Driver #19367 (A, Figure 10) to press out the guides.
6 Figure 13 4. Support valve side of cylinder head on clean shop rags. Place valve springs and valve spring retainers over valve stems. Using thumbs, press against each retainer until it securely locks into groove in valve stem (Figure 14). Figure 15 6 Figure 16 Figure 14 Install Cylinder Head 1. Coat threads of all cylinder head screws with Valve Guide Lubricant #93963. 2. Using a new head gasket, install cylinder head on cylinder and start screws by hand.
6 Figure 18 NOTE: Do not torque each screw in one step as it may result in a warped cylinder head. Steptorque all screws to approximately 1/3 of final torque value, then to 2/3 final torque value, then finish at final torque value. 6 3. Install push rod guide and rocker arm studs (models 97700, 99700). Torque studs to values listed in Section 12 Engine Specifications. -OR4. Install rocker arm studs (models 110000, 120000, 150000). Torque to values listed in Section 12 - Engine Specifications.
Remove Cylinder Head Models 200000, 210000, 280000, 310000, 330000 1. Remove four screws from rocker cover, then remove cover and gasket (A, Figure 20). 6 Figure 21 2. Remove the rocker arm studs. Figure 20 2. Remove cylinder head screws, then remove head and gasket from cylinder. 3. Using thumbs, press down on each valve spring retainer and disengage retainer (A, Figure 22) from valve stem (B). Remove retainers, springs, valves, and intake valve stem seal/washer, if equipped. 3.
mm) or more, replace the entire head. If plug gauge is not available, see Section 12 - Engine Specifications for the valve guide reject dimension. 3. If guides are replaced, or the original guides still meet specifications, use Finish Reamer #19066 and Reamer Guide #19191 to ensure proper sizing and to clean out the guides. Thoroughly clean all reaming debris from cylinder head. 6 4. Inspect valves for wear or damage. Replace if necessary.
4. Install push rods through guides and into same positions as removed. Ensure rods are seated in valve tappets. Place valve stem caps (if used) on valve stems (Figure 29). 6 Figure 26 Figure 29 5. Place rocker arms and rocker balls on rocker arm studs. Install rocker arm screws and/or lock nuts on studs and tighten until there is zero clearance between the valve stem caps and the rocker arms. Figure 27 6 6. Rotate crankshaft at least twice to ensure proper movement of the push rods and rocker arms.
6 6 102
SECTION 7 - STARTERS REWIND STARTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 REMOVE BLOWER HOUSING / STARTER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 HORIZONTAL MODELS 110000, 120000, 150000, 200000, 210000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 VERTICAL MODELS 97700, 99700- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
REWIND STARTERS On some engines, the rewind starters are attached to the blower housing with screws and can be quickly removed. 7 Other starters are riveted or spot welded to the blower housing and must be drilled to remove, following the procedures below. For installation, screws and nuts are available separately from the Illustrated Parts List and are included with complete replacement starters. Figure 2 Remove Blower Housing / Rewind Starter Horizontal Models 110000, 120000, 150000, 200000, 210000 1.
7 Figure 4 5. Carefully drill through all rivet heads and remove rewind starter. Do not allow drill bit to cut into the holes in the starter housing. Figure 6 4. Remove screws (D, Figure 7) and screw and spacer (E), then remove tank from engine. NOTE: Do not attempt to drill out the rivets while the blower is still on the engine. The rivets are made of steel and the shavings will collect on the flywheel magnets. Vertical Models 110000, 120000 1. Drain fuel tank or close fuel shut-off valve.
5. If rewind starter is riveted, carefully drill through all rivet heads and remove rewind starter. Do not allow drill bit to cut into holes in the starter housing. NOTE: Do not attempt to drill out the rivets while the blower is still on the engine. The rivets are made of steel and the shavings will collect on the flywheel magnets. 7 Service Rewind Starter Figure 8 6. Carefully drill through all rivet heads and remove rewind starter. Do not allow drill bit to cut into the holes in the starter housing.
Inspect Rewind Starter Parts NOTE: Do not remove the spring from the pulley. Both parts are serviced only as an assembly. 1. Inspect the pulley for wear, cracks, rough edges, or burrs in the rope groove and look for wear in the center hole. If wear or damage is found, replace the pulley and spring assembly. 2. Inspect the spring for broken ends, kinks, or burrs. If damage is found, replace the pulley and spring assembly. 3.
Vertical Models 97700, 99700 1. Install the screws to the blower housing (D, Figure 11), torquing screws to values listed in Section 12 - Engine Specifications. 2. Install the oil fill tube and dipstick (C). 7 Figure 13 2. Install screws (D, Figure 14) and spacer (E), then install tank from engine. Torque screws to values listed in Section 12 Engine Specifications. Figure 11 3.
5. Fill fuel tank or open fuel shut-off valve. Connect fuel hose to carburetor and connect spark plug wire. Service Starter Clutch Some Vertical model 280000s utilized a sealed starter clutch on the rewind starters. The starter clutch assembly consists of a seal (A, Figure 18), ratchet (B), clutch housing (C), retainer cover (D), and 6 ball bearings (E). 7 Figure 16 Vertical Model 280000 1.
2. Wipe off any excess oil from the top of the ratchet, then place the ratchet on the housing. 3. Install the retainer cover and seal over the ratchet and press into housing until fully closed. Install retaining screws (if used). 4. Place one drop of clean engine oil on top of crankshaft pilot, then install clutch on crankshaft. Using the Starter Clutch Wrench and Flywheel Strap Wrench, tighten the clutch to the value listed in Section 12 - Engine Specifications.
Remove Starter Drive and Clutch 1. Remove E-ring (A, Figure 20). 2. Remove three screws (B) holding gear cover. 3. Lift clutch assembly and gears from shaft. 12 Volt Starters Check Starter Drive and Clutch When starter switch is activated, pinion gear should engage the ring gear and crank engine. The clutch should not slip during engine cranking and pinion gear shouldn’t bind on the helix. NOTE: Do not oil the pinion gear or helix. 1. Remove the starter from the engine. 2.
7 Figure 24 2. Remove retainer (A, Figure 24), return spring (B), flat washer (C), wave washer (D), pinion gear (E), and starter clutch (F). Figure 26 2. Install pinion gear (C, Figure 26) with beveled edge of teeth up. Install return spring (D) into recess of pinion gear. 7 Figure 25 Figure 27 Assemble Starter Motor Drive - C-Ring Retainer 1. Place clutch on starter shaft (A, Figure 25). Rotate clutch until it drops into place (B). 112 3.
7 Figure 28 Figure 30 4. Place new C-ring over chamfered end of shaft. 5. Align one of the slots (G, Figure 28) of CRing Installer #19435 with open end of Cring (H). 6. Press on tool until C-ring snaps into groove in shaft. 7. Manually actuate pinion gear on helix to ensure proper movement. 7 Figure 31 2. Remove retainer (B), washer (C), pinion gear (D), and starter clutch (E) from starter shaft. Figure 29 Disassemble Starter Drive - Roll Pin Retainer 1.
Assemble Starter Drive - Roll Pin Retainer 1. Place clutch (E, Figure 31) on starter shaft and rotate clutch until it drops into place. 7 Figure 32 2. Install pinion gear (D) with beveled edge of teeth up. 3. Place washer (C) and retainer (B) on starter shaft. 4. Press new roll pin (A) through retainer slot and starter shaft hole until pin is centered in shaft. 5. Manually actuate pinion gear on helix to ensure proper movement. 7 120-Volt Starters The 120-Volt AC starter motors are not serviceable.
SECTION 8 - LUBRICATION SYSTEMS EXTENDED OIL FILL AND DIPSTICK- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -116 BREATHERS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -116 HORIZONTAL MODELS 110000, 120000, 150000, 200000, 210000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -116 VERTICAL MODELS 97700, 99700, 110000, 120000 - - - - - - - - - - - - - - - - - - - - - -
EXTENDED OIL FILL AND DIPSTICK Horizontal Models 110000, 120000, 150000, 200000, 210000 These models use a plastic extended oil fill tube and a quarter-turn dipstick. The oil fill tube screws into the crankcase cover. Vertical Models 90000, 110000, 120000, 210000, 280000, 310000, 330000 These models use a plastic extended oil fill tube and a quarter-turn, dipstick. An o-ring seals the tube in the crankcase cover and a retaining bracket and screw secure it to the engine.
8 Figure 2 Figure 3 Check Breather 1. Check for movement of the disc valve in the breather assembly. If disc is stuck or binding, replace the breather assembly. Install Breather 1. Install new breather passage gasket and breather passage cover on top of cylinder. Torque four screws to values listed in Section 12 - Engine Specification. 2. Visually inspect the assembly for warping, wear, or damage. If these conditions are found, replace the breather assembly. 3.
NOTE: Do not apply force to the wire gauge! The disc valve is retained by an internal bracket which will be distorted if pressure is applied to disc. 8 date code 070719xx) or clean off sealant (after date code 070718xx). Figure 6 Figure 4 Install Breather 1. Place new gasket and breather assembly on cylinder. Torque to screws to values listed in Section 12 - Engine Specifications. Check Breather 1. Remove and check breather reed (A, Figure 7).
Install Breather 1. Install reed with the metal tab facing outside of the engine, as shown in Figure 8. Torque screw to values listed in Section 12 - Engine Specifications. values listed in Section 12 - Engine Specifications. 3. Securely install breather tube in breather cover. 2. Place new gasket or sealant on cylinder. Install breather cover and torque screws to LUBRICATION SYSTEMS Four types of lubrication systems are available: 1. Oil Dipper on connecting rod. 2. Oil Slinger on governor gear. 3.
Oil Slinger with Pressure Filtration Vertical Models 120000, 210000, 280000, 310000, 330000 Some of these models are equipped with a gerotor pump that draws oil from the sump, pumps it through the oil filter, and back to the sump (Figure 11). The gerotor pump is driven by the cam gear. The slinger splashes oil throughout the crankcase. NOTE: This system does not supply oil under pressure to any of the bearing surfaces.
Figure 15 2. Carefully remove inner (C) and outer rotors (D). 8 Figure 17 Current oil pump screen must be driven out from inside the sump (Figure 18). NOTICE: Depending on Model Series, inner rotor may include the drive shaft or the drive shaft may be a separate part. Remove shaft, when it is a separate part. Remove Pump Screen Three types of oil pump screens have been used on models 280000, 310000, 330000.
Inspect Oil Pump Parts 1. Inspect surfaces of outer and inner rotors, pump housing, cover, and shaft for wear and scoring. Replace parts if necessary. 2. Inspect pump housing and passages for debris. Clean as required. 3. Inspect screen for clogging or damage. Replace as necessary. 8 Install Screen and Gerotor Pump 1. Install pump screen until fully seated, or secure with screw, depending on design. 2. Insert drive shaft, if removed separately. 3.
8 Figure 24 Inspect 1. Check adapter for cracks or damage to the sump and filter mounting surfaces. Replace adapter if necessary. 2. Clean all oil passages in adapter and in sump. Install 1. Using new gasket, place adapter on sump and install screws. Torque screws to values listed in Section 12 - Engine Specifications. 2. Apply a thin film of clear oil filter gasket. Install filter until gasket contacts the adapter, then tighten 1/2 to 2/3 turn more.
The engine can be restarted, but will only run briefly. 8 Figure 27 There are two types of Oil Gard systems in use: • Start Sense • Run Sense Identification Start Sense is designed to prevent the engine from starting if the oil level is too low. It will not start an engine that is already running. Type of Starter Lead Wire Colors Rewind Gray/Gray Yellow/Black Electric Yellow/Yellow Run Sense will stop a running engine if the oil level runs below the ADD level on the dipstick.
SECTION 9 - CYLINDERS, COVERS AND SUMPS CYLINDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126 INSPECT CYLINDER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126 RECONDITIONING BORE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126 RESIZING BORE- - - - - - - -
CYLINDER Inspect Cylinder 1. Visually check cylinder for cracks, stripped threads, and bore damage. • If cracks are found, replace the cylinder. • Stripped threads can sometimes be repaired using a helicoil, but if multiple holes have thread damage, replace the cylinder. Compare measurements to the standard cylinder bore sizes provided in Section 12 - Engine Specifications. If the cylinder bore is more than 0.003” (0.08 mm) oversize, or 0.0015” (.04 mm) out of round, it must be resized.
Cleaning Cylinder 1. Wash the cylinder thoroughly in a solvent such as kerosene or other commercial solvent. 2. Wash cylinder again using a stiff brush with soap and hot water. 3. Rinse cylinder thoroughly with hot running water. When cylinder and crankcase have been thoroughly cleaned, use a clean white rag to wipe the cylinder bore. If honing grit is still present, it will appear as a grey residue on the rag. Re-wash and rinse entire cylinder then check again.
replace the affected cylinder, crankcase cover, or sump (Figure 6). NOTE: Standard and reject sizes for the main bearings are shown in Section 12 - Engine Specifications. 9 Model Series 110000 120000 All 150000 H/S 210000 H/S 210000 V/S 280000 V/S 310000 V/S 330000 V/S PTO Bearing Tools Bushing Cylinder Driver Support Replace Crankcase Cover or Sump Replace Crankcase Cover 19179 19227 Replace Sump Replace Sump Replace Sump Replace Sump Figure 8 Figure 6 Replace Bearings Replace DU™ Bearings 1.
9 Figure 10 5. Place cylinder or cover/sump on cylinder support (B, Figure 11) with large opening facing bearing. 6. Align oil holes in bearing with oil holes in cylinder or cover/sump, then press in new bearing to correct depth with bushing driver (A). Figure 11 7. Stake bearing into notch (A, Figure 12) with 1/8” round pin punch to prevent bearing from turning. Figure 12 Replace Ball Bearing Horizontal Models 120000, 150000 1. Select tools needed from charts below.
9 Figure 13 3. Assemble washer (C, Figure 14) to puller screw (D) and insert through large end of removal driver (B). Place open end of support (A) against ball bearing. 4. Insert screw with washer and driver through ball bearing and thread into support. Continue tightening screw until ball bearing is removed. Figure 15 NOTE: Always install new oil seals when engine is reassembled or when replacing bearings. Always use the correct seal protector to prevent damaging the oil seal during installation.
4. Insert screw, with washer and driver through the ball bearing and thread into support. Continue tightening screw until ball bearing is removed. Bearing Removal Tools Tool/Part Tool/Part # Description Washer 690582 Puller Screw 19318 Removal Driver 19401 Removal Support 19454 Bearing Installation Tools Tool/Part Tool/Part # Description Washer 690582 Puller Screw 19318 Installation Driver 19396 Installation Support 19454 Figure 16 5. Lubricate outside diameter of new ball bearing.
NOTE: Always install new oil seals when engine is reassembled or when replacing bearings. Always use the correct seal protector to prevent damaging the oil seal during installation. 9 Figure 19 COVERS AND SUMPS Installation 1. Select correct seal protector for Kit #19356, to protect oil seal when installing cover or sump. 2. Make sure mechanical governor gear and oil pump (when used) is engaged with cam gear. Do not force cover or sump. 3.
9 Figure 22 Figure 23 9 Figure 24 133
9 9 134
SECTION 10 - CRANKSHAFTS, CAMSHAFTS, BALANCING SYSTEMS, AND GEAR REDUCTIONS CRANKSHAFTS AND CAMSHAFTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -136 REMOVE CRANKSHAFT AND CAMSHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -136 INSPECT CRANKSHAFT AND CAMSHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -136 INSTALL CRANKSHAFT AND CAMSHAFT - - - - - - -
CRANKSHAFTS AND CAMSHAFTS Remove Crankshaft and Camshaft 1. Drain oil from engine and all fuel from fuel tank. Drain oil from gear reduction unit (if equipped) and remove from engine (A, Figure 1). 2. Remove blower housing/rewind assembly and flywheel/fan assembly. 10 3. Remove burrs and clean crankshaft, then remove crankcase cover or sump. Set aside. NOTE: If crankcase cover or sump sticks, tap lightly with soft hammer on alternate sides near dowel pins (B). It is not necessary to remove dowel pins. 6.
7. On horizontal crankshaft engines, make sure the paddle on the governor shaft (B, Figure 6) is rotated in line with the governor cup inside the crankcase cover. 8. On vertical crankshaft engines, assemble governor gear/oil slinger (B, Figures 7 and 8) to camshaft. Make sure the paddle on the governor shaft is contacting the governor cup (C). 10 Figure 4 Figure 6 Figure 5 2. Using a dial caliper, measure the journal diameters and cam lobes.
Install Crankcase Cover or Sump 1. Using a new gasket install crankcase cover or sump using seal protectors. Do not force cover or sump on cylinder. NOTE: It may be necessary to rotate crankshaft to get oil pump (if equipped) to engage drive slot in camshaft. For horizontal crankshafts, it may be necessary to rotate idler gear to mesh with timing gear when installing cover. 2. Install screws in sequence shown in Figures 9, 10, 11, and 12.
Check and Adjust Crankshaft End Play When crankcase cover or sump is installed with a standard gasket, end play should match values listed in Section 12 - Engine Specifications. If end play is less than specified, remove cover or sump and install an additional gasket. Do not use more than two gaskets. If end play is more than specified, remove cover or sump and install a shim per the Illustrated Parts List, or replace the cover or sump.
GEAR REDUCTION Disassemble Gear Reduction 1. Note orientation of gear reduction assembly on engine. Place an oil collection pan beneath the assembly. 2. Remove oil vent plug (C, Figure 17) and set aside. 3. Loosen four cap screws (D) that secure the gear case cover assembly. Pull cover (A) away from gear case (B) and allow oil to drain into pan. 10 4. After gear case is drained, remove screws and cover. Inspect Gear Reduction Parts 1. Inspect seals for cracks, tears, or hardening.
Fill Gear Case with Lubricant 1. Remove oil level plug (C, Figure 22) and vent plug (A). 2. Fill gear case with SAE oil: • Above 40°F (10°C) use 80w90 for Horizontal Models 120000, 150000. • Above 40°F (10°C) use 30w for Horizontal Models 200000, 210000. • Below 40°F (10°C) use 10w30 for all gear reductions. 3. Fill gear case just to the point of overflowing at the oil level hole (B). Figure 20 10 4. Install and tighten both plugs securely.
AUXILIARY PTO 10 Some models of the vertical shaft 110000 and 120000 engines were equipped with an auxiliary PTO shaft. The auxiliary PTO shaft (E, Figure 23) extends through the side of the sump, perpendicular to the crankshaft. Rotation can be either clockwise or counterclockwise, as viewed from the end of the shaft. The oil slinger (A), camshaft (C), and worm gear (D) are preassembled and must be serviced as a set.
COUNTERBALANCE SYSTEMS Two styles of counterbalance systems are used on Vertical crankshaft engines. Models 280000 and 310000 (built before July 2001) have the Synchro-Balance® system. Models 280000 and 310000 built July 2001 and later, and all models 210000 and 330000 have the AVS® system. Both systems use a counterweight that oscillates opposite the direction of the piston, to reduce engine vibration (Figure 25). Disassemble 1. Remove crankshaft gear (A, Figure 26).
Assemble 1. Lubricate all bearing surfaces with clean engine oil. 2. Slide magneto-side counterweight (A, Figure 28) on flywheel end of crankshaft. 3. Place crankshaft and counterweight in a vise with soft jaws or shop rags to protect magneto journal. 4. Slip link (C) over dowel pin (D) with rounded edge (E) up. Fit dowel pin into magneto counterweight. 10 5. Slide PTO counterweight (F) on dowel pin and crankshaft eccentric (G). 6.
AVS® Balance System Remove 1. Remove blower housing, flywheel, cylinder head, and sump. Discard gaskets. 2. Remove connecting rod and piston assembly. 3. Remove crankshaft and counterweight assembly. Disassemble 1. Remove the crankshaft gear (F, Figure 30) from the crankshaft (A). If the gear is tight, pry it off using two screwdrivers, being careful not to damage the gear. 2. The woodruff key (E) can be removed, if required. 3.
10 10 146
SECTION 11 - PISTONS, RINGS AND CONNECTING RODS REMOVE PISTON AND CONNECTING ROD- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -148 DISASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -148 INSPECT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -148 ASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
PISTONS, RINGS, & CONNECTING RODS Remove Piston and Connecting Rod 1. Carefully remove any carbon or ridge at top of cylinder bore to prevent ring breakage. 4. Using Piston Ring Expander #19340 (Figure 3), remove rings one at a time. Note the order and orientation of the rings before removal. 2. Remove rod bolts and connecting rod cap (A, Figure 1). 3. Push piston and rod assembly out through top of cylinder bore.
Engine Specifications. If clearance is greater than shown the piston must be replaced. Check Connecting Rod If the crankpin bearing (A, Figure 6) or the piston pin bearing (B) is scored, the rod must be replaced. 1. Reinstall rod cap and bolts on rod. 2. Using a dial caliper or plug gauge, measure the two bearing diameters. Compare with reject dimensions listed in Section 12 - Engine Specifications. If either bearing exceeds the reject dimensions, the rod must be replaced. 3. Remove rod bolts and rod cap.
NOTE: For Vertical Model 120000 ONLY, install piston with notch or arrow (A, Figure 8) facing away from “MAG” on the rod. When installed in engine, the notch will face the PTO. 9 Figure 9 Figure 8 3. Install a pin retainer into groove on open side of piston pin bore. Ensure retainers are firmly seated in grooves. 4. Using Piston Ring Expander #19340, install oil ring and spring expander, then the center ring, then the top ring.
SECTION 12 - ENGINE SPECIFICATIONS MODEL 110000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -152 MODEL 120000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -154 MODEL 150000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -156 MODEL 200000 HORIZONTAL SERIES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
MODEL 110000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base / Backplate Armature Blower Housing Bracket to Carburetor (Snow) Carburetor Bowl Screw Carburetor to Cylinder Head Connecting Rod Control Bracket Control Panel Trim Crankcase Cover Cylinder Head Cylinder Head Plate Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Flywheel Guard Fuel Tan
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round .876 in. (22.25 mm) .5008 in. (12.72 mm) 2.688 in. (68.28 mm) N/A .878 in. (22.30 mm) .5040 in. (12.80 mm) 2.692 in. (68.38 mm) .0015 in. (.04 mm) .249 in. (6.32 mm) .247 in. (6.28 mm) .247 in. (6.28 mm) .267 in. (6.78 mm) .244 in. (6.20 mm) .244 in. (6.20 mm) 1.063 in. (27.00 mm) .501 in. (12.72 mm) 1.065 in. (27.05 mm) .504 in. (12.80 mm) 1.098 in. (27.89 mm) .874 in. (22.20 mm) 1.
MODEL 120000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base / Backplate Armature Blower Housing Bracket to Carburetor (Snow) Carburetor Bowl Screw Carburetor to Cylinder Head Connecting Rod Control Bracket Control Panel Trim Crankcase Cover Cylinder Head Cylinder Head Plate Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Flywheel Guard Fuel Tan
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round .876 in. (22.25 mm) .5011 in. (12.72 mm) 2.970 in. (75.44 mm) N/A .878 in. (22.30 mm) .5040 in. (12.80 mm) 2.974 in. (75.54 mm) .0015 in. (.04 mm) .249 in. (6.32 mm) .247 in. (6.28 mm) .247 in. (6.28 mm) .267 in. (6.78 mm) .244 in. (6.20 mm) .244 in. (6.20 mm) 1.063 in. (27.00 mm) .501 in. (12.72 mm) 1.065 in. (27.05 mm) .504 in. (12.80 mm) 1.098 in. (27.89 mm) .874 in. (22.20 mm) 1.
MODEL 150000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base / Backplate Armature Blower Housing Bracket to Carburetor (Snow) Carburetor Bowl Screw Carburetor to Cylinder Head Connecting Rod Control Bracket Control Panel Trim Crankcase Cover Cylinder Head Cylinder Head Plate Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Flywheel Guard Fuel Tan
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round .876 in. (22.25 mm) .5011 in. (12.72 mm) 2.970 in. (75.44 mm) N/A .878 in. (22.30 mm) .5040 in. (12.80 mm) 2.974 in. (75.54 mm) .0015 in. (.04 mm) .249 in. (6.32 mm) .247 in. (6.28 mm) .247 in. (6.28 mm) .267 in. (6.78 mm) .244 in. (6.20 mm) .244 in. (6.20 mm) 1.063 in. (27.00 mm) .501 in. (12.72 mm) 1.065 in. (27.05 mm) .504 in. (12.80 mm) 1.098 in. (27.89 mm) .874 in. (22.20 mm) 1.
MODEL 200000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base / Backplate Armature Blower Housing Bracket to Carburetor (Snow) Carburetor Bowl Screw / Solenoid Carburetor to Cylinder Head Connecting Rod Control Bracket Control Panel Trim Crankcase Cover Cylinder Head Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Flywheel Guard Fuel Tank Governor
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round .876 in. (22.25 mm) .5011 in. (15.88 mm) 2.688 in. (65.10 mm) N/A .878 in. (22.30 mm) .504 in. (12.80 mm) 2.691 in. (68.33 mm) .0015 in. (.04 mm) .249 in. (6.32 mm) .247 in. (6.28 mm) .247 in. (6.28 mm) .267 in. (6.78 mm) .244 in. (6.20 mm) .244 in. (6.20 mm) 1.063 in. (27.00 mm) .501 in. (12.72 mm) 1.065 in. (27.05 mm) .504 in. (12.80 mm) 1.098 in. (27.89 mm) .874 in. (22.19 mm) 1.
MODEL 210000 HORIZONTAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base / Backplate Armature Blower Housing Bracket to Carburetor (Snow) Carburetor Bowl Screw / Solenoid Carburetor to Cylinder Head Connecting Rod Control Bracket Control Panel Trim Crankcase Cover Cylinder Head Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Flywheel Guard Fuel Tank Governor
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round 1.1825 in. (30.03 mm) .5011 in. (12.72 mm) 3.300 in. (83.82 mm) N/A 1.184 in. (30.07 mm) .5040 in. (12.80 mm) 3.304 in. (83.92 mm) .0015 in. (.04 mm) .236 in. (5.99 mm) .234 in. (5.93 mm) .234 in. (5.93 mm) .240 in. (6.10 mm) .233 in. (5.92 mm) .233 in. (5.92 mm) 1.1825 in. (30.03 mm) .501 in. (12.72 mm) 1.184 in. (30.07 mm) .504 in. (12.80 mm) 1.2485 in. (31.71 mm) 1.1795 in. (29.
MODELS 97700 & 99700 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Alternator Air Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base Alternator Armature Blower Housing Breather Brake Bracket Carburetor Bowl Nut Carburetor to Cylinder Head Connecting Rod Crankcase Sump Cylinder Head Cylinder Head Plate Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Fuel Tank (Side) Fuel Tank (Top) Governor Lever Nut Muff
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round .876 in. (22.25 mm) .625 in. (15.88 mm) 2.563 in. (65.10 mm) N/A .878 in. (22.30 mm) .622 in. (15.80 mm) 2.567 in. (65.20 mm) .0015 in. (.04 mm) .249 in. (6.32 mm) .247 in. (6.28 mm) .247 in. (6.28 mm) .267 in. (6.78 mm) .244 in. (6.20 mm) .244 in. (6.20 mm) 1.063 in. (27.00 mm) .501 in. (12.72 mm) 1.065 in. (27.05 mm) .504 in. (12.80 mm) 1.123 in. (28.53 mm) .874 in. (22.19 mm) 1.
MODEL 110000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Elbow Alternator Armature Blower Housing Breather Brake Bracket Carburetor Bowl Nut Connecting Rod Crankcase Sump Cylinder Head Cylinder Head Plate Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Fuel Tank (Side) Fuel Tank (Top) Governor Lever Nut Muffler To Cylinder Head Oil Drain Plug Rewind Starter Rocker Ball
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round .876 in. (22.25 mm) .5011 in. (12.72 mm) 2.688 in. (68.28 mm) N/A .878 in. (22.30 mm) .504 in. (12.80 mm) 2.692 in. (68.38 mm) .0015 in. (.04 mm) .249 in. (6.32 mm) .247 in. (6.28 mm) .247 in. (6.28 mm) .267 in. (6.78 mm) .244 in. (6.20 mm) .244 in. (6.20 mm) 1.063 in. (27.00 mm) .501 in. (12.72 mm) 1.065 in. (27.05 mm) .504 in. (12.80 mm) 1.123 in. (28.53 mm) .874 in. (22.19 mm) 1.
MODEL 120000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Elbow Alternator Armature Blower Housing Breather Brake Bracket Carburetor Bowl Nut Connecting Rod Crankcase Sump Cylinder Head Cylinder Head Plate Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Fuel Tank (Side) Fuel Tank (Top) Governor Lever Nut Muffler To Cylinder Head Oil Drain Plug Rewind Starter Rocker Ball
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round .876 in. (22.25 mm) .5011 in. (12.72 mm) 2.688 in. (68.28 mm) N/A .878 in. (22.30 mm) .504 in. (12.80 mm) 2.692 in. (68.38 mm) .0015 in. (.04 mm) .249 in. (6.32 mm) .247 in. (6.28 mm) .247 in. (6.28 mm) .267 in. (6.78 mm) .244 in. (6.20 mm) .244 in. (6.20 mm) 1.063 in. (27.00 mm) .501 in. (12.72 mm) 1.065 in. (27.05 mm) .504 in. (12.80 mm) 1.123 in. (28.53 mm) .874 in. (22.19 mm) 1.
MODEL 210000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base Alternator Armature Blower Housing Breather Breather Reed Carburetor to Intake Manifold Carburetor Solenoid Connecting Rod Control Bracket Crankcase Sump Cylinder Head Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Fuel Pump Fuel Tank Fuel Tank Bracket Governor Lever Nut Intake Manifold
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round 1.3795 in. (35.04 mm) .5011 in. (15.88 mm) 3.437 in. (87.30 mm) N/A 1.383 in. (35.13 mm) .504 in. (12.80 mm) 3.441 in. (87.40 mm) .0015 in. (.04 mm) .237 in. (6.02 mm) .235 in. (5.97 mm) .235 in. (5.97 mm) .240 in. (6.10 mm) .233 in. (5.92 mm) .233 in. (5.92 mm) 1.6265 in. (41.31 mm) .501 in. (12.72 mm) 1.629 in. (27.05 mm) .504 in. (12.80 mm) 1.4985 in. (38.06 mm) 1.3775 in. (34.
MODEL 280000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base Alternator Armature Blower Housings Blower Housing Brackets Breather Carburetor to Intake Manifold Carburetor Solenoid Connecting Rod Control Bracket Crankcase Cover Cylinder Head Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Fuel Pump Governor Lever Nut Intake Manifold to Cylinder Hea
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round 1.3795 in. (35.04 mm) .5011 in. (15.88 mm) 3.437 in. (87.30 mm) N/A 1.383 in. (35.13 mm) .504 in. (12.80 mm) 3.441 in. (87.40 mm) .0015 in. (.04 mm) .237 in. (6.02 mm) .235 in. (5.97 mm) .235 in. (5.97 mm) .240 in. (6.10 mm) .233 in. (5.92 mm) .233 in. (5.92 mm) 1.3795 in. (35.03 mm) .501 in. (12.72 mm) 1.383 in. (35.13 mm) .504 in. (12.80 mm) 1.098 in. (27.89 mm) 1.3775 in. (35.
MODEL 310000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base Alternator Armature Blower Housings Blower Housing Brackets Breather Carburetor to Intake Manifold Carburetor Solenoid Connecting Rod Control Bracket Crankcase Sump Cylinder Head Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Fuel Pump Governor Lever Nut Intake Manifold to Cylinder Head
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round 1.3795 in. (35.04 mm) .5011 in. (15.88 mm) 3.563 in. (90.50 mm) N/A 1.383 in. (35.13 mm) .504 in. (12.80 mm) 3.567 in. (90.60 mm) .0015 in. (.04 mm) .237 in. (6.02 mm) .235 in. (5.97 mm) .235 in. (5.97 mm) .240 in. (6.10 mm) .233 in. (5.92 mm) .233 in. (5.92 mm) 1.063 in. (27.00 mm) .501 in. (12.72 mm) 1.065 in. (27.05 mm) .504 in. (12.80 mm) 1.4982 in. (38.05 mm) 1.3775 in. (35.
MODEL 330000 VERTICAL SERIES ENGINE SPECIFICATIONS Armature Air Gap Crankshaft End Play Spark Plug Gap Valve Clearance – Intake Valve Clearance – Exhaust FASTENER TORQUE SPECIFICATIONS Air Cleaner Base Alternator Armature Blower Housing Breather Carburetor to Intake Manifold Carburetor Solenoid Connecting Rod Control Bracket Crankcase Sump Cylinder Head Cylinder Shield Exhaust Manifold / Adapter Flywheel Nut Flywheel Fan Fuel Pump Governor Lever Nut Intake Manifold to Cylinder Head Muffler Oil Drain Plug –
REJECT DIMENSIONS CYLINDER STANDARD SIZE REJECT SIZE Main Bearing Camshaft Bearing Bore Diameter Bore Out-Of-Round 1.6248 in. (41.27 mm) .5011 in. (15.88 mm) 3.701 in. (94.01 mm) N/A 1.629 in. (41.38 mm) .504 in. (12.80 mm) 3.705 in. (94.11 mm) .0015 in. (.04 mm) .237 in. (6.02 mm) .235 in. (5.97 mm) .235 in. (5.97 mm) .240 in. (6.10 mm) .233 in. (5.92 mm) .233 in. (5.92 mm) 1.6248 in. (41.27 mm) .501 in. (12.72 mm) 1.629 in. (41.38 mm) .504 in. (12.80 mm) 1.6235 in. (41.24 mm) 1.6235 in. (41.
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