Briggs and Stratton Vanguard Engine Manual 272144 - Watermarked
Briggs and Stratton Vanguard Engine Manual 272144 - Watermarked
Briggs and Stratton Vanguard Engine Manual 272144 - Watermarked
For - Vanguard
Briggs V-Twin
& Stratton Discount Parts Call 606-678-9623 or 606-561-4983
To go to the beginning of each section,
click below. TABLE OF CONTENTS
To go back to Table of Contents, click on
"Bookmark" to the left
SAFETY, MAINTENANCE AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . Section 1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5
STARTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 7
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• Start and run engine outdoors. • Operate equipment with guards in place.
• DO NOT start or run engine in enclosed area, • Keep hands and feet away from rotating
even if doors or windows are open. parts.
• Inhalation of high concentrations of vapor, • Tie up long hair and remove jewelry.
even for short periods can cause uncon-
sciousness or might prove fatal. • DO NOT wear loose-fitting clothing,
dangling drawstrings or items that could
• Inhalation may cause irritation to the nose and become caught.
throat, headache, nausea vomiting, dizziness,
and drowsiness.
• Unconsciousness or asphyxiation may result
in poorly ventilated areas or confined spaces.
WARNING
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For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983
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. The first digit after the displacement indicates the BASIC DESIGN SERIES, relating to cylinder
construction, ignition, general configuration, etc.
C. The second digit after the displacement indicates ORIENTATION OF CRANKSHAFT.
D. The third digit after the displacement indicates TYPE OF BEARINGS, and whether or not the
engine is equipped with REDUCTION GEAR or AUXILIARY DRIVE.
E. The last digit indicates the TYPE OF STARTER.
BRIGGS & STRATTON MODEL NUMBERING SYSTEM
FIRST DIGIT SECOND DIGIT THIRD DIGIT FOURTH DIGIT
AFTER DISPLACEMENT AFTER DISPLACEMENT AFTER DISPLACEMENT AFTER DISPLACEMENT
A B C D E
PTO BEARING,
REDUCTION GEAR,
CUBIC INCH BASIC CRANKSHAFT AUXILIARY DRIVE,
DISPLACEMENT DESIGN SERIES ORIENTATION LUBRICATIONă TYPE OF STARTER
ă6 0 0 to 4 - Horizontal Shaft 0 - Plain Bearing/DU 0 - Without Starter
ă8 1 5 to 9 - Vertical Shaft NonĆFlange Mount 1 - Rope Starter
ă9 2 A to G - Horizontal Shaft 1 - Plain Bearing 2 - Rewind Starter
10 3 Flange Mounting
11 4 H to Z - Vertical Shaft 3 - Electric Starter Only
2 - Sleeve Bearing 110 or 230 Volt Gear
12 5 Flange Mounting
13 6 Drive
Splash Lube 4- Electric Starter/110 or
16 7
18 8 3 - Ball Bearing 230 Volt Gear Drive
19 9 Flange Mounting with Alternator
20 A to Z Splash Lube 5- Electric Starter Only
21 4 - Ball Bearing 12 or 24 Volt Gear
22 Flange Mounting Drive
23 Pressure Lubrication 6- Alternator Only
24 5 - Plain Bearing
25 7- Electric Starter
Gear Reduction 12 or 24 Volt Gear
28 (6 to 1) CCW Rotation
29 Drive with Alternator
Flange Mounting
30 8- Vertical Pull Starter or
6 - Ball Bearing Side Pull Starter
31 Gear Reduction
32 (2 to 1) CCW Rotation 9- Mechanical Starter
35 A- Electric Starter
38 7 - Plain Bearing
Pressure Lubrication 12 or 24 Volt Gear
40 Drive with Alternator
42 8 - Plain Bearing and Inverter
43 Auxiliary Drive (PTO)
44 Perpendicular to
46 Crankshaft
47 9 - Plain Bearing
52 Auxiliary Drive
54 Parallel to Crankshaft
58 A - Plain Bearing
Pressure Lubrication
Without Oil Filter
EXAMPLE - To identify Model 303447:
30 3 4 4 7
30 Cubic Inch Design Series 3 Horizontal Shaft Ball Bearing Electric Starter
Flange Mounting 12 or 24 Volt Gear Drive
Pressure Lubrication with Alternator
TYPE 1234Ć01, The type number identifies the engines mechanical parts, color of paint, decals, governed speed, and Original
Equipment Manufacturer.
CODE 01061201, The code is the manufacturing date and is read as follows:
YEAR MONTH DAY ASSEMBLY LINE AND MANUFACTURING PLANT
01 06 12 01
Revised 4/04
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DANGER
Fuel Recommendations
AVOID INJURY! Gaseous fuel
systems should only be worked
on in a very well ventilated area.
Gasoline Engines
• Use clean, fresh regular unleaded gasoline with a • Many state, county and city governments
minimum of 85 octane. Fresh fuel prevents gum require that service be performed ONLY
from forming in the fuel system or on essential outdoors.
carburetor parts. Purchase fuel in a quantity that • Have a fan blowing across the engine BEFORE
can be used within 30 days. loosening fuel line connections!
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The following maintenance schedule is a general guide. See the Engine Operating & Maintenance Instructions
for details on specific engine models.
* Change oil after the first 5 to 8 hours of operation (break-in period), then after every 50 hours or every season.
NOTE: #1 – Change oil every 25 hours when operating under heavy load or in high temperatures.
NOTE: #2 – Clean more often under dusty conditions or when airborne debris is present. Replace air cleaner
parts when dirty.
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ÌÌ
WARNING Ì
AVOID FIRES!
1. Remove cover (1), knob (2), plate (3), and air 4. Squeeze dry in a clean cloth. Set aside.
cleaner cartridge (4) with pre-cleaner (5), Fig. 1
or Fig. 2. 5. Inspect cartridge. Replace if damaged or dirty.
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Fig. 4
2. Remove cartridge (4) and pre-cleaner (5) from CAUTION: DO NOT clean or oil these filters.
cover. DO NOT use pressurized air to clean or dry filters.
3. Wash pre-cleaner in liquid detergent and water. REPLACE filters if damaged or dirty
CAUTION: DO NOT use petroleum solvents to NOTE: DO NOT remove the safety filter (2) as part
clean paper cartridge. of the inspection.
DO NOT oil paper cartridge. If it is necessary to remove the safety filter,
DO NOT use pressurized air to clean or dry paper Fig. 5, be sure all debris is removed from the
cartridge. air cleaner housing before removal.
Replace the safety filter with every third
6. Install pre-cleaner in cover with foam toward replacement of the primary filter, or if
cover. (Nylon screen toward paper element.) damaged or dirty.
8. Reinstall cover assembly on air cleaner body. 6. Reinstall air cleaner cover.
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Initial Adjustment
Fig. 5 1. Turn idle mixture screw (1), Fig. 7, CLOCKWISE
until it just seats. DO NOT FORCE.
2. Turn valve COUNTERCLOCKWISE 1-1/4
ARMATURE AIR GAP ADJUSTMENT turns.
This setting will permit engine to start. Final adjust-
1. Loosen screws holding armature in place. Slide
ment will be made with engine running.
armature away from flywheel and tighten one of
the screws.
NOTE: Parts removed for clarity.
2. Rotate flywheel until magnet is under armature
laminations.
Fig. 7
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ÌÌ
ÌÌ
ÌÌ
Fig. 8 Fig. 10
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Fig. 12 Fig. 14
Fig. 13
b. Press limiter into position using Knock Out
Pin, #19135 (6) as shown.
Fig. 15
11. With equipment control lever in SLOW position 4. Turn idle mixture screw slowly CLOCKWISE (3)
and engine running at governed idle, use Tang until engine speed just starts to slow (LEAN
Bender, #19352 (9), to bend throttle restrictor mixture), Fig. 16.
tang (8) so that tang just contacts governor lever
(10), Fig. 14. 5. Then turn idle mixture valve COUNTERCLOCK-
WISE (5) until engine speed just starts to slow
12. Move equipment control to FAST position. (RICH mixture).
Engine should accelerate smoothly.
6. Turn valve to mid point (4) between RICH and
LEAN.
Re-adjust idle mixture valve 1/8 turn richer if
necessary. 7. Re-adjust idle speed to 1750 RPM.
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ÌÌ
Ì
ÌÌ
Ì
Fig. 16
Final Adjustment
Carburetor adjustments performed with engine run-
ning must be made with the air cleaner correctly
installed.
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Fig. 19
5. Then turn idle mixture screw (3) COUNTER-
CLOCKWISE 3/8 turn, Fig. 20. Fig. 21
6. Adjust idle mixture screw for #2 cylinder as a. Position limiter cap (8) so that stop on limiter
described in steps 4 and 5. cap is at mid point between stops on carbu-
retor body. Press limiter into position using
7. If necessary, re-adjust idle speed screw to RPM Knock Out Pin #19135 (7) as shown in,
shown below. Fig. 22.
a. 1200 RPM – Governed Idle Spring #805453 b. Repeat for other idle mixture valve.
(RED).
b. 900 RPM – Governed Idle Spring #805454
(WHITE).
8. Release throttle lever. Note RPM.
Fig. 22
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WARNING
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ÌÌ
Ì
2. Remove the panel (2).
Ì
Ì Ì
Ì
Fig. 28
Fig. 26
Fig. 29
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Fig. 35
Fig. 33
3. Use Tool #19352 (1) to bend throttle restrictor
4. Refer to Service Engine Sales Microfiche, tang (4) so that it just contacts governor lever (5),
MS-6225 or the Service Engine Sales Manual, Fig. 36.
MS-4052, for Top No-Load RPM by engine
Model and Type Number.
5. Move control throttle lever to FAST position and
check engine RPM.
6. Use Tool #19352 (1) to bend tang (6) UP (7) to
increase and DOWN (8) to decrease engine
speed, to obtain desired Top No-Load RPM,
Fig. 34.
NOTE: Air cleaner removed for clarity.
Fig. 36
NOTE: Be sure the governor spring is installed in #1
hole in governor lever (9), Fig. 37.
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Fig. 40
10. Engage fixed speed adjustable control nut (8)
and adjust to Regulated No-Load RPM for the
type of generator listed in Table 1, Fig. 41.
a. Turn nut CLOCKWISE (10) to increase
speed.
b. Turn nut COUNTERCLOCKWISE (9) to
decrease speed.
NOTE: Final adjustment should be made with
generator loaded to rated capacity or to
manufacturer’s specifications.
Fig. 42
Start engine. Run for approximately 5 minutes to
allow engine to warm up.
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Fig. 43 Fig. 45
Oil Cooler
7. With equipment control lever in SLOW position Some engines are equipped with an oil cooler,
and engine running at governed idle RPM, use Fig. 46. The oil cooler is mounted on the blower
Tang Bender #19352 (1), and bend throttle housing. Filtered oil is routed through the oil cooler
restrictor tang (7) so that tang just contacts through two oil lines from a special oil filter adapter.
governor lever (8), Fig. 44. Forced air from the flywheel fan flows through the oil
cooler fins dissipating heat from the engine oil.
The oil cooler fins should be cleaned every 100
hours, checked periodically for debris, and cleaned
with compressed air or a soft bristle brush.
Fig. 44
Fig. 46
8. Refer to Service Engine Sales Microfiche,
MS-6225 or the Service Engine Sales Manual,
MS-4052, for Top No-Load RPM by engine Spark Plugs
Model and Type Number. Replace spark plugs every 100 hours of operation or
every season, whichever occurs first. Replace spark
9. Move control throttle lever to FAST position and plugs if electrodes are burned away, or if the
check engine RPM. porcelain is cracked.
10. Bend tang (8) with Tool #19352 (1) to obtain de- NOTE: Do not blast-clean spark plugs. Spark plugs
sired top no-load RPM, Fig. 45. should be cleaned by scraping or hand wire
brushing and washing in a commercial
solvent.
NOTE: Engine Model 303447 Type 0411-01 – Set
Use a wire gauge (1) to set spark plug gap, Fig. 47.
Top No-Load Speed to 2900 RPM 50
RPM. Torque spark plugs to 180 in. lbs. (20 Nm).
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Fig. 47
Models 540000, 610000 2. Use a feeler gauge (1) to measure the valve
clearance. Valve clearance should be 0.005”
(0.13 mm) for the intake and exhaust valve.
Resistor spark plug recommended by Briggs &
Stratton:
NOTE: Measure valve clearance with the engine
COLD.
• B&S #692051
3. If the valve clearance requires adjustment,
Gap to 0.020” (0.51 mm). loosen the lock nut (2) with a wrench (4). Use a
hex wrench (5) to turn the adjusting screw (3) to
adjust the valves, Fig. 49.
Speed Control Wire Adjustment 4. With the valve clearance correctly adjusted,
hold the adjusting screw. Torque the lock nut to
70 in. lbs. (8 Nm).
NOTE: Manual friction and remote control 5. Repeat for No. 2 cylinder.
adjustment procedure is identical.
1. Loosen control casing clamp screw (1) at
governor control bracket, Fig. 48.
2. Move speed control lever to FAST position (in-
set, Fig. 48).
3. Move control casing and wire until governor
control swivel is at end of travel.
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OVERHAUL PROCEDURE
The following Overhaul Procedure is intended to help you to establish a systematic method of repairing Briggs
& Stratton OHV engines. These steps may be performed in a different order but best efficiency is obtained when
the repairs are performed in the same sequence every time. The exact procedure will vary according to the engine
model being repaired. Be careful to locate the instructions covering the specific model being repaired.
Disassemble
1. Drain oil. Remove oil filter. 12. Electric starter.
2. Remove spark plugs. 13. Breather. Valve covers and valley cover.
5. Rewind starter (if equipped). 17. Valves, springs and seals. Inspect valve guides
and seats.
6. Exhaust manifold, muffler(s). 18. Check crankshaft end play. Remove burrs from
7. Intake manifold and carburetor. crankshaft extension.
8. Check throttle shaft and bushings for wear. 19. Crankcase cover. Inspect bearings. Remove oil
seal.
9. Disassemble carburetor. 20. Cam gear and tappets. Inspect governor.
10. Check armature air gap. Remove armatures. 21. Connecting rods and pistons.
11. Flywheel. 22. Inspect crankshaft.
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6. Reface and lap valves and seats. 17. Check and adjust mechanical governor.
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Ignition If the engine runs, but misses under load, test the
ignition by installing an Ignition Tester #19368 (2)
Test Using Electric Starter between the spark plug lead (1) and each spark plug
(3), Fig. 2. A spark miss will be readily apparent
NOTE: MagnetronR ignition systems require a when the engine is running. If the spark appears
minimum of 350 RPM to produce spark. good in the tester but the engine misses, check for
a fouled spark plug.
WARNING
AVOID ELECTRICAL SHOCK!
• A partially sheared flywheel key will affect
ignition timing and engine performance.
• Spark can still occur with a sheared flywheel
key. A severe shock or kickback hazard may
exist.
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Compression
Compression Test
Briggs & Stratton does not publish compression
pressures, as it is difficult to obtain an accurate
reading without special equipment. An assessment
of the engine’s compression can be made as follows:
Remove both spark plugs and insert a compression
gauge into either cylinder (one cylinder at a time).
Turn engine over with engine starter until there is no
further increase in gauge pressure reading. Record
this reading. Repeat procedure on other cylinder and
Fig. 3 record that reading. Divide the difference between the
cylinders by the compression pressure of the higher
of the two cylinders. A difference over 25% between
Carburetion the cylinders indicates a loss of compression in the
cylinder with lower pressure. See example below.
NOTE: Gaseous fuel engines use carburetors that
must be serviced by a certified gaseous fuel
installer or by a certified dealer for the equip- Engine #1 Engine #2
ment powered. Cylinder #1 65 PSI 75 PSI
If plugs are wet, look for – 3. Burned valves, burned and/or loose valve seats
1. Overchoking 4. Insufficient valve clearance
2. Excessively rich fuel mixture 5. Warped cylinder head
3. Water in fuel 6. Warped valve stems
4. Float needle valve stuck open 7. Worn bore and/or rings
5. Plugged air cleaner 8. Broken connecting rods
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The alternator systems installed on Briggs & Stratton OHV V-Twin Cylinder Engines can be identified by the color
of the stator output wires and the connector.
TABLE 1
5 Amps AC (Lights)
AC Only Black White 35
Unregulated
5 Amps + DC (Charging)
Tri-Circuit Black Green 38
5 Amps – DC (Lights)
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NOTE: Does NOT include engines with the Power- Digital Multimeter
Linkt system. The Digital Multimeter #19464, Fig. 8, is available
from your Briggs & Stratton source of supply. The
The V-Twin flywheels have a ring of magnets (1) on Digital Multimeter can be used to read volts, ohms,
the inside of the flywheel, Fig. 7, that provides the amperes, and to test diodes.
magnetic field for the charging systems. The size of
the magnet determines the alternator output.
Fig. 8
DC Shunt
The Digital Multimeter will withstand DC input of 10
- 20 amps for up to 30 seconds. When checking DC
Fig. 7 output on 16 and 20 amp regulated systems, use the
DC Shunt #19359, Fig. 9, to avoid blowing a fuse in
the Multimeter.
Table 2 identifies the magnet size used with the
different charging systems. NOTE: The Digital Multimeter is equipped with two
TABLE 2 fuses to prevent damage to the meter if the
input limits of the meter are exceeded.
Check the fuses if the meter displays a read-
Alternator Small Large 20A Fly- ing of 0.00 when testing DC output (V==).
Magnet Magnet wheel Refer to the FLUKE Operators Manual for
this procedure. Replacement fuses, Part #
Magnet Size 7/8 X 7/8 X 1-3/32 X
19449, are available from your Briggs &
21/32” 29/32” 29/32” Stratton source of supply.
(22 X 17 (22 X 23 (27 X
mm) mm) 23mm)
AC Only S
DC Only S
Dual Circuit S
Tri-Circuit S
Regulated 5 A S
Regulated 9 A S
Regulated 10 A S
Regulated 16 A S
Regulated 20 A S Fig. 9
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AC Alternator
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2
ÌÌ
1. Stator assembly (1), Fig. 12.
Diode Test
NOTE: The battery MUST be in good condition to 2. Insert BLACK test lead (2) into COM receptacle
perform this test. in meter.
WHEN CHECKING ALTERNATOR COM-
PONENTS, PERFORM THE TEST IN THE 3. Rotate selector to +))))) (DIODE TEST) position.
FOLLOWING SEQUENCE:
4. Attach RED test lead clip to point A and BLACK
test lead clip to the stator output lead (3), Fig. 14.
1. Insert RED test lead into 10A receptacle in (It may be necessary to pierce the wire with a pin
meter. as shown.)
2. Insert BLACK test lead into COM receptacle. a. If meter BEEPS once, diode is OK.
3. Rotate selector to A== (DC amps) position. b. If meter makes a CONTINUOUS TONE,
diode is defective (shorted). Replace diode.
4. Attach RED test lead clip (1) to DC output
c. If meter displays OL proceed to step 5.
terminal, Fig. 13.
5. Reverse test leads.
5. Attach BLACK test lead clip to POSITIVE (+)
battery terminal (2). a. If meter BEEPS once, diode is installed
backwards. Replace diode.
6. With engine running at 3600 RPM, output should
be 2 - 4 amps DC. b. If meter still displays OL, diode is open.
Replace diode.
NOTE: The output will vary with the battery voltage. 6. If diode tests OK, check stator for bare wires or
If the battery is at maximum voltage the out- other obvious defects. If bad or grounded leads
put will be approximately 2 amps. are not visible, replace the stator.
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A
Fig. 15
Fig. 14
DC Output Test
NOTE: The battery MUST be in good condition to
NOTE: Service replacement diode harnesses are perform this test.
available. Use resin core solder when
1. Insert RED test lead into 10A receptacle in meter.
installing new harness. Use shrink tubing or
tape all connections. 2. Insert BLACK test lead into COM receptacle in
DO NOT USE CRIMP CONNECTORS. meter.
3. Rotate selector to A== (DC AMPS) position.
4. Attach RED test lead clip (1) to DC output pin (6)
Dual Circuit Alternator in connector (4), Fig. 16.
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2
ÌÌÌ
a pin as shown.)
Ì
a. If meter BEEPS once, diode is OK.
b. If meter makes a CONTINUOUS TONE,
diode is shorted. Replace diode.
c. If meter displays OL, proceed to step 5.
5. Reverse test leads.
a. If meter BEEPS once, diode is installed
backwards. Replace diode.
b. If meter still displays OL, diode is open.
Replace diode.
6. If diode tests OK, check stator for bare wires or
other obvious defects. If grounded leads are not
visible, replace the stator. Fig. 18
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Connector (3).
3. Rotate selector to V~ (AC VOLTS) position. 4. Attach BLACK test lead clip (2) to point A of the
RED wire (3), Fig. 21. (It may be necessary to
4. Attach RED test lead clip (1) to output terminal pierce wire with a pin as shown.)
(GREEN connector), 20.
5. Insert RED test lead (1) into harness connector.
5. Attach BLACK test lead clip (2) to engine a. If meter BEEPS once, diode is OK.
ground. b. If meter makes a CONTINUOUS TONE,
diode is shorted. Replace harness.
6. With engine running at 3600 RPM, output should
be no less than 28 VOLTS AC. c. If meter displays OL proceed to step 6.
6. Reverse test leads.
7. If NO output or LOW output is found, replace
stator. a. If meter BEEPS ONCE, diode is installed
backwards. Replace harness.
8. If alternator output is good, test the diodes in the b. If meter still displays OL, diode is open.
wiring harness. Replace harness.
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2
A
A
Fig. 21
Fig. 22
NOTE: Service replacement diode harnesses are
available. Fig. 23
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2
ÌÌ
3. Insert RED test lead (1) into V receptacle in
meter. Connect to RED post terminal (3) on
shunt, Fig. 28.
4. Insert BLACK test lead (2) into COM receptacle
in meter and connect to BLACK post terminal (5)
on shunt.
5. Rotate selector to 300mV position.
6. With the engine running at 3600 RPM, the output
should be:
• 3-10 Amps – 10 Amp System
• 3-16 Amps – 16 Amp System
NOTE: The amperage produced depends on
battery voltage. If the battery is below 11
Fig. 27 volts, the output would be 10 or 16 amps
depending on the alternator system being
5. With the engine running at 3600 RPM output tested. The amperage will be less at
should be no less than: maximum battery voltage.
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Required tools:
• Digital Multimeter, Tool #19464
• PowerLinktTest Box, Tool #19528
1. Test the GFCI (previous procedure).
2. Test the parking brake interlock switch.
3. Test the PowerLinkt reset (ON-OFF) switch on
the tractor.
4. Check alternator output.
Testing the GFCI With the meter in the +))))) (DIODE TEST) position,
and the test leads attached to the grounds, a
1. The engine must be running with the parking CONTINUOUS TONE indicates CONTINUITY
brake (1) set and the PTO DISENGAGED. (complete circuit). NO TONE indicates NO
2. Plug in a trouble light or radio to confirm that CONTINUITY (open circuit). Open circuits are
electrical power is present. displayed as OL.
1. Insert RED test lead into V receptacle in meter.
3. Press the GFCI test button (1) to trip the GFCI,
Fig. 34. 2. Insert BLACK test lead into COM receptacle.
If the device is still being powered the GFCI is NOT 3. Test for continuity between the inverter case and
working correctly. Replace the GFCI. the engine frame, Fig. 35.
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Fig. 36
The meter should display BATTERY VOLTAGE. If Testing PowerLinkt Alternator Output
the meter does not display battery voltage there is a
problem with the equipment wiring or the interlock NOTE: It may be necessary to remove the inverter
switch. Refer to the equipment repair manual. from the equipment.
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– +
9V
Fig. 39
Plunger should retract freely.
When battery connection is removed, plunger
Fig. 38 should return.
3. Set Digital Multimeter (2) to read AC Volts. Replace solenoid if plunger sticks or doesn’t move.
NOTE: Model 350400 with Mikuni carburetor:
4. Insert meter test leads into either receptacle in
With 9 volt battery applied to solenoid, apply
test box.
finger pressure to tip of solenoid. The tip
5. Start engine. Set speed to 1800 RPM. must be retracted manually approximately
0.030” (0.8 mm) before the solenoid will
NOTE: DO NOT exceed 1800 RPM. energize.
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2
WARNING
Equipment Wiring Test
1. With key switch OFF, disconnect equipment Batteries give off explosive gasses!
wiring harness connector (1) from engine wiring DO NOT smoke. Sparking can
harness. ignite nearby flammable gasses,
resulting in explosion and/or fire.
2. Attach RED meter test lead (2) into equipment
wiring harness connector (1) (side opposite • DO NOT store, charge or service a battery near
raised rib). an open flame or any device that uses a pilot
light or creates sparks.
3. Attach BLACK test lead to a good ground, Fig. 41. • Before servicing the battery, disconnect the
NEGATIVE (–) battery cable first, then
4. Turn key switch ON. Meter should display disconnect the POSITIVE (+) battery cable.
Arcing can occur when improperly
battery voltage.
disconnecting battery cables.
If meter does not display battery voltage, the
problem is with the equipment wiring harness. If The typical battery used is a 12 volt, lead acid, wet
meter displays battery voltage, test engine harness. cell type. This battery is available as a maintenance-
free or a dry-charged battery.
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KEY SWITCH
7. Turn switch to START. Meter should display 9
volts or more when cranking engine. If less than
AC
OUTPUT 2 3 9 volts, replace battery.
WIRES
4
DC OUTPUT 1 5
WIRE 8. With battery fully charged, check specific gravity
6 readings of each cell (2) with a hydrometer (1) and
REGULATOR
RECTIFIER record readings, Fig. 43. All readings should be
SOLENOID TAB
TERMINAL above 1.250 (compensating for temperature). If
STARTER specific gravity readings vary .50 or if all cells read
TERMINAL
less than 1.225, replace battery.
HEAD SOLENOID
LIGHT BATTERY
SWITCH TERMINAL
- +
STARTER
12 VOLT MOTOR
HEAD
LIGHTS BATTERY
Fig. 42
Test Battery
Fig. 43
1. Physical check – clean if necessary.
a. Corrosion Charge Indicator Test
b. Dirt • SYMPTOM: Charge Indicator Light Will Not Light
– Key Switch ON – Engine Not Running
c. Terminal and clamps (secure-good condition)
To identify whether the problem is related to the
2. Bring battery to full charge.
regulator/rectifier or the charging indicator wiring
system, the test procedure must be followed in the
CAUTION: DO NOT exceed a charge rate of
sequence listed.
1/10 ampere for every ampere of battery
rating! A known good battery is required for this test.
Consult battery manufacturer for charging
recommendations. NOTE: Verify alternator and regulator/rectifier out-
Overcharging may cause battery failure. put before testing the charging indicator
system.
a. Use a taper charger (automatically reduces Output values are the same as the 10 amp
charge rate). and 16 amp system.
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Fig. 46
Engine Wiring
1. With key switch OFF, re-connect equipment
wiring harness to engine wiring harness.
Disconnect harness at solenoid.
2. Insert RED meter test lead (2) into GRAY wire
(1) in solenoid connector. Fig. 47
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2
GROUND WIRE
HARNESS
CARBURETOR
SOLENOID
DIODE DIODE
ENGINE HARNESS
_ +
2 3 EQUIPMENT
4 SWITCH
1 5
6
Won’t Run
(No Spark) 2 Closed Diodes
Engine Runs
Engine Won’t Shut Off 2 Open Diodes
(Both Cylinders)
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Test Switch
Oil Pressure – measured @ 70º F (21º C): 4. Meter must indicate CONTINUITY between
terminals with key switch in position shown. See
• 10~50 psi (0.7~3.5 Bar) number sequence of terminals shown in Fig. 50.
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2
OFF
1+3+6
RUN
2+5+6
START
2+4+5
2 3 2 3
4 4
1 5 1 5
6 6
OFF RUN
4
1 5
6
START
Terminal Positions
Fig. 50
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Wiring Diagram For Starter Panel & Key Switch For V-Twin Engines
ANTI-AFTERFIRE STOP
SOLENOID SWITCH
2 3
WHITE BLACK
4
1 5
KEY SWITCH
6
RED
REGULATOR-
RECTIFIER
ORANGE YELLOW
WIRES SUPPLIED BY
EQUIPMENT MANUFACTURER
SOLENOID
– +
STARTER MOTOR
12 VOLT BATTERY
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2
Troubleshooting
CAUTION: Do not clamp motor housing in a vise
If a starting problem is encountered, check the or strike with a hammer. Starter motors contain
engine to eliminate it as the cause of the problem. ceramic magnets that can be damaged if the motor
Check the engine for freedom of rotation by housing is hit, deformed or dented.
removing the spark plugs and turning the crankshaft
over slowly by hand. 3. The DC Shunt (6) MUST be installed on the
Test the battery, see page 47. NEGATIVE (-) battery terminal as shown in
Fig. 51.
Engine Cranks Slowly 4. Insert RED test lead (4) into V receptacle in
a. Additional load affecting performance (see meter. Connect to RED post terminal on shunt.
above). 5. Insert BLACK test lead (3) into COM receptacle
b. Faulty electrical connection (battery circuit). in meter. Connect to BLACK post terminal on
c. Discharged battery (also see alternators). shunt.
d. Dirty or worn starter motor commutator, 6. Rotate selector to 300mV position.
bearing, weak magnets, etc.
7. Connect a lead from the POSITIVE (+) battery
e. Worn brushes or weak brush spring. terminal to the connector on the starter.
f. Wrong oil viscosity for temperature
expected. NOTE: If an optional starter switch (2) is NOT USED
g. Battery leads too long or wire too small. connecting the POSITIVE lead will activate
the starter motor.
h. Battery too small.
8. Activate the starter motor. Note reading on
Engine Will Not Crank meter and RPM on tachometer (1).
a. Faulty safety interlocks.
b. Discharged or defective battery. NOTE: Take reading after meter stabilizes (approxi-
mately 2 – 3 seconds).
c. Faulty electrical connections.
d. Faulty starter motor switch (open circuit). 9. A starter motor in good condition will be within
e. Open circuit in starter motor. specifications listed.
f. Brushes sticking, etc. • Minimum RPM – 6500
g. Faulty solenoid. • Maximum Amperes – 35
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Fig. 51
Solenoid Test
The starter solenoid is a normally open, electrically
activated switch. When the key switch is turned to
the START position, the switch closes, allowing
battery current to flow to the starter motor and crank
the engine.
1. The solenoid may be tested while mounted on
engine. A jumper test lead (1) is required for this
test.
2. Remove POSITIVE battery cable from battery.
Remove battery cable from stud terminal on – +
solenoid.
3. Disconnect YELLOW wire from tab terminal on
solenoid.
4. Key switch must be in OFF position.
5. Insert RED test lead into V receptacle in meter. Fig. 52
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2
carburetor
IDLE
solenoid WHITE BLUE DOWN
DEVICE
50 CYCLE – 3000
RPM LOOP
STOP
GREEN
SWITCH
TERMINAL MODULE ACTUATOR
RED
ALTERNATOR *yellow
KEY
SWITCH
2 3 GREY BLACK
AC OUTPUT
WIRES
4
DC OUTPUT
WIRE
1 5
STOP SWITCH HARNESS
6 DIODE
DIODE
REGULATOR
RECTIFIER SOLENOID TAB
TERMINAL
BATTERY
TERMINAL STARTER
TERMINAL
IGNITION COILS
SOLENOID
* Yellow Wire – Models 290000 – 303000
Red Wire – Models 350000 – 380000
- +
STARTER
MOTOR
12 VOLT BATTERY
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Fig. 55
Fig. 53
3. Actuator should move throttle lever to wide open
3. With engine running at top governed speed, position (5), Fig. 56.
attach one end of a jumper (2) wire to BLUE wire a. If actuator does not move it is defective.
from control module (1). Attach the other end of Replace.
the jumper wire (3) to a good ground, Fig. 54. b. If actuator moves throttle to WOT, position,
After 4 – 6 seconds engine speed should return the module is defective. Replace.
to idle (approximately 1750 RPM).
Fig. 56
Replacing Actuator
Removal
1. Disconnect RED and GREEN wires from control
Fig. 54
module to actuator.
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2
Installation
1. Assemble actuator to governor control bracket
(3), Fig. 57. Torque screws (4) and nuts (1) to 30
in. lbs. (3 Nm).
NOTE: Hold screws (2) with a wrench when
torquing nuts. Screws must NOT turn while
torquing nuts.
2. Assemble governor link to actuator. Make sure
link snaps into hole in actuator grommet.
3. Assemble throttle return spring through slot in Fig. 57
governor control bracket with open end of spring
facing out and through small hole in governor 5. Rotate actuator lever to position shown and
bracket. connect governor link to carburetor.
4. Assemble governor control bracket assembly to 6. Connect RED and GREEN wires from control
engine. module to actuator.
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2
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LPG-Only Operation
NOTE: The main adjustment is the large brass NOTE: If the application is designed so that the
adjustment screw (1) just to the left of the engine normally operates on NG, but
solenoid (2) and capped port (3), Fig. 58. defaults to LPG if the NG supply is
The idle adjustment is located below and to interrupted, no adjustments for LPG
the left of the main adjustment. An accurate operation are required. The following steps
CO meter is required to adjust the gaseous describe the setting procedure when the
fuel mixture. engine is ONLY powered by LPG.
1. Follow steps 1 through 4 above. The same
components (regulators, lock-off, fuel lines, etc.)
1. Start the engine. Set the main mixture adjust- used with the NG installation are used for the
ment at high speed under load to achieve 1/2 – LPG installation.
1% CO in the exhaust.
2. Connect the fuel transfer solenoid to a 12 volt
DC power supply. As an alternative the main
2. Allow the engine to warm up at top speed for 2 adjustment screw may be turned in until
minutes. completely seated eliminating the need for
applying power to the solenoid.
3. Slow the engine to between 1100 – 1750 no-load 3. Start the engine and run it at top speed for 2
RPM. Adjust the idle mixture to achieve 1/2 – 1% minutes to warm up. The engine uses a fixed
CO in the exhaust. main jet for LPG operation, no adjustment is
necessary.
4. Return the engine to high speed full-load. If 4. Slow the engine to 1100 – 1750 RPM no-load.
required, readjust the setting to 1/2 – 1% CO. Adjust the idle mixture to achieve a reading of up
to 3% CO.
5. Stop the engine. Install the anti-tampering 5. Stop the engine. Install the anti-tampering
plugs. plugs.
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2
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3
2 ROTATING SCREEN
3 CARBURETOR COVER
4 BLOWER HOUSING
5 INTAKE MANIFOLD
AND CARBURETOR
6 CHOKE BRACKET 4
8 EXHAUST MANIFOLD 2
9 GOVERNOR LEVER 13
10 GOVERNOR
CONTROL BRACKET 10
11 VALLEY COVER
12 CYLINDER SHIELDS 11
9
13 VALVE COVERS
12
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21
14
18
20
14 #2 CYLINDER HEAD
15 #1 CYLINDER HEAD
18 ARMATURES
19 BACKPLATE
20 STARTER MOTOR
21 BREATHER
17
27
24
16
25
19
23
28
22
26
22 CRANKCASE COVER OR SUMP
26 CRANKSHAFT
27 VALVES
28 CYLINDER
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3
Fig. 1
Fig. 3
Early style: (Square cartridge), Fig. 2.
1. Remove air cleaner cover. Early style: (Square cartridge), Fig. 4.
2. Remove four screws (6), lock washers (4) and 1. Remove air cleaner cover.
flat washers (7). 2. Remove four screws (2).
3. Remove air cleaner base (5) and breather tube. 3. Remove air cleaner base (1) and breather tube.
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Fig. 4
1. Remove air cleaner cover, cartridge and pre- Remove Blower Housing and Fan
cleaner. 1. Remove blower housing (1) and debris screen
(2), Fig. 7.
2. Remove five screws (1) and carburetor shield
(2), Fig. 5.
3. Disconnect breather tube at air cleaner base
ÎÎ Î
and remove air cleaner base (3).
Î
Fig. 7
2. Remove two screws (5), fan retainer (6) and fan
(7), Fig. 8.
NOTE: If engine is equipped with rewind starter hub
(4), remove starter hub screw (3) first.
Fig. 5
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3
1. Remove air cleaner assembly. 4. Disconnect governor link and spring (4) from
retainer (3) and throttle lever (2).
2. Remove two screws (2) and choke control
bracket, Fig. 9. 5. Disconnect governor link.
Fig. 11
Fig. 10
Horizontal Crankshaft – All Models Fig. 12
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Fig. 13 Fig. 15
CAUTION
AVOID INJURY!
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3
CAUTION
Fig. 18
Required Tools
5. Place the flywheel puller over the pilot. Back out
NOTE: The components of Flywheel Puller #19534, the puller screw (5) until the flange on the puller
are shown in Fig. 17. This tool is RE- is flush with the flange on the flywheel, Fig. 19.
QUIRED to service the flywheel on engines
with the PowerLinkt system. 6. Align the holes in the puller flange with the holes
in the flywheel. Install the puller screws (4) and
tighten until the screws are flush with the flange
1. Puller on the puller.
2. Vanguardt Pilot 7. While holding the hex on the puller, tighten the
puller screw until the flywheel loosens.
3. Intekt Pilot
8. Continue tightening the puller screw until the fly-
4. Screws wheel is clear of the stator and can be lifted from
the crankshaft. Leave the puller screw in this
position.
9. Leave the puller attached to the flywheel, and
place the flywheel on a clean work surface with
the ring gear side down, until the flywheel is
ready to be installed.
Fig. 17
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Fig. 22
3. Remove head bolts (5, 6, 7, 8) and cylinder
head, Fig. 23. Discard cylinder head gasket.
Fig. 23
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3
11
Fig. 25 Fig. 27
Remove Crankshaft
Remove Camshaft
Remove crankshaft (1) from cylinder, Fig. 28.
1. Remove governor spool (8) from camshaft (7),
Fig. 26. Discard gasket and O-ring.
2. Rotate crankshaft and camshaft until timing
marks (9) align. Remove camshaft.
3. Remove tappets.
Fig. 28
AFTER DISASSEMBLY
• Remove gasket material from ALL surfaces.
• Remove oil seals.
• Thoroughly clean parts in solvent.
• Organize all components. Keep parts that are
Fig. 26 assemblies together.
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4
Fig. 3
9. If necessary remove 4 screws and 2 flywheel
Fig. 1 side fuel tank base supports (8), Fig. 4.
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Fig. 7
2. Remove air cleaner nut (3), top plate (4) and air
cleaner element, Fig. 8.
Fig. 5
Fig. 8
Fig. 6
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4
Inspect the fuel hose from the fuel tank (3), the fuel
hose to the carburetor (1) and the vacuum pulse
hose. Replace any hose that is stiff or brittle.
NOTE: The fuel pump is available only as an
assembly.
Fig. 10
ÒÒÒ
Ò
Ò ÒÒ
6. Remove the fuel tank.
ÒÒ ÒÒÒÒ
ÒÒÒÒÒÒÒÒÒ
Ò ÒÒ
Installation
ÒÒ ÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒÒÒ
Ò
ÒÒÒÒÒÒÒ
Ò Ò ÒÒÒÒÒÒÒ
Ò
ÒÒÒÒ
ÒÒ
1. Hold the fuel tank above the engine. Connect
the fuel hose to the carburetor fuel inlet. Insert
the fuel valve shut-off knob to the shut-off link.
Fuel Pump
General Information
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CARBURETION
NOTE: Some Briggs & Stratton V-Twin engines
operate on gaseous fuels. Information on
the gaseous fueled engines is in
Troubleshooting, Section 2.
Carburetor Removal
Typical
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4
Fig. 16 Fig. 18
5. Remove air cleaner elbow support screw (8),
Fig. 19.
6. Remove 3 intake elbow screws and carburetor
assembly.
Models 351400 and 380400 7. Remove carburetor spacer (10) and gaskets (9).
Fig. 19
Fig. 17
8. Remove two nuts (13) and two screws (14).
Separate air cleaner elbow (12) and intake
elbow (15) from carburetor, Fig. 20.
4. Unhook governor link spring (7) from throttle
lever. Disconnect governor link, Fig. 18. 9. Discard gaskets (11).
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13
14
11
15
Fig. 22
Models 290700, 303700, 350700 2. Remove float bowl (3). Discard bowl gasket (2).
(After 950930xx)
Check Throttle, Choke Shaft and Body For Wear
NOTE: The measurement in Step 1 is taken with the
carburetor off of the intake manifold.
1. Lay carburetor on flat surface and check throttle
and choke shaft clearance (1) as shown, Fig. 21.
Fig. 23
Fig. 21
CAUTION: Float hinge pin is a press fit.
Throttle shaft and choke shaft clearance must not Use care when removing.
exceed 0.010” (0.25 mm).
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4
11
Fig. 24
13
Fig. 25
Fig. 28
NOTE: Consult the IPL to get the high altitude jet
10. Use a punch as shown and remove throttle shaft
part number if required.
welch plug (14), Fig. 29.
6. Remove idle jet plug (10) and idle jet (9), Fig. 26.
ÔÔÔ
ÔÔÔ
ÎÎ
14
ÔÔÔ
ÎÎ
ÎÎ
ÔÔÔ
ÎÎ
ÔÔÔ
ÔÔÔ
Fig. 29
Fig. 26
11. Remove snap ring (16) and washer (15), Fig. 30.
7. Use a pliers to remove the idle mixture screw
adjustment limiter cap (11) if equipped, Fig. 27. 12. Remove throttle shaft, collar (17) and seal (18).
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ÎÎÎÎ
ÔÔ ÔÔÔ
ÔÔÔÔÔ
Fig. 30 Fig. 32 ÔÔÔÔÔ
This completes the carburetor disassembly
procedure.
13. Remove screw (25) and choke plate (24), Clean Carburetor
Fig. 31.
1. Disassemble carburetor.
2. Remove and discard all old gaskets, seals and
sealing material.
CAUTION
CAUTION
AVOID EYE INJURY!
AVOID INJURY!
• Carburetor body has a detent ball (19) and
spring (20) that keeps tension on choke shaft. • Wear suitable protection when using cleaners.
Wear eye protection. Follow instructions on container.
• Use caution when removing shaft!
3. Use commercial carburetor cleaning solvents
(such as Briggs & Stratton Spray Cleaner, Part
#100041 or #100042) to clean carburetor parts
and body.
14. Remove E-ring (23), washer (22) choke shaft
and seal (21). 4. When cleaning non-metallic parts (plastic, ny-
lon, Minlon, etc.), do not leave in commercial
carburetor cleaner more than 15 minutes.
ÔÔÔÓ
22 23 NOTE: Parts containing rubber, such as seals,
O-rings, inlet needles, seats or pump
19 20
21 22
ÔÔÔÓ 21
diaphragms should never be placed in
commercial carburetor cleaner.
23
CAUTION
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4
Fig. 35
12. Install choke shaft.
13. Install choke plate as shown, Fig. 35.
14
15
Fig. 36
17. Check float adjustment, Fig. 37.
a. Hold carburetor in vertical position with float
hinge up as shown.
Fig. 34 b. Float should be parallel (17) to bowl
mounting surface.
7. Install throttle plate. c. Bend tang (16) if required.
NOTE: Use LOCTITE 222 on screw threads. NOTE: DO NOT press on float to adjust.
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16
24
23
17
25
Fig. 37
26
27
18. Install idle jet (18), plug (19) and gasket (20),
Fig. 38. Fig. 40
18
19 Mikuni Carburetor
20
Models 290700, 303700, 350700 (Before
951001xx)
21
22
Fig. 41
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4
Fig. 42
Fig. 44
Disassemble
Fig. 45
11
12
14
Fig. 43
Fig. 46
NOTE: Float hinge pin (8) is swaged on one end.
Drive hinge pin out from side opposite 8. Remove two screws (18) and the throttle plate
swage. (17), Fig. 47.
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15
14
14 16
17
16
18
19
Fig. 49
Fig. 47
2. Install 1/4” x 20 Nut #92278 (2) and Washer
12. Remove two screws (20), choke plate (21), #224061 (3) from #19332 Tool Kit onto screw,
shaft, seal (24) and washer (25), Fig. 48. Fig. 50.
3. Place a 1/4” drive 9 mm (3/8”) socket (4) over
CAUTION seat body.
4. Install screw, washer and nut. Thread nut down
AVOID EYE INJURY!
on washer.
• Carburetor body has a detent ball (22) and 5. Continue turning until seat body is removed.
spring (23) that keeps tension on choke shaft. Remove fuel inlet seat (5).
Wear eye protection.
This completes the carburetor disassembly
• Use caution when removing shaft!
procedure.
25
23
22 24
21
20
Fig. 48 Fig. 50
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4
1. Disassemble carburetor. 1. Install new inlet seat (1) with chamfered end
down, Fig. 51.
2. Remove and discard all old gaskets, seals and
sealing material. 2. Press in new body (3) using Knockout Pin
#19135 (2).
CAUTION
AVOID INJURY!
AVOID EYE INJURY!
5. Use only compressed air (blowing in both
directions) to clean out all openings and
passages.
NOTE: Do not use wire, drills or other mechanical
devices to clean out metering holes or Fig. 52
passages.
7. Install new choke shaft seal (16) with sealing lip
out, Fig. 53.
Inspect Carburetor
8. Assemble washer (15) onto choke shaft.
Inspect all parts for wear, cracks, nicks and burrs. 9. Insert spring (12) and check ball (13) in to spring
Inspect float for leaks. Replace damaged parts. pocket. Compress with a small round punch
(14).
Assemble Carburetor 10. Push choke shaft into hole until ball engages
groove in choke shaft, inset, Fig. 53.
When assembling carburetor, use new seals and
gaskets. 11. Install choke plate (11) as shown.
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12 13
14
23
11
15
Fig. 55
24
17
19 Fig. 56
Fig. 54
28
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4
Models 351700, 351400, 380700, 380400 Replace the carburetor of the body is worn or if either
shaft clearance exceeds 0.010” (0.25 mm) when a
new shaft is used.
Check Throttle, Choke Shaft and Body For Wear
1. Lay carburetor on 1/4” (6.35 mm) raised flat NOTE: The carburetors used on vertical
surface (1). Check throttle and choke shaft crankshaft Models 351700 and 380700,
clearance with a feeler gauge (2) as shown in and horizontal crankshaft Models 351400
Fig. 58. and 380400 are similar enough that the
Throttle shaft and choke shaft clearance must not disassembly and reassembly procedures
exceed 0.010” (0.25 mm). can be considered the same. The only
significant differences in the carburetors
are the location of the idle mixture screws
and the fixed main jet orifice sizes.
Fig. 58
NOTE: The inspection in Step 2 is performed after
the carburetor has been disassembled.
2. Inspect throttle shaft and choke shaft for wear
(3). Replace if worn, Fig. 59.
Fig. 60
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Model 351700
Left (#1) cylinder is equipped with #118 main jet. 5. Remove pilot jets (11), Fig. 63.
Right (#2) cylinder is equipped with #116 main jet.
6. Remove float bowl drain screw (13) and spring
Model 380400 (12).
12
13
Fig. 63
14
15
16
Fig. 61
17
Fig. 64
4. Remove carburetor lower body screws (9). Lift
lower body straight away from upper body, 9. Remove idle mixture screws (19) and springs
Fig. 62. Discard gasket (10). (20), Fig. 65.
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4
28
19
20
26 27
18 Fig. 67
Clean Carburetor
1. Disassemble carburetor.
2. Remove and discard all old gaskets, seals and
Fig. 65 sealing material.
CAUTION
10. Mark throttle plates (24) before removing to
ensure reinstallation in the original position,
Fig. 66. AVOID INJURY!
11. Remove throttle shaft (22), spacer (21) and seal • Wear suitable protection when using cleaners.
(23). Follow instructions on container.
23 CAUTION
24
25
22
AVOID EYE INJURY!
Fig. 66
• Wear eye protection whenever using com-
pressed air to clean parts.
12. Mark choke plate (26) before removing to en-
sure reinstallation in the original position, 5. Use only compressed air (blowing in both
Fig. 67. directions) to clean out all openings and
passages.
13. Remove choke shaft (27) and seal (28).
NOTE: Do not use wire, drills or other mechanical
This completes the carburetor disassembly devices to clean out metering holes or
procedure. passages.
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13
Fig. 70
Fig. 71
Fig. 69 11. Install fuel bowl drain screw (19) and spring (18).
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19
18
Fig. 72 Fig. 74
14. Assemble lower body with main jet plugs (23)
12. Install fixed main jets (20), Fig. 73, plugs and facing throttle shaft side (24) of carburetor. Make
washers. sure gasket remains in position, Fig. 75. Tighten
Model 351700 screws (22) securely.
15. Install anti-afterfire solenoid with washer.
Left (#1) cylinder is equipped with #98 main jet.
Torque to 90 in. lbs. (10 Nm).
Right (#2) cylinder is equipped with #100 main jet.
Model 351400
22
Left (#1) cylinder is equipped with #94 main jet.
23
Right (#2) cylinder is equipped with #98 main jet.
Model 380700
Left (#1) cylinder is equipped with #118 main jet.
Right (#2) cylinder is equipped with #116 main jet.
Model 380400 24
20 Nikki Carburetor
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Fig. 76
NOTE: The inspection in Step 2 is performed after Fig. 79
the carburetor has been disassembled.
If idle mixture screw is equipped with adjustment
2. Inspect throttle shaft and choke shaft for wear limiter cap (9), use a pliers to remove it before
(3), Fig. 77. Replace if worn. removing idle mixture screw (inset), Fig. 80.
4. Remove idle mixture screw (3) and spring (4),
Fig. 80.
5. Remove anti-afterfire solenoid (8), if equipped,
or plug (7) and washer (6).
6. Remove fixed main jet (5) using Screwdriver,
#19062.
Fig. 77
Replace either shaft if worn.
Replace the carburetor if the body is worn or if either
shaft clearance exceeds 0.010” (0.25 mm) when a
new shaft is used.
Disassemble
1. Remove four screws and upper body (1),
Fig. 80
Fig. 78. Do not damage emulsion tube (2) in
upper body. 7. Remove pilot jet (10) using Screwdriver #19061,
Fig. 81.
Fig. 78
2. Remove and discard gasket. Fig. 81
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ÒÒÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒÒÒ
11 ÒÒÒÒÒÒÒÒÒ
Fig. 84
Clean Carburetor
12
13 1. Disassemble carburetor.
14
2. Remove and discard all old gaskets, seals and
sealing material.
CAUTION
Fig. 82
AVOID INJURY!
11. Mark choke plate (15) before removal to ensure 3. Use a commercial carburetor cleaner (such as
reinstallation in the original position. Briggs & Stratton Spray Cleaner, #100041 or
#100042) to clean carburetor parts and body.
12. Remove choke shaft (18) and spacer (17).
NOTE: Do not use commercial carburetor cleaners
13. Remove seal (16). on parts containing rubber, such as seals,
O-rings, inlet needles, seats or pump
diaphragms.
Do not leave non-metallic parts (plastic,
15 nylon, Minlon, etc.) in commercial
carburetor cleaner more than 15 minutes.
16
17
18 CAUTION
Fig. 83
4. Use only compressed air (blowing in both
directions) to clean out all openings and
14. Remove transitional hole welch plug (20) with a passages.
punch as shown, Fig. 84.
NOTE: Do not use wire, drills or other mechanical
This completes the carburetor disassembly devices to clean out metering holes or
procedure. passages.
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Assemble Carburetor
When assembling carburetor, use new seals and
gaskets.
1. Install new transitional hole welch plug (1),
Fig. 85.
2. Use a round punch (2). Tap in plug until it is flat.
3. Use a sealant such as Permatex #2 or nail
polish on outside diameter of plug to prevent
air leaks. Fig. 87
10. Install pilot jet (11) using Screwdriver #19061,
Fig. 88.
11
Fig. 85
4. Install new choke shaft seal with sealing lip in. Fig. 88
5. Install choke shaft and spacer (5), Fig. 86. 11. Install fixed main jet (14) using Screwdriver
6. Install choke plate (3) with vent hole facing bowl #19062, Fig. 89.
vent nipple (4). 12. Install washer (15) and plug (16) or anti-afterfire
solenoid (17). Torque to 45 in. lbs. (5 Nm).
NOTE: Use LOCTITE 222 on screw threads.
13. Install idle mixture screw (13) and spring (12).
NOTE: DO NOT tighten screw. DO NOT install
limiter cap at this time.
12 17
13
14 15
Fig. 86 16
7. Install new throttle shaft seal (6) with sealing lip in,
Fig. 87.
Fig. 89
8. Install throttle shaft (7) and spacer (8).
14. Assemble inlet needle to float. Install float
9. Install throttle plate (9) to throttle shaft. assembly (18), Fig. 90.
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A B
21
Fig. 90
The fuel inlet seat orifice size and inlet needle are
ÒÒ 20 20
22
A color code on the side of the carburetor (19) is used
to identify the carburetor by engine model and fuel 22
delivery system, Fig. 91.
21 – Vertical Line
NOTE: See the “Fuel System Identification Table” in 22 – Machined Surface of Carburetor
the Appendix for information.
23 – Top of Float (Before Radius)
Fig. 92
To adjust float level, hold float arm at (26) with needle
nose pliers, Fig. 93. Carefully bend tang CLOCK-
WISE (25) to raise the float level, COUNTER-
CLOCKWISE (28) to lower the float level. DO NOT
ÒÒ 19
ÒÒ
26
Fig. 91
25
Set Float Height
The float height setting on Nikki carburetors 28
depends upon whether the engine uses a fuel pump 27
(illustration A) or gravity feed fuel delivery system
(illustration B), Fig. 92. The procedure for checking Fig. 93
the float height setting is unique to each carburetor.
4. Place new gasket (31) on lower carburetor body
1. Hold the carburetor in one hand and place the (32). Make sure holes in body line up with holes
index finger on the float hinge pin (20). in gasket, Fig. 94.
2. While holding the float hinge pin down, turn the 5. Install upper carburetor body (30). Tighten
carburetor to a position PAST VERTICAL (21) screws (29) securely.
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Fig. 94
ÒÒÒ
Mikuni Carburetor
Models 290400, 303400, 350400 (Before
950801xx)
ÒÒÒ
Carburetor Identification
ÒÒÒÒ
Two carburetor bodies are used, depending upon
the use of a fuel pump (illustration A) or gravity feed
(illustration B) fuel delivery system, Fig. 95.
ÒÒ
Besides a change in jetting, the end of the discharge
nozzle is machined at a different angle. Since the
discharge nozzle is an integral part of the carburetor
body the carburetor bodies are not interchangeable.
The carburetor bodies can be identified by looking
down the carburetor throat and comparing the end of Fig. 96
the discharge nozzle (1) in relation to the choke shaft
(2), Fig. 95. On a fuel pump carburetor the end of the NOTE: The inspection in Step 2 is performed after
nozzle is at approximately a 20° angle (3) to the choke the carburetor has been disassembled.
shaft (2). On a gravity feed carburetor the end of the
nozzle is approximately parallel (4) to the choke shaft.
2. Inspect throttle shaft and choke shaft for wear
The fixed main jet used with a fuel pump system is
numbered 110. The fixed main jet used with a gravity (3), Fig. 97. Replace if worn.
system is numbered 117.5.
A
B Fig. 97
Replace either shaft if worn.
Replace the carburetor if the body is worn or if the
clearance on either shaft exceeds 0.010” (0.25 mm)
when a new shaft is used.
Disassemble
1. Remove pilot jet (1), Fig. 98.
2. Remove four screws (2) and upper body (3).
Fig. 95 Discard gasket (4).
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9. Remove fuel bowl drain screw (15) and spring.
14
Fig. 98
17
ÒÒ
18 20
19
ÒÒÒ
21
Fig. 99
19 18
4. Remove anti-afterfire solenoid (10) or plug (9),
Fig. 100.
Ò
ÒÒ
5. Remove fixed jet plug (13) and washer (12).
6. Remove fixed main jet (11) with Jet Screwdriver
ÒÒÒ
#19062. 22
7. Remove emulsion tube (8).
Fig. 102
14. Mark choke plate before removal to ensure
re-installation in the original position. Top and
bottom edges are beveled. Remove screws (27)
and choke plate (28), Fig. 103.
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ÒÒ
ÒÒ
29
24
23
25
Clean Carburetor
Remove Fuel Inlet Body and Seat
1. Disassemble carburetor.
The fuel inlet body must be removed before the inlet 2. Remove and discard all old gaskets, seals and
seat can be removed. sealing material.
3. Install 1/4” x 20 Nut #92278 (6) and Washer AVOID EYE INJURY!
#224061 (5) from Tool Kit #19332 onto screw,
Fig. 105.
• Wear eye protection whenever using com-
pressed air to clean parts.
4. Place a 1/4” drive 3/8” (9 mm) socket (4) over
seat body.
4. Use only compressed air (blowing in both
5. Install screw, washer and nut to seat body. directions) to clean out all openings and
Thread nut down on washer. passages.
6. Continue turning until seat body is removed. NOTE: Do not use wire, drills or other mechanical
devices to clean out metering holes or
7. Remove fuel inlet seat (3). passages.
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4
3. Install new throttle shaft seals (5) with sealing lip NOTE: Fixed main jets are numbered (13) for the
out, Fig. 107. type of fuel delivery system used. Install
#110 jet if engine is equipped with a fuel
4. Install throttle shaft with spacer (4) and foam
pump. Install #117.5 jet if engine is equipped
seal (8).
with a gravity fuel tank.
5. Install foam seal (7) and retainer (6).
6. Install throttle plate. 17
ÒÒÒ
ÒÒ
ÒÒ
ÒÒÒ 16
15
ÒÒ
13
14
ÒÒÒ
18
Ò Fig. 109
16. Install bowl drain screw (19) and spring,
Fig. 110.
Fig. 107 17. Install idle mixture screw (20) and spring.
DO NOT tighten screw.
7. Install new choke shaft seals (10) with sealing lip
out, Fig. 108. DO NOT install limiter cap at this time.
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26
19 25
20 27
Fig. 110
28
18. Assemble inlet needle retainer (21) to inlet
needle (22). Assemble to float (23), Fig. 111. Fig. 112
19. Install float (23) and needle to upper carburetor 21. Place new gasket (31) on lower carburetor body.
body. Insert hinge pin (24). Make sure holes in body line up with holes in
gasket, Fig. 113.
23
21 22. Install upper carburetor body. Tighten screws
(30) securely.
22
23. Install pilot jet (29).
24. Install washer (34) and plug (35) or anti-afterfire
24
solenoid (33). Torque to 45 in. lbs. (5 Nm).
30
29
Fig. 111 31
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Model 540000
General Information
The Vanguardt Model 540000 OHV V-Twin utilizes a fixed jet, two barrel, side draft, flo-jet carburetor. Except
for idle speed, the carburetor is non-adjustable. The carburetor incorporates a fuel shut-off (anti-afterfire) solenoid
that controls fuel flow to the fuel metering system. The solenoid is controlled by the ignition switch.
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Fig. 116
Disassemble
Check Throttle, Choke Shaft and Body
1. Remove carburetor, see Section 3.
NOTE: The measurement in Step 1 is taken with the 2. Remove two screws and float bowl (2), Fig. 117.
carburetor off of the intake manifold. Discard O-ring.
Throttle shaft and choke shaft clearance (1) must not CAUTION: Do not damage fixed main jet and
exceed 0.010” (0.25 mm). housing when removing solenoid.
Fig. 117
Fig. 115
2. Inspect throttle shaft and choke shaft for wear on 6. Remove emulsion tube body (7) and gasket (6).
the shaft bore surfaces (2), Fig. 116. Discard gasket.
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15
Fig. 118 Fig. 121
17
11
16
Fig. 122
Fig. 119
12. Remove screws, throttle plates and throttle shaft
with seal. Discard seal (17).
8. Remove screws and choke plate (12), Fig. 120. This completes the carburetor disassembly
procedure.
9. Remove choke shaft. Discard seal (13).
Clean Carburetor
12 1. Disassemble carburetor.
CAUTION
13 AVOID INJURY!
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CAUTION
Assemble Carburetor
When assembling carburetor, use new seals and
gaskets.
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11
Fig. 126
Fig. 128
8. Assemble bowl gasket (9) to body.
9. Install main jet, according to engine model.
6. Install emulsion tube body (8) with new gasket 10. Install the float bowl assembly to the carburetor
(19), Fig. 127. Tighten screw securely. body.
11. Assemble fuel solenoid (13) to float bowl (12),
Fig. 129. Use a 13 mm thin profile wrench to
tighten the solenoid.
CAUTION: Use care when tightening solenoid to
prevent damage to fixed main jet and housing.
19
12
Fig. 127
13
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Model 610000
General Information
The Vanguardt Model 610000 OHV V-Twin utilizes a fixed jet, two barrel, side draft, flo-jet carburetor. The
carburetor incorporates a fuel shut-off (anti-afterfire) solenoid that controls fuel flow to the fuel metering system.
The solenoid is controlled by the ignition switch.
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12
13
18 14
17
16
15
Fig. 132
Fig. 130
This completes the carburetor disassembly
3. Remove main jets (4) from float bowl, Fig. 131. procedure.
Clean Carburetor
1. Disassemble carburetor.
CAUTION
Fig. 131
AVOID INJURY!
4. Remove float hinge pin (18), float (5) and inlet
needle (6) from carburetor body, Fig. 132. • Wear suitable protection when using cleaners.
Follow instructions on container.
5. Remove limiter caps (8) and mixture adjustment
screws (7).
3. Use a commercial carburetor cleaner such as
6. Remove screws (9) and choke plate (10). Briggs & Stratton Spray Cleaner #100041 or
7. Remove choke shaft (13) and bushings (11, 12) #100042 to clean carburetor parts and body.
from carburetor body.
8. Mark throttle plates (15) before removal so they NOTE: Parts containing rubber, such as seals,
will be re-installed in the original position. Sides O-rings, inlet needles, seats or pump
of throttle plate are beveled. diaphragms should not be placed in
commercial carburetor cleaner.
9. Remove screws (9), throttle plates and throttle Do not leave non-metallic parts (plastic,
shaft (14) with bushings (16) and seal (17). nylon, Minlon, etc.), in commercial
Discard seal. carburetor cleaner more than 15 minutes.
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• Wear eye protection when using com- NOTE: The tab on the float bowl gasket (1) goes in
pressed air. the slot in the float bowl carburetor body (2).
Inspect Carburetor
Inspect all parts for wear, cracks, nicks and burrs.
Inspect float for leaks. Replace damaged or worn
parts.
Fig. 133
Assemble Carburetor
Use new seals and gaskets when assembling 6. Install the carburetor jets to the float bowl.
carburetor. 7. Install the float bowl assembly to the carburetor
1. Assemble new seal and bushings to throttle body.
shaft. Insert into carburetor body.
NOTE: The float hinge pin is not secured in the
NOTE: Install one throttle plate at a time. Check hinge pin posts. Be sure the hinge pin
throttle for freedom of operation before remains in the posts until the float bowl is
installing other throttle plate. installed.
Use LOCTITER 222 on screw threads.
8. Assemble fuel solenoid to float bowl.
2. Insert bushings and choke shaft into carburetor
body. CAUTION: Do not damage the float bowl when
tightening the solenoid. Do not overtighten.
3. Install choke plate.
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Fig. 4
GOVERNORS
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Fig. 7
7. Remove crankcase cover, Fig. 6. 4. Check governor shaft and bushings for wear or
damage.
8. Discard gasket and O-ring.
Ó
Replace as required.
Ó
ÔÔ ÔÔ
ÔÔÖÖ
Ö
ÔÔ
ÔÔÖÖ
Ö
ÔÔ
Fig. 6 Fig. 8
2. Flyweights (2) must move freely on hinge pins NOTE: Lower bushing is a slip fit. If bearing for
(1). Replace camshaft if hinge pins are loose or lower bushing (3) is worn, the crankcase
governor spool does not move freely on journal. cover must be replaced.
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Fig. 9 Fig. 11
2. Insert proper seal protector through oil seal.
Install Governor Shaft 3. Install crankcase cover or sump with new
1. Assemble lower bushing to governor shaft with gasket. Torque screws in sequence shown to
thrust flange (4) down, Fig. 10. 150 in. lbs. (17 Nm), Fig. 12.
2. Slide shaft up through lower bearing and upper 4. Reinstall oil fill tube and dipstick assembly.
bushing.
3. Install new seal (3), collar (1) and cotter pin (2). 3 1
Governor shaft must rotate freely.
4. Rotate governor shaft (arrow) so that paddle 5
rests against camshaft bearing support (5). 8
ÔÔ 6
ÔÔ
ÖÖ
ÔÔ
Ö
7
ÔÔ
ÖÖ
ÔÔ
Ö
9 4
ÔÔ
2
Fig. 12
5. Reassemble governor lever (6) to shaft, Fig. 13.
a. Reassemble governor link and spring (5) at
carburetor.
b. Reassemble governed idle spring (4).
Fig. 10 NOTE: DO NOT tighten nut (7) at this time.
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Fig. 13
WARNING
Inspect Governor Gear
Static adjustment of the governor 1. Check the governor gear assembly for worn
must be completed BEFORE starting weights or weight pins. Inspect the governor
or running engine! cup, washer and gear for wear or damage.
• Failure to make static governor adjustments 2. Inspect the governor gear shaft (1) for wear or
first could result in engine overspeeding and damage, Fig. 16.
consequential engine damage, property
damage or personal injury.
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Install Governor Crank
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Fig. 2
Style 2: Engines manufactured before 960401xx
but after 931031xx are equipped with cast aluminum
rocker arms (3) with a rocker arm shaft, Fig. 3.
Style 1: Engines manufactured before date code
931101xx were equipped with stamped steel rocker
arms (4) with a rocker arm shaft, Fig. 3.
Fig. 3
CYLINDER HEAD SERVICE
Remove Cylinder Head
1. Remove two rocker studs (1) supports (2) and
rocker arm assemblies (3), Fig. 4 (current) or
Fig. 1 Fig. 5 (early). Remove rocker arm shaft (4, early
versions).
1. Screw
2. Remove push rods.
2. Rocker Arm Support
NOTE: Label push rods for reassembly in the
3. Rocker Arm original location.
4. Valve Spring Retainer Locks
5. Valve Spring Retainer
6. Valve Spring
7. Cylinder Head
8. Valve
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Fig. 5
3. Remove head bolts (5, 6, 7, 8) and cylinder Fig. 7
head, Fig. 6. Discard cylinder head gasket. 6. Remove and discard valve stem seals, Fig. 8.
NOTE: Engines manufactured before 940501xx
were equipped with sealing washers under
cylinder head bolts (5) and (6).
Repeat for other cylinder head.
Fig. 8
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Fig. 10
Replace Valve Guide
1. Press out old valve guide (2) using Bushing
Driver (1), #19367, Fig. 11.
Fig. 13
ÏÏÏ ÏÏ
ÏÏÏ ÏÏ
1/16” – 3/64”
(0.8 MM – 1.2 MM) 45°
60° CUTTER
Fig. 14
Fig. 12
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Fig. 15
2. Valve faces can be resurfaced to 455. See
Fig. 16 for dimensions for valves.
3. Lap the valves and seats with Valve Lapper Fig. 18
#19258 and Valve Lapping Compound #94150. NOTE: Place a shop rag or short section of rubber
NOTE: In most instances it is more economical to fuel line under valves inside combustion
replace the valves than to reface them. chamber to hold valve in place while
1/32” (0.8 MM)
compressing spring.
3/64” – 1/16”
MINIMUM
(1.2 MM TO 1.6 MM)
CAUTION
Fig. 19
6. Make sure the retainer locks are seated into the
valve stem groove and valve retainer. Gradually
release pressure on the valve spring compressor.
Fig. 17
Repeat procedure for other valve. Remove rocker
2. Install valves, Fig. 18. studs.
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1. Install cylinder head with NEW gasket, Fig. 20. NOTE: Rocker shaft support (3) holes are offset.
Install with holes facing ends of rocker shaft,
Fig. 22.
1. Lubricate rocker arms (4) and shaft (2) with
clean engine oil.
2. Assemble rocker arms, shaft, supports and
studs (1) and install on cylinder head, Fig. 22.
Torque studs to 140 in. lbs. (16 Nm).
Fig. 20
NOTE: Engines manufactured BEFORE 940501xx
were equipped with sealing washers under
#1 and #3 cylinder head bolts.
2. Lubricate threads of head bolts with Valve Guide
Lubricant #93963.
Fig. 22
3. Torque bolts in the sequence shown, Fig. 20, to
165 in. lbs. (19 Nm).
Install Push Rods
NOTE: Models 540000, 610000 torque to 350 in.
lbs. (40 Nm). NOTE: All models except 540000, 610000 –
Exhaust valve push rods are aluminum.
Models 540000, 610000 – All push rods are
aluminum.
Install Rocker Arms
1. Compress valve spring (3) with rocker arm (2)
Current Style and insert push rod (1) into rocker arm socket,
Fig. 23.
1. Lubricate rocker arm supports (2) with clean
engine oil.
NOTE: Seat push rods into recess in tappets.
2. Assemble rocker studs (1), rocker arm supports
and rocker arms (3) to cylinder head, Fig. 21.
Torque studs to 100 in. lbs. (11 Nm).
Fig. 23
2. Repeat for No. 2 cylinder.
Fig. 21 3. Adjust valve clearance. See Section 1.
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Fig. 1
Steel Pinion Fig. 4
The starter motor shown in Fig. 2 has a steel pinion
gear and is used only with flywheels equipped with
a steel ring gear. The flywheel ring gear is NOT
replaceable.
Fig. 5
Fig. 2
Solenoid Shift
The starter motor in Fig. 3 uses a solenoid to engage
the flywheel, and is equipped with a steel ring gear.
The flywheel ring gear is NOT replaceable.
Fig. 6
Fig. 3
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Fig. 9
Roll Pin Style
Disassemble
1. Place starter drive retainer on support block,
Fig. 10.
NOTE: See Section 13, Appendix, for support block
dimensions.
2. Drive out roll pin with a 5/32” (4 mm) pin punch.
Discard roll pin.
3. Remove retainer, washer, pinion gear, and
starter clutch.
Fig. 7
Assemble
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Fig. 11
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13
14 Fig. 15
Inspect Armature Commutator
Fig. 13
The armature commutator shown in Fig. 16 (A) can
be cleaned with fine sandpaper. DO NOT use emery
cloth. The commutator can be machined a diameter
1. Remove pinion gear assembly. of NO LESS THAN 1.230” (31.24 mm).
2. Remove thru bolts (2) and drive end cap (4). Slots between commutator bars should be cleaned
as shown in Fig. 16 (A) after sanding or machining.
Check the armature for shorts with a growler.
NOTE: The style armature commutator shown in
Fig. 16 (B) cannot be machined.
11
12
A B
13 Fig. 16
Inspect Brushes
Fig. 14
Check the brushes for proper seating, weak brush
springs, dirt, oil or corrosion. Brush springs should
3. Hold the armature (3) and commutator end cap be strong enough to ensure good brush contact with
(5) against a work surface while sliding housing armature. Replace the brushes if worn to 1/4” (6
(1) off the armature, Fig. 15. mm) (1) or less Fig. 17 (A), or 1/8” (3 mm) (2) or
less, Fig. 17 (B). Lengths of new brushes (3) are
shown for reference.
NOTE: This allows the brush retainer to remain as-
sembled to commutator for inspection of Verify that the brushes are not sticking in their
brush-to-commutator contact. holders.
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A B
Fig. 17 Fig. 20
Fig. 19 Fig. 21
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Fig. 22
Fig. 26
Fig. 23
Assemble Housing
1. Install positive (7) and negative (8) brushes with The starter housing (1) has a large notch (3) which
beveled edge UP in position shown, Fig. 24. indexes over the insulated terminal, Fig. 27.
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Fig. 27
Fig. 28 Fig. 30
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Disassemble Starter
For ease of disassembly and assembly, clamp drive
end housing in a vise as shown, Fig. 32.
1. Remove solenoid.
2. Remove starter thru bolts.
3. Remove brush end cap, Fig. 31.
NOTE: To prevent losing brush springs, do not
Fig. 33
remove brush retainer (1) until starter
housing has been removed from drive end 6. Remove spacer from armature shaft.
cap, Fig. 31. 7. Use a 14 mm Carburetor Socket #19458 to drive
retainer from C-ring, Fig. 34. Remove and
discard C-ring and retainer.
NOTE: Always use a new C-ring and retainer.
Fig. 31
4. Remove starter housing from drive end cap,
Fig. 32.
Fig. 34
Fig. 32 Fig. 35
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1.062”
(27.0 MM)
Fig. 38
3. Attach either test lead to starter housing,
Fig. 40.
Fig. 36
Inspect Brushes
Minimum brush dimension (1) is 1/4” (6 mm). If
brushes are worn less than specification, replace the
starter housing, Fig. 37.
Fig. 39
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Fig. 40
Assemble Pinion Gear
1. Lubricate helix with a light coat of grease.
Assemble pinion gear and clutch.
2. Assemble new retainer to shaft.
3. Install new C-ring. Fig. 42
4. Pry up on retainer until C-ring snaps into groove
in retainer, Fig. 39.
5. Assemble spacer to armature shaft, Fig. 41. 2. Assemble starter housing to drive housing,
engaging notch in housing with tab on drive lever
NOTE: Lip (1) on spacer must face bearing in drive support, Fig. 43.
end cap.
Fig. 41
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Fig. 44
Fig. 46 Fig. 48
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Fig. 49
1. Rewind Starter.
2. Air Inlet Slots – larger on current starters.
3. Retainer – nylon on current starters, metal on
early starters.
4. Starter Dogs – nylon on current starters, metal
on early starters.
5. Starter Cup – large notches on current starters,
small notches on early starters. ÓÓÓ
ÓÓÓÓ
REWIND STARTER SERVICE
Remove Rewind Starter Fig. 50
1. Remove four screws and rewind starter (1),
Fig. 50.
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ÓÓÓ ÓÓÓ
ÓÓÓÓ way out on rope.
ÓÓÓ ÓÓÓÓ
ÓÓÓ
ÓÓ
ÓÓÓÓ
ÓÓÓ
ÓÓ
9. Let pulley and spring slowly rewind pulling rope
into temporary knot.
Fig. 51
Install Rope
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1. Remove rope.
2. Remove shoulder screw (1) and retainer (2),
Fig. 56.
3. Lift out dogs (3) and dog springs (4).
Fig. 58
Inspect starter housing for wear or sharp edges at
rope eyelet (4), center pivot post (5), and inner
spring anchor (3) tab, Fig. 59. Replace housing if
worn or damaged.
Fig. 56
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4. Install rope.
Fig. 60
3. Rotate pulley COUNTERCLOCKWISE until
slight resistance is felt, indicating that spring is
engaged in spring tab in housing, Fig. 61.
Fig. 63
Early Style
Fig. 61
1. Remove rope.
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Ó
Fig. 64
Fig. 67
3. Lift out dogs (6) and dog springs (7). Inspect starter housing for wear and sharp edges at
4. Rotate pulley (8) until it disengages spring. rope eyelet (5), center pivot post (4), and at inner
spring anchor (6), Fig. 68. Replace if worn or
5. Carefully lift out pulley, Fig. 65. damaged.
ÓÓ
ÓÓ ÓÓ
ÓÓ ÓÓ
ÓÓÓÓÓÓÓÓ
ÓÓÓÓÓÓÓÓ
ÓÓÓÓ
ÓÓÓÓÓÓÓÓ
ÓÓÓÓ
ÓÓÓÓ
Fig. 68
Fig. 65
Install Spring, Cup Assembly and Pulley In
The starter spring and cup will normally remain as an Starter Housing
assembly in starter housing. 1. Place spring and cup assembly in pulley with
6. Remove spring and cup assembly (9) from outer end of spring tab (2) between two wide
starter housing, Fig. 66. lugs in pulley (1) and spring cup projections (3)
ÓÓÓÓÓÓÓÓÓ ÓÓÓ
Ó
ÓÓÓÓÓÓÓÓÓ ÓÓÓ
ÓÓÓ
ÓÓÓ
ÓÓÓÓÓÓÓÓÓ ÓÓÓ
ÓÓ
ÓÓÓÓ
Ó
ÓÓÓ
ÓÓÓ
ÓÓÓÓÓÓÓÓÓ ÓÓÓ
ÓÓ
ÓÓÓÓ ÓÓÓ
ÓÓÓÓÓÓÓÓÓ
Ó ÓÓÓ
ÓÓÓÓ ÓÓÓ
ÓÓ
ÓÓÓ
ÓÓ
ÓÓÓÓ
ÓÓÓ Ó
ÓÓÓÓÓÓÓÓ
ÓÓ
ÓÓÓÓ
ÓÓÓ
Fig. 66 Fig. 69
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ÓÓ
sembly, Fig. 70.
ÓÓÓÓ
ÓÓÓÓ
ÓÓÓÓ
ÓÓÓÓ
Fig. 72
2. Place large washer (7), brake spring (6) and
retainer (5) on pulley, Fig. 73.
3. Place small washer (4) on shoulder screw (3).
Install screw and washer in center pivot post.
4. Position tabs of retainer inside dogs. Torque
screw to 70 in. lbs. (8 Nm).
5. Install rope.
Fig. 70
ÓÓ
ÓÓ
4. Invert assembly, rotate pulley counterclockwise
until inner spring tab engages spring anchor,
Fig. 71.
Fig. 73
Install Rewind Starter
ÓÓÓÓÓÓÓÓÓÓÓÓ
Ó Ó
1. Install rewind starter on blower housing and
install screws (1) finger tight, Fig. 74.
ÓÓÓÓÓÓÓÓÓÓÓÓ
ÓÓÓ Ó Ó Ó ÓÓ 2. Pull rope to engage dogs in starter cup.
ÓÓÓ
ÓÓÓ
ÓÓÓ
ÓÓÓÓÓÓÓÓÓÓÓÓ
ÓÓÓÓÓÓÓÓÓÓÓÓ
ÓÓÓ
lbs. (7 Nm).
ÓÓÓÓÓÓÓÓÓÓÓÓ
Fig. 71
ÓÓÓ
ÓÓÓ
Install Dogs, Dog Springs, Retainer Assembly
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Fig. 7
ÓÓ
Ó
ÓÓ
Ó
Install Reed Valve Breather
1. Place breather (2) on gasket (3), Fig. 8.
2. Assemble large O-ring (1) onto mounting screw.
3. Install screw. Torque to 30 in. lbs. (3 Nm).
Fig. 5
Checking Reed Valve Breather
The reed valve is spring loaded and must make a
complete seal around the vent hole (1) in breather
body, Fig. 6. Check to see that reed valve is not
deformed.
Fig. 8
Install Fiber Disc Breather
1. Place breather on gasket.
2. Place large O-ring (1) on breather, Fig. 9.
3. Assemble washer (3) and small O-ring (2) to
screw.
4. Install screw. Torque to 30 in. lbs. (3 Nm).
Fig. 6
Checking Fiber Disc Breather
If the fiber disc valve (3) is stuck or binding, the
breather assembly (1) must be replaced. A 0.045”
(1.14 mm) wire gauge (2) should not enter the space
between the fiber disc valve and body, Fig. 7.
CAUTION: Do not use force on the fiber disc.
Fig. 9
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Fig. 12
Fig. 10
Install Breather
1. Assemble reed valve and reed stop to breather
body, Fig. 13. Tighten screws securely.
Checking Breather
NOTE: Holes in reed and reed stop are offset.
1. Remove two screws, reed stop and reed valve. Assemble so that holes are aligned.
2. Place reed valve on flat surface. 2. Assemble baffle and cover to valve cover with
new gasket.
3. Check reed valve for distortion with feeler
gauge, Fig. 11. 3. Torque screws to 30 in. lbs. (3 Nm).
Fig. 13
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Fig. 16
The oil fill tube (3) and the dipstick (1) are equipped
Install Breather with O-rings (2) and/or a grommet (4) for proper
sealing, Fig. 17.
NOTE: For correct alignment, the breather
components have one corner that is a NOTE: A leak at the seal between the tube and
sharper radius than the others. DO NOT sump, or at the seal at the upper end of the
force components into an incorrect position. dipstick, can result in a loss of crankcase
vacuum and a discharge of oil or smoke
1. Install the inner baffle with raised edges facing through the muffler.
OUT.
2. Install the reed valve assembly into the valve
cover, reed valve facing out.
3. Install the O-ring over the reed valve assembly.
Use fingertips to seat the O-ring into the valve
cover.
4. Position the outer baffle into the breather cover
with the 3 bosses facing OUT.
5. Install the breather cover and baffle onto the
valve cover.
6. Reinstall screws. Fig. 17
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For proper sealing on these models, the oil fill cap (5)
has an O-ring, the dipstick has a grommet (6), Fig. 18.
Fig. 18
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A
Fig. 4
Cleaning
CAUTION: Honing grit is highly abrasive and
will cause rapid wear to all the internal compo-
nents of the engine unless it is completely re-
ÓÓÓ ÓÓ
ÓÓÓ
moved. The entire cylinder and crankcase
MUST be THOROUGHLY cleaned after honing.
ÓÓÓ ÓÓ
ÓÓÓ
ÓÓÓ ÓÓÓÓÓ First wash the cylinder and crankcase carefully in a
ÓÓÓ ÓÓÓ
ÓÓ
B
solvent such as kerosene or commercial solvent.
Then thoroughly wash cylinder and crankcase using
ÓÓÓ ÓÓ ÓÓÓ a stiff brush with soap and hot water. Rinse
ÔÔ
and rinsing until all traces of honing grit are gone.
ÓÓÓÔÔ ÓÓ
ÓÓÓ NOTE: When cylinder and crankcase have been
ÓÓÓÔÔÔÔÓÓ
ÓÓÓ
thoroughly cleaned, use a clean white rag or
napkin to wipe the cylinder bore. If honing
ÓÓÓ ÔÔ grit is present it will appear as a gray residue
ÓÓÓÔÔ ÔÔ
C
on rag. If any honing grit is evident, re-wash
ÓÓÓ
ÔÔÔÔ
and rinse entire cylinder and crankcase and
check again. When there is no trace of
ÔÔÔÔ Fig. 3
honing grit on rag, the cylinder has been
properly cleaned. Oil the cylinder bore to
prevent rusting.
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Fig. 7
4. Stake bearing in top notch (2) with 1/8” round
pin punch to prevent bearing from turning,
Fig. 8.
Fig. 5
Remove
1. Remove the oil seal.
2. Insert Bushing Driver #19450 (1) into bearing
from oil seal side, Fig. 6. Fig. 8
3. Place a reference mark (2) on driver to indicate 5. Install new oil seal with sealing lips facing in. Use
proper depth when installing new bearing. Cylinder Support #19227. Press oil seal until
flush with cylinder.
Mag Bearing – Before 970501xx
Check
1. Check magneto bearing for damage. Check for
wear at several locations using #19380 plug
gauge or appropriate measuring tools, Fig. 9. If
plug gauge is not available see reject dimension
in Section 13.
2. Replace bearing if damaged or worn.
Fig. 6
4. Place cylinder on Cylinder Support #19227 with
large opening facing bearing.
5. Press out bearing with bushing driver (1), Fig. 7.
Install
1. Place cylinder on Cylinder Support #19227 with
large opening facing bearing, Fig. 7.
2. Align oil holes in bearing with oil holes in cylinder.
3. Press in new bearing to correct depth with
bushing driver (1). Fig. 9
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Fig. 10
Install
1. Place cylinder on Cylinder Support #19227 with Fig. 13
large opening facing bearing.
2. Align oil holes in bearing with oil holes in cylinder. PTO Ball Bearing
3. Press in new bearing to correct depth with Check
Bushing Driver #19349 (3), Fig. 11.
Ball bearings must rotate freely, Fig. 14. If any rough
spots are felt replace the ball bearing.
Fig. 11
4. Grind off the taper (5), approximately 1/8” (3
mm) (4), from one end of new roll pin as shown,
Fig. 12.
a. Quench pin in water periodically to prevent
loss of temper.
b. Remove all burrs and clean thoroughly. Fig. 14
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Fig. 17
Fig. 16
Fig. 18
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Fig. 2
INSPECT FLYWHEEL
Check flywheel keyway (1) for damage. Replace
flywheel if it has cracks, broken fins or keyway
damage, Fig. 3.
Fig. 1
Crankshaft crankpin may be re-ground for 0.020”
undersize connecting rods when available. See IPL
for part number. Accurately measure and grind the
crankpin diameter (A), throw (T) and fillet radius (R),
Fig. 2. Discard any crankshaft that is worn beyond
reject specifications listed in Section 13. Fig. 3
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Fig. 4
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Resize a cylinder bore if it is more than 0.003” (0.08 1. Check side clearance of ring grooves using a
mm) oversize, or 0.0015” (0.04 mm) out of round. feeler gauge and NEW piston rings (3), Fig. 3.
Replace the piston if the ring groove is worn
beyond specification.
Disassemble Side Clearance Reject Dimension:
All Except Models 540000, 610000
1. Remove piston rings using Ring Expander
#19340 (1), Fig. 1. • Compression Rings – 0.004” (0.10 mm)
• Oil Rings – 0.008” (0.20 mm)
2. Remove oil control ring coil expander and oil Models 540000, 610000
control rings.
• Top Compression Ring – 0.009” (0.23 mm)
• Center Compression Ring – 0.006” (0.15 mm)
• Oil Rings – 0.004” (0.10 mm)
Fig. 1
Fig. 3
3. Disassemble piston from connecting rod, Fig. 2.
2. Check ring end gap, Fig. 4. Clean carbon from
a. Remove piston pin locks (2). end of rings and insert approximately 1” (25
mm) into cylinder.
b. Piston pin is a slip fit in piston and
connecting rod. End Gap Reject Dimension
Keep pistons and connecting rods together as an as- All Except Models 540000, 610000
sembly. Do not mix. • All Rings – 0.030” (0.76 mm)
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Fig. 6
2. Check connecting rod bearings, Fig. 7.
ÎÎ
ÎÎ NOTE: Undersize (0.020”) connecting rods are
ÎÎ
available for use on a reground crankpin
journal on some engines. See IPL for
Fig. 4 availability. If crankpin bearing is scored or
worn replace the connecting rod.
3. Check piston pin bore, Fig. 5. Replace piston if
worn beyond reject dimension or 0.0005” (0.01 Piston Pin Bearing (1) Reject Dimension
mm) out of round.
• Models 290000 – 351000 – 0.674” (17.12 mm)
• Model 380000 – 0.711” (18.06 mm)
Piston Pin Bore Reject Dimension
• Model 540000 – 0.828” (21.03 mm)
• Models 290000 – 351000 – 0.674” (17.12 mm)
• Model 380000 – 0.711” (18.06 mm) Crankpin Bearing (2) Reject Dimension
• Model 540000 – 0.828” (21.03 mm) • All Except Model 540000 – 1.461” (37.12 mm)
• Model 540000 – 1.658” (42.11 mm)
Fig. 5 Fig. 7
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ÔÔÔÔ
ÔÔÔÔ
#2
Fig. 10
Fig. 9
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Section 12
Engine Assembly
Page
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Install Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Install Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Install Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Install Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Install Crankcase Cover or Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Install Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Install Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Install Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Install Starter Motor, Breather, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Install Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Flywheel – All Models Except POWERLINKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Flywheel – POWERLINKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Torque Flywheel Nut – 290000, 300000, 540000, 610000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Torque Flywheel Nut – 350000, 380000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Install Fan – 350000, 380000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Install Armatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Install Control Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Install Carburetor and Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Vertical Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Horizontal Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Install Blower Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Install Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Vertical Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Horizontal Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Final Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Static Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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Fig. 3
4. Assemble connecting rod cap to rod with match
marks aligned, Fig. 4. Torque screws to 115 in.
Fig. 1 lbs. (13 Nm).
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Fig. 7
ÏÏÏÏ
Fig. 5
Fig. 6
Vertical Crankshaft
1. Make sure the oil pickup screen (3) is clean and
in position. Fig. 9
2. Place new O-rings (1) on the screws (2). Install 5. Check crankshaft end play. End play should be
to sump, Fig. 7. 0.003 – 0.015” (0.08 – 0.40 mm).
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4. Insert push rods into recess in tappets. 1. Lubricate rocker arms (4) and shaft (2) with
clean engine oil.
NOTE: All Models except 540000, 610000 –
2. Assemble rocker arms, shaft, supports and
Exhaust valve push rods are aluminum.
studs (1) and install on cylinder head, Fig. 12.
Models 540000, 610000 – All push rods are
aluminum. 3. Torque studs to 140 in. lbs. (16 Nm).
Fig. 12
Fig. 10
1. Lubricate rocker arm supports (2) with clean NOTE: Be sure push rods remain seated in recess
engine oil. in tappets.
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Fig. 13 Fig. 15
2. Install valve covers with new gaskets and valve Install Flywheel
cover seals (6), Fig. 14. Torque nuts (7) to 25 in.
lbs. (3 Nm). All models except Engines with POWERLINKt
NOTE: Models 540000, 610000 – 70 in. lbs. (8 Nm) CAUTION: Clean flywheel and crankshaft taper.
Remove ALL oil, dirt and grease.
3. Repeat for No. 2 cylinder.
1. Assemble flywheel to crankshaft and align key-
4. Adjust valve clearance. See Section 1.
ways.
2. Insert flywheel key into crankshaft.
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Fig. 20
Install Control Bracket Fig. 22
1. Install cylinder shields (4) and valley cover (1),
Fig. 21. Torque screws to 65 in. lbs. (7 Nm). Early style: Fig. 23
1. Insert carburetor mounting screws (5) through
carburetor, gasket (1), spacer (4) and gasket (1).
2. Assemble carburetor to manifold.
a. Make sure that locating pin on carburetor
spacer (2) fits in recess in manifold (3).
b. Torque screws to 65 in. lbs. (7 Nm).
Fig. 23
Fig. 21
Models 351700, 380700
2. Connect ground wire harness to stop switch 1. Assemble gaskets (2) and spacer (1) to intake
terminal. manifold.
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Fig. 26
3. Connect choke link (7) to choke lever and install
choke control bracket (5), single barrel
Fig. 24 carburetor, Fig. 27, two barrel carburetor,
Fig. 28. Torque screws (6) to 65 in. lbs. (7 Nm).
All Models
1. Connect governor link (3) to throttle lever (1).
Snap retainer (2) over link, single barrel
carburetor, Fig. 25, two barrel carburetor,
Fig. 26.
Fig. 28
4. Install fuel line and clamp.
Horizontal Crankshaft
Models 290400, 303400, 350400
Fig. 25
1. Assemble gaskets (1), spacer (3) and
carburetor to intake manifold, Fig. 29.
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Fig. 30
3. Connect governor link (9) to throttle lever (7) and
snap retainer (8) over link, Fig. 31.
4. Install governor link spring in loop on retainer.
5. Assemble choke link (6) to carburetor and choke
lever and install choke bracket (10). Torque
screws to 65 in. lbs. (7 Nm).
6. Install fuel line and clamp. Install fuel line at
carburetor. Rotate fuel line clamp tabs
horizontally to prevent interference with air
cleaner base.
NOTE: If carburetor is equipped with anti-afterfire so-
lenoid, route wire under intake manifold and
Fig. 32
through hole in #1 cylinder shield at this time.
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15
14
Fig. 35
11
Fig. 36
Vertical Crankshaft
Models 290700, 303700, 350700
12
Current Style: (Round cartridge) Fig. 37.
1. Install new air cleaner base gasket (6).
Fig. 34 2. Guide breather tube (5) onto nipple on breather
and install air cleaner base on carburetor mount-
8. Connect governor link (14) to throttle lever and ing studs.
snap retainer over link, Fig. 35.
3. Install carburetor mounting nuts (2). Do not
9. Install governor link spring in loop on retainer. tighten nuts at this time.
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Fig. 39
Fig. 40
3. Install two air cleaner base screws (4). Do not
tighten at this time.
4. Install breather deflector (3) and three screws
Fig. 38
(2). Torque all screws to 65 in. lbs. (7 Nm).
Models 351700, 380700 Make sure air inlet tube is installed correctly in air
cleaner base.
1. Install new air cleaner mounting gasket with
adhesive side toward air cleaner base, Fig. 39.
Early Style: (Square cartridge)
2. Guide breather tube onto breather nipple. Install
1. Install new air cleaner base gasket.
air cleaner base on carburetor mounting studs.
2. Guide breather tube onto nipple on breather.
3. Install carburetor shield (2).
Install air cleaner base (1) on carburetor and
4. Install nuts (3) and screws (1) finger tight. support bracket, Fig. 41.
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Fig. 41
3. Install breather deflector (2) and two screws (3). Fig. 43
Do not tighten at this time.
4. Install two air cleaner support screws (4). Torque
screws to 65 in. lbs. (7 Nm).
Make sure air inlet tube is installed correctly in air 2. With the outlet tube (7) to the LEFT, service cover
cleaner base. (3) to the RIGHT, install the mounting band (4).
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WARNING
AVOID INJURY! Complete the
governor static adjustment BEFORE
starting or running engine.
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Dimensional Specifications
NOTE: All dimensions in Inches (Millimeters)
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Description Torque
Air Cleaner Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Guide Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Block Plate Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. lbs. (3 Nm)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 in. lbs. (2 Nm)
Alternator Harness Clamp Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Cleaner Base (to carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Air Cleaner Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 in. lbs. (3 Nm)
Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Blower Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. lbs. (3 Nm)
Carburetor to Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 in. lbs. (13 Nm)
Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 in. lbs. (19 Nm)
Cylinder Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Fan Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 ft. lbs. (170 Nm)
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 in. lbs. (5 Nm)
Governor Control Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Governor Lever Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Rewind Starter (to blower housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Rocker Arm Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
Rocker Arm Stud
– Current Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in. lbs. (11 Nm)
– Early Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 in. lbs. (20 Nm)
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
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Dimensional Specifications
NOTE: All dimensions in Inches (Millimeters)
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Description Torque
Air Cleaner Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Guide Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Block Plate Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. lbs. (3 Nm)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 in. lbs. (2 Nm)
Alternator Harness Clamp Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Cleaner Base (to carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Air Cleaner Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 in. lbs. (3 Nm)
Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Blower Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. lbs. (3 Nm)
Carburetor to Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 in. lbs. (13 Nm)
Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 in. lbs. (19 Nm)
Cylinder Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Fan Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 ft. lbs. (170 Nm)
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 in. lbs. (5 Nm)
Governor Control Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Governor Lever Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Rewind Starter (to blower housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Rocker Arm Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
Rocker Arm Stud
– Current Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in. lbs. (11 Nm)
– Early Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 in. lbs. (20 Nm)
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
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Dimensional Specifications
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Description Torque
Air Cleaner Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Guide Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Block Plate Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. lbs. (3 Nm)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 in. lbs. (2 Nm)
Alternator Harness Clamp Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Cleaner Base (to carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Air Cleaner Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 in. lbs. (3 Nm)
Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Blower Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. lbs. (3 Nm)
Carburetor to Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 in. lbs. (13 Nm)
Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 in. lbs. (19 Nm)
Cylinder Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Fan Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. lbs. (17 Nm)
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 ft. lbs. (170 Nm)
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 in. lbs. (5 Nm)
Governor Control Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Governor Lever Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Rewind Starter (to blower housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Rocker Arm Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
Rocker Arm Stud
– Current Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in. lbs. (11 Nm)
– Early Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 in. lbs. (20 Nm)
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
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Dimensional Specifications
NOTE: All dimensions in Inches (Millimeters)
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Description Torque
Air Cleaner Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 in. lbs. (21 Nm)
Air Guide Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Block Plate Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 in. lbs. (4 Nm)
Alternator Harness Clamp Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Air Cleaner Base (to carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Air Cleaner Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. lbs. (7 Nm)
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 in. lbs. (4 Nm)
Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Blower Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 in. lbs. (5 Nm)
Carburetor to Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Carburetor Intake Elbow to Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 in. lbs. (14 Nm)
Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 in. lbs. (23 Nm)
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 in. lbs. (40 Nm)
Cylinder Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 in. lbs. (23 Nm)
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 ft. lbs. (203 Nm)
Flywheel Fan Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 in. lbs. (5 Nm)
Governor Control Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 in. lbs. (23 Nm)
Governor Lever Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
Ignition Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. lbs. (3 Nm)
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 in. lbs. (20 Nm)
Oil Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 in. lbs. (20 Nm)
Oil Pickup to Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 in. lbs. (9 Nm)
Oil Pump to Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Regulator Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 in. lbs. (10 Nm)
Rocker Arm Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
Rocker Arm Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in. lbs. (11 Nm)
Rotating Screen Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in. lbs. (11 Nm)
Rotating Screen Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 in. lbs. (14 Nm)
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 in. lbs. (20 Nm)
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. lbs. (16 Nm)
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 in. lbs. (8 Nm)
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10”
(254 mm)
8-9/16”
(217 mm)
10”
2” (254 mm)
(51 mm)
8-5/32”
(207 mm)
13/32” Thru Hole (4)
(10 mm)
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