Briggs & Stratton Single Cylinder OHV Air-Cooled Engine Service Repair Workshop Manual

Briggs & Stratton SINGLE CYLINDER OHV AIR-COOLED ENGINES 273521 Twin Cylinder OHV Air-Cooled Engines 271172 Twin Cylinder L-Head Air-Cooled Engines 270962 Single Cylinder L-Head Air-Cooled Engines 276535 Two-Cycle Snow Engines CE8069 Out of Production Engines (1919-1981) Repair Manuals for other Briggs & Stratton Engines: Single Cylinder OHV Air-Cooled Engines POST OFFICE BOX 702 MILWAUKEE, WI 53201 USA ©2009 Briggs & Stratton Corporation BRIGGS&STRATTON CORPORATION Part No. 276781-8/09 Quality Starts With A Master Service Technician www.ThePowerPortal.com (Dealers) BRIGGSandSTRATTON.COM (Consumers)

FORWARD This manual was written to assist engine technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton engines. It assumes that persons using this manual have been properly trained in and are familiar with the servicing procedures for these products, including the proper use of required tools and safety equipment and the application of appropriate safety practices. Persons untrained or unfamiliar with these procedures or products should not attempt to perform such work. Proper maintenance and repair is important to safe, reliable operation of all engines and engine-driven systems. The troubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate for the Briggs & Stratton engines described herein. Alternative methods or procedures may pose risk to personal safety and the safety and/or reliability of the engine and are not endorsed or recommended by Briggs & Stratton. All information, illustrations, and specifications contained in this manual were based on the data available at the time of publication. Briggs & Stratton Corporation reserves the right to change, alter, or otherwise improve the product or the product manuals at any time without prior notice. Briggs & Stratton offers two complementary publications to enhance understanding of engine technology, maintenance, and repair. (Neither publication, however, is a substitution for a recognized training program for engine technicians.) • For consumers, Small Engine Care & Repair (p/n 274041) provides a comprehensive overview of how small air-cooled engines work, basic troubleshooting, and step-by-step maintenance procedures. • For engine technicians and consumers alike, an in-depth study of engine theory and operation can be found in the textbook Small Engines (p/n CE8020). Both publications can be purchased at BRIGGSandSTRATTON.COM or through a local Authorized Briggs & Stratton Service Dealer. Copyright © 2009 Briggs & Stratton Corporation All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying or recording by any information storage and retrieval system, without prior written permission from Briggs & Stratton Corporation.

6 This Engine Repair Manual includes the following Engine Models: • MODEL 110000 HORIZONTAL SERIES • MODEL 120000 HORIZONTAL SERIES • MODEL 150000 HORIZONTAL SERIES • MODEL 200000 HORIZONTAL SERIES • MODEL 210000 HORIZONTAL SERIES • MODELS 97700 & 99700 VERTICAL SERIES • MODEL 110000 VERTICAL SERIES • MODEL 120000 VERTICAL SERIES • MODEL 210000 VERTICAL SERIES • MODEL 280000 VERTICAL SERIES • MODEL 310000 VERTICAL SERIES • MODEL 330000 VERTICAL SERIES

7 1 2 3 4 5 6 8 9 10 11 12 SECTION 1 - Safety, Maintenance and Adjustments SECTION 2 - Troubleshooting SECTION 3 - Exhaust Systems SECTION 5 - Governor Systems SECTION 6 - Cylinder Heads and Valves SECTION 7 - Starters SECTION 8 - Lubrication Systems SECTION 9 - Cylinders, Covers and Sumps SECTION 10 - Crankshafts, Camshafts, Balancing Systems, and Gear Reductions SECTION 11 - Pistons, Rings and Connecting Rods SECTION 12 - Engine Specifications SECTION 4 - Fuel Systems and Carburetion

THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE, ECONOMICAL AND RELIABLE

3 1 1 SECTION 1 - SAFETY, MAINTENANCE, AND ADJUSTMENTS ENGINE SAFETY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 BRIGGS & STRATTON NUMERICAL IDENTIFICATION SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - 7 ENGINE MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 FUEL AND OIL RECOMMENDATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 MAINTENANCE CHART - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 FLYWHEEL BRAKE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 COMBUSTION CHAMBER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11 AIR FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11 SNOW HOOD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 OIL AND OIL FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14 SPARK PLUG - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14 COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15 ENGINE ADJUSTMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16 ADJUST REMOTE CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16 GOVERNOR ADJUSTMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 ADJUST VALVE CLEARANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

4 1 1 ENGINE SAFETY This repair manual contains safety information that is designed to: • Make you aware of hazards associated with engines. • Inform you of the risk of injury associated with those hazards. • Tell you how to avoid or reduce the risk of injury. Signal Words in Safety Messages The safety alert symbol ( ) is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, could result in minor or moderate injury. NOTICE indicates a situation that could result in damage to the product. Prior to work, read and understand the section(s) of this manual that pertain to the job. Follow all safety warnings. • Wear suitable eye protection. • When servicing engines or equipment, prevent accidental starting by disconnecting spark plug wire from the spark plug(s) and disconnect negative battery cable. • Periodically clean engine. Keep governor parts free of dirt, grass, and other debris which can affect engine speed and cooling. • Always use fresh gasoline. Stale fuel can cause gum deposits in the carburetor and cause leakage, flow restrictions, or other failures. • Check fuel lines and fittings frequently for cracks or leaks and replace if necessary. Hazard Symbols and Meanings WARNING Before attempting to service this equipment, read and understand this manual and the operating instructions of the engine and the equipment it powers. Failure to follow instructions could result in property damage, serious injury (including paralysis) or even death.

5 1 1 WARNING Briggs & Stratton does not approve or autho- rize the use of these engines on 3-wheel All Terrain Vehicles (ATV’s), motor bikes, fun/rec- reational go-karts, aircraft products, or vehicles intended for use in competitive events. Use of these engines in such applications could result in property damage, serious injury (including paralysis), or even death. WARNING The engine exhaust from this product contains chemicals known the State of California to cause cancer, birth defects, and other repro- ductive harm. WARNING Gasoline and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. When adding fuel: • Turn engine OFF and let engine cool for at least 2 minutes before removing the fuel cap. • Fill fuel tank outdoors or in a well-ventilated area. • Do not overfill fuel tank. To allow for expansion of the gasoline, do not fill above the bottom of the fuel tank neck. • Keep gasoline away from sparks, open flames, pilot lights, heat and other ignition sources. • Check fuel lines, tank, cap, and fittings frequently for cracks or leaks. Replace if necessary. • If fuel spills, wait until it evaporates before starting engine. When starting engine: • Make sure spark plug, muffler, fuel cap, and air cleaner are in place. • Do not crank engine with spark plug removed. • If fuel spills, wait until it evaporates before starting engine. • If engine floods, set choke (if equipped) to OPEN/RUN posi- tion. Place throttle (if equipped) in FAST and crank until engine starts. When operating equipment: • Do not tip engine or equipment at an angle which would cause fuel to spill. • Do not choke carburetor to stop engine. • Never start or run the engine with the air cleaner assembly (if equipped) or the air filter (if equipped) removed. When changing oil: • If you drain the oil from the top oil fill tube, the fuel tank must be empty or fuel can leak out and result in a fire or explosion. When transporting equipment: • Transport with fuel tank empty or with fuel shut-off valve set to OFF. When storing gasoline or equipment with fuel in the tank: • Store away from furnaces, stoves, water heaters, or other appliances that have a pilot light or other ignition source because they can ignite gasoline vapors. WARNING Running engines produce heat. Engine parts, especially mufflers, become extremely hot. Severe thermal burns can occur on contact. Combustible debris, such as leaves, grass, brush, etc. can catch fire. • Allow muffler, engine cylinder fins, and radiator to cool before touching. • Remove accumulated debris from muffler area and cylinder fins. • It is a violation of California Public Resource Code, Section 4442, to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other States and Federal juris- dictions may have similar laws. Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine. WARNING Unintentional sparking can result in fire or electrical shock. Unintentional start-up can result in entanglement, traumatic amputation, or severe lacerations. Before performing adjustments or repairs: • Disconnect spark plug wire and keep it away from spark plug. • Disconnect the negative (-) battery terminal. When testing for spark: • Use approved spark plug tester. • Do not check for spark with spark plug removed. WARNING Engines give off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause nausea, fainting, or death. • Start and run engine outdoors. • Do not start or run engine in an enclosed area, even if doors and windows are open.

6 1 1 WARNING Starting engine creates sparking. Sparking can ignite nearby flammable gases. Explosion and fire could result. • If there is a natural or LP gas leak in the area, do not start engine. • Do not use pressurized starting fluids because vapors are flammable. WARNING Rotating parts can contact or entangle hands, feet, hair, clothing, or accesso- ries. Traumatic amputation or severe lacerations can result. • Operate equipment with guards in place. • Keep hands and feet away from rotating parts. • Tie up long hair and remove jewelry. • Do not wear loose-fitting clothing, dangling drawstrings, or items that could become entan- gled in the equipment. WARNING Charging batteries produce hydrogen gas. Do not store or charge a battery near an open flame or device that uti- lizes a pilot light or can create a spark. WARNING Kerosene and its vapors are extremely flammable and should be handled with the same precautions as gasoline. WARNING Damaged, worn, or loose fuel components can leak fuel. Explosion or fire could result. • All fuel components should be in good condition and properly maintained. • Repairs should only be made with factory approved parts. • Repair work should be done by a qualified technician. • Flexible supply lines should be checked regu- larly to make sure they are in good condition. WARNING Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go. Broken bones, fractures, bruises, or sprains could result. • When starting engine, pull the starter cord slowly until resistance is felt and then pull rap- idly to avoid kickback. • Remove all external equipment/engine loads before starting engine. • Direct-coupled equipment components, such as but not limited to blades, impellers, pulleys, and sprockets, must be securely attached. WARNING Prolonged or repeated contact with used motor oil could cause injury. • Used motor oil has been shown to cause skin cancer in certain laboratory animals. • Thoroughly wash exposed areas with soap and water.

7 1 1 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 TYPE 1234–01 , 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 12/08 FIRST DIGIT AFTER DISPLACEMENT SECOND DIGIT AFTER DISPLACEMENT THIRD DIGIT AFTER DISPLACEMENT FOURTH DIGIT AFTER DISPLACEMENT A B C D E CUBIC INCH DISPLACEMENT BASIC DESIGN SERIES CRANKSHAFT ORIENTATION PTO BEARING, REDUCTION GEAR, AUXILIARY DRIVE, LUBRICATION TYPE OF STARTER 2 5 6 8 9 10 11 12 13 15 16 18 19 20 21 22 23 24 25 28 29 30 31 32 35 38 40 42 43 44 46 47 49 52 54 58 61 0 1 2 3 4 5 6 7 8 9 A to Z 0 to 4 - Horizontal Shaft 5 to 9 - Vertical Shaft A to G - Horizontal Shaft H to Z - Vertical Shaft 0 - Plain Bearing/DU Non–Flange Mount 1 - Plain Bearing Flange Mounting 2 - Sleeve Bearing Flange Mounting Splash Lube 3 - Ball Bearing Flange Mounting Splash Lube 4 - Ball Bearing Flange Mounting Pressure Lubrication 5 - Plain Bearing Gear Reduction (6 to 1) CCW Rotation Flange Mounting 6 - Ball Bearing Gear Reduction (2 to 1) CCW Rotation 7 - Plain Bearing Pressure Lubrication 8 - Plain Bearing Auxiliary Drive (PTO) Perpendicular to Crankshaft 9 - Plain Bearing Auxiliary Drive Parallel to Crankshaft A - Plain Bearing Pressure Lubrication Without Oil Filter 0 - Without Starter 1 - Rope Starter 2 - Rewind Starter 3 - Electric Starter Only 110 or 230 Volt Gear Drive 4 - Electric Starter/ 110 or 230 Volt Gear Drive with Alternator 5 - Electric Starter Only 12 or 24 Volt Gear Drive 6 - Alternator Only 7 - Electric Starter 12 or 24 Volt Gear Drive with Alternator 8 - Vertical Pull Starter or Side Pull Starter 9 - Mechanical Starter A - Electric Starter 12 or 24 Volt Gear Drive with Alternator and Inverter EXAMPLE - To identify Model 303447: 30 3 4 4 7 30 Cubic Inch Design Series 3 Horizontal Shaft Ball Bearing Flange Mounting Pressure Lubrication Electric Starter 12 or 24 Volt Gear Drive with Alternator

Briggs & Stratton Single Cylinder OHV Air-Cooled Engine Service Repair Workshop Manual

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