Briggs and Stratton Gasoline and Electric Outboard Engines OEM Service & Repair Manual

Troubleshooting & Repair Manual Gasoline and Electric OUTBOARDS www.mymowerparts.com

FORWARD This manual was written to assist technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton electric- and gasoline-powered outboards. 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 equipment. The troubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate for the Briggs & Stratton products described herein. Alternative methods or procedures may pose risk to personal safety and the safety and/or reliability of the product 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 technician training program.) 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 www.BRIGGSandSTRATTON.com or through a local Authorized Briggs & Stratton Service Dealer. Copyright © 2008 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.

TABLE OF CONTENTS INTRODUCTION Section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING Section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY Section 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHAUL Section 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY Section 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX Section 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Section 1 INTRODUCTION Section Contents Page SAFETY ALERT SYMBOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN THE INTEREST OF SAFETY 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL RECOMMENDATIONS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL RECOMMENDATIONS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication System 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL DRAIN PLUG, OIL FILL AND DIPSTICK 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR SELECTOR 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING GEAR CASE OIL ELECTRIC OUTBOARD 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 CAUTION: Salt water is extremely corrosive to outboard components. Failure or damage related to salt water corrosion is NOT covered under the BRIGGS & STRATTON Warranty. DESIGNED FOR FRESH WATER Rotating parts can contact or entangle hands, feet, hair, clothing, or accessories. Traumatic amputation or severe laceration can result. WARNING •Avoid contact with propeller. Keep people and pets away from propeller while the engine is running. •DO NOT run the outboard out of the water. •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, dan- gling drawstrings or items that could become caught. •Keep lines, rigging and other equipment inside the boat. Starting engine creates sparking. Sparking can ignite nearby flammable gasses. Explosion and fire could result, causing serious injury or death. WARNING •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. Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. ADDING FUEL •Fill fuel tank outdoors or in well ventilated area. •Do not fill portable fuel tank while it is in the boat or inside a vehicle. Always place tank on the ground when filling with gasoline. •Do not overfill tank. Fill tank to approximately 1-1/2 inches below top of neck to allow for fuel expansion. •Keep all fuel away from sparks, open flames, pilot lights, heat, and other ignition sources. •Do not smoke when refueling. •Check fuel lines, tank, cap and fittings frequently for cracks or leaks. Replace if necessary. •Locate the fuel tank in a position that keeps the vent higher than the fuel level. STARTING ENGINE •Make sure spark plug, muffler and fuel cap are in place. •Line from fuel tank is correctly connected to the engine. •Do not crank engine with spark plug removed. •If fuel spills, wait until it evaporates before starting engine. •If engine floods, set choke to RUN position (choke open), place throttle in FAST position and crank until engine starts. TRANSPORTING EQUIPMENT •Transport outboard with transport valve in the OFF position. STORING EQUIPMENT •Store away from furnaces, stoves, water heaters, clothes dryer or other appliances that have pilot light or other ignition source because they can ignite fuel vapors. WARNING

3 HAZARD SYMBOLS AND MEANINGS Unstable Condition Toxic Fumes Electrocution Hot Surface Kickback Fire Moving Parts Explosion Pressure Chemical Burns Eye Protection Required Storage batteries give off explosive hydrogen gas during recharging. Hydrogen gas stays around battery for a long time after battery has been charged. Slightest spark will ignite hydrogen and cause explosion. You can be blinded or severely injured. Battery electrolyte fluid contains acid and is extremely caustic. Contact with battery fluid will cause severe chemical burns. DANGER •Do not allow any open flame, spark, heat, or lit cigarette around battery during, and for several minutes after charging. •Wear protective goggles, rubber apron, and rubber gloves. WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 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. •Be sure the shift selector is in NEUTRAL position before attempting to start the outboard. •When starting engine, pull cord slowly until resistance is felt, then pull rapidly. •Allow the cord to retract slowly. WARNING Running engines produce heat. Temperature of muffler and nearby areas can reach or exceed 150°F (65°C). Severe burns can occur. •Do not touch hot surfaces. •Allow equipment to cool before touching. WARNING Unintentional sparking can result in fire or electric shock. Unintentional start-up can result in entanglement, traumatic amputation, or laceration. BEFORE PERFORMING ADJUSTMENTS OR REPAIRS •Disconnect spark plug wire and keep it away from spark plug. WHEN TESTING FOR SPARK •Use approved BRIGGS & STRATTON spark plug tester Part No. 19368. •Do not check for spark with spark plug removed.

4 IN THE INTEREST OF SAFETY Safety Alert Symbols 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 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, might result in death or serious injury. CAUTION: When used without the alert symbol, indicates a situation that could result in damage to equipment. NOTE: This notation is used to inform you of a method, reference or procedure that could assist with specific operations or decisions. CAUTION Before attempting to service this equipment, read the entire owner’s manual and operating instructions. •Death, personal injury and/or property damage may occur unless service instructions are followed carefully. wFailure to follow the warnings listed below could result in death, serious injury (including paralysis) or property damage. •DO NOT run engine in an enclosed area. (Exhaust gases contain carbon monoxide, an odorless and deadly poison.) •DO NOT place hands or feet near moving or rotating parts. •DO NOT operate engine if gasoline is spilled or when smell of gasoline is present or other explosive conditions exist. (Move equipment away from spill and avoid any ignition until gasoline has evaporated.) •DO NOT tamper with links or other parts to increase engine speed. (This engine uses a non-adjustable, electronic engine speed limiter.) •DO NOT run engine without the blower housing or with other safety shields removed when doing repairs. •DO NOT crank engine with spark plug removed. (If engine is flooded, place throttle in the FAST position and crank until engine starts.) •DO NOT operate engine without a muffler. (Inspect periodically and replace if worn or leaking. If engine is equipped with muffler deflector, inspect periodically and replace if necessary. Replacement parts must be same as on original equipment.) •DO NOT run the outboard unless the propeller is either removed from the outboard or in water. Remove the spark plug lead and select NEUTRAL when servicing the outboard. Re- move the propeller whenever it is necessary to test run the outboard. •PRIOR TO WORK, read and understand the section(s) of this manual that pertain to the job. Follow all safety warnings. •PULL STARTER CORD SLOWLY until resistance is felt. Then pull cord rapidly to avoid kickback and prevent hand or arm injury. •WEAR suitable eye protection (safety glasses, goggles or face shield) when performing repair procedures. •PREVENT ACCIDENTAL STARTING by remov- ing spark plug wire from spark plug when servicing engine or equipment. •USE fresh gasoline. Stale fuel can gum carburetor and cause leakage. •CHECK fuel lines and fittings frequently for cracks or leaks. Replace if necessary. •USE Genuine Briggs & Stratton Parts or their equivalent ONLY . The use of replacement parts, which are not of equivalent quality, may damage the engine.

5 FUEL RECOMMENDATIONS Gasoline Use clean, fresh, unleaded gasoline. Leaded gasoline may be used if unleaded is not available. A minimum of 85 octane is recommended. The use of unleaded gasoline results in fewer combustion deposits and longer valve life. NOTE: We do not recommend the use of gasoline that contains alcohol, such as gasohol. However, if used, it must not contain more than 10 percent Ethanol and must be removed from the engine during storage. Do not use gasoline that contains Methanol. Only purchase a 30-day supply of gasoline. Fresh gasoline minimizes gum deposits and also will en- sure fuel volatility tailored for the season in which the engine will be operated. NOTE: The use of a fuel additive, such as Briggs & Stratton Gasoline Additive (#5041) or equivalent, will minimize the formation of fuel gum deposits during storage. Such an additive may be added to the fuel tank or storage container. OIL RECOMMENDATIONS Lubrication System Oil has four purposes. It cools, it cleans, it seals, and it lubricates. This engine is lubricated with an oil slinger. During normal operation, small particles of dust, metal from the cylinder walls, pistons, bearings, and combustion deposits will gradually contaminate the oil. If the oil is not changed regularly, these foreign particles can cause increased friction and an abrasive action, which shortens the life of the engine. Fresh oil also assists in cooling. Old oil gradually becomes thick and loses its cooling ability and lubricating qualities. Engine Oil Use a high quality detergent oil classified “For Service SF, SG, SH, SJ” or higher. Briggs & Stratton strongly recommends the use of synthetic oil such as Briggs & Stratton (#100030C) or equivalent. If not available, SAE 30 weight oil is an acceptable substitute. No special additives should be used with recommended oils. Do not mix oil with gasoline. °C -30 STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE °F -20 0 20 40 60 80 100 -20 -10 0 10 20 30 40 ** 32 SAE 30 Air-cooled engines run hotter than automotive engines. The use of multi-viscosity oils, (10W-30 etc.) in ambient temperatures above 40°F (4°C), will result in high oil consumption. If multi-viscosity oil is used, check oil level more frequently to prevent any possible engine damage due to lack of lubrication. SAE 30 oil, if used in ambient temperatures below 40°F (4°C), will result in hard starting and possible engine damage due to inadequate lubrication. Synthetic oil meeting ILSACGF-2, API certification mark and API service symbol with “SJ/CF ENERGY CONSERVING” rating or higher, is acceptable oil at all temperatures. NOTE: Use of synthetic oil does not alter the required oil change intervals. OIL DRAIN PLUG, OIL FILL AND DIPSTICK 1. Change oil every 25 hours. 2. Position the engine vertically to check or change the oil. 3. Remove oil drain plug (Figure 1) . Drain oil while engine is still warm. Fig. 1 − Oil Drain Plug  4. Install drain plug. Torque to 10 ft. lbs. (14 Nm). 5. Remove dipstick (Figure 2) . Refill slowly with 24 oz. (0.75 qt., 0.7 L) of new oil with the proper service classification and viscosity grade. Do not overfill.

6 Fig. 2 − Dipstick  6. Install the dipstick. 7. Start and run engine at idle to check for oil leaks. 8. Check the oil level. The oil level should be between the ADD and FULL marks on the dipstick. Add new oil if required (Figure 3). Fig. 3 − Dipstick Markings GEAR SELECTOR Operation The outboard operator selects gears with the shift lever handle (Figure 4)  on the starboard (right) side of the outboard which acts on the shift cam/rod assembly . The shift lever is connected to the shift cam/rod by an upper rod . The rods are connected with a clamp  that also provides for NEUTRAL adjustment. Fig. 4 − Gear Selector Operation     The forward gear (Figure 5) 12 and reverse gear  are driven simultaneously by the pinion gear 11 and spin freely on the propeller shaft . The spring  inside the propeller shaft applies forward pressure on the roll pin , sliding clutch  and shift cam follower . The shift cam/rod  is stepped to control the location of the sliding clutch through the shifter pin. The sliding clutch is splined to the propeller shaft. Fig. 5 − Forward Gear         12 11

7 Reverse When the shifter is moved to the REVERSE position, the shift cam (Figure 6)  is pressed down to its lowest position in the gear case. The highest surface of the cam presses the cam follower  rearward, engaging the sliding clutch  to the REVERSE gear . Fig. 6 − Reverse     Neutral When the shifter is in the NEUTRAL position the shift cam (Figure 7)  is in the middle position. The cam- follower  is on the middle detent of the shifter cam. The sliding clutch  is not engaged to either the FORWARD or the REVERSE gears. Fig. 7 − Neutral    Forward When the shifter is set to the FORWARD position, the shift cam (Figure 8)  is pulled to its highest position in the gear case. The spring  inside the propeller shaft pushes the sliding clutch  and cam follower  forward, engaging the sliding clutch to the FORWARD gear . Fig. 8 − Forward      CHANGING GEAR CASE OIL 1. Remove oil drain/fill plug (Figure 9)  and vent plug . Fig. 9 − Gear Case Oil   2. Drain the gear lube into an approved container. 3. Fill gear case with 4 oz. of 80-90W gear oil. Insert the tip of the oil bottle into the oil fill (lower) hole. Squeeze the bottle until the oil is just to the point of overflowing at the vent (upper) hole. 4. Install vent plug in top hole. Torque to: 20 in. lbs. (2 Nm). 5. Install oil drain/fill plug in lower hole. Torque to: 45 in. lbs. (5 Nm).

Briggs and Stratton Gasoline and Electric Outboard Engines OEM Service & Repair Manual

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