Section 1 GENERAL INFORMATION
CORRECT LUBRICATION IS IMPORTANT
TUNE-UP PROCEDURE
OVERHAUL PROCEDURE
REPAIRS
CHECK - UP
Check Carburetion
BRIGGS & STRATTON NUMERICAL MODEL NUMBER SYSTEM
Repair Instructions IV (Form 4750) Section 2 IGNITION
SPECIFICATIONS FOR ALL POPULAR ENGINE MODELS
Fig. 5 - MAGNETRON" Module
INSTALLING MAGNETRONT" MODULE
Removing Breaker Cover
Breaker Point Plunger
Adjust Armature Air Gap
Adjust and Clean Breaker Points
TIMING MAGNETRONTM IGNITION
ADJUST ARMATURE TIMING
REPLACING BREAKER PLUNGER AND BUSHING
MAGNA-MATIC SYSTEM
Armature Air Gap
Replace Coil or Armature or Both
Remove Breaker Box
Clean Breaker Points
Section 3 CARBURETION
OIL FOAM AIR CLEANER VARIATIONS
CARTRIDGE AIR CLEANER - REVERSE AIR FLOW
Fig. 8 - Style of Carburetors (Contd.)
REPAIR PROCEDURE
Fig. 10 - Checking Tank Top Flatness
Fig. 15 -- Inserting Choke Link
Fig. 18 - Removing Mounting Bolts
Fig. 20 - Removing Fuel Tank Assembly
Removing Nylon Choke and Shaft
Carburetor Assembly, Zinc and "Minion"
Assembly, Carburetor to Tank, Choke-A-Matic, Model Series 82000, 92000
Choke-A-Matlc Adjustment
Carburetor and Tank Assembly - TM-5-4240-501-14P_108
Fig. 46 - Removing and Inserting Spiral
Choke-A-Matic Linkage
Install Carburetor - TM-5-4240-501-14P_111
Carburetor and Tank Assembly - TM-5-4240-501-14P_112
Fig. 64 - Replacing Nylon Fuel Pipe
Install Carburetor - TM-5-4240-501-14P_114
Disassemble Carburetor, Small One-Piece Flo-Jet
Inspection - TM-5-4240-501-14P_116
Checking Float Level
CARBURETION - TM-5-4240-501-14P_118
Remove Throttle Shaft and Bushings
CARBURETION - TM-5-4240-501-14P_120
Idling Device and Throttle Control
CARBURETION - TM-5-4240-501-14P_122
Carburetor Adjustments
CARBURETION L. P. Fuel Governed Idle
Adjusting Carburetor, L.P. Fuel System
CARBURETION Kerosene and Fuel Pumps
Fuel Pumps (Crankcase Vacuum Operated)
Operation - TM-5-4240-501-14P_128
To Install Fuel Pump
Section 4 GOV. CONTROLS & CARB. LINKAGE
GOV. CONTROLS & CARB. LINKAGE General
GOV. CONTROLS & CARB. LINKAGE
GOV. CONTROLS & CARB. LINKAGE Models 6, 8, 60000, 80000 Horiz. Shaft
GOV. CONTROLS & CARB. LINKAGE Models 6, 8, 60000, 80000 Vertical Shaft
GOV. CONTROLS & CARB. LINKAGE Models 6, 8, 60000, 80000, 82000, 92000 Vertical Shaft
REMOVAL AND INSTALLATION OF GOVERNOR SPRING ON MODEL SERIES 92500 AND 92900
REMOVAL AND INSTALLATION OF GOVERNOR SPRING ON MODEL SERIES 92500 AND 92900 (cont)
alluminum engine model
governed idle
cast iron engine model
REMOTE GOVERNOR CONTROL
AIR VANE GOVERNOR
Fig. 5 - Install Crank and Lever
Adjustment - TM-5-4240-501-14P_144
MECHANICAL GOVERNOR
Re-Assembly
Fig. 17. Showing Governor Shaft in Proper Position
Fig. 21. Setting Top No Load Speed
OBTAINING CLOSER GOVERNING (Generator Applications Only)
Section 6 COMPRESSION
TABLE NO. 1 CYLINDER HEAD TORQUE
TABLE NO. 2 VALVE TAPPET CLEARANCE
Valve Guides
Installing Replacement Bushing
TABLE NO. 3 VALVE SEAT INSERTS
To Remove Valve Seat Insert
To Drive In New Valve Seat Insert
Valves, Valve Conversions
TO CONVERT FROM STANDARD EXHAUST VALVE TO STELLITEC EXHAUST VALVE WITH VALVE ROTATOR
TABLE NO. 7
Section 7 STARTERS & CHARGING SYSTEMS
Fig. 6 - Install Spring
Old Style with Guide Lug
WINDUP STARTER
Inspect Starter Parts
Fig. 28 - Removing Spring Anchor
Fig. 35 -- Installing Spring
Equipment to Test Starter Motors
TROUBLESHOOTING 12 VOLT & 120 VOLT STARTING SYSTEMS
Starter Motor Spins; But Does Not Crank Engine
Cranks Engine Slowly
BATTERY CHARGER TESTER
CHECKING THE STARTER MOTOR DRIVE AND CLUTCH
DISASSEMBLY OF STARTER MOTOR - TM-5-4240-501-14P_174
ASSEMBLY OF STARTER MOTOR
STARTERS Nicad System
Checking Battery - TM-5-4240-501-14P_177
STARTERS
CHECKING STARTER MOTOR DRIVE - TM-5-4240-501-14P_179
CHECKING THE 120 VOLT AC STARTER MOTOR
CHECKING THE RECTIFIER ASSEMBLY 120 VAC STARTER MOTOR
INSTALL LEADS IN EXACT POSITION SHOWN
GEAR DRIVE STARTERS
CHECKING STARTER MOTORS - TM-5-4240-501-14P_184
ASSEMBLING STARTER MOTOR DRIVE
STARTERS-Briggs & Stratton Gear Drive 12V & 120V
Fig. 95 - Removing Motor Housing
DISASSEMBLING CONTROL ASSEMBLY
ASSEMBLY OF STATOR MOTOR
Fig. 107 - Assembling Armature to End Cap
Checking Starter Motors - TM-5-4240-501-14P_191
Fig. 111 - Starter Motors ... Exploded Views
12 VOLT DC STARTER MOTORS
DISASSEMBLY OF STARTER MOTORS
Fig. 119 - Checking Rectifier Assembly
CHECKING STARTER MOTOR DRIVE - TM-5-4240-501-14P_196
DISASSEMBLY OF STARTER MOTOR - TM-5-4240-501-14P_197
Fig. 128 - Installing Brushes
Emergency Winter Operation
STARTER-GENERATOR WIRING DIAGRAM
CHECKING BATTERY - TM-5-4240-501-14P_201
CHECKING STARTER-GENERATOR AND REGULATOR
Belt Adjustment Procedure
Final Check (120 Volt AC Starter Motor)
Fig. 141 - Adjust Belt
ALTERNATOR TROUBLESHOOTING
Equipment to Test Alternators
AMP ALTERNATOR Used on Model Series 130000
Fig. 156 Stator Assembly Location
Replacing Defective Rectifier Box
AC Only Alternator
5 Amp AC - 3 Amp DC - Rectifier Plug Type
TESTING FOR SHORT IN ALTERNATOR SYSTEM
TESTING ALTERNATOR AC CIRCUIT (Lighting)
Dual Circuit Alternator with Fuse
Testing for Short in Stator or in Rectifier
Testing Rectifier - TM-5-4240-501-14P_217
Condition Found (Fuse Blown)
Testing Isolation Diode
Testing Rectifier - TM-5-4240-501-14P_220
Fig. 197 - Testing Output
4 AMP NON-REGULATED ALTERNATOR
Testing Stator
THE TRI-CIRCUIT ALTERNATOR
TESTING STATOR COILS
10 AMP REGULATED ALTERNATOR
Fig. 216 - Testing Stator Coils for Continuity
10 AMP REGULATED ALTERNATOR Used on Model Series 320400
Testing Rectifier-Regulator Assembly
Capacity Chart
Change Oil (Gear Reduction) Cast Iron Engines
Checking Breathers
OIL SLINGER Aluminum Alloy Engines
Section 9 PISTONS - RINGS - RODS
Check Rings
Assemble Piston and Connecting Rod
Fig. 11. Connecting Rod Installation
Section 10 CRANKSHAFTS & CAM GEARS
Fig. 4. Remove or Install Crankshaft
CHECKING CRANKSHAFT
CHECKING CAM GEAR
Checking Compression Release Cam
INSTALL CRANKSHAFT AND CAM GEAR
Aluminum Engines -- Ball Bearing
Fig. 20. Checking Crankshaft End Play
CHECKING AND CORRECTING CRANKSHAFT END PLAY
CHECK CAM GEAR
CAM GEAR DISASSEMBLY - EARLY DESIGN
REMOVE CONTROL LEVER SHAFT
Section 11 CYLINDERS & BEARINGS
Fig. 2 - Honing Cylinder
To Hone Cylinder
CYLINDER FINISH AND CLEANING
Fig. 6 - Checking Bearing
TABLE NO. 3 MAIN BEARING TOOL CHART
Fig. 8 - Notching Cylinder Hub
MAGNETO BEARING
CHECKING CAM GEAR BEARINGS
Cylinders
Section 12 SYNCHRO-BALANCE
Fig. 3 -- Installing and Timing PTO Drive Gear
ASSEMBLY OF COUNTERWEIGHTS
Fig. 9 - Disassembling Counterweight
Section 13 TOOLS
BRIGGS & STRATTON REPAIR TOOLS
BRIGGS & STRATTON REPAIR TOOLS (cont)
valve seat repair tools
hone set
REAMERS
PLUG GAUGES
CRANKCASE SUPPORT JACK
Section 14 THEORIES OF OPERATION
Compression
piston displacement
relative importance of valves
valve part names
margin dimensions
Atmospheric Pressure
Airfoil
Idle Valve
VACU-JET CARBURETORS OR SUCTION FEED - TM-5-4240-501-14P_282
VACU-JET CARBURETORS OR SUCTION FEED - TM-5-4240-501-14P_283
PULSA- JET CAR BURETORS
Gas and Oil
IGNITION - TM-5-4240-501-14P_286
IGNITION - TM-5-4240-501-14P_287
IGNITION (cont) - TM-5-4240-501-14P_288
IGNITION (cont) - TM-5-4240-501-14P_289
"EASY SPIN" STARTING
GOVERNING
counterweights
CORRECT LUBRICATION IS IMPORTANT
TUNE-UP PROCEDURE
OVERHAUL PROCEDURE
REPAIRS
CHECK - UP
Check Carburetion
BRIGGS & STRATTON NUMERICAL MODEL NUMBER SYSTEM
Repair Instructions IV (Form 4750) Section 2 IGNITION
SPECIFICATIONS FOR ALL POPULAR ENGINE MODELS
Fig. 5 - MAGNETRON" Module
INSTALLING MAGNETRONT" MODULE
Removing Breaker Cover
Breaker Point Plunger
Adjust Armature Air Gap
Adjust and Clean Breaker Points
TIMING MAGNETRONTM IGNITION
ADJUST ARMATURE TIMING
REPLACING BREAKER PLUNGER AND BUSHING
MAGNA-MATIC SYSTEM
Armature Air Gap
Replace Coil or Armature or Both
Remove Breaker Box
Clean Breaker Points
Section 3 CARBURETION
OIL FOAM AIR CLEANER VARIATIONS
CARTRIDGE AIR CLEANER - REVERSE AIR FLOW
Fig. 8 - Style of Carburetors (Contd.)
REPAIR PROCEDURE
Fig. 10 - Checking Tank Top Flatness
Fig. 15 -- Inserting Choke Link
Fig. 18 - Removing Mounting Bolts
Fig. 20 - Removing Fuel Tank Assembly
Removing Nylon Choke and Shaft
Carburetor Assembly, Zinc and "Minion"
Assembly, Carburetor to Tank, Choke-A-Matic, Model Series 82000, 92000
Choke-A-Matlc Adjustment
Carburetor and Tank Assembly - TM-5-4240-501-14P_108
Fig. 46 - Removing and Inserting Spiral
Choke-A-Matic Linkage
Install Carburetor - TM-5-4240-501-14P_111
Carburetor and Tank Assembly - TM-5-4240-501-14P_112
Fig. 64 - Replacing Nylon Fuel Pipe
Install Carburetor - TM-5-4240-501-14P_114
Disassemble Carburetor, Small One-Piece Flo-Jet
Inspection - TM-5-4240-501-14P_116
Checking Float Level
CARBURETION - TM-5-4240-501-14P_118
Remove Throttle Shaft and Bushings
CARBURETION - TM-5-4240-501-14P_120
Idling Device and Throttle Control
CARBURETION - TM-5-4240-501-14P_122
Carburetor Adjustments
CARBURETION L. P. Fuel Governed Idle
Adjusting Carburetor, L.P. Fuel System
CARBURETION Kerosene and Fuel Pumps
Fuel Pumps (Crankcase Vacuum Operated)
Operation - TM-5-4240-501-14P_128
To Install Fuel Pump
Section 4 GOV. CONTROLS & CARB. LINKAGE
GOV. CONTROLS & CARB. LINKAGE General
GOV. CONTROLS & CARB. LINKAGE
GOV. CONTROLS & CARB. LINKAGE Models 6, 8, 60000, 80000 Horiz. Shaft
GOV. CONTROLS & CARB. LINKAGE Models 6, 8, 60000, 80000 Vertical Shaft
GOV. CONTROLS & CARB. LINKAGE Models 6, 8, 60000, 80000, 82000, 92000 Vertical Shaft
REMOVAL AND INSTALLATION OF GOVERNOR SPRING ON MODEL SERIES 92500 AND 92900
REMOVAL AND INSTALLATION OF GOVERNOR SPRING ON MODEL SERIES 92500 AND 92900 (cont)
alluminum engine model
governed idle
cast iron engine model
REMOTE GOVERNOR CONTROL
AIR VANE GOVERNOR
Fig. 5 - Install Crank and Lever
Adjustment - TM-5-4240-501-14P_144
MECHANICAL GOVERNOR
Re-Assembly
Fig. 17. Showing Governor Shaft in Proper Position
Fig. 21. Setting Top No Load Speed
OBTAINING CLOSER GOVERNING (Generator Applications Only)
Section 6 COMPRESSION
TABLE NO. 1 CYLINDER HEAD TORQUE
TABLE NO. 2 VALVE TAPPET CLEARANCE
Valve Guides
Installing Replacement Bushing
TABLE NO. 3 VALVE SEAT INSERTS
To Remove Valve Seat Insert
To Drive In New Valve Seat Insert
Valves, Valve Conversions
TO CONVERT FROM STANDARD EXHAUST VALVE TO STELLITEC EXHAUST VALVE WITH VALVE ROTATOR
TABLE NO. 7
Section 7 STARTERS & CHARGING SYSTEMS
Fig. 6 - Install Spring
Old Style with Guide Lug
WINDUP STARTER
Inspect Starter Parts
Fig. 28 - Removing Spring Anchor
Fig. 35 -- Installing Spring
Equipment to Test Starter Motors
TROUBLESHOOTING 12 VOLT & 120 VOLT STARTING SYSTEMS
Starter Motor Spins; But Does Not Crank Engine
Cranks Engine Slowly
BATTERY CHARGER TESTER
CHECKING THE STARTER MOTOR DRIVE AND CLUTCH
DISASSEMBLY OF STARTER MOTOR - TM-5-4240-501-14P_174
ASSEMBLY OF STARTER MOTOR
STARTERS Nicad System
Checking Battery - TM-5-4240-501-14P_177
STARTERS
CHECKING STARTER MOTOR DRIVE - TM-5-4240-501-14P_179
CHECKING THE 120 VOLT AC STARTER MOTOR
CHECKING THE RECTIFIER ASSEMBLY 120 VAC STARTER MOTOR
INSTALL LEADS IN EXACT POSITION SHOWN
GEAR DRIVE STARTERS
CHECKING STARTER MOTORS - TM-5-4240-501-14P_184
ASSEMBLING STARTER MOTOR DRIVE
STARTERS-Briggs & Stratton Gear Drive 12V & 120V
Fig. 95 - Removing Motor Housing
DISASSEMBLING CONTROL ASSEMBLY
ASSEMBLY OF STATOR MOTOR
Fig. 107 - Assembling Armature to End Cap
Checking Starter Motors - TM-5-4240-501-14P_191
Fig. 111 - Starter Motors ... Exploded Views
12 VOLT DC STARTER MOTORS
DISASSEMBLY OF STARTER MOTORS
Fig. 119 - Checking Rectifier Assembly
CHECKING STARTER MOTOR DRIVE - TM-5-4240-501-14P_196
DISASSEMBLY OF STARTER MOTOR - TM-5-4240-501-14P_197
Fig. 128 - Installing Brushes
Emergency Winter Operation
STARTER-GENERATOR WIRING DIAGRAM
CHECKING BATTERY - TM-5-4240-501-14P_201
CHECKING STARTER-GENERATOR AND REGULATOR
Belt Adjustment Procedure
Final Check (120 Volt AC Starter Motor)
Fig. 141 - Adjust Belt
ALTERNATOR TROUBLESHOOTING
Equipment to Test Alternators
AMP ALTERNATOR Used on Model Series 130000
Fig. 156 Stator Assembly Location
Replacing Defective Rectifier Box
AC Only Alternator
5 Amp AC - 3 Amp DC - Rectifier Plug Type
TESTING FOR SHORT IN ALTERNATOR SYSTEM
TESTING ALTERNATOR AC CIRCUIT (Lighting)
Dual Circuit Alternator with Fuse
Testing for Short in Stator or in Rectifier
Testing Rectifier - TM-5-4240-501-14P_217
Condition Found (Fuse Blown)
Testing Isolation Diode
Testing Rectifier - TM-5-4240-501-14P_220
Fig. 197 - Testing Output
4 AMP NON-REGULATED ALTERNATOR
Testing Stator
THE TRI-CIRCUIT ALTERNATOR
TESTING STATOR COILS
10 AMP REGULATED ALTERNATOR
Fig. 216 - Testing Stator Coils for Continuity
10 AMP REGULATED ALTERNATOR Used on Model Series 320400
Testing Rectifier-Regulator Assembly
Capacity Chart
Change Oil (Gear Reduction) Cast Iron Engines
Checking Breathers
OIL SLINGER Aluminum Alloy Engines
Section 9 PISTONS - RINGS - RODS
Check Rings
Assemble Piston and Connecting Rod
Fig. 11. Connecting Rod Installation
Section 10 CRANKSHAFTS & CAM GEARS
Fig. 4. Remove or Install Crankshaft
CHECKING CRANKSHAFT
CHECKING CAM GEAR
Checking Compression Release Cam
INSTALL CRANKSHAFT AND CAM GEAR
Aluminum Engines -- Ball Bearing
Fig. 20. Checking Crankshaft End Play
CHECKING AND CORRECTING CRANKSHAFT END PLAY
CHECK CAM GEAR
CAM GEAR DISASSEMBLY - EARLY DESIGN
REMOVE CONTROL LEVER SHAFT
Section 11 CYLINDERS & BEARINGS
Fig. 2 - Honing Cylinder
To Hone Cylinder
CYLINDER FINISH AND CLEANING
Fig. 6 - Checking Bearing
TABLE NO. 3 MAIN BEARING TOOL CHART
Fig. 8 - Notching Cylinder Hub
MAGNETO BEARING
CHECKING CAM GEAR BEARINGS
Cylinders
Section 12 SYNCHRO-BALANCE
Fig. 3 -- Installing and Timing PTO Drive Gear
ASSEMBLY OF COUNTERWEIGHTS
Fig. 9 - Disassembling Counterweight
Section 13 TOOLS
BRIGGS & STRATTON REPAIR TOOLS
BRIGGS & STRATTON REPAIR TOOLS (cont)
valve seat repair tools
hone set
REAMERS
PLUG GAUGES
CRANKCASE SUPPORT JACK
Section 14 THEORIES OF OPERATION
Compression
piston displacement
relative importance of valves
valve part names
margin dimensions
Atmospheric Pressure
Airfoil
Idle Valve
VACU-JET CARBURETORS OR SUCTION FEED - TM-5-4240-501-14P_282
VACU-JET CARBURETORS OR SUCTION FEED - TM-5-4240-501-14P_283
PULSA- JET CAR BURETORS
Gas and Oil
IGNITION - TM-5-4240-501-14P_286
IGNITION - TM-5-4240-501-14P_287
IGNITION (cont) - TM-5-4240-501-14P_288
IGNITION (cont) - TM-5-4240-501-14P_289
"EASY SPIN" STARTING
GOVERNING
counterweights
