Briggs & Stratton 090600 Manuel utilisateur

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.

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.

This engine repair manual includes the following

engine models:

• MODEL 090600

• MODEL 100600

• MODEL 100800

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

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THISPROPER SERVICE AND REPAIR IS IMPORTANT

TO THE SAFE, ECONOMICAL AND RELIABLE

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SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS

SAFETY INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

ENGINE MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

FUEL AND OIL RECOMMENDATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

MAINTENANCE CHART - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

OIL CHANGE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

AIR FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

SPARK PLUG - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

CHARGING BATTERY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

COMBUSTION CHAMBER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10

ENGINE ADJUSTMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10

THROTTLE CABLE ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10

GOVERNOR ADJUSTMENTS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10

ADJUST VALVE CLEARANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12

ADJUST READYSTART® CHOKE LINK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12

ADJUST ARMATURE AIR GAP- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13

ADJUST ALTERNATOR AIR GAP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14

FLYWHEEL BRAKE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15

SAFETY INFORMATION

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.

• Always use fresh gasoline. Stale fuel can

cause gum deposits in the carburetor

and cause leakage, flow restrictions, or

other problems.

• 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.

FIRE EXPLOSION ELECTRIC

SHOCK

EXPLOSIVE

PRESSURE

HOT

SURFACE GOGGLES

ENTANGLEMENT KICKBACK AMPUTATION

TOXIC

FUMES

READ

MANUAL

CHEMICAL

BURNS

WARNING

Battery posts, terminals, and related accesso-

ries contain lead and lead compounds - chem-

icals known to the State of California to cause

cancer and reproductive harm. Wash hands

after handling.

WARNING

Certain components in this product and its

related accessories contain chemicals known

to the State of California to cause cancer, birth

defects, or other reproductive harm. Wash

hands after handling.

WARNING

Briggs & Stratton does not approve or autho-

rize the use of these engines on 3-wheel All

Terrain Vehicles (ATVs), motor bikes, fun/rec-

reational go-karts, aircraft products, or vehi-

cles 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

Running engines produce heat.

Severe burns can occur on contact.

• Allow muffler, engine cylinder fins, and

radiator to cool before touching.

• Remove accumulated combustibles from

muffler area and cylinder area.

• 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 jurisdic-

tions may have similar laws. Contact the

original equipment manufacturer, retailer,

or dealer to obtain spark arrester

designed for the exhaust system installed

on this engine.

WARNING

Fuel and its vapors are extremely flam-

mable 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-venti-

lated 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 fre-

quently for cracks or leaks. Replace if nec-

essary.

• 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 position. 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

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 termi-

nal.

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.

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 lacera-

tions 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

entangled 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

Damaged, worn, or loose fuel compo-

nents 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

regularly to make sure they are in good

condition.

WARNING

Rapid retraction of starter cord (kick-

back) 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

rapidly to avoid kickback.

• Remove all external equipment/engine

loads before starting engine.

• Direct-coupled equipment components,

such as but not limited to blades, impel-

lers, 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.

ENGINE MAINTENANCE

Fuel and Oil Recommendations

Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.

• A minimum of 87 octane / 87 AKI

(90 RON).

• Gasoline with up to 10% ethanol

(gasahol) or up to 15% MTBE (methyl

tertiary butyl ether) is acceptable.

NOTICE: Do not use unapproved gasoline, such

as E85. Do not mix oil in gasoline or modify the

engine to run on alternate fuels. This will damage

the engine components and void the engine

warranty.

To protect the fuel system from gum formation,

mix a fuel stabilizer into the fuel. All fuel is not the

same. If starting or performance problems occur,

change fuel providers or change brands. This

engine is certified to operate on gasoline. The

emissions control system for this engine is EM

(Engine Modifications).

High Altitude

At altitudes over 5,000 feet (1524 meters), a

minimum 85 octane / 85 AKI (89 RON) gasoline

is acceptable. To remain emissions compliant,

high altitude adjustment is required. Operation

without this adjustment will cause decreased

performance, increased fuel consumption, and

increased emissions.

Operation of the engine at altitudes below 2,500

feet (762 meters) with the high altitude kit is not

recommended.

Fresh Start®Fuel Cap

Some engines are equipped with a Fresh Start®

fuel cap. The Fresh Start fuel cap is designed to

hold a cartridge (sold separately) that contains

fuel stabilizer.

Oil must meet these requirements:

• Briggs & Stratton warranty certified oils

are recommended for best performance.

• Other high-quality detergent oils are

acceptable if classified for service SF,

SG, SH, SJ or higher.

• Do not use special additives.

Outdoor temperatures determine the proper oil

viscosity for the engine.

Use the chart (Figure 1-1) to select the best

viscosity for the outdoor temperature range

expected.

Figure 1 - 1

MAINTENANCE CHART

* In dusty conditions or when airborne debris is

present, clean more often.

First 5 Hours

• Change oil

Every 8 Hours or Daily

• Check engine oil level

• Clean area around muffler and

controls

• Clean finger guard

Every 25 Hours or Annually

• Clean air filter*

• Clean pre-cleaner*

Every 50 Hours or Annually

• Change engine oil

• Check muffler and spark arrester

Annually

• Replace air filter

• Replace pre-cleaner

• Replace spark plug

• Replace fuel filter

• Clean air cooling system*

Oil Change

Change oil after the first 5 hours of operation.

After that, change oil after every 50 hours of

operation. Change oil more often if engine is

operated in dirty or dusty conditions, under

heavy loads, or in high ambient temperatures.

1. Remove oil drain plug from side or bottom

of engine and drain oil while the engine is

still warm.

2. Install drain plug.

3. Fill crankcase with correct amount of new

oil.

4. Start engine and run at idle for a minute or

so.

5. Shut engine off and wait for oil to settle

back into the cylinder.

6. Check dipstick. If necessary, add more oil

slowly to bring level to FULL mark on

dipstick.

Air Filter

A correctly serviced air filter protects internal

engine parts from airborne dirt and dust. Poor

filter maintenance will allow dirt and dust to be

drawn into the engine, causing wear to the intake

system and contamination of the oil. Dirt in the oil

forms an abrasive mixture which wears down

moving parts.

NOTE: Do not use pressurized air or solvents to

clean the filter. Pressurized air can damage the

filter and solvents will dissolve the filter.

1. Remove air cleaner cover (Aand B,

Figure 1-2). Remove pre-cleaner (C) from

cartridge (D).

2. Gently tap air filter cartridge on a hard

surface to loosen debris. Replace

cartridge if very dirty.

3. Wash foam pre-cleaner in warm, soapy

water, then rinse and allow to air dry.

4. Reassemble the air cleaner system.

Figure 1 - 2

Spark Plug

The spark plug should be replaced every year.

NOTE: In some areas, local law requires using

resistor spark plugs to suppress radio frequency

interference.

1. Disconnect spark plug wire.

2. Remove and inspect spark plug for wear

and damage. Replace spark plug if

electrodes are burned away, or the

porcelain is cracked.

WARNING

Fuel and its vapors are extremely flam-

mable and explosive.

Fire or explosion can cause severe

burns or death.

• Never start or run the engine with the air

cleaner assembly or the air filter removed.

NOTICE

Spark plugs have different thread lengths

and heat ranges. When changing a spark

plug, use only the specified replacement,

otherwise engine damage could occur.

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