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  5. User Manual

Vanguard OHV V-Twin User Manual

Summary of OHV V-Twin

  • Page 1

    Table of contents safety, maintenance and adjustments section 1 . . . . . . . . . . . . . . . . . . Troubleshooting section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine disassembly section 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 2: Section 1

    1 locked for printing – select sect. Needed > 1 section 1 safety, maintenance and adjustments page air cleaner service 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Round air cleaner 9 . . . . . . . . . . . . . . . . . . ....

  • Page 3

    1 2 in the interest of safety danger • before attempting to service this equipment, read and understand this manual and the operating instructions. • failure to follow instructions could result in death, serious injury (including paral- ysis) or property damage. Follow instructions carefully ! * bri...

  • Page 4

    1 locked for printing – select sect. Needed > 3 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 at least 2 minutes before removing gas cap. • fill fuel tank outdoors or in a well...

  • Page 5

    1 4 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 enclosed area, even if doors or windows are open. • inhalation of high concentrations of v...

  • Page 6

    1 locked for printing – select sect. Needed > 5 additional precautions before working on the engine, read and understand the applicable sections of this manual. Follow all safety warnings. Death, personal injury and/or prop- erty damage may occur unless service instructions are followed carefully. D...

  • Page 7

    6 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...

  • Page 8

    1 locked for printing – select sect. Needed > 7 fuel & oil recommendations fuel recommendations gasoline engines • use clean, fresh regular unleaded gasoline with a minimum of 85 octane. Fresh fuel prevents gum from forming in the fuel system or on essential carburetor parts. Purchase fuel in a quan...

  • Page 9

    1 8 oil recommendations oil has four purposes. It cools, cleans, seals and lu- bricates. During normal operation, small particles of metal from the cylinder walls, pistons, bearings and combustion deposits contaminate the oil. Dust par- ticles from the air also contaminate the oil, forming an abrasi...

  • Page 10

    1 locked for printing – select sect. Needed > 9 air cleaner service avoid fires! Warning • never operate an engine with the air cleaner assembly or air cleaner cartridge removed! A properly serviced air cleaner protects internal en- gine parts from airborne dirt and dust particles. If air cleaner in...

  • Page 11

    1 10 caution: do not use petroleum solvents to clean paper cartridge. Do not oil paper cartridge. Do not use pressurized air to clean or dry paper cartridge. 6. Reinstall pre-cleaner over cartridge. 7. Install cartridge to air cleaner. 8. Install plate, knob and air cleaner cover. Square air cleaner...

  • Page 12

    1 locked for printing – select sect. Needed > 11 fig. 5 armature air gap adjustment 1. Loosen screws holding armature in place. Slide armature away from flywheel and tighten one of the screws. 2. Rotate flywheel until magnet is under armature laminations. 3. Place thickness gauge (1) between magnet ...

  • Page 13

    1 12 fig. 8 final adjustment all carburetor adjustments performed with the en- gine running must be made with the air cleaner installed. • tools required, fig. 9: tachometer #19200 or #19389 tang bender #19352 1. Start engine. Run for approximately 5 minutes to allow engine to warm up. 2. Move contr...

  • Page 14

    1 locked for printing – select sect. Needed > 13 fig. 12 10. If the carburetor is equipped with an idle mixture limiter cap install it at this time. A. Position limiter cap (7) so that stop(s) on limiter cap are at mid point between stop(s) on carburetor body, fig. 13. Fig. 13 b. Press limiter into ...

  • Page 15

    1 14 note: idle speed may vary according to oem specifications. Fig. 16 ÌÌ ÌÌ ÌÌ ÌÌ Ì Ì Ì Ì 8. Deactivate idle-down device, or remove jumper wire. Engine should accelerate smoothly to top governed speed. Re-adjust idle mixture screw 1/8 turn richer if necessary. 9. If the carburetor is equipped with...

  • Page 16

    1 locked for printing – select sect. Needed > 15 4. While holding throttle lever, slowly turn idle mixture screw for #1 cylinder clockwise until engine speed just starts to slow (lean mixture). Fig. 19 5. Then turn idle mixture screw (3) counter- clockwise 3/8 turn, fig. 20. Note: it may be necessar...

  • Page 17

    1 16 fig. 23 11 choke control adjustment note: be sure choke control wire is installed in #2 hole (2) in choke lever, fig. 24. Fig. 24 1. Place choke control lever on equipment in choke position. 2. Loosen control casing clamp screw (4). 3. Move control casing and wire (3) until choke is completely ...

  • Page 18

    1 locked for printing – select sect. Needed > 17 models 540000, 610000 1. Use acoin or screwdriver to twist the easy clean access panel fasteners (1), fig. 26 counterclockwise until a click is heard (approx. 3/4 turn). 2. Remove the panel (2). Fig. 26 3. Blow compressed air from the pto side to clea...

  • Page 19

    1 18 the crankcase capacity of vanguard v-twin engines is approximately: • all (except model 540000) – 48 oz. (1.4 liters) with filter • models 540000, 610000 – 79 oz. (2.3 liters) with filter • models 540000, 610000 – 71 oz. (2.1 liters) without filter note: when checking oil level, screw the dipst...

  • Page 20

    1 locked for printing – select sect. Needed > 19 fig. 32 3. With equipment control lever in slow position and engine running at governed idle rpm, use tang bender #19352 (1), to bend throttle restrictor tang (4) so that it just contacts governor lever (5), fig. 33. Fig. 33 4. Refer to service engine...

  • Page 21

    1 20 5. Turn fixed speed adjustable control nut (6) clockwise (8) to increase or counter-clockwise (7) to decrease engine speed until desired top no-load rpm is obtained, fig. 37. Fig. 37 fixed speed adjustable – generators no governed idle spring is used with this system. No throttle restrictor adj...

  • Page 22

    1 locked for printing – select sect. Needed > 21 table no. 1 generator type top no-load rpm regulated no-load rpm 3600 rpm 60 cycle 4250 rpm 3750 rpm 3000 rpm 50 cycle 3600 rpm 3150 rpm fig. 40 10. Engage fixed speed adjustable control nut (8) and adjust to regulated no-load rpm for the type of gene...

  • Page 23

    1 22 fig. 43 7. With equipment control lever in slow position and engine running at governed idle rpm, use tang bender #19352 (1), and bend throttle restrictor tang (7) so that tang just contacts governor lever (8), fig. 44. Fig. 44 8. Refer to service engine sales microfiche, ms-6225 or the service...

  • Page 24

    1 locked for printing – select sect. Needed > 23 fig. 47 all except models 540000, 610000 resistor spark plugs recommended by briggs & stratton: • b&s #491055 (champion rc12yc) or • b&s #496018 (champion rc14yc) gap to 0.030” (0.76 mm). Models 540000, 610000 resistor spark plug recommended by briggs...

  • Page 25

    1 24 tune-up procedure a “tune-up,” see the steps listed below, would normally be performed on relatively new engines brought in for minor difficulties. By performing these steps you will either be sure that the engine is functioning properly or will know what major repairs should be made. The steps...

  • Page 26

    1 locked for printing – select sect. Needed > 25 23. Cylinder – check cylinder bores and bearings. Remove oil seal. 24. Disassemble and check connecting rods, pistons, piston pins and rings. 25. Disassemble and inspect oil pump. Inspection and repairs 1. Clean parts. 2. Resize cylinder bore as requi...

  • Page 27

    1 26.

  • Page 28: Section 2

    2 locked for printing – select sect. Needed > 27 section 2 troubleshooting page electrical systems 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternators 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 29

    2 28 most complaints concerning engine operation can be classified as one or more of the following: 1. Will not start 2. Hard starting 3. Lack of power 4. Runs rough 5. Vibration 6. Overheating 7. High oil consumption note: what appears to be an engine problem may actually be the fault of the powere...

  • Page 30

    2 locked for printing – select sect. Needed > 29 fouled plug or dead cylinder to test for a fouled spark plug or a non-functioning cylinder, attach ignition tester #19368 (2) between the spark plug lead (1) and each spark plug (4). With engine running at top no-load speed, use a screwdriver (3) with...

  • Page 31

    2 30 cylinder leakdown test use a leakdown tester to test the sealing capability of each cylinder. Follow the instructions for the leak- down tester you are using to determine the likely problem area(s). 1. Run engine for 5 minutes allowing engine to reach operating temperature. Note: if the engine ...

  • Page 32

    2 locked for printing – select sect. Needed > 31 fig. 6 4. Ground the other spark plug and again note the rpm loss. If the difference between the two cylinders does not exceed 75 rpm, the amount of work the two cylinders are doing is considered equal. An rpm loss greater than 75 rpm indicates that t...

  • Page 33

    2 32 electrical systems alternators alternator system diagnosis the following list is provided to help diagnose alternator system problems. Complaint possible causes battery not charging • engine rpm too low. • inline fuse “blown” (if equipped). • defective battery. • loose, pinched, or corroded bat...

  • Page 34

    2 locked for printing – select sect. Needed > 33 charging system identification table no. 1 provides a means of identifying the various alternator systems. The alternator systems installed on briggs & stratton ohv v-twin cylinder engines can be identified by the color of the stator output wires and ...

  • Page 35

    2 34 flywheel magnet identification note: does not include engines with the power- link t system. The v-twin flywheels have a ring of magnets (1) on the inside of the flywheel, fig. 7, that provides the magnetic field for the charging systems. The size of the magnet determines the alternator output....

  • Page 36

    2 locked for printing – select sect. Needed > 35 testing alternator output when testing alternators, perform the tests in the following sequence. Note: before testing alternator output, use an accurate tachometer to temporarily adjust the engine speed to the rpm specified in the test instructions. 1...

  • Page 37

    2 36 dc alternator the dc alternator provides dc current for charging a 12 volt battery. The current from the alternator is unregulated and is rated at 3 amps. The output rises from 2 amps @ 2400 rpm, to 3 amps @ 3600 rpm. 1. Stator assembly (1), fig. 12. 2. One red lead from stator (2). 3. Diode en...

  • Page 38

    2 locked for printing – select sect. Needed > 37 a fig. 14 note: service replacement diode harnesses are available. Use resin core solder when installing new harness. Use shrink tubing or tape all connections. Do not use crimp connectors. Dual circuit alternator dual circuit alternators use a polari...

  • Page 39

    2 38 diode test in the diode test position, the meter will display the forward voltage drop across the diode(s). If the voltage drop is less than 0.7 volts, the meter will beep once and display the voltage drop. A continuous tone indicates continuity (shorted diode) an incomplete circuit (open diode...

  • Page 40

    2 locked for printing – select sect. Needed > 39 the battery is not used for the lights, so lights are available even if the battery is disconnected or removed. Current for the lights is available when the engine is running. The output varies with engine rpm, so the brightness of the lights changes ...

  • Page 41

    2 40 fig. 21 a lighting circuit test (white wire) 1. Insert red test lead into v receptacle in meter. 2. Insert black test lead into com receptacle. 3. Rotate selector to + ) ) ) )) (diode test) position. 4. Attach red test lead clip (1) to point a, of the white wire (3) fig. 22. (it may be necessar...

  • Page 42

    2 locked for printing – select sect. Needed > 41 output test when checking alternator components make tests in the following sequence: temporarily disconnect stator wire harness from regulator-rectifier. 1. Insert red test lead into v receptacle in meter. 2. Insert black test lead into com receptacl...

  • Page 43

    2 42 2. Two black leads (2) from stator. 3. Yellow connector (3) with two pin terminals. 4. Two yellow leads (4) to regulator-rectifier. 5. Regulator-rectifier (5). 6. One red lead from regulator-rectifier to red connector output lead (6). Fig. 26 output test temporarily, disconnect stator wire harn...

  • Page 44

    2 locked for printing – select sect. Needed > 43 7. If no or low output is found, be sure that regulator-rectifier is grounded properly and all connections are clean and secure. If there is still no or low output, replace the regulator-rectifier. Fig. 28 regulator-rectifier with charge indicator reg...

  • Page 45

    2 44 4. Attach red (2) and black (1) test lead probes to the yellow wire (4) ac output terminals (6), of the connector (3), as shown in fig. 31. (meter test clip leads may be attached to either ac out- put terminal.) 5. If no or low output is found check for bare wires or other defects. If shorted l...

  • Page 46

    2 locked for printing – select sect. Needed > 45 powerlink t system some v-twin engines are equipped with the power- link tsystem, an on-board generator system for riding tractors that provides 120 volt, 60 cycle ac to a gfci receptacle provided by the oem. The powerlink t system will not function u...

  • Page 47

    2 46 4. Test for continuity between the inverter case and the gfci ground. There should be continuity in step 3 and step 4. If there is no continuity a problem exists in the ground circuit. Fig. 35 test parking brake interlock switch digital multimeter #19464 is used for this test. Set the meter in ...

  • Page 48

    2 locked for printing – select sect. Needed > 47 if the previous tests have not revealed a faulty component it is necessary to check the alternator output. If the alternator output is within specification the inverter box is faulty and must be replaced. Required tools to test the powerlink t system ...

  • Page 49

    2 48 test equipment digital multimeter #19464. The following tests will be performed with the meter in the v== (dc volts) position, fig. 40. Fig. 40 equipment wiring test 1. With key switch off, disconnect equipment wiring harness connector (1) from engine wiring harness. 2. Attach red meter test le...

  • Page 50

    2 locked for printing – select sect. Needed > 49 installation 1. Before installing battery, connect all equipment to be operated. See typical wiring diagram, fig. 42. 2. Place battery in holder with a flat base. Tighten hold downs evenly until snug. Do not over- tighten. 3. Connect positive terminal...

  • Page 51

    2 50 a jumper wire is required for this test. Make sure key switch is off before connecting jumper wire. Note: mark or identify the charging indicator wire in the output harness before disconnecting the harness from the connector. Caution: if the jumper wire contacts the charg- ing output wire durin...

  • Page 52

    2 locked for printing – select sect. Needed > 51 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. 3. Attach black test lead to a good...

  • Page 53

    2 52 engine harness connector engine runs (both cylinders) 1 closed diode engine won’t shut off only one cylinder shuts off 1 open diode 2 closed diodes 2 open diodes switch on cause won’t run (no spark) engine runs (both cylinders) engine runs on 1 cylinder switch off shuts off ok diode ground wire...

  • Page 54

    2 locked for printing – select sect. Needed > 53 oil pressure test switch use digital multimeter #19464. Set meter to test for continuity. Remove pressure switch. Connect one tester lead to the switch terminal and the other lead to the metal body of the switch, fig. 48. The tester should indicate co...

  • Page 55

    2 54 note: terminals #1, #3 and #6 are grounded to key switch case when key switch is off. Meter must indicate continuity between these terminals and the key switch case when key switch is off. When testing run and start terminals, meter should show continuity between terminals, with key switch in p...

  • Page 56

    2 locked for printing – select sect. Needed > 55 terminal no. Wire color function 1 not used 2 white to carburetor solenoid (when used) 3 black to stop switch terminal on engine 4 yellow to solenoid (tab terminal) 5 orange to battery (battery terminal on solenoid) 6 red to regulator/rectifier soleno...

  • Page 57

    2 56 starter motor conditions affecting starter motor performance 1. Bound or seized starter motor bearings. 2. A shorted, open or grounded armature. A. Shorted armature (wire insulation worn and wires touching one another) will be indicated by low or no rpm. B. Open armature (wire broken) will be i...

  • Page 58

    2 locked for printing – select sect. Needed > 57 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 so...

  • Page 59

    2 58 performance control electronic governor some v-twin engines are equipped with the performance control  electronic governor system for generator or welder applications. The electronic governor provides more responsive governing than a mechanical system. Engines equipped with the performance con...

  • Page 60

    2 locked for printing – select sect. Needed > 59 governor test dynamic check perform dynamic check exactly in order shown. 1. Start engine and check rpm. Top governed speed should be: a. 3600 rpm – 60 cycle applications. B. 3000 rpm – 50 cycle applications (yellow or red loop removed). 2. Manually m...

  • Page 61

    2 60 2. Remove air cleaner assembly. 3. Disconnect governor link at carburetor. 4. Remove governor control bracket with actuator. 5. Disconnect governor link from actuator and remove throttle return spring. 6. Remove two screws, nuts and actuator from control bracket. Installation 1. Assemble actuat...

  • Page 62

    2 locked for printing – select sect. Needed > 61 gaseous fueled engines troubleshooting guide symptom potential cause action plugged vent ports on the regulator. Remove plastic shipping plugs. Less than 11 inches of water pressure at the inlet of the secondary regulator. Adjust the primary regulator...

  • Page 63

    2 62 troubleshooting guide (continued) out of fuel. Refuel the tank. Fuel supply shut off. Open fuel tank. Engine will not start. Filter or vacuum lock off is not opening. Check for proper operation of all fuel lock-off (safety) devices. If electrically actuated, check for dead battery or blown fuse...

  • Page 64

    2 locked for printing – select sect. Needed > 63 gaseous fuel carburetor adjustment some briggs & stratton v-twinengines were available factory-built to operate on liquefied petroleum gas (lpg) or natural gas (ng). To maintain the california air resource board (carb) emissions certification on these...

  • Page 65

    2 64 equipment problems affecting engine operation frequently, what appears to be an engine problem may be the fault of the equipment powered rather than the engine itself. Since many types of equipment are powered by briggs & stratton engines, it is impossible to list all the conditions that can ex...

  • Page 66: Section 3

    3 locked for printing – select sect. Needed > 65 section 3 engine disassembly page after disassembly 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine disassembly 68 . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 67

    3 66 parts identification carburetor cover valley cover blower housing rotating screen governor lever intake manifold and carburetor choke bracket governor control bracket air cleaner support exhaust manifold cylinder shields air cleaner base valve covers 3 4 5 6 7 2 8 12 11 10 9 13 1 2 3 4 5 6 7 8 ...

  • Page 68

    3 locked for printing – select sect. Needed > 67 armatures crankshaft backplate alternator #2 piston and connecting rod assembly starter motor breather #1 piston and connecting rod assembly crankcase cover or sump camshaft and governor spool flywheel and fan #2 cylinder head 14 15 16 17 18 19 20 21 ...

  • Page 69

    3 68 engine disassembly preparation • drain oil. Remove and discard oil filter. • disconnect choke and throttle control cables. • remove engine from equipment. • remove spark plugs. • remove muffler and exhaust manifold. Remove air cleaner assembly vertical crankshaft – models 290700 – 380700 curren...

  • Page 70

    3 locked for printing – select sect. Needed > 69 fig. 4 horizontal crankshaft– models 351400 – 380400 1. Remove air cleaner cover, cartridge and pre- cleaner. 2. Remove five screws (1) and carburetor shield (2), fig. 5. 3. Disconnect breather tube at air cleaner base and remove air cleaner base (3)....

  • Page 71

    3 70 remove carburetor and intake manifold vertical crankshaft, all models 1. Remove air cleaner assembly. 2. Remove two screws (2) and choke control bracket, fig. 9. 3. Disconnect choke link (1) from carburetor. Note: if engine is equipped with anti-afterfire solenoid, air cleaner bracket (3) must ...

  • Page 72

    3 locked for printing – select sect. Needed > 71 fig. 13 remove flywheel flywheel nut – models 290000, 303000, 540000, 610000 1. Prevent the flywheel from turning with flywheel strap wrench, #19433 (5) around outer rim of fly- wheel, fig. 14. 2. Turn the flywheel nut counterclockwise (arrow) with a ...

  • Page 73

    3 72 flywheel – models with powerlink t caution • the flywheel magnets are very powerful and can rapidly draw the flywheel to the engine. Exercise caution and use the proper tools when servicing the flywheel. Avoid hand and/or finger injury! Required tools note: the components of flywheel puller #19...

  • Page 74

    3 locked for printing – select sect. Needed > 73 remove breather and starter motor 1. Remove breather (3), alternator (6), backplate (5) and starter motor (4), fig. 20. Fig. 20 2. Remove crankcase cover/sump. Remove cylinder head 1. Remove two rocker studs (1) supports (2) and rocker arm assemblies ...

  • Page 75

    3 74 fig. 24 fig. 25 remove camshaft 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. 26 remove pistons and connecting rods note: remove any carbon or ridge at ...

  • Page 76: Section 4

    4 locked for printing – select sect. Needed > 75 section 4 fuel systems and carburetion page carburetion 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor identification 79 . . . . . . . . . . . . . ....

  • Page 77

    4 76 fuel systems 7 quart fuel tank removal 1. Remove air cleaner knob (1) and cover (2), fig. 1. 2. Remove air cleaner nut (3), top plate (4) and element (5). Fig. 1 3. Turn the fuel shut-off to the off position. Disconnect fuel valve shut-off link. 4. Remove 2 screws (flywheel side) and 2 shoulder...

  • Page 78

    4 locked for printing – select sect. Needed > 77 note: install the supports over the governor control bracket, one side at a time to avoid disturbing the governor adjustment. Install the screws in the same order as removed. 3. Install the fuel tank base plate. Torque screws to 140 in. Lbs. (16 nm). ...

  • Page 79

    4 78 5. Lift the fuel tank. Disconnect the fuel hose from the carburetor fuel inlet (6), fig. 10. Remove the fuel valve shut-off knob from the shut-off link (7). Fig. 10 6. Remove the fuel tank. Installation 1. Hold the fuel tank above the engine. Connect the fuel hose to the carburetor fuel inlet. ...

  • Page 80

    4 locked for printing – select sect. Needed > 79 fuel filter replace the inline fuel filter yearly or every 100 hours, whichever occurs first. Replace the filter if dirt or water are present. See the ipl for correct fuel filter. Inspect the carburetor connection (6) and fuel shut- off valve (5) for ...

  • Page 81

    4 80 fig. 16 models 351400 and 380400 the blower housing must be removed so that anti- afterfire solenoid wire can be properly routed during reassembly. 1. Disconnect fuel line at carburetor. 2. Remove anti-afterfire solenoid ground wire (5). 3. Remove choke control bracket (6) and disconnect link (...

  • Page 82

    4 locked for printing – select sect. Needed > 81 fig. 20 11 12 13 14 15 11 carburetor service aisan carburetor models 290700, 303700, 350700 (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 ...

  • Page 83

    4 82 fig. 24 4. Remove fixed main jet (7) using screwdriver #19062, fig. 25. 5. Reach into carburetor throat with flat blade screwdriver and push down on end of emulsion tube (8). Fig. 25 note: consult the ipl to get the high altitude jet part number if required. 6. Remove idle jet plug (10) and idl...

  • Page 84

    4 locked for printing – select sect. Needed > 83 fig. 30 15 17 18 16 13. Remove screw (25) and choke plate (24), fig. 31. Caution • carburetor body has a detent ball (19) and spring (20) that keeps tension on choke shaft. Wear eye protection. • use caution when removing shaft! Avoid eye injury! 14. ...

  • Page 85

    4 84 note: do not use wire, drills or other mechanical devices to clean out metering holes or passages. Inspect carburetor inspect all parts for wear, cracks, nicks and burrs. Inspect float for leaks. Replace damaged parts. Assemble when assembling carburetor, use new seals and gaskets. 1. Install n...

  • Page 86

    4 locked for printing – select sect. Needed > 85 fig. 37 16 16 17 18. Install idle jet (18), plug (19) and gasket (20), fig. 38. Fig. 38 18 19 20 19. Install idle mixture screw (21) and spring (22), fig. 39. Note: do not tighten screw. Do not install the limiter cap at this time. Fig. 39 21 22 20. I...

  • Page 87

    4 86 fig. 42 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 anti-afterfire solenoid (2) or bowl screw (1), washer and bowl (3), fig. 43. Remove bowl gasket (4). Fig. 43 2. ...

  • Page 88

    4 locked for printing – select sect. Needed > 87 note: the top and bottom edges of the throttle plate are beveled. Mark throttle plate before removing to ensure reinstallation in the original position. 9. Remove retainer (15). 10. Remove throttle shaft and spacer (19). 11. Remove seals (14) and foam...

  • Page 89

    4 88 clean carburetor 1. Disassemble carburetor. 2. Remove and discard all old gaskets, seals and sealing material. Avoid injury! • wear suitable protection when using cleaners. Follow instructions on container. Caution 3. Use a commercial carburetor cleaner (such as briggs & stratton spray cleaner ...

  • Page 90

    4 locked for printing – select sect. Needed > 89 note: use loctite  222 on screw threads. Fig. 53 14 15 16 11 12 13 12 13 12. Assemble inlet needle retainer (19) to inlet needle (18). Assemble to float (17), fig. 54. 13. Install float to carburetor body. Install float hinge pin (20) with swaged end...

  • Page 91

    4 90 nikki carburetor models 351700, 351400, 380700, 380400 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 1/4” (6.35 mm) raised flat surface (1). Check throttle and choke shaft clearance wit...

  • Page 92

    4 locked for printing – select sect. Needed > 91 fixed main jet sizes model 351700 left (#1) cylinder is equipped with #98 main jet. Right (#2) cylinder is equipped with #100 main jet. Model 351400 left (#1) cylinder is equipped with #94 main jet. Right (#2) cylinder is equipped with #98 main jet. M...

  • Page 93

    4 92 note: if idle mixture screws are equipped with adjustment limiter caps, remove the caps (18) before removing idle mixture screws, inset, fig. 65. Fig. 65 18 19 20 10. Mark throttle plates (24) before removing to ensure reinstallation in the original position, fig. 66. 11. Remove throttle shaft ...

  • Page 94

    4 locked for printing – select sect. Needed > 93 inspect carburetor inspect all parts for wear, cracks, nicks and burrs. Inspect float for leaks. Replace damaged parts. Assemble carburetor when assembling carburetor, use new seals and gaskets. 1. Install new throttle shaft seal (3) with sealing lip ...

  • Page 95

    4 94 fig. 72 17 18 19 12. Install fixed main jets (20), fig. 73, plugs and washers. Model 351700 left (#1) cylinder is equipped with #98 main jet. Right (#2) cylinder is equipped with #100 main jet. Model 351400 left (#1) cylinder is equipped with #94 main jet. Right (#2) cylinder is equipped with #...

  • Page 96

    4 locked for printing – select sect. Needed > 95 fig. 76 note: the inspection in step 2 is performed after the carburetor has been disassembled. 2. Inspect throttle shaft and choke shaft for wear (3), fig. 77. Replace if worn. Fig. 77 replace either shaft if worn. Replace the carburetor if the body ...

  • Page 97

    4 96 8. The top and bottom edges of the throttle plate are beveled. Mark throttle plate (11), fig. 82 before removal to ensure reinstallation in the original position. 9. Remove throttle shaft (13) and spacer (14). 10. Remove throttle shaft seal (12). Fig. 82 11 12 13 14 support upper body on a vise...

  • Page 98

    4 locked for printing – select sect. Needed > 97 inspect carburetor inspect all parts for wear, cracks, nicks and burrs. Inspect float for leaks. Replace damaged parts. Assemble carburetor when assembling carburetor, use new seals and gaskets. 1. Install new transitional hole welch plug (1), fig. 85...

  • Page 99

    4 98 note: use brass inlet needle for fuel pump carburetors. Use aluminum inlet needle for gravity feed carburetors. Fig. 90 18 the fuel inlet seat orifice size and inlet needle are different, depending upon the type of fuel delivery system used. The carburetor bodies and inlet needles are not inter...

  • Page 100

    4 locked for printing – select sect. Needed > 99 fig. 94 29 30 31 32 mikuni carburetor models 290400, 303400, 350400 (before 950801xx) carburetor identification two carburetor bodies are used, depending upon the use of a fuel pump (illustration a) or gravity feed (illustration b) fuel delivery syste...

  • Page 101

    4 100 fig. 98 3. Remove float (5) and fuel inlet needle (6), fig. 99. Note: float hinge pin (7) is swaged on one end. Drive hinge pin out from side opposite swage. Fig. 99 4. Remove anti-afterfire solenoid (10) or plug (9), fig. 100. 5. Remove fixed jet plug (13) and washer (12). 6. Remove fixed mai...

  • Page 102

    4 locked for printing – select sect. Needed > 101 fig. 103 23 24 25 26 27 28 29 25 remove fuel inlet body and seat the fuel inlet body must be removed before the inlet seat can be removed. 1. Use self-threading screw #93029 (1) from fly- wheel puller #19165. Thread screw into seat body (2) 3 - 4 tur...

  • Page 103

    4 102 inspect carburetor inspect all parts for wear, cracks, nicks and burrs. Inspect float for leaks. Replace damaged parts. Assemble carburetor when assembling carburetor, use new seals and gaskets. Install fuel inlet seat and body 1. Install new inlet seat (3) with chamfered end down, fig. 106. 2...

  • Page 104

    4 locked for printing – select sect. Needed > 103 fig. 110 19 20 18. Assemble inlet needle retainer (21) to inlet needle (22). Assemble to float (23), fig. 111. 19. Install float (23) and needle to upper carburetor body. Insert hinge pin (24). Fig. 111 21 22 23 24 20. Invert upper carburetor body as...

  • Page 105

    4 104 nikki carburetor model 540000 general information the vanguard t 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 control...

  • Page 106

    4 locked for printing – select sect. Needed > 105 remove carburetor from manifold remove carburetor gaskets (2) and spacer (1), fig. 114. Discard carburetor gaskets. Fig. 114 check throttle, choke shaft and body note: the measurement in step 1 is taken with the carburetor off of the intake manifold....

  • Page 107

    4 106 fig. 118 7. Remove cover plate (10). Discard gasket (11), fig. 119. Fig. 119 11 8. Remove screws and choke plate (12), fig. 120. 9. Remove choke shaft. Discard seal (13). Fig. 120 13 12 10. Remove nozzle body (14), fig. 121. Discard gasket (15). Fig. 121 15 14 11. Mark throttle plates (16), fi...

  • Page 108

    4 locked for printing – select sect. Needed > 107 note: parts containing rubber, such as seals, o-rings, inlet needles, seats or pump diaphragms should not be placed in commercial carburetor cleaner. Do not leave non-metallic parts (plastic, nylon, minlon , etc.), in commercial carburetor cleaner m...

  • Page 109

    4 108 fig. 126 6. Install emulsion tube body (8) with new gasket (19), fig. 127. Tighten screw securely. Fig. 127 19 7. Assemble inlet needle (10) to float (11) and install float, fig. 128. Fig. 128 11 8. Assemble bowl gasket (9) to body. 9. Install main jet, according to engine model. 10. Install t...

  • Page 110

    4 locked for printing – select sect. Needed > 109 aisan carburetor model 610000 general information the vanguard t 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 t...

  • Page 111

    4 110 disassemble carburetor 1. Remove four screws (1) and float bowl (2), fig. 130. Discard gasket. 2. Use 13 mm thin profile wrench to remove fuel solenoid (3) from float bowl. Discard gasket. Fig. 130 3. Remove main jets (4) from float bowl, fig. 131. Fig. 131 4. Remove float hinge pin (18), floa...

  • Page 112

    4 locked for printing – select sect. Needed > 111 caution • wear eye protection when using com- pressed air. Avoid eye injury! 4. 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 meteri...

  • Page 113

    4 112.

  • Page 114: Section 5

    5 locked for printing – select sect. Needed > 113 section 5 governor page general information 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor controls 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 115

    5 114 general information note: see section 2 for performance control t electronic governor service information. Vanguard  ohv v-twin engines may be equipped for remote control, manual friction, or fixed speed adjustable governor controls. Remote control and manual friction remote governor controls...

  • Page 116

    5 locked for printing – select sect. Needed > 115 3. Loosen governor lever nut (3). 4. Remove governor lever (2) from shaft. Fig. 5 5. Remove rust, nicks or burrs from crankshaft. 6. Remove oil fill tube and dipstick assembly. 7. Remove crankcase cover, fig. 6. 8. Discard gasket and o-ring. Fig. 6 Ó...

  • Page 117

    5 116 fig. 9 ÔÔ ÔÔ ÔÔ ÖÖ ÖÖ ÔÔÔ ÔÔÔ Ö Ö ÖÖ ÖÖ install governor shaft 1. Assemble lower bushing to governor shaft with thrust flange (4) down, fig. 10. 2. Slide shaft up through lower bearing and upper bushing. 3. Install new seal (3), collar (1) and cotter pin (2). Governor shaft must rotate freely....

  • Page 118

    5 locked for printing – select sect. Needed > 117 fig. 13 9. Perform governor adjustments, see trouble- shooting, section 2. Static adjustment of the governor must be completed before starting or running engine! • failure to make static governor adjustments first could result in engine overspeeding ...

  • Page 119

    5 118 fig. 17 2. If necessary remove the crank from the cylinder block. Mark the governor lever and the governor crank to aid in reassembly. Remove the governor lever from the crank (3). Remove the upper and lower retaining rings (4) and the washer (5). Slide the crank out of the bushings (7). 3. Re...

  • Page 120: Section 6

    6 locked for printing – select sect. Needed > 119 section 6 cylinder heads and valves page cylinder head service 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove cylinder head 120 . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 121

    6 120 parts identification compression testing information and procedure is described in section 2 – troubleshooting. Fig. 1 shows the components of a typical v-twin ohv cylinder head. Fig. 1 1. Screw 2. Rocker arm support 3. Rocker arm 4. Valve spring retainer locks 5. Valve spring retainer 6. Valv...

  • Page 122

    6 locked for printing – select sect. Needed > 121 fig. 5 3. Remove head bolts (5, 6, 7, 8) and cylinder head, fig. 6. Discard cylinder head gasket. Note: engines manufactured before 940501xx were equipped with sealing washers under cylinder head bolts (5) and (6). Repeat for other cylinder head. Fig...

  • Page 123

    6 122 • caution: do not resurface cylinder head mounting surfaces. 2. Check valve guide bushings for wear using plug gauge (2) #19382, fig. 10. Replace valve guide if gauge enters guide 1/4” (6 mm) or more. Fig. 10 replace valve guide 1. Press out old valve guide (2) using bushing driver (1), #19367...

  • Page 124

    6 locked for printing – select sect. Needed > 123 1. Measure valve stem diameter approximately 1-1/2” (38 mm) from end of valve, fig. 15. Replace valve if stem diameter is less than 0.233” (5.92 mm). Fig. 15 1.5” (38 mm) 2. Valve faces can be resurfaced to 45 5. See fig. 16 for dimensions for valves...

  • Page 125

    6 124 install cylinder heads 1. Install cylinder head with new gasket, fig. 20. 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. 3. Torque bolts in the sequ...

  • Page 126: Section 7

    7 125 section 7 starters page general information 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rewind starter identification 137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 127

    7 126 general information the starter motor uses a gear engagement method, similar to an automotive starter. When the starter motor is activated, the pinion gear engages a ring gear attached to the engine flywheel and cranks the engine. Three starter motors are used on vanguard  v-twin engines, fig...

  • Page 128

    7 127 c-ring style disassemble caution prevent eye injury! • wear eye protection when removing c-ring. 1. Place the counterbored side of c-ring remover #19436 (2) over retainer. Align drive pins (1) with open end of c-ring, fig. 7. Note: if retainer (3) has a notch (4) as shown, do not align drive p...

  • Page 129

    7 128 assemble 1. Assemble clutch drive (5) to starter shaft. Rotate clutch until it drops into place, fig. 11. 2. Install pinion gear (4) with beveled side of teeth up. 3. Install washer (3) and retainer (1). 4. Install new roll pin (2). Note: slot in roll pin should face up. Fig. 11 steel pinion s...

  • Page 130

    7 129 fig. 13 11 12 13 14 1. Remove pinion gear assembly. 2. Remove thru bolts (2) and drive end cap (4). Fig. 14 11 12 13 3. Hold the armature (3) and commutator end cap (5) against a work surface while sliding housing (1) off the armature, fig. 15. Note: this allows the brush retainer to remain as...

  • Page 131

    7 130 fig. 17 a b replace brushes three different brush end caps are used. Refer to fig. 18 for radial flat coil spring end caps. Fig. 18 refer to fig. 19 for radial compression spring end caps. Fig. 19 refer to fig. 20 for axial compression spring end caps and for the correct location of positive b...

  • Page 132

    7 131 brush retainers can be made from part #26634 control wire or similar material. The retainer is u shaped, with two legs 1/2” (13 mm) high (2), 3/4” (19 mm) long (3), fig. 22, inset. 1. Install brush spring and brush into holder. 2. Compress brush and spring. Install retainer. 3. Repeat for rema...

  • Page 133

    7 132 1. Push down on armature and brush end cap. 2. Slide starter housing (1) over armature (2), aligning notch with insulated terminal. Note: use care to prevent damage to magnets in starter housing. Fig. 27 install drive end cap 1. Assemble spacer washer (1) and spring washer (2, if equipped) to ...

  • Page 134

    7 133 pinion gear pinion gear replacement requires complete starter motor disassembly. A thorough inspection of all components should be performed at that time. Disassemble starter for ease of disassembly and assembly, clamp drive end housing in a vise as shown, fig. 32. Note: do not damage drive ho...

  • Page 135

    7 134 clean and inspect helix. If helix is damaged, replace starter. Inspect bearing journals on armature shaft for wear or damage. If bearing journals are worn or damaged, replace starter. Note: bearings in drive and brush end cap are not replaceable. Inspect armature commutator the armature commut...

  • Page 136

    7 135 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. 4. Pry up on retainer until c-ring snaps into groove in retainer, fig. 39. 5. Assemble spacer to armature shaft, fig. 41. Note...

  • Page 137

    7 136 fig. 44 4. Insert brushes into brush holder, fig. 45. 5. Compress springs with needle nose pliers and insert spring behind brushes. Fig. 45 6. Install brush retainer plate (7), fig. 46. 7. Assemble rubber seal to starter housing. Be sure notch in rubber seal (8) is inserted over tab on housing...

  • Page 138

    7 137 rewind starter identification two rewind starters are used on v-twin engines. The rewind starter components (including the starter and cup) are not interchangeable between starters. Figure 49 shows how to identify the rewind starters. Current style early style fig. 49 1. Rewind starter. 2. Air...

  • Page 139

    7 138 replace rope remove rope 1. Pull rope out partially. Tie a temporary knot (4), fig. 51. 2. Remove insert (1) from rope handle (2). Pull knot out of rope insert. 3. Untie knot. Remove insert and handle from rope. 4. Pull rope (3) out as far as it will go. 5. While holding rewind pulley, grasp k...

  • Page 140

    7 139 fig. 55 ÓÓÓ ÓÓÓ ÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓ ÓÓÓ ÓÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ replace pulley and spring current style caution prevent eye injury! • wear eye protection when working on starter pulley and spring. • pulley and spring is serviced as an assembly. Do not remove spring from pulley. 1. Remove ro...

  • Page 141

    7 140 assemble pulley to housing 1. Lay starter housing on work bench. 2. Assemble starter pulley (1) and spring assembly to center pivot post (2) in housing, fig. 60. Fig. 60 3. Rotate pulley counterclockwise until slight resistance is felt, indicating that spring is engaged in spring tab in housin...

  • Page 142

    7 141 fig. 64 Ó 3. Lift out dogs (6) and dog springs (7). 4. Rotate pulley (8) until it disengages spring. 5. Carefully lift out pulley, fig. 65. Fig. 65 ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ the starter spring and cup will normally remain as an assembly in starter housing. 6. Rem...

  • Page 143

    7 142 2. Note location of spring tab (5) and location of spring anchor (4) on center post of starter housing. 3. Lower starter housing onto pulley and spring as- sembly, fig. 70. Fig. 70 ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ 4. Invert assembly, rotate pulley counterclockwise until inner spring tab engages spring anch...

  • Page 144: Section 8

    8 locked for printing – select sect. Needed > 143 section 8 lubrication systems page crankcase breather identification 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase breather service 145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 145

    8 144 general information briggs & stratton vanguard t ohv v-twins use a full pressure lubrication system with an oil filter. The gear driven oil pump (1) draws oil from a screened oil pickup (2) in the sump and pumps the oil through the oil filter (3). The lubrication systems shown are: horizontal ...

  • Page 146

    8 locked for printing – select sect. Needed > 145 crankcase breather service models 290000 – 351000 remove the air cleaner assembly. Remove breather assembly (1). Discard gasket (2), fig. 5. Ó Ó ÓÓ ÓÓ Ó Ó Ó fig. 5 checking reed valve breather the reed valve is spring loaded and must make a complete ...

  • Page 147

    8 146 model 380000 remove two screws. Separate breather assembly from valve cover, fig. 10. Fig. 10 checking breather 1. Remove two screws, reed stop and reed valve. 2. Place reed valve on flat surface. 3. Check reed valve for distortion with feeler gauge, fig. 11. Replace reed valve if the maximum ...

  • Page 148

    8 locked for printing – select sect. Needed > 147 models 540000, 610000 1. Remove two screws (6) and breather cover (5), fig. 15. 2. Lift off the outer baffle (4). 3. Remove the reed valve assembly (3) and o-ring. 4. Remove the inner baffle (2) from the valve cover (1). Fig. 15 check breather check ...

  • Page 149

    8 148 models 540000, 610000 for proper sealing on these models, the oil fill cap (5) has an o-ring, the dipstick has a grommet (6), fig. 18. Note: the oil dipstick tube (7) is not removeable/ serviceable on these models. If damaged replace the crankcase cover. Fig. 18.

  • Page 150: Section 9

    9 locked for printing – select sect. Needed > 149 section 9 cylinders and crankcase covers/sumps page cylinders 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect and measure 150 . . . . . . . . . . ...

  • Page 151

    9 150 cylinders inspect and measure 1. Check cylinder for cracks, stripped threads or broken fins. Check cylinder bores for damage or scoring. 2. Check cylinder head mounting surface for dis- tortion with a straight edge, fig. 1. Replace the cylinder if the mounting surfaces are distorted more than ...

  • Page 152

    9 locked for printing – select sect. Needed > 151 note: recondition the cylinder bores to restore the crosshatch finish whenever new piston rings are installed to a cylinder that is within specification. Be careful not to hone the cylinder oversize or it will be necessary to resize the cylinder. Lub...

  • Page 153

    9 152 engine bearings mag bearing – after 970430xx check 1. Check magneto bearing for damage. Check for wear at several locations using plug gauge #19219 (1) or appropriate measuring tools, fig. 5. If plug gauge is not available see reject dimension in section 13. 2. Replace bearing if damaged or wo...

  • Page 154

    9 locked for printing – select sect. Needed > 153 insert bushing driver #19349 into bearing from oil seal side. Place a reference mark on driver to indicate proper depth of bushing when installing new bearing, as shown, fig. 6. Remove the magneto bearing has a roll pin installed in the oil gallery t...

  • Page 155

    9 154 the following tools are recommended to replace the ball bearing, fig. 15. (1) washer #224061 (2) puller screw #19318 (3) pilot #19396 (4) driver #19401 (5) support #19440 fig. 15 remove 1. Assemble washer (1), to puller screw (2). Insert through large end of driver (4), fig. 16. 2. Place open ...

  • Page 156: Section 10

    10 155 section 10 crankshafts and camshafts page inspect camshaft 156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect crankshaft 156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 157

    10 156 inspect crankshaft inspect crankshaft threads (1) and keyways (2, 8), fig. 1. Replace crankshaft if threads or keyways are damaged or worn. Check magneto (3) and pto (7) journals for scoring. Measure journals for wear. Replace crankshaft if journals are scored, or worn past reject sizes liste...

  • Page 158

    10 157 inspect camshaft inspect gear teeth (4), lobes (9, 10), compression release balls (7) and camshaft bearing journals (6, 11) for wear and nicks, fig. 4. Camshaft journal and lobe reject sizes are shown in specifications page in appendix. Replace cam gear if not to specification. Governor spool...

  • Page 159

    10 158.

  • Page 160: Section 11

    11 locked for printing – select sect. Needed > 159 section 11 pistons, rings and connecting rods page assemble piston and connecting rod 161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assemble rings to piston 162 . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 161

    11 160 general information install new piston rings whenever the engine is disassembled for major servicing or overhaul, providing that cylinder bores are within specification. 1. Remove any carbon or ridge at the top of the cylinder bore. This will prevent breaking the rings when removing the pisto...

  • Page 162

    11 locked for printing – select sect. Needed > 161 models 540000, 610000 • top compression ring – 0.030” (0.76 mm) • center compression ring – 0.030” (0.76 mm) • oil rings – 0.040” (1.0 mm) fig. 4 ÎÎ ÎÎ ÎÎ 3. Check piston pin bore, fig. 5 . Replace piston if worn beyond reject dimension or 0.0005” (...

  • Page 163

    11 162 fig. 8 #1 3. Lubricate parts with engine oil. Assemble #2 piston and connecting rod, fig. 9. • arrow, notch or casting mark on piston must face flywheel side. • the designation “out 2” or the number ‘‘2” on the connecting rod must face pto side (opposite arrow on piston). 4. Install piston pi...

  • Page 164: Section 12

    12 locked for printing – select sect. Needed > 163 section 12 engine assembly page engine assembly 164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install crankshaft 164 . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 165

    12 164 engine assembly install crankshaft lubricate mag bearing and lips of oil seal with engine oil. Install crankshaft, fig. 1. Fig. 1 install piston and connecting rods note: install #1 piston and connecting rod first. 1. Oil piston rings and piston skirt. Compress rings with piston ring compress...

  • Page 166

    12 locked for printing – select sect. Needed > 165 3. Align timing marks on camshaft and crankshaft timing gear. Install camshaft, fig. 5. 4. Assemble governor spool (2) to camshaft (except models 540000, 610000). A. Install new o-ring (3) in cylinder. B. Make sure that spool engages flyweights and ...

  • Page 167

    12 166 crankshaft end play is adjusted by adding or removing a thrust washer. Thrust washer kit #807625 contains shims with the following thickness; 0.039” (1.0 mm), 0.049” (1.25 mm) and 0.059” (1.5 mm). The thrust washer is installed on the pto side of the crankshaft next to the timing gear. Instal...

  • Page 168

    12 locked for printing – select sect. Needed > 167 fig. 13 2. Install valve covers with new gaskets and valve cover seals (6), fig. 14. Torque nuts (7) to 25 in. Lbs. (3 nm). Note: models 540000, 610000 – 70 in. Lbs. (8 nm) 3. Repeat for no. 2 cylinder. 4. Adjust valve clearance. See section 1. Fig....

  • Page 169

    12 168 models 350000, 380000 1. Install washer and flywheel nut. 2. Assemble flywheel holder #19321 (2) to retainer, fig. 17. 3. Use a torque wrench (1) and 30 mm socket (3) to torque flywheel nut to 125 ft. Lbs. (175 nm). 4. Install starter hub and screw (if equipped). Torque to 35 ft. Lbs. (48 nm)...

  • Page 170

    12 locked for printing – select sect. Needed > 169 install armatures 1. Assemble armature to engine, fig. 20. 2. Install ground wire onto tab terminal on armatures. Note: mounting holes in armature are slotted. Push armature away from flywheel (arrow) as far as possible. Tighten either screw (4) to ...

  • Page 171

    12 170 2. Assemble carburetor onto mounting studs, fig. 24. Fig. 24 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. 2. Install governor link spring (4) in loop on retainer. Note: if the car...

  • Page 172

    12 locked for printing – select sect. Needed > 171 fig. 29 a. Be sure locating pin (2) in spacer fits in recess (4) in manifold. B. Torque screws to 65 in. Lbs. (7 nm). 2. Install new gaskets (5) and carburetor/manifold assembly (6) to cylinder heads, fig. 30. Torque screws to 140 in. Lbs. (16 nm). ...

  • Page 173

    12 172 3. Assemble choke link (6) to choke lever, fig. 33. Fig. 33 4. Assemble carburetor (3), gasket (7), spacer (8) and gasket (9) to intake manifold. 5. Route both solenoid wires (10) through hole in intake manifold. Torque three screws to 65 in. Lbs. (7 nm). 6. Install solenoid ground wire (11)....

  • Page 174

    12 locked for printing – select sect. Needed > 173 4. Install breather deflector (4) and three screws (3). Torque nuts and screws to 65 in. Lbs. (7 nm). Make sure air inlet tube (1) is installed correctly in air cleaner base. Fig. 37 early style: (square cartridge) fig. 38. 1. Insert mounting screws...

  • Page 175

    12 174 fig. 41 3. Install breather deflector (2) and two screws (3). 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 cleaner base. Models 351400, 380400 1. Install new air cleaner ...

  • Page 176

    12 locked for printing – select sect. Needed > 175 final engine assembly • install muffler and exhaust manifold. Torque to 150 in. Lbs. (17 nm). Note: models 540000, 610000 torque screws to 180 in. Lbs. (20 nm). • install spark plugs. Torque spark plugs to 180 in. Lbs. (20 nm). • install engine into...

  • Page 177

    12 176.

  • Page 178: Section 13

    13 177 section 13 engine specifications page engine specifications 178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Models 290000, 300000 178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 179

    13 178 models 290000, 300000 common specifications note: all dimensions in inches (millimeters) armature air gap 0.008 – 0.012 (0.20 – 0.30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft end play 0.002 – 0.030 (0.05 – 0.76) . . . . . . . . . . ....

  • Page 180

    13 locked for printing – select sect. Needed > 179 torque values description torque air cleaner mounting 90 in. Lbs. (10 nm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air guide mounting screws 90 in. Lbs. (10 nm) . . . . . . ....

  • Page 181

    13 180 model 350000 common specifications note: all dimensions in inches (millimeters) armature air gap 0.008 – 0.012 (0.20 – 0.30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft end play 0.002 – 0.030 (0.05 – 0.76) . . . . . . . . . . . . . . . ...

  • Page 182

    13 locked for printing – select sect. Needed > 181 torque values description torque air cleaner mounting 90 in. Lbs. (10 nm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air guide mounting screws 90 in. Lbs. (10 nm) . . . . . . ....

  • Page 183

    13 182 model 380000 common specifications note: all dimensions in inches (millimeters) armature air gap 0.008 – 0.012 (0.20 – 0.30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft end play 0.002 – 0.030 (0.05 – 0.76) . . . . . . . . . . . . . . . ...

  • Page 184

    13 locked for printing – select sect. Needed > 183 torque values description torque air cleaner mounting 90 in. Lbs. (10 nm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air guide mounting screws 90 in. Lbs. (10 nm) . . . . . . ....

  • Page 185

    13 184 models 540000, 610000 common specifications note: all dimensions in inches (millimeters) armature air gap 0.005 – 0.007 (0.13 – 0.18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft end play 0.002 – 0.012 (0.05 – 0.30) . . . . . . . . . . ....

  • Page 186

    13 locked for printing – select sect. Needed > 185 torque values description torque air cleaner mounting 190 in. Lbs. (21 nm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air guide mounting screws 90 in. Lbs. (10 nm) . . . . . . ...

  • Page 187

    13 186 vanguard t engines – honing fixture 1-7/8” 6-11/32” cylinder mounting hardware fasteners required: 4 @ crankcase cover screws, 4 @ flat washers 3/8” (9.5 mm) i.D. 10” 10” 13/32” thru hole (4) material: wood 2” x 10” x 10” (51 mm x 254 mm x 254 mm) 2” 8-9/16” 8-5/32” 3” 3-1/4” (254 mm) (254 mm...

  • Page 188

    13 locked for printing – select sect. Needed > 187 starter motor support block a starter motor support block can be made from stock 1” (25.4 mm) thick as shown in fig. 1. The dimensions for the block are: 1. 1” (25.4 mm) 2. 0.4” (10.2 mm) 3. 2” (51 mm) 4. 1” (25 mm) 5. 5” (127 mm) fig. 1 starter mot...

  • Page 189

    13 188 fuel system identification model fuel system type color code 290400 gravity yellow 290400 pump white 294400 gravity pump 294400 pump none 303400 gravity blue 303400 pump none 350400 gravity blue 350400 pump none carburetor main jets model jet number 351400 left cylinder (#1) #94 right cylinde...

  • Page 190

    13 locked for printing – select sect. Needed > 189 drill size – decimal equivalent (inches) 60 0.040 9/64 0.1406 e, 1/4 0.250 59 0.041 27 0.144 f 0.257 58 0.042 26 0.147 g 0.261 57 0.043 25 0.1495 17/64 0.2656 56 0.0465 24 0.152 h 0.266 55 0.052 23 0.154 i 0.272 54 0.055 5/32 0.1562 j 0.277 53 0.059...

  • Page 191

    13 190 english to metric conversion table fraction decimal mm fraction decimal mm 1/64 0.0156 0.396 33/64 0.5156 13.096 1/32 0.0313 0.795 17/32 0.5313 13.495 3/64 0.0469 1.191 35/64 0.5469 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.0781 1.984 37/64 0.5781 14.684 3/32 0.0938 2.383 19/32 0.593...