Vanguard 540000 User Manual

Operating & Maintenance

Instructions

Model Series

Covered in

This Manual

470000

540000

Model

Type

Code

Note: General Model Series numbers noted above are inclusive of the specific model

number found on your engine. To get replacement parts or technical assistance in

the future, write your engine Model, Type, Code and date of purchase here.

Month Day Year

WARNING

TABLE OF CONTENTS

Emission Information . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Engine Information . . . . . . . . . . . . . . . . . . . . . . 5-7

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fuel and Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Starting and Stopping . . . . . . . . . . . . . . . . . . . . . 10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 11-14

Parts and Service & Storage . . . . . . . . . . . . . . . 16

Warranty Information . . . . . . . . . . . . . . . . . . . . . 17

Briggs & Stratton does not approve or authorize the use of

these engines on 3-wheel All Terrain Vehicles (ATVs), motor

bikes, fun/recreational go-karts, aircraft products or vehicles

intended for use in competitive events. Use of these engines in

such applications could result in property damage, serious

injury (including paralysis), or even death.

Need assistance? Go to www.briggsandstratton.com

for detailed information regarding Briggs & Stratton engines.

Or call, 1-800-233-3723, (U.S.A. and Canada)

to hear a menu of pre-recorded messages

offering engine maintenance information.

PRINTED IN U.S.A.

FORM NO. 275723-7/04

BEFORE OPERATING ENGINE

• Read entire Operating & Maintenance Instructions AND the

instructions for the equipment this engine powers.*

• Failure to follow instructions could result in serious injury or

death.

THE OPERATING & MAINTENANCE INSTRUCTIONS

CONTAIN SAFETY INFORMATION TO

• Make you aware of hazards associated with engines

• Inform you of the risk of injury associated with those hazards, and

• Tell you how to avoid or reduce the risk of injury.

The safety alert symbol

information about hazards that can result in personal injury.

( )

is used to identify safety

HAZARD SYMBOLS AND MEANINGS

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.

Fire

Explosion

Moving Parts

Shock

DANGER indicates a hazard which, if not

avoided, will result in death or serious injury.

Toxic Fumes

Hot Surface

WARNING indicates a hazard which, if not

avoided, could result in death or serious injury.

Kickback

Hot Liquid or Steam

CAUTION indicates a hazard which, if not

avoided, might result in minor or moderate

injury.

THE INTERNATIONAL SYMBOLS USED

ON THE ENGINE OR

CAUTION, when used without the alert symbol,

indicates a situation that could result in damage

to the engine.

IN THIS MANUAL INCLUDE:

WARNING

On Off

Read Owner’s Manual

Safety Alert

The engine exhaust from this

product contains chemicals known

to the State of California to cause

cancer, birth defects, or other

reproductive harm.

Oil

Choke

Stop Fuel Shutoff

Fuel

Briggs & Stratton does not necessarily know what equipment this engine will power. For that reason, you should carefully read

and understand the operating instructions for the equipment on which your engine is placed.

SAFETY

WARNING

Gasoline and its vapors are extremely flam-

mable and explosive.

Starting engine creates sparking.

Sparking can ignite nearby flammable gases.

Explosion and fire could result.

Fire or explosion can cause severe burns or

death.

WHEN ADDING FUEL

• If there is natural or LP gas leakage in area, do not start

engine.

• Turn engine OFF and let engine cool at least 2 minutes

• Do not use pressurized starting fluids because vapors

before removing gas cap.

are flammable.

• Fill fuel tank outdoors or in well-ventilated area.

• Do not overfill fuel tank. Fill tank to approximately 1-1/2

inches below top of neck to allow for fuel expansion.

• Keep gasoline away from sparks, open flames, pilot

lights, heat, and other ignition sources.

• Check fuel lines, tank, cap, and fittings frequently for

cracks or leaks. Replace if necessary.

WARNING

WHEN STARTING ENGINE

Rapid retraction of starter cord (kickback) will pull

hand and arm toward engine faster than you can let

go.

• 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.

Broken bones, fractures, bruises or sprains could

result.

• If engine floods, set choke to OPEN/RUN position, place

throttle in FAST and crank until engine starts.

• When starting engine, pull cord slowly until resistance is

felt, then pull rapidly.

WHEN OPERATING EQUIPMENT

• Do not tip engine or equipment at angle which causes

gasoline to spill.

• Remove all external equipment/engine loads before

starting engine.

• Direct coupled equipment components such as, but not

limited to, blades, impellors, pulleys, sprockets, etc.,

must be securely attached.

• Do not choke carburetor to stop engine.

WHEN TRANSPORTING EQUIPMENT

• Transport with fuel tank EMPTY or with fuel shut-off valve

OFF.

WHEN STORING GASOLINE OR EQUIPMENT

WITH FUEL IN TANK

WARNING

• Store away from furnaces, stoves, water heaters or other

appliances that have pilot light or other ignition source

because they can ignite gasoline vapors.

Rotating parts can contact or entangle hands,

feet, hair, clothing, or accessories.

Traumatic amputation or severe laceration 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 caught.

SAFETY

WARNING

Running engines produce heat. Engine parts,

especially muffler, become extremely hot.

Engines give off carbon monoxide, an odorless,

colorless, poison gas.

Severe thermal burns can occur on contact.

Breathing carbon monoxide can cause nausea,

fainting or death.

Combustible debris, such as leaves, grass,

brush, etc. can catch fire.

• Start and run engine outdoors.

• Allow muffler, engine cylinder and fins to cool before

touching.

• Do not start or run engine in enclosed area, even if doors

or windows are open.

• Remove accumulated combustibles from muffler area

and cylinder area.

• Install and maintain in working order a spark arrester

before using equipment on forest-covered, grass-cov-

ered, brush-covered unimproved land. The state of

California requires this (Section 4442 of the California

Public Resources Code). Other states may have similar

laws. Federal laws apply on federal land.

WARNING

Never remove radiator cap or radiator reservoir

cap while the engine is hot or running. Severe

thermal burns or injury can occur by escaping

steam or hot engine coolant.

Unintentional sparking can result in fire or

electric shock.

Unintentional start-up can result in entangle-

ment, traumatic amputation, or laceration.

Before Performing Adjustments or Repairs

• Disconnect spark plug wire and keep it away from spark

plug.

• Stop engine and allow to cool before removing radiator or

reservoir cap.

• To remove reservoir cap after engine is cool, place a thick

• Disconnect battery at negative terminal (only engines

cloth over cap and remove it slowly.

with electric start).

• To remove radiator cap after engine is cool, place a thick

cloth over cap and rotate it slowly counter-clockwise to

the first stop. Pressurized steam may emit from the cap,

stand back to avoid injury. Once all pressure is released,

rotate cap counter-clockwise while pushing down on cap

to remove.

When Testing For Spark

• Use approved spark plug tester.

• Do not check for spark with spark plug removed.

ENGINE INFORMATION

TECHNICAL INFORMATION

POWER RATINGS: The power ratings for an individual engine

model are initially developed by starting with SAE (Society of

Automotive Engineers) code J1940 (Small Engine Power &

Torque Rating Procedure) (Revision 2002-05). Given both the

wide array of products on which our engines are placed, and the

variety of environmental issues applicable to operating the

equipment, it may be that the engine you have purchased will not

develop the rated horsepower when used in a piece of power

equipment (actual “on-site” power). This difference is due to a

variety of factors including, but not limited to, the following:

differences in altitude, temperature, barometric pressure,

humidity, fuel, engine lubrication, maximum governed engine

speed, individual engine to engine variability, design of the

particular piece of power equipment, the manner in which the

engine is operated, engine run-in to reduce friction and clean out

of combustion chambers, adjustments to the valves and

carburetor, and other factors. The power ratings may also be

adjusted based on comparisons to other similar engines utilized

in similar applications, and will therefore not necessarily match the

values derived using the foregoing codes.

ENGINE INFORMATION

MODEL SERIES 470000

1. Oil fill cap

12. Air Cleaner

2. Dipstick

13. Fuel pump (if equipped)

14. Muffler

15. Choke control

16. Throttle control

(2 possible locations)

17. Radiator reservoir

18. Oil filter

3. Spark plug (2 locations)

4. Starter solenoid

5. Starter

6. Oil drain plug (2 locations)

7. Fan belt

8. Fuel filter

9. Radiator drain plug

10. Radiator screen and handle

11. Radiator and radiator cap

19. Oil pressure sensor

20. Engine Model label

Model

Type

Code

xxxxxxxx

xxxxxx

xxxx xx

GENERAL INFORMATION

TUNE-UP SPECIFICATIONS

MODEL SERIES 470000

Armature air gap . . . . . . . . . 0.008 – 0.012 in. (0.20 – 0.30 mm)

Spark plug gap . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in. (0.51 mm)

Valve clearance with valve springs installed and piston 1/4 in. (6 mm)

past top dead center (check when engine is cold).

This is a twin cylinder, overhead valve (OHV), liquid-cooled

engine. It is a low emissions engine.

In the state of California, Model Series 470000 engines are

certified by the California Air Resources Board to meet emissions

standards for 250 hours. Such certification does not grant the

purchaser, owner or operator of this engine any additional

warranties with respect to the performance or operational life of

this engine. This engine is warranted solely according to the

product and emissions warranties stated elsewhere in this

manual.

Intake . . . . . . . . . . . . . . . . . . . 0.007 – 0.009 in. (0.18 – 0.23 mm)

Exhaust . . . . . . . . . . . . . . . . . 0.007 – 0.009 in. (0.18 – 0.23 mm)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 in. (81 mm)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.87 in. (73 mm)

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . 45.9 cu. in. (752 cc)

Note: For practical operation, the horsepower loading should not

exceed 85% of rated horsepower. Engine power will decrease

3-1/2% for each 1,000 feet (300 meters) above sea level and 1%

for each 10° F (5.6° C) above 77° F (25° C). Engine will operate

satisfactorily at an angle up to 25°.

ENGINE INFORMATION

MODEL SERIES 540000

1. Choke control

10. Carburetor

2. Breather/Breather tube

3. Spark plug (2 locations)

4. Engine Model label

11. Mechanical fuel pump

12. Air cleaner

13. Oil Fill

Model

Type

Code

xxxxxxxx

14. Dipstick

xxxxxx

xxxx xx

15. Regulator/Rectifier

16. Starter solenoid

17. Starter

18. Exhaust system/Muffler

19. Throttle control (2 locations)

5. Oil pressure sensor

6. Oil filter

7. Oil drain plug (2 locations)

8. Rotating screen

9. Carburetor cover (Removed)

GENERAL INFORMATION

TUNE-UP SPECIFICATIONS

MODEL SERIES 540000

Armature air gap . . . . . . . . . 0.005 – 0.008 in. (0.13 – 0.20 mm)

Spark plug gap . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in. (0.51 mm)

Valve clearance with valve springs installed and piston 1/4 in. (6 mm)

past top dead center (check when engine is cold).

This is a twin cylinder, overhead valve (OHV), air-cooled engine.

It is a low emissions engine.

In the state of California, Model Series 540000 engines are

certified by the California Air Resources Board to meet emissions

standards for 1000 hours. Such certification does not grant the

purchaser, owner or operator of this engine any additional

warranties with respect to the performance or operational life of

this engine. This engine is warranted solely according to the

product and emissions warranties stated elsewhere in this

manual.

Intake . . . . . . . . . . . . . . . . . . . 0.004 – 0.006 in. (0.10 – 0.15 mm)

Exhaust . . . . . . . . . . . . . . . . . 0.004 – 0.006 in. (0.10 – 0.15 mm)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.5 mm (3.36 in.)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 mm (3.07 in.)

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . 895 cc (54.6 cu. in.)

Note: For practical operation, the horsepower loading should not

exceed 85% of rated horsepower. Engine power will decrease

3-1/2% for each 1,000 feet (300 meters) above sea level and 1%

for each 10° F (5.6° C) above 77° F (25° C). Engine will operate

satisfactorily at an angle up to 25°.

OIL

SAE Viscosity Grades

CAUTION: This engine is shipped from Briggs & Stratton

without oil. Check oil level before starting engine. If you start

the engine without oil, the engine will be damaged beyond

repair and will not be covered under warranty.

OIL CAPACITY

Model Series

Capacity

87 oz. (2.6 l)*

80 oz. (2.3 l)*

470000

540000

-20

-30

32 40

100

°F

-20

-10

°C

*Approximate amount when changing oil and filter.

STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

TYPE OF OIL TO USE

• Use a high quality detergent oil classified “For Service SF, SG,

SH, SJ” or higher, such as Briggs & Stratton 30, Part Number

100005 (20 oz) or 100028 (48 oz).

• Do not use special additives.

• Do not mix gasoline with oil.

CAUTION: The use of non-synthetic multi-viscosity oils

(5W-30, 10W-30, etc.) in temperatures above 40° F (4° C)

will result in higher than normal oil consumption. When

using a multi-viscosity oil, check oil level more frequently.

** CAUTION:SAE 30 oil, if used below 40° F (4° C), will result

in hard starting and possible engine bore damage due to

inadequate lubrication.

• Choose a viscosity according to the table opposite.

Note: Synthetic oil meeting ILSAC GF-2, API

certification mark and API service symbol

(shown at left) with “SJ/CF ENERGY

CONSERVING” or higher, is an acceptable oil

at all temperatures. Use of synthetic oil does

not alter required oil change intervals.

CHECKING AND ADDING OIL

• Check oil level before starting the engine.

• Check level daily, or after every eight (8) hours.

• Keep oil level at FULL.

• Do not overfill.

Oil filling procedure:

First add 67 ounces (2 liters). Start and run engine at idle for 30

seconds. See Starting Instructions.

Shut engine off and wait 30 seconds.

OIL FILL

Then add more oil slowly to bring level to Full mark on dipstick.

Oil checking procedure:

[1.] Place engine level.

Clean around oil fill and dipstick.

[2.] Remove dipstick and wipe clean with cloth.

[3.] Then push dipstick back in and remove to check oil level. Oil

should be at FULL line on dipstick.

[4.] If oil is needed, add slowly.

[5.] Fill to FULL line on dipstick – recheck.

[6.] Replace dipstick firmly.

FULL

DIPSTICK

FUEL

TYPE OF FUEL TO USE

• 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 quantity that

can be used within 30 days.

CAUTION: Some fuels, called oxygenated or reformulated

gasoline, are gasoline blended with alcohols or ethers.

Excessive amounts of these blends can damage the fuel

system or cause performance problems. If any undesirable

operating symptoms occur, use gasoline with a lower percent-

age of alcohol or ether.

• Do not use gasoline which contains Methanol.

• Do not mix oil with gasoline.

• For engine protection use Briggs & Stratton Gasoline Additive

available from your Authorized Briggs & Stratton Dealer (P/N

5041 or single use pouch).

• This engine is certified to operate on gasoline. Exhaust

Emission Control System: EM (Engine Modifications).

ADDING FUEL

WARNING

[1.] Remove cap. Fill tank to approximately 1-1/2 inches below

top of neck to allow for fuel expansion. Be careful not to

overfill.

Briggs & Stratton Smart-Fill® fuel can fills to the correct

level and automatically shuts off, reducing spills and

emissions.

• Turn engine OFF and let engine cool at least 2 minutes

before removing gas cap.

• Fill fuel tank outdoors or in well-ventilated area.

• Keep gasoline away from sparks, open flames, pilot lights,

[2.] Replace cap before starting.

heat, and other ignition sources.

• If fuel spills, wait until it evaporates before starting engine.

COOLANT

MODEL 470000

• Do not touch radiator or open

radiator cap, or open reservoir

when engine is hot or running.

WARNING

• Allow engine to cool before

changing or adding coolant.

• This engine is liquid cooled.

• A 50/50% mixture is required of phosphate-free antifreeze and

tap water for heat dissipation, rust resistance and lubrication.

ADDING COOLANT

• Fill radiator to bottom of filler neck, and fill reservoir between

FULL and LOW.

COOLANT LEVEL

IN RESERVOIR

• Start and run engine for 30 seconds.

See Starting Instructions.

• Shut engine off and allow it to cool.

Recheck coolant levels in radiator and reservoir.

STARTING & STOPPING

OIL PRESSURE SWITCH

CAUTION

BEFORE STARTING ENGINE FOR THE FIRST TIME:

• Fill and check oil level.

If engine is equipped with an oil pressure switch, the switch will

either activate a warning device or stop the engine when the

engine runs low on oil. (Read the operating instructions supplied

by the equipment manufacturer to determine if and how your

engine is equipped.)

• Fill with fresh gasoline.

See OIL PRESSURE on page 12 for oil filling instructions.

• Fill and check coolant level.

• Charge battery as the equipment manufacturer

TEMPERATURE LIGHT (If equipped)

MODEL 470000 ONLY

recommends.

If temperature light comes on, engine is overheating.

• The manufacturer of equipment

WARNING

on which this engine is installed

specifies top speed at which

engine will be operated. DO NOT

EXCEED this speed.

CAUTION:

DO NOT OPERATE If the temperature light is on. Check

coolant levels, fan belt, and any restriction to air flow. If light

persists, see an Authorized Service Dealer.

STARTING IN COLD WEATHER:

♦ Use correct type of oil for expected starting temperature. See

♦ Open fuel shut-off valve, if equipped, before starting engine.

Oil.

♦ Allow engine to warm up several seconds to several

minutes, depending on outside temperature.

♦ Use fresh gasoline, which has higher volatility to improve

♦ Gradually open choke.

starting.

♦ For maximum performance and life, operate engine with

♦ Remove external equipment/engine loads.

choke in OPEN and throttle in FAST.

(See equipment operating instructions.)

TO START ENGINE

[1.] Check oil level (see p. 8).

Typical Controls

[2.] Open fuel shut-off valve (if equipped).

[3.] Move choke control to CHOKE or START.

[4.] Move throttle (if equipped) to FAST.

[5.] Push rocker switch (if equipped)

to ON or RUN.

[6.] Insert key and turn to START.

CAUTION: To prolong starter life, use short starting

cycles (5 seconds maximum, then wait one minute).

Follow equipment manufacturer’s recommendations

for charging battery.

Fuel Shut-off

Choke

Throttle

[7.] Let engine warm up.

If choke equipped: Slowly adjust toward RUN position.

Wait until engine runs smoothly before each choke

adjustment.

TO STOP ENGINE

[1.] Move throttle to SLOW (if equipped).

STOP

Stop Switch

RUN

[2.] Turn key to OFF. Remove key and store out of reach of children.

[3.] Push rocker switch (if equipped) to OFF or STOP.

[4.] Close fuel shut-off valve (if equipped).

Key

MAINTENANCE

Regular maintenance will improve the performance and extend the life of the engine. See any Authorized Briggs & Stratton Dealer for

service. Use only genuine Briggs & Stratton parts. Other parts may not perform as well, may damage the engine, and may result in

injury. In addition, use of other parts may void your warranty.

ENGINE AND ENGINE PARTS

We recommend that you see an authorized Briggs & Stratton Service Dealer for all maintenance and service of the engine and engine

parts. Use only genuine Briggs & Stratton parts.

Perform the following at recommended intervals:

Task

EMISSION CONTROL

Maintenance, replacement or repair of the emission control

devices and systems may be performed by any nonroad

engine repair establishment or individual. However, to obtain

no charge repairs under the terms and provisions of the Briggs &

Stratton warranty statement, any service or emission control part

repair or replacement must be performed by a factory authorized

dealer.

Perform task at hourly

or calendar interval,

whichever comes first.

Check oil level

Check for

oil leaks

WARNING

Change oil

If you perform any maintenance on the engine, first

disconnect the spark plug wires from the spark

plugs, and disconnect the battery at the negative

terminal (electric starter engines only) to prevent

unintentional sparking. Unintentional sparking can

result in fire or electric shock. Unintentional start-up

can result in entanglement, traumatic amputation or

laceration. Use only correct tools.

Change oil filter

Clean

air cleaner

Replace air cleaner

cartridge

Check valve

clearance

Check battery

electrolyte

Change

spark plugs

WARNING

• Do not strike the flywheel with a hammer or hard object

because the flywheel may later shatter during operation.

Change fuel filter

Clean spark

arrestor (if equipped)

• Do not tamper with governor spring, links or other parts to

increase engine speed.

MODEL 540000 ONLY

Replace Safety

filter cartridge

SPARK PLUG

Change spark plugs yearly. Use only Briggs & Stratton Spark

Tester (part number 19368) to check for spark.

MODEL 470000 ONLY

Check coolant

Note: In some areas, local law

requires using resistor spark plug

to suppress ignition signals. If this

engine was originally equipped

with resistor spark plugs, use

same type for replacement.

.020” (0.51 mm)

WIRE GAGE

Change coolant

Check fan belt

Change oil and filter after first 50 hours of use, then every

100 hours or every season. Change oil every 50 hours when

operating the engine under heavy load or in high

temperatures.

Check valve clearance after first 50 hours of use, then

every 250 hours.

** Clean more often under dusty conditions or when airborne

debris is present. Replace air cleaner parts, if very dirty.

VALVE CLEARANCE

*** If an extended life coolant is used, interval may be increased

to once every 3000 hours.

Check valve clearance every 250 hours.

(See Tune-up Specifications on page 6).

MAINTENANCE

CHANGING OIL AND OIL FILTER

Change oil and filter after first 50 hours and every 100 hours thereafter.

[1.] With engine OFF but still warm, remove oil drain plug and drain oil into

appropriate receptacle. Reinstall drain plug

OIL FILTER

[2.] Remove oil filter. Before installing new filter, lightly oil filter gasket with

fresh, clean oil.

[3.] Screw filter on by hand until gasket contacts oil filter adapter. Tighten

1/2 to 3/4 turn more.

[4.] Place engine level. Remove oil fill cap and add fresh oil.

Oil filling procedure: First, add 67 ounces (2 liters). Start and run

engine at idle for 30 seconds. Shut engine off and wait 30 seconds.

Then, add more oil slowly to bring level to Full mark on dipstick. Do

not overfill.

OIL DRAIN PLUG

OIL FILL

[5.] Replace oil fill cap and dipstick

CAUTION: Used oil is a hazardous waste product. Dispose of used oil

properly. Do not discard with household waste. Check with your local

authorities, service center, or dealer for safe disposal/recycling facilities.

OIL PRESSURE

If oil pressure drops below 1-4 psi (.1-.2 kg/cm ), an oil pressure switch (if

engine is equipped) will either activate a warning device or stop the engine.

Check oil level with dipstick. If oil level is between ADD and FULL mark on

dipstick, Do not try to restart engine. Contact an Authorized Briggs & Stratton

Service Dealer. Do not operate engine until oil pressure is corrected.

FULL

DIPSTICK

If oil level is below ADD mark on dipstick, add oil to bring level to FULL mark.

Restart engine and check oil pressure. If pressure is normal, continue to

operate engine.

Note: Oil pressure gauge, if engine is equipped, is supplied by manufactur-

er of equipment.

AIR CLEANER

CLAMPS

CAUTION: Do not use pressurized air or solvents to

clean cartridge. Pressurized air can damage cartridge;

solvents will dissolve cartridge.

AIR

CLEANER

BODY

COVER

Clean cartridge every 100 hours. To clean cartridge, gently tap on

end with handle of screwdriver. Replace cartridge every 600

hours. Clean and replace more often under dusty conditions.

AIR FILTER

CARTRIDGE

Model 5400 Safety Filter Installation

[1.] Unlock clamps and remove cover.

SAFETY FILTER

AIR FILTER

[2.] Remove cartridge from air cleaner body, and inspect.

Replace if very dirty or any damage occurs to cartridge.

CARTRIDGE

[3.] Carefully clean out air cleaner cover.

[4.] Install cartridge in body.

[5.] Install cover and lock clamps with rubber valve down.

AIR

CLEANER

BODY

AIR

CLEANER

BODY

Model 5400 Safety Filter Installation

Replace cartridge every 600 hours, or with every other air filter

cartridge replacement. To replace cartridge, pull carefully to

remove from air cleaner body, ensure no debris enters engine.

Install new safety cartridge first, then install air filter cartridge over

safety filter.

MAINTENANCE

CHANGING COOLANT (MODEL 470000)

Coolant should be replaced every year, unless an approved

extended life coolant is used. Then replace every 3000 hours.

WARNING

• A 50/50% mixture is required of phosphate-free antifreeze and

Never remove radiator cap or radiator reservoir

cap while the engine is hot or running. Severe

thermal burns or injury can occur by escaping

steam or hot engine coolant.

tap water for heat dissipation, rust resistance and lubrication.

[1.] Remove drain plug. As coolant is running out, open radiator

cap to allow any trapped coolant to drain. Replace drain

plug.

• Stop engine and allow to cool before removing radiator or

reservoir cap.

[2.] Remove reservoir bottle, drain it and reinstall.

• To remove reservoir cap after engine is cool, place a thick

cloth over cap and remove it slowly.

[3.] Fill radiator to bottom of filler neck and reservoir between

FULL and LOW. Replace radiator cap.

• To remove radiator cap after engine is cool, place a thick

cloth over cap and rotate it slowly counter-clockwise to

the first stop. Pressurized steam may emit from the cap,

stand back to avoid injury. Once all pressure is released,

rotate cap counter-clockwise while pushing down on cap

to remove.

[4.] Start and run engine for 30 seconds.

[5.] Shut engine off and allow it to cool. Recheck coolant levels in

radiator and reservoir.

CAUTION: Used coolant is a hazardous waste product.

Dispose of used coolant properly. Check with your local

authorities, service center, or dealer for safe disposal/re-

cycling facilities.

[6.] Coolant level in reservoir should be between FULL and LOW

when engine is cold.

Normal coolant temperature

gauge (if equipped) should

read between 175° and 195° F

(80° and 90° C) when engine is

running.

WARNING

If coolant temperature rises above 220° F (105° C), the

temperature light (if equipped) will illuminate. Idle engine down

for a while. Then stop engine. Once engine is cooled, check

coolant level, fan belt tension and clean any clogged radiator

fins.

COOLANT LEVEL

IN RESERVOIR

RADIATOR

DRAIN PLUG

Side view

Front view

FAN BELT (MODEL 470000)

♦ Check condition of fan belt.

♦ Replace if damaged or worn.

FAN BELT

BOLT “A”

To adjust fan belt tension

[1.] First, loosen bolt A and bolt B.

TORQUE

WRENCH

TORQUE

WRENCH

SQUARE

TORQUE

HOLE

[2.] Fit torque wrench in the square

torque hole located on the bracket.

SQUARE

TORQUE HOLE

BOLT “B”

[3.] Apply 115 in-lbs of torque in the

direction of the arrow.

FAN

BELT

[4.] While belt is being tensioned per

step [3], torque bolt A and B to 135

in-lbs.

BOLT “B”

MAINTENANCE

CLEANING DEBRIS

Daily or before every use, clean accumulated debris from engine.

Keep linkage, springs and controls clean. Keep area around and

behind muffler free of any combustible debris.

Model 470000: Use the handle on the radiator screen to lift off for

cleaning. Clean screen thoroughly and clean radiator fins.

Model 540000: Remove front carburetor cover, and clean around

intake manifold and carburetor.

CLEAN DEBRIS

RADIATOR

SCREEN

HANDLE

CLEAN DEBRIS

CAUTION: Do not use water to clean engine parts. Water could

contaminate fuel system. Low pressure compressed air may be

used, be careful not to damage radiator fins.

Engine parts should be kept

clean to reduce the risk of over-

heating and ignition of accumu-

lated debris.

WARNING

FUEL FILTER

MUFFLER/FUEL SYSTEM

Drain fuel tank or close fuel shut-off

Replacement parts for the muffler

WARNING must be the same and installed in

the same position as the original

valve before replacing fuel filter.

Otherwise, fuel can leak out,

creating a fire/explosion hazard.

When replacing fuel filter, ensure

clamps are tight and fuel flows into

the same direction as the arrow

marked FLOW.

WARNING

parts, otherwise fire can occur.

Replacement parts for fuel system

(cap, hoses, tanks, filters, etc.) must be the same as original

parts, otherwise fire can occur.

PART NO. 807241

STORAGE

Then, engine and fuel can be stored up to 24 months.

[2.] While engine is still warm, change oil.

STORAGE

Engines stored over 30 days need special attention.

[3.] Remove spark plugs and pour about 1 oz. (30 ml) of engine

oil into each cylinder. Replace spark plugs and crank slowly

to distribute oil.

[1.] To prevent gum from forming in fuel system or on essential

carburetor parts:

a) if fuel tank contains oxygenated or reformulated gasoline

(gasoline blended with an alcohol or an ether), run engine

until it stops from lack of fuel, or b) if fuel tank contains

gasoline, either run engine until it stops from lack of fuel, or add

a gasoline additive to the gas in the tank. (See parts list.

Single-use pouches of gas additive are available from your

service dealer.) If you use a gas additive, run the engine for

several minutes to circulate the additive through the carburetor.

[4.] Clean engine of surface debris, chaff or grass.

[5.]

Store in a clean, dry area. Do not

store in same area as a stove,

furnace, water heater, or other

appliance that uses a pilot light or

has a device that can create a

spark.

WARNING

SERVICE

See an Authorized Briggs & Stratton Service Dealer. Each one

carries a stock of Genuine Briggs & Stratton Parts and is equipped

with special service tools. Trained mechanics assure expert repair

service on all Briggs & Stratton engines. Only dealers advertising

as “Authorized Briggs & Stratton” are required to meet Briggs &

Stratton standards.

PARTIAL LIST OF

GENUINE BRIGGS & STRATTON PARTS

PART

PART NO.

Air cleaner cartridge (Model 470000) . . . . . . . . . . . . . . . 820263

Air cleaner cartridge (Model 540000) . . . . . . . . . . . . . . . 809670

Safety air cleaner cartridge (Model 540000) . . . . . . . . . . 821136

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100028

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492932

Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691035

Fuel pump (Model 470000) . . . . . . . . . . . . . . . . . . . . . . . 807242

Fuel pump (Model 540000) . . . . . . . . . . . . . . . . . . . . . . . 809669

Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807243

Gas additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5041

Resistor spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692051

Spark plug wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19374

When you purchase equipment powered by a Briggs

& Stratton engine, you are assured of highly skilled,

reliable service at more than 30,000 Authorized

Service Dealers worldwide, including more than

6,000 Master Service Technicians. Look for these

signs wherever Briggs & Stratton service is offered.

You may locate your nearest Authorized Briggs & Stratton Service

Dealer in our dealer locator map on our web site

www.briggsandstratton.com or in the “Yellow Pages™”

Spark tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19368

Oil pump kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5056

(uses standard electric drill to remove oil from engine quickly)

directory under “Engines, Gasoline” or “Gasoline En-

gines,” or “Lawn Mowers” or similar category.

™

Repair Manual (Model 470000) . . . . . . . . . . . . . . . . . . . . 275429

An illustrated shop manual includes common

specifications and detailed information cover-

ing adjustment, tune-up and repair of Briggs &

Stratton OHV, twin cylinder, 4 cycle engines. It

is available for purchase from an Authorized

Briggs & Stratton Service Dealer or you can

order it from the factory. Write: Briggs & Stratton

Corporation, Attn: Service Division

P. O. Box 1144, Milwaukee, WI 53201

LIMITED WARRANTY

Briggs & Stratton Corporation will repair or replace, free of charge, any part(s) of the engine that is defective in material or workmanship or both.

Transportation charges on parts submitted for repair or replacement under this warranty must be borne by purchaser. This warranty is effective for the

time periods and subject to the conditions stated below. For warranty service, find the nearest Authorized Service Dealer in our dealer locator map

at www.briggsandstratton.com, or by calling 1-800-233-3723, or as listed in the ‘Yellow Pages™’.

THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM PURCHASE, OR TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED

WARRANTIES ARE EXCLUDED. LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ARE EXCLUDED TO THE EXTENT

EXCLUSION IS PERMITTED BY LAW. Some states or countries do not allow limitations on how long an implied warranty lasts, and some states or

countries do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to you.

This warranty gives you specific legal rights and you may also have other rights which vary from state to state and country to country.

(Kool Bore)

(Sleeve Bore)

Consumer Use

Commercial Use

2 years

1 year

2 years

90 days

1 year

90 days

2 years

1 year

Note the following special warranty periods: 2 years for Classic™ engines in the European Union and Eastern European countries, for all consumer

products in the European Union, and for emission control systems on engines certified by EPA and CARB. 5 years for Consumer use, 90 days for

Commercial use of Touch-N-Mow® starter on Quantum® and Intek™ engines. One year for Consumer use, 90 days for Commercial use on engines

certified to operate on Kerosene fuel. Engines used on Home Standby Generator applications are warranted under Consumer use only. This warranty

does not apply to engines on equipment used for prime power in place of a utility. Engines used in competitive racing or on commercial or rental

tracks are not warrantied.

The warranty period begins on the date of purchase by the first retail consumer or commercial end user, and continues for the period of time stated in the table above. “Consumer use”

means personal residential household use by a retail consumer. “Commercial use” means all other uses, including use for commercial, income producing or rental purposes. Once an

engine has experienced commercial use, it shall thereafter be considered as a commercial use engine for purposes of this warranty.

NO WARRANTY REGISTRATION IS NECESSARY TO OBTAIN WARRANTY ON BRIGGS & STRATTON PRODUCTS. SAVE YOUR PROOF OF PURCHASE

RECEIPT. IF YOU DO NOT PROVIDE PROOF OF THE INITIAL PURCHASE DATE AT THE TIME WARRANTY SERVICE IS REQUESTED, THE

MANUFACTURING DATE OF THE PRODUCT WILL BE USED TO DETERMINE THE WARRANTY PERIOD.

)

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EMISSION CONTROL WARRANTY COVERAGE IS APPLICABLE TO CERTIFIED ENGINES PURCHASED IN CALIFORNIA IN 1995 AND THERE-

AFTER, WHICH ARE USED IN CALIFORNIA, AND TO CERTIFIED MODEL YEAR 1997 AND LATER ENGINES WHICH ARE PURCHASED AND

USED ELSEWHERE IN THE UNITED STATES (AND AFTER JANUARY 1, 2001 IN CANADA).

The California Air Resources Board (CARB), U.S. Elsewhere in the United States, new non-road, Your emission control system includes parts

EPA and B&S are pleased to explain the Emission spark-ignition engines certified for model year such as the carburetor, air cleaner, ignition sys-

Control System Warranty on your model year 1997 and later must meet similar standards set tem, muffler and catalytic converter. Also in-

2002 and later small off-road engine (SORE). In forth by the U.S. EPA. B&S must warrant the emis- cluded may be connectors and other emission

California, new small off-road engines must be de- sion control system on your engine for the periods related assemblies.

signed, built and equipped to meet the State’s of time listed below, provided there has been no

Where a warrantable condition exists, B&S will

repair your small off-road engine at no cost to

you including diagnosis, parts and labor.

stringent anti-smog standards.

abuse, neglect or improper maintenance of your

small off-road engine.

Small off-road engines are warranted relative to emission control parts defects for a period of two years, subject to provisions set forth below. If any

covered part on your engine is defective, the part will be repaired or replaced by B&S.

As the small off-road engine owner, you are re- As the small off-road engine owner, you should The undisputed warranty repairs should be

sponsible for the performance of the required however be aware that B&S may deny you war- completed in a reasonable amount of time, not

maintenance listed in your Operating and Main- ranty coverage if your small off-road engine or a to exceed 30 days.

tenance Instructions. B&S recommends that part has failed due to abuse, neglect, improper

you retain all your receipts covering mainte- maintenance or unapproved modifications.

If you have any questions regarding your war-

ranty rights and responsibilities, you should con-

nance on your small off-road engine, but B&S

You are responsible for presenting your small

tact

B&S Service Representative at

cannot deny warranty solely for the lack of re-

off-road engine to an Authorized B&S Service

1-414-259-5262.

ceipts or for your failure to ensure the perfor-

mance of all scheduled maintenance.

Dealer as soon as a problem exists.

The emission warranty is a defects warranty.

Defects are judged on normal engine perfor-

mance. The warranty is not related to an in-use

emission test.

The following are specific provisions relative to your Emission Control Defects Warranty Coverage. It is in addition to the B&S engine warranty for non-

regulated engines found in the Operating and Maintenance Instructions.

1. Warranted Parts

subsequent purchaser that the Warranted

Parts shall be free from defects in materials

and workmanship which caused the failure

B&S is not liable to cover failures of War-

ranted Parts caused by the use of add-on,

non-original, or modified parts.

Coverage under this warranty extends only

to the parts listed below (the emission con-

trol systems parts) to the extent these parts

were present on the engine purchased.

a. Fuel Metering System

of the Warranted Parts for a period of two 5. Maintenance

years from the date the engine is delivered to

a retail purchaser.

3. No Charge

Any Warranted Part which is not scheduled

for replacement as required maintenance or

which is scheduled only for regular inspec-

tion to the effect of “repair or replace as nec-

essary” shall be warranted as to defects for

the warranty period. Any Warranted Part

which is scheduled for replacement as re-

quired maintenance shall be warranted as to

defects only for the period of time up to the

first scheduled replacement for that part. Any

replacement part that is equivalent in perfor-

mance and durability may be used in the per-

formance of any maintenance or repairs.

The owner is responsible for the perfor-

mance of all required maintenance, as de-

fined in the B&S Operating and Maintenance

Instructions.

•

Cold start enrichment system

Carburetor and internal parts

Fuel Pump

Repair or replacement of any Warranted

Part will be performed at no charge to the

owner, including diagnostic labor which

leads to the determination that a Warranted

Part is defective, if the diagnostic work is

performed at an Authorized B&S Service

Dealer. For emissions warranty service

contact your nearest Authorized B&S Ser-

vice Dealer as listed in the “Yellow Pages”

under “Engines, Gasoline,” “Gasoline En-

gines,” “Lawn Mowers,” or similar category.

b. Air Induction System

•

Air cleaner

Intake manifold

•

c. Ignition System

•

Spark plug(s)

Magneto ignition system

•

d. Catalyst System

•

Catalytic converter

Exhaust manifold

Air injection system, Pulse valve 4. Claims and Coverage Exclusions

e. Miscellaneous Items

Warranty claims shall be filed in accordance

with the provisions of the B&S Engine War-

ranty Policy. Warranty coverage shall be ex- 6. Consequential Coverage

cluded for failures of Warranted Parts which

are not original B&S parts or because of

abuse, neglect or improper maintenance as

set forth in the B&S Engine Warranty Policy.

•

Vacuum, temperature, position,

time sensitive valves

and switches

Coverage hereunder shall extend to the fail-

•

Connectors and assemblies

ure of any engine components caused by

the failure of any Warranted Part still under

warranty.

2. Length of Coverage

B&S warrants to the initial owner and each

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4 , 8 7 5

4 , 8 1 9

4 , 7 2 0

4 , 7 1 9

4 , 6 3 3

4 , 6 3 0

4 , 5 2 2

4 , 5 2 0

4 , 5 1 2

4 , 4 5 3

4 , 4 3 0

, 4 4 8

, 5 9 3

, 6 3 8

, 6 8 2

, 5 5 6

, 4 9 8

, 0 8 0

, 2 8 8

, 4 9 9

, 5 0 7

, 9 8 4

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INFORMATIONS IMPORTANTES

CORPORATION BRIGGS & STRATTON

FAMILLE YBSXS.3192VA 274812

CE MOTEUR EST CONFORME AUX NORMES

ANTIPOLLUTION 2000 – 2001 DE CALIFORNIE

POUR LES PETITS MOTEURS HORS ROUTE ET

AUX NORMES ENVIRONNEMENTALES

AMÉRICAINES (EPA PHASE 2) POUR LES

PETITS MOTEURS HORS ROUTE. CONSULTEZ

LE MANUEL DU PROPRIÉTAIRE POUR LES

SPÉCIFICATIONS, L’ENTRETIEN ET LES

AJUSTEMENTS. CONFORME À LA PÉRIODE

D’ÉMISSION EPA : CATÉGORIE : C

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