SMALL ENGINE ®

A step-by-step guide to maintaining your small engine

www.briggsandstratton.com
 INTRODUCTION
Briggs & Stratton has been a major learning from the company that has set
force behind the explosion in small engine the industry standard for decades.
popularity. This quintessential American You’re also developing skills that apply
company builds more than two-thirds of all to more than lawn equipment. With the
lawn mower engines and is a major producer information in this book, you can maintain
of four-stroke small engines for almost every and repair small engines on a variety of
application. You may find many brands of power equipment—from generators and
mowers, tractors and other equipment at pressure washers, to hydraulic lifts. In this
your power equipment retailer. Look closely: booklet, we’ll cover the basic procedures
chances are good the engines are built by for maintaining your small engine. For
Briggs & Stratton. Retailers like to point more in depth explanation of engine
this out because the name stands for quality systems, maintenance and repair,
and experience. go to www.briggsandstratton.com or look
Briggs & Stratton’s knowledge and expertise for Briggs & Stratton Small Engine Care
is second to none. When you learn from & Repair at your local Briggs & Stratton
Briggs & Stratton technicians, you’re authorized dealer.

Contents
Introduction to Engines &
SAFETY
Engine Components 3 Small engines must burn fuel and induce • Make sure the air cleaner assembly and
electricity. Each of these involves special blower housing are in place before starting
Maintenance Checklist 4 safety considerations—so you need to the engine.
observe the precautions for both. Keep in • Remove any fuel from the tank and close
Checking & Changing Oil 5 mind all operational procedures as outlined the fuel shutoff valve before transporting
Checking & Replacing in your owners manual when working with an engine.
Spark Plugs 6 your engine. Additionally, by following the
simple safety rules for engine maintenance, • Use only the original manufacturer’s
you will simplify the job of safely operating, replacement parts; any other parts may
Checking & Changing damage the engine and create safety
Air Filters 7 maintaining and repairing your small engine.
hazards.
Troubleshooting Guide Safe maintenance • Keep engine speed settings within
manufacturer specifications. Higher speeds
To make small engine maintenance and can ruin the engine.
repair tasks easier and safer:
• Make sure you have ample work space,
Protecting your health
with easy access to the tools you need. Fire, electric shock and asphyxiation are not
• Use the correct tools for each job. the only dangers when working with small
engines. Take care to avoid long-term or
• Keep an approved fire extinguisher in a sudden injury to your eyes, ears, lungs, feet
WHERE TO FIND US familiar location near your work area. and back:
You never have to look far to find Briggs • Learn engine shutoff procedures so you
can respond quickly in an emergency. • Keep your feet, hands and clothing
& Stratton support and service for your away from moving engine and equip-
small engine. Consult your Yellow Pages • Disengage the cutting blade, wheels or ment components.
other equipment, if possible, before
under “Engines-Gasoline,” “Gasoline- starting the engine. • Use eye protection when you work with
Engines,” “Lawn Mowers” or similar engines or power tools.
• Disconnect the spark plug wire to prevent
categories. There are over 30,000 Briggs accidental starting when you are servicing • Wear ear protection to reduce the risk of
the engine. gradual hearing loss from exposure to
& Stratton authorized service dealers engine noise.
worldwide who provide quality service. • Always disconnect the wire from the
negative terminal when servicing an • Wear a face mask, if required, when
You can also contact Briggs & Stratton working with chemicals.
electric starter motor.
Customer Service by phone at 1-800- • Wear specially designed gloves to
• Check that a spark plug or spark plug
233-3723, or on the Internet at tester is attached to the engine before protect against heat, harmful chemicals
http://www.briggsandstratton.com. cranking. and sharp objects.
• Avoid contact with hot engine parts, • Wear safety shoes to protect against falling
such as the muffler, cylinder head or objects; safety shoes have soles that won’t
cooling fins. deteriorate when exposed to gasoline or oil.
• Never strike the flywheel with a hammer • Use proper lifting techniques and seek help
or hard object; it may cause the flywheel to with heavy lifting.
shatter during operation.

2 THE GUIDE TO SMALL ENGINES

 INTRODUCTION TO ENGINES
The four-stroke small engine that powers The carburetor draws in fuel from the fuel tank A flywheel brake and stop switch are included
your lawn mower, tiller, generator and many and outside air to form a combustible vapor that on engines for equipment such as mowers that
other types of equipment is a gasoline engine is fed into the combustion chamber. require constant supervision. The two compon-
that generates the precise amount of power ents are designed to stop the engine if you
Intake and exhaust valves open and close at release the controls.
necessary to get the job done. Here’s how the precisely timed intervals to let air and fuel enter
components in your engine interact. the engine and to let spent gases exit. An air vane or flyweights monitor engine
RPMs so the governor can maintain the selected
Engine components & The piston is pushed through the cylinder by the engine speed.
their function force of expanding gases. The piston’s motion
causes the crankshaft to turn. Momentum then Cooling fins help reduce engine tempera-
The rewind cord is pulled to start the carries the piston back toward the top of tures when air circulates across the hottest
combustion process. On some models, a the cylinder. engine surfaces.
starter motor replaces the rewind, drawing
on battery power to start the engine. Oil stored in the crankcase circulates through
the engine to lubricate key components like the
Revolving magnets work in conjunction with the piston and crankshaft and to provide generalized
ignition armature and spark plug to produce a cooling by drawing away heat from internal
spark in the combustion chamber. engine surfaces.

Parts of the small engine – front view Parts of the small engine – side view

Fuel cap Fuel tank and shroud Fuel tank and shroud

Rewind rope Rewind Rewind

Oil fill cap

Blower housing

Blower housing

Air cleaner element Flywheel

Primer bulb
Carburetor
Ignition armature
Flywheel brake Flywheel
Dipstick
Spark plug lead

Intake valve spring

Intake valve

Piston

Cylinder head Connecting rod

Piston Crankcase
Air cleaner cover Spark plug

Cylinder head

Muffler

Engine block Intake valve Exhaust valve Crankshaft

Crankshaft Exhaust valve Exhaust valve spring

THE GUIDE TO SMALL ENGINES 3

MAINTENANCE
Regular maintenance schedule
You can avoid many small engine problems and save money on parts and
repairs if you follow a regular maintenance schedule. Make good maintenance
a habit when your engine is new, and always consult your owner’s manual for
special guidelines for your make and model. Service the engine more
frequently if you use it heavily or under dusty or dirty conditions.

After the first five hours of use:

• Change the oil and filter.

After each use:

• Check the oil.
• Remove debris around the muffler.

Every 25 hours or every season:

• Change the oil if operating under heavy load
or in hot weather.
• Service the air cleaner assembly.
• Clean the fuel tank and line.
• Clean the carburetor float bowl, if equipped.
• Inspect the rewind rope for wear.
• Clean the cooling fins on the engine block.
• Remove debris from the blower housing.
• Check engine compression.
• Inspect governor springs and linkages.
• Inspect ignition armature and wires.
• Inspect the muffler.
• Check the valve tappet clearances.
• Replace the spark plug.
• Adjust the carburetor.
• Check the engine mounting bolts/nuts.

Every 100 hours or every season:

• Clean the cooling system.*
• Change the oil filter, if equipped.
• Decarbonize the cylinder head.
*Clean more often if the engine operates under
dusty conditions or in tall, dry grass.

4 THE GUIDE TO SMALL ENGINES

CHECKING & CHANGING OIL
When you pour fresh oil into the crankcase, it’s a golden or amber
color. Gradually, the heat, dirt particles and agitated air in the Tools & materials:
crankcase cause the oil to darken. Dark oil is not only dirty; it has also Socket wrench set, box\wrench or adjustable wrench,
lost much of its ability to coat and protect engine components.
screwdriver or hex key, oil filter or pipe wrench
Manufacturers recommend changing the oil in your small engine after
every 25 hours of operation. For a new engine, you’ll also need to (for models with filters), oil drain pan, funnel.
change the oil after the first five hours of operation. New engines
require this extra step to flush out small particles that accumulate Time required:
naturally during the break-in period.
30 minutes.
Hours of use are just one factor in determining how often the oil
should be changed; the amount of wear and tear is equally important.
Just like the oil in a vehicle operated in extremely dirty or dusty
conditions or at high speeds, the oil in a lawn mower or other small Changing the oil
engine breaks down faster under tough conditions, such as wet grass, Once you decide the oil needs changing,
heavy dust, high temperatures and rough or hilly terrain. check your owner’s manual to determine the
type of oil, and make sure you have enough
on hand. Then, run the engine for several
minutes. Draining the oil while it’s warm will
Checking the oil carry off many floating particles that would
Make it a habit to check the oil level and otherwise settle in the engine.
appearance each time you’re about to start a 1. Stop the engine, disconnect the spark
small engine. Checking the oil while the plug lead and secure it away from the spark
engine is cold and most of the oil is in the plug. Then, locate the oil drain plug. On
crankcase yields the most accurate reading. A
mowers, the plug is typically below the deck
You won’t need to change or add oil every and may be obscured by a layer of grass and
time. But you’ll ensure a better-running debris.
engine and avoid problems down the road if
you keep the crankcase full and change the 2. Wipe the area with a rag to prevent debris
oil on schedule and any time the oil loses its from falling into the crankcase when you
amber hue. open the drain plug. Tilt the mower deck and
position some newspaper and an oil pan or
1. Start by locating the oil fill cap on the jug beneath the mower. Use a socket wrench
crankcase (photo A). Fill cap locations vary, to turn the plug counterclockwise, allowing
depending on the make and model of your the old oil to drain (photo A). If the plug also
A engine. On newer models, look for an oil can serves as a fill cap, it may have two prongs so
symbol or the word “oil” or “fill” stamped on you can loosen it by hand or use a
the plug. On small tractors, you may have to screwdriver or hex key for additional torque.
lift the hood to locate this cap. B
Replace the drain plug by twisting clockwise
Some engines contain either an extended oil and tightening with a box wrench or
fill tube or a standard fill hole with a dipstick adjustable wrench.
for inspection. Others require you to remove 3. If your engine has a filter, replace it at
the fill cap to check that the oil is at the fill least once a season, more often under heavy
line or the top of the fill hole. use. Replace the filter by twisting counter-
2. To prevent dirt and debris from falling clockwise on the body, using a filter wrench
into the crankcase, wipe the area around the or pipe wrench.
cap with a clean cloth before removing the 4. Lightly oil the filter gasket with clean
B cap. If there is no dipstick, dab the oil with engine oil. Install a new filter rated for your
a clean tip of the cloth to inspect the oil engine. Screw in the filter by hand until the
(photo B). gasket contacts the filter adapter (photo B).
Tighten the filter an additional 1⁄2 to 3⁄4 turn.
C
3. If the engine includes a dipstick cap,
remove the dipstick and wipe it with a clean 5. Add the appropriate quantity of oil (see
cloth. To ensure an accurate reading, reinsert your owner’s manual). Then, run the engine
the dipstick completely. Then, remove it at idle and check for leaks.
again and check the oil level. If the dipstick
cap is a screw-in type, ensure an accurate 6. After an oil change, dispose of oil and
reading by screwing it in all the way before soiled rags in accordance with local
remov-ing it a second time to check the level. environmental statutes (photo C). In many
The oil mark on the dipstick should be areas, oil can be left at curbside with other
between the lines shown on the dipstick recyclables, provided it is sealed in a
C (photo C). It should never be above the FULL recyclable container. Check the regulations
line or below the ADD line. in your area.

THE GUIDE TO SMALL ENGINES 5

CHECKING SPARK PLUGS
Tools & materials:
Spark tester, spark plug
socket (sizes vary), socket
wrench, wire brush,
plug/point cleaner,
spark plug gauge.

Time required:
15 minutes.
A

The electrodes on a spark plug must be necessary, use a spark plug gauge to adjust 3. If you see a spark jump the gap in the
clean and sharp to produce the powerful the gap by gently bending the curved elec- tester, the ignition is functioning. The
spark required for ignition. The more worn trode. When the gap is correct, the gauge will absence of a visible spark indicates a problem
or dirty a spark plug, the more voltage—and drag slightly as you pull it through the gap. in the ignition system.
the greater the tug on the rewind—required 6. Reinstall the plug, taking care not to
to produce an adequate spark. overtighten. Then, attach the spark plug lead. Checking for spark miss
If you haven’t tuned your engine recently A spark plug that is fouled or improperly
and have to tug repeatedly on the rewind to Checking ignition with gapped may not allow sparks to jump the gap
start the engine, a damaged spark plug may a spark tester between electrodes consistently. The spark
be the culprit. plug will fire erratically or may occasionally
A spark tester offers an inexpensive, easy way fail to spark. Test for this problem—known as
Luckily, a spark plug is one of the easiest to diagnose ignition problems (see “Checking spark “miss”—if your engine stumbles, with a
engine components to repair and an for Spark Miss”). noticeable decrease in engine sound. Spark
inexpensive one to replace. And your miss can also cause the engine to emit black
standard socket set may already include the If you find a problem, remove and inspect the
spark plug. Replace the spark plug if you find smoke or a popping sound, as unburned fuel
most important tool—a spark plug socket. exits with the exhaust and ignites inside the
evidence of wear or burning at the spark plug
tip. Spark plugs are inexpensive and a new muffler.
one may solve the problem. 1. With the spark plug screwed into the
1. Connect the spark plug lead to the long cylinder head, attach the spark plug lead to
Cleaning and inspecting the long terminal of the spark tester. Attach
terminal of your tester and ground the tester
a spark plug to the engine with the tester’s alligator clip the tester’s alligator clip to the spark plug
(photo C).
1. Disconnect the spark plug lead. Then, (photo B).
clean the area around the spark plug to avoid
2. Use the rewind or electric starter to crank 2. Start the engine and watch the tester’s
getting debris in the combustion chamber spark gap. You’ll recognize spark miss by the
the engine, and look for a spark in the tester’s
when you remove the plug. uneven timing of the sparks in the tester.
window.
2. Remove the spark plug using a spark plug
socket.
3. Clean light deposits from the plug with a
wire brush and spray-on plug cleaner. Then,
use a sturdy knife if necessary to scrape off
tough deposits. NOTE: Never clean a spark
plug with a shot blaster or abrasives.
4. Inspect the spark plug for very stubborn
deposits, or for cracked porcelain or
electrodes that have been burned away. If any
of these conditions exists, replace the spark
plug.
5. Use a spark plug gauge to measure the
gap between the two electrodes (one straight,
one curved) at the tip of your spark plug
(photo A). Many small engines require a .030"
gap. Check the specifications for your model B C
with your power equipment dealer. If

6 THE GUIDE TO SMALL ENGINES

 SERVICING AIR CLEANERS
A properly maintained air cleaner is your engine’s first line of defense
against the destructive effects of dirt. When the air cleaner is in good Tools & materials:
condition, it keeps airborne dirt particles from entering through the Engine oil, screwdrivers, liquid detergent.
carburetor. If the air cleaner is not maintained, dirt and dust will
gradually make their way into the engine. And don’t underestimate
dirt’s potential to cause damage. It can lead to a sharp drop in engine Time required:
power, or—worse—cause premature wear of critical engine
components.
30 minutes.
Many types of air cleaners are used in small engines. Most contain a
foam or pleated-paper element. Pleats in a paper element that are discolored, bent or
Dual-element air cleaners contain a pleated-paper element with a water-damaged can no longer provide adequate air
foam pre-cleaner, offering two layers of protection. Discard the paper to the carburetor. Replace the element when it
approaches this condition.
element when you can no longer remove dirt from the pleats by
tapping the element on a hard, dry surface. You may be able to wash
and reuse the foam pre-cleaner. Foam elements can be cleaned with
hot water and liquid dish detergent that contains a grease-cutting Servicing a pleated-paper or
agent.
dual-element air cleaner
Single-element air cleaners should be serviced every 25 hours (or once
a season). In a dual-element system, the pre-cleaner should be cleaned Dual-element air cleaners come in a variety
every 25 hours. The cartridge should be cleaned every 100 hours. of designs. Two of the most common are
shown here.
1. With the cover removed, separate the pre-
cleaner (if equipped) from the cartridge
(photo C).
2. Tap the cartridge gently on a flat surface Pre-cleaner
Servicing a foam air cleaner to remove any loose dirt. Inspect the element
1. Loosen the screws or wing nuts that hold and replace it if it is heavily soiled, wet or Pleated-paper
the air cleaner assembly in place (photo A). crushed. element
Disassemble. 3. Inspect the pre-cleaner, if equipped. Note
2. Inspect the foam element. Replace it if it the mesh backing, designed to act as a barrier
is torn or shows signs of considerable wear. between the oily pre-cleaner and the pleated-
paper element. Replace it when soiled or
4. Saturate the element with engine oil worn. C
(photo B). Then, squeeze it to spread the oil
throughout. 4. Look for oiling instructions on the pre-
Don’t wait until your air
cleaner (photo D). If directed, lubricate the Pleated-paper
cleaner element looks like 5. Inspect the rubbery sealing gasket pre-cleaner with oil. NOTE: Not all foam pre- element
this to replace it. If your between the air cleaner and carburetor. cleaners should be oiled. Pre-cleaner
element has become Replace it if it is worn.
permanently discolored
5. Clean the cartridge housing with a dry
or has begun to break 6. Reassemble and reinstall the air cleaner. cloth (photo E). Do not clean with solvents or
down or tear, extend the compressed air.
life of your small engine
by installing a new one.
6. Reassemble the air cleaner. If the pre-
cleaner is the oiled type, take care to insert
the mesh toward the paper element so that
the paper is never exposed to the oil. D
7. Reinstall, making sure that any tabs on
the cartridge are in their slots on the engine
housing. Gaps around the cartridge permit
unfiltered air and damaging dirt particles to
enter the engine.

A B E

THE GUIDE TO SMALL ENGINES 7

TROUBLESHOOTING *Refer to Briggs & Stratton Small Engine
Care & Repair for complete procedures.

If the engine won’t start If the engine runs poorly

Ask this If the answer Ask this If the answer
question: is yes: question: is yes:
(Fuel line) Fill fuel tank; if engine Is the fuel mixture Adjust the carburetor.* (Engine smokes)
Is the fuel tank
empty? is still hot, wait until it too rich?
cools before filling tank.
Is the air filter Replace the air cleaner.
Is the shut-off
Open fuel shut-off valve. plugged?
valve closed?

Is the fuel diluted Empty tank, replace fuel

and check for leaks in Is the engine dirty? Clean the engine.* (Engine overheats)
with water?
fuel tank cap.

Disconnect inlet screen Add oil to the engine.

Is the fuel line from engine and clean NOTE: Never add oil to
Is the oil level low?
or inlet screen using compressed air. the gasoline for a four-
blocked? Do not use compressed stroke engine.*
air near engine.*

Is the fuel tank Make sure cap is vented Are any shrouds or Install new parts as
cap clogged or and air holes are not cooling fins needed.*
unvented? clogged.* missing or broken?

(Carburetor) Is the fuel mixture

Remove spark plug lead Adjust the carburetor.*
too lean?
and spark plug; pour
teaspoon of fuel directly Is there a leaky
Is the carburetor into cylinder; reinsert Replace the gasket.*
gasket?
blocked? spark plug and lead;
start engine; if it runs
Is the fuel tank
shortly before quitting, Clean the fuel tank vent
vent or fuel tank
overhaul carburetor.* and fuel tank screen.*
screen plugged?
Is the engine Adjust float in fuel bowl, (Engine knocks)
Does the combust-
flooded? if adjustable; make sure Clean carbon from the
ion chamber contain
choke isn’t set too high.* piston and head.*
excess carbon?
(Ignition) Is the spark plug Remove spark plug;
fouled? clean contacts or Is the flywheel Inspect the flywheel and
replace plug. loose? key; replace as needed.*

Is the spark plug Remove spark plug; Is the spark plug (Spark plug misses
gap set incorrectly? reset gap. fouled? Clean the spark plug. under load)
Is the spark plug Test lead with spark
lead faulty? tester, then test engine. Is the spark plug Replace the spark plug
faulty or gap or adjust the spark
Is the kill switch Repair or replace kill incorrect? plug gap.
shorted? switch.*

Replace flywheel key, Are the breaker Install a solid-state

then try to start engine; points faulty? ignition.*
Is the flywheel if it still won’t start,
key damaged? check ignition arma-
ture, wire connections Is the carburetor
Adjust the carburetor.
or points.* set incorrectly?

(Compression) Perform compression Is the valve Replace the valve spring.

Are the valves, test. If test indicates spring weak?
piston, cylinder poor compression,
or connecting inspect valves, piston Is the valve Adjust the valve
rod damaged? and cylinder for damage clearance set clearance to
and repair as needed.* incorrectly? recommended settings.

Printed in U.S.A. © 2001 Briggs & Stratton Corporation Form MS-6605-2/01