Briggs & Stratton Vanguard 430000 Repair Manual

11SEPTEMBER, 2000Section 1General InformationBRIGGS & STRATTON DAIHATSU 3 CYLINDERLIQUID-COOLED GASOLINE ENGINE REPAIR MANUAL (MS-0750)Section Con

2 2CYLINDER HEAD AND VALVESREMOVE CYLINDER HEADDrain cooling system and disconnect radiator hosesand bypass hose at water pump.1. Remove the following

1121ELECTRICAL SYSTEMREMOVING PINION GEAR ASSEMBLY1. Remove solenoid.2. Remove starter thru bolts.3. Place starter on bench with drive housing up.4. W

11 22ELECTRICAL SYSTEMINSTALL PINION GEAR ASSEMBLY1. Lubricate helix with a light coat of grease andassemble pinion gear and clutch.2. Assemble new lo

1123ELECTRICAL SYSTEMDISASSEMBLE STARTER MOTORIf starter motor is to be disassembled to inspectbrushes or commutator, DO NOT remove drivehousing.1. Re

11 24ELECTRICAL SYSTEMINSPECT ARMATURE COMMUTATORThe armature commutator may be cleaned with finesandpaper (#300 – 500 grit). DO NOT use emery cloth.C

1125ELECTRICAL SYSTEMREPLACE BRUSHES1. Cut off brush lead wires at terminals as shown.NOTE:For purposes of identification terminals arelettered A, B,

11 26ELECTRICAL SYSTEMASSEMBLE STARTER1. Assemble drive lever to pinion and install armatureand drive lever into drive housing, Fig. 71.Fig. 71 – Inst

1127ELECTRICAL SYSTEM4. Insert brush springs.5. Install brushes, Fig. 74.a. Use a small screw driver to compress spring.Fig. 74 – Installing Brushes6.

121SEPTEMBER, 2000Recommended SAE Viscosity Grades°C-34STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE°F-30 -10 10 50 70 90 110-23 -12 0

12 2LUBRICATION SYSTEMDESCRIPTIONBriggs & Stratton Daihatsu gasoline and diesel engines use a full pressure lubrication system with an oil filter.

123LUBRICATION SYSTEMCHECK OIL PRESSURE1. Oil level should be between the LOW and FULLmark on dipstick. If oil level is low, check for leaksand add to

23CYLINDER HEAD AND VALVES3. Remove valve cover, Fig. 5.Fig. 5 – Remove Valve Cover4. Set No. 1 piston at TDC:a. Rotate crankshaft pulley until timing

12 4LUBRICATION SYSTEMExploded ViewDISASSEMBLE GEAR CASERemove Oil PumpRemove spark plugs. Remove V belt and fan (ifequipped). Drain oil from engine.N

125LUBRICATION SYSTEM3. Install flywheel holder, Tool # 19418.LEAVE TOOL INSTALLED THROUGH STEP 8.a. Remove crankshaft pulley using Tool #19420,Fig. 8

12 6LUBRICATION SYSTEM11. Remove and check pressure relief valve assem-bly, Fig. 12.a. Make sure plunger has no nicks or burrs.b. Check pressure relie

127LUBRICATION SYSTEMEngine models 430000 and 580000 after date code990111007 are equipped with right angle helical timinggears. Timing marks are iden

12 8LUBRICATION SYSTEM8. Install oil pick-up tube and strainer with new gasket.Torque to 8.0 Nm (70 in. lbs.).a. Apply a small bead of PermatexR No. 2

129LUBRICATION SYSTEMADJUST GOVERNOR1. Move governor control lever up to end of travel andhold in this position (throttle wide open), Fig. 24.a. Rotat

131SEPTEMBER, 2000Section 13Cooling SystemGENERAL INFORMATIONBriggs & Stratton Daihatsu gasoline and diesel engines use a pressurized, forced circ

13 2COOLING SYSTEMCHECKING COOLING SYSTEMWARNING: the cooling system is pressurized. Do not remove the radiator cap while the engine is hot. To avoids

133COOLING SYSTEM3. Fill radiator with 50% solution of phosphate freeantifreeze.4. Start and run engine until thermostat opens (whencoolant level drop

13 4COOLING SYSTEMINSPECTING WATER PUMPInspect water pump for signs of leaking at vent holes,mounting surfaces and water pump pulley shaft,Fig. 6.1. R

2 4CYLINDER HEAD AND VALVESFig. 9 – Cylinder Head ComponentsDISASSEMBLE CYLINDER HEAD1. Cylinder Head Assembly2. Cylinder Head Gasket3. Valve Stem Cap

135COOLING SYSTEMINSTALLING WATER PUMP1. Install water pump with new gasket, Fig. 10.a. Torque screws and nuts to 19.0 Nm (180 in. lbs.).After install

141SEPTEMBER, 2000Section 14TOOLSBRIGGS & STRATTON DAIHATSU 3 CYLINDERLIQUID-COOLED GASOLINE ENGINE REPAIR MANUAL (MS-0750)It is assumed that Brig

14 2TOOLSBRIGGS & STRATTON REPAIR TOOLS (Cont’d.)VALVE SEAT CUTTER KIT 19446 Recondition 30° and 45° Valve SeatsIncludes 15° cutter for top cuttin

143TOOLSBRIGGS & STRATTON REPAIR TOOLS (Cont’d.)DESCRIPTION TOOL NO. USERING EXPANDER 19340 Remove and Install Piston Rings The following tools ar

14 4TOOLSBRIGGS & STRATTON REPAIR TOOLS (Cont’d.)DESCRIPTION TOOL NO. USEDIGITAL MULTIMETER 19464 Measure electrical equipmentAC Volts, 0 to 750DC

145TOOLSBRIGGS & STRATTON REPAIR TOOLS (Cont’d.)DESCRIPTION PART NO. USEFLYWHEEL HOLDER 19418 For Holding FlywheelPISTON PIN FIXTURE 19419 For Rem

14 6TOOLSBRIGGS & STRATTON REPAIR TOOLS (Cont’d.)DESCRIPTION PART NO. USECAMSHAFT BEARING DRIVER 19422 For Installing Camshaft BearingSEAL DRIVER

147TOOLSBRIGGS & STRATTON REPAIR TOOLS (Cont’d.)DESCRIPTION PART NO. USEFIX-A-THREAD KITS For Repairing Damaged and Stripped Threads100010 Thread

25CYLINDER HEAD AND VALVESINSPECT AND REPAIR1. Check cylinder head, Fig. 12.Be sure all gasket material is removed from surfacesbefore checking. Use a

2 6CYLINDER HEAD AND VALVES4. Using bushing driver, Tool #19416, press in newvalve guide bushing until tool bottoms on cylinderhead, Fig. 16.Fig. 16 –

27CYLINDER HEAD AND VALVES8. Inspect valve stem cap for wear, Fig. 20.Replace if cap is worn recessed.Fig. 20 – Check Valve Stem Cap9. Check valve spr

2 8CYLINDER HEAD AND VALVES10. Check rocker arms and shafta. Check rocker arm-bearing.Replace if greater than 10.03 mm (0.395”).b. Check rocker arm sh

29CYLINDER HEAD AND VALVESASSEMBLE CYLINDER HEADFig. 25 – Cylinder Head Components1. Cylinder Head 2. Cylinder Head Gasket3. Valve Stem Cap4. Valve Sp

2 10CYLINDER HEAD AND VALVES2. Install valve spring seats, Fig. 27.Note: Lightly coat valve stems with Valve GuideLubricant #93963 before installing v

211CYLINDER HEAD AND VALVES4. Install valve stem caps on valve stems. Installrocker arm assembly, Fig. 31. Install washers andtorque nuts to 19.0 Nm (

1 2GENERAL INFORMATIONIN THE INTEREST OF SAFETYTHIS SAFETY ALERT SYMBOL INDICATES THAT THIS MESSAGE INVOLVES PERSONAL SAFETY.SIGNAL WORDS DANGER, WARN

2 12CYLINDER HEAD AND VALVES8. Install exhaust manifold with new gasket, Fig. 35.a. Torque screws to 19.0 Nm (170 in. lbs.).Fig. 35 – Install Exhaust

213CYLINDER HEAD AND VALVESADJUST VALVES1. Before adjusting valves, make sure that No. 1 cyl-inder is at TDC – compression stroke, Fig. 39.Fig. 39 – S

31SEPTEMBER, 2000 BRIGGS & STRATTON DAIHATSU 3 CYLINDERLIQUID-COOLED GASOLINE ENGINE REPAIR MANUAL (MS-0750)Section 3Mechanical Governor/Timing Ge

3 2GOVERNOR, TIMING GEARS AND GEAR CASEREMOVING TIMING GEARCOVER AND GEARSMake sure that #1 cylinder is at TDC, compressionstroke. See Section 2.Remov

33GOVERNOR, TIMING GEARS AND GEAR CASE5. Remove governor gear, Fig. 5.a. Governor cupb. E-ringc. Governor geard. Thrust washer6. Remove oil pump drive

3 4GOVERNOR, TIMING GEARS AND GEAR CASEREMOVE GEAR CASE1. Remove parts in sequence shown, Fig. 9.a. Remove 3 screws and camshaft retainer.b. Remove re

35GOVERNOR, TIMING GEARS AND GEAR CASEASSEMBLE GOVERNOR ASSEMBLY1. Assemble governor gear to shaft, Fig. 13.a. Thrust washerb. Governor gearc. E-ringd

3 6GOVERNOR, TIMING GEARS AND GEAR CASE3. Make sure crankshaft key is at 12 o’clock positionas shown in Fig. 17.Fig. 17 – Crankshaft PositionCRANKSHAF

37GOVERNOR, TIMING GEARS AND GEAR CASE7. Install timing gear cover with new gasket. Noteposition, length and number of screws as shown,Fig. 21.a. M6 x

3 8GOVERNOR, TIMING GEARS AND GEAR CASE12. Insert governor spring into original hole in gover-nor lever.Note: Normal spring position is in center hole

13GENERAL INFORMATIONENGINE VIEWSFRONTBACKRIGHTSIDELEFTSIDE

39ELECTRONIC GOVERNORThe ignition module and related wiring for the electronic governor is supplied by the equipment manufacturer.Note: Engines equipp

3 10ELECTRONIC GOVERNORREMOVE GOVERNOR ACTUATOR1. Disconnect governor link spring and link.2. Remove two screws and actuator.Fig. 30 – Removing Govern

41SEPTEMBER, 2000Section 4Flywheel And Rear Seal RetainerSection ContentsPageREMOVING OIL PAN AND FLYWHEEL 1. . . . . . . . . . . . . . . . . . . . .

4 2FLYWHEEL AND REAR SEAL RETAINERREMOVE REAR SEAL RETAINERRemove rear seal retainer and discard gasket, Fig. 3.Fig. 3 – Removing Seal RetainerREPLACI

43FLYWHEEL AND REAR SEAL RETAINER2. Install flywheel, Fig. 7.Note: Apply PermatexR No. 2 or similar sealant toflywheel screws.a. Torque flywheel screw

51SEPTEMBER, 2000Section 5 Cylinder Block DisassemblySection ContentsPageENGINE STAND FIXTURE 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

5 2CYLINDER BLOCK DISASSEMBLYAn automotive type engine stand is recommended when complete engine disassembly is required. See drawingsbelow for dimens

53CYLINDER BLOCK DISASSEMBLY1. Remove cylinder head. See Sec. 2.2. Remove oil pan, timing cover, gears and case. SeeSec. 3.3. Remove flywheel and rear

5 4CYLINDER BLOCK DISASSEMBLY8. Remove oil pick-up tube and strainer, Fig. 5.Discard gasket.Fig. 5 – Removing Oil Pick-UpOIL PICK-UP TUBE9. Remove con

61SEPTEMBER, 2000BRIGGS & STRATTON DAIHATSU 3 CYLINDERLIQUID-COOLED GASOLINE ENGINE REPAIR MANUAL (MS-0750)Section 6Cylinder Block Inspection And

1 4GENERAL INFORMATIONENGINE SPECIFICATIONSModel 430447 580447TypeGasoline, 4-cycle, 3 cylinder, in-line, liquidcooledValve mechanism OHV, gear driven

6 2CYLINDER BLOCK INSPECTION AND REPAIR3. Check cylinder bores for wear, Fig. 3.Standard Bore Size:Model Series 430000 68.00 – 68.030 mm(2.6770 – 2.67

63CYLINDER BLOCK INSPECTION AND REPAIR2. Install camshaft bearing, Fig. 7.a. Use camshaft bearing driver, Tool #19422.Fig. 7 – Installing Cam BearingR

6 4CYLINDER BLOCK INSPECTION AND REPAIR2. Remove timing gear oil nozzle, Fig. 11.Fig. 11 – Removing Oil NozzleOIL NOZZLE3. When reinstalling oil nozzl

71SEPTEMBER, 2000Section 7Crankshaft, Camshaft And BearingsSection ContentsPageCHECKING CRANKSHAFT 1. . . . . . . . . . . . . . . . . . . . . . . . .

7 2CRANKSHAFT, CAMSHAFT AND BEARINGS3. Check crankshaft timing gear teeth for damagedteeth, Fig. 3.Note: See Section 3 for procedure to check cranksha

73CRANKSHAFT, CAMSHAFT AND BEARINGSCHECKING CONNECTING ROD BEARINGCLEARANCESIf connecting rod bearings show signs of flaking orscoring, bearings must

7 4CRANKSHAFT, CAMSHAFT AND BEARINGSCHECKING CAMSHAFT1. Measure camshaft lobe height, Fig. 11. If lobes arenot to specification, replace the camshaft.

81SEPTEMBER, 2000BRIGGS & STRATTON DAIHATSU 3 CYLINDERLIQUID-COOLED GASOLINE ENGINE REPAIR MANUAL (MS-0750)Section 8Piston, Rings and Connecting R

8 2PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLYCHECKING PISTON AND RINGSIf the cylinder bore is to be resized there is no reason tocheck t

83PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY2. Check piston pin bearing, Fig. 7.a. Replace if greater than 17.98 mm (0.708”) or.01 mm (.

15GENERAL INFORMATIONCOOLING SYSTEMCooling Method Liquid cooled, forced circulationCoolant Capacity (engine only) Approximately 1.8 ltr (1.9 qt)Coolin

8 4PISTON, RINGS AND CONNECTING ROD INSPECTION AND ASSEMBLY2. Insert piston pin stop in bottom of piston support,Fig. 11.a. With arrow on piston up, p

91SEPTEMBER, 2000Section 9Cylinder Block AssemblySection ContentsPageINSTALL CRANKSHAFT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 2CYLINDER BLOCK ASSEMBLY3. Install crankshaft with gear facing front of cylinderblock, Fig. 3. Take care not to damage journals orbearings.a. Instal

93CYLINDER BLOCK ASSEMBLYRotate crankshaft so that crankpin is at bottom ofstroke. Then, lubricate cylinder walls, piston and rings,bearings and crank

9 4CYLINDER BLOCK ASSEMBLYINSTALL TIMING GEAR CASE,CAMSHAFT AND GEARS1. Lubricate oil pump rotor with engine oil and installin cylinder block, Fig. 10

95CYLINDER BLOCK ASSEMBLY5. Assemble idler gear shaft with ID mark up, asshown in Fig. 14.Fig. 14 – Assemble Idler Gear ShaftIDLER GEARSHAFTID MARKUPE

9 6CYLINDER BLOCK ASSEMBLY9. Install crankshaft pulley with timing mark at12 o’clock position (#1 cylinder), Fig. 18.Note: Be sure alignment pin in cr

101SEPTEMBER, 2000Section 10Carburetor And Related ComponentsSection ContentsPageMANUAL CHOKE CARBURETORREMOVE CARBURETOR 3. . . . . . . . . . . . . .

10 2Manual Choke CarburetorAutomatic Choke Carburetor

103CARBURETOR AND RELATED COMPONENTSMANUAL CHOKE CARBURETORREMOVE CARBURETORDisconnect fuel line. Remove air cleaner tube fromcarburetor air horn. Dis

1 6GENERAL INFORMATIONFastener SpecificationsDescription Wrench/Socket Size TorqueAlternator Adjust. Bracket. 12 mm 19.0 Nm (170 in. lbs.)Alternator

10 4CARBURETOR AND RELATED COMPONENTS4. Remove nuts, air horn, carburetor and insulator,Fig. 4. Discard gaskets.Fig. 4 – Removing CarburetorINSULATORG

105CARBURETOR AND RELATED COMPONENTS4. Remove fixed high speed jet using screwdriver,Tool #19062, Fig. 8.a. Remove emulsion tube.Note: Consult the ill

10 6CARBURETOR AND RELATED COMPONENTSNote: If engine is equipped with electronic governorsystem, DO NOT remove throttle plate or throttleshaft. This i

107CARBURETOR AND RELATED COMPONENTSASSEMBLE CARBURETORWhen assembling carburetor, use new seals andgaskets.1. Install throttle shaft, Fig. 15.a. Inst

10 8CARBURETOR AND RELATED COMPONENTS5. Install gasket and float bowl, Fig. 19.Fig. 19 – Install Float BowlBOWLWASHERSCREWGASKETSOLENOID6. Install idl

109CARBURETOR AND RELATED COMPONENTSINITIAL CARBURETOR ADJUSTMENTTurn idle mixture screw clockwise until it just seats. DONOT FORCE. Turn screw counte

10 10CARBURETOR AND RELATED COMPONENTSAUTOMATIC CHOKE CARBURETORThe automatic choke consists of a vacuum choke break and a thermostat. Intake manifold

1011CARBURETOR AND RELATED COMPONENTSAUTOMATIC CHOKE CARBURETORREMOVE CARBURETORDisconnect fuel line and remove air cleaner tube fromcarburetor air ho

10 12CARBURETOR AND RELATED COMPONENTSNote: Float hinge pin is swaged on one side. Whenremoving, drive hinge pin from side oppositeswage.2. Drive out

1013CARBURETOR AND RELATED COMPONENTS7. Remove screw and choke pre-load lever, Fig. 33.8. Remove two screws, choke plate and choke shaft,Fig. 33.Fig.

17GENERAL INFORMATIONBRIGGS & STRATTON DAIHATSU NUMERICAL NUMBER SYSTEMAll Briggs & Stratton Daihatsu engines have a unique numerical designat

10 14CARBURETOR AND RELATED COMPONENTSNote: If engine is equipped with electronic governorsystem, DO NOT remove throttle plate orthrottle shaft. This

1015CARBURETOR AND RELATED COMPONENTSASSEMBLE CARBURETORWhen assembling carburetor, use new seals andgaskets.1. Install throttle shaft and new seal, F

10 16CARBURETOR AND RELATED COMPONENTS5. Install choke shaft through pivot arm bushing andinto carburetor body, Fig. 44.Note: Specification between ar

1017CARBURETOR AND RELATED COMPONENTS10. Install float, Fig. 48.a. Assemble inlet valve to float.b. Install float hinge pin.c. Install idle passage pl

10 18CARBURETOR AND RELATED COMPONENTSADJUSTING CHOKE PRE-LOAD LEVER1. Release vacuum pump so that choke closes.2. Manually open choke to end of trave

1019CARBURETOR AND RELATED COMPONENTSINITIAL CARBURETOR ADJUSTMENTTurn idle mixture screw clockwise until it just seats. DONOT FORCE. Turn screw count

10 20CARBURETOR AND RELATED COMPONENTSFuel Pump SpecificationsType 12 Volt Electro magnetic 12 Volt Electro magneticDelivery Output-Minimum 800 cc/min

1021CARBURETOR AND RELATED COMPONENTSCHECKING FUEL PUMP OUTPUTA graduated container is required when testing the fuelpump.1. Disconnect fuel line at c

10 22CARBURETOR AND RELATED COMPONENTSANTI-AFTERFIRE SOLENOIDSome carburetors are equipped with an Anti-Afterfire solenoid controlled by the equipment

1023CARBURETOR AND RELATED COMPONENTSTESTING SOLENOID1. Remove solenoid from carburetor.2. Place either terminal of a 9 volt transistor batteryon the

1 8GENERAL INFORMATIONMaintenance ScheduleMore frequent service is required when operating in adverse conditions (note 4 below).MaintenanceOperationDa

111SEPTEMBER, 2000BRIGGS & STRATTON DAIHATSU 3 CYLINDERLIQUID-COOLED GASOLINE ENGINE REPAIR MANUAL (MS-0750)Section 11Electrical SystemsIgnition S

11 2ELECTRICAL SYSTEMIGNITION SYSTEM COMPONENTSThe ignition system consists of three major components, Fig. 1:1. A permanent magnet trigger and signal

113ELECTRICAL SYSTEMTEST EQUIPMENTThe digital multimeter, Tool #19390 is required to testthe ignition components, Fig. 2.NOTE:All ignition tests are p

11 4Top View Of Module Showing Terminal PositionsTerminal Not UsedB+GT1 T2#1#2 #3#1, #2, #3Negative Side OfCoilG – GroundB+ – Ignition Switch &

1151.5 M toOL1.5 M toOL1.5 M toOL1.5 M toOL1.5 M toOL1.5 M toOL1.5 M toOL1.5 M toOLTop View Of Module Showing Terminal Positio

11 6ELECTRICAL SYSTEMTESTING IGNITION COILSThe following test will be performed with the meter inΩ position.1. Check coil primary resistance between +

117ELECTRICAL SYSTEM12 VOLT BATTERY14 AMPALTERNATORREGULATORRECTIFIERSTARTER MOTORFUEL PUMPTRIGGERBLACKLT. BLUE1 32IGNITIONMODULECHARGE INDICATORLIGHT

11 8ELECTRICAL SYSTEMTEST EQUIPMENTThe digital multimeter, Tool #19390 and the DC shunt,Tool #19468, Fig. 11, are required to test the chargingsystem.

119ELECTRICAL SYSTEMCHARGING INDICATOR CIRCUITThe green wire from the regulator-rectifier is used toactivate the charging indicator light. With the ke

11 10ELECTRICAL SYSTEM4Fig. 1740 Amp Charging System+-12 VOLT BATTERY40 AMPALTERNATORSTARTER MOTORTRIGGER1 32IGNITIONMODULECHARGE INDICATORLIGHTIGNITI

21SEPTEMBER, 2000Section 2Cylinder Head and ValvesOverhead Valve TrainBRIGGS & STRATTON DAIHATSU 3 CYLINDERLIQUID-COOLED GASOLINE ENGINE REPAIR MA

1111ELECTRICAL SYSTEM40 AMP CHARGING SYSTEMFig. 17 shows wiring diagram for 40 amp chargingsystem.The 40 amp charging system consists of a belt driven

11 12ELECTRICAL SYSTEMDISASSEMBLE ALTERNATOR1. Remove pulley nut using tool #SST and 10 mmdeep socket as shown in Fig. 21.a. Remove pulley and spacer.

1113ELECTRICAL SYSTEM6. Remove four stator lead screws from rectifier,Fig. 25.a. Carefully straighten stator leads.b. Remove rectifier.Fig. 25 – Remov

11 14ELECTRICAL SYSTEMINSTALL BALL BEARING1. Lightly lubricate bearing O.D. with engine oil.2. Press in new bearing using bearing driver #19226,Fig. 2

1115ELECTRICAL SYSTEMCHECK REGULATORThe following test will be made with the meter in the“Diode Test Position” .1. Attach BLACK meter test lead to te

11 16ELECTRICAL SYSTEM3. Assemble brush end housing to drive end housingwith reference marks aligned, Fig. 37.NOTE:Do not damage stator leads.4. Insta

1117ELECTRICAL SYSTEM9. Install brush holder.Important: Length of brush retainer screws aredifferent. Install as shown.Screw “A” – 11.5 mmScrew “B” –

11 18ELECTRICAL SYSTEMSTARTER SYSTEMThe starter system consists of a 12 volt automotivetype electric starter with a solenoid, Fig. 44. When thesolenoi

1119ELECTRICAL SYSTEMTESTING STARTERNOTE:To prevent engine from starting, removespark plug wires from spark plugs. Leavespark plugs installed.The star

11 20ELECTRICAL SYSTEMEQUIPMENT TO TEST SOLENOIDThe solenoid test is performed with the starterremoved from the engine.The following equipment is reco