Briggs & Stratton 5 HP Outboard Troubleshooting & Repair Manual – PDF DOWNLOAD

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Briggs & Stratton 5 HP Outboard Troubleshooting & Repair Manual – PDF DOWNLOAD

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Briggs & Stratton 5 HP Outboard Troubleshooting & Repair Manual – PDF DOWNLOAD

Language : English
Pages : 76
Downloadable : Yes
File Type : PDF
Size: 3.44 MB

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DESCRIPTION:

Briggs & Stratton 5 HP Outboard Troubleshooting & Repair Manual – PDF DOWNLOAD

FORWARD:

• This guide has been written and published by Briggs & Stratton Corporation to aid our dealers’ mechanics and
  company service personnel when servicing the products described herein.
• It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar
  products, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in the
  recommended servicing procedures for these products, which includes the use of mechanics hand tools and any
  special tools that might be required.
• Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems.
  The troubleshooting, testing, service and repair procedures described in this guide are effective methods of
  performing such operations.
• We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a
  service might be performed, nor of any possible hazards and/or results of each procedure or method. We have
  not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by
  the manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be
  endangered by the service or operating procedure selected.
• All information, illustrations, and specifications contained in this guide are based on the latest production
  information available at the time of publication. However, Briggs & Stratton Corporation reserves the right to
  change, alter, or otherwise improve the product at any time without prior notice.

TABLE OF CONTENTS:

Briggs & Stratton 5 HP Outboard Troubleshooting & Repair Manual – PDF DOWNLOAD

1 INTRODUCTION
2 TROUBLESHOOTING
3 DISASSEMBLY
In the Interest of Safety 5
Safety Alert Symbols 5
Fuel Recommendations 6
Gasoline 6
Oil Recommendations 6
Lubrication System 6
Engine Oil 6
Oil Drain Plug, Oil Fill and Dipstick 6
Gear Selector 7
Operation 7
Reverse 8
Neutral 8
Forward 8
Changing Gear Case Oil 9
Check Lower Unit 13
No Start – Hard Start 13
Vibration 13
Power Loss 13
Noise 13
Cooling 13
Check Ignition 14
Armature Test 15
Tests for No Spark 15
Neutral Switch Test 16
Check Compression 17
Cylinder Leak Down Test 17
Check Carburetion 18
Steering Tension 18
Propeller Service 19
Cooling Shroud 23
Removal 23
Power Head 23
Blower Housing 24
Magnetron™ Ignition 24
Flywheel 25
Inspect Flywheel Key, Keyway,
Flywheel and Crankshaft 26
Carburetor 26
Disassemble Carburetor 27
Carburetor Cleaning 27
Cylinder Head 28
Prepare Cylinder Head for Removal 28
Remove Valve Cover 28
Disassemble Cylinder Head 28
Crankshaft & Camshaft 29
Oil Slinger Lubrication 29
Piston and Connecting Rod 30
Gear Case Disassembly 30
Sliding Clutch 32
Midsection 33
Disassembly 33
Throttle Cable 34
Replacement 34
Rewind Starter 34
Remove Rope 34
Inspect Rope 34
Remove Pulley and Spring 34
Inspect Spring, Starter Housing and Pulley 35
2
TABLE OF CONTENTS
Table of Contents
5 HP Outboard • Troubleshooting & Repair Manual
4 OVERHAUL
Magnetron Ignition 39
Remove Armature 39
Inspect Valve Springs 39
Inspect Valve Guides 39
Finish Ream Valve Guides 39
Reface Valves and Seats 39
Remove Piston Rings 39
Check Piston Ring Groove Wear 40
Check Piston Ring End Gap 40
Check Connecting Rod 40
Undersized Connecting Rods 40
Check Piston Pin and Piston Pin Bore 41
Inspect Crankshaft 41
Inspect Camshaft 42
Check Cylinder 42
Cylinder Resizing 42
Set Up For Honing 42
Hone Cylinder 43
Cylinder Finish (“Cross Hatch”) 43
Cylinder Cleaning 44
Check Camshaft Bearings 44
Check Crankshaft Bearings 44
Remove DU™ Magneto Bearing 44
Install DU™ Magneto Bearing 45
Oil Seals 45
5 ASSEMBLY
Piston and Connecting Rod 49
Piston Rings 49
Compress Piston Rings 49
Crankshaft Installation 50
Install Connecting Rod & Piston 50
Install Camshaft 51
Install Sump 51
Crankshaft End Play 51
Install Flywheel 52
Install Armature 52
Armature Air Gap 52
Cylinder Head Assembly 53
Install Cylinder Head Plate and
Rocker Arm Studs 53
Install Valves 53
Install Valve Springs and Retainers 53
Install Cylinder Head 54
Install Rocker Arms 54
Adjust Valve Clearance 55
Install Valve Cover 55
Carburetor Assembly 55
Install Welch Plug 55
Install Choke Shaft 56
Install Throttle Shaft 56
Install Inlet Needle and Float 56
Install Carburetor 57
Install Pulley and Spring 57
Install Pawls, Pawl Springs & Retainer 58
Wind Spring & Install Rope 58
Install Blower Housing 59
Gear Case Assembly 59
Mid Section Assembly 62
Install Power Head 63
Cooling Shroud Installation 64
Adjust Throttle Cable 64
Idle Adjustment 65
6 APPENDIX
Outboard Engine Fastener Specifications 68
Lower Unit Fastener Specifications 68
Ignition System Wiring Diagram 69
Component Location – Gear Case 70
Component Location-Midsection 72

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