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Briggs & Stratton 5 HP User Manual
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5 HP Outboard
Troubleshooting & Repair Manual
Electronic Version #275110 3/03
Please click the “Bookmarks” tab at left to enable the
search and navigational features of this document.
®
For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com
2
Table of Contents
Default Chapter
3
Table of Contents
3
Introduction
5
Starting Engine
6
In the Interest of Safety
7
Safety Alert Symbols
7
Fuel Recommendations
8
Gasoline
8
Oil Recommendations
8
Lubrication System
8
Engine Oil
8
Oil Drain Plug, Oil Fill and Dipstick
8
Gear Selector
9
Operation
9
Reverse
10
Neutral
10
Forward
10
Changing Gear Case Oil
11
Troubleshooting
13
Check Lower Unit
15
No Start - Hard Start
15
Vibration
15
Power Loss
15
Noise
15
Cooling
15
Check Ignition
16
Armature Test
17
Tests for no Spark
17
Neutral Switch Test
18
Check Compression
19
Cylinder Leak down Test
19
Check Carburetion
20
Steering Tension
20
Propeller Service
21
Disassembly
23
Cooling Shroud
25
Removal
25
Power Head
25
Blower Housing
26
Magnetron™ Ignition
26
Flywheel
27
Inspect Flywheel Key, Keyway, Flywheel and Crankshaft
28
Carburetor
28
Disassemble Carburetor
29
Carburetor Cleaning
29
Cylinder Head
30
Prepare Cylinder Head for Removal
30
Remove Valve Cover
30
Disassemble Cylinder Head
30
Crankshaft & Camshaft
31
Oil Slinger Lubrication
31
Piston and Connecting Rod
32
Gear Case Disassembly
32
Sliding Clutch
34
Midsection
35
Disassembly
35
Throttle Cable
36
Replacement
36
Rewind Starter
36
Remove Rope
36
Inspect Rope
36
Remove Pulley and Spring
36
Inspect Spring, Starter Housing and Pulley
37
Overhaul
39
Magnetron Ignition
41
Remove Armature
41
Inspect Valve Springs
41
Inspect Valve Guides
41
Finish Ream Valve Guides
41
Reface Valves and Seats
41
Remove Piston Rings
41
Check Piston Ring Groove Wear
42
Check Piston Ring End Gap
42
Check Connecting Rod
42
Undersized Connecting Rods
42
Check Piston Pin and Piston Pin Bore
43
Inspect Crankshaft
43
Inspect Camshaft
44
Check Cylinder
44
Cylinder Resizing
44
Set up for Honing
44
Hone Cylinder
45
Cylinder Finish ("Cross Hatch")
45
Cylinder Cleaning
46
Check Camshaft Bearings
46
Check Crankshaft Bearings
46
Remove DU™ Magneto Bearing
46
Install DU™ Magneto Bearing
47
Oil Seals
47
Assembly
49
Piston and Connecting Rod
51
Piston Rings
51
Compress Piston Rings
51
Crankshaft Installation
52
Install Connecting Rod & Piston
52
Install Camshaft
53
Install Sump
53
Crankshaft End Play
53
Install Flywheel
54
Install Armature
54
Armature Air Gap
54
Cylinder Head Assembly
55
Install Cylinder Head Plate and Rocker Arm Studs
55
Install Valves
55
Install Valve Springs and Retainers
55
Install Cylinder Head
56
Install Rocker Arms
56
Adjust Valve Clearance
57
Install Valve Cover
57
Carburetor Assembly
57
Install Welch Plug
57
Install Choke Shaft
58
Install Throttle Shaft
58
Install Inlet Needle and Float
58
Install Carburetor
59
Install Pulley and Spring
59
Install Pawls, Pawl Springs & Retainer Assembly
60
Wind Spring & Install Rope
60
Install Blower Housing
61
Gear Case Assembly
61
MID Section Assembly
64
Install Power Head
65
Cooling Shroud Installation
66
Adjust Throttle Cable
66
Idle Adjustment
67
Appendix
69
Outboard Engine Fastener Specifications
70
Lower Unit Fastener Specifications
70
Ignition System Wiring Diagram
71
Component Location - Gear Case
72
Component Location - Gear Case
73
Component Location-Midsection
74
Component Location-Midsection
75
4
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Briggs & Stratton 5 HP Specifications
General
Brand
Briggs & Stratton
Model
5 HP
Category
Outboard Motor
Language
English
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