Briggs & Stratton 402500 Series Setup guide

COPYRIGHT by BRIGGS & STRATTON CORPORATION
All rights reserved. No part of this material may be reproduced or transmitted,
in any form or by any means, electronic or mechanical, including photocopying,
recording or by any information storage and retrieval system, without permission
in writing from Briggs & Stratton Corporation.
PRINTED IN U.S.A.
FORM MS−5762−06/20/2006
REPLACES FORM MS−5762−11/18/2005
FILE IN SECT. 2 OF SERVICE MANUAL
402500
Illustrated Parts List
Model Series
402500
TYPE NUMBERS
0025 through 0365.
TABLE OF CONTENTS
Air Cleaner 5. . . . . . . . . . . . . . . . . . . . . . . . .
Alternator 7. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Housing 5. . . . . . . . . . . . . . . . . . . . .
Camshaft 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 2. . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 3. . . . . . . . . . . . . . . . . . . . . .
Electric Starter 6. . . . . . . . . . . . . . . . . . . . . .
Engine Sump 2. . . . . . . . . . . . . . . . . . . . . . .
Flywheel 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Supply 4. . . . . . . . . . . . . . . . . . . . . . . . .
Gasket Set −Engine 4. . . . . . . . . . . . . . . . .
Gasket Set −Valve 4. . . . . . . . . . . . . . . . . .
Governor Spring 6. . . . . . . . . . . . . . . . . . . .
Ignition 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 3. . . . . . . . . . . . . . . . . . . . .
Kit −Carburetor Overhaul 4. . . . . . . . . . . .
Lubrication 2. . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Rings, Connecting Rod 2. . . . . . .
Valves 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−2Assemblies include all parts shown in frames. 06/20/2006
2
415
8
20
691 552
1017
12
10
9
11
718
3
1058 OPERATOR’S MANUAL
2
1
22
4
943
750
1035
1024
965
718
46
24
26
28
25
27
27
741
146
16
32
29
287
842
524
523
525
847
1330 REPAIR MANUAL
1280
710
741
146
16A 32 29
15
252 250

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−3Assemblies include all parts shown in frames. 06/20/2006
3
914
212
53
654
337
635
383
13
1023A
1023
1022
1022
1026
45
1026A
798 192
1022
1100
1029
7
36
35
33
34
868
5
883
42
51E
798
5A
883
1022
1100
1029
7
36 35
33
34
868
42
192
51E
54
50
51
51E
51E
51
122A

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−4Assemblies include all parts shown in frames. 06/20/2006
4
918
387
628
788
240
385
1022
868
1095 VALVE GASKET SET
7883
51
51D
51E
187D
601
601
187B
943
1022
12
9
7
3
358B ENGINE GASKET SET
868
842
691
524
51
20
51E
51D
883
601A
118E
947
133B
98
104
1127A
987A
130A
105
127
125C
117E
131A
975B
95
108A
231
141A
137A
51
51D
135B
137A
121C CARBURETOR OVERHAUL KIT
104
987A
977C CARBURETOR GASKET SET
137A
105
51 51D 51E
51D
51
51E
633A
633A
276A
276A
276A

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−5Assemblies include all parts shown in frames. 06/20/2006
5
447
865
573
304
967
445
865A
447A
865B
447A
405A
703
1036 EMISSIONS LABEL
431
305
305A
968B
467A
51D

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−6Assemblies include all parts shown in frames. 06/20/2006
6
363
1070
75
332
1005
668
74
73
271
742
552
616
213
216
269 268
270 220
615
209
211 267
265
188
219
265
552A
404
552A
691
1090
797
311
579
802
310
801
783
513
309
510
697
267
222
1051
801
544
803
562
505
227
278
23
165
695726

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−7Assemblies include all parts shown in frames. 06/20/2006
7
1119
851
334
635 333
NOTE: All stators use a No. mounting screw.
1119
NOTE: The proper flywheel part number and/or the alternator magnet size will
determinethe alternator type or output. See repair instruction manual
for additional information.
789B
474C
CIRCUIT
DUAL
1059
877C
878C
789A

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−8Assemblies include all parts shown in frames. 06/20/2006
8
zIncluded in Carburetor Gasket Set−Ref. No. 977C.
∆Included in Valve Gasket Set−Ref. No 1095.
KIncluded in Engine Gasket Set−Ref. No.358B.
DIncluded in Carburetor Overhaul Kit−Ref. No. 121C.
1 699751 Cylinder Assembly
2 499585 Kit−Bushing/Seal
(Magneto Side)
3K391086s Seal−Oil
(Magneto Side)
4 699747 Sump−Engine
5 792299 Head−Cylinder
(Cylinder #1)
5A 792300 Head−Cylinder
(Cylinder #2)
7K∆690962 Gasket−Cylinder Head
8 792185 Breather Assembly
9K690937 Gasket−Breather
10 691108 Screw
(Breather Assembly)
11 792184 Tube−Breather
12 K697227 Gasket−Crankcase
13 791130 Screw
(Cylinder Head)
15 691680 Plug−Oil Drain
(3/8” Standard)
16 699700 Crankshaft
(Used After Code Date
04010800).
16A 699701 Crankshaft
(Used Before Code
Date 04010900).
20 K690947 Seal−Oil
(PTO Side)
22 694966 Screw
(Crankcase Cover/
Sump)
23 691054 Flywheel
24 222698s Key−Flywheel
(.020” Oversize)
25 499588 Piston Assembly
(Standard)
−−−−−−− Note −−−−−
499590 Piston
Assembly
(.020” Oversize)
26 499604 Ring Set
(Standard)
−−−−−−− Note −−−−−
499606 Ring Set
(.020” Oversize)
27 690975 Lock−Piston Pin
28 690229 Pin−Piston
(Standard)
29 699699 Rod−Connecting
(Used After Code Date
04010800).
−−−−−−− Note −−−−−
(Used Before Code
Date 04010900).
(For Replacement Rod
See Ref 16A)
32 690976 Screw
(Connecting Rod)
33 499596 Valve−Exhaust
34 792200 Valve−Intake
35 694865 Spring−Valve
(Intake)
36 694865 Spring−Valve
(Exhaust)
42 499586 Keeper−Valve
45 690977 Tappet−Valve
46 790562 Camshaft
50A 699801 Manifold−Intake
51KDz∆699803Gasket−Intake
51DKDz∆699800Gasket−Intake
51EKDz∆690949Gasket−Intake
53 690951 Stud
(Carburetor)
54 699816 Screw
(Intake Manifold)
(Used After Code Date
04110400).
−−−−−−− Note −−−−−
695240 Screw
(Intake Manifold)
(Used Before Code
Date 04110500).
73 494439 Screen−Rotating
74 698425 Screw
(Rotating Screen)
75 691056 Washer
(Flywheel)
95 690718 Screw
98 699721 Kit−Idle Speed
104 D694918 Pin−Float Hinge
105 D698537 Valve−Float Needle
108A 699808 Valve−Choke
117E 791406 Jet−Main
(Standard)
118E 699820 Jet−Main
(High Altitude)
121C 699814 Kit−Carburetor
Overhaul
122A 699802 Spacer−Carburetor
125C 699807 Carburetor
127 698810 Plug−Welch
130A 699809 Valve−Throttle
131A 699812 Kit−Throttle Shaft
133B 694914 Float−Carburetor
135B 792022 Tube−Fuel Transfer
137A D698781 Gasket−Float Bowl
141A 699811 Kit−Choke Shaft
146 690979 Key−Timing
165 693148 Nut
(Ring Gear)
187B 791872 Line−Fuel
(Formed Hose)
187D 791744 Line−Fuel
(Formed)(Cut to
Required Length)
188 691003 Screw
(Control Bracket)
192 690083 Adjuster−Rocker Arm
209 692909 Spring−Governor
(Yellow)
211 691019 Spring−Governed Idle
212 699805 Link−Throttle
212B 792265 Link−Throttle
213 691021 Bracket−Choke
Control
216 691022 Link−Choke
219 698231 Gear−Governor
220 690412 Washer
(Governor Gear)
222 698761 Bracket−Control
227 792492 Lever−Governor
Control
231 690718 Screw(Choke Valve)
(Choke Valve)
240 691035 Filter−Fuel
250 690957 Retainer−Breather
252 690956 Collector−Oil
265 691024 Clamp−Casing
267 695134 Screw (Casing Clamp)
268 691025 Casing−Control Wire
(Cut to Required
Length)
REF. PART REF. PART REF. PART
NO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−9Assemblies include all parts shown in frames. 06/20/2006
9
KIncluded in Engine Gasket Set−Ref. No.358B.
DIncluded in Carburetor Overhaul Kit−Ref. No. 121C.
zIncluded in Carburetor Gasket Set−Ref. No. 977C.
∆Included in Valve Gasket Set−Ref. No 1095.
269 691026 Wire−Control
(Cut to Required
Length)
270 691027 Nut
(Control Wire Casing)
271 691028 Lever−Control
276A D695410 Washer−Sealing
278 792651 Washer
(Governor Control
Lever)
287 691108 Screw
(Dipstick Tube)
304 790688 Housing−Blower
(Black)
305 691005 Screw
(Blower Housing)
305A 698336 Screw
(Blower Housing)
309 497595 Motor−Starter
310 690323 Bolt
(Starter Motor)
311 497608 Brush Set
332 691059 Nut
(Flywheel)
333 691060 Armature−Magneto
334 691061 Screw
(Magneto Armature)
337 491055s Plug−Spark
358B 699823 Gasket Set−Engine
363 19203 Flywheel Puller
383 19374s Wrench−Spark Plug
385 691108 Screw
(Fuel Pump)
387 808656 Pump−Fuel
404 690442 Washer
(Governor Crank)
405A 697820 Screw
(Back Plate)
(Mounting)
415 690283 Plug
431 699806 Elbow−Intake
445 499486s Filter−Air Cleaner
Cartridge
447 691003 Screw
(Air Guide Cover)
447A 691108 Screw
(Air Guide Cover)
467A 691008 Screw
(Air Filter Cover)
474C 696459 Alternator
(Dual Circuit)
505 691029 Nut
(Governor Control
Lever)
510 696541 Drive−Starter
513 692024 Clutch−Drive
523 691036 Dipstick
524 K691032 Seal−Dipstick Tube
525 691037 Tube−Dipstick
544 Armature−Starter
(Service with 497595
Starter Motor)
552 690552 Bushing−Governor
Crank
552A 690553 Bushing−Governor
Crank
562 690311 Bolt
(Governor Control
Lever)
573 790444 Plate−Back
579 691029 Nut
(Starter Cable)
601 791850 Clamp−Hose
(Green)
601A 691038 Clamp−Hose
(Black)
615 698290 Shaft−Governor
Retainer
616 691045 Crank−Governor
(Intake Manifold)
628 691108 Screw
(Fuel Pump Bracket)
633A D695414 Seal−Choke/Throttle
Shaft
635 66538s Boot−Spark Plug
654 690958 Nut
(Carburetor)
668 691215 Spacer
691 K690657 Seal−Governor Shaft
695 693149 Screw
(Ring Gear)
697 690372 Screw
(Drive Cap)
703 691010 Clip
710 697474 Cover−Oil Filter
718 690959 Pin−Locating
726 499612 Gear−Ring
741 690980 Gear−Timing
742 690328 Retainer−E Ring
750 696999 Screw
(Oil Pump Cover)
783 695708 Gear−Pinion
788 691039 Bracket−Fuel Pump
789A 790544 Harness−Wiring
789B 698330 Harness−Wiring
(6 Pin Customer
Conversion)
797 693167 Nut
(Brush Retainer)
798 697890 Screw
(Rocker Arm)
801 691283 Cap−Drive
802 691286 Cap−End
803 Housing−Starter
(Service with 497595
Starter Motor)
842 K691031 Seal−O Ring
(Dipstick)
847 499602 Dipstick/Tube
Assembly
851 493880s Terminal−Spark Plug
865 691012 Cover−Air Guide
(Cylinder #1)
865A 691014 Cover−Air Guide
(Cylinder #2)
865B 691015 Cover−Air Guide
(Valley)
868 K∆690968 Seal−Valve
877C 393456 Wire/Connector−
Alternator
(Dual Circuit)
878C 398661 Harness−Alternator
(Dual Circuit)
883 K∆690970 Gasket−Exhaust
914 691127 Screw
(Rocker Cover)
918 694000 Hose−Vacuum
943 K690589 Seal−O Ring
(Oil Pump Cover)
947 699728 Solenoid−Fuel
965 499613 Cover−Oil Pump
967 273638s Filter−Pre Cleaner
968B 790095 Cover−Air Cleaner
REF. PART REF. PART REF. PART
NO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

402500
Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine.
5762−10 Assemblies include all parts shown in frames. 06/20/2006
10
zIncluded in Carburetor Gasket Set−Ref. No. 977C.
∆Included in Valve Gasket Set−Ref. No 1095.
KIncluded in Engine Gasket Set−Ref. No.358B.
DIncluded in Carburetor Overhaul Kit−Ref. No. 121C.
975B 699502 Bowl−Float
977C 699815 Gasket Set−Carburetor
987A D699813 Seal−Throttle Shaft
1005 499603 Fan−Flywheel
(Used After Code Date
04071900).
−−−−−−− Note −−−−−
790698 Fan−Flywheel
(Used Before Code
Date 04072000).
1017 690770 Screen−Oil Pump
1022 K∆690971 Gasket−Rocker Cover
1023 499599 Cover−Rocker Arm
(Cylinder #1)
1023A 499600 Cover−Rocker Arm
(Cylinder #2)
1024 499054 Pump−Oil
1026 690981 Rod−Push
(Steel)
1026A 690982 Rod−Push
(Aluminum)
1029 690972 Arm−Rocker
1035 691042 Shaft−Pump
1036 Label−Emissions
(Available from an
Authorized Briggs and
Stratton Service
Dealer.)
1051 691265 Ring−Retaining
1058 276245 Operator’s Manual
1059 698516 Kit−Screw/Washer
1070 690372 Screw
(Fan Retainer)
1090 691293 Retainer−Brush
1095 699822 Gasket Set−Valve
1100 791959 Pivot−Rocker Arm
1119 691183 Screw
(Alternator)
1127A 695407 Screw
(Float Bowl)
1280 697475 Seal−O Ring
(Oil Filter Cover)
1330 273521 Manual−Repair
REF. PART REF. PART REF. PART
NO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION