Briggs & Stratton 440000 Intek Extended Life Series User manual

Operator’s Manual
Intek
Extended Life Series
Model 400000 Model 440000
BRIGGSandSTRATTON.com
ECopyright Briggs & Stratton Corporation
Milwaukee, Wisconsin 53201 U.S.A.
Form No. 277103-3/07
Printed in U.S.A.
Intek
Extended Life Series

2
Safety References
The safety alert symbol is used to identify safety
information about hazards that can result in personal
injury. A signal word (DANGER, WARNING, or
CAUTION) is used with the alert symbol to indicate the
likelihood and the potential severity of injury. In addition,
a hazard symbol may be used to represent the type of
hazard.
DANGER indicates a hazard which, if not
avoided, will result in death or serious
injury.
WARNING indicates a hazard which, if not
avoided, could result in death or serious
injury.
CAUTION indicates a hazard which, if not
avoided, might result in minor or moderate
injury.
CAUTION, when used without the alert
symbol, indicates a situation that could result
in damage to the engine.
This manual contains safety
information to make you aware of
the hazards and risks associated with engines, and
how to avoid them. Because Briggs & Stratton does
not necessarily know what equipment this engine will
power, it is important that you read and understand
these instructions and the instructions for the
equipment this engine powers.
Table of Contents
Safety References 2. . . . . . . . . . . . . . . . . . . . . . . . .
Features 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . .
Starting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage and Service 15. . . . . . . . . . . . . . . . . . . . . .
Specifications and Emission Information 16. . . . .
Warranty Information 17. . . . . . . . . . . . . . . . . . . . . .
SYMBOLS ASSOCIATED
WITH THIS ENGINE:
Explosion
Toxic F ume s
Moving Parts
Shock
Hot Surface
Kickback
Fire
On Off
Fuel Shutoff
Read
Operating
Manual
Fuel
Choke
Oil
Run
Stop
Slow Fast
Hazardous
Chemical
WARNING
Briggs & Stratton does not approve or authorize
the use of these engines on 3-wheel All Terrain
Vehicles (ATVs), motor bikes, aircraft products
or vehicles intended for use in competitive
events. Use of these engines in such applica-
tions could result in property damage, serious
injury (including paralysis), or even death.
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
WARNING
This engine is shipped from Briggs & Stratton
without oil. If you start the engine without oil, the
engine will be damaged beyond repair and will
not be covered under warranty.
CAUTION

3
Features
1. Dipstick/Oil fill
2. Rotating screen
3. Fuel pump
4. Air cleaner
5. Intake manifold
6. Choke control bracket
7. Carburetor
8. Speed control bracket
9. Engine Identification
(Model-Type-Code)
10. Spark plug wire
11. Oil filter
12. Fuel filter (if equipped)
13. 12V electric starter
14. Oil drain plug
10
1
2
5
6
89
11
12
13
14
10
7
3
4
3
4
1

4
Safety Information
Gasoline and its vapors are extremely
flammable and explosive.
Fire or explosion can cause severe
burns or death.
WHEN ADDING FUEL
STurn engine OFF and let engine cool at least 2
minutes before removing gas cap.
SFill fuel tank outdoors or in well-ventilated
area.
SDo not overfill fuel tank.
SKeep gasoline away from sparks, open
flames, pilot lights, heat, and other ignition
sources.
SCheck fuel lines, tank, cap, and fittings
frequently for cracks or leaks. Replace if
necessary.
WHEN STARTING ENGINE
SMake sure spark plug, muffler, fuel cap and air
cleaner are in place.
SDo not crank engine with spark plug removed.
SIf fuel spills, wait until it evaporates before
starting engine.
SIf engine floods, set choke to OPEN/RUN
position, place throttle in FAST and crank until
engine starts.
WHEN OPERATING EQUIPMENT
SDo not choke carburetor to stop engine.
WHEN TRANSPORTING EQUIPMENT
STransport with fuel tank EMPTY.
WHEN STORING GASOLINE OR EQUIPMENT
WITH FUEL IN TANK
SStore away from furnaces, stoves, water
heaters or other appliances that have pilot
light or other ignition source because they can
ignite gasoline vapors.
WARNING
Engines give off carbon monoxide, an
odorless, colorless, poison gas.
Breathing carbon monoxide can
cause nausea, fainting or death.
SStart and run engine outdoors.
SDo not start or run engine in enclosed area,
even if doors or windows are open.
WARNING
Starting engine creates sparking.
Sparking can ignite nearby flammable
gases.
Explosion and fire could result.
SIf there is natural or LP gas leakage in area, do
not start engine.
SDo not use pressurized starting fluids because
vapors are flammable.
WARNING
Rapid retraction of starter cord (kickback) will
pull hand and arm toward engine faster than
you can let go.
Broken bones, fractures, bruises or
sprains could result.
SWhen starting engine, pull cord slowly until
resistance is felt, then pull rapidly.
SDirect coupled equipment components such as,
but not limited to, blades, impellers, pulleys,
sprockets, etc., must be securely attached.
WARNING

5
Safety Information
Rotating parts can contact or entangle
hands, feet, hair, clothing, or accesso-
ries.
Traumatic amputation or severe lacera-
tion can result.
SOperate equipment with guards in place.
SKeep hands and feet away from rotating parts.
STie up long hair and remove jewelry.
SDo not wear loose-fitting clothing, dangling
drawstrings or items that could become
caught.
WARNING
SAllow muffler, engine cylinder and fins to cool
before touching.
SRemove accumulated combustibles from
muffler area and cylinder area.
SInstall and maintain in working order a spark
arrester before using equipment on
forest-covered, grass-covered,
brush-covered unimproved land. The state of
California requires this (Section 4442 of the
California Public Resources Code). Other
states may have similar laws. Federal laws
apply on federal land.
Running engines produce heat.
Engine parts, especially muffler,
become extremely hot.
Severe thermal burns can occur on
contact.
Combustible debris, such as leaves,
grass, brush, etc. can catch fire.
WARNING
Unintentional sparking can result in
fire or electric shock.
Unintentional start-up can result in
entanglement, traumatic amputation,
or laceration.
BEFORE PERFORMING ADJUSTMENTS
OR REPAIRS
SDisconnect spark plug wire and keep it away
from spark plug.
SDisconnect battery at negative terminal (only
engines with electric start.)
SDo not strike the flywheel with a hammer or
hard object because the flywheel may later
shatter during operation.
SDo not tamper with governor spring, links or
other parts to increase engine speed.
SUse only correct tools.
WHEN TESTING FOR SPARK
SUse approved spark plug tester.
SDo not check for spark with spark plug
removed.
WARNING

6
Starting
1. Check oil level. Ensure level is at FULL mark on
dipstick. Use a high quality motor oil. Review oil
recommendations for selection of oil grade for
expected starting temperature.
2. Open the fuel shut-off valve, if equipped.
3. Move choke control to CHOKE and speed control to
FAST or RUN.
4. Insert key and turn to START.
Note: To prolong starter life, use short starting
cycles (5 seconds maximum, then wait one
minute). Follow equipment manufacturer’s
recommendations for charging battery.
5. Let engine warm up.
6. Choke Equipped: Move choke control lever toward
RUN a short distance at a time over several
seconds in warm weather or minutes in cold
weather. Let engine run smoothly before each
change.
7. Operate with choke in RUN or OPEN position.
CAUTION
Operation of this engine is for the application it
was intended. All the components used to build
this engine assembly must remain in place for
the proper operation of this engine.
OIL PRESSURE SWITCH
If engine is equipped with an oil pressure switch, read the
operating instructions supplied by the equipment
manufacturer to understand how the switch functions.
Engines give off carbon
monoxide, an odorless, colorless,
poison gas.
Breathing carbon monoxide can
cause nausea, fainting or death.
WARNING
Stopping
1. Move speed control to SLOW, if equipped.
2. Turn key to OFF. Remove key and store out of
reach of children.
3. Close fuel shut-off valve, if equipped.
WARNING
DO NOT stop engine by choking
carburetor. Backfire, fire or engine
damage could occur.
1-800-233-3723
(USA and Canada ONLY, Pre-recorded message.)
www.briggsandstratton.com
Need assistance?

7
SAdd clean fresh fuel.
SEnsure there is nothing blocking the air intake of the
engine. Check the air cleaner cartridge for dirt or
debris that may be clogging air movement. If very
dirty replace with new cartridge.
Engine will not start.
SDrain excess oil from engine to bring level to FULL mark
on dipstick.
SCheck air cleaner filter for oil saturation.
If saturated, clean or replace filter.
DO NOT OVERFILL.
Overfilling crankcase with oil
may cause smoking, hard
starting, spark plug fouling or
oil saturation of air filter.
CAUTION
SRemove spark plug. Clean, check gap, re-install. Refer to
Maintenance section for details.
WARNING
SEnsure fuel cap, and air
cleaner are in place
before starting engine.
SBefore refueling −turn
engine OFF and let
engine cool at least 2
minutes before
removing gas cap.
SCheck fuel lines, tank,
cap, and fittings for
cracks or leaks.
Replace if necessary.
SDo not crank engine with
spark plug removed.
Engine is Smoking or Running Rough.
If engine is tipped to transport
equipment, to remove debris,
to drain oil, etc., keep the
spark plug side of engine
up.
CAUTION
SCheck oil level with dipstick.
SRefer to Oil Pressure Switch in Maintenance section of
this manual.
Troubleshooting
rOut of Fuel
SMove CHOKE to RUN position. Turn engine over
(use short starting cycles 5 seconds, then wait a
minute) until engine starts.
rEngine Flooded
rLow Oil
rSpark Plug Fouling
rOil Level is OVER FULL mark on dipstick.
rSpark Plugs Fouled
SCheck and ensure the spark plugs are clean. Check the
gap with a feeler gauge. If necessary, reset to .76 mm
or .030 in.
SReplace the spark plugs if upon inspection the
electrode is burned or worn.
rAir Cleaner Dirty

8
Oil
Capacity
Engine without oil filter holds approximately 1-7/8 quarts
(60 ounces; 1.8 liter).
Engine equipped with oil filter holds approximately
2 quarts (64 ounces; 1.9 liters).
Recommendations
SUse a high quality detergent motor oil, such as
Briggs & Stratton 30W, Part Number 100005 (20 oz)
or 100028 (48 oz).
SDO NOT use special additives.
SChoose a viscosity according to the table shown.
Note: Synthetic oil meeting ILSAC GF-2,
API certification mark and API service sym-
bol (shown at left) with “SJ/CF ENERGY
CONSERVING” or higher, is an acceptable
oil at all temperatures. Use of synthetic oil
does not alter required oil change
intervals.
*Air cooled engines run hotter than
automotive engines. The use of
non-synthetic multi-viscosity oils (5W-30,
10W-30, etc.) in temperatures above 40°F
(4°C) will result in higher than normal oil
consumption. When using a multi-viscosity
oil, check oil level more frequently.
** SAE 30 oil, if used below 40°F (4°C), will
result in hard starting and possible engine
bore damage due to inadequate lubrication.
°F-20 0 20 40 60 80 100
°C-30 -20 -10 0 10 20 30 40
STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
*
**
32
SAE Viscosity Grades
CAUTION
Checking and Adding Oil
1. Place engine level. Clean around dipstick and oil fill.
2. Remove dipstick and wipe clean with cloth.
3. Tighten dipstick down. Remove & check oil level.
4. If oil is needed, slowly pour into oil fill tube.
Add only a couple ounces and recheck level.
5. Fill to FULL line on dipstick.
6. Replace dipstick. Tighten down firmly.
8 oz.

9
Fuel
Recommendations
SUse clean, fresh, regular unleaded gasoline with a
minimum of 85 octane. Fresh fuel prevents gum from
forming in the fuel system or on essential carburetor
parts. Purchase fuel in quantity that can be used
within 30 days.
SDo not use gasoline which contains Methanol.
SDo not mix oil with gasoline.
SFor engine protection use Briggs & Stratton
Gasoline Additive available from your Authorized
Briggs & Stratton Dealer (P/N 5041 or single use
pouch).
SThis engine is certified to operate on gasoline.
Exhaust Emission Control System: EM (Engine
Modifications).
Adding Fuel
1. Clean area around fuel cap and remove.
2. Replace cap before starting.
Some fuels, called oxygenated or reformulated
gasoline, are gasoline blended with alcohols or
ethers. Excessive amounts of these blends can
damage the fuel system or cause performance
problems. If any undesirable operating
symptoms occur, use gasoline with a lower
percentage of alcohol or ether.
CAUTION
STurn engine OFF and let engine
cool at least 2 minutes before
removing fuel cap.
SFill fuel tank outdoors or in
well-ventilated area.
SDO NOT overfill fuel tank. Fill tank
to approximately 1-1/2 inches
below top of neck to allow for fuel
expansion.
SIf fuel spills, wait until it evaporates
before starting engine.
SKeep fuel away from sparks, open
flames, pilot lights, heat and other
ignition sources.
SCheck fuel lines, tank, cap, and
fittings frequently for cracks or
leaks. Replace if necessary.
WARNING

10
Maintenance
Regular maintenance will improve the performance and
extend the life of the engine. See any Authorized Briggs
& Stratton Dealer for service. Use only genuine
Briggs & Stratton parts. Other parts may not
perform as well, may damage the engine, and may
result in injury.In addition, use of other parts may void
your warranty.
Emission Control
Maintenance, replacement or repair of the emission
control devices and systems may be performed by
any nonroad engine repair establishment or
individual. However, to obtain no charge repairs under
the terms and provisions of the Briggs & Stratton
warranty statement, any service or emission control
part repair or replacement must be performed by a
factory authorized dealer. See Emission Warranty
section for details.
Follow the instructions and
schedules indicated below.
Unintentional sparking can result
in fire or electric shock.
Fire or explosion can cause
severe burns or death.
Unintentional start-up can result
in entanglement, traumatic
amputation, or laceration.
Before performing maintenance:
SDisconnect spark plug wire and
keep it away from spark plug.
SDisconnect battery at negative
terminal (only engines with electric
start).
SDo not strike the flywheel with a
hammer or hard object because the
flywheel may later shatter during
operation.
SDo not tamper with governor spring,
links or other parts to increase
engine speed.
SUse only correct tools.
When testing for spark:
SUse approved spark plug tester.
SDo not check for spark with spark
plug removed.
WARNING
Clean Combustion Chamber
Task
Perform task at hourly
or calendar interval,
whichever comes first.
Check Oil Level
Clean Debris
Clean Air Cooling System
Replace Spark Plugs
Change Oil **
Service Air Cleaner*
Replace Fuel Filter, If Equipped
* Clean more often under dusty conditions or when airborne debris is present. Replace air cleaner, if very dirty.
** Change oil after first 5 to 8 hours of use, then every 50 hours. Change oil every 25 hours when operating the
engine under heavy load or in high temperatures.