Briggs & Stratton 54000 Series Installation and operation manual

Operating & Maintenance
Instructions
Model 54000 Series covered in this manual
FORM NO. 276354-8/05
PRINTED IN U.S.A.
©Copyright 2005 by Briggs & Stratton Corporation
www.briggsandstratton.com
The Power That Works For You®

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 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Information 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYMBOLS ASSOCIATED
WITH THIS ENGINE:
Explosion
Toxic Fumes
Moving Parts
Shock
Hot Surface
Kickback
Fire
Fuel Shutoff
Read
Manual
Choke
Oil
Fuel
On Off
Stop
Wear Eye
Protection
Frostbite
Slow
Fast
WARNING
Briggs & Stratton does not approve or authorize the
use of these engines on 3-wheel All Terrain
Vehicles (ATVs), motor bikes, fun/recreational
go-karts, aircraft products or vehicles intended for
use in competitive events. Use of these engines in
such applications 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. Choke Control (if equipped)
2. Breather/Breather Tube
3. Spark Plug (2 locations)
4. Engine Model Label
5. Oil Pressure Sensor
6. Oil Filter
7. Oil Drain Plug (2 locations)
8. Rotating Screen
9. Cover-Carburetor
10. Carburetor
11. Mechanical Fuel Pump
12. Air Cleaner
13. Oil Fill
14. Dipstick
15. Regulator/Rectifier
16. Starter Solenoid
17. Starter
1
7
3
2
9
12
8
11
15
16
17
4
10
13
7
12
5
6
14
9

4
Safety Information
Gasoline and its vapors are extremely
flammable and explosive.
Fire or explosion can cause severe
burns or death.
WHEN ADDING FUEL
•Turn engine OFF and let engine cool at least
2 minutes before removing gas cap.
•Fill fuel tank outdoors or in well-ventilated
area.
•Do not overfill fuel tank.
•Keep gasoline away from sparks, open
flames, pilot lights, heat, and other ignition
sources.
•Check fuel lines, tank, cap, and fittings
frequently for cracks or leaks. Replace if
necessary.
WHEN STARTING ENGINE
•Make sure spark plug, muffler, fuel cap and
air cleaner are in place.
•Do not crank engine with spark plug removed.
•If fuel spills, wait until it evaporates before
starting engine.
•If engine floods, set choke to OPEN/RUN
position, place throttle in FAST and crank
until engine starts.
WHEN OPERATING EQUIPMENT
•Do not choke carburetor to stop engine.
WHEN TRANSPORTING EQUIPMENT
•Transport with fuel tank EMPTY.
WHEN STORING GASOLINE OR
EQUIPMENT WITH FUEL IN TANK
•Store away from furnaces, stoves, water
heaters or other appliances that have pilot
light or other ignition source because they
can ignite gasoline vapors.
WARNING
Starting engine creates sparking.
Sparking can ignite nearby flammable
gases.
Explosion and fire could result.
•If there is natural or LP gas leakage in area,
do not start engine.
•Do not use pressurized starting fluids because
vapors are flammable.
WARNING
WARNING
Engines give off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide can
cause nausea, fainting or death.
•Start and run engine outdoors.
•Do not start or run engine in enclosed area,
even if doors or windows are open.
WARNING
Rotating parts can contact or en-
tangle hands, feet, hair, clothing, or
accessories.
Traumatic amputation or severe
laceration can result.
•Operate equipment with guards in place.
•Keep hands and feet away from rotating parts.
•Tie up long hair and remove jewelry.
•Do not wear loose-fitting clothing, dangling
drawstrings or items that could become
caught.
•Allow muffler, engine cylinder and fins to cool
before touching.
•Remove accumulated debris from muffler area
and cylinder area.
•Install 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

5
Safety Information
Before performing maintenance or repairs:
•Disconnect spark plug wire and keep it away
from spark plug.
•Disconnect battery at negative terminal (only
engines with electric start).
•Use only correct tools.
•Do not strike the flywheel with a hammer or
hard object because the flywheel may later
shatter during operation.
•Do not tamper with governor spring, links or
other parts to increase engine speed.
When testing for spark:
•Use approved spark plug tester.
•Do not check for spark with spark plug
removed.
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.
WARNING
Oil
Capacity
The engine holds approximately 80 oz (2.3 liters).
Oil Recommendation
•Use a high quality detergent oil classified “For
Service SG, SH, SJ, SL” or higher, such as Briggs
& Stratton 30, Part Number 100005 (20 oz) or
100028 (48 oz).
•Do not use special additives.
•Do not mix gasoline with oil.
•Choose a viscosity according to the table.
Note: Synthetic oil meeting ILSAC GF-2, API
certification mark and API service symbol (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.
STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
* Use of SAE 30 oil below 40°F (4°C) will result in
hard starting and possible engine damage due to
inadequate lubrication.
* * 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.
CAUTION
*
**
*
SAE Viscosity Grades

6
Adding Oil
1. First add 67 oz (2 liters).
2. Start and run engine at idle for 30 seconds.
See Starting Instructions.
3. Shut engine off and wait 30 seconds.
4. Then add more oil slowly to bring level to FULL
mark on dipstick. DO NOT OVERFILL.
Checking Oil Level
•Check oil level before starting the engine.
•Keep oil level at FULL. Do not overfill.
•Check level daily, or after every eight (8) hours of
operation.
1. Place engine level and clean around oil filler plug.
2. Remove dipstick and wipe clean with cloth.
3. Push dipstick back in and remove to check oil
level. Oil level should be at FULL line on dipstick.
4. If oil is needed, add slowly.
5. Fill to FULL line on dipstick – re-check.
6. Replace dipstick firmly.
Full Line
Oil Fill
Dipstick
Oil Fill Cap
Fuel
•Use 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.
•For engine protection use Briggs & Stratton
Gasoline Additive available from your Authorized
Briggs & Stratton Dealer.
•Do not use gasoline which contains Methanol.
•Do not mix oil with gasoline.
•This engine is certified to operate on gasoline.
Exhaust Emission Control System: EM (Engine
Modifications).
Adding Fuel
1. Turn engine OFF and let engine cool at least 2
minutes before removing gas cap.
2. Remove cap. Fill tank to approximately 1-1/2
inches below top of neck to allow for fuel
expansion. Be careful not to overfill.
3. Replace cap before starting.
Cold Weather Starting
•Use correct type of oil for expected starting
temperature. See Oil.
•Use fresh gasoline, which has higher volatility to
improve starting.
•Remove external equipment and engine loads.
(See equipment operating instructions.)
Some fuels, called oxygenated or reformulated
fuels, are fuels 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

7
Starting
Gasoline Powered Engines
The controls used for starting are located on the engine
or on the equipment for which it powers. Read your
operating manual and become familiar with the use of
the controls before starting your engine.
Use short starting cycles (5 seconds, wait one
minute between cycles). Follow equipment
manufacturer’s recommendations for charging
battery.
CAUTION
1. Check oil level.
2. Open fuel shut-off valve (if equipped).
3. Move choke control to CHOKE or START.
4. Move throttle (if equipped) to FAST.
5. Push rocker switch (if equipped) to ON or RUN.
6. Insert key and turn to START.
7. Let engine warm up.
The manufacturer of the equipment on which
this engine is installed specifies top speed at
which the engine will be operated. DO NOT
EXCEED this speed.
CAUTION
Operating
•Allow engine to warm up several seconds to
several minutes depending on outside
temperature.
•Gradually open choke.
•For maximum performance and life, operate
engine with choke in OPEN and throttle in FAST.
Note: If choke equipped, slowly adjust toward RUN
position. Wait until engine runs smoothly before each
choke adjustment.
•For maximum performance and life, operate
engine with choke in OPEN and throttle in FAST.
Oil Pressure
If oil pressure drops below 7-10 psi (0.1-0.2 kg/cm@), an
oil pressure switch (if engine is equipped) will either
activate a warning device or stop the engine. Check oil
level with dipstick.
If oil level is between ADD and FULL mark on dipstick
do not try to restart engine. Contact an Authorized
Briggs & Stratton Service Dealer. Do not operate
engine until oil pressure is corrected.
If oil level is below ADD mark on dipstick, add oil to
bring level to FULL mark. Restart engine and check oil
pressure. If pressure is normal, continue to operate
engine.
Note: Oil pressure gauge, if engine is equipped, is
supplied by manufacturer of equipment.
Stopping
WARNING
•Do not stop engine by moving choke
control to CHOKE. Backfire, fire or engine
damage could occur.
1. Move throttle to SLOW (if equipped).
2. Turn key to OFF. Remove key and store out of
reach of children.
3. Push rocker switch (if equipped) to OFF or STOP.
4. Close fuel shut-off valve (if equipped).
Need assistance?
1-800-233-3723 (USA and Canada ONLY, Pre-recorded message.)
www.briggsandstratton.com

8
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.
Before performing maintenance or repairs:
•Disconnect spark plug wire and keep it away
from spark plug.
•Disconnect battery at negative terminal (only
engines with electric start).
•Use only correct tools.
•Do not strike the flywheel with a hammer or
hard object because the flywheel may later
shatter during operation.
•Do not tamper with governor spring, links or
other parts to increase engine speed.
When testing for spark:
•Use approved spark plug tester.
•Do not check for spark with spark plug
removed.
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.
WARNING
Follow the instructions and schedules indicated below.
Task
Perform task at hourly
or calendar interval,
whichever comes first.
Check Oil Level and for Oil Leaks
Change Oil and Oil Filter**
Clean Spark Arrestor (if equipped)
Clean Air Cleaner*
Check Battery Electrolyte
Replace Air Cleaner Cartridge*
Change Fuel Filter
Change Spark Plugs
Replace Safety Filter Cartridge
Check Valve Clearance
Every 8 Hours
or Daily
50
Hours
100
Hours
250
Hours
400
Hours
600
Hours
Yearly
* 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 100 hours. Change oil every 25 hours when operating the
engine under heavy load or in high temperatures. Check valve clearance after first 50 hours of use, then every
250 hours on gasoline powered engines.

9
Changing Oil and Oil Filter
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.
Oil Filter
Oil Drain Plug
1. With engine OFF but still warm, remove oil drain
plug and drain oil into appropriate receptacle.
Reinstall drain plug.
2. Remove oil filter. Before installing new filter,
lightly oil filter gasket with fresh, clean oil.
3. Screw filter on by hand until gasket contacts oil
filter adapter. Tighten 1/2 to 3/4 turn more.
4. Place engine level and follow Adding Oil to add
fresh oil.
5. Replace oil fill cap and dipstick.
Used oil is a hazardous waste product. Dispose
of used oil properly. Do not discard with
household waste. Check with your local
authorities, service center, or dealer for safe
disposal/recycling facilities.
CAUTION
Adding Oil
1. First add 67 oz (2 liters).
2. Start and run engine at idle for 30 seconds.
See Starting Instructions.
3. Shut engine off and wait 30 seconds.
4. Then add more oil slowly to bring level to FULL
mark on dipstick.
5. Replace oil fill cap and dipstick.
Checking Oil Level
•Check oil level before starting the engine.
•Keep oil level at FULL. Do not overfill.
•Check level daily, or after every eight (8) hours of
operation.
Full Line
Oil Fill
Dipstick
Oil Fill Cap
1. Place engine level and clean around oil filler plug.
2. Remove dipstick and wipe clean with cloth.
3. Push dipstick back in and remove to check oil
level. Oil level should be at FULL line on dipstick.
4. If oil is needed, add slowly.
5. Fill to FULL line on dipstick – re-check.
6. Replace dipstick firmly.

10
Air Cleaner
Clean cartridge every 100 hours. To clean cartridge,
gently tap on end with handle of screwdriver. Replace
cartridge every 400 hours. Clean and replace more
often under dusty conditions.
1. Unlock and remove cover..
2. Remove air cleaner cartridge from body and
inspect. Replace if very dirty or any damage
occurs to cartridge.
3. Carefully clean out cover and around body. Do
not allow debris to enter engine.
4. Install cleaned or new cartridge in body.
5. Install cover and lock with clamps.
Do not use pressurized air or solvents to clean
foam. Pressurized air can damage foam; solvents
will dissolve foam.
CAUTION
Safety Filter Installation
Several models with the cyclonic air cleaner are also
equipped with a safety filter. Replace safety filter
cartridge every 600 hours, or with every other air filter
cartridge replacement. To replace:
1. Pull carefully to remove from air cleaner body,
ensure no debris enters engine.
2. Install new safety cartridge first, then install air
filter cartridge over safety filter.
Cover
Air cleaner cartridge
Safety Filter Cartridge
Rubber Valve
Air cleaner body
Ensure air cleaner and cover are properly
installed before starting engine.
WARNING
Spark Plug
Check the spark plug every 100 hours. Replace the
spark plug if upon inspection the electrode is burned
or worn. Ensure the spark plug is clean. Check the gap
with a wire gauge  and reset to .76 mm or 0.030
in. if necessary. Use only Briggs & Stratton Spark Tester
(part number 19368) to check for spark.


Note: In some areas, local law requires using resistor
spark plug to suppress ignition signals. If this engine
was originally equipped with resistor spark plug, use
same type for replacement.
Fuel Filter
•Drain fuel tank or close fuel shut-off
valve before replacing fuel filter.
Otherwise, fuel can leak out creating a
fire/explosion hazard.
WARNING
When replacing fuel filter, ensure clamps are tight and
fuel flows in the same direction as the arrow marked
FLOW.
Muffler/Fuel System
WARNING
•Replacement parts for muffler and fuel system
(cap, hoses, tanks, filters, etc.) must be the
same and installed in the same position as
original parts, otherwise fire can occur.