Briggs & Stratton Classic 100000 Series Installation and operation manual

BRIGGS Operating & Maintenance
Instructions
Model Series
Covered in
This Manual
90000
100000
[Model Type Code 1
Note: General Model Series numbers noted above are inclusive of the specific model
number found on your engine. To get replacement parts or technical assistance in
the future, write your engine Model, Type, Code and date of purchase here. fl°ith/ _aY ( Yiar
TABLE OF CONTENTS
Safety ................................. 3-5
Engine Information ........................ 6
Oil ....................................... 7
Fuel ..................................... 8
Starting Information ....................... 9
Starting and Stopping ..................... 10
Maintenance ......................... 11-13
Adjustments ............................. 14
Parts and Service & Storage ............ 15-16
Warranty Information ..................... 17
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 applications
could result in property damage, serious injury (including
paralysis), or even death.
PRINTED iN U.S.A. c_)Copyright 2003 by Briggs & Stratton Corporation FORM NO. 275508-5/03

The Power That Works For You. TM
Thank you for selecting a Briggs & Stratton engine to power your equipment.
Briggs & Stratton is committed to producing a line of engines which will make your life's chores easier to
perform. We have, at the same time, improved the design of our engines so they are environmentally
friendly. Since 1995, we have succeeded in reducing smog-forming exhaust emissions from our engines
by 70%. Briggs & Stratton's efforts have not stopped there. We are also committed to designing and
introducing even cleaner engines in the future, while maintaining our reputation for excellent utility and
value.
Briggs & Stratton's environmental awareness has resulted in the engineering of the "Smart-Fillc_" gas
can, featuring a spill resistant nozzle which opens only when fully inserted into the gas tank, and which
shuts off automatically when the tank is full. Because refueling spills can harm the environment, the
Smart-Fill_e container helps preserve a stronger ecosystem by reducing this source of pollution.
We hope you will enjoy your new engine and equipment. We welcome you to our worldwide family of
Briggs & Stratton engine users.
Best Wishes Always,
The Employees of Briggs & Stratton Corporation
This is a generic representation
of the emissionlabel typically
found on a certified engine.
FAMILYYBSXS.14_1HH 274459

I, _F_]I BEFORE OPERATING ENGINE
• Read entire Operating & Maintenance Instructions AND
the instructions for the equipment this engine powers.*
• Failure to follow instructions could result in serious injury
or death.
275508
THE OPERATING & MAINTENANCE INSTRUCTIONS
CONTAIN SAFETY INFORMATION TO
• Make you aware of hazards associated with engines
• Inform you of the risk of injury associated with those hazards, and
• Tell you how to avoid or reduce the risk of injury.
\
The safety alert symbol _m, lL )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.
_k 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.
WARNING
The engine exhaust from this prod-
uct contains chemicals known to the
State of California to cause cancer,
birth defects, or other reproductive
harm.
HAZARD SYMBOLS AND MEANINGS
Fire Explosion Moving Parts
Toxic Fumes Hot Surface Shock
Kickback
THE INTERNATIONAL SYMBOLS USED
ON THE ENGINE OR
Oil Stop Fuel Shutoff Choke Fuel
Briggs & Stratton does not necessarily know what equipment this engine will power. For that reason, you should carefully read
and understand the operating instructions for the equipment on which your engine is placed.

SAFETY [B,, GsSTRA O.]
, WARNING
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. Fill tank to approximately
1-1/2 inches below top of neck to allow for fuel
expansion.
• 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 tip engine or equipment at angle which
causes gasoline to spill.
• Do not choke carburetor to stop engine.
WHEN TRANSPORTING EQUIPMENT
• Transport with fuel tank EMPTY or with fuel shut-off
valve OFF.
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
• 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
• When starting engine, pull cord slowly until
resistance is felt, then pull rapidly.
• Remove all external equipment/engine loads
before starting engine.
• Direct coupled equipment components such as,
but not limited to, blades, impellors, pulleys,
sprockets, etc., must be securely attached.
, WARNING
• 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.

I B. GSST.A O.JSAFETY
WARNING
•Start and run engine outdoors.
•Do not start or run engine in enclosed area, even if
doors or windows are open.
WARNING
i
• Allow muffler, engine cylinder and fins to cool
before touching.
• Remove accumulated combustibles 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.
, WARNING
;>lJill
I
ill=
BEFORE PERFORMING ADJUSTMENTS OR
REPAIRS
• Disconnect spark plug wire and keep it away from
spark plug.
• Disconnect battery at negative terminal (only
engines with electric start).
WHEN TESTING FOR SPARK
• Use approved spark plug tester.
• Do not check for spark with spark plug removed.
[ BRIG S&StrA'rrorJENGINE INFORMATION I
TECHNICAL INFORMATION
POWER RATINGS: The power ratings for an individual engine
model are initially developed by starting with SAE (Society of Auto-
motive Engineers) code J1940 (Small Engine Power & Torque
Rating Procedure) (Revision 2002-05). Given both the wide array
of products on which our engines are placed, and the variety of en-
vironmental issues applicable to operating the equipment, it may
be that the engine you have purchased will not develop the rated
horsepower when used in a piece of power equipment (actual "on-
site" power). This difference is due to a variety of factors including,
but not limited to, the following: differences in altitude, tempera-
ture, barometric pressure, humidity, fuel, engine lubrication, maxi-
mum governed engine speed, individual engine to engine variabil-
ity, design of the particular piece of power equipment, the manner
in which the engine is operated, engine run-in to reduce friction
and clean out of combustion chambers, adjustments to the valves
and carburetor, and other factors. The power ratings may also be
adjusted based on comparisons to other similar engines utilized
in similar applications, and wil! therefore not necessarily match the
values derived using the foregoing codes.

I ENGINE INFORMATION
1. Carburetor
2. Air cleaner
3. Rope handle
4. Finger guard
5. Oil fill/Dipstick
6. Enoine Model Type Code
XXXXX XXXX XX XXXXXXXX
7. Muffled(Muffler guard, if equipped)/
(Spark arrester, if equipped)
8. Spark plug wire
9. Governor control lever
10. Primer bulb
11. Fuel tank
12. Fuel fill
13. Flywheel
GENERAL INFORMATION
This is a single cylinder, L-head, air-cooled engine. It is a
low emissions engine.
MODEL SERIES 90000
Bore .......................... 2-9/16 in. (65.09 mm)
Stroke ......................... 1-3/4 in. (44.45 mm)
Displacement .................. 9.02 cu. in. (147.8 cc)
MODEL SERIES 100000
Bore .......................... 2-9/16 in. (65.09 mm)
Stroke ......................... 1-7/8 in. (47.63 mm)
Displacement .................. 9.67 cu. in. (158.6 cc)
TUNE-UP SPECIFICATIONS
Armature air gap . .. 0.006 - 0.010 in. (0.15 - 0.25 mm)
Spark plug gap .................. 0.030 in. (0.76 mm)
Valve clearance with valve springs installed and piston 1/4 in.
(6 mm) past top dead center (check when engine is cold).
See Repair Manual P/N 270962.
Intake ............. 0.005 - 0.007 in. (0.13 - 0.18 mm)
Exhaust ........... 0.007 - 0.009 in. (0.18 - 0.23 mm)
Note: For practical operation, the horsepower loading
should not exceed 85% of rated horsepower. Engine power
will decrease 3-1/2% for each 1,000 feet (300 meters)
above sea level and 1% for each 10° F (5.6° C) above 77° F
(25 ° C). It will operate satisfactorily at an angle up to 15°.

275508
OlL
CAUTION: This engine is shipped from Briggs &
Stratton without oil. Check oil level before starting
engine. If you start the engine without oil, the engine
will be damaged beyond repair and will not be
covered under warranty. _ i[i]'iT_D]
OIL CAPACITY
The engine holds approximately 5/8 qt (20 ozs; 0.6 liter).
TYPE OF OIL TO USE
• Use a high quality detergent oil classified "For Service
SF, SG, SH, SJ" or higher, such as Briggs &Stratton
SAE 30.
• Do not use special additives.
• Choose a viscosity according to the table opposite.
Note: Synthetic oil meeting ILSAC GF-2, API
certification mark and API service symbol
(shown at left) with "SJ/CF ENERGY CON-
SERVING" or higher, is an acceptable oil at all
temperatures. Use of synthetic oil does not
alter required oil change intervals.
SAE Viscosity Grades
**i
I I
=_F20 t 22 s_41 6o so 11o
_'O n0 _0 1_} 0 1_ 2_0 _0 4_0
STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
CAUTION: 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.
CAUTION: SAE 30 oil, if used below 40° F (4° C), will
result in hard starting and possible engine bore
damage due to inadequate lubrication.
CHECKING AND ADDING OIL
• Check oil level before starting the engine.
• Check level daily, or after every eight (8) hours.
• Keep oil level at FULL.
CAUTION: Do not overfill. Overfilling with oil may cause:
Smoking,
Hard starting,
Spark plug fouling, or
Oil saturation of air filter.
High Oil Fill
(if equipped)
[1] Place engine level and
clean around oil fill area.
[2] Remove dipstick and wipe clean with cloth.
[3] Replace and tighten dipstick. Remove and
check oil level. Oil level should be at FULL
line on dipstick.
[4]
[5]
If needed, add oil slowly -
recheck. Do not over fill.
Replace and tighten dipstick.
Low Oil Fill
(if equipped)
[1] Place engine level and
clean around oil fill area.
[2] Remove dipstick and wipe clean with cloth.
[3] Replace and tighten dipstick. Remove and
check oil level. Oil level should be at FULL
line on dipstick.
[4]
[5]
If needed, add oil slowly -
recheck. Do not over fill.
Replace and tighten dipstick.

FUEL _BRIGGS & STRATrONJ
TYPE OF FUEL TO USE
•Use clean, fresh, regular unleaded gasoline with a
minimum of 77 octane. Fresh fuel prevents gum from
forming in thefuel system or on essential carburetor parts.
Purchase fuel in quantity that can be used within 30 days.
• Do not use gasoline which contains Methanol.
• Do not mix oil with gasoline.
• For engine protection use Briggs & Stratton Gasoline
Additive available from your Authorized Briggs &
Stratton Dealer.
• This engine is certified to operate on gasoline. Exhaust
Emission Control System: EM (Engine Modifications).
CAUTION: 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 oper-
ating symptoms occur, use gasoline with a lower
percentage of alcohol or ether.
ADDING FUEL
, WARNING
• Turn engine OFF and let engine cool at least 2
minutes before removing gas cap.
• Fill fuel tank outdoors or in well-ventilated area.
• Keep gasoline away from sparks, open flames,
pilot lights, heat, and other ignition sources.
• If fuel spills, wait until it evaporates before
starting engine.
Fuel Fill
Neck
[1] Remove cap. Fill tank to approximately 1-1/2
inches below top of neck to allow for fuel
expansion. Be careful not to overfill.
Briggs & Stratton Smart-fill® fuel can fills to the
correct level and automatically shuts off, reduc-
ing spills and emissions.
[2] Replace cap before starting.

STARTI NG
WARNING
•Do not use pressurized starting fluids.
• Vapors are flammable.
• 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.
•Store and fuel • Periodically remove
equipment in level grass buildup under
position, mower deck. (See
•Use fresh fuel. (See Maintenance.)
Fuel.)
•Use correct type of
oil for expected
starting tempera-
ture. (See Oil.)
• Remove external
equipment/engine
loads. (See equip-
ment operating
instructions.)
• Start lawn mower
on hard surface or
over previously cut
grass.
•After engine has
started, let it warm
up several seconds
to several minutes
depending on out-
side temperature.
• For maximum per-
formance and life,
operate engine with
throttle in FAST.
If you are starting your engine for the
FIRST time, read the information
outlined under Starting A New Engine.
CAUTION:
This engine is shipped from Briggs & Stratton
without oil. Check oil level before starting engine.
If you start the engine without oil, the engine will be
damaged beyond repair and will not be covered
under warranty.
CAUTION:
If engine is tipped to transport equipment, remove
grass, drain oil, etc., keep spark plug side of
engine uJ2. Tipping engine with spark plug down
may cause:
• Smoking,
• Hard starting,
• Spark plug fouling,
• Oil saturation of air filter.
KEEP SPARK PLUG UP
\
STARTING ANEW ENGINE
Add oil and fuel as instructed in this manual prior to
attempting to start engine. (See Oil and Fuel)
[1] Move throttle to FAST.
(if equipped)
[2] Firmly push primer bulb 5 times.
Continue at step [4] under TO START ENGINE.
Primer
bulb

STARTING AND STOPPING
REWIND (MANUAL) STARTER
TO START ENGINE
When starting engine thereafter, push primer bulb firmly 3 times as illustrated below and pull starter rope as instructedbelow.
[1] Check oil level (see p. 8).
[2] Move throttle
(if equipped) to FAST.
[3] Firmly push primer
bulb 3 times.
[4]
Primer
bulb
Close safety brake handle on lawn mowers
and any other equipment with this feature.
[5] Grasp rope handle. Pull slowly until resistance is
felt, then pull rapidly to start engine and avoid
kickback.
_,WARNING • When starting engine,
pull cord slowly until
resistance is felt, then
pull rapidly.
[6] Let engine warm up.
Operate engine with
throttle in FAST.
I I
TO STOP ENGINE
CAUTION:
Do not stop engine by
moving choke control
to CHOKE. Backfire,
fire or engine damage
could occur.
[1]
I I
I I
Move throttle (if equipped)
to SLOW, then [2] Release safety brake con-
trol handle.
10