Briggs & Stratton Vanguard 540000 Series Operating and installation instructions

ADVANCEPRODUCT
SERVICEINFORMATION
INFORMATIONBULLETIN NO.42 DATE:7-03-2003
SUBJECT:31 HPAirCooledV-TwinEngineFILEIN:272144
IntroducingthenewBriggs&StrattonVanguardt31 HP,V-TwinOHVEngine,ModelSeries540000.Thisisthe
largest2-cylinderaircooledengineBriggs&Stratton haseverproduced,deliveringhorsepowerandtorquenumbers
rivalingthebest2-cylinderliquidcooledenginesbutinalighter,less expensive,easiertomaintainpackage.It
featuresfull pressurelubrication,aDonaldson2StageCyclonicaircleaner,aSuperLo-Tonemufflersystem,and
thenewAdvancedDebrisManagementSystemt.Afull twoyearcommercial-usewarrantyapplies.Thefollowing
preliminaryservicespecificationsaresubject tochange.
VanguardModelSeries540000
AirFilter-Primary(Outer)
CommonMaintenanceParts
809670
AirFilter-Safety(Inner)
FuelFilter
FuelStabilizer(4.2oz.)
Oil -4-Cycle30W(48 oz.)
Oil Filter
Oil PumpKit(RemovesOil FromEngine)
SparkPlug
SparkPlugWrench
SparkTester
821136
691035 or5065D
100002 or5041D
Oil -4-Cycle5W-30 Synthetic(32 oz.)
100028
100074
492932sor5049D
5056D
692051
89838 or5067D
19368
CommonSpecifications
AirCleanerType2StageCyclonic
AlternatorOutput&Type20 Amp-Regulated
ArmatureAirGap0.005 -0.007”(0.13 -0.18 mm)
Bore3.366”(85.5mm)
BoreTypeCastIronSleeve
CompressionRatio8.25:1
CrankshaftEndPlay.002 -.012”(.05 -.30 mm)
Displacement54 ci.(895 cc)
FuelFilterTypeSpin-OnCartridge
GovernorSystemMechanical
LubricationSystemFull Pressure
MaximumHorsepower@3600 PRM31
MaximumTorque@2400 RPM47 ft-lbs.
MufflerSystem5”Round-SingleOutlet
Oil Capacity-withFilter79 oz.(2.3L)
Oil Capacity-withoutFilter71 oz.(2.1L)
Oil Fill StyleInValveCover
SparkPlugGap0.020”(0.51 mm)
Stroke3.071”(78.0mm)
TimingSetting23°BTDC
ValveClearance(Cold)-Int.andExh.0.004 -0.006”(0.10 -0.15 mm)
Not for
Reproduction

FastenerSpecifications
DescriptionWrench/SocketSizeTorque
AirCleanerMounting12 mm 90 in-lbs(10 Nm)
AirGuideMountingScrews10 mm 90 in-lbs(10 Nm)
AirBlockPlateMountingScrewsPhillips30 in-lbs(3Nm)
AlternatorHarness ClampScrew10 mm 90 in-lbs(10 Nm)
BackplateMountingScrews10 mm 90 in-lbs(10 Nm)
BlowerHousingNutstoStuds10 mm 90 in-lbs(10 Nm)
BlowerHousingStudstoCylinder12 mm 90 in-lbs(10 Nm)
BreatherCover8mm 30 in-lbs(3Nm)
CarburetorIntakeElbowtoCarburetor10 mm 35 in-lbs(4Nm)
CarburetortoIntakeManifold10 mm 90 in-lbs(10 Nm)
ConnectingRod10 mm 125 in-lbs(14 Nm)
CrankcaseCover13 mm 200 in-lbs(23 Nm)
CylinderHead14 mm 350 in-lbs(40 Nm)
ExhaustManifold(Muffler)12 mm /T40 180 in-lbs(20 Nm)
FlywheelFanScrews10 mm 90 in-lbs(10 Nm)
FlywheelNut32 mm 125 ft-lbs(169 Nm)
FuelPump8mm 45 in-lbs(5Nm)
GovernorControlBracket12 mm 90 in-lbs(10 Nm)
GovernorLeverNut10 mm 70 in-lbs(8Nm)
IgnitionArmature7mm 30 in-lbs(3Nm)
IntakeManifold10 mm 90 in-lbs(10 Nm)
ManifoldHeatShieldtoMuffler10 mm 90 in-lbs(10 Nm)
Oil DrainPlug16 mm 180 in-lbs(20 Nm)
Oil PickuptoPump10 mm 90 in-lbs(10 Nm)
Oil PressureSwitch26 mm -12 pt80 in-lbs(9Nm)
Oil PumpBaffle10 mm 90 in-lbs(10 Nm)
Oil PumptoCrankcaseCover10 mm 90 in-lbs(10 Nm)
Regulator/Rectifier10 mm 90 in-lbs(10 Nm)
RockerArmLockNut13 mm 70 in-lbs(8Nm)
RockerArmStud10 mm 100 in-lbs(11 Nm)
RotatingScreenScrews4mm 100 in-lbs(11 Nm)
RotatingScreenStuds13 mm 125 in-lbs(14 Nm)
SparkPlug5/8”180 in-lbs(20 Nm)
StarterMotortoCylinder12 mm 130 in-lbs(15 Nm)
ValveCover10 mm 70 in-lbs(8Nm)
Not for
Reproduction

StandardandRejectDimensions
DescriptionStandardDimensionRejectDimension
Cylinder
PistonBore3.366”(85.50 mm)3.369”(85.57 mm)
Out-of-Round.0015”(.04 mm)
MagBearing1.775”(45.09 mm)1.7765”(45.12 mm)
CamBearing.788”(20.02 mm).790”(20.07 mm)
CylinderHead
ValveSeatAngle(IntakeandExhaust)45°
ValveGuide(IntakeandExhaust).237”(6.02 mm).240”(6.09 mm)
ValveStem(IntakeandExhaust).234”(5.94 mm).233”(5.92 mm)
CrankcaseCover
PTOBearing1.775”(45.09 mm)1.7765”(45.12 mm)
CamBearing.788”(20.02 mm).790”(20.07 mm)
Crankshaft
CrankpinJournal1.654”(42.01 mm)1.6525”(41.97 mm)
Mag,PTOJournals1.771”(44.98 mm)1.7695”(44.95 mm)
Camshaft
Mag,PTOJournals.786”(19.96 mm).7845”(19.93 mm)
ConnectingRod
CrankpinBearing1.656”(42.06 mm)1.658”(42.11 mm)
PistonPinBearing.828”(21.03 mm).8285”(21.04 mm)
Piston
PistonPin.8268”(21.00 mm).8258”(20.98 mm)
PistonPinBearing.8271”(21.01 mm).8281”(21.03 mm)
PistonRing
EndGap-Top.007 -.013”(.20 -.35 mm).030”(.76 mm)
Center.013 -.021”(.35 -.55 mm).030”(.76 mm)
Oil .007 -.027”(.20 -.70 mm).040”(1.0mm)
SideClearance-Top.003”(.07 mm).006”(.15 mm)
Center.002”(.05 mm).005”(.13 mm)
Oil .0015”(.04 mm).004”(.10 mm)
AirCleaningSystemMaintenance
NOTE:TheVacuatortt Valve(5)
automaticallydischargesdust
and debris.Thereshould be
minimaldebrisfor removal.
DONOTremovethesafety
filter(2)unless theairclean-
erhousinghasbeenthor-
oughlycleanedout.
1.Removedebrisfromtheaircleaner
cover(4)bysqueezingthe endsofthe
VacuatortValve(5).
2.Removethecoverfromtheaircleaner
housing(1).
3.Removetheprimary(3)filterandin-
spect.Replacethefilterifdamagedor
dirty.
NOTE:Replacethesafetyfilterwith
everythirdreplacementof
theprimaryfilter.
4.Reinstall filter(s).
5.Reinstall aircleanercover.
3
4
5
1
2
Not for
Reproduction

AirCoolingSystemMaintenance
WARNING
SWeareyeprotectionwheneverusing
compressedairtocleanthe engine.
AVOIDEYEINJURY!
ThisenginehastheAdvancedDebrisManagementSystemtthatreduces chafbuildup byusingtherotatingscreentocut
airbornedebrisintosmall piecesthatare easilypassedthroughthecoolingsystem.TheEasyCleanAccesstallowsyou
tocleanthecoolingfinswithouthavingtoremovetheblowerhousing.Tocleanthecoolingfins see below.
6.Useacoinorscrewdrivertotwisteach
EasyCleanAccesstpanelfastener(1)
COUNTERCLOCKWISEuntil it
“CLICKS”(approx.1/2turn).
7.RemovetheEasyCleanAccesstpanel
(2).
8.Usecompressedairtocleanthecoolingfins
aroundeachcylinder(3),andtobackflush
thecoolingsystem.
9.Insert theaccess paneltab(5)intothe
blowerhousingslot(4).Becertaintheac-
cess panel is correctlyengagedtothecool-
inghousing.Pushtheaccess panelcom-
pletelyintothehousing.Twisteachaccess
panelfastener(1)CLOCKWISEuntil it
“CLICKS”(approx.1/2turn).
CAUTION:DONOTrun the engineunless the
EasyCleanAccesstt panel iscorrectlyinstalled.
3
4
5
2
1 1
3
1
BRIGGS&STRATTONCORPORATION
DistributionSales&CustomerSupportDivision
Not for
Reproduction