Briggs & Stratton Vanguard 610000 User manual

Operator’s Manual
Vanguard
Model 540000 Model 610000
BRIGGSandSTRATTON.com
ECopyright Briggs & Stratton Corporation
Milwaukee, Wisconsin 53201 U.S.A.
Form No. 277112-9/06
Printed in U.S.A.
Vanguard

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 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 9-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications and Emission Information 16. . . . . . . . . . .
Warranty Information 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYMBOLS ASSOCIATED
WITH THIS ENGINE:
Explosion
Toxic Fu m es
Moving Parts
Shock
Hot Surface
Kickback
Fire
Fuel Shutoff
Read
Manual
Choke
Oil
Fuel
On Off
Stop
Wear Eye
Protec-
tion
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. Air cleaner (standard)
2. Air cleaner (optional)
3. Front panel (standard)
4. Front panel with controls (optional)
5. Throttle control (optional)
6. Choke control (optional)
7. Key switch (optional)
8. Carburetor / LPG or NG fuel mixer
9. Fuel pump
10. Breather
11. Spark plug
12. Engine Model no. label
13. Oil pressure sensor
14. Oil filter
15. Oil cooler
16. Oil drain plug
17. Rotating screen
18. Oil level dipstick
19. Oil fill cap
20. Regulator or rectifier
21. Electric starter
22. Remote throttle locations
23. Muffler
8
18
14
15
3
16
1
7
19
12
20
10
2
7
6
5
4
9
11
1
13
21
22
23

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
Gaseous fuels, such as liquid
petroleum gas (LPG) and natural
gas (NG), are extremely flammable
and can readily form explosive
air-vapor mixtures at moderate
temperatures.
WARNING
IF YOU SMELL GAS:
•DO NOT start the engine.
•DO NOT actuate any electrical switches.
•DO NOT use the phone in the vicinity.
•Evacuate the area.
•Contact the gas supplier or fire department.
REMEMBER:
•LPG vapor is heavier than air and tends to
collect in low areas. NG vapor is lighter then
air and tends to collect in high areas. Both may
travel to remote locations.
•Keep all flames, sparks, pilot lights and other
ignition sources away from the area where the
engine is operated or repaired.
•DO NOT smoke when operating or repairing
the engine.
•DO NOT store gasoline or other flammable
vapors or liquids in the vicinity of the engine.
•BEFORE doing any service work to the
engine, shut off the gas supply.
•After initial installation or servicing, check for
gas leaks. DO NOT use an open flame. Apply
very soapy water or leak test solution with a
brush and look for bubbles.
•Keep the equipment and the area surrounding
the engine free of debris.
•Install the fuel system according to applicable
fuel/gas codes.
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.

5
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.
•When starting engine, pull cord slowly until
resistance is felt, then pull rapidly.
•Direct coupled equipment components such
as, but not limited to, blades, impellers,
pulleys, sprockets, etc., must be securely
attached.
WARNING
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
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
Wear eye protection when doing
repair work.
Frostbite can result from skin/eye
contact with leaking LP liquid.
•Installation, adjustment and repair work
should be done by a qualified technician.
•Flexible supply lines should be checked
regularly to make sure they are in good
condition. Replace damaged or leaking
components.
WARNING

6
Before Starting
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.
°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
* 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
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.
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.
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.
Oil Pressure
If oil pressure drops below 1−4 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.

7
Before Starting
Fuel
Gasoline Powered Engines
•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.
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
Liquid Propane Gas (LPG)
Natural Gas (NG) Powered Engines
•Use clean, dry fuel, free of moisture or any
particulate material. Using fuels outside the
following recommended values may cause
performance problems.
•In engines set to run on LPG, commercial grade
HD5 LPG is recommended. Recommended fuel
composition is fuel with a minimum fuel energy of
2500 BTU’s/ft#with maximum propylene content
of 5% and butane and heavier gas content of
2.5% and minimum propane content of 90%.
•LPG or NG engines are certified to operate on
liquid propane gas or natural gas. Exhaust
Emission Control System: EM (Engine
Modifications).
Adding Fuel
Read the operating instructions supplied by the
equipment manufacturer for information on refueling
natural or LP gas engine.
LPG/NG Engines: The equipment on
which this engine is mounted is
equipped with an automatic safety gas
“fuel lock-off” valve. DO NOT operate
the equipment if the “fuel lock-off” valve
is missing or inoperative.
WARNING

8
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.)
•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.
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.
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.
Note: If choke equipped, slowly adjust toward RUN
position. Wait until engine runs smoothly before each
choke adjustment.
Liquid Propane Gas (LPG)
Natural Gas (NG) Powered Engines
1. Insert key and turn to START.
2. Let engine warm up.
Use short starting cycles (5 seconds, wait one
minute between cycles). Follow equipment
manufacturer’s recommendations for charging
battery.
CAUTION
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
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

9
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.
Wear eye protection when doing repair
work.
Frostbite can result from skin/eye
contact with leaking LP liquid.
WARNING
•Installation, adjustment and repair work should
be done by a qualified technician.
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
On NG / LPG Engines
−Check Valve Clearance
On Gasoline Engines
−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 50 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.

10
Changing Oil and Oil Filter
Change oil after first 5 to 8 hours of use, then every
100 hours. Change oil every 50 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.