Vanguard 540000 series User manual

Revision: A

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Reproduction

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Not for

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This manual contains safety information to make you aware of the hazards and

risks associated with engines and how to avoid them. It also contains instructions

for the proper use and care of the engine. Because Briggs & Stratton, LLC 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. Save these

original instructions for future reference.

Note:The figures and illustrations in this manual are provided for reference only and

may differ from your specific model. Contact your dealer if you have questions.

For replacement parts or technical assistance, record below the engine model, type,

and code numbers along with the date of purchase. These numbers are located on your

engine (see the Features and Controls section).

Date of Purchase

Engine Model - Type - Trim

Engine Serial Number

European Office Contact

Information

For questions regarding European emissions, please contact our European office at:

Max-Born-Straße 2, 68519 Viernheim, Germany.

European Union (EU) Stage

V (5): Carbon Dioxide (CO2)

Values

Carbon dioxide values of Briggs & Stratton® EU Type-Approval Certificate engines can

be found by entering CO2 into the search window on BriggsandStratton.com.

Recycling Information



Recycle all packaging, used oil, and batteries according to

applicable government regulations.

Operator Safety

Safety Alert Symbol and Signal Words

The safety alert symbol identifies 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,couldresult in minor or

moderate injury.

NOTICEindicates information considered important but not hazard-related.

Hazard Symbols and Meanings

Safety information about

hazards that can result in

personal injury.

Read and understand the

Operator's Manual before

operating or servicing the

unit.

Fire hazard Explosion hazard

Shock hazard Toxic fume hazard

Hot surface hazard Noise hazard - Ear protection

recommended for extended

use.

Thrown object hazard -

Wear eye protection.

Explosion hazard

Frostbite hazard Kickback hazard

Amputation hazard -

moving parts

Chemical hazard

Thermal heat hazard Corrosive

Safety Messages

WARNING

Briggs & Stratton® Engines are not designed for and are not to be used to power:

fun-karts; go-karts; children's, recreational, or sport all-terrain vehicles (ATVs);

motorbikes; hovercraft; aircraft products; or vehicles used in competitive events not

sanctioned by Briggs & Stratton. For information about competitive racing products,

see www.briggsracing.com. For use with utility and side-by-side ATVs, please contact

Briggs & Stratton Power Application Center, 1-866-927-3349. Improper engine

application may result in serious injury or death.

WARNING

Fuel 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 the fuel

cap.

• Fill fuel tank outdoors or in well-ventilated area.

• Do not overfill fuel tank. To allow for expansion of the fuel, do not fill above the

bottom of the fuel tank neck.

• Keep fuel 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.

• If fuel spills, wait until it evaporates before starting engine.

When Starting Engine

• Make sure that spark plug, muffler, fuel cap and air cleaner (if equipped) are in

place and secured.

• Do not crank engine with spark plug removed.

• If engine floods, set choke (if equipped) to OPEN / RUN position, move throttle (if

equipped) to FAST position and crank until engine starts.

When Operating Equipment

• Do not tip engine or equipment at angle which causes fuel to spill.

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• Do not choke the carburetor to stop engine.

• Never start or run the engine with the air cleaner assembly (if equipped) or the air

filter (if equipped) removed.

When Changing Oil

• If you drain the oil from the top oil fill tube, the fuel tank must be empty or fuel can

leak out and result in a fire or explosion.

When Tipping Unit for Maintenance

• When performing maintenance that requires the unit to be tipped, the fuel tank, if

mounted on the engine, must be empty or fuel can leak out and result in a fire or

explosion.

When Transporting Equipment

• Transport with fuel tank EMPTY or with fuel shut-off valve in the CLOSED

position.

When Storing Fuel Or Equipment With Fuel In Tank

• Store away from furnaces, stoves, water heaters or other appliances that have

pilot lights or other ignition sources because they can ignite fuel 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

POISONOUS GAS HAZARD. Engine exhaust contains carbon monoxide, a

poisonous gas that could kill you in minutes. You CANNOT see it, smell it, or

taste it. Even if you do not smell exhaust fumes, you could still be exposed

to carbon monoxide gas. If you start to feel sick, dizzy, or weak while using

this product, get to fresh air RIGHT AWAY. See a doctor. You may have carbon

monoxide poisoning.

• Operate this product ONLY outside far away from windows, doors and vents to

reduce the risk of carbon monoxide gas from accumulating and potentially being

drawn towards occupied spaces.

• Install battery-operated carbon monoxide alarms or plug-in carbon monoxide

alarms with battery back-up according to the manufacturer's instructions. Smoke

alarms cannot detect carbon monoxide gas.

• DO NOT run this product inside homes, garages, basements, crawlspaces,

sheds, or other partially-enclosed spaces even if using fans or opening doors and

windows for ventilation. Carbon monoxide can quickly build up in these spaces

and can linger for hours, even after this product has shut off.

• ALWAYS place this product downwind and point the engine exhaust away from

occupied spaces.

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.

• When starting engine, pull the starter cord slowly until resistance is felt and then

pull rapidly to avoid kickback.

• Remove all external equipment / engine loads before starting engine.

• Direct-coupled equipment components such as, but not limited to, blades,

impellers, pulleys, sprockets, etc., must be securely attached.

WARNING

Rotating parts can contact or entangle 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.

WARNING

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.

• Allow muffler, engine cylinder and fins to cool before touching.

• Remove accumulated debris from muffler area and cylinder area.

• It is a violation of California Public Resource Code, Section 4442, to use or

operate the engine on any forest-covered, brush-covered, or grass-covered land

unless the exhaust system is equipped with a spark arrester, as defined in Section

4442, maintained in effective working order. Other states or federal jurisdictions

may have similar laws. Contact the original equipment manufacturer, retailer, or

dealer to obtain a spark arrester designed for the exhaust system installed on this

engine.

WARNING

Unintentional sparking can result in fire or electric shock.

Unintentional start-up can result in entanglement, traumatic amputation, or

laceration.

Fire hazard

Before performing adjustments or repairs:

• Disconnect the spark plug wire and keep it away from the spark plug.

• Disconnect battery at negative terminal (only engines with electric start.)

• Use only correct tools.

• Do not tamper with governor spring, links or other parts to increase engine speed.

• Replacement parts must be of the same design and installed in the same position

as the original parts. Other parts may not perform as well, may damage the unit,

and may result in injury.

• Do not strike the flywheel with a hammer or hard object because the flywheel may

later shatter during operation.

When testing for spark:

• Use approved spark plug tester.

• Do not check for spark with spark plug removed.

Features and Controls

Engine Controls

Compare the illustration (Figure: 1, 2, 3, 4) with your engine to familiarize yourself with

the location of various features and controls.

A. Engine Identification Numbers Model - Type - Code

B. Spark Plug

C. Air Cleaner, Cyclonic

D. Air Cleaner, Low Profile

E. Dipstick

F. Oil Fill

G. Oil Filter

H. Oil Drain Plug

I. Oil Pressure Sensor

J. Finger Guard

K. Electric Starter

L. Starter Solenoid

M. Regulator/Rectifier

N. Carburetor - Carburetor Models

O. Oil Cooler (if equipped)

P. Muffler (if equipped)

Q. Fuel Pump

R. Starter Switch 1

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S. Throttle Control 1

T. Choke Control - Carburetor Models 1

U. Fuel Filter (if equipped)

1 Some engines and equipment have remote controls. See the equipment manual

for location and operation of remote controls.

Engine Control Symbols and Meanings

Engine speed - FAST Engine speed - SLOW

Engine speed - STOP ON - OFF

Engine start - Choke

CLOSED

Engine start - Choke OPEN

Fuel Cap

Fuel Shut-off - OPEN

Fuel Shut-off - CLOSED

Fuel level - Maximum

Do not overfill

Operation

Oil Recommendations

Oil Capacity: See the Specifications section.

NOTICE

Some engines are shipped from Briggs & Stratton with or without oil. Always make

sure that the engine has oil. If you start the engine without oil, it will be damaged

beyond repair and will not be included under the warranty.

We recommend the use of Briggs & Stratton® Warranty Certified oils for best

performance. Other high-quality detergent oils are permitted if classified for service SF,

SG, SH, SJ or higher. Do not use special additives.

Outdoor temperatures determine the correct oil viscosity for the engine. Use the chart

to select the best viscosity for the outdoor temperature range expected. Engines on

most outdoor power equipment operate well with 5W-30 Synthetic oil. For equipment

operated in hot temperatures, Vanguard ® 15W-50 Synthetic oil gives the best

protection.

A SAE 30 - Below 40 °F (4 °C) the use of SAE 30 will result in hard starting.

B 10W-30 - Above 80 °F (27 °C) the use of 10W-30 may cause increased oil

consumption. Checkthe oil level frequently.

C 5W-30

D Synthetic 5W-30

EVanguard ® Synthetic 15W-50

Check Oil Level

See Figure: 5

Before adding or checking the oil

• Make sure the engine is level.

• Clean the oil fill area of any debris.

1. Remove the dipstick (A, Figure 5) and wipe with a clean cloth.

2. Fully install the dipstick (A, Figure 5).

3. Remove the dipstick and check the oil level. Correct oil level is at the top of the full

indicator (B, Figure 5) on the dipstick.

4. If oil level is low, slowly add oil into the engine oil fill (C, Figure 5). Do not overfill.

After adding oil, wait one minute and then recheck the oil level.

5. Fully install the dipstick (A, Figure 5).

Low Oil Protection System (if equipped)

Some engines are equipped with a low oil sensor. If the oil is low, the sensor will either

activate a warning light or stop the engine. Stop the engine and follow these steps

before restarting the engine.

• Make sure the engine is level.

• Check the oil level. See the Check Oil Level section.

• If the oil level is low, add the proper amount of oil. Start the engine and make sure

the warning light (if equipped) is not activated.

• If the oil level is not low, do not start the engine. Contact a Briggs & Stratton

Authorized Service Dealer to have the oil problem corrected.

Fuel Recommendations

Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.

• A minimum of 87 octane/87 AKI (91 RON). High altitude use, see below.

• Gasoline with up to 10% ethanol (gasohol) is acceptable.

NOTICE Do not use unapproved gasolines, such as E15 and E85. Do not mix oil in

gasoline or modify the engine to run on alternate fuels. Use of unapproved fuels will

damage the engine components, which will not be covered under warranty.

To protect the fuel system from gum formation, mix a fuel stabilizer into the fuel.

SeeStorage.All fuel is not the same. If start or performance problems occur, change

fuel providers or brands. This engine is certified to operate on gasoline. The emissions

control system for carbureted engines is EM (Engine Modifications). The emissions

control systems for engines with electronic fuel injection are ECM (Engine Control

Module), MPI (Multi Port Injection), and if equipped an O2S (Oxygen Sensor).

High Altitude

At altitudes over 5,000 feet (1524 meters), a minimum 85 octane/85 AKI (89 RON)

gasoline is acceptable.

For carbureted engines, high altitude adjustment is required to maintain performance.

Operation without this adjustment will cause decreased performance, increased fuel

consumption, and increased emissions. Contact a Briggs & Stratton Authorized Service

Dealer for high altitude adjustment information. Operation of the engine at altitudes

below 2,500 feet (762 meters) with the high altitude adjustment is not recommended.

For Electronic Fuel Injection (EFI) engines, no high altitude adjustment is necessary.

Add Fuel



WARNING

Fuel 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 the fuel

cap.

• Fill fuel tank outdoors or in well-ventilated area.

• Do not overfill fuel tank. To allow for expansion of the fuel, do not fill above the

bottom of the fuel tank neck.

• Keep fuel 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.

Not for

Reproduction

• If fuel spills, wait until it evaporates before starting engine.

1. Clean the fuel cap area of dirt and debris. Remove the fuel cap.

2. Fill the fuel tank (A, Figure6) with fuel. To allow for expansion of the fuel, do not

fill above the bottom of the fuel tank neck (B).

3. Install the fuel cap.

Start and Stop Engine

See Figure: 7

Start Engine

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

When Starting Engine

• Ensure that spark plug, muffler, fuel cap and air cleaner (if equipped) are in place

and secured.

• Do not crank engine with spark plug removed.

• If engine floods, set choke (if equipped) to OPEN / RUN position, move throttle (if

equipped) to FAST position and crank until engine starts.

WARNING

POISONOUS GAS HAZARD. Engine exhaust contains carbon monoxide, a

poisonous gas that could kill you in minutes. You CANNOT see it, smell it, or

taste it. Even if you do not smell exhaust fumes, you could still be exposed to

carbon monoxide gas. If you start to feel sick, dizzy, or weak while using this

product, shut it off and get to fresh air RIGHT AWAY. See a doctor. You may

have carbon monoxide poisoning.

• Operate this product ONLY outside far away from windows, doors and vents to

reduce the risk of carbon monoxide gas from accumulating and potentially being

drawn towards occupied spaces.

• Install battery-operated carbon monoxide alarms or plug-in carbon monoxide

alarms with battery back-up according to the manufacturer's instructions. Smoke

alarms cannot detect carbon monoxide gas.

• DO NOT run this product inside homes, garages, basements, crawlspaces,

sheds, or other partially-enclosed spaces even if using fans or opening doors and

windows for ventilation. Carbon monoxide can quickly build up in these spaces

and can linger for hours, even after this product has shut off.

• ALWAYS place this product downwind and point the engine exhaust away from

occupied spaces.

NOTICE This engine was shipped from Briggs & Stratton without oil. Before you

start the engine, make sure you add oil according to the instructions in this manual.

If you start the engine without oil, it will be damaged beyond repair and will not be

covered under warranty.

Determine The Starting System

Before starting the engine, you must determine the type of starting system that is on

your engine. Your engine will have one of the following types.

•Electronic Fuel Injection (EFI) System: This features Electronic Fuel Injection. It

does not have a choke or a primer.

•Choke System: This features a choke to be used for starting in cool

temperatures. Some models will have a separate choke control while others will

have a combination choke and throttle control. This type does not have a primer.

Note:Equipment may have remote controls. See the equipment manual for location and

operation of remote controls.

Electronic Fuel Injection (EFI) System

1. Check the engine oil. See the Check Oil Level section.

2. Make sure equipment drive controls, if equipped, are disengaged.

3. Move the fuel shut-off (A, Figure 7), if equipped, to the OPEN position.

4. Move the throttle control (B, Figure 7), if equipped, to the FAST position. Operate

the engine in the FAST position.

5. Push the stop switch (D, Figure 7), if equipped, to the ON position.

6. Turn the electric start switch (E, Figure 7) to the ON or START position.

NOTICE To extend the life of the starter, use short starting cycles (five seconds

maximum). Wait one minute between starting cycles.

Note:If the engine does not start after repeated attempts, contact you local dealer or go

to VanguardEngines.com or call 1-800-999-9333 (in USA).

Choke System

1. Check the engine oil. See the Check Oil Level section.

2. Make sure equipment drive controls, if equipped, are disengaged.

3. Move the fuel shut-off (A, Figure 7), if equipped, to the OPEN position.

4. Move the throttle control (B, Figure 7), if equipped, to the FAST position. Operate

the engine in the FAST position.

5. Move the choke control (C, Figure 7), or the combination choke and throttle, to the

CLOSED position.

Note:To start the engine with a dry fuel system (first time starting or after running out of

fuel), additional cranking time in the choke position will be required. This will give the fuel

pump time to prime the fuel system.

6. Push the stop switch (D, Figure 7), if equipped, to the ON position.

7. Turn the key switch (E, Figure 7) to the ON or START position.

8. If the engine fires but will not continue to run, move the choke control (C, Figure 7)

to the OPEN position to start the engine.

NOTICE To extend the life of the starter, use short starting cycles (five seconds

maximum). Wait one minute between starting cycles.

9. As the engine warms up, move the choke control (C, Figure 7) to the OPEN

position.

Note:If the engine does not start after repeated attempts, contact you local dealer or go

to VanguardEngines.com or call 1-800-999-9333 (in USA).

Stop Engine

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

• Do not choke the carburetor to stop the engine.

1. Stop Switch, if equipped: Move the stop switch (D, Figure 7) to the OFF position.

Key Switch, if equipped: With the throttle control in the SLOW position, turn the

key switch (E, Figure 7) to the OFF position. Remove the key and keep in a safe

place out of the reach of children.

2. After the engine stops, move the fuel shut-off (A, Figure 7), if equipped, to the

CLOSED position.

Maintenance

NOTICE If the engine is tipped during maintenance, the fuel tank, if mounted on

engine, must be empty and the spark plug side must be up. If the fuel tank is not

empty and if the engine is tipped in any other direction, it may be difficult to start due

to oil or gasoline contaminating the air filter and/or the spark plug.

WARNING

When performing maintenance that requires the unit to be tipped, the fuel tank, if

mounted on the engine, must be empty or fuel can leak out and result in a fire or

explosion.

We recommend that you see any Briggs & Stratton Authorized Service Dealer for all

maintenance and service of the engine and engine parts.

NOTICE All the components used to build this engine must remain in place for

proper operation.

WARNING

Unintentional sparking can result in fire or electric shock.

Unintentional start-up can result in entanglement, traumatic amputation, or

laceration.

Fire hazard

Before performing adjustments or repairs:

• Disconnect the spark plug wire and keep it away from the spark plug.

• Disconnect battery at negative terminal (only engines with electric start).

• Use only correct tools.

• Do not tamper with governor spring, links or other parts to increase engine speed.

Not for

Reproduction

8 VanguardEngines.com

• Replacement parts must be of the same design and installed in the same position

as the original parts. Other parts may not perform as well, may damage the unit,

and may result in injury.

• Do not strike the flywheel with a hammer or hard object because the flywheel may

later shatter during operation.

When testing for spark:

• Use approved spark plug tester.

• Do not check for spark with spark plug removed.

Emissions Control Service

Maintenance, replacement, or repair of the emissions control devices and

systems may be performed by any off-road engine repair establishment or

individual. However, to obtain "no charge" emissions control service, the work must be

performed by a factory authorized dealer. See the Emissions Control Statements.

Maintenance Schedule

Every 8 Hours or Daily

• Check engine oil level

• Clean area around muffler and controls

Every 100 Hours or Annually

• Replace spark plugs

• Change engine oil

• Replace oil filter (if equipped)

•Service air filter 1, 2

•Clean pre-cleaner (if equipped) 1

• Service exhaust system

Every 250 Hours

• Check valve clearance. Adjust if necessary.

Every 400 Hours or Annually

•Replace air filter 2

• Replace fuel filter

•Service cooling system 1

•Clean oil cooler fins 1

Every 600 Hours or Annually

• Replace safety filter (if equipped)

1 In dusty conditions or when airborne debris is present, clean more often.

2 Every third air filter change, replace the inner safety filter (if equipped).

Electronic Fuel Injection (EFI) System

The EFI System monitors engine temperature, engine speed, and battery voltage for

engine starting and warm up. There are no adjustments on the system. If starting or

operation problems occur, contact a Briggs & Stratton Authorized Service Dealer.

NOTICE Make sure to follow the steps below or the EFI System could be damaged.

• Never start the engine if the battery cables are loose.

• Turn the key to the off position before disconnecting, removing and or installing the

battery.

• Never use a battery charger to start the engine.

• Never disconnect the battery cables while the engine is running.

• When connecting the battery cables, first connect the positive (+) cable and then

connect the negative (-) cable to the battery.

• When charging the battery, turn the ignition switch to the off position and

disconnect the negative (-) battery cable from the battery.

• Do not spray water directly on the Electronic Control Module.

Carburetor and Engine Speed

Never make adjustments to the carburetor or engine speed. The carburetor was set at

the factory to operate efficiently under most conditions. Do not tamper with the governor

spring, linkages, or other parts to change the engine speed. If any adjustments are

required contact a Briggs & Stratton Authorized Service Dealer for service.

NOTICE The equipment manufacturer specifies the maximum speed for the engine

as installed on the equipment.Do not exceedthis speed. If you are not sure what the

equipment maximum speed is, or what the engine speed is set to from the factory,

contact a Briggs & Stratton Authorized Service Dealer for assistance. For safe and

proper operation of the equipment, the engine speed should be adjusted only by a

qualified service technician.

Service Spark Plug

See Figure:8

Check the gap (A, Figure8) with a wire gauge (B). If necessary, reset the gap. Install

and tighten the spark plug to the recommended torque. For gap setting or torque, see

theSpecificationssection.

Note:In some areas, local law requires using a resistor spark plug to suppress ignition

signals. If this engine was originally equipped with a resistor spark plug, use the same

type for replacement.

Service Exhaust System