Briggs & Stratton 90000 series User manual

Operator’s Manual

BRIGGSandSTRATTON.com

ECopyright Briggs & Stratton Corporation

Milwaukee, Wisconsin 53201 U.S.A.

Form No. 277098-9/06

Printed in U.S.A.

Model 90000 I/C 475/525 Series

Power Built 475/525 Series

TABLE OF CONTENTS

Safety 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Information 4-5. . . . . . . . . . . . . . . . . . . . . . . . .

Oil 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping 8. . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 9-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service & Storage 13. . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Information 14-17. . . . . . . . . . . . . . . . . . . .

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 “Engine Information” page).

Date of purchase:

Engine model:

MM / DD / YYYY

Model: Code:Type:

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.

THE OPERATING & MAINTENANCE INSTRUC-

TIONS 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.

*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.

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.

WARNING

The engine exhaust from this product

contains chemicals known to the

State of California to cause cancer,

birth defects, or other reproductive

harm.

HAZARD SYMBOLS AND MEANINGS

Explosion

Toxic Fumes

Moving Parts

ShockHot Surface

Kickback

Fire

THE INTERNATIONAL SYMBOLS USED

ON THE ENGINE OR

IN THIS MANUAL INCLUDE:

On Off

Fuel Shutoff

Read Owner’s

Manual

Stop Fuel

Choke

Safety Alert

Oil

Frostbite

Wear Eye Protection

SAFETY

Gasoline and its vapors are extremely

flammable and explosive.

Fire or explosion can cause severe burns

or death.

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.

Starting engine creates sparking.

Sparking can ignite nearby flammable

gases.

Explosion and fire could result.

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

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.

•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

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.

SAFETY

Engines give off carbon monoxide, an

odorless, colorless, poison gas.

Breathing carbon monoxide can cause

nausea, fainting or death.

WARNING

•Start and run engine outdoors.

•Do not start or run engine in enclosed area, even if

doors or windows are open.

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 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

Unintentional sparking can result in fire or

electric shock.

Unintentional start-up can result in en-

tanglement, traumatic amputation, or lac-

eration.

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.

ENGINE INFORMATION

TECHNICAL INFORMATION

Engine Power Rating Information

The gross power rating for individual gas engine models

is labeled in accordance with SAE (Society of Automotive

Engineers) code J1940 (Small Engine Power & Torque

Rating Procedure), and rating performance has been

obtained and corrected in accordance with SAE J1995

(Revision 2002-05). Actual gross engine power will be

lower and is affected by, among other things, ambient

operating conditions and engine-to-engine variability.

Given both the wide array of products on which engines

are placed and the variety of environmental issues

applicable to operating the equipment, the gas engine

will not develop the rated gross power when used in a

given piece of power equipment (actual “on-site” or net

horsepower). This difference is due to a variety of factors

including, but not limited to, accessories (air cleaner,

exhaust, charging, cooling, carburetor, fuel pump, etc.),

application limitations, ambient operating conditions

(temperature, humidity, altitude), and engine-to-engine

variability. Due to manufacturing and capacity limitations,

Briggs & Stratton may substitute an engine of higher

rated power for this Series engine.

ENGINE INFORMATION

1. Rope Handle for Rewind Starter

2. Oil Drain Plug

3. Choke Control Lever

4. Throttle Lever

5. Air Cleaner

6. Fuel Tank Cap

7. Spark Plug / Spark Plug Wire

8. Muffler

9. Engine Model Type Code

xxxxx xxxx xx xxxxxxxx

10. Stop Switch Wire (if equipped)

11. Oil Fill Cap

12. Fuel Fill

13. Throttle/Choke Control

14. Air Cleaner

15. Stop Switch

GENERAL INFORMATION

ENGINE MODEL

This is a single cylinder, L-head, air-cooled engine. It is a low emis-

sions engine.

MODEL 90000

Bore 2-9/16 in. (65.09 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke 1-3/4 in. (44.45 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement 9.02 cu. in. (148.0 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). . . . . . . . . . . . . . .

For practical operation, the horsepower loading should not ex-

ceed 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). Engine will operate

satisfactorily at an angle up to 15°.

OIL

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.

Note: If this engine is equipped with gear reduction, gear

reduction case must be filled with oil prior to operating en-

gine. See gear reduction oil filling instructions on page 12.

OIL CAPACITY

The engine holds approximately 2/3 qt. (21 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 30,

Part Number 100005 (20 oz) or 100028 (48 oz).

•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.

°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

*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.

SAE Viscosity Grades

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.

•Do not overfill.

[1] Place engine level and clean around oil fill area.

[2] Remove oil fill cap.

[3] Add oil, if needed.

[4] Pour slowly. Fill to point of overflowing.

[5] Replace and tighten oil fill cap.

OIL LEVEL

Oil Fill

FUEL

TYPE OF FUEL TO USE

•Use clean, fresh, regular unleaded gasoline with a

minimum of 77 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.

•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 (P/N 5041 or single use pouch).

•This engine is certified to operate on gasoline. Exhaust

Emission Control System: EM (Engine Modifications).

CAUTION: Some fuels, called oxygenated or reformu-

lated 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 operating symptoms occur, use gasoline

with a lower percentage of alcohol or ether.

ADDING FUEL

WARNING

[1] Remove cap. Fill tank to

approximately 1/2 inch below

lowest portion of fill opening to

allow for fuel expansion. Be careful

not to overfill.

[2] Replace cap before starting.

Fuel Fill

•Fill fuel tank outdoors or in well-ventilated area, away

from sparks, open flames, pilot lights, heat, and other

ignition sources.

•If fuel spills, wait until it evaporates before starting

engine.

•Turn engine OFF and let engine cool at least 2

minutes before removing gas cap.

STARTING AND STOPPING

STARTING AND OPERATING TIPS

♦Store and fuel equipment in

level position.

♦Use fresh fuel. (See Fuel.)

♦Use correct type of oil for

expected starting tempera-

ture. (See Oil.)

♦Remove external equip-

ment/engine loads. (See

equipment operating

instructions.)

♦Periodically remove any de-

bris buildup from the ma-

chine. (See Maintenance.)

♦After engine has started, let

it warm up several seconds

to several minutes, depend-

ing on outside temperature.

♦For maximum performance

and life, operate engine with

choke in RUN and throttle in

FAST.

WARNING

•Do not use pressurized

starting fluids.

•Vapors are flammable.

REWIND (MANUAL) STARTER

TO START ENGINE

[1] Check oil level (see p. 8).

[2] Move throttle to FAST. Operate engine with throttle in

FAST.

[3] Move choke control lever to CHOKE.

[4] Move stop switch to ON

(if equipped).

[5] When starting engine, pull cord slowly until resistance

is felt, then pull rapidly.

[6] Allow engine to warm up.

Adjust Choke: Slowly adjust toward RUN position. Wait

until engine runs smoothly before each choke adjust-

ment.

WARNING

OIL LEVEL

OFF

Stop Switch

Throttle

Choke

TO STOP ENGINE

[1] Move throttle control to SLOW,

then to STOP (if equipped).

[2] Push stop switch

(if equipped) to OFF.

CAUTION: Do not stop engine

by moving choke control to

CHOKE. Backfire, fire or engine

damage could occur. Stop Switch

OFF

Throttle

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.

Follow the instructions and schedules indicated below.

Task

Perform task at hourly

or calendar interval,

whichever comes first.

Every 8 Hours

or Daily

25 Hours or

Every Season

50 Hours or

Every Season

100 Hours or

Every Season

100-300 Hours

Check Oil Level 4

Change Oil 4*

Change oil in gear

reduction (if equipped) 4

Service air cleaner

pre-cleaner (if equipped) 4**

Service air cleaner car-

tridge (if not equipped

with pre-cleaner)

4**

Service air cleaner car-

tridge (if equipped with

pre-cleaner)

4**

Inspect spark arrester

(if equipped) 4

Replace spark plug 4

Clean cooling system 4**

Clean combustion

chamber 4

*Change oil after first 5 to 8 hours of use, then every

50 hours or every season. Change oil every 25 hours

when operating the engine under heavy load or in high

temperatures.

** Clean more often under dusty conditions or when

airborne debris is present. Replace air cleaner parts, if

very dirty.

CAUTION: 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.

CHANGING OIL

Change oil after first 5 hours of use.

WARNING

Typical Drain Plugs

1/4” HEX PIPE

OIL

DRAIN

PLUG

[1] Place engine level.

[2] Place engine level. Dis-

connect spark plug wire

and keep it away from

spark plug.

[3] With engine OFF but still warm remove oil drain

plug and drain oil into appropriate receptacle.

[4] Reinstall oil drain plug. Remove oil fill cap.

[5] Add about 2/3 quart (21 ounces; 0.6 liter) new oil.

Fill to point of overflowing.

[6] Replace oil fill cap.

OIL FILL

CAP

OIL LEVEL

MAINTENANCE

AIR CLEANER

CAUTION: Do not use pressurized air or solvents to

clean cartridge. Pressurized air can damage

cartridge; solvents will dissolve cartridge.

COVER

CARTRIDGE

BASE

To Remove

To Install

PUSH TABS IN

WHILE PULLING

ON COVER TO

REMOVE

COVER

REMOVING AND RE-INSTALLING AIR CLEANER

[1] Push in the tabs located on the sides of the air cleaner

cover, while pulling cover off.

[2] Remove cartridge carefully to prevent debris from

entering carburetor.

[3] Re-install new air cleaner assembly in base.

[4] Replace cover by snapping tabs back into place.

Pre-cleaner

To clean pre-cleaner (if equipped), separate it from

cartridge and wash in liquid detergent and water. Air dry

thoroughly. Do not oil. Re-install dry pre-cleaner on clean

cartridge.

CAUTION: Do not use pressurized air or solvents to

clean cartridge. Pressurized air can damage

cartridge; solvents will dissolve cartridge.

ÌÌÌÌÌÌÌÌÌ

SCREWS

COVER

CARTRIDGE

P/N 491588

OR 5043

PRE-CLEANER

P/N 491435

BASE

REMOVING AND RE-INSTALLING AIR CLEANER

[1] Loosen screws and remove cover.

[2] Remove pre-cleaner (if equipped) and cartridge

carefully to prevent debris from entering carburetor.

[3] Re-install clean (or new) air cleaner assembly in base.

[4] Replace cover and tighten screws.

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