Small Engine
Reassembly
Briggs & Stratton OHV
A Visual Guide
Objectives:
 Reassemble an engine following concise steps and
detailed notes taken by the student.
 Utilize proper tool ...
Procedure Notes:
 Follow the reassembly steps precisely.
 Be sure to reference notes and sketches you
created during eng...
Pre-Assembly Cleaning
Clean all internal parts in the parts cleaning cabinets. Remove
excess solvent with compressed air. ...
Step 1: Install the Crankshaft
Reminder: Tapered end to the front of the engine.
Pre-operation grease
Step 2: Reassemble the Piston Rings
and Connecting Rod
Reminder: The rings must be replaced correctly. Review your
sketch ...
Step 2: Reassemble the Piston Rings
and Connecting Rod
Connecting rod & piston orientation. Arrow
on piston and MAG abbrev...
Step 3: Install the Piston and
Connecting Rod in the Cylinder
Reminder: Clean and coat cylinder wall with lubricant. Use
p...
Step 3: Install the Piston and
Connecting Rod in the Cylinder
Use your thumbs or the
handle of a mallet to gently
insert t...
Step 4: Replace Connecting Rod Cap
Reminder: Lubricate interior of rod cap and connecting rod. Replace cap and rod in the
...
Step 5: Replace Tappets
Note: Lubricate each tappet
Step 6: Replace Cam Gear
Reminder: Make sure journal is secure. Line up timing marks.
Lubricate all bearing surfaces.
Step 7: Install Crankcase Cover
Reminder: Use correct gasket. Tighten bolts in correct sequence by skipping
across the cov...
Step 8: Install Flywheel
Install flywheel
and key.
Install Starter
Cup and Nut
Torque flywheel nut
using a strap wrench
an...
Installing Cylinder
Head & Adjusting
Overhead Valves
Return to your measurement sheets
in Chapter 9 to record your
measure...
Step 9: Insert Valves Into Head
Insert valves from the bottom of
the head, while using your
thumbs to lock the valve retai...
Step 10: Install the Cylinder Head
Reminder: Install head gasket first. Torque head bolts in a crisscross
pattern.
Step 11: Install Pushrods & Valve
Wear Plates
Pushrod
Valve
Wear Plates
Step 12: Align Rocker Arms with Push
Rods & Valve Wear Plates
Reminder: Use the rocker arm as a fulcrum to slightly compre...
Step 13: Prepare the Cylinder for
Valve Adjustment
Reminder: Rotate piston to TDC compression. Use a screwdriver in the
sp...
Step 14: Check Valve Clearance
Reminder: According to specification, insert a flat feeler gauge
between the rocker arm and...
Step 15: Adjusting Valve Clearance
1. Insert feeler gauge
2. Loosen locking screw, while
holding adjustment nut.
3. Adjust...
Note: Don’t forget gasket. Short bolt to the top.
Step 16: Replace Valve Cover
Step 17: Install
Armature
Note: Thread kill wire through port in block.
Bolt armature to block. Adjust armature air
gap wi...
Step 18: Insert Heat Shield
Note: One screw only
Reminder: Refer to your drawings to ensure all linkage is correctly assembled.
Carburetor
Linkage
Governor
Arm
4 Bolts
Ste...
Step 20: Replace Carburetor
1. Attach spring &
linkage to
carburetor
2. Insert both
gaskets & spacer.
Step 21: Reset Governor (IMPORTANT)(IMPORTANT)
Reminder: Ensure that all linkage travels freely.
Confirm that throttle
but...
Step 21: Reset Governor (IMPORTANT)(IMPORTANT)
Procedure: Use a 1/4” nut driver and 3/8”. Rotate governor
shaft counter cl...
Step 22: Insert Spark Plug
Step 23: Replace Blower Housing
Note: Linkage plate flange mounts with the blower housing
top. Weave the blower housing ov...
Step 24: Replace Muffler
Note: Include gasket. #30 star
tool required. Replace muffler
guard. One bolt at rear of
muffler ...
Step 25: Replace Fuel Tank
Note: Replace fuel line. Four bolts front and back.
Step 26: Replace Throttle & Fuel Valve
Cover Plate
Note: Fuel valve must be in off position. Throttle must be at half.
Step 27: Replace Air Cleaner
Mounting Plate
& Gasket Filter & Cover
Steps 28-29:
 Fill Crankcase with clean oil.
 Fill fuel tank 1/3 full with gasoline.
 Be sure to add gasoline, not any ...
Step 30: Start and Run Engine
Turn run switch “ON” and set throttle to 1/2. No starting
fluid should be needed.
Reminder: ...
Step 31: Adjust Carburetor & Take
Measurements
Temperature
Readings
Full Throttle RPM &
Carburetor Adjustment
Let engine o...
Step 32: Remove Fuel & Lubricant
Place fuel and lubricant into their appropriate containers.
Reassembly Wrap-Up
 Place a piece of tape on your engine that has your
name as well as a report of how the engine ran.
 ...
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Ohv.reassembly

  1. 1. Small Engine Reassembly Briggs & Stratton OHV A Visual Guide
  2. 2. Objectives:  Reassemble an engine following concise steps and detailed notes taken by the student.  Utilize proper tool techniques.  Reinforce lecture-based theoretical discussions.  Utilize and reference engine standards with appropriate engine manuals.
  3. 3. Procedure Notes:  Follow the reassembly steps precisely.  Be sure to reference notes and sketches you created during engine disassembly.  Your engine may not be exactly like the engine in this presentation. Even if your Briggs & Stratton OHV engine is not exactly like the model used in this presentation, many of the procedures will be the same.  Use reassembly grease on all internal parts and follow all specifications!
  4. 4. Pre-Assembly Cleaning Clean all internal parts in the parts cleaning cabinets. Remove excess solvent with compressed air. Eye protection and chemical resistant gloves are required.
  5. 5. Step 1: Install the Crankshaft Reminder: Tapered end to the front of the engine. Pre-operation grease
  6. 6. Step 2: Reassemble the Piston Rings and Connecting Rod Reminder: The rings must be replaced correctly. Review your sketch of connecting rod and piston ring orientation.
  7. 7. Step 2: Reassemble the Piston Rings and Connecting Rod Connecting rod & piston orientation. Arrow on piston and MAG abbreviation to the magneto side of the engine. wrist pin clips
  8. 8. Step 3: Install the Piston and Connecting Rod in the Cylinder Reminder: Clean and coat cylinder wall with lubricant. Use piston ring compressor. Install in the correct orientation.
  9. 9. Step 3: Install the Piston and Connecting Rod in the Cylinder Use your thumbs or the handle of a mallet to gently insert the piston assembly. Rotate the crankshaft to prevent it from striking the connecting rod during reassembly.
  10. 10. Step 4: Replace Connecting Rod Cap Reminder: Lubricate interior of rod cap and connecting rod. Replace cap and rod in the correct direction. Replace oil splash and rod cap lock. Torque screws properly. Arrow toward cylinderShort screw and oil splash away from cylinder
  11. 11. Step 5: Replace Tappets Note: Lubricate each tappet
  12. 12. Step 6: Replace Cam Gear Reminder: Make sure journal is secure. Line up timing marks. Lubricate all bearing surfaces.
  13. 13. Step 7: Install Crankcase Cover Reminder: Use correct gasket. Tighten bolts in correct sequence by skipping across the cover. Replace oil seal if needed. Adjust end play if needed.
  14. 14. Step 8: Install Flywheel Install flywheel and key. Install Starter Cup and Nut Torque flywheel nut using a strap wrench and ft.lb. torque wrench.
  15. 15. Installing Cylinder Head & Adjusting Overhead Valves Return to your measurement sheets in Chapter 9 to record your measurements.
  16. 16. Step 9: Insert Valves Into Head Insert valves from the bottom of the head, while using your thumbs to lock the valve retainer. Oil seal on intake valve Exhaust valve guide rises
  17. 17. Step 10: Install the Cylinder Head Reminder: Install head gasket first. Torque head bolts in a crisscross pattern.
  18. 18. Step 11: Install Pushrods & Valve Wear Plates Pushrod Valve Wear Plates
  19. 19. Step 12: Align Rocker Arms with Push Rods & Valve Wear Plates Reminder: Use the rocker arm as a fulcrum to slightly compress each valve spring in order to slide its opposite end on top of the push rod.
  20. 20. Step 13: Prepare the Cylinder for Valve Adjustment Reminder: Rotate piston to TDC compression. Use a screwdriver in the sparkplug opening as a guide or align the PTO keyway to the cylinder. Now rotate the flywheel clockwise until the magnet points straight up. This disengages the compression release on the camshaft.
  21. 21. Step 14: Check Valve Clearance Reminder: According to specification, insert a flat feeler gauge between the rocker arm and valve wear plate. Make adjustments if out of gap tolerance.
  22. 22. Step 15: Adjusting Valve Clearance 1. Insert feeler gauge 2. Loosen locking screw, while holding adjustment nut. 3. Adjust clearance with the adjustment nut. 4. Hold adjustment nut and lock rocker arm.
  23. 23. Note: Don’t forget gasket. Short bolt to the top. Step 16: Replace Valve Cover
  24. 24. Step 17: Install Armature Note: Thread kill wire through port in block. Bolt armature to block. Adjust armature air gap with shim or business card.
  25. 25. Step 18: Insert Heat Shield Note: One screw only
  26. 26. Reminder: Refer to your drawings to ensure all linkage is correctly assembled. Carburetor Linkage Governor Arm 4 Bolts Step 19: Replace Linkage Plate Insert Kill Wire
  27. 27. Step 20: Replace Carburetor 1. Attach spring & linkage to carburetor 2. Insert both gaskets & spacer.
  28. 28. Step 21: Reset Governor (IMPORTANT)(IMPORTANT) Reminder: Ensure that all linkage travels freely. Confirm that throttle butterfly is open completelySet throttle to full
  29. 29. Step 21: Reset Governor (IMPORTANT)(IMPORTANT) Procedure: Use a 1/4” nut driver and 3/8”. Rotate governor shaft counter clockwise until it stops (do not force). Tighten governor arm lock with 3/8” wrench.
  30. 30. Step 22: Insert Spark Plug
  31. 31. Step 23: Replace Blower Housing Note: Linkage plate flange mounts with the blower housing top. Weave the blower housing over, under, and over.
  32. 32. Step 24: Replace Muffler Note: Include gasket. #30 star tool required. Replace muffler guard. One bolt at rear of muffler and four screws at front.
  33. 33. Step 25: Replace Fuel Tank Note: Replace fuel line. Four bolts front and back.
  34. 34. Step 26: Replace Throttle & Fuel Valve Cover Plate Note: Fuel valve must be in off position. Throttle must be at half.
  35. 35. Step 27: Replace Air Cleaner Mounting Plate & Gasket Filter & Cover
  36. 36. Steps 28-29:  Fill Crankcase with clean oil.  Fill fuel tank 1/3 full with gasoline.  Be sure to add gasoline, not any other fuels.
  37. 37. Step 30: Start and Run Engine Turn run switch “ON” and set throttle to 1/2. No starting fluid should be needed. Reminder: Only while instructor is present. Use engine stand and vice.
  38. 38. Step 31: Adjust Carburetor & Take Measurements Temperature Readings Full Throttle RPM & Carburetor Adjustment Let engine operate for approx. 5 min.Let engine operate for approx. 5 min.
  39. 39. Step 32: Remove Fuel & Lubricant Place fuel and lubricant into their appropriate containers.
  40. 40. Reassembly Wrap-Up  Place a piece of tape on your engine that has your name as well as a report of how the engine ran.  Return engine to storage area.  Inventory and clean all tools in your assigned box.  Clean and return your engine storage bin to its storage area.  Clean and straighten your area.

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