Outboard Repair Manual E-Book_275110 BRIGGS & STRATTON.pdf

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5 HP Outboard
Troubleshooting & Repair Manual
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This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and
company service personnel when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar
products, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in the
recommended servicing procedures for these products, which includes the use of mechanics hand tools and any
special tools that might be required.
Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems.
The troubleshooting, testing, service and repair procedures described in this guide are effective methods of
performing such operations.
We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a
service might be performed, nor of any possible hazards and/or results of each procedure or method. We have
not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by
the manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be
endangered by the service or operating procedure selected.
All information, illustrations, and specifications contained in this guide are based on the latest production
information available at the time of publication. However, Briggs & Stratton Corporation reserves the right to
change, alter, or otherwise improve the product at any time without prior notice.
Some components or assemblies of the product described in this guide may not be considered repairable.
Disassembly, repair and reassembly of such components may not be included in this guide.
Copyright © 2003 Briggs & Stratton Corporation
All rights reserved.
No part of this material may be reproduced or transmitted, in any form or by any means, electronic or
mechanical, including photocopying, recording or by any information storage and retrieval system, without prior
permission in writing from Briggs & Stratton Corporation.
5 HP Outboard • Troubleshooting & Repair Manual
Table of Contents
TABLE OF CONTENTS
1
3
INTRODUCTION
DISASSEMBLY
In the Interest of Safety
5
Cooling Shroud
23
Safety Alert Symbols
5
Removal
23
Fuel Recommendations
6
Power Head
23
Gasoline
6
Blower Housing
24
Oil Recommendations
6
Magnetron™ Ignition
24
Lubrication System
6
Flywheel
25
Engine Oil
6
Inspect Flywheel Key, Keyway,
Flywheel and Crankshaft
26
Oil Drain Plug, Oil Fill and Dipstick
6
Carburetor
26
Gear Selector
7
Disassemble Carburetor
27
Operation
7
Carburetor Cleaning
27
Reverse
8
Cylinder Head
28
Neutral
8
Prepare Cylinder Head for Removal
28
Forward
8
Remove Valve Cover
28
Changing Gear Case Oil
9
Disassemble Cylinder Head
28
2
TROUBLESHOOTING
Crankshaft & Camshaft
29
Oil Slinger Lubrication
29
Check Lower Unit
13
Piston and Connecting Rod
30
No Start - Hard Start
13
Gear Case Disassembly
30
Vibration
13
Sliding Clutch
32
Power Loss
13
Midsection
33
Noise
13
Disassembly
33
Cooling
13
Throttle Cable
34
Check Ignition
14
Replacement
34
Armature Test
15
Rewind Starter
34
Tests for No Spark
15
Remove Rope
34
Neutral Switch Test
16
Inspect Rope
34
Check Compression
17
Remove Pulley and Spring
34
Cylinder Leak Down Test
17
Inspect Spring, Starter Housing and Pulley
35
Check Carburetion
18
Steering Tension
18
Propeller Service
19
1
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5 HP Outboard • Troubleshooting & Repair Manual
Table of Contents
TABLE OF CONTENTS
4
Install Flywheel
52
OVERHAUL
Install Armature
52
Magnetron Ignition
39
Armature Air Gap
52
Remove Armature
39
Cylinder Head Assembly
53
Inspect Valve Springs
39
Install Cylinder Head Plate and
Rocker Arm Studs
53
Inspect Valve Guides
39
Install Valves
53
Finish Ream Valve Guides
39
Install Valve Springs and Retainers
53
Reface Valves and Seats
39
Install Cylinder Head
54
Remove Piston Rings
39
Install Rocker Arms
54
Check Piston Ring Groove Wear
40
Adjust Valve Clearance
55
Check Piston Ring End Gap
40
Install Valve Cover
55
Check Connecting Rod
40
Carburetor Assembly
55
Undersized Connecting Rods
40
Install Welch Plug
55
Check Piston Pin and Piston Pin Bore
41
Install Choke Shaft
56
Inspect Crankshaft
41
Install Throttle Shaft
56
Inspect Camshaft
42
Install Inlet Needle and Float
56
Check Cylinder
42
Install Carburetor
57
Cylinder Resizing
42
Install Pulley and Spring
57
Set Up For Honing
42
Install Pawls, Pawl Springs & Retainer
58
Hone Cylinder
43
Wind Spring & Install Rope
58
Cylinder Finish (“Cross Hatch”)
43
Install Blower Housing
59
Cylinder Cleaning
44
Gear Case Assembly
59
Check Camshaft Bearings
44
Mid Section Assembly
62
Check Crankshaft Bearings
44
Install Power Head
63
Remove DU™ Magneto Bearing
44
Cooling Shroud Installation
64
Install DU™ Magneto Bearing
45
Adjust Throttle Cable
64
Oil Seals
45
Idle Adjustment
65
5
ASSEMBLY
6
APPENDIX
Piston and Connecting Rod
49
Outboard Engine Fastener Specifications
68
Piston Rings
49
Compress Piston Rings
49
Lower Unit Fastener Specifications
68
Ignition System Wiring Diagram
69
Crankshaft Installation
50
Install Connecting Rod & Piston
50
Component Location - Gear Case
70
Install Camshaft
51
Component Location-Midsection
72
Install Sump
51
Crankshaft End Play
51
2
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5 HP Outboard • Troubleshooting & Repair Manual
Section 1 • Introduction
Introduction
1
In the Interest of Safety
5
Safety Alert Symbols
5
Fuel Recommendations
6
Gasoline
6
Oil Recommendations
6
Lubrication System
6
Engine Oil
6
Oil Drain Plug, Oil Fill and Dipstick
6
Gear Selector
7
Operation
7
Reverse
8
Neutral
8
Forward
8
Changing Gear Case Oil
9
3
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