Briggs & Stratton 420000 Series Manual

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Model Series

Covered in

This Manual

420000

460000

Operating & Maintenance

Instructions

Model Type Code

Month Day Year

Note: General Model Series number noted above is inclusive of the specific model

number found on your engine. To get replacement parts or technical assistance in

the future, write your engine Model, Type, Code and date of purchase here.

TABLE OF CONTENTS

Safety 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Information 6. . . . . . . . . . . . . . . . . . . . . . . .

Oil 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel and Starting Information 8. . . . . . . . . . . . . . .

Starting and Stopping 9-10. . . . . . . . . . . . . . . . . . .

Maintenance 11-14. . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 14-15. . . . . . . . . . . . . . . . . . . . . . . . . .

Parts and Service & Storage 16. . . . . . . . . . . . . . .

Warranty Information 17. . . . . . . . . . . . . . . . . . . . .

WARNING

Briggs & Stratton does not approve or authorize the use of

these engines on 3-wheel All Terrain Vehicles (ATVs), motor

bikes, 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.

Need assistance? Go to www.briggsandstratton.com

for detailed information regarding

Briggs & Stratton engines.

Or call, 1-800-233-3723, (U.S.A. and Canada)

to hear a menu of pre-recorded messages

offering engine maintenance information.

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The Power That Works For You.

Look For Relevant Emissions Durability Period and Air Index Informa-

tion On Your Engine Emissions Label

Engines that are certified to meet the California Air Resources Board (CARB) Tier 2 Emission Standards must

display information regarding the Emissions Durability Period and the Air Index. Briggs & Stratton makes this

information available to the consumer on our emission labels. The engine emission label will indicate certification

information.

The Emissions Durability Period describes the number of hours of actual running time for which the engine is

certified to be emissions compliant, assuming proper maintenance in accordance with the Operating &

Maintenance Instructions. The following categories are used:

Moderate: Engine is certified to be emission compliant for 125 hours of actual engine running time.

Intermediate: Engine is certified to be emission compliant for 250 hours of actual engine running time.

Extended: Engine is certified to be emission compliant for 500 hours of actual engine running time.

For example, a typical walk-behind lawn mower is used 20 to 25 hours per year. Therefore, the Emissions

Durability Period of an engine with an intermediate rating would equate to 10 to 12 years.

The Air Index is a calculated number describing the relative level of emissions for a specific engine family. The

lower the Air Index,the cleaner the engine. This information is displayed in graphical form on the emissions

label.

After July 1, 2000, Look For Emissions Compliance Period On

Engine Emissions Compliance Label

After July 1, 2000 certain Briggs & Stratton engines will be certified to meet the United States Environmental

Protection Agency (USEPA) Phase 2 emission standards. For Phase 2 certified engines, the Emissions

Compliance Period referred to on the Emissions Compliance label indicates the number of operating hours for

which the engine has been shown to meet Federal emission requirements. For engines less than 225 cc

displacement, Category C = 125 hours, B = 250 hours and A = 500 hours. For engines of 225 cc or more,

Category C = 250 hours, B = 500 hours and A = 1000 hours.

The displacement of Model Series 420000 engines is 694 cc. The displacement of Model Series 460000 engines

is 745 cc.

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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 INSTRUCTIONS

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.

274796

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 prod-

uct 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

*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.

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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.

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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

POWER RATINGS: The power ratings for an individual engine

model are initially developed by starting with SAE (Society of Auto-

motive Engineers) code J1940 (Small Engine Power & Torque

Rating Procedure) (Revision 2002-05). Given both the wide array

of products on which our engines are placed, and the variety of en-

vironmental issues applicable to operating the equipment, it may

be that the engine you have purchased will not develop the rated

horsepower when used in a piece of power equipment (actual “on-

site” power). This difference is due to a variety of factors including,

but not limited to, the following: differences in altitude, tempera-

ture, barometric pressure, humidity, fuel, engine lubrication, maxi-

mum governed engine speed, individual engine to engine variabil-

ity, design of the particular piece of power equipment, the manner

in which the engine is operated, engine run-in to reduce friction

and clean out of combustion chambers, adjustments to the valves

and carburetor, and other factors. The power ratings may also be

adjusted based on comparisons to other similar engines utilized

in similar applications, and will therefore not necessarily match the

values derived using the foregoing codes.

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ENGINE INFORMATION

1. Spark plug wire

2. Carburetor

3. Air cleaner

4. Rotating screen

5. Emission label and Engine

Model Type Code label

xxxxxx xxxx xx xxxxxxxx

6. Oil drain plug

7. Crankshaft

8. 12V electric starter

9. Fuel filter

10. Oil fill/Dipstick

11. Blower housing

GENERAL INFORMATION

ENGINE MODEL

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

emissions engine.

In the state of California, the 420000 and 460000 series

engines covered in this manual are certified by the

California Air Resources Board to meet emissions stan-

dards for 125 hours. Such certification does not grant the

purchaser, owner or operator of this engine any additional

warranties with respect to the performance or operational

life of this engine. This engine is warranted solely according

to the product and emissions warranties stated elsewhere

in this manual.

MODEL SERIES 420000

Bore 3-7/16 in. (87.31 mm). . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke 2-9/32 in. (57.94 mm). . . . . . . . . . . . . . . . . . . . . . . .

Displacement 42.33 cu. in. (694.0 cc). . . . . . . . . . . . . . . .

MODEL SERIES 460000

Bore 3-9/16 in. (90.49 mm). . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke 2-9/32 in. (57.94 mm). . . . . . . . . . . . . . . . . . . . . . . .

Displacement 45.48 cu. in. (745.2 cc). . . . . . . . . . . . . . . .

TUNE-UP SPECIFICATIONS

Armature air gap 0.010 – 0.014 in. (0.25 – 0.36 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 271172.

Intake 0.006 – 0.008 in. (0.15 – 0.20 mm). . . . . . . . . . . . .

Exhaust 0.009 – 0.011 in. (0.23 – 0.28 mm). . . . . . . . . . .

Note: For practical operation, the horsepower loading

should not exceed 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). It will operate satisfactorily at an angle up to 15°.

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OIL

274796

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.

OIL CAPACITY

Engine without oil filter holds approximately 1-1/2 quarts

(48 ounces; 1.4 liter).

Engine equipped with oil filter holds approximately

1-3/4 quarts (56 ounces; 1.7 liters).

TYPE OF OIL TO USE

•Use a high quality detergent oil classified “For Service

SF, SG, SH, SJ” or higher, such as Briggs & Stratton

30W, 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: Use 5W-30 oil or synthetic oil if anticipated

temperatures are below 40°F (4°C) to prevent

internal engine damage at startup due to inadequate

lubrication. Air cooled engines run hotter than

automotive engines. The use of non-synthetic

multi-viscosity oils, e.g. 5W-30, 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. Clean

around oil fill and dipstick.

[2] Remove dipstick and wipe clean with cloth.

[3] Then push dipstick back in and remove to check oil level.

FULL

ÏÏ

Oil Fill

Dipstick

[4] Remove dipstick. Pour oil

slowly.

[5] Fill to FULL line on dipstick

– recheck. [6] Replace dipstick firmly.

FULL

ÏÏ

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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 1-1/2

inches below top of neck to allow for fuel

expansion. Be careful not to overfill.

Briggs & Stratton Smart-fill)fuel can fills to the

correct level and automatically shuts off, reduc-

ing spills and emissions.

[2] Replace cap before starting.

•Turn engine OFF and let engine cool at least 2

minutes before removing gas cap.

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

•Keep gasoline away from sparks, open flames,

pilot lights, heat, and other ignition sources.

•If fuel spills, wait until it evaporates before

starting engine.

STARTING

WARNING

•Do not use pressurized starting fluids.

•Vapors are flammable.

OIL PRESSURE SWITCH

If engine is equipped with an oil pressure switch, the switch

will either activate a warning device or stop the engine

when the engine runs low on oil. (Read the operating

instructions supplied by the equipment manufacturer to

determine which way your engine is equipped because the

equipment manufacturer supplies the oil pressure gauge.)

See oil pressure on page 12 for oil filling instructions.

STARTING AND OPERATING TIPS

♦Store and fuel equipment in level position.

♦Use fresh fuel. (See Fuel.)

♦Use correct type of oil for expected starting

temperature. (See Oil.)

♦Remove external equipment/engine loads. (See

equipment operating instructions.)

♦Start lawn mower on hard surface or over previously

cut grass.

♦Periodically remove grass buildup under mower

deck. (See Maintenance.)

♦After engine has started, let it warm up several

seconds to several minutes, depending on outside

temperature.

♦For maximum performance and life, operate engine

with choke in RUN and throttle in FAST.

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STARTING AND STOPPING

REWIND (MANUAL) STARTER

TO START ENGINE

[1] Check oil level (see p. 7).

[2] Open fuel shut-off valve

(if equipped).

[3] Move choke control to CHOKE or

START.

[4] Move throttle to FAST

(if equipped). Operate en-

gine with throttle in FAST.

Choke

FULL

ÏÏ

[5] Grasp rope handle. Pull slowly

until resistance is felt, then pull

rapidly to start engine and avoid

kickback.

[6] Let engine warm up.

Choke Equipped: Move

choke control lever

toward RUN a short dis-

tance at a time over sev-

eral seconds in warm

weather or minutes in cold

weather. Let engine run

smoothly before each

change. Operate with

choke in RUN.

WARNING

Rewind starter Rope starter

TO STOP ENGINE

[1] Move throttle

(if equipped) to

SLOW, then to STOP.

[2] Close fuel shut-off

valve

(if equipped).

CAUTION:

Do not stop engine

by moving choke

control to CHOKE.

Backfire, fire or en-

gine damage

could occur.

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STARTING AND STOPPING

ELECTRIC (KEY) STARTER (if equipped)

TO START ENGINE

[1] Check oil level.

[2] Open fuel shut-off valve

(if equipped).

[3] Move choke control to CHOKE or

START.

[4] Move throttle to FAST (if

equipped). Operate en-

gine with throttle in FAST.

Choke

FULL

ÏÏ

[5] Insert key and turn to

START.

CAUTION:

To prolong starter life,

use short starting cycles

(5 seconds maximum,

then wait one minute).

Follow equipment

manufacturer’s recom-

mendations for charging

battery.

[6] Let engine warm up. Choke

Equipped: Move choke

control lever toward RUN a

short distance at a time over

several seconds in warm

weather or minutes in cold

weather. Let engine run

smoothly before each

change. Operate with choke

in RUN.

TO STOP ENGINE

[1] Move throttle

(if equipped) to SLOW.

[2] Turn key to OFF.

Remove key and

store out of reach of

children.

[3] Close fuel shut-off

valve (if equipped).

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