EUROPE

EUROPEAN HEAD OFFICE

Briggs & Stratton AG Zrcherstrasse 4 CH 8852 Altendorf Switzerland Tel: +41 (0) Fax: +41 (0) Email: info.ch@basco.com
EUROPEAN DISTRIBUTION CENTER
Briggs & Stratton Netherlands B.V. Hogelandseweg 19 NL-6545 AC Nijmegen The Netherlands Tel: +31 (0) 620 Fax: +31 (0) 291
AUSTRIA Briggs & Stratton Austria GMBH Halleiner Landesstrasse 37C AT-5061 Elsbethen Austria
Tel: +43 (0) 3360 Fax: +43 (0) 3364 E-mail: info.at@basco.com
BELGIUM Denserco S.A. Rue du Mange, no 18 B-1301 Bierges Belgium
Tel: +32 (0) Fax: +32 (0) E-mail: info@denserco.be
BULGARIA Dezmomotors Ltd. Drujbal near bl. 86A BG-Sofia 1592 Bulgaria
Tel: +Fax: +77 E-mail: markovad@dezmomotors.com
CROATIA MPS Savska 12 HR - 10310 Ivani Grad Croatia
Tel: +385 (0) 165 Fax: +385 (0) 159 E-mail: vukas.cedomir@mpsmotor.hr
CZECH REPUBLIC Briggs & Stratton Czech Republic s.r.o. Pekarska 12 CZ - Praha 5 Czech Republic
Tel: +420 (0) Fax: +420 (0) E-mail: info.praha@basco.com
Briggs & Stratton (Czech) Power Products s.r.o. Jureckova 20 Tel: +CZ - 70200 Ostrava Fax: +Czech Republic E-mail: czinfo@basco.com
DENMARK Ketner Outdoor A/S Stamholmen 93 DK 2650 Hvidovre Denmark
Tel: +45 (0) Fax: +45 (0) E-mail: mail@ketneroutdoor.dk
ESTONIA Mecro Ltd. Peterburi Tee 44 EE - Tallinn 11415 Estonia Tel: +372 (0) 1107 Fax: +372 (0) 1172 E-mail: alari@mecro.ee
FINLAND Oy. Promotor AB Sahaajankatu 41 FI - 00880 Helsinki Finland
Tel: +358 (0) Fax: +358 (0) E-mail: promotor@saunalahti.fi
FRANCE Briggs & Stratton France, S.A.R.L. 43, Avenue des 3 Peuples FR - 78180 Montigny-le-Bretonneux France
Tel: +33 (0) Fax: +33 (0) E-mail: info.fr@basco.com
GERMANY Briggs & Stratton Germany GmbH Max-Born-Strasse 2 - 4 DE - 68519 Viernheim Germany
Tel: +49 (0) 0 Fax: +49 (0) 81 E-mail: info.de@basco.com
GREECE PETROS PETROPOULOS AEBE 96-104 lera Odos GR - Athens Greece or PO BOX 41018 GR - Athens
Tel: +30 (0) 9200 Fax: +30 (0) 3404 E-mail: contact@petropoulos.com
HUNGARY Horoszcoop, Kft. lli t 310 HU - 1184 Budapest Hungary
Tel: +36 (0) Fax: +36 (0) E-mail: horoszcoop@horoszcoop.hu
ICELAND M.H.G. Verslun Ltd Akralind 4 IS - 201 Kopavogur Iceland
Tel: +4656 Fax: +4657 E-mail: mhg@mhg.is
ITALY Briggs & Stratton Italy srl Via Daniele Monterumici 8 IT - 31100 Treviso Italy
Tel: +557 Fax: +235 E-mail: info.it@basco.com
RAMA MOTORI S.p.A. Via Agnoletti - Zona Annonaria IT - 42100 Reggio Emilia Italy
Tel: +39 (0) 711 Fax: +39 (0) 730 E-mail: spredieri@rama.it
LATVIA Gamma SIA Jelgavas str. 36 LV - 1004 Riga Latvia
Tel: +45 Fax: +20 E-mail: gammar@parks.lv
LITHUANIA Swedish Transport Technics Pramones pr. 11 LT - 51327 Kaunas Lithuania
Tel: +37 (0) or 69066 Fax: +37 (0) E-mail: info@sodotechnika.lt
LUXEMBOURG Denserco S.A. Rue Du Foyer Schaerbeekois, 105 BE - 1030 Bruxelles Belgium
MALTA Gaetano Caruana Ltd GCL Buildings, Triq Ix-Xghir C/W Mdina Road MT Zebbug ZBG 05 Malta
Tel: +356 (21) 81 Fax: +356 (21) 24 E-mail: info@gaecar.com
THE NETHERLANDS Motor Snelco B.V. Bedrijfsweg 130 NL - 8304 AA Emmeloord The Netherlands
Tel: +31 (0) Fax: +31 (0) E-mail: info@motorsnelco.nl
NORWAY Safe Motor A/S Olaf Schous Vei 6 NO - 0572 Rodelokka-Oslo 5 Norway
Tel: +47 (0) Fax: +47 (0) E-mail: firmapost@safemotor.no
POLAND Briggs & Stratton Poland Ul. Garncarska 21/5 PL - 76-200 Slupsk Poland
Tel: +Fax: +E-mail: jasinski.wojtek@basco.com
Chabin Service UL Lomzynska 20/22 PL- 93-176 Lodz Poland

4. Attach RED test lead to point A and BLACK test lead to point B. (It may be necessary to pierce wire with a pin as shown.) a. If meter beeps once, diode is OK. b. If meter makes a continuous tone, diode is defective (shorted). c. If meter displays OL, proceed to step 5. 5. Reverse test leads. a. If meter beeps once, diode is installed backwards. b. If meter still displays OL, diode is defective (open).
TEST LEAD FROM METER BUMP ON CONNECTOR INDICATES DIODE SIDE

3 Amp DC

B TEST LEAD FROM METER CONNECTOR DIODE
Dual Circuit Charging Unit
WIRE FOR CHARGING CIRCUIT TEST LEAD FROM METER

DIODE A

DIODE WIRE FOR LIGHTING CIRCUIT
Tri-Circuit Charging Circuit
Tri-Circuit Lighting Circuit

RED Test Lead B C C D

BLACK Test Lead A B D A

Beep Yes Yes Yes Yes

NOTE: Metal cased rectifiers must also be tested for grounds, as follows: With BLACK test lead probe contacting rectifier case, touch each terminal, A D, with RED test lead probe. Meter should display OL at each terminal. If meter makes a continuous tone at any terminal, rectifier is defective (grounded).

120 Volt Rectifier

DC SHUNT
Have you ever wanted one tool in your toolbox that would make your life so much easier that it would pay for itself after the first couple of uses? That tool might well be the 19359 DC shunt. The DC shunt is a device that enables the technician to make several electrical tests with only one hook-up to the equipment. By using the DC shunt, we can test for system draw with the key switch off, system draw with the key switch on, starter peak amp and steady amp draw, and alternator charging. All of these tests can be done in about 30 seconds taking all the guess work out of the process. Electricity is one of those mysterious entities that most of us are at best, very leery of or at worst, down right frightened of. But once we have a basic understanding of electrical theory, and acknowledge that electricity has to follow strict physical properties, electrical testing becomes one of the easiest troubleshooting problems we will encounter.

How Does A Shunt Work?

Several years ago we introduced the 19359 DC Shunt as a complement to the Fluke Digital Multi-meter. Though a very effective and useful tool, two questions usually come up: Why is a reading taken in millivolts to read amperage? Can I use the shunt with another brand of meter? The shunt works by adding a measured load (resistance) to a DC series circuit. Any load in a circuit will cause a voltage drop across that particular part of the total load. The two meter connecting posts are across part of the total load. The load in this case is the resistance to the flow of electrons through the shunt body between the posts. The meter must be set to the millivolt scale in order to obtain the correct reading. This is actually a much safer approach than working with higher amperage. 4

NEGATIVE BATTERY TERMINAL
2. Insert RED test lead into v receptacle in meter and RED receptacle on shunt. 3. Insert BLACK test lead into COM receptacle in meter and BLACK receptacle on shunt. 4. Rotate selector switch to
ATTACH NEGATIVE BATTERY CABLE
ATTACH NEGATIVE BATTERY CABLE WITH 3/8"-16 NUT NEGATIVE BATTERY TERMINAL

Standard Mount

Tab Mount

Side Mount

NOLOAD STARTER CURRENT DRAW 12 VOLT STARTER MOTORS 300mV
(STARTER MOTOR REMOVED FROM ENGINE) To check the no-load amperage draw of a 12 volt starter motor that is removed from the engine, a fixture as shown in the figure should be used. See the diagram for the parts necessary to make a test set-up. CAUTION: DO NOT clamp motor housing in a vise. Starter motors contain two ceramic magnets which can be broken or cracked if the motor housing is deformed or dented. NOTE: When checking starter current draw, battery voltage must not be below 11.7 volts. 1. Install shunt on - (negative) battery terminal. 2. Insert RED test lead into v receptacle in meter and RED receptacle on shunt. 3. Insert BLACK test lead into COM receptacle in meter and BLACK receptacle on shunt.
TACHOMETER NOTE RPM OF STARTER MOTOR TEST LEAD FROM METER PRESS TO START
12 Volt Starter Current Draw DC Shunt
DRILL TWO HOLES 3/8" DIA. FOR STARTER MOUNTING BRACKET PART NUMBER 392749 DRILL TWO HOLES FOR MOUNTING 2-1/4" BRIGGS & STRATTON 57.2 MM PART NUMBER 19200 TACHOMETER #7 DRILL TAP HOLE FOR 1/4-20 NC SCREWS 3-1/2" 89 MM
EXTRA HOLE FOR MOUNTING STARTER BRACKETS

4" 102 MM

3-1/2" 89 MM

1" 25.4 MM

10" 254 MM
METAL STOCK 1/4" THICK STEEL TEST BRACKET

2" 51 MM

Starter Motor Housing Length TABLE 1
How to Make the Test Mounting Bracket
12 VOLT STARTER MOTOR SPECIFICATIONS MOTOR HOUSING LENGTH 3" (76 mm) 3-5/8" (92 mm) 3-3/4" (95 mm) 4-3/8" (111 mm) 4-1/2" (114 mm) MINIMUM RPM 6500

MAXIMUM AMPERAGE 35

4. Rotate meter selector to
5. Activate the starter switch: a. Note RPM on vibration tachometer. b. Note amperage on meter. 6. Note starter motor housing length and refer to
Table 1 for test specifications for starter motor being tested. 7. If the starter motor does not meet the specifications shown in the chart, refer to the Repair Instruction Manual, Section 7, for service and repair procedure. 8
STARTER CURRENT DRAW 12 VOLT STARTER MOTORS 300mV
(STARTER MOTOR MOUNTED ON ENGINE) To check the amperage draw of a starter motor mounted on the engine, the procedure is similar to checking the starter motor off the engine. The battery cable and key switch harness installed in the equipment may be substituted for the test harness shown. When making this current draw test, it is important to monitor the engine RPM, amperage draw and battery voltage. On all 12 volt starter systems, make sure the test is performed with the correct oil in engine, and belts removed from the PTO shaft. Remove the spark plug(s) and ground the spark plug wire(s) using Ignition Tester(s), Tool part number 19368. Also the engine temperature should be at least 68 to 70 F (20 C). Note: When checking starter current draw, battery voltage must not be below 11.7 volts. 1. Install shunt on - (negative) battery terminal. receptacle in 2. Insert RED test lead into v meter and RED receptacle on shunt. 3. Insert BLACK test lead into COM receptacle in meter and BLACK receptacle on shunt. 4. Rotate meter selector to position. 5. Activate the starter switch: a. Note RPM on vibration tachometer. b. Note amperage on meter. 6. If the amperage draw exceeds 100 amps and the engine RPM is less than 350, it could indicate a starter motor problem. Check the starting system, such as the battery, cables, solenoid and connections. Then proceed to check the starter motor by performing the no-load starter motor test as indicated on page 8 or refer to the Briggs & Stratton Repair Instruction Manual, Section 7.

TABLE 3 ALTERNATOR TYPE 1/2 AMP, SYSTEM 3 & 4 DC ONLY (VANGUARD) (1.2 AMP) DC ONLY (MODEL 130000) (1.5 AMP) DC ONLY (3 AMPS) DUAL CIRCUIT *QUAD-CIRCUIT *5 AMPS REGULATED *9 AMPS REGULATED *10 AMPS REGULATED *16 AMPS REGULATED *20 AMPS REGULATED DC OUTPUT.5 AMP 1.2 AMP 1.5 AMP **24 AMPS **24 AMPS **38 AMPS **35 AMPS **39 AMPS **310 AMPS **316 AMPS **320 AMPS
LEAD TO POSITIVE BATTERY TERMINAL

DC Amperage Output Check

* Connect test leads before starting engine. Be sure connections are secure. If a test lead vibrates loose while engine is running, the regulator/ rectifier may be damaged. 11
** Amperage will vary with battery voltage. If battery voltage is at its maximum, the amperage will be less than the higher value shown.
CHECKING DC AMPERAGE OUTPUT 16 & 20 AMP REGULATED ALTERNATOR
To avoid blowing fuse in meter when testing DC output of 16 and 20 amp system the DC Shunt, Tool part number 19468, is required. The DC Shunt must be installed on the - (negative) terminal of the battery. All connections must be clean and tight for correct amperage readings. 1. Install shunt on negative battery terminal. receptacle in 2. Insert RED test lead into v meter and RED receptacle on shunt. 3. Insert BLACK test lead into COM receptacle in meter and BLACK receptacle on shunt. 4. Rotate selector to

TEST LEAD

TERMINAL
5. With engine running at 3600 RPM, DC output reading should be close to specifications listed in Table 3.
DC SHUNT PART NUMBER 19468
DC Amperage Output Check 16 and 20 Amp System DC Shunt
STARTER MOTOR CURRENT DRAW 120 VOLT STARTER MOTORS A
Use Line Current Adapter, Tool part number 19358, when checking current draw on 120 volt starter motors. Use the same test fixture used in the 12 volt starter test to check the current draw and free running RPM of motor. The following test procedure must be used to avoid any accidental shock hazard to the service technician. 1. Insert BLACK test lead from adapter, Tool part number 19358, into the COM receptacle in meter. 2. Insert white test lead from adapter, Tool part number 19358, into the receptacle in meter. 3. Plug the adapter cord (female end) into the switch box receptacle of the starter motor. 4. Plug the adapter cord (male end) into the previously tested wall outlet. 5. Rotate selector to A position. 6. Refer to specifications, Table 4, and note maximum allowable amperage draw for motor being tested. 7. Depress starter switch button. When meter reading stabilizes, (approximately 3 seconds) amperage should not exceed the specification shown in Table 4.

TABLE 4

CAUTION: If amperage is higher than specification in Table 4, immediately stop the test! An amperage reading higher than number in chart, indicates a shorted starter motor, which could be dangerous.
AC LINE VOLTAGE MUST BE NO LESS THAN 110 VOLTS
PUSH SWITCH TO ACTIVATE STARTER
TACHOMETER READ RPM OF STARTER MOTOR
120 Volt AC Starter Motor Current Draw with Line Current Adapter
120 VOLT STARTER MOTOR SPECIFICATIONS STARTER MOTOR IDENTIFICATION American Bosch SME110C3 SME110C6 SME110C8 American Bosch 0602628M030SM Mitsubishi J282188 Briggs & Stratton 3-1/2 (75.45 mm) Motor Housing MAXIMUM AMPERAGE 3.5 MINIMUM RPM 7400

3.0 3.5 2.7

8. If starter motor amperage is within specification, check RPM using vibration tachometer, Tool part number 19200. 9. RPM should be close to specifications listed in Table 4. 13
10.If the starter motor does not meet the given specifications, refer to the Repair Instructions Manual, Section 7.
Electric Starter Kits Quick Reference
Engine Model 190400-196499 190700-195799 252700-252799 253700-253799 194700-198799 195400-195799 19E400-19E499 19F400-19F499 19G400-19G499 19K400-19K499 280700-289799 28A700-28W799 Single Cylinder Intek Engines 120100-15D699786 20A100-21P792157 310700-310799 311700-311799 312700-312799 400400-422499 400700-422799 42A700-42E799 406700-461799 V-Twin Vanguard Engines 303400-303499 354400-354499 350700-350799 380400-381499 380700-381799 303700-303799 304400-304499 350400-350499 351400-351499 351700-351799 381400-381499 381700-381799 V-Twin Intek Engines 405700-405799 406700-406799 407700-407799 445700-445799
RETAINING RING CLUTCH DRIVE RETAINER SPRING WASHER RETURN SPRING STARTER DRIVE ASSEMBLY
Starter Assembly# (Plastic Ring Gear) (Alum. Ring Gear) (Steel Ring Gear) (Plastic Ring Gear/Starter Housing is Over 4" in Length) (Alum. Ring Gear/Starter Housing is Over 4" in Length) (Steel Ring Gear/Starter Housing is Over 4" in Length)
Starter Gear Only# 693713 (Plastic Ring Gear) (Alum. Ring Gear) (Steel Ring Gear)
Drive Assy. # (Bendix) 693699 (C Ring Type) (Roll Pin Type) (Steel Ring Gear)

Single Cylinder Engines

120 volt (60Hz Starter Assembly) 230 volt (50Hz Starter Assembly) 120 volt (60HZ Starter Assembly) 230 volt (50Hz Starter Assembly) (Plastic Ring Gear) (Alum. Ring Gear) (Steel Ring Gear) (3 5/8" Housing) (4 3/8" Housing) (Plastic Ring Gear) (Alum. Ring Gear) (Steel Ring Gear) (Steel Ring Gear) (C Ring Type) (Roll Pin Type) (Steel Pinion Gear) 696541 (C Ring Type)

Briggs & Stratton Switch Terminal Positions Terminal No. 1-G 2-L 3-M 4-S 5-B Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid) Brand X Switch Terminal Positions Terminal Function No. 1-A 2-M 3-R 4-S 5-B
Accessory To Stop Switch Terminal On Engine (Ground) To Regulator (Charging) To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid)

Figure 1

Figure 2
It is not possible to show all of the wiring diagrams or keyswitch combinations that are used by equipment manufacturers. However, the following wiring diagrams for the most popular Briggs & Stratton engines may be used as a guide when replacing an engine. The wiring diagrams show the type of keyswitch that is compatible with the alternator system shown. 21

ALTERNATOR

ANTI-AFTERFIRE SOLENOID

STOP SWITCH TERMINAL

KEY SWITCH
AC OUTPUT WIRE DC OUTPUT WIRE
AMMETER HEADLIGHTS HEADLIGHT SWITCH

BATTERY TERMINAL

SOLENOID TAB TERMINAL STARTER TERMINAL

SOLENOID

12 VOLT BATTERY

STARTER MOTOR

Typical Dual Circuit Alternator Wiring Diagram Original 5 Pole Switch Superceded to 6 Pole Switch, Briggs & Stratton Part Number 692318
Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 2+5 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case

Terminal No. 5

Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid)

AMMETER

AMMETER (OPTIONAL) HEADLIGHTS HEADLIGHT SWITCH BATTERY TERMINAL
Typical Dual Circuit Alternator Wiring Diagram 6 Pole Switch Briggs & Stratton Part Number 692318 With ammeter shown in optional position, note that and + symbols are reversed. The + symbol must always be connected to the alternator side. Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 + 6 2+5+6 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Terminal No. Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid) To Alternator (DC Output)

STARTER SOLENOID STATOR

STARTER
DIODE WHITE CONNECTOR RED DC OUTPUT

BLACK AC OUTPUT

LIGHT SWITCH
AMMETER BATTERY START SWITCH 6 1
Typical Dual Circuit System

ALTERNATOR KEY SWITCH

AC OUTPUT WIRE

DC OUTPUT WIRE

SOLENOID TAB TERMINAL BATTERY TERMINAL STARTER TERMINAL
HEADLIGHTS HEADLIGHT SWITCH SOLENOID
Typical 16 Amp Regulated Alternator Wiring Diagram 5 Pole Switch Briggs & Stratton Part Number 692318
AMMETER REGULATOR/ RECTIFIER

AMMETER (OPTIONAL)

SOLENOID TAB TERMINAL

STARTER TERMINAL

HEADLIGHTS HEADLIGHT SWITCH
Typical 16 Amp Regulated Alternator Wiring Diagram 6 Pole Switch Briggs & Stratton Part Number 692318 With ammeter shown in optional position, note that and + symbols are reversed. The + symbol must always be connected to the alternator side. Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 + 6 2+5+6 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Terminal No. Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid) To Alternator (DC Output)

CHARGE INDICATOR LIGHT

BLUE WIRE
REGULATOR/ RECTIFIER RED WIRE DC OUTPUT RAISED RIB
Typical 16 Amp Regulated Alternator Wiring Diagram With Charge Indicator Light 6 Pole Switch Briggs & Stratton Part Number 692318 With ammeter shown in optional position, note that and + symbols are reversed. The + symbol must always be connected to the alternator side. Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 + 6 2+5+6 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Terminal No. Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid) To Alternator (DC Output)
GROUND WIRE TERMINAL ALTERNATOR
STARTER STARTER RELAY AMMETER

B SEAT SWITCH A C

LIGHT SWITCH BATTERY ELECTRIC CLUTCH

B CLUTCH BRAKE SWITCH

E D C A B

Typical 10/16 Amp System

TRI-CIRCUIT STATOR
AMMETER (OPTIONAL) BATTERY TERMINAL
Typical 5/9 Amp Regulated Alternator Wiring Diagram With Charge Indicator Light 6 Pole Switch Briggs & Stratton Part Number 692318 With ammeter shown in optional position, note that and + symbols are reversed. The + symbol must always be connected to the alternator side. Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 + 6 2+5+6 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Terminal No. Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid) To Alternator (DC Output)

- DC OUTPUT WIRE HEADLIGHT SWITCH

+ DC OUTPUT WIRE

AMMETER (OPTIONAL) HEADLIGHTS CLUTCH SWITCH BATTERY TERMINAL

ELECTRIC CLUTCH

Typical Tri-Circuit Alternator Wiring Diagram 6 Pole Switch Briggs & Stratton Part Number 692318 With ammeter shown in optional position, note that and + symbols are reversed. The + symbol must always be connected to the alternator side. Key Switch Test Switch Position 1. OFF 2. RUN 3. START Continuity *1 + 3 + 6 2+5+6 2+4+5 *Terminal 1 Grounded Internally To Key Switch Case Terminal No. Function Ground (Used only with insulated panel) To Carburetor Solenoid To Stop Switch Terminal On Engine To Solenoid (Tab terminal) To Battery (Battery terminal on solenoid) To Alternator (DC Output)
BATTERY STARTER SOLENOID STARTER

PTO SWITCH

25W RESISTOR

INTERLOCK SWITCH

E D C B A STATOR LIGHT SWITCH

START SWITCH

CLUTCH GREEN CONNECTOR
Simplified Tri-Circuit System
TRI-CIRCUIT STATOR STOP SWITCH TERMINAL
AC OUTPUT WIRE ANTI-AFTERFIRE SOLENOID

SEE NOTE

- DC OUTPUT WIRE + DC OUTPUT WIRE

HEADLIGHT SWITCH

AMMETER RESISTOR
BATTERY TERMINAL SOLENOID TAB TERMINAL

HEADLIGHTS

CLUTCH SWITCH
Note: If clutch switch is in ON position with keyswitch OFF, battery will discharge through clutch.
To prevent this, route wire B to #2 terminal on key-switch. However, anti-afterfire solenoid will not shut off. Remove anti-afterfire solenoid or convert system to 6 pole switch.
Key Switch Test Continuity *1 + 3 2+5 2+4+5

Switch Position

1. OFF

2. RUN

3. START
*Terminal 1 Grounded Internally To Key Switch Case
Typical Tri-Circuit Alternator Wiring Diagram With Resistor 5 Pole Switch Briggs & Stratton Part Number 692318

RESISTOR

CLUTCH DPDT SWITCH

SOLENOID STARTER MOTOR

Typical Tri-Circuit Alternator Wiring Diagram With Resistor 6 Pole Switch Briggs & Stratton Part Number 692318

BATTERY

START SWITCH CLUTCH/ BRAKE SWITCH B E D C PTO SWITCH B A A C D

STARTER RELAY

A SEAT SWITCH B STATOR GREEN CONNECTOR

PTO CLUTCH

A LIGHT SWITCH
Typical Complex Tri-Circuit System

V-Twin Wire Harness Description M40/44 with #2 side regulator, w/o EFM Associated Parts Shield/Nut Assembly #1 side Bracket, Hold Down (wire) Tie wrap for regulator wires (inside blower) 693876 na na yes yes M49 with #1 side regulator, w/o EFM 795361 M40/44/49 with #1 side regulator, with EFM 796376
2 pin, standard Used with (RED, regulator out) (Jumper Wire) 6 pin, standard 6 pin with oil pressure switch 6 pin with hour meter or oil minder Used with 694215, 694216 and 696505. RED wire from regulator to 2 pin

Typical 6-pin connector

CYL. 1

6 PIN CONNECTOR CYL. 2

CURRENT FLOW
DETAIL K KEY 6 DIODES CRIMPED CONNECTION SHRINK TUBING DETAIL K
EACH DIODE ASSEMBLY MUST BE INDIVIDUALLY WRAPPED IN SHRINK TUBING. AN ADDITIONAL SHRINK WRAP MUST ALSO BE ASSEMBLED OVER BOTH DIODE ASSEMBLIES.

1 D 3 9

"ROUTE" TO TERMINAL HOLE No's AS SHOWN.

SEE DETAIL K

JUMPER WIRE BETWEEN 1&4
WIRE IDENTIFICATION REFERENCE TERMINAL ENGINE TERMINATION POINT A CYLINDER #1 COIL B CYLINDER #2 COIL C CARB SOLENOID D GROUND E POWER SUPPLY TO REGULATOR F EFM IGNITION PULSE
SOCKETS MUST BE PUSHED INTO HOUSING UNTIL TANGS SNAP OPEN OVER PLASTIC TO INSURE THAT SOCKETS CANNOT BACK OUT (4 PLACES)

8-WAY CONNECTOR

EFM CONTROL MODULE
6-pin wire harness with efm
8-WAY CONNECTOR TERMINAL #

SIGNAL ---

CARB MANIFOLD ASSEMBLY

12 VOLT POWER (GND)

TERMINAL # 7 8
12 VOLT POWER (+) ----12 VOLT POWER (GND) 12 VOLT POWER (+) ---
SIGNAL STEPPER MOTOR WIRE E (12 VOLT (+) INPUT STEPPER MOTOR WIRE A STEPPER MOTOR WIRE B IGNITION WIRE PRIMARY STEPPER MOTOR WIRE D STEPPER MOTOR WIRE C

STEPPER MOTOR ASSEMBLY

2-WAY CONNECTOR SIGNAL

TERMINAL #

THERMISTOR (SIGNAL)

THERMISTOR (GND)

GRAY GRAY
CARB SOLENOID BLACK GRAY BLACK BLACK
THERMISTER EFM PULSE SIGNAL BLACK
GROUND (ON CYLINDER SHIELD)

AWG gauge Metric 2.Metric 1.Metric 1.Metric 1.Metric 1.Metric 1.Metric 40
Conductor Diameter Inches 0.46 0.4096 0.3648 0.3249 0.2893 0.2576 0.2294 0.2043 0.1819 0.162 0.1443 0.1285 0.1144 0.1019 0.0907 0.0808 0.072 0.0641 0.0571 0.0508 0.0453 0.0403 0.0359 0.032 0.0285 0.0254 0.0226 0.0201 0.0179 0.0159 0.0142 0.0126 0.0113 0.01 0.0089 0.008 0.00787 0.0071 0.00709 0.0063 0.0063 0.0056.00551 0.005.00492 0.0045.00441 0.004.00394 0.0035 0.0031
Conductor Diameter mm 11.684 10.40384 9.26592 8.25246 7.34822 6.54304 5.82676 5.18922 4.62026 4.1148 3.66522 3.2639 2.90576 2.58826 2.30378 2.05232 1.8288 1.62814 1.45034 1.29032 1.15062 1.02362 0.91186 0.8128 0.7239 0.64516 0.57404 0.51054 0.45466 0.40386 0.36068 0.32004 0.28702 0.254 0.22606 0.2032 0.200 0.18034 0.180 0.16002 0.16002 0.14224.140 0.127 0.125 0.1143 0.112 0.1016 0.1000 0.0889 0.07874
Ohms per 1000 ft. 0.049 0.0618 0.0779 0.0983 0.1239 0.1563 0.197 0.2485 0.3133 0.3951 0.4982 0.6282 0.7921 0.9989 1.26 1.588 2.003 2.525 3.184 4.016 5.064 6.385 8.051 10.15 12.8 16.14 20.36 25.67 32.37 40.81 51.47 64.9 81.83 103.2 130.1 164.1 169.39 206.9 207.5 260.9 260.339 414.8 428.2 523.1 533.8 659.6 670.2 831.8 1049
Ohms per km 0.16072 0.202704 0.255512 0.322424 0.406392 0.512664 0.64616 0.81508 1.027624 1.295928 1.634096 2.060496 2.598088 3.276392 4.1328 5.20864 6.56984 8.282 10.44352 13.17248 16.60992 20.9428 26.40728 33.292 41.984 52.9392 66.7808 84.1976 106.1736 133.8568 168.8216 212.872 268.4024 338.496 426.728 538.248 555.61 678.632 680.55 855.752 855.752 1079.2728 3440
Maximum amps for chassis wiring 4.7 3.5 2.7 2.2 1.7 1.4 1.2 0.86 0.7 0.53 0.51 0.43 0.43 0.33 0.33 0.27 0.26 0.21 0.20 0.17 0.163 0.13 0.126 0.11 0.09
Maximum amps for power transmission 12 9.3 7.4 5.9 4.7 3.7 2.9 2.3 1.8 1.5 1.2 0.92 0.729 0.577 0.457 0.361 0.288 0.226 0.182 0.142 0.113 0.091 0.088 0.072 0.072 0.056 0.056 0.044 0.043 0.035 0.034 0.0289 0.0277 0.0228 0.0225 0.0175 0.0137
Maximum frequency for 100% skin depth for solid conductor copper 125 Hz 160 Hz 200 Hz 250 Hz 325 Hz 410 Hz 500 Hz 650 Hz 810 Hz 1100 Hz 1300 Hz 1650 Hz 2050 Hz 2600 Hz 3200 Hz 4150 Hz 5300 Hz 6700 Hz 8250 Hz 11 kHz 13 kHz 17 kHz 21 kHz 27 kHz 33 kHz 42 kHz 53 kHz 68 kHz 85 kHz 107 kHz 130 kHz 170 kHz 210 kHz 270 kHz 340 kHz 430 kHz 440 kHz 540 kHz 540 kHz 690 kHz 690 kHz 870 kHz 900 kHz 1100 kHz 1150 kHz 1350 kHz 1400 kHz 1750 kHz 1750 kHz 2250 kHz 2900 kHz
Alternator & Connector
Red to 10 amp Amps DC 2,800rpm 0.5 amps DC minimum

Tester Settings

Tester Leads

Speed & Readings

SYSTEM 3 & 4 also quantum 120000 1/2 amp DC Red to 10 amp Amps DC 3,600rpm 1.0 amps DC minimum

DC only 1.2 amp DC

DC only 1.5 amp DC

Red to 10 amp

Amps DC
3,600rpm 1.2 amps DC minimum
AC only 14 volts AC Earth

Red to V

free electron: An electron that is capable of jumping in or out of the outer orbit. frequency: 1. The number of complete electrical cycles per second (cps). full-wave rectification: The process of rectifying AC and recovering the B- pulse of AC that the diode blocks. full power outlet: Enables you to draw the full power of the generator out of one outlet. fuse: An excess current protection device with a thin metal strip that melts and opens the circuit when a short circuit or excess current condition occurs.
DC amperage test: A test that uses a digital multimeter or other suitable test instrument to indicate the current that should enter the battery if all connections to the battery are good. depletion region: The region of a diode which separates P-type material and N-type material. digital multimeter (DMM): A test tool used to measure two or more electrical values. diode: An electrical semiconductor device that can be used to convert AC to DC. direct current (DC): The flow of electrons in one direction only. dynamo: A machine for converting mechanical energy into electrical energy by electromagnetic induction a generator.
generator: An electrical device that produces an AC sine wave as a wire coil is rotated in a magnetic field or as magnets are rotated inside a wire coil. ground: A connection, intentional or accidental, between an electrical circuit and the earth or some conduction body serving in the place of the earth. half-wave rectifier: An electronic device used in a charging system that converts AC to DC by blocking one-half of the AC sine wave to allow current to flow in only one direction. hertz (Hz): The international unit of frequency equal to one cycle per second. horsepower (HP): A unit of power equal to 746 watts (W) or 33,000 lb.-ft. per minute (550 lb.-ft. per second). idle control: A system that controls the idle speed of the engine in direct relation to the electrical load. ignition armature: A component containing two or more coils which, when acted upon by a magnetic field, induces electrical energy. ignition coil: A device used to supply DC voltage to the spark plugs. ignition system: A system that provides a high voltage spark in the combustion chamber at the proper time. induction: The production of voltage and current by the proximity and motion of a magnetic field or electric charge. induction principle: A theory which states that with a conductor, any one of the following (current, a magnetic field, or motion) can be produced by the remaining two.
eddy current: Undesirable current induced in the metal structure of an electrical device due to the rate of change in the induced magnetic field. electrical symbols: Graphic illustrations used in electrical system diagrams to show the function of a device or component. electricity: Energy created by the flow of electrons in a conductor. electric starting system: A group of electrical components activated by the operator to rotate the crankshaft when starting an engine. electro-motive force (EMF): The force which causes current to flow in a conductor; in other words, the voltage potential. electrolyte: A mixture of water and sulfuric acid (H2SO4) used in a lead-acid battery. electrons: The parts of an atom that have a negative electrical charge

rated speed: Revolutions per minute at which the set is designed to operate.
rated voltage: The rated voltage of an engine generator set is the voltage at which it is designed to operate. rear bearing carrier: The casting which houses the rotor bearing which supports the rotor shaft. rectifier: An electrical component that converts AC to DC by allowing the current to flow in only one direction. regulator/rectifier: An electrical component that contains one or more diodes and a zener diode. relay: An electrically operated switch usually used in control circuits and whose contacts are considered low amperage, compared to a contactor. reserve capacity: The amount of time a battery can produce 25A at 80 F (26 degrees C). resistance (R): The opposition to the flow of electrons. resistive load: An applied load that reduces the possibility of the alternator system delivering full amperage through the circuit. rotor: The rotating element of a generator. secondary winding: A coil in which high voltage is induced for use at the spark plug. self-inductance: A magnetic field created around a conductor whenever current moves through the conductor. series circuit: A circuit having two or more components connected so that there is only one path for current flow. series/parallel circuit: A circuit that contains a combination of components connected in series and parallel. short circuit: An undesirable complete circuit path that bypasses the intended path and has very little resistance. silicon controlled rectifier (SCR): A semiconductor that is normally an open circuit until voltage is applied, which switches it to the conducting state in one direction. single phase: An AC load, or source of power normally having only two input terminals if a load or two output terminals if a source. solenoid: A device that converts electrical energy into linear motion. spark gap: The distance from the center electrode to the ground electrode on the spark plug. 47
spark plug: A component that isolates the electricity induced in the secondary windings and directs a high voltage charge to the spark gap at the tip of the spark plug. spark tester: A test tool used to test the condition of the ignition system on a small engine. starter motor: An electric motor that drives the engine flywheel when starting. starter solenoid: An electrical switch, with internal contacts opened or closed, using a magnetic field produced by a coil. stator: An electrical component that has a continuous copper wire (stator winding) wound on separate stubs exposing the wire to a magnetic field. switch: Any component that is designed to start, stop, or redirect the flow of current in an electrical circuit.

695730 Since 2000

694457 Since 1999

696578 Since 1973

393809 Since 1978

AC only Alternator

14 Volts AC unregulated

Dual circuit Alternator

460000

1Black Wire 1 Red Wire

Amp DC / 5 Amp AC 14 Volts AC unregulated

201000 210000

1 Black Wire, 1 Red Wire

210000

Diode 790292 790292

2 White Connectors

391595

Since 1974 Small magnets

698230 Since 2002
1 Red Wire 1 Yellow Wire 1 Black Wire

696742 Since 2002

696459 Since 2007

46X700

15X000 20X000 21X000

790292

793118 Since 2007 795498
4 Amp Regulated Alternator

Brass Connector

4 Amp DC regulated
5 or 9 Amp Regulated Alternator
5 or 9 Amp regulated, Tri-circuit
5 or 9 Amp Regulated or Tri-circuit Alternator

Green Connector

Black Wire 5 or 9 Amp DC regulated, Tri-circuit
Plastic sleeves Green Wires to regulator, 1 Green, 1 Red between Armatures

187400

698315

794360 Green Connector

1 Yellow Wire

691955

691188 794360

715200

Green Connector 1 Yellow Wire Red Connector 1 Red Wire
Small magnet 28 Volts AC 5 Amp DC regulated Large magnet 40 Volts AC 9 Amp DC regulated
Tri-circuit Diode Wire Green Connector
with 2 diodes leading to 1 Red Wire and 1 White Wire Red Wire = 2-5 Amp DC unregulated for battery charge White Wire = 2-5 Amp DC negative for lights

Red Connector 1 Red Wire

715255

Since 1994 Small magnets

1 Red Wire, 2 Green Wires, 1 Black Wire

Yellow Connector

698314 Since 2002

696457

Since 1988 (5 & 9 Amp) 1976 Tri-circuit

10 Amp Alternator

2 Black Wires 10 Amp DC regulated

691185

Black Connector

2 Black Wires

10 Amp DC regulated High Output

120000

399916 To be ordered separately Green Wires

10 Amp DC regulated

No Connector

185400 691185

23X400 24X400
399916 Shipped loose 2 Green Wires

790325

695466

Since 2000 Small magnets

2 Yellow Wires

2 Black Connectors

790320 Since 2004
2 Yellow Wires 1 Red Wire
2 Black Wires, 1 Red Wire

715194

Since 1974 Medium magnets

715798 Since 2001

715262 Since 1988
13 Amp Power Link Alternator
White Connector Black Connector

Ivory sheathed wires

691573
115 Volts - 60 Hz, 13 Amp DC regulated