Professional Documents
Culture Documents
BRIGGS & Stratton
BRIGGS & Stratton
DIRECTORS
IDNNetwork
DELTA
BRITISH COLUMBIA
ALBERTA
SASKATCHEWAN
MANITOBA
ONTARIO
QUEBEC
TUALATIN
A
OAKVILLE
ANOKA
CASTLETON
MEQUON
COLUMBUS
EDWARDSVILLE
PENDERGRASS
Magneto Power
MWE
Preferred Power
Atlantic Power
SEDCO
9/09
Anoka (Minneapolis)
MN
55303
Robert Moe
800-248-4016
Dallas
TX
75235
Robert Ortolani
262-834-4394
Mequon (Milwaukee)
WI
53092
Robert Moe
262-834-4300
Tualatin (Portland)
OR
97062
Greg Muse
800-338-5168
Aurora (Chicago)
IL
60504
Tom Ziemann
630-862-3100
Edwardsville (KC)
KS
66111
Tom Ziemann
913-543-7600
Visalia
CA
93291
John Reid
800-683-8484
UT
84120
Tom Ziemann
801-886-2350
Charlotte
NC
28216
Steve Krcelic
800-288-5310
Delta (Vancouver)
BC
V3M 6R9
Mike Gulley
604-520-1294
Oakville (Toronto)
ON
L6H 6X5
Mike Gulley
905-829-0006
Castleton
NY
12033
Art Falk
800-456-5692
Columbus
OH
43228
Pat Earnest
614-534-2152
Tampa
FL
33610
Ray Coyle
614-534-2140
7. SEDCO, INC
Pendergrass (Atlanta)
GA
30567
SEDCO, Inc.
Wayne Crosby
800-346-4260
Pendergrass (Atlanta)
GA
30567
SEDCO, Inc.
Mark Thomas
800-346-4260
01/11
BRIGGS&STRATTON
CORPORATION
MS-0415-02/11
CUSTOMER EDUCATION
post office box 702
milwaukee, WI 53201 USA
800 934 7730 | cust.ed@basco.com
Copyright 2011. All rights reserved.
ENGINE
ALTERNATOR
REPOWER GUIDE
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Features
10/23/2008
10:24
Page 1
DC only Alternator
0.5 Amp DC unregulated
Output @ 2800 rpm
97700
99700
100600
100800
110000
120000
Engine
110000
120000
200000
White Connector
1 Red Wire
Engine
3 Amp DC unregulated
Engine
104700
130000
12X400
15X400
20X400
21X400
White Connector
1 Black Wire
Engine
130200
Diode 391507
Red Connector
1 Black Wire
Red Connector
Diode 391507
White Connector
1 Black Wire
691991
794103
Engine
Since 1989
Alternator outside the flywheel
System 3 / System 4
DC only Alternator
Engine
Diode 391507
90000
110000
White Connector
3 Amp DC unregulated
Red
Connector
1 Black Wire
2 - 4 Amp DC unregulated
Engine
110000
120000
200000
210000
2 - 4 Amp DC unregulated
Engine
110000
120000
150000
200000
White Connector
1 Red Wire
Red Connector
1 Red Wire
Diode 391507
1 Red Wire
E-parts Look-Up
Diode
391507
397880
Since 1981
Alternator outside the flywheel
AC only Alternator
14 Volts AC
unregulated
White Connector
1 Black Wire
Engine
2 4 Amp DC / 5 Amp AC
14 Volts AC unregulated
White Connector
160000
170000
190000
210000
220000
243000
250000
280000
310000
320000
400000
420000
460000
1Black Wire
1 Red Wire
Engine
2 4 Amp DC / 5 Amp AC
14 Volts AC unregulated
White Connector
201000
210000
Diode 391507
Engine
150000
201000
210000
Diode
391507
790292
1 Red Wire
1 Yellow Wire
1 Black Wire
Engine
170000
190000
210000
220000
240000
250000
280000
300000
310000
326000
350000
380000
Engine
115400
117400
118000
185400
187400
Engine
790292
2 White
Connectors
1 Red Wire
1 Yellow Wire
1 Black Wire
793118
Since 2007
795498
691188
794360
696457
Engine
160000
170000
190000
210000
220000
250000
256000
280000
290000
300000
310000
320000
330000
350000
380000
400000
420000
440000
460000
698315
Diode 391507
White Connector
1 Yellow Wire
Yellow Connector
Engine
15X000
20X000
21X000
691955
Green Connector
2 4 Amp DC / 5 Amp AC
14 Volts AC unregulated
Black Wire
691188
794360
715200
Diode
391507
Green Connector
110000
120000
150000
200000
210000
280000
300000
698315
Green Connector
1 Black Wire
1 Red Wire
1 Yellow Wire
1 Black Wire
Engine
170000
190000
210000
220000
240000
250000
280000
290000
300000
310000
320000
330000
350000
380000
46X700
4 Amp DC regulated
Brass Connector
2 White
Connectors
2 White Connectors
1 Red Wire
1 Yellow Wire
1 Black Wire
Since 1994
Small magnets
2 4 Amp DC / 5 Amp AC
14 Volts AC unregulated
White Connector
790292
790292
715255
2 - 4 Amp DC unregulated
1 Red Wire
Diode 391507
Diode 391507
Since 1974
Small magnets
Red Connector
2 White Connectors
391595
Engine
170000
190000
210000
220000
240000
250000
280000
300000
310000
326000
350000
380000
10 Amp Alternator
whats new?
10 Amp DC regulated
Yellow Connector
Engine
Black Connector
110000
120000
200000
210000
2 Black Wires
2 Black Wires
10 Amp DC regulated
High Output
10 Amp DC regulated
Yellow Connector
Engine
120000
No Connector
Engine
10 Amp DC regulated
2 Black Wires
117400
138400
185400
Engine
23X400
24X400
Yellow Connector
10 Amp DC regulated
691185
691185
Engine
230400
240400
691185
790325
Yellow Connector
695466
Yellow Connector
2 Black Connectors
2 Yellow Wires
Red Connector
Since 2000
Small magnets
Yellow Connector
2 Yellow Wires
1 Red Wire
715194
Red Connector
Since 1974
Medium magnets
1 Red Wire
2 Yellow Wires
Red Connector
1 Red Wire
691573
Engine
44X700
White Connector
2 Yellow Wires
697261
Black Connector
697261
Engine
691185
35X400
Orange Connector
1 Orange Wire
Engine
305000
356000
White Connector
697261
2 Yellow Wires
Black Connector
White Connector
Black Connector
Yellow Connector
691573
1 Orange Wire
Black Connector
2 Yellow Wires
1 Black Wire
697261
Red Connector
697992
1 Black Wire
1 Orange Wire
Yellow Connector
2 Black Wires
Yellow Connector
2 Yellow Wires
White Connector
1 Brown Wire
1 Orange Wire
1 Red Wire
10 A Since 1978
397809
16 A Since 1983
Quad Circuit Since 1984
493219
808877
Engine
(10 A.) (16 A.)
160000
170000
190000
220000
250000
280000
290000
303000
310000
320000
330000
350000
380000
400000
420000
460000
(13 A.)
400000
420000
14 Amp DC regulated
20 Amp DC regulated
White Connector
691573
691362
1 Red Wire
White Connector
White Connector
825003
White Connector
2 Yellow Wires
White Connector
697992
Engine
430000
520000
580000
2 Yellow Wires
1 Red Wire
1 Red Wire
1 Black Wire
1 Yellow Wire
2 Blue Wires
1 Green Wire
40 Amp DC regulated
Engine
697992
White Connector 1 Blue Wire
White Connector 2 Red Wires
Black Connector
White Connector
Yellow Sheath 1 White Wire,
(QUAD)
170000
190000
220000
250000
280000
460000
1 Black Wire
40 Amp Alternator
290000
300000
350000
380000
470000
540000
220000
250000
280000
290000
303000
310000
320000
350000
380000
400000
420000
460000
Black Connector
2 Yellow Wires,
1 Red Wire
Black Connector
2 Black Wires
White Connector
809176
Connector Orange
1 Red Wire
Yellow Connector
697992
Engine
35X700
1 Orange Wire
1 Black Wire
Orange Connector
2 Yellow Wires
1 Red Wire
Orange Connector
Black Connector
696579
Since 1995
Large magnets
60 Amp DC regulated
Black Connector
20 Amp DC regulated
2 Black Wires
Engine
20H400
21A400
790325
2 Black
Connectors
2 Black Wires
1 Red Wire
793660
2 Black Connectors
793658
Since 2007
795498
Flywheel / Magnets
60 Amp Alternator
Engine
Engine
290000
303000
310000
350000
351000
380000
470000
540000
610000
Engine
430000
520000
580000
430000
520000
580000
841170
2 White Connector
SMALL:
SMALL:
MEDIUM:
MEDIUM:
LARGE:
LARGE:
Note : Unless specified, all tests must be carried out with the engine running at 3600 rpm.
The values indicated are minimium values. If the value measured is lower than
indicated a repeat test is advised before proceding any further.
MS-2288FL - 11/08
www.thepowerportal.com
Table of Contents
Continuity Checks Switches
DC Voltage Battery Test V
........................................................................................................................................ 2
.................................................................................................................................................. 2
................................................................................................................................................................. 3
DC Shunt.................................................................................................................................................................................. 4
How Does A Shunt Work?...................................................................................................................................................... 4
DC Shunt Instructions............................................................................................................................................................. 7
NoLoad Starter Current Draw 12 Volt Starter Motors 300mV
Starter Current Draw 12 Volt Starter Motors 300mV
AC Voltage Output Check V
DC Amperage Output Check
................................................................................... 8
............................................................................................... 9
.............................................................................................................................................10
...................................................................................................................................11
..................................................................................................13
Alternator Identification..........................................................................................................................................................15
Engine/Alternator Replacement Information.......................................................................................................................17
Replacing Briggs & Stratton Engines................................................................................................................................17
Briggs & Stratton Engine/Replacing Engine Of Another Manufacturer..........................................................................20
6-Pin Deutsch Connector......................................................................................................................................................35
6-Pin Wire Harness...............................................................................................................................................................36
Typical 6-Pin Connector........................................................................................................................................................38
6-Pin Wire Harness With Efm..............................................................................................................................................39
Big Block Engine Typical 8-Pin Connector.......................................................................................................................41
Big Block Application (Equipment) Connector................................................................................................................41
Ferris/Snapper Pro Engine to Equipment Wire Harness..............................................................................................42
Alternator Harness and Repair Leads.................................................................................................................................44
Alternator Wire Assembly and Stop Wires..........................................................................................................................46
Wire Harness and Assemblies.............................................................................................................................................49
Performance Control Electronic Governor...........................................................................................................................50
Electrical Connector Method Of Crimping...........................................................................................................................51
Connector Crimping and Wire Stripping Tools....................................................................................................................51
AWG Wire Sizes ...................................................................................................................................................................53
Metric Wire Gauges ..............................................................................................................................................................53
Load Carrying Capacities ....................................................................................................................................................53
Glossary Of Terms.................................................................................................................................................................56
1
receptacle in
receptacle in
3. Rotate selector to
COM
PUSH BUTTON
SWITCH
(ELECTRIC
START)
position.
ROTARY
KEY SWITCH
IGNITION
STOP SWITCH
Continuity Checks
receptacle in
receptacle in
3. Rotate selector to V
COM
LEAD
LEAD
position.
RESISTANCE CHECKS
1. Insert RED test lead into v
meter.
receptacle in
receptacle in
3. Rotate selector to
COM
position.
Resistance Checks
DIODE CHECKS
In the Diode Test position, the meter will display
the forward voltage drop across the diode(s). If the
voltage drop is less than 0.7 volt, the meter will
beep once, as well as display the voltage drop. A
continuous tone indicates continuity (shorted diode).
An incomplete circuit (open diode) will be displayed
as OL.
TEST
LEAD FROM
METER
receptacle in
TEST
LEAD FROM
METER
COM
receptacle in
position.
3. Rotate selector to
DIODE
CONNECTOR
WIRE
FROM STATOR
3 Amp DC
TEST
LEAD FROM
METER
BUMP ON
CONNECTOR
INDICATES
DIODE SIDE
A
B
DIODE
TEST
LEAD FROM
METER
WIRE
FROM STATOR
CONNECTOR
WIRE
FOR CHARGING
CIRCUIT
TEST
LEAD FROM
METER
TEST
LEAD FROM
METER
B
DIODE
A
TEST
LEAD FROM
METER
DIODE
WIRE
FOR LIGHTING
CIRCUIT
Beep
Yes
Yes
Yes
Yes
A
D
B
C
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.
RESISTANCE
SECTION
CONNECTS TO NEGATIVE
BATTERY CABLE
CONNECTS TO NEGATIVE
BATTERY POST
Previous Style
Current Style
Note: Meter and battery connections to shunt are the same as the previous DC shunt as shown above.
1 volt
1 amp = --------1 ohm
Lets take a look at units of measure. The prefix milli is Latin for 1/1000 of a unit. For example, 0.001 inch
could be called a milliinch. Therefore, 1/1000 of an amp equals 0.001 amp or one milliamp. Also, one millivolt
is 1/1000th of a volt or 0.001 volt. Applying these units of measurement for Briggs & Stratton shunt into Ohms
Law gives us:
1 millivolt
0.001 volt
1 amp = ----------------- = ----------------1 milliohm
0.001 ohm
The above equation shows that across the posts on the Briggs & Stratton shunt, 1 milliohm equals 1 amp of
current flowing in the circuit. This is why the test meter is set to the millivolt range.
Now, lets add charging current from the alternator system flowing through the shunt. Resistance through the
shunt will stay the same. We know the current will change. Since the shunt measures voltage drop, we have
to be interested in the voltage or pressure in the system. The resistance value of the shunt is set so that we
know there is a 1 to 1 ratio between amps and millivolts. Therefore, a reading of 2 millivolts on the meter face
is equal to 2 amps of current, 3 equals 3, etc.
From this discussion, it should be clear that any meter capable of reading millivolts can be used with the DC
shunt.
DC SHUNT INSTRUCTIONS
The DC shunt, part number 19468 readily adapts
to standard mount, side mount or tab type battery
terminals. The shunt must be installed on the
- (negative) terminal of the battery.
For standard terminals, attach ring terminal on shunt
to post terminal on battery. For tab terminal batteries,
attach shunt to battery terminal using 1/4" 20 stud
and wing nut. For side terminal batteries, remove
post terminal from shunt and thread into side terminal
on battery. Attach battery cable to shunt using
3/8" 16 nut from post terminal.
The Digital Multimeter will withstand DC input of
10 20 Amps for up to 30 seconds. To avoid blowing
fuse in meter, use the DC shunt when checking
current draw of 12 volt starter motors or DC output
on 16 Amp regulated alternator.
Charging output can be checked with the engine
running. All connections must be clean and tight for
correct amperage readings.
1. Install shunt on negative battery terminal.
LEAD
LEAD
NEGATIVE
BATTERY
TERMINAL
ATTACH NEGATIVE
BATTERY CABLE
ATTACH NEGATIVE
BATTERY CABLE
300mV
NEGATIVE BATTERY
TERMINAL
NEGATIVE BATTERY
TERMINAL
ATTACH
NEGATIVE
BATTERY
CABLE WITH
3/8"-16 NUT
NEGATIVE BATTERY
TERMINAL
Standard Mount
Tab Mount
Side Mount
position.
TEST LEAD
FROM
METER
PRESS TO
START
NOTE RPM OF
STARTER MOTOR
TACHOMETER
4"
102 MM
3-1/2"
89 MM
1"
25.4 MM
10"
254 MM
TEST BRACKET
MINIMUM RPM
MAXIMUM AMPERAGE
6500
18
6500
18
6500
19
6500
20
6500
35
300mV
position.
IGNITION TESTER
TOOL PART
NUMBER 19368
TEST
LEADS FROM
METER
NEGATIVE
BATTERY
TERMINAL
DUAL
CIRCUIT
WHITE
CONNECTOR
receptacle in
COM
receptacle in
RED CLIP TO
AC SIDE OF
HARNESS
(BLACK WIRE)
TEST CLIP TO
A GOOD GROUND
SURFACE
TABLE 2
YELLOW
CONNECTOR
ALTERNATOR
AC ONLY
14 VOLTS
DUAL CIRCUIT
14 VOLTS
5 AMP REGULATED
28 VOLTS
9 AMP REGULATED
40 VOLTS
TRI-CIRCUIT
28 VOLTS
QUAD-CIRCUIT
30 VOLTS
10 AMP REGULATED
20 VOLTS
16 AMP REGULATED
30 VOLTS
16 AMP REGULATED
26 VOLTS
20 AMP REGULATED
29 VOLTS
TEST CLIP TO
AC OUTPUT PIN
WHITE
CONNECTOR
GREEN
CONNECTOR
ATTACH
METER
TEST
CLIPS
QUAD-CIRCUIT
10 AMP CIRCUIT
16 AMP CIRCUIT
TEST
CLIP
9 AMP REGULATED
TRI-CIRCUIT
TEST
CLIP
SINGLE CIRCUIT
AC ONLY
10
BUMP ON CONNECTOR
INDICATES THE DC
OUTPUT PIN LOCATION
AC
OUTPUT
PIN
COM
DUAL
CIRCUIT SYSTEM
DC
OUTPUT
PIN
receptacle in
TEST LEAD
TO DC OUTPUT PIN
position.
LEAD TO
POSITIVE
BATTERY
TERMINAL
DC OUTPUT
.5 AMP
1.2 AMP
1.5 AMP
DC ONLY (3 AMPS)
**24 AMPS
DUAL CIRCUIT
**24 AMPS
TRI CIRCUIT
5 or 9 AMP
DUAL CIRCUIT
5 AMP DC
*QUAD-CIRCUIT
**38 AMPS
*5 AMPS REGULATED
**35 AMPS
*9 AMPS REGULATED
**39 AMPS
**310 AMPS
**316 AMPS
**320 AMPS
CHECKING DC AMPERAGE
OUTPUT
TEST LEAD
TEST LEAD
300mV
TERMINAL
position.
DC SHUNT
PART NUMBER
19468
TERMINAL
12
PUSH
SWITCH TO
ACTIVATE
STARTER
position.
TACHOMETER
READ RPM OF
STARTER MOTOR
TABLE 4
120 VOLT STARTER MOTOR SPECIFICATIONS
STARTER MOTOR
IDENTIFICATION
MAXIMUM
AMPERAGE
MINIMUM
RPM
American Bosch
SME110C3
SME110C6
SME110C8
3.5
7400
American Bosch
0602628M030SM
3.0
7400
Mitsubishi
J282188
3.5
7800
2.7
6500
Starter Assembly#
754185 (Kit)
12C300
754185 (Kit)
12C400
754185 (Kit)
12D300
754185 (Kit)
12D400
754185 (Kit)
699786 (Kit)
792157 (Kit)
190400-196499
693054
695708
696541
(C Ring Type)
190700-195799
693054
695708
696540
693713
693699
696541
(C Ring Type)
693713
252700-252799
693551
253700-253799
795121
194700-198799
795121
195400-195799
693552
19E400-19E499
19F400-19F499
19G400-19G499
19K400-19K499
280700-289799
28A700-28W799
Single Cylinder Intek Engines
120100-15D100
20A100-21P200
793667
120 volt
(60Hz Starter Assembly)
699786
230 volt
(50Hz Starter Assembly)
795909
120 volt
(60HZ Starter Assembly)
792157
230 volt
(50Hz Starter Assembly)
310700-310799
497595
695708
311700-311799
497595
695708
312700-312799
693551
693699
695708
497596
(3 5/8" Housing)
400700-422799
498148
(4 3/8" Housing)
42A700-42E799
696541
(C Ring Type)
696540
496181
406700-461799
V-Twin Vanguard Engines
303400-303499
499521
354400-354499
691564
695708
(Steel Pinion Gear)
N/A
696541
(C Ring Type)
496881
696541
(C Ring Type)
496881
(C Ring Type)
350700-350799
380400-381499
380700-381799
303700-303799
499521
304400-304499
691564
N/A
695708
691564
695708
696541
695708
696541
350400-350499
351400-351499
351700-351799
381400-381499
381700-381799
V-Twin Intek Engines
405700-405799
499521
406700-406799
407700-407799
445700-445799
14
RETAINING RING
CLUTCH
DRIVE
RETAINER
STARTER DRIVE
ASSEMBLY
DUST COVER
ROLL
PIN-SLOT
UP
RETURN SPRING
RETAINING RING
UPPER RETAINER
PINION
GEAR
SPRING
FLAT WASHER
WASHER
BEVELED EDGE UP
WAVE WASHER
CLUTCH
LOWER
RETAINER
STARTER
MOTOR
STARTER
CLUTCH
PINION
GEAR
HELIX
C-Ring Type
ALTERNATOR IDENTIFICATION
Briggs & Stratton engines are equipped with a
number of different alternator systems to meet the
requirements of equipment manufacturers. For
example, a large lawn tractor with accessories may
require a 16 amp regulated system, whereas a snow
thrower with a single headlight requires an AC Only
system. Knowing the type of alternator system an
STATOR OUTPUT
WIRE(S) AND
CONNECTOR
(TYPICAL)
TO EQUIPMENT
HARNESS
CONNECTOR
OUTPUT LEAD
DIODE
TO EQUIPMENT
HARNESS
AC Only
DC Only
LEAD AC
OUTPUT
LEAD DC
OUTPUT
TO EQUIPMENT
HARNESS
CONNECTOR
OUTPUT LEAD
DC CHARGING CIRCUIT
RED LEAD
TO EQUIPMENT
HARNESS
ONE RED
LEAD
CONNECTOR
LEAD
AC FOR LIGHTS
Dual Circuit
TO EQUIPMENT
HARNESS
5 AMP DC (-)
TO LIGHTS
WHITE LEAD
REGULATOR/
RECTIFIER
10 OR 16 Amp Regulated
CONNECTOR
CONNECTOR
TWO YELLOW LEADS
Tri-Circuit
TO EQUIPMENT
HARNESS
10 amp AC.
One BLACK lead from stator.
Green connector.
Two diodes encased in wire harness.
RED and white output leads.
CHARGING INDICATOR
CONNECTOR
TO EQUIPMENT
HARNESS
LEAD
FROM ENGINE
(STATOR)
CONNECTOR
CONNECTOR
YELLOW
WIRE
TWO YELLOW
LEADS
REGULATOR/
RECTIFIER
CONNECTOR
5 or 9 Amp Regulated
493219 Regulator/Rectifier
Used With Charge Indicator Circuit
ALTERNATOR
MAGNETS
*Small Magnet
7/8" x 11/16"
(22mm x 18mm)
*Large Magnet
1-1/16" x 15/16"
(27mm x 24mm)
17
The following are alternator replacement combinations which require an adapter harness. All of the
necessary components are shown.
1. Original engine equipped with AC Only alternator. Replacement engine equipped with Dual Circuit
alternator.
Modify 398661 harness supplied with replacement engine by removing RED DC wire. Then, splice 393537
connector into white AC wire and connect to equipment harness. See Fig. 1
393456 - DUAL CIRCUIT
REPLACEMENT CONNECTOR HARNESS
DUAL CIRCUIT CONNECTOR - MALE
(FROM ENGINE)
EQUIPMENT
HARNESS - FEMALE
WHITE CONNECTOR
AC WHITE WIRE
398661
HARNESS - FEMALE
AC
DC
SPLICE
DIODE
RIB
393537 - GREEN
CONNECTOR - MALE
RIB
BLACK WIRE
Fig. 1
2. Original engine equipped with DC Only alternator. Replacement engine equipped with Dual Circuit
alternator.
Modify 398661 harness supplied with replacement engine by removing white AC wire. Then, splice 393537
connector into RED DC wire and connect to equipment harness. See Fig. 2
393456 - DUAL CIRCUIT
REPLACEMENT CONNECTOR HARNESS
DUAL CIRCUIT CONNECTOR - MALE
(FROM ENGINE)
398661
HARNESS - FEMALE
EQUIPMENT
HARNESS - FEMALE
WHITE CONNECTOR
DC RED WIRE
AC
DC
DIODE
RIB
RIB
Fig. 2
18
SPLICE
393537 - GREEN
CONNECTOR - MALE
BLACK WIRE
3. Original engine equipped with Dual Circuit alternator. Replacement engine equipped with 5, 9, 10 or 16
amp regulated system.
Modify 692306 harness supplied with replacement engine by splicing in 399916 connector assembly. Connect
to equipment harness. See Fig. 3
NOTE: THE DIODES MUST BE REMOVED FROM THE EQUIPMENT HARNESS.
399916 CONNECTOR
ASSEMBLY - MALE
OUTPUT CONNECTOR
FROM REGULATOR - MALE
RED WIRE
RED CONNECTOR
398661 EQUIPMENT
HARNESS - FEMALE
SPLICE
692306
RED WIRE
HARNESS - FEMALE
BLACK WIRE
RIB
RIB
END PROFILE
MALE
FEMALE
Fig. 3
4. Original engine equipped with Tri-Circuit alternator. Replacement engine equipped with 5, 9, 10 or 16
amp regulated system.
Modify 692306 harness supplied with replacement engine by splicing into charging circuit wire and lighting
circuit wire in equipment harness. See Fig. 4
NOTE: THE DIODES MUST BE REMOVED FROM THE 692306 HARNESS BEING CONNECTED TO THE
EQUIPMENT HARNESS.
SPLICE
OUTPUT CONNECTOR
FROM REGULATOR - MALE
EQUIPMENT
HARNESS
RED WIRE
RED CONNECTOR
692306
HARNESS - FEMALE
Fig. 4
19
5. Original engine equipped with Dual Circuit alternator. Replacement engine equipped Tri-Circuit
alternator.
Discard 691955 diode harness supplied with new engine. Install 794360 regulator/rectifier. Add 692306
harness and modify by splicing in 399916 connector assembly. Connect to equipment harness. See Fig. 5
399916 CONNECTOR
ASSEMBLY - MALE
SPLICE
692306
HARNESS - FEMALE
BLACK
WIRE
RIB
RIB
398661 - EQUIPMENT
HARNESS - FEMALE
794360
REGULATOR/RECTIFIER
Fig. 5
6. Original engine equipped with 5 amp regulated system. Replacement engine equipped with Tri-Circuit
alternator.
Discard 691955 diode harness supplied with new engine. Transfer 491546 regulator/rectifier from original
engine to the new engine. Connect to equipment harness.
The following alternator replacement combinations require no modifications.
7. Original engine equipped with DC Only alternator. Replacement engine equipped with 5, 9, 10 or 16
amp regulated system. Direct Replacement. Connect to equipment harness.
8. Original engine equipped with 5 amp regulated system. Replacement engine equipped with 9, 10 or 16
amp regulated system. Direct Replacement. Connect to equipment harness.
9. Original engine equipped with 9 amp regulated system. Replacement engine equipped with 10 or 16
amp regulated system. Direct Replacement. Connect to equipment harness.
10. Original engine equipped with 10 amp regulated system. Replacement engine equipped with 9 or 16
amp regulated system. Direct Replacement. Connect to equipment harness.
appear to be identical, there are internal differences to keyswitches. Therefore it is necessary to have
a diagram of the keyswitch showing the terminal positions and their functions. For example, see the
5 terminal switch diagrams in Figure 1 and Figure 2. The keyswitch in Figure 1 is compatible with all Briggs &
Stratton alternators. Note in Figure 2, that when the brand X keyswitch is in the START position there is no
battery voltage available to the #2 switch terminal. Consequently, if the replacement Briggs & Stratton engine
was equipped with a carburetor solenoid, it would not function. This is why it is important to have a diagram
of the keyswitch when replacing engines, or replace the keyswitch with one that is compatible with all Briggs
& Stratton alternator systems.
NOTE: The 5 terminal Briggs & Stratton keyswitch, part number 490066, shown in Figure 1 has been
replaced by a 6 terminal keyswitch, part number 692318. The additional terminal provides a direct
connection for the charging lead at the keyswitch.
This is a "Truth Table"
Briggs & Stratton KEY
Switch 5 Terminal Positions
Terminal
No.
Function
1-G
2-L
To Carburetor Solenoid
3-M
4-S
5-B
4S
4S
4S
START
RUN
OFF
Figure 6
Part# 490066
Function
1-A
Accessory
2-M
3-R
To Regulator (Charging)
4-S
5-B
4S
4S
4S
START
RUN
OFF
Figure 7
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.
Terminal
NO.
Function
To Carburetor Solenoid
5 S
6 A
21
5 S
6 A
4
5 S
6 A
OFF
RUN
START
1-6-3
2-5-6
2-4-5
Figure 8
Part# 692318
STOP
SWITCH
TERMINAL
ANTI-AFTERFIRE
SOLENOID
ALTERNATOR
DIODE
AC OUTPUT
WIRE
KEY SWITCH
DC OUTPUT
WIRE
RED
RED
AMMETER
SOLENOID TAB
TERMINAL
HEADLIGHTS
HEADLIGHT
SWITCH
TO STARTER
TERMINAL
TO BATTERY
TERMINAL
RED
SOLENOID
RED
RED
RED
STARTER MOTOR
12 VOLT BATTERY
Function
Continuity
1. OFF
*1 + 3
To Carburetor Solenoid
2. RUN
2+5
2+4+5
3. START
22
STOP
SWITCH
TERMINAL
ANTI-AFTERFIRE
SOLENOID
ALTERNATOR
DIODE
KEY SWITCH
RED
DC OUTPUT
WIRE
AC OUTPUT
WIRE
AMMETER
RED
AMMETER
(OPTIONAL)
HEADLIGHTS
HEADLIGHT
SWITCH
RED
SOLENOID TAB
TERMINAL
TO STARTER
TERMINAL
TO BATTERY
TERMINAL
SOLENOID
RED
RED
+
STARTER MOTOR
12 VOLT BATTERY
Function
Continuity
1. OFF
*1 + 3 + 6
To Carburetor Solenoid
2. RUN
2+5+6
3. START
2+4+5
23
24
BATTERY
RED
RED
WHITE
CONNECTOR
BLACK
AC
OUTPUT
RED
DC
OUTPUT
DIODE
RED
STATOR
START
SWITCH
RED
STARTER
SOLENOID
RED
RED
STARTER
AMMETER
LIGHT
SWITCH
STOP
SWITCH
TERMINAL
ANTI-AFTERFIRE
SOLENOID
ALTERNATOR
KEY SWITCH
AC OUTPUT
WIRE
YELLOW
DC OUTPUT
RED WIRE
REGULATOR/
RECTIFIER
+
AMMETER
SOLENOID TAB
TERMINAL
RED
TO BATTERY
TERMINAL
HEADLIGHTS
TO STARTER
TERMINAL
RED
SOLENOID
HEADLIGHT
SWITCH
RED
RED
STARTER MOTOR
12 VOLT BATTERY
Terminal No.
Function
Continuity
1. OFF
*1 + 3
To Carburetor Solenoid
2. RUN
2+5
2+4+5
3. START
25
STOP
SWITCH
TERMINAL
ANTI-AFTERFIRE
SOLENOID
ALTERNATOR
KEY SWITCH
AC OUTPUT
WIRE
DC OUTPUT
RED WIRE
YELLOW
1
6
AMMETER
REGULATOR/
RECTIFIER
AMMETER
(OPTIONAL)
SOLENOID TAB
TERMINAL
RED
TO BATTERY
TERMINAL
TO STARTER
TERMINAL
HEADLIGHTS
SOLENOID
HEADLIGHT
SWITCH
RED
RED
+
STARTER MOTOR
12 VOLT BATTERY
Function
Continuity
1. OFF
*1 + 3 + 6
To Carburetor Solenoid
2. RUN
2+5+6
3. START
2+4+5
26
ALTERNATOR
STOP
SWITCH
TERMINAL
ANTI-AFTERFIRE
SOLENOID
CHARGE
INDICATOR
LIGHT
AC OUTPUT
WIRE
YELLOW
BLUE WIRE
1
6
AMMETER
REGULATOR/
RECTIFIER
RED WIRE
DC OUTPUT
RAISED RIB
SOLENOID TAB
TERMINAL
AMMETER
(OPTIONAL)
TO BATTERY
TERMINAL
RED
TO STARTER
TERMINAL
HEADLIGHTS
SOLENOID
HEADLIGHT
SWITCH
RED
RED
+
STARTER MOTOR
12 VOLT BATTERY
Function
Continuity
1. OFF
*1 + 3 + 6
To Carburetor Solenoid
2. RUN
2+5+6
3. START
2+4+5
27
28
STARTER
ALTERNATOR
BATTERY
LIGHT
SWITCH
RED
RED
RED
RED
SEAT
SWITCH
AMMETER
ELECTRIC
CLUTCH
STARTER
RELAY
- +
RED
A
B
D
C
C
A
CLUTCH
BRAKE
SWITCH
TRI-CIRCUIT
STATOR
STOP
SWITCH
TERMINAL
ANTI-AFTERFIRE
SOLENOID
ALTERNATOR
KEY SWITCH
AC OUTPUT
WIRE
DC OUTPUT
RED WIRE
GREEN
AMMETER
REGULATOR/
RECTIFIER
SOLENOID TAB
TERMINAL
AMMETER
(OPTIONAL)
TO BATTERY
TERMINAL
RED
TO STARTER
TERMINAL
HEADLIGHTS
SOLENOID
HEADLIGHT
SWITCH
RED
RED
STARTER MOTOR
12 VOLT BATTERY
Function
Continuity
1. OFF
*1 + 3 + 6
To Carburetor Solenoid
2. RUN
2+5+6
3. START
2+4+5
29
TRI-CIRCUIT
STATOR
AC OUTPUT
WIRE
ALTERNATOR
STOP
SWITCH
TERMINAL
ANTI-AFTERFIRE
SOLENOID
KEY SWITCH
GREEN
- DC OUTPUT
WIRE
+ DC OUTPUT
WIRE
HEADLIGHT
SWITCH
6
AMMETER
RED
RED
AMMETER
(OPTIONAL)
HEADLIGHTS
TO BATTERY
TERMINAL
SOLENOID TAB
TERMINAL
TO STARTER
TERMINAL
CLUTCH
SWITCH
SOLENOID
RED
RED
ELECTRIC
CLUTCH
+
STARTER MOTOR
12 VOLT BATTERY
Terminal No.
Function
Continuity
1. OFF
*1 + 3 + 6
To Carburetor Solenoid
2. RUN
2+5+6
3. START
2+4+5
Switch Position
30
31
B
LIGHT
SWITCH
PT O
SWITCH
GREEN
CONNECTOR
INTERLOCK
SWITCH
RED
STATOR
25W RESISTOR
WHITE WIRE
RED
BATTERY
RED
STARTER
SOLENOID
RED
CLUTCH
START
SWITCH
STARTER
32
RED
AMMETER
ELECTRIC CLUTCH
RESISTOR
RED
SEE NOTE
12 VOLT BATTERY
SOLENOID
KEY SWITCH
TO BATTERY
TERMINAL
ANTI-AFTERFIRE
SOLENOID
RED
STARTER
TERMINAL
SOLENOID TAB
TERMINAL
STOP
SWITCH
TERMINAL
STARTER MOTOR
Typical Tri-Circuit Alternator Wiring Diagram With Resistor 5-Pole Switch Briggs & Stratton Part# 692318
2+4+5
2+5
2. RUN
3. START
*1 + 3
Continuity
1. OFF
Switch Position
CLUTCH
SWITCH
ON
OFF
+ DC OUTPUT
RED WIRE
GREEN
AC OUTPUT
WIRE
HEADLIGHTS
HEADLIGHT
SWITCH
- DC OUTPUT
WIRE
ALTERNATOR
TRI-CIRCUIT
STATOR
33
RED
CLUTCH
DPDT
SWITCH
ON
OFF
ELECTRIC
CLUTCH
RESISTOR
TO BATTERY
TERMINAL
RED
ANTI-AFTERFIRE
SOLENOID
12 VOLT BATTERY
SOLENOID
RED
KEY SWITCH
RED
TO STARTER
TERMINAL
STARTER
MOTOR
SOLENOID TAB
TERMINAL
STOP
SWITCH
TERMINAL
Typical Tri-Circuit Alternator Wiring Diagram With Resistor 6-Pole Switch Briggs & Stratton Part# 692318
2+4+5
2+5
2. RUN
3. START
*1 + 3
+ DC OUTPUT
WIRE
GREEN
AC OUTPUT
WIRE
AMMETER
Continuity
1. OFF
Switch Position
HEADLIGHTS
HEADLIGHT
SWITCH
- DC OUTPUT
WIRE
ALTERNATOR
TRI-CIRCUIT
STATOR
34
START
SWITCH
BATTERY
RED
RED
RED
- +
STATOR
SEAT
SWITCH
D
C
B
A
CLUTCH/
BRAKE
SWITCH
FUSE
GREEN
CONNECTOR
RED
WHITE WIRE
C
PT O
SWITCH
AMMETER
PT O
CLUTCH
LIGHT
SWITCH
RED
STARTER
RELAY
RED
STARTER
M40/44/49 with #1
side regulator,
with EFM
2 pin, standard
691220
691220
na
691208
797463
797463
na
797424
796860
698330
797460
797492
696576
797461
796960
796852
796852
796852
na
797454
797454
na
yes
yes
6 pin, standard
Associated Parts
Shield/Nut Assembly #1 side
EQUIPMENT CONNECTION
EQUIPMENT CONNECTION
EQUIPMENT CONNECTION
TERMINAL
END
WIRE
END
WIRE
END
WIRE
END
TERMINAL
END
VIEW FROM
TERMINAL END
TERMINAL
END
VIEW FROM
VIEW FROMTERMINAL END
TERMINAL END
IF APPLICABLE
OIL PRESSURE
(GREEN)
OIL PRESSURE (GREEN)
IF APPLICABLE
IF APPLICABLE
VOLTAGE REGULATOR
VOLTAGE
REGULATOR
VOLTAGE
REGULATOR
(RED
WIRE)
(RED
WIRE)
(RED WIRE)
STARTER
SOLENOID
STARTER
SOLENOID
STARTER
SOLENOID
( YELLOW
WIRE)
( YELLOW
WIRE)
( YELLOW
WIRE)
FUEL SHUT-OFF
FUEL SHUT-OFF
(GRAY WIRE)
(GRAY WIRE)
FUEL SHUT-OFF
(GRAY WIRE)
INSTALLPLUG
SEALING PLUG
INSTALL SEALING
EMPTY #6 POSITION
#6IN
POSITION
IN EMPTY IN
#6 EMPTY
POSITION
1
2
IGNITION KILL
IGNITION KILL
(BLACK WIRE)IGNITION KILL
(BLACK WIRE)
IGNITION (BLACK)
* IGNITION*(BLACK)
(BLACK WIRE)
* IGNITION (BLACK)
GROUND (BROWN)
GROUND (BROWN)
VOLTAGE (RED)
REGULATOR (RED)
VOLTAGE REGULATOR
STARTER
SOLENOID (YELLOW)
STARTER SOLENOID
(YELLOW)
FUEL
CUT-OFF (GRAY)
FUEL CUT-OFF
(GRAY)
GROUND (BROWN)
DEUTSCH
DEUTSCH
1PD-USA
1PD-USA
DEUTSCH
DT06-6S
DT06-6S
OIL (GREEN)
PRESSURE (GREEN) OIL PRESSURE (GREEN)
OIL PRESSURE
* TO KILL
ENGINE
* TO KILL ENGINE
CONNECT
TOCONNECT
GROUND TO GROUND
GROUND GROUND
(BROWN WIRE)
(BROWN WIRE)
DEUTSCH
DEUTSCH
1PD-USA
1PD-USA
DT04-6PDT04-6P
GROUND
(BROWN WIRE)
1PD-USA
DT06-6S
35
DEUTSCH
1PD-USA
DT04-6P
L
Red jumper wire
790544 - Wire/Connector-ALT
Magnetron Armature
Fuel Solenoid
L
Ground
Alternator System
Fuel Solenoid
Ground
Alternator System
Fuel Solenoid
Stop Switch
Alternator System
Series
Fuel Solenoid
Stop Switch
Oil Pressure Switch
Alternator System
Stop Switch
Alternator System
36
GREEN
GRAY
GRAY
REGULATOR
(IF EQUIPPED)
OPEN
BLACK
GREEN
BLACK
RED
DUAL CIRCUIT
ALTERNATOR
(IF EQUIPPED)
TOP
RED
ORANGE
ORANGE
BOTTOM
37
38
E
15
SEE DETAIL K
GRAY
DETAIL K KEY
6
DIODES
CRIMPED CONNECTION
14
15
SHRINK TUBING
6 PIN
CONNECTOR
DETAIL
K
RED
14
JUMPER WIRE
BETWEEN 1&4
RED
4
1
3
2
6
5
"ROUTE" TO TERMINAL
HOLE No's AS SHOWN.
RIB
14
BLACK
CURRENT FLOW
CYL. 2
CYL. 1
6 5
THERMISTOR (SIGNAL)
THERMISTOR (GND)
SIGNAL
2-WAY CONNECTOR
SIGNAL
---
TERMINAL #
TERMINAL #
1
2
3
4
5
6
7
8
8-WAY CONNECTOR
39
STATOR
YELLOW
RED
RED
GRAY
5 & 9 AMP
CIRCUIT OPTION
CARB SOLENOID
3
5
RED
RED
GRAY
BLACK
RED
WIRE COLOR
6 PIN CONNECTOR
(ENGINE SIDE)
RED
2
3
4
5
6
TERMINAL #
BLACK
GROUND
(ON CYLINDER SHIELD)
16 AMP
CIRCUIT OPTION
BLACK
BLACK
GRAY
6 PIN CONNECTOR
YELLOW
GRAY
TERMINAL
THERMISTER
BLACK
GRAY
STEPPER MOTOR
ASSEMBLY
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
8-WAY CONNECTOR
DIODE
DIODE
CYLINDER #1
ARMATURE
CYLINDER #2
ARMATURE
BLACK
CARB SOLENOID
WIRE CONNECTORS
V-TWIN 6 PIN CONNECTOR
ENGINE CONNECTION
APPLICATION CONNECTION
RIB IS AT HOLE #1
TO LIGHT SWITCH
"A" TERMINAL
HOLE #2 "MAGNETO" COLOR: BLACK
KEYSWITCH "M" TERMINAL
HOLE #6 "OPEN"
TO OIL LIGHT
HOLE #3 "FUEL SOLENOID" COLOR: GREY
HOLE #6 "OPEN"
KEYSWITCH "L" TERMINAL
APPLICATION CONNECTION
TO LIGHT SWITCH
ENGINE CONNECTION
APPLICATION CONNECTION
APPLICATION CONNECTION
ENGINE CONNECTION
APPLICATION CONNECTION
40
41
TO MAIN
HARNESS
(BLACK)
WIRE
END
WIRE
END
13
VIEW FROM
TERMINAL END
TERMINAL
END
(GREY)
(BROWN)
(BROWN)
(GREEN)
(GREY)
(BLACK)
WHT
O/W
VIO
ENGINE
ENGINE
5020090
STARTER
SOLENOID
3.00
TIE WRAP
3/8 X 9
TO MAIN
HARNESS
5020091
5.0
TIE WRAP
3/8 X 9
AIR-COOLEDKawasaki
KAWASAKI
JUMPER
WIRE
HARNESS
- 799615
Air-Cooled
Jumper
Wire
Harness
- 5402307
(GREEN)
(YELLOW)
(RED)
GROUND
(BLACK)
STARTER SOLENOID
BATTERY + (ORANGE)
OPEN SLOT
TERMINAL
END
IGNITION KILL
(BLACK)
GROUND (BROWN)
(BROWN)
VIEW FROM
TERMINAL END
FUEL CUT-OFF
(GRAY)
OPEN SLOT
STARTER
SOLENOID
TAB (YELLOW)
VOLTAGE REGULATOR
(RED)
WIRE
END
ORANGE/WHITE 3
TIE WRAP
GROUND
VIOLET 3
O/W
VIO
YEL
WHT
5020914
WHT
O/W
WHITE 3
VIOLET 3
VIO
5020907
5100357
O/W
VIO
YEL
WHT
5021461
5020914
VIO
O/W
TO MAIN
HARNESS
5020906
5020907
YEL
WHT
YELLOW 14
ORANGE/WHITE 6
WHITE 6
VIOLET 6
BLACK 17
GROUND
5020087
ENGINE
5023171
5023172
O/W
VIO
TO MAIN
HARNESS
5020906
5020907
YEL
WHT
YELLOW 14
ORANGE/WHITE 6
WHITE 6
VIOLET 6
BLACK 17
GROUND
5020087
YELLOW 8
YELLOW 8
TIE WRAP
STARTER
SOLENOID
5023206
TIE WRAP
VIOLET 6
VIOLET 6
O/W
O/W
VIO
O/W
WHT
O/W
WHT
5020914 TO ENGINE
5021517
5020914
TO ENGINE
VIO5021517
ORANGE/WHITE 6
ORANGE/WHITE 6
WHITE/RED 6
WHITE/RED 6
WHT
O/W
VIO
3.00
VIOLET 8
ENGINE
3.00
TIE WRAP
TIE WRAP
3/8 X 9
3/8 X 9 ENGINE
5020090
ENGINE
5020090
GROUND
5020087
GROUND
5020087
WHITE 8
VIO
TO MAIN
WHITE 8
HARNESS
WHT
O/W
VIOLET 8
ENGINE
ORANGE/WHITE 8
ORANGE/WHITE 8
TO MAIN
HARNESS
ENGINE
5023171
5023172
TO MAIN
YEL
VIO WHT
HARNESS
MAIN O/W
5020906 TOO/W
YEL
VIO
WHITE 6
5020907 HARNESS
5020906
O/W O/W
WHITE 6
5020907
WHT
TO STARTER
SOLENOID
5020090 TO STARTER
SOLENOID
5020090
STARTER
SOLENOID
5023206
STARTER
SOLENOID
KOHLER
ENGINE
HARNESS
- 799616
JUMPER - TWR WIRE HARNESS - 799617
Kohler
Engine
WireWIRE
Harness
- 5406515
ELS Jumper - TWR Wire Harness - 5402519
3.00
TIE WRAP
ENGINE
5020090
ORANG
IS2000
Kawasaki
26 HP
Jumper
Wire Harness
- 5401951
IS2000
KAWASAKI
26
799618
IS2000
Kawasaki
26HP
HPJUMPER
JumperWIRE
Wire HARNESS
Harness -- 5401951
ELS Jumper - TWR Wire
Harness
- 5402519
42
WIRE
END
43
TO STARTER
TO
STARTER
SOLENOID
SOLENOID
VIO
VIO
WHITE 8
WHITE 8
O/W
O/W
WHT
WHT
VIOLET 8
VIOLET 8
ENGINE
ENGINE
TIE WRAP
3/8 X 9
3/8 X 9
ENGINE
ENGINE
5020090
5020090
VIOLET 8
VIOLET 8
TIE WRAP
TIE WRAP
VIO
VIO
BLK
BLK
WHT
WHT
O/W
O/W
TO
TO
HARNESS
HARNESS
5023495
5023495
5020014
5020014
YELLOW 9
YELLOW 9
BLACK 17
BLACK 17
5.00
5.00
TIE WRAP
TIE WRAP
TO MAIN
TO MAIN
HARNESS
HARNESS
3/8 X 9
3/8 X 9
GROUND
GROUND
TO MAIN
TO MAIN
HARNESS
HARNESS
WHITE 6
WHITE 6
ORANGE/WHITE 6
ORANGE/WHITE 6
VIOLET 6
VIOLET 6
3/8 X 9
3/8 X 9
O/W
O/W
O/W
BLK
WHT
YELLOW 9
VIO
ORANGE/WHITE 3
YEL
TO MAIN
HARNESS
1.50
1/2 X 3
TIE WRAP
TO ENGINE
VIOLET 5
3/8 X 3
TO ENGINE
BLACK 9
TO STARTER
SOLENOID
S800S800
Kawasaki
Jumper
WireWIRE
Harness
- 5404653
KAWASAKI
JUMPER
HARNESS
- 799621
2X0
2X0
VIO
VIO
WHITE 8
WHITE 8
O/W
O/W
WHT
WHT
BLACK 9
BLACK 9
Briggs
Briggs &
& Stratton
Stratton Jumper
Jumper Wire
Wire Harness
Harness -- IS20000Z
IS20000Z
TO MAIN
TO MAIN
HARNESS
HARNESS
ORANGE/WHITE 8
ORANGE/WHITE 8
GROUND
GROUND
5020087
5020087
Briggs
Jumper
Wire
Harness
-- 5401204
Briggs &
&
Stratton
Jumper
Wire
Harness
5401204
BRIGGS
& Stratton
STRATTON
JUMPER
WIRE
HARNESS
- 799620
3.00
3.00
TO ENGINE
TO
ENGINE
5023171
5023171
5023172
5023172
WRAP
FERRIS/SNAPPER PRO ENGINE TO TIE
EQUIPMENT
WIRE HARNESS
TO MAIN
TO MAIN
HARNESS
HARNESS
ORANGE/WHITE 8
ORANGE/WHITE 8
WHT
WHT VIO
VIO
44
4.25
4.25
45
45
7.5
47.25
7.5
7.125
45
16.0
7.0
8.0
8.0
7.0
7.0
46.5
46.5
46
6.5
20.0
8.5
14.5
14.5
15.0
13.5
9.5
8.75
16.0
47
7.75
12.25
15.5
7.0
14.0
18.5
48
8.5
12.5
11.25
14.5
5.0
2.25
2.25
5.5
14.25
6.5
2.5
49
(BLACK)
(BLACK)
(BLACK)
(YELLOW)
(BLACK)
(YELLOW)
WHITE
(YELLOW)
WHITE
(YELLOW)
WHITE
WHITE
(BROWN)
(BROWN)
(BROWN)
(Wire Ties)
(YELLOW)
(BROWN)
(ORANGE)
(RED)
(ORANGE)
(RED)
(ORANGE)
(RED)
(ORANGE)
(RED)
WHITE
IDLE
DOWN
DEVICE
BLUE
50 CYCLE
3000 RPM
LOOP
MODULE
STOP
SWITCH
TERMINAL
GREEN
ACTUATOR
RED
YELLOW
ALTERNATOR
KEY SWITCH
AC OUTPUT
WIRES
DC OUTPUT
WIRE
1
6
GREY
BLACK
4
STOP SWITCH HARNESS
DIODE
DIODE
REGULATOR/
RECTIFIER
SOLENOID TAB
TERMINAL
BATTERY
TERMINAL
STARTER
TERMINAL
IGNITION COILS
SOLENOID
+
STARTER
MOTOR
12 VOLT BATTERY
50
INCORRECT
CORRECTLY CRIMPED
CORRECT
51
52
53
AWG gauge
0000
000
00
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Metric 2.0
33
Metric 1.8
34
Metric 1.6
35
Metric 1.4
36
Metric 1.25
37
Metric 1.12
38
Metric 1
39
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
260.9
329
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
1079.12
1114
1360
1404
1715
1750
2163
2198
2728
3440
54
Maximum
amps for
chassis wiring
380
328
283
245
211
181
158
135
118
101
89
73
64
55
47
41
35
32
28
22
19
16
14
11
9
7
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
302
239
190
150
119
94
75
60
47
37
30
24
19
15
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
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
55
Red
to V
Regulated
two output pins with heat sink
Regulated
two output pin
Regulated
one output pin
Tri Circuit
28 volts AC
Output
From Regulator
From Stator
From Regulator
From Stator
Red to
10 amp
Red
to V
Red
to V
Red
to V
Red
to V
Red
to V
Red
to V
Red
to V
Red
to V
Volts
AC
Red to
10 amp
DC only
2-4 amps DC
From Stator
Amps
DC
Red
to V
AC only
14 volts AC
Dual Circuit
2-4 amps DC
14 volts AC
Amps
DC
Red to
10 amp
DC only
1.5 amp DC
300mV
Volts
AC
300mV
Volts
AC
300mV
Volts
AC
300mV
Volts
AC
Volts
AC
Amps
DC
Amps
DC
Red to
10 amp
DC only
1.2 amp DC
Amps
DC
Red to
10 amp
Tester Settings
SYSTEM 3 & 4
also quantum 120000
1/2 amp DC
Shunt on
Negative
Terminal
Yellow
Wire
Shunt on
Negative
Terminal
Either
Pin
Shunt on
Negative
Terminal
Shunt on
Negative
Terminal
Black
Wire
Red
Wire
Earth
Earth
Earth
3,600rpm
14 volts AC minimum
3,600rpm
2 to 4 amps DC
3,600rpm
2 to 4 amps DC
3,600rpm
14 volts AC minimum
3,600rpm
1.2 amps DC minimum
3,600rpm
1.0 amps DC minimum
2,800rpm
0.5 amps DC minimum
3,600rpm
20 volts AC minimum for 10 & 13 amp 30 volts
AC minimum for 16 amp
Shunt on 3,600rpm
Negative Test with regulator fully wired. Output up to 20
Terminal amps according to battery state
3,600rpm
26 volt AC minimum
Shunt on 3,600rpm
Negative Test with regulator fully wired. Output up to
Terminal 10/13/16 amps according to battery state
Other
Pin
Shunt on 3,600rpm
Negative Test with regulator fully wired. Output up to 5 or 9
Terminal amps according to battery state
3,600rpm
28 volts AC minimum for 5 amp
40 volts AC minimum for 9 amp
3,600rpm
Shunt on
up to 5 amps for battery
Negative
Refer to service & repair instructions for
Terminal
additional information
Shunt on
3,600rpm
Negative
28 volts AC minimum
Terminal
Tester Leads
GLOSSARY OF TERMS
In this day of lightning fast communications and an ever increasing level of sophistication in our day to day
activities, the spoken word has become one of the most important tools in our toolboxes. Word Power is
the natural extension of your thought processes. Without a high caliber vocabulary, communication with our
peers and/or our customers can be severely hampered. Customers will measure us more than we might
imagine, when we are unable to express our knowledge and expertise accurately and concisely. Exercising
the vocabulary is every bit as important as learning the latest new service procedure.
B
battery: An electrical energy storage device.
battery charge rectifier: A component which
changes AC voltage from the battery charge
windings (within the STATOR) to DC voltage. This
voltage could be used to charge a battery.
battery loading device: An electrical test tool
that applies an electrical load to the battery while
measuring amperage and voltage.
breaker point ignition system: An ignition system
that uses a mechanical switch to control timing of
ignition.
breaker points: An ignition system component that
has two points (contact surfaces) that function as a
mechanical switch.
bridge rectifier: A device that uses four
interconnected diodes to change one cycle of AC
current into two DC pulses.
brushes: Carbon components, in contact with the
commutator, that carry battery current to operate the
starter motor.
56
GI
E
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
F
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.
L
lamination stack: An electrical component that
consists of thin iron layers used to focus and control
the lines of magnetic flux.
57
MN
magnet: A material that attracts iron and produces
a magnetic field.
magnetic field: An area of magnetic force created
and defined by lines of magnetic flux surrounding a
material in three dimensions.
magnetic flux: The invisible lines of force in a
magnetic field.
magnetism: An atomic level force derived from
the atomic structure and motion of certain orbiting
electrons in a substance.
magneto: An alternator with permanent magnets
used to generate current for ignition in an internal
combustion engine.
RS
OP
Ohm: Unit of electrical resistance. One volt will
cause a current of one flow through a resistance of
one ohm.
Ohms law: A law that states the relationship
between voltage, current, and resistance in any
circuit.
parallel circuit: A circuit that has two or more paths
(branches) for current flow.
pathway: A conductor (commonly copper wire),
which connects different parts of the circuit.
permanent (hard) magnet: A magnet that retains
its magnetism after a magnetizing force has been
removed.
phase: The uniform periodic change in amplitude
or magnitude of an alternating current. Three phase
alternating current consists of three different sine
wave current consists of three different sine wave
current flows, different in phase by120 degrees from
each other.
TZ
temporary (soft) magnet: A magnet that can only
become magnetic in the presence of an external
magnetic field.
trigger: A magnetic pick-up located near the
crankshaft pulley that senses and counts crankshaft
rotation.
troubleshooting: The systematic elimination of
the various parts of a system or process to locate a
malfunctioning part.
vibration mount: A rubber device located between
the engine or generator and the cradle to minimize
vibration.
volt (V): The unit of measure for electrical pressure
difference between two points in a conductor or
device.
59
60
ThePowerPortal.com
Your One
Stop
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Your
One
Stop Source
Information
Source
Briggs & Stratton has developed a powerful and flexible private web-based portal for its
family of products, ThePowerPortal.com.
Features
10/23/2008
10:24
Page 1
DC only Alternator
0.5 Amp DC unregulated
Output @ 2800 rpm
97700
99700
100600
100800
110000
120000
Engine
110000
120000
200000
White Connector
1 Red Wire
Engine
3 Amp DC unregulated
Engine
104700
130000
12X400
15X400
20X400
21X400
White Connector
1 Black Wire
Engine
130200
Diode 391507
Red Connector
1 Black Wire
Red Connector
Diode 391507
White Connector
1 Black Wire
691991
794103
Engine
Since 1989
Alternator outside the flywheel
System 3 / System 4
DC only Alternator
Engine
Diode 391507
90000
110000
White Connector
3 Amp DC unregulated
Red
Connector
1 Black Wire
2 - 4 Amp DC unregulated
Engine
110000
120000
200000
210000
2 - 4 Amp DC unregulated
Engine
110000
120000
150000
200000
White Connector
1 Red Wire
Red Connector
1 Red Wire
Diode 391507
1 Red Wire
E-parts Look-Up
Diode
391507
397880
Since 1981
Alternator outside the flywheel
AC only Alternator
14 Volts AC
unregulated
White Connector
1 Black Wire
Engine
2 4 Amp DC / 5 Amp AC
14 Volts AC unregulated
White Connector
160000
170000
190000
210000
220000
243000
250000
280000
310000
320000
400000
420000
460000
1Black Wire
1 Red Wire
Engine
2 4 Amp DC / 5 Amp AC
14 Volts AC unregulated
White Connector
201000
210000
Diode 391507
Engine
150000
201000
210000
Diode
391507
790292
1 Red Wire
1 Yellow Wire
1 Black Wire
Engine
170000
190000
210000
220000
240000
250000
280000
300000
310000
326000
350000
380000
Engine
115400
117400
118000
185400
187400
Engine
790292
2 White
Connectors
1 Red Wire
1 Yellow Wire
1 Black Wire
793118
Since 2007
795498
691188
794360
696457
Engine
160000
170000
190000
210000
220000
250000
256000
280000
290000
300000
310000
320000
330000
350000
380000
400000
420000
440000
460000
698315
Diode 391507
White Connector
1 Yellow Wire
Yellow Connector
Engine
15X000
20X000
21X000
691955
Green Connector
2 4 Amp DC / 5 Amp AC
14 Volts AC unregulated
Black Wire
691188
794360
715200
Diode
391507
Green Connector
110000
120000
150000
200000
210000
280000
300000
698315
Green Connector
1 Black Wire
1 Red Wire
1 Yellow Wire
1 Black Wire
Engine
170000
190000
210000
220000
240000
250000
280000
290000
300000
310000
320000
330000
350000
380000
46X700
4 Amp DC regulated
Brass Connector
2 White
Connectors
2 White Connectors
1 Red Wire
1 Yellow Wire
1 Black Wire
Since 1994
Small magnets
2 4 Amp DC / 5 Amp AC
14 Volts AC unregulated
White Connector
790292
790292
715255
2 - 4 Amp DC unregulated
1 Red Wire
Diode 391507
Diode 391507
Since 1974
Small magnets
Red Connector
2 White Connectors
391595
Engine
170000
190000
210000
220000
240000
250000
280000
300000
310000
326000
350000
380000
10 Amp Alternator
whats new?
10 Amp DC regulated
Yellow Connector
Engine
Black Connector
110000
120000
200000
210000
2 Black Wires
2 Black Wires
10 Amp DC regulated
High Output
10 Amp DC regulated
Yellow Connector
Engine
120000
No Connector
Engine
10 Amp DC regulated
2 Black Wires
117400
138400
185400
Engine
23X400
24X400
Yellow Connector
10 Amp DC regulated
691185
691185
Engine
230400
240400
691185
790325
Yellow Connector
695466
Yellow Connector
2 Black Connectors
2 Yellow Wires
Red Connector
Since 2000
Small magnets
Yellow Connector
2 Yellow Wires
1 Red Wire
715194
Red Connector
Since 1974
Medium magnets
1 Red Wire
2 Yellow Wires
Red Connector
1 Red Wire
691573
Engine
44X700
White Connector
2 Yellow Wires
697261
Black Connector
697261
Engine
691185
35X400
Orange Connector
1 Orange Wire
Engine
305000
356000
White Connector
697261
2 Yellow Wires
Black Connector
White Connector
Black Connector
Yellow Connector
691573
1 Orange Wire
Black Connector
2 Yellow Wires
1 Black Wire
697261
Red Connector
697992
1 Black Wire
1 Orange Wire
Yellow Connector
2 Black Wires
Yellow Connector
2 Yellow Wires
White Connector
1 Brown Wire
1 Orange Wire
1 Red Wire
10 A Since 1978
397809
16 A Since 1983
Quad Circuit Since 1984
493219
808877
Engine
(10 A.) (16 A.)
160000
170000
190000
220000
250000
280000
290000
303000
310000
320000
330000
350000
380000
400000
420000
460000
(13 A.)
400000
420000
14 Amp DC regulated
20 Amp DC regulated
White Connector
691573
691362
1 Red Wire
White Connector
White Connector
825003
White Connector
2 Yellow Wires
White Connector
697992
Engine
430000
520000
580000
2 Yellow Wires
1 Red Wire
1 Red Wire
1 Black Wire
1 Yellow Wire
2 Blue Wires
1 Green Wire
40 Amp DC regulated
Engine
697992
White Connector 1 Blue Wire
White Connector 2 Red Wires
Black Connector
White Connector
Yellow Sheath 1 White Wire,
(QUAD)
170000
190000
220000
250000
280000
460000
1 Black Wire
40 Amp Alternator
290000
300000
350000
380000
470000
540000
220000
250000
280000
290000
303000
310000
320000
350000
380000
400000
420000
460000
Black Connector
2 Yellow Wires,
1 Red Wire
Black Connector
2 Black Wires
White Connector
809176
Connector Orange
1 Red Wire
Yellow Connector
697992
Engine
35X700
1 Orange Wire
1 Black Wire
Orange Connector
2 Yellow Wires
1 Red Wire
Orange Connector
Black Connector
696579
Since 1995
Large magnets
60 Amp DC regulated
Black Connector
20 Amp DC regulated
2 Black Wires
Engine
20H400
21A400
790325
2 Black
Connectors
2 Black Wires
1 Red Wire
793660
2 Black Connectors
793658
Since 2007
795498
Flywheel / Magnets
60 Amp Alternator
Engine
Engine
290000
303000
310000
350000
351000
380000
470000
540000
610000
Engine
430000
520000
580000
430000
520000
580000
841170
2 White Connector
SMALL:
SMALL:
MEDIUM:
MEDIUM:
LARGE:
LARGE:
Note : Unless specified, all tests must be carried out with the engine running at 3600 rpm.
The values indicated are minimium values. If the value measured is lower than
indicated a repeat test is advised before proceding any further.
MS-2288FL - 11/08
www.thepowerportal.com
ALBERTA
SASKATCHEWAN
MANITOBA
ONTARIO
QUEBEC
TUALATIN
A
OAKVILLE
ANOKA
CASTLETON
MEQUON
COLUMBUS
EDWARDSVILLE
PENDERGRASS
Magneto Power
MWE
Preferred Power
Atlantic Power
SEDCO
9/09
Anoka (Minneapolis)
MN
55303
Robert Moe
800-248-4016
Dallas
TX
75235
Robert Ortolani
262-834-4394
Mequon (Milwaukee)
WI
53092
Robert Moe
262-834-4300
Tualatin (Portland)
OR
97062
Greg Muse
800-338-5168
Aurora (Chicago)
IL
60504
Tom Ziemann
630-862-3100
Edwardsville (KC)
KS
66111
Tom Ziemann
913-543-7600
Visalia
CA
93291
John Reid
800-683-8484
UT
84120
Tom Ziemann
801-886-2350
Charlotte
NC
28216
Steve Krcelic
800-288-5310
Delta (Vancouver)
BC
V3M 6R9
Mike Gulley
604-520-1294
Oakville (Toronto)
ON
L6H 6X5
Mike Gulley
905-829-0006
Castleton
NY
12033
Art Falk
800-456-5692
Columbus
OH
43228
Pat Earnest
614-534-2152
Tampa
FL
33610
Ray Coyle
614-534-2140
7. SEDCO, INC
Pendergrass (Atlanta)
GA
30567
SEDCO, Inc.
Wayne Crosby
800-346-4260
Pendergrass (Atlanta)
GA
30567
SEDCO, Inc.
Mark Thomas
800-346-4260
01/11
BRIGGS&STRATTON
CORPORATION
MS-0415-02/11
CUSTOMER EDUCATION
post office box 702
milwaukee, WI 53201 USA
800 934 7730 | cust.ed@basco.com
Copyright 2011. All rights reserved.
ENGINE
ALTERNATOR
REPOWER GUIDE