Part of the John Deere Repair Manuals.
Hunting for a John Deere 250G technical manual PDF? This 174-page factory technical manual (OEM #TM1791) covers the whole generator family: 250G, 440G, 550GE, G2500K, G4400K, G5500K, and G5500KE. You get factory electrical schematics with circuit-by-circuit wire tracing, rotor and stator resistance tests, GFCI checks, and a full troubleshooting section for no-start, idle-control, and no-voltage conditions. Exploded views of the generator end, control panels, and recoil starter back up page after page of step-by-step procedures, from carburetor rebuilds to crankshaft end play adjustment. Torque the flywheel nut to 88 N-m (65 lb-ft) and pull the cylinder head cap screws down to 18.7 N-m before you button up the engine. No more chasing wiring faults with a multimeter and a prayer. Bookmarked with a live text layer: search any spec, jump straight to the test you need, and get your generator back online.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction and Safety | 3-6 | Recognize Safety Information, Prevent Acid Burns, Handle Fuel Safely, Service Generators Safely, Operating Precautions |
| General Specifications and Service Data | 9-25 | Model Specifications for 250G, 440G, 550GE, G2500K, G4400K, G5500K and G5500KE, Break-In and Service Oils, Fuel Type and Capacities, Metric and Inch Fastener Torque Values |
| Engine Troubleshooting, Tests and Adjustments | 26-29 | Engine Will Not Start or Runs Rough, Idle Control Faults, Slow and Fast Idle Adjustment, Engine Under Load Symptoms |
| Engine Repair - Briggs & Stratton 5 Hp and 8 Hp | 30-78 | Carburetor Removal, Disassembly and Installation, Muffler, Cylinder Head Inspection, Valve Guide Rebush and Seat Reconditioning, Valve Lapping, Governor Lever and Bushing, Piston and Connecting Rod Service, Piston Rings, Crankshaft End Play, Cylinder Deglazing and Rebore, Main Journal Rebush, Recoil Starter |
| Engine - Kawasaki FE170 (5.3 Hp) | 79-100 | FE170D Specifications, Valve Clearance Check, Automatic Compression Release Test, Ignition Coil Air Gap, Flywheel and Cylinder Head Service, Valve and Seat Reconditioning, Crankcase Cover, Tappets, Piston and Rod Service, Crankshaft and Cylinder Block Inspection |
| Engine - Kawasaki FE250/FE350 (8 Hp and 11 Hp) | 101-138 | FE250/FE350 Specifications and Repair Limits, Valve Clearance (G4400K), Ignition Coil Air Gap, Carburetor Service, Rocker Arm Inspection, Cylinder Head Service, Camshaft Removal and Inspection, Reciprocating Balancer, Crankshaft Removal and End Play, PTO Oil Seal, Oil Filter Manifold |
| Electrical System - Schematics and Diagnostics | 141-146 | Reading Electrical Schematics, Theory of Operation, Common Circuit Tests (Short, Open, High Resistance, Ground), Component Location |
| Generator End and Control Panel | 147-152 | End Bell, Stator and Harness, Rotor and Brush Head (250G/G2500K and 440G/G4400K/550GE/G5500K/G5500KE), Receptacles, Switches, Control Board, Circuit Breaker, Full Electrical Schematics |
| Electrical Troubleshooting and Tests | 153-162 | Voltage at Receptacles, Generator Tester Procedure, Rotor and Stator Resistance, Idle-Start Switch Test, Electromagnet Adjustment, Gfci Checks, Engine Oil Switch Test, Diode Test |
| Generator Repair and Assembly | 163-174 | Generator Disassembly and Reassembly Methods, Generator Tester Use, Field Flashing, Control Panel Removal and Wiring Connections |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| 250G, G2500K | ||
| Engine (250G, G2500K) | Briggs & Stratton 133412, 5 hp @ 3250 rpm, 206 cc | p. 23 |
| Engine oil capacity - 5 hp | 0.62 L (21 U.S. oz.) | p. 23 |
| 440G, 550GE | ||
| Engine (440G, 550GE) | Briggs & Stratton 196412, 8 hp @ 3250 rpm, 319 cc | p. 51 |
| Engine oil capacity - 8 hp | 1.42 L (48 U.S. oz.) | p. 51 |
| Kawasaki-powered units | ||
| Engine (Kawasaki option) | Kawasaki FE170D, 3.95 kW (5.3 hp) @ 3600 rpm | p. 81 |
| G4400K, G5500K, G5500KE | ||
| Engine oil capacity - FE250/FE350 | 1.4 L (3.0 pt.) | p. 103 |
| Spark plug torque - Kawasaki | 25 N•m (221 lb-in.) | p. 83 |
| 250G, 440G, 550GE, G2500K | ||
| Spark plug torque - Briggs & Stratton | 20 N•m (180 lb-in.) | p. 24 |
| Briggs & Stratton engines | ||
| Cylinder head cap screw torque | 18.7 N•m (165 lb-in.) | p. 54 |
| Flywheel nut torque | 88 N•m (65 lb-ft) | p. 54 |
| Valve clearance - intake | 0.13-0.18 mm (0.005-0.007 in.) | p. 24 |
| All Models | ||
| End bell to engine torque | 13.6-16.9 N•m (120-150 lb-in.) | p. 13 |
| Fuel type | Unleaded gasoline, 87 octane | p. 23 |
