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ADVANCE PRODUCT SERVICE INFORMATION SUBJECT: NEW 700 SERIES™ DIRECT OVERHEAD VALVE (DOV™) ENGINE
No: #54 DATE: 2/14/07 MODEL: 100600 Briggs & Stratton has recently introduced the new 700 Series™ Direct Overhead Valve (DOV™) engine family, designed with a unique lever arm valve actuating system. Patented by Briggs & Stratton, the benefit of the new lever arm concept reduces noise, vibration, and weight. The 700 Series™ engine features a 1.6 qt. (1.5 L) plastic fuel tank, a mechanical governor system, splash lubrication, and a 2-year consumer/90-day commercial limited warranty. Standard troubleshooting and failure analysis methods apply. The attached procedures and specifications are PRELIMINARY and subject to change. This APSI also provides a preview of a new approach to service and repair information that we will be implementing as part of a long-term publications improvement program. We hope you’ll find this pictorial format more informative and easier to use.
BRIGGS AND STRATTON CORPORATION Distribution Sales & Customer Support
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700 Series (Model 100600)
Direct Overhead Valve (DOV) EngineAdvance Product Service Information
1
• Start and run engine outdoors, not in an enclosed area, even if doors and windows are open.
• The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
• Work in a well-ventilated area, away from sparks, open flames, pilot lights, heat, and other ignition sources.
• Gasoline, it’s vapors and other gaseous vapors are extremely flammable and explosive.
Review the following before performing any service on the engine.WARNING
SAFETY 1
OVERVIEW 2
EXPLODED VIEW with Quick References 4
Partial List of GENUINE PARTS and TOOLS 10
PROCEDURES 11
ADJUSTMENTS 15
MAINTENANCE 18
Toxic Fumes
HazardousChemical
Moving Parts
Shock
Fire
Fire
Explosion
Hot Surface
Shatter
Wear eye protection when servicing engine.
The Safety Alert Symbol is used to identify safety information about hazards that can result in personal injury or death.
• Disconnect the spark plug wire from the spark plug, and disconnect the battery at the negative terminal (electric starter engines ) to prevent unintentional sparking. Unintentional sparking can result in fire or electric shock. Unintentional start-up can result in entanglement, traumatic amputation or laceration.
• When testing for spark: Use approved Spark Plug Tester (Page 10). Do not check for spark with spark plug removed.
• Allow muffler, engine cylinder and fins to cool before touching.
• Do not strike the flywheel with a hammer or hard object because the flywheel may later shatter during operation. Use approved Flywheel Strap Wrench and Puller (Page 10). Do not tamper with governor spring, links or other parts to increase engine speed.
• Fuel stabilizer is a hazardous chemical. (See product label for safety information).
Table of ContentsPage
OVERVIEW
2
Direct Overhead Valve (DOV) Engine
A Readystart™ Carburetor
B Splash Lubrication
C Polymer Timing Gear
D Single Lobe Cam Gear
E Mechanical Compression Release
F Lever Arms
G Patented Valve Train Design
H Valve Clearance Adjusters
I Readystart™ Thermostat (Automatic Choke)
J Flex-head Valves
K Iron Plated Piston
L Readystart™ Armature
A
B
CD E F
G
H
I
J
K
L
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3
BLOWER HOUSING, FUEL TANK, OIL
145 lb-in(16 Nm)
3/8"Drive
12 lb-in(1.5 Nm)
A B C D E F
8 mm
85 lb-in(10 Nm)
10 mm
30 lb-in(3.5 Nm)
8 mm
85 lb-in(10 Nm)
12 mm
D
A
C
B*
F
E
If nut (B*) does not loosen from stud (C), tightenthe nut until the stud is secure, then unscrewnut (B).
SUGGESTION
Use PLASTIC BAGS and aPERMANENT MARKER - toorganize components beingremoved.
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WARNING
DISCONNECT:
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NOTE:
4
AIR CLEANER, CARBURETOR
V
V
C
D
E
2
3
B
A
1
V
C
8 mm
40 lb-in(4.5 Nm)
17.5 lb-in(2 Nm)
8 mm
B E
8 mm
85 lb-in(10 N m)
T25 Torx™
D
17 mm
Tightensecurely.
A
10 mm
30 lb-in(3 Nm)
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Page 18
Page 17
Page 15
*
*
*
***
*
STOP SWITCH (1) - used on rewind start versions. PARTS (2) serviced as an assembly only. Optional (3)( ) KIT, Carburetor Overhaul (See Page 10)
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*
NOTES:
•
• •
A B C D E
ARMATURE, ALTERNATOR, BRAKE, STARTER
85 lb-in(10 Nm)
47 lb-in(5.5 Nm) 85 lb-in
(10 Nm)
85 lb-in(10 Nm)
40 lb-in(4.5 Nm)
60 lb-in(8 Nm)
12 mm 13 mm12 mm 8 mm8 mm
13 mm
A B C
E
D
A B
D
1
REWIND START
ELECTRIC START
5
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Ground Wire is attached to a CLIP (1) under flywheel guard.
NOTE:
•
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BREATHER, FLYWHEEL, MUFFLER
A CB FD E
60 lb-ft(81 Nm)
40 lb-in(4.5 Nm)
24 mm 8 mm
23 lb-in(2.5 Nm)
8 mm
55 lb-in(6 Nm)
8 mm
45 lb-in(5 Nm)
7/32"KEY
G
6
E
D
C
A
B
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ELECTRICSTART
REWINDSTART
FGH
FGH
85 lb-in(10 Nm)
13 mm
H
REWIND START ONLY
REWIND or ELECTRICSTART
Lock TAB
CYLINDER HEAD ASSEMBLY
A
B
D
C
210 lb-in(24 Nm)
25 lb-in(3 Nm)
10 mm8 mm
55 lb-in(6 Nm)
10 mm
2.5 mmAllen
5/8"
B CA D
SUGGESTION
Use PLASTIC BAGS and a PERMANENT MARKER - to organizecomponents being removed.
7
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Page 19
Page 16
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1
CUT AWAY VIEW (1) - showing Lever Arms installed.
NOTE:
•
1
2
3
46
7
8
5
ENGINE SUMP, CAM GEAR, GOVERNOR GEAR
110 lb-in(12 Nm)
8 mm
A
1
3
4
5
6
9
7
2
A
8
8
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Important: To protect Crankshaft Threads, reinstall Flywheel Nut (1).
TORQUE SEQUENCE (2)
CUT AWAY VIEW - Retaining Rib (3) in governor gear.
Pry off Governor Gear (4) with screw driver. Replace with new governor gear.
Oil Slinger Assembly (5) (not serviceable)
Cam Gear (6)
When assembling Cam Gear align marks as shown (7).
Governor Crank (8)
Install Governor Crank as shown (9).
NOTES:
•
• •
•
• • •
• •
A B
97.5 lb-in(11 Nm)
PISTON ASSEMBLY, CRANKSHAFT
8 mm
A B
9
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Page 14
10
Partial List of: GENUINE PARTS Partial List of: GENUINE TOOLS
Air Cleaner
PART # DESCRIPTION
793676 Pre-Cleaner (foam)
792038 Cartridge
Spark Plug
Used on Types:
692051 0015, 0100, 0121
292720 0110, 0111, 0112, 0115, 0116, 0118, 0119, 0122, 0123
Carburetor
793493 Assembly, Carburetor, READYSTART™ (with standard Main Jet)
793622 KIT, Carburetor Overhaul
Gasket Sets
793624 SET, Valve Gasket (Includes items with [ ] below.)
793623 SET, Engine Gasket (Includes all items below.) *Seal, Valve *Gasket, Cylinder Head *Gasket, Intake *Gasket, Exhaust *Gasket, Rocker Cover Seal, Oil (Megneto side) Gasket, Breather Gasket, Crankcase (.015˝ thick)
Seal, Oil (PTO side) Gasket, Air Cleaner
PART # DESCRIPTION
5056 Oil Evacuator Pump 19433 Flywheel Strap Wrench 19069 Flywheel Puller 19070 Piston Ring Compressor 19400 Spark Testor 19374 Spark Plug Wrench
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RECYCLERECYCLERECYCLE
1. Make sure fuel cap (B) is installed tightly.
DRAINING FUEL TANK (Steps 2 thru 4)
WARNING IS
11
PROCEDURES
Note: The fuel tank has a 150-micron fuel filter (A) molded into fuel outlet.
4. Hold the line over a fuel can and release the clamp (E).
5. Fuel flow should be as wide as the inside diameter of the fuel line. If it isn’t remove fuel cap and then check flow. A cap that doesn’t vent properly [(breather holes (F)], will not allow fuel to flow from the tank to the carburetor.
6. If needed, clean or replace appropriate parts, fuel line, cap, or tank.
CHECKING FUEL FLOW (Steps 1 thru 6)
E
D
F
SERVICE TOOL TIP
Place a piece of fuel line over each jaw.
2. With a pliers loosen and slide hose clamp (C) away from the carburetor.
3. Clamp fuel line (D) an inch from the carburetor then turn and pull until line releases.
DISCONNECT:
WARNING
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A
B
C
CUT AWAY VIEW
1. Place rag (A) in the combustion chamber, to hold valve in place while compressing spring (B).
2. Orient opening (C) in retainer toward you.
3. Press down on retainer (D) and
4. Push away to release.
Note: Keep assembly parts together (E).
REMOVING RETAINER LOCKS
Important: To remove and install engine brakefasteners (A), first compress bracket to releasetension.
A
ENGINE BRAKE
12
A
B
C
Level Engine while draining.
DRAINING OIL (3 OPTIONS)
Clean Drain Plug before removing.Tools: wire brush and rag.
Clean dip stick cap before removing.
Keep air cleaner UP when tipping.•
•
•
Level engine while draining.
• •
Clean dip stick cap before removing. •
• Oil Evacuator Pump Part Number 5056
D
E
RECYCLE
145 lb-in(16 Nm)
3/8"Drive
ININ
USED OILRECYCLERECYCLERECYCLE
RECYCLE
C
UP
PROCEDURES
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FLYWHEEL
Installation
WARNING
DO NOT DROP or STRIKE flywheel with a hard object or a metal tool as this may cause flywheel to shatter in operation. Always use approved flywheel removal tools.
13
1. REMOVE FLYWHEEL NUT (C) with strap (A), breaker bar (D), and 24 mm socket (E).
Flywheel Strap Wrench (A)Part Number 19433
Flywheel Puller Part Number 19069
Tighten puller nuts (B) equally until flywheelloosens.
Tighten puller bolts (A) equally until secure. •
•
RECYCLERECYCLERECYCLE
A
2. To PULL FLYWHEEL OFF:
Important: Keep strap below fins on flywheel. See Step 1.
CE
D
A
A
B
3/8˝ 7/16˝
60 lb-ft(80 Nm)
PROCEDURES
Removal
CHECKING THE IGNITION
1. Connect spark plug lead (A) to the long terminal (B) on tester, and ground tester to engine with alligator clip (C).
2. Use the rewind or electric starter to crank the engine. The ignition is functioning if a spark (D) jumps the gap.
Spark Tester Part Number: 19400
A
B
C
D
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PISTON INSTALLATION
14
• •
•
RECYCLERECYCLERECYCLE
PROCEDURES
D
*
*
*
*E
*
Piston Ring CompressorPart Number 19070
*
TABLE
J K
1/8˝
1. Install rings on piston by hand :
OIL RING (A) WIPER RING (B) - Note: The Wiper Ring has an identifying DOT on top of the ring. Always install ring with dot facing top of piston. COMPRESSION RING (C)
4. Space ring gaps (F) as shown before installing piston in compressor.
5. Insert piston in compressor (G) and tighten with a 1/4˝ DRIVE (H).
6. Loosen compressor so there is slight resistence.
7. Rotate and lift piston out 1/8˝ (I). This will help line it up with cylinder when installing.
2. Clean and lubricate parts (D).3. Install crankshaft and postion as shown (E).
G H
I
L
FF
F
**
C
AB
8. Place piston assembly with compressed rings into cylinder with notch (J) on piston facing down (flywheel side of engine).
Note: CUT AWAY VIEW (K) of cylinder.
9. Place shop rag (L) over ring compressor to protect hands. Push piston into cylinder with a smooth and quick action.
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1. Disconnect spark plug boot (A) from plug. 2. Loosen screw (B) and stud (C) clockwise.3. Slide armature (D) back.4. Tighten stud (C) counterclockwise to secure armature.5. Line up flywheel magnets (E) with armature.
ARMATURE ADJUSTMENT
.15 - .35 mm.
(.006 - .014" )
8. Tighten fasteners (B)(C) and torque as shown.9. Remove spacer (F) while rotating flywheel.
6. Insert spacing tool (F): .15 -.35 mm (.006 -.014˝)7. Loosen stud (C) allowing armature to contact magnets (E).
1. Place throttle control lever (A) in positions as shown.
2. Make measurements: (B) 2-1/8" (54 mm) minimum, (C) 1-3/8" (35 mm) minimum travel.
3. If not within the minimum, loosen screw (D).
4. Pull cable (E).
5. Tighten screw (D). Torque as shown.
SLOW
FAST85 lb-in(10 Nm)
8 mm
THROTTLE CABLE ADJUSTMENT
A
A
A
BC
C
D
E
E
F
B
D
C
E
ADJUSTMENTS
15
25 lb-in(2.8 Nm)
F
STOP
STOP
RECYCLERECYCLERECYCLE
B C
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DISCONNECT:
WARNING
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NEGNEG
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NEG —
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16
RECYCLERECYCLERECYCLE
ADJUSTMENTS
VALVE CLEARANCE (VC)
GAUGE, VALVE CLEARANCE (A)
SCREW, LEVER ARM ADJUSTING (B)
NUT, ADJUSTING SCREW (C)
ARM, LEVER (D)
CAP, VALVE (E)
RETAINER, VALVE SPRING (F)
SPRING, VALVE (G)
VALVE (H)
PISTON (I)
TOP DEAD CENTER (TDC)
• • • • • • • • • • •
VALVE CLEARANCE ADJUSTMENT
1. Engine should be COLD.
2. Insert a pencil (J) or a narrow screw driver into the spark plug hole (K) and touch the piston. This will be used to gauge the piston’s range of motion.
Note: CUT AWAY VIEW with piston shown (L).
3. Turn the flywheel (M) clockwise past Top Dead Center (TDC) on the compression stroke until the piston has moved down 1/4 in. (6.4 mm).
INTAKE
EXHAUST
.10 - .15 mm (.004 - .006 in.)
.36 - .41 mm (.014 - .016 in.)
Valve Clearance (VC)
VC
E
4. Check the Valve Clearance (VC) by placing the correct feeler gauge (A) between the lever arm adjusting screw (B) and the valve cap (E) .
5. Loosen the adjusting screw nut (C) with a 8 mm wrench.
6. Adjust the clearances as required by turning the adjusting screw (B). Use allen wrench 2.5 mm.
7. Once the adjustments are complete, tighten the adjusting screw nut (C). Torque: 70 in. lb. (8 Nm).
TDC
1/4˝
C DB
A
F G IH
COLD
K
L
70 lb-in(8 Nm)
8 mm A
C
B
E
2.5 mmAllen
M
J
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CHOKE LEVER GAP ADJUSTMENT STATIC GOVERNOR ADJUSTMENT
17
CHOKE LEVER GAP (A)CHOKE LEVER (B)CHOKE LINK (C)ADJUSTING LOOP (D)THERMOSTAT (E)
• • • • •
CD
G
1. Engine should be COLD.
2. Using pliers, bend adjusting loop (D) on choke link (C) to adjust the choke lever gap (A). When properly adjusted, choke plate (F) will be fully closed.
3. Reshape wire keeping it parallel (G) after adjusting loop.
COLD
1. Loosen bolt (A) until control lever (B) moves freely from governor crank (C).
2. Move throttle linkage (D) until the throttle plate lever (E) is wide OPEN.
NOTE: Choke plate (F) closes when opening throttleplate lever.
30 lb-in (3 Nm)
RECYCLERECYCLERECYCLE
.000 - .060˝(1/16˝)(.000 - 1.52 mm)
B
A
C
ED
CB
F
3. Hold the linkage (D) and the governor crank (C) (using a 4 mm wrench turning it clockwise) then tighten the governor lever clamp bolt (A). Torque: 30 lb-in (3 Nm).
ADJUSTMENTS
FD
B
A
C
CA
D
EOPEN
CLOSED
10 mm
4 mm10 mm
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CAUTION: Spark plugs have different heat ranges. Itis important the correct spark plug is used, otherwiseengine damage can occur.
NOTE: In some areas, local law requires using resistor spark plugs to suppress radio frequencyinterference.
SPARK PLUG
Inspect for Wear And DamageReplace if necessary.
R
MAINTENANCE
Important: If tipping engine during service, keep -
BREATHER / AIR FILTER
UP
FUEL
• Clean, fresh, unleaded gasoline.
• A minimum of 87 octane / 87 AKI (90 RON).
• Gasoline with up to 10% ethanol (gasohol) or up to 15% MTBE (methyl tertiary butyl ether) is acceptable.
• CAUTION: Do not use unapproved gasolines, such as E85. Do not mix oil in gasoline or modify the engine to run on alternate fuels. This will damage the engine components and void the engine warranty.
Fuels musts meet these requirements:
OIL
DO NOT use special oil additives.
NOTE: The use of synthetic oils does not alter the oil changeintervals.
** Above 80° F (27° C) the use of 10W30 may cause increased oil consumption. Check oil level more frequently.
* Below 40° F (4° C) the use of SAE 30 will result in hard starting.
32
14
-4
68
50
°F104
86
°C
-22
0
-10
-20
20
10
40
30
-30
SA
E 3
0 *
10W
30 *
*
Syn
thet
ic 5
W30
5W30
To protect the fuel system from gum formation, mix afuel stabilizer into the fuel. All fuel is not the same. Ifstarting or performance problems occur, change fuelproviders or change brands. This engine is certified tooperate on gasoline. The emissions control system for this engine is EM (Engine Modifications).
High AltitudeAt altitudes over 5,000 feet (1524 meters), a minimum85 octane / 85 AKI (89 RON) gasoline is acceptable. To remain emissions compliant, high altitudeadjustment is required. Operation without thisadjustment will cause decreased performance,increased fuel consumption, and increased emissions.See an Authorized Briggs & Stratton Dealer for high altitude adjustment information.
18
RECYCLERECYCLERECYCLE
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DISCONNECT:
WARNING
NEG( — — )
NEGNEG
POSPOS
NEG
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NEG
Check Gap
Installation
Tighten with Wrench: 1/2 turn - when reinstalling the original plug.1/4 turn - when installing a new plug.
Finger tighten then:
Clean with:
• Wire Brush
• Sturdy Knife
• CAUTION: DO NOT USE Abrasives
Use a Spark Plug Feeler Gauge (A) to check the gapbetween the two electrodes. When the gap is correct,the gauge will drag slightly as you pull it through thegap.
If necessary, use the bending tool (B) on the gauge toadjust the gap by gently bending the curvedelectrode without touching the center electrode or theporcelain (C).
.020˝(0.51 mm)
Spark Plug Wrench
Fits 5/8˝ and 3/16˝ Hex Spark Plugs
Part Number: 19374
C
A
B
19
5/8˝
RECYCLERECYCLERECYCLE
Cartridge
Replace cartridge if dirty.
Pre-cleaner (Optional)
1. Wash in warm soapy water (A) (liquid detergent).
AIR CLEANER
A
DO NOT use solvent, compressed air, or water toclean cartridge.
2. Squeeze dry in a clean cloth (B).
3. Do not oil.
B
DO NOT use solvent, or compressed air to cleanpre-cleaner.
MAINTENANCE
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RECYCLERECYCLERECYCLE
BRIGGS & STRATTON CORPORATION Distribution Sales & Customer Support Milwaukee, Wisconsin 53201
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