ADVANCE PRODUCT SERVICE INFORMATION

SUBJECT: No: DATE: MODEL: NEW 700 SERIES DIRECT OVERHEAD VALVE (DOV) ENGINE #54 2/14/07 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 youll find this pictorial format more informative and easier to use.

BRIGGS AND STRATTON CORPORATION Distribution Sales & Customer Support

700 Series (Model 100600)

Direct Overhead Valve (DOV) Engine Advance Product Service Information

Table of Contents
SAFETY OVERVIEW EXPLODED VIEW with Quick References Partial List of PROCEDURES ADJUSTMENTS MAINTENANCE GENUINE PARTS and TOOLS

Page 1 2 4 10 11 15 18

WARNING

Review the following before performing any service on the engine.

The Safety Alert Symbol is used to identify safety information about hazards that can result in personal injury or death. Wear eye protection when servicing engine.

Toxic Fumes Fire

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.

Explosion

Gasoline, its vapors and other gaseous vapors are extremely flammable and explosive.

Moving Parts

Fire

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.

Shock

Hot Surface

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).

Shatter

Hazardous Chemical

OVERVIEW
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

L K J

H B C D E F G

BLOWER HOUSING, FUEL TANK, OIL

A 8 mm B 8 mm 30 lb-in (3.5 Nm) 12 lb-in (1.5 Nm) 85 lb-in (10 Nm) 145 lb-in (16 Nm) 85 lb-in (10 Nm) C 12 mm D 10 mm 3/8" Drive E F

B*

NOTE: If nut (B * ) does not loosen from stud (C), tighten the nut until the stud is secure, then unscrew nut (B).

WARNING C DISCONNECT:

Page 12
NEG

()

D
G E S O P P P

N E G
N

Page 11

SUGGESTION Use PLASTIC BAGS and a PERMANENT MARKER - to organize components being removed.

Page 12 E

AIR CLEANER, CARBURETOR

A 10 mm B 8 mm C 8 mm D 17 mm E

NOTES:
8 mm T25 Torx 17.5 lb-in (2 Nm)

Tighten securely. 40 lb-in (4.5 Nm) 85 lb-in (10 N m)

30 lb-in (3 Nm)

STOP SWITCH (1) - used on rewind start versions. PARTS (2) serviced as an assembly only. Optional (3) (*) KIT, Carburetor Overhaul (See Page 10)

Page 17

A 2 Page 18

Page 17
V

* *
1

Page 15

* * *

*
E

C D

*
V

ARMATURE, ALTERNATOR, BRAKE, STARTER

A 12 mm B 12 mm C 8 mm D 13 mm E 8 mm

85 lb-in (10 Nm)

40 lb-in (4.5 Nm) 13 mm 85 lb-in (10 Nm)

47 lb-in (5.5 Nm)

Page 15
85 lb-in (10 Nm)

B Page 12 D

60 lb-in (8 Nm)

NOTE:

Ground Wire is attached to a CLIP (1) under flywheel guard.

Page 12 Page 15 A B C D REWIND START 1

E ELECTRIC START

BREATHER, FLYWHEEL, MUFFLER

A
24 mm

B
KEY

C
8 mm

D
8 mm

E
7/32"

F
8 mm

G
13 mm

60 lb-ft (81 Nm)

40 lb-in (4.5 Nm)

55 lb-in (6 Nm)

45 lb-in (5 Nm)

23 lb-in (2.5 Nm)

Page 13 ELECTRIC START REWIND START

85 lb-in (10 Nm)

D Lock TAB B

REWIND START ONLY H G F

H G

REWIND or ELECTRIC START

CYLINDER HEAD ASSEMBLY

A
5/8"

B
10 mm

C
8 mm 25 lb-in (3 Nm)

D
10 mm

NOTE:

CUT AWAY VIEW (1) - showing Lever Arms installed.

55 lb-in (6 Nm)

2.5 mm Allen

210 lb-in (24 Nm)

Page 19 A D

Page 16 C 1

Page 12

SUGGESTION Use PLASTIC BAGS and a PERMANENT MARKER - to organize components being removed.

ENGINE SUMP CAM GEAR, GOVERNOR GEAR ,

A
8 mm

2 NOTES: 6 4

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). A 3

110 lb-in (12 Nm)

7 6

8 4 5 3

PISTON ASSEMBLY, CRANKSHAFT

8 mm

97.5 lb-in (11 Nm)

Page 14

Partial List of:

GENUINE PARTS

Partial List of:

GENUINE TOOLS

Air Cleaner
PART # 793676 792038 DESCRIPTION Pre-Cleaner (foam) Cartridge PART # 5056 19433 19069 19070 19400 19374 DESCRIPTION Oil Evacuator Pump Flywheel Strap Wrench Flywheel Puller Piston Ring Compressor Spark Testor Spark Plug Wrench

Spark Plug
Used on Types: 692051 292720 0015, 0100, 0121 0110, 0111, 0112, 0115, 0116, 0118, 0119, 0122, 0123

Carburetor
793493 Assembly, Carburetor, READYSTART (with standard Main Jet) KIT, Carburetor Overhaul

793622

Gasket Sets
793624 793623 SET, Valve Gasket (Includes items with [ * ] below.) 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

10

PROCEDURES
WARNING DISCONNECT:
NEG

B
N E G

CUT AWAY VIEW

()

N G E S O P

WARNING

IS

CHECKING FUEL FLOW (Steps 1 thru 6)

Note: The fuel tank has a 150-micron fuel filter (A) molded into fuel outlet. 1. Make sure fuel cap (B) is installed tightly.

DRAINING FUEL TANK (Steps 2 thru 4)

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.

SERVICE TOOL TIP Place a piece of fuel line over each jaw. F

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 isnt remove fuel cap and then check flow. A cap that doesnt 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.

11

PROCEDURES

DRAINING OIL

(3 OPTIONS)

ENGINE BRAKE
Important: To remove and install engine brake fasteners (A), first compress bracket to release tension. A

Clean Drain Plug before removing. Tools: wire brush and rag.
Level Engine while draining.

145 lb-in (16 Nm)

3/8" Drive

RECYCLE

Clean dip stick cap before removing.

Level engine while draining.

Oil Evacuator Pump Part Number 5056

REMOVING RETAINER LOCKS

1. Place rag (A) in the combustion chamber, to hold valve in place while compressing spring (B).

IN
IN

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). E

RECYCLE

USED OIL

Clean dip stick cap before removing. Keep air cleaner UP when tipping. UP A D B C

RECYCLE

12

PROCEDURES

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.

1. REMOVE FLYWHEEL NUT (C) with strap (A), breaker bar (D), and 24 mm socket (E).

D E

Spark Tester

Part Number: 19400 A A

B Flywheel Puller Part Number 19069 C 2. To PULL FLYWHEEL OFF:

FLYWHEEL
Removal

Tighten puller bolts (A) equally until secure. Tighten puller nuts (B) equally until flywheel loosens.

3/8 A

7/16

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.

Flywheel Strap Wrench (A) Part Number 19433

Installation
Important: Keep strap below fins on flywheel. See Step 1. 60 lb-ft (80 Nm)

13

PROCEDURES

PISTON INSTALLATION
1. Install rings on piston by hand :

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.

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)

F G H

F TABLE

2. Clean and lubricate parts (D). 3. Install crankshaft and postion as shown (E). D

I 1/8

*
E 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.

*
*

* *
*

*
Piston Ring Compressor Part Number 19070

14

ADJUSTMENTS
WARNING DISCONNECT:
NEG

ARMATURE ADJUSTMENT
1. 2. 3. 4.
N E G
N G E

()

Disconnect spark plug boot (A) from plug. Loosen screw (B) and stud (C) clockwise. Slide armature (D) back. Tighten stud (C) counterclockwise to secure armature. 5. Line up flywheel magnets (E) with armature. A C B D

THROTTLE CABLE ADJUSTMENT

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.

S O P

6. Insert spacing tool (F): .15 -.35 mm (.006 -.014) 7. Loosen stud (C) allowing armature to contact magnets (E). F .15 (.0 - .35 06 m - .0 m. 14 ") C

E
SLOW
STOP

8. Tighten fasteners (B)(C) and torque as shown. 9. Remove spacer (F) while rotating flywheel. B 25 lb-in (2.8 Nm)

C B
FAST

STOP

8 mm 85 lb-in (10 Nm)

15

ADJUSTMENTS

VALVE CLEARANCE ADJUSTMENT

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) A E J COLD L K M

Valve Clearance (VC)

INTAKE .10 - .15 mm (.004 - .006 in.) VC 1/4 EXHAUST .36 - .41 mm (.014 - .016 in.)

8 mm

A C

70 lb-in (8 Nm)

2.5 mm Allen

BC D E F G

TDC

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 pistons 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).

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).

16

ADJUSTMENTS

CHOKE LEVER GAP ADJUSTMENT

CHOKE LEVER GAP (A) CHOKE LEVER (B) CHOKE LINK (C) ADJUSTING LOOP (D) THERMOSTAT (E) B

STATIC GOVERNOR ADJUSTMENT

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.

COLD C

NOTE: Choke plate (F) closes when opening throttle plate lever. CLOSED

10 mm OPEN .000 - .060(1/16) (.000 - 1.52 mm) D A E E

C B C

F A 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. D C 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). 10 mm 4 mm D

30 lb-in (3 Nm)

17

MAINTENANCE
WARNING DISCONNECT:
NEG

FUEL
Fuels musts meet these requirements:

()

Clean, fresh, unleaded gasoline. A minimum of 87 octane / 87 AKI (90 RON). Gasoline with up to 10% ethanol (gasohol) or up to
N E G
N G E S O P

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.

Important: If tipping engine during service, keep BREATHER / AIR FILTER

UP

To protect the fuel system from gum formation, mix a fuel stabilizer into the fuel. All fuel is not the same. If starting or performance problems occur, change fuel providers or change brands. This engine is certified to operate on gasoline. The emissions control system for this engine is EM (Engine Modifications). High Altitude At altitudes over 5,000 feet (1524 meters), a minimum 85 octane / 85 AKI (89 RON) gasoline is acceptable. To remain emissions compliant, high altitude adjustment is required. Operation without this adjustment will cause decreased performance, increased fuel consumption, and increased emissions. See an Authorized Briggs & Stratton Dealer for high altitude adjustment information.

OIL
F SAE 30 *
104 86 68 50 32 14 -4 -22

C
40

SPARK PLUG
CAUTION: Spark plugs have different heat ranges. It is important the correct spark plug is used, otherwise engine damage can occur. NOTE: In some areas, local law requires using resistor spark plugs to suppress radio frequency interference.

Synthetic 5W30

10W30 **

30 20 10 0

5W30

-10 -20 -30

Inspect for Wear And Damage

Replace if necessary.

* Below 40 F (4 C) the use of SAE 30 will result in hard starting. ** Above 80 F (27 C) the use of 10W30 may cause increased oil consumption. Check oil level more frequently.

DO NOT use special oil additives. NOTE: The use of synthetic oils does not alter the oil change intervals.

18

MAINTENANCE

Clean with:
Wire Brush Sturdy Knife

AIR CLEANER
Pre-cleaner (Optional)
1. Wash in warm soapy water (A) (liquid detergent). DO NOT use solvent, or compressed air to clean pre-cleaner. A

CAUTION: DO NOT USE Abrasives

Check Gap
Use a Spark Plug Feeler Gauge (A) to check the gap between the two electrodes. When the gap is correct, the gauge will drag slightly as you pull it through the gap. If necessary, use the bending tool (B) on the gauge to adjust the gap by gently bending the curved electrode without touching the center electrode or the porcelain (C). A .020 (0.51 mm) B C 2. Squeeze dry in a clean cloth (B). 3. Do not oil. B

Cartridge
Replace cartridge if dirty. DO NOT use solvent, compressed air, or water to clean cartridge.

Installation
Finger tighten then: Tighten with Wrench: 1/2 turn - when reinstalling the original plug. 1/4 turn - when installing a new plug.

5/8

Spark Plug Wrench

Part Number: 19374

Fits 5/8 and 3/16 Hex Spark Plugs

19

BRIGGS & STRATTON CORPORATION

Distribution Sales & Customer Support Milwaukee, Wisconsin 53201