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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.
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
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.
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
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
NOTES:
8 mm T25 Torx 17.5 lb-in (2 Nm)
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
Page 15
85 lb-in (10 Nm)
B Page 12 D
60 lb-in (8 Nm)
NOTE:
E ELECTRIC START
B
KEY
C
8 mm
D
8 mm
E
7/32"
F
8 mm
G
13 mm
55 lb-in (6 Nm)
45 lb-in (5 Nm)
D Lock TAB B
H G
B
10 mm
C
8 mm 25 lb-in (3 Nm)
D
10 mm
NOTE:
55 lb-in (6 Nm)
2.5 mm Allen
Page 19 A D
Page 16 C 1
Page 12
SUGGESTION Use PLASTIC BAGS and a PERMANENT MARKER - to organize components being removed.
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
7 6
8 4 5 3
Page 14
GENUINE PARTS
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
()
N G E S O P
WARNING
IS
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.
3/8" Drive
RECYCLE
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
1. REMOVE FLYWHEEL NUT (C) with strap (A), breaker bar (D), and 24 mm socket (E).
D E
Spark Tester
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.
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
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
15
ADJUSTMENTS
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
COLD C
NOTE: Choke plate (F) closes when opening throttle plate lever. CLOSED
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
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
* 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
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
19