Summary of Contents for Briggs & Stratton 700 DOV Series
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Repair Manuals for other Briggs & Stratton Engines: 273521 Twin Cylinder OHV Air-Cooled Engines 276781 Single Cylinder OHV Air-Cooled Engines 271172 Twin Cylinder L-Head Air-Cooled Engines 270962 Single Cylinder L-Head Air-Cooled Engines 700/750 Series DOV 276535 Two-Cycle Snow Engines CE8069 Out of Production Engines (1919-1981) Air-Cooled Engines Quality Starts With A Master Service Technician...
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FORWARD This manual was written to assist engine technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton engines. It assumes that persons using this manual have been properly trained in and are familiar with the servicing procedures for these products, including the proper use of required tools and safety equipment and the application of appropriate safety practices.
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This engine repair manual includes the following engine models: • MODEL 090600 • MODEL 100600 • MODEL 100800...
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SECTION 1 - Safety, Maintenance and Adjustments SECTION 2 - Troubleshooting SECTION 3 - Exhaust Systems SECTION 4 - Fuel Systems and Carburetion SECTION 5 - Governor Systems SECTION 6 - Cylinder Heads and Valves SECTION 7 - Starters SECTION 8 - Lubrication Systems SECTION 9 - Cylinders, Covers and Sumps SECTION 10 - Crankshafts, Camshafts, Balancing Systems, and Gear Reductions SECTION 11 - Pistons, Rings and Connecting Rods...
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THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE, ECONOMICAL AND RELIABLE...
SAFETY INFORMATION This repair manual contains safety information that is designed to: • Make you aware of hazards associated WARNING with engines. Before attempting to service this equipment, • Inform you of the risk of injury associated read and understand this manual and the with those hazards.
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WARNING Fuel and its vapors are extremely flam- WARNING mable and explosive. Fire or explosion can cause severe Battery posts, terminals, and related accesso- burns or death. ries contain lead and lead compounds - chem- icals known to the State of California to cause When adding fuel: cancer and reproductive harm.
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WARNING WARNING Unintentional sparking can result in fire Charging batteries produce hydrogen or electrical shock. gas. Do not store or charge a battery Unintentional start-up can result in near an open flame or device that uti- entanglement, traumatic amputation, or lizes a pilot light or can create a spark.
ENGINE MAINTENANCE Fuel and Oil Recommendations viscosity for the outdoor temperature range expected. Fuel must meet these requirements: • Clean, fresh, unleaded gasoline. • A minimum of 87 octane / 87 AKI (90 RON). • Gasoline with up to 10% ethanol (gasahol) or up to 15% MTBE (methyl tertiary butyl ether) is acceptable.
Oil Change 2. Gently tap air filter cartridge on a hard surface to loosen debris. Replace Change oil after the first 5 hours of operation. cartridge if very dirty. After that, change oil after every 50 hours of 3. Wash foam pre-cleaner in warm, soapy operation.
3. Do not sand-blast or bead-blast the spark plug. Clean by scraping or wire brushing, and then washing in a commercial solvent. 4. Using a wire gage, check and set the gap (A, Figure 1-3) per Section 12 - Specifications. Figure 1 - 4 Charging Battery 1.
Combustion Chamber cylinder. Do not damage bore, top of piston, cylinder head, or gasket mounting surfaces. Remove combustion chamber deposits every 500 hours or whenever the cylinder head is removed. It is not necessary to remove the discoloration marks on the piston, valves, and/or cylinder With the piston at Top Dead Center (TDC), head.
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NOTE: Choke valve (F) closes when opening the throttle plate. 3. While holding linkage, tighten governor lever nut. Torque to values listed in Section 12 - Engine Specifications. 4. Before starting engine, manually actuate throttle linkage to check for binding. Figure 1 - 8 Figure 1 - 7 Top No-Load Adjustment...
Adjust Valve Clearance Adjust ReadyStart Choke Link Perform this adjustment while the engine is cold. NOTE: Check valve clearance while the engine 1. Using pliers, bend adjusting loop (A, is cold. Figure 1-10) on choke link (B) until choke lever gap (C) measures 0.000 - 0.060 in. 1.
Adjust Armature Air Gap 1. Disconnect spark plug boot (A, Figure 1- 11) and secure away from spark plug. 2. Loosen screw (B) and stud (C). 3. Slide armature (D) away from flywheel. 4. Tighten stud to secure armature. 5. Line up flywheel magnets (E) with armature.
Adjust Alternator Air Gap 1. Remove spark plug. 2. Loosen alternator screws (A, Figure 1-12). and slide alternator (B) away from flywheel. 3. Tighten one screw to secure alternator. 4. Line up flywheel magnet (D) with alternator. 5. Insert a strip of gauge material (C) (0.006-0.014 in.
Flywheel Brake 6. Using a torque wrench (A, Figure 1-13) and socket to fit the flywheel nut, turn The flywheel brake is part of the safety control flywheel clockwise with brake engaged. system required for some applications. While While turning at a steady rate, torque running at the FAST speed position, the flywheel value should be 26 lb.-in.
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Remove Flywheel Brake 1. Disconnect and remove spring from brake anchor. 2. Disconnect safety control cable from brake assembly. 3. Loosen brake screw (A, Figure 1-14) but do not remove. 4. Rotate bracket to relieve tension on screw (B) and remove, then remove screw (A). 5.
SYSTEMS CHECK Most complaints concerning engine operation Once equipment sources are ruled out, the can be classified as one or a combination of the cause for most of these symptoms can be following: determined by performing a systems check in the following order: •...
A simple check to determine if the fuel is getting to the combustion chamber through the carburetor is to remove the spark plug and pour a small quantity of gasoline through the spark plug hole. Replace the plug. If the engine fires a few times and then stops, look for the same conditions as for a dry plug.
ELECTRICAL SYSTEMS Equipment Used for Testing Digital Multimeter A digital multimeter is recommended for all electrical testing of Briggs & Stratton engines. The meter can be used to read volts, ohms, amperes, and to test diodes. The Fluke® Digital Multimeter #19464 and the UNI-T®...
Alternator Testing 5. Attach RED test clip to output lead (A, Figure 2-7). The following alternator test procedures were 6. Attach BLACK test clip to charging lead developed using the Fluke® Digital Multimeter. (B). When performing alternator tests with the UNI-T®...
Starter Motor Testing Check Starter Motor Drive and Clutch When the starter switch is activated, the pinion Before assuming an electric starter requires gear should rise, engage the flywheel ring gear, service, check the engine for freedom of rotation and crank the engine. The pinion gear must by removing the spark plug and turning the rotate counterclockwise, as viewed from the crankshaft over by hand.
5. Activate starter motor and note readings of Battery Testing meter and tachometer.Take reading after A 12 Volt, lead acid, wet cell battery is required meter stabilizes (approximately 2-3 to operate the starter motor. This type is seconds). available as a wet charge or dry charge battery. With a fully-charged battery, the starter motor The wet charged maintenance-free battery is should deliver 6500 RPM (minimum) and 35...
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4. Disconnect wire from spark plug and ground ignition using Ignition Tester #19368. WARNING 5. Attach RED meter test clip to positive (+) battery terminal. Attach BLACK meter test Battery posts, terminals, and related lead to negative (-) battery terminal. accessories contain lead and lead compounds - chemicals known to the State 6.
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Some engines may be equipped with an exhaust Install Muffler and Guard system (muffler, bracket, and hardware) supplied 1. Insert screws with new screw lock into by the equipment manufacturer. Contact the muffler and place new exhaust gasket on equipment manufacturer for muffler service end of screws.
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Removal 1. Drain the fuel into an appropriate container. WARNING 2. Remove air cleaner cover (A, Figure 4-1) Gasoline and its vapors are extremely and gas cap. flammable and explosive. 3. Remove screws and the static guard/ Fire or explosion can cause severe rewind assembly (B).
The DOV, 700/750-Series engine is equipped Inspect and Clean Carburetor with a ReadyStart® Carburetor, which utilizes a 1. Inspect openings in the carburetor body thermostatically controlled choke system, for evidence of wear or damage. If found, requiring no primer or manual choke. The replace the entire carburetor assembly.
Linkage and Spring Orientation Governor Service Be sure to note orientation of linkages and The mechanical governor is part of the oil slinger springs before removing (Figure 5-2). assembly (A, Figure 5-1) attached to the sump. The governor crank (B) is mounted in the cylinder assembly.
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Assemble Governor 1. Install governor crank from inside cylinder. Slide washer on crank and install new push nut or clip. 2. Install governor gear on spindle in sump. Using thumbs, press firmly until gear clicks into place. 3. Align dot on timing gear with notch in cam gear and place cam gear on boss in cylinder (Inset, Figure 5-1).
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Before the cylinder head can be removed, other Assemble external parts must be removed, such as the air 1. Lightly coat valve stems with Valve Guide cleaner, fuel tank, oil fill tube, blower housing, Lubricant #93963, then insert valves into muffler, carburetor, control bracket assembly, cylinder head.
12 Volt Starter Inspect Starter Parts 1. Inspect drive gear and pinion gear for Ring Gear worn or broken teeth. Replace if The ring gear on this engine is made of steel and necessary. is heat shrunk to the flywheel. It is not repairable. 2.
The rewind starter mechanism installed on this engine is non-serviceable. The rope and handle are the only serviceable parts. Inspect Rewind Starter Parts 1. Remove fasteners (A, Figure 7-2) and lift static guard/rewind assembly (B) off blower housing. 2. Inspect the starter assembly for wear or burrs at the rope eyelet, the center pivot post, and the anchor tab.
Oil Fill Tube and Dipstick Oil Slinger Lubrication This engine uses a plastic extended oil fill tube The governor gear/oil slinger (J) is used on (A, Figure 8-1) and a quarter-turn dipstick with o- vertical shaft engines. It is mounted to the sump ring (B).
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Inspect Cylinder Resizing Bore If the cylinder bore is worn more than 0.003” 1. Remove oil seal and discard. Using a (0.08 mm) oversize, or is 0.0015” (.04 mm) out of plastic scraper, remove all traces of head round, it must be resized. gasket and sump gasket material.
Inspect Sump Oil Seals 1. Remove oil seal and discard. Cylinder 2. Visually inspect sump for cracks, stripped Press in new oil seal to a depth of 0.156 - 0.206 threads, and wear in bearing surfaces. If in. (3 - 5mm) (Figure 9-2). damage is found, replace the sump.
Remove Crankshaft Install Sump to Cylinder 1. Drain oil from engine and all fuel from fuel 1. Insert correct seal protector from Kit tank into appropriate container. #19356, to protect oil seal when installing sump. 2. Remove external components including flywheel assembly.
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PISTON, RINGS, AND CONNECTING ROD Figure 11 - 1...
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Remove Piston and Connecting Rod 5. Repeat procedure for wiper ring groove and oil control ring groove. 1. Carefully remove any carbon or ridge at 6. Compare with reject dimensions listed in top of cylinder bore (A, Figure 11-1) to Section 12 - Engine Specifications.
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1. Clean all carbon from the rings and the NOTE: The notch or arrow on the piston and cylinder bore. “MAG” on the rod must face the same direction. 2. Insert one of the original rings approximately one inch down the cylinder bore.
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• Install the spring expander on top of the lower rail, then install the upper steel rail. 5. Using Piston Ring Expander #19340, install the wiper ring, then the compression ring. NOTE: If installing the original rings, ensure the top sides are facing the top of the piston. If installing a new ring set, follow the instructions provided with the set.
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ENGINE SPECIFICATIONS MODEL 090600 ENGINE SPECIFICATIONS Alternator Air Gap .006 - .014 in. (.15 - .33 mm) Armature Air Gap .006 - .014 in. (.15 - .33 mm) Crankshaft End Play .002 - .038 in. (.05 - .97 mm) Spark Plug Gap .020 in.
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REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Bore Diameter 2.520 in. (64.00 mm) 2.525 in. (64.14 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .200 in. (5.08 mm) .203 in.
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MODEL 100600 ENGINE SPECIFICATIONS Alternator Air Gap .006 - .014 in. (.15 - .33 mm) Armature Air Gap .006 - .014 in. (.15 - .33 mm) Crankshaft End Play .002 - .038 in. (.05 - .97 mm) Spark Plug Gap .020 in.
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REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Bore Diameter 2.520 in. (64.00 mm) 2.525 in. (64.14 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .200 in. (5.08 mm) .203 in.
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MODEL 100800 ENGINE SPECIFICATIONS Alternator Air Gap .006 - .014 in. (.15 - .33 mm) Armature Air Gap .006 - .014 in. (.15 - .33 mm) Crankshaft End Play .002 - .038 in. (.05 - .97 mm) Spark Plug Gap .020 in.
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REJECT DIMENSIONS STANDARD SIZE REJECT SIZE CYLINDER Main Bearing .876 in. (22.25 mm) .878 in. (22.30 mm) Bore Diameter 2.520 in. (64.00 mm) 2.525 in. (64.14 mm) Bore Out-Of-Round .0015 in. (.04 mm) CYLINDER HEAD Valve Guide .200 in. (5.08 mm) .203 in.