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Briggs & Stratton 700 DOV Series, Repair Manual

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Briggs & Stratton 700 DOV Series Repair Manual Download Page 5

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SECTION 1 - Safety, Maintenance and Adjustments

SECTION 2 - Troubleshooting

SECTION 3 - Exhaust Systems

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

SECTION 12 - Engine Specifications

 

SECTION 4 - Fuel Systems and Carburetion

Summary of Contents for 700 DOV Series

Page 1: ...es 276535 Two Cycle Snow Engines CE8069 Out of Production Engines 1919 1981 Repair Manuals for other Briggs Stratton Engines 700 750 Series DOV Air Cooled Engines Post office box 702 Milwaukee WI 5320...

Page 2: ......

Page 3: ...anual were based on the data available at the time of publication Briggs Stratton Corporation reserves the right to change alter or otherwise improve the product or the product manuals at any time wit...

Page 4: ...6 This engine repair manual includes the following engine models MODEL 090600 MODEL 100600 MODEL 100800...

Page 5: ...N 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 Ge...

Page 6: ...THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE ECONOMICAL AND RELIABLE...

Page 7: ...MAINTENANCE CHART 7 OIL CHANGE 8 AIR FILTER 8 SPARK PLUG 8 COOLING SYSTEM 9 CHARGING BATTERY 9 COMBUSTION CHAMBER 10 ENGINE ADJUSTMENTS 10 THROTTLE CABLE ADJUSTMENT 10 GOVERNOR ADJUSTMENTS 10 ADJUST V...

Page 8: ...death or serious injury CAUTION indicates a hazard which if not avoided could result in minor or moderate injury NOTICE indicates a situation that could result in damage to the product Prior to work...

Page 9: ...el cap and air cleaner are in place Do not crank engine with spark plug removed If fuel spills wait until it evaporates before starting engine If engine floods set choke if equipped to OPEN RUN posi t...

Page 10: ...g dangling drawstrings or items that could become entan gled in the equipment WARNING Charging batteries produce hydrogen gas Do not store or charge a battery near an open flame or device that uti liz...

Page 11: ...l consumption and increased emissions Operation of the engine at altitudes below 2 500 feet 762 meters with the high altitude kit is not recommended Fresh Start Fuel Cap Some engines are equipped with...

Page 12: ...NOTE Do not use pressurized air or solvents to clean the filter Pressurized air can damage the filter and solvents will dissolve the filter 1 Remove air cleaner cover A and B Figure 1 2 Remove pre cle...

Page 13: ...he engine Figure 1 4 Charging Battery 1 Clean the battery of all dirt and corrosion 2 Clean then lightly grease the terminals 3 Bring the battery to full charge using a taper charge automatically redu...

Page 14: ...USTMENTS Throttle Cable Adjustment The remote control wire should measure 2 125 54mm when extended outside the casing A Figure 1 6 After installation the travel B of the remote control wire must be at...

Page 15: ...heck for binding Figure 1 7 Top No Load Adjustment 1 Start engine and run at idle speed until it reaches operating temperature 2 Place throttle lever G Figure 1 8 in FAST position 3 Using Tachometer 1...

Page 16: ...the lever arm adjusting screw F and the valve cap G 4 Loosen the adjusting screw nut H with a wrench 5 Using an allen wrench turn the adjusting screw F to obtain the correct clearance 6 Tighten the a...

Page 17: ...n stud to secure armature 5 Line up flywheel magnets E with armature 6 Insert a strip of gauge material F 0 006 0 014 in or 0 15 0 36 mm between flywheel magnet and both legs of armature 7 Loosen stud...

Page 18: ...ternator 4 Line up flywheel magnet D with alternator 5 Insert a strip of gauge material C 0 006 0 014 in or 0 15 0 36 mm between flywheel magnet and both legs of alternator 6 Loosen screw and allow ma...

Page 19: ...dipstick and oil fill tube 5 Unscrew and remove blower housing Figure 1 13 6 Using a torque wrench A Figure 1 13 and socket to fit the flywheel nut turn flywheel clockwise with brake engaged While tur...

Page 20: ...h if equipped Figure 1 14 Install Flywheel Brake 1 Install stop switch wire and bend end of wire 90 Install wires on interlock switch if equipped 2 Install brake assembly on cylinder and torque mounti...

Page 21: ...2 TROUBLESHOOTING SYSTEMS CHECK 18 CHECK IGNITION 18 CHECK CARBURETION 19 CHECK COMPRESSION 19 ELECTRICAL SYSTEMS 20 EQUIPMENT USED FOR TESTING 20 ALTERNATOR TESTING 21 STARTER MOTOR TESTING 22 BATTE...

Page 22: ...ving parts of equipment Grass build up under deck No lubrication in equipment gear box Excessive belt tension Once equipment sources are ruled out the cause for most of these symptoms can be determine...

Page 23: ...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 th...

Page 24: ...red DC Shunt The Fluke meter will withstand DC input of 10 20 amps for up to 30 seconds The UNI T meter will withstand DC input of 10 amps for up to 10 seconds When checking DC output on 10 and 16 amp...

Page 25: ...tegral part of the engine and is separate from the starting and ignition system It is intended to provide DC charging current for a 12 Volt battery Unregulated 0 5 Amps DC for charging battery One bla...

Page 26: ...nion gear Damaged pinion or ring gear Starter motor clutch slipping Incorrect rotation due to reversed motor polarity Check Starter Motor Drive and Clutch When the starter switch is activated the pini...

Page 27: ...re based on the minimum temperature expected and the correct weight of oil being used 30 Amp Hr 20 F 6 C or higher 40 Amp Hr 5 F 20 C or higher 50 Amp Hr 15 F 26 C or higher The following cable sizes...

Page 28: ...s vary by 0 050 or if all cells read less than 1 225 replace the battery Figure 2 9 2 Set the digital multimeter to DC volts position 3 Install the battery in the equipment 4 Disconnect wire from spar...

Page 29: ...25 1 3 SECTION 3 EXHAUST SYSTEM EXHAUST SYSTEM 26 REMOVE GUARD AND MUFFLER 27 INSPECT EXHAUST SYSTEM 27 INSTALL GUARD AND MUFFLER 27...

Page 30: ...26 1 3 EXHAUST SYSTEM Figure 3 1...

Page 31: ...haust system is disassembled Check the muffler mounting bracket and or muffler adapters for cracked welds or breakage Check the muffler for split seams loose internal parts or cracked welds Replace an...

Page 32: ...28 1 3...

Page 33: ...29 4 4 SECTION 4 FUEL SYSTEM AND CARBURETION FUEL TANK 30 CARBURETOR 32...

Page 34: ...30 4 4 FUEL TANK Figure 4 1...

Page 35: ...ol for at least 2 minutes before removing the fuel cap Fill fuel tank outdoors or in a well ventilated area Do not overfill fuel tank To allow for expansion of the gasoline do not fill above the botto...

Page 36: ...32 4 4 CARBURETOR Figure 4 2...

Page 37: ...amage If found replace the entire carburetor assembly 3 Using Carb Choke Cleaner 100041 or 100042 clean inside and outside surfaces of carburetor then follow with compressed air to dry NOTE Do not soa...

Page 38: ...34 4 4...

Page 39: ...35 4 5 SECTION 5 GOVERNOR SYSTEM GOVERNOR SYSTEM 36 LINKAGE AND SPRING ORIENTATION 37 TOP NO LOAD RPM 37 GOVERNOR SERVICE 37...

Page 40: ...36 4 5 GOVERNOR SYSTEM Figure 5 1...

Page 41: ...attached to the sump The governor crank B is mounted in the cylinder assembly Disassemble 1 Drain oil from engine into an appropriate container 2 Remove burrs and clean the crankshaft PTO the careful...

Page 42: ...or lever on crank and finger tighten bolt and nut until crank turns with slight resistance 5 Rotate crank so that paddle will be aligned with cup on governor gear when sump is installed 6 Install new...

Page 43: ...39 6 6 SECTION 6 CYLINDER HEAD AND VALVES CYLINDER HEAD AND VALVES 40 REMOVE CYLINDER HEAD 41 DISASSEMBLE 41 INSPECTION 41 ASSEMBLE 41 INSTALL CYLINDER HEAD 41...

Page 44: ...40 6 6 CYLINDER HEAD AND VALVES Figure 6 1...

Page 45: ...necessary 3 Oil the intake valve stem then insert valve into head 4 Using Valve Lapping Tool 19258 and Lapping Compound 94150 lap valve and seat together to assure a good sealing surface Remove valve...

Page 46: ...42 6 6...

Page 47: ...SECTION 7 STARTERS ELECTRIC STARTER 44 RING GEAR 45 DISASSEMBLE STARTER DRIVE 45 CHECK STARTER DRIVE OPERATION 45 ASSEMBLE STARTER DRIVE 45 REWIND STARTER 46 INSPECT REWIND STARTER PARTS 47 REPLACE R...

Page 48: ...44 7 7 ELECTRIC STARTER Figure 7 1...

Page 49: ...x C from starter gear D by rotating helix back and forth while pulling 4 Remove three screws B that secure the cover E to the starter drive assembly 5 Remove and discard felt washer F Disassemble the...

Page 50: ...46 7 7 REWIND STARTER Figure 7 2...

Page 51: ...re 7 3 Figure 7 4 Figure 7 5 Figure 7 6 1 Hold rewind assembly firmly A Figure7 3 and pull out rope B until pulley stops NOTE Spring tension in pulley will increase as rope is pulled out 2 Line up hol...

Page 52: ...48 7 7...

Page 53: ...49 4 8 SECTION 8 LUBRICATION LUBRICATION SYSTEM 50 OIL FILL TUBE AND DIPSTICK 51 BREATHER 51 OIL SLINGER LUBRICATION 51...

Page 54: ...50 4 8 LUBRICATION SYSTEM Figure 8 1...

Page 55: ...roperly and must be replaced 2 Inspect the oil drain back hole in the breather cavity Insert a fine wire to ensure the opening is not plugged Install Breather 1 Install reed with the metal tab facing...

Page 56: ...52 4 8...

Page 57: ...53 4 9 SECTION 9 CYLINDER AND SUMP CYLINDER AND SUMP 54 INSPECT CYLINDER 55 INSPECT SUMP 56 MAIN BEARINGS 56 OIL SEALS 56...

Page 58: ...54 4 9 CYLINDER AND SUMP Figure 9 1...

Page 59: ...sshatch of approximately 45 C ensures proper lubrication and piston ring break in NOTE IT IS MOST IMPORTANT THAT THE ENTIRE CYLINDER BE THOROUGHLY CLEANED AFTER HONING Resizing Bore If the cylinder bo...

Page 60: ...e are gone Main Bearings Plain Bearings Plain or machined bearings are not repairable If a plain bearing is scored or worn beyond reject its size the cylinder or cover sump must be replaced DP Bearing...

Page 61: ...57 4 10 SECTION 10 CRANKSHAFT CRANKSHAFT 58 REMOVE CRANKSHAFT 59 INSPECT CRANKSHAFT 59 INSTALL CRANKSHAFT 59 INSTALL SUMP 59 CHECK AND ADJUST CRANKSHAFT END PLAY 59...

Page 62: ...58 4 10 CRANKSHAFT Figure 10 1...

Page 63: ...into the cylinder 3 Rotate crankshaft until crankpin journal fits into connecting rod 4 Lubricate the crankpin journal with engine oil then assemble connecting rod to crankshaft and torque cap screws...

Page 64: ...60 4 10...

Page 65: ...61 4 11 SECTION 11 PISTON RINGS AND CONNECTING ROD PISTON RINGS AND CONNECTING ROD 62 REMOVE PISTON AND CONNECTING ROD 63 DISASSEMBLE 63 INSPECT 63 ASSEMBLE 64...

Page 66: ...62 4 11 PISTON RINGS AND CONNECTING ROD Figure 11 1...

Page 67: ...d in Section 12 Engine Specifications If pin bore meets or exceeds reject dimension replace the piston 3 Measure outside diameter of pin and compare to the reject dimensions listed in Section 12 Engin...

Page 68: ...e 11 3 Assemble 1 Install a pin retainer clip into one groove in the pin bore 2 Oil the piston pin bore connecting rod pin bearing and the pin Insert rod into piston then slip pin through piston and r...

Page 69: ...ll piston with notch or arrow toward flywheel side of engine taking care not to damage crankpin journal or connecting rod bearing 4 Fit connecting rod bearing on crankpin journal then install rod cap...

Page 70: ...66 4 11...

Page 71: ...67 12 SECTION 12 ENGINE SPECIFICATIONS MODEL 090600 68 MODEL 100600 70 MODEL 100800 72...

Page 72: ...n 5 Nm Bowl Nut 90 lb in 10 Nm Carburetor to Cylinder Head 85 lb in 10 Nm Casing Clamp 20 lb in 2 Nm Connecting Rod 95 lb in 11 Nm Control Bracket 95 lb in 11 Nm Control Panel Trim 40 lb in 5 Nm Crank...

Page 73: ...in 22 20 mm 873 in 22 17 mm PTO Side Journal 1 061 in 26 96 mm 1 060 in 26 92 mm CONNECTING ROD Crank Pin Bearing 1 100 in 27 94 mm 1 102 in 27 99 mm Piston Pin Bearing 491 in 12 47 mm 493 in 12 52 mm...

Page 74: ...Nut 90 lb in 10 Nm Carburetor to Cylinder Head 85 lb in 10 Nm Casing Clamp 20 lb in 2 Nm Connecting Rod 95 lb in 11 Nm Control Bracket 95 lb in 11 Nm Control Panel Trim 40 lb in 5 Nm Crankcase Sump 1...

Page 75: ...in 22 20 mm 873 in 22 17 mm PTO Side Journal 1 061 in 26 96 mm 1 060 in 26 92 mm CONNECTING ROD Crank Pin Bearing 1 100 in 27 94 mm 1 102 in 27 99 mm Piston Pin Bearing 491 in 12 47 mm 493 in 12 52 mm...

Page 76: ...Nut 90 lb in 10 Nm Carburetor to Cylinder Head 85 lb in 10 Nm Casing Clamp 20 lb in 2 Nm Connecting Rod 95 lb in 11 Nm Control Bracket 95 lb in 11 Nm Control Panel Trim 40 lb in 5 Nm Crankcase Sump 1...

Page 77: ...in 22 20 mm 873 in 22 17 mm PTO Side Journal 1 061 in 26 96 mm 1 060 in 26 92 mm CONNECTING ROD Crank Pin Bearing 1 100 in 27 94 mm 1 102 in 27 99 mm Piston Pin Bearing 491 in 12 47 mm 493 in 12 52 mm...

Page 78: ...74 12...

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