Service Engine

Engine Warranty Maintenance Statement

Maintenance, repair or replacement of the emission control devices and systems on this engine, which are being done at the customers expense, may be performed by any non-road engine repair establishment or individual. Warranty repairs must be performed by an authorized John Deere dealer.

Avoiding Fumes

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

· Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

· Allow fresh outside air into the work area to clear the exhaust fumes out.

Engine Oil

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Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following John Deere oils are preferred:

· John Deere TURF-GARD®

· John Deere PLUS-4®

The following oils are also recommended, based on their specified temperature range:

· SAE 5W-20

· SAE 10W-30/SAE 10W-40

· SAE 30

· SAE 40

Other oils may be used if above John Deere oils are not available, provided they meet the following specification:

· API Service Classification SF, SG, SH or SJ

Checking Engine Oil Level


IMPORTANT: Avoid damage! Failure to check the oil level regularly could lead to serious engine problems if oil level is low: · Check oil level before operating. · Check oil level when the engine is cold and not running. · Keep level between the FULL and the ADD marks. · Shut off engine before adding oil.

NOTE: Check oil twice a day if you run engine over 4 hours in a day.

Make sure engine is cold when checking engine oil level.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

3. Unlatch and lift thigh pad.

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4. Clean area around dipstick cap (A).

5. Remove dipstick cap (A). Wipe dipstick clean.

NOTE: Do not tighten dipstick cap when checking oil level.

6. Insert dipstick in tube. Do not tighten cap.

7. Remove dipstick. Check oil level on dipstick. Oil level should be in crosshatch area between ADD and FULL marks.

· If oil is low, add oil to bring oil level no higher than FULL mark on dipstick.

· If oil level is above FULL mark, drain to proper level.


IMPORTANT: Avoid damage! To prevent extensive engine wear or damage, always maintain the proper engine oil level. Never operate the engine with the oil level below the ADD mark or over the FULL mark.

8. Insert dipstick. Tighten cap.


MODEL	Oil Capacity With Filter
647	1.6 L (1.7 qt)
657	1.6 L (1.7 qt)
667	1.6 L (1.7 qt)

Changing Engine Oil and Filter

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine and components will be hot if the engine has been running. Allow the engine to cool before servicing.


IMPORTANT: Avoid damage! Change the oil more often if the machine is used in extreme conditions: · Extremely dusty conditions. · Frequent slow or low-speed operation. · Frequent short trips.

1. Start engine and run until it reaches normal operating temperature.

2. Park machine safely. (See Parking Safely in the SAFETY section.)

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3. Attach plastic drain tube (A) to drain opening (B).

4. Put oil drain pan under drain tube.

5. Turn drain valve (C) counterclockwise to open.

6. Allow oil to drain into an oil drain pan.

7. After oil drains, turn drain valve (C) clockwise to close. Remove plastic drain tube (A).

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8. Turn oil filter (D) counterclockwise to remove.

9. Apply a film of clean engine oil to gasket of new filter.

10. Install filter. Turn filter clockwise until gasket makes contact with mounting surface. Tighten 1/2 to 3/4 turn after gasket contact.

11. Unlatch and lift thigh pad.

12. Clean area around dipstick cap.

13. Remove dipstick cap.

14. Add approximately 1.4 L (1.5 qt) of oil.

15. Insert dipstick. Tighten cap.

16. Start engine and run at slow throttle for approximately two minutes. Check for leaks around filter and drain valve.

17. Stop engine.

18. Check oil level:

· Remove dipstick cap. Wipe dipstick clean.

NOTE: Do not tighten dipstick cap when checking oil level.

· Insert dipstick. Do not tighten cap.

· Remove dipstick. Oil level should be between the ADD and FULL marks. Add oil if needed.

19. Insert dipstick. Tighten cap.

Cleaning Engine Air Intake Screen and Fan

c CAUTION: Avoid injury! Avoid injury from foreign particles when using compressed air for cleaning purposes. Clear area of bystanders, and wear personal eye protection to guard against flying debris.


IMPORTANT: Avoid damage! An obstructed air intake screen can cause engine damage due to overheating. Keep the air intake screen area and other external surfaces of the engine clean at all times.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

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2. Clean outer air intake screen (A) with a rag, brush or compressed air.

3. Remove four nuts (B) securing outer air intake screen (A).

4. Clean inner screen (C) with a rag, brush or compressed air.

5. Remove three nuts (D) securing inner screen (E). Remove inner screen.

6. Clean fan with a rag, brush or compressed air.

7. Install inner screen and secure it with three nuts.

8. Install outer air intake screen and secure it to the engine with four nuts.

Checking and Cleaning Air Filter Elements

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine and components will be hot if the engine has been running. Allow the engine to cool before servicing.


IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element: · Do not wash paper element. · Do not attempt to clean paper element by tapping against another object. · Do not use pressurized air to clean element. · Replace element only if it is very dirty, damaged or the seal is cracked.

NOTE: It may be necessary to check the air filter more frequently if operating machine in dusty conditions.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

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2. Remove air cleaner cover retaining knobs (A) and remove the air cleaner cover (B).

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3. Inspect foam precleaner (C) without removing.

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4. If foam precleaner (C) is dirty, carefully remove it from filter, leaving paper element (D) on the air cleaner housing:

· Wash foam precleaner in a solution of warm water and liquid detergent. Squeeze out excess water in a dry cloth until precleaner is completely dry. (Do not wring.)


IMPORTANT: Avoid damage! A damaged paper element (D) can allow dirt into the carburetor and can cause poor engine performance, engine damage or failure: · Do not attempt to clean paper element (D) by tapping against another object. · Replace element (D) only if very dirty. · Do not use pressurized air to clean element. · If element is damaged or the seal is cracked, replace.

5. Remove wing nuts (E) and replace paper element (D).

6. Install wing nuts (E).

7. Install cleaned foam precleaner (C) on new paper element (D).

8. Install air cleaner cover (B) and retaining knobs (A).

Checking Spark Plugs

c CAUTION: Avoid injury! Touching hot surfaces can burn skin. The engine and components will be hot if the engine has been running. Allow the engine to cool before servicing.


IMPORTANT: Avoid damage! Do not clean spark plugs with abrasives.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Clean area around both spark plugs.

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Picture Note: Spark plug on left side shown.

3. Disconnect spark plug wire (A) from each plug (B).

4. Remove and inspect spark plugs:

· Clean each plug and check for damage; replace if necessary.

· If plugs are in good condition, check gap.

M85200

5. Check and adjust spark plug gap (C) to 0.75 mm (0.030 in.).

6. Install spark plugs.

· Tighten to 22 N·m (16 lb-ft).

7. Install both spark plug wires.

Cleaning Engine Oil Cooling Fins

c CAUTION: Avoid injury! Help prevent injury from foreign particles when using compressed air for cleaning purposes. Clear area of bystanders, and wear personal eye protection to guard against flying debris.


IMPORTANT: Avoid damage! To ensure proper cooling, keep engine oil cooling fins and other external surfaces of engine clean at all times. Operating engine with obstructed cooling fins could cause engine damage due to overheating.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Remove spark plug wires from both spark plugs.

3. With compressed air, thoroughly clean grass buildup and debris from the following areas:

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Picture Note: Back of machine with rear shield removed.

· Engine cooling fins (A) at rear of engine.

· Area between engine and machine frame.

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· Engine cooling fins located under the air cleaner and above the muffler.

· Area behind each spark plug access hole (B).

4. Install spark plug wires.

Adjusting Carburetor

NOTE: Carburetor is calibrated by the engine manufacturer and is not adjustable.

If engine is operated at altitudes above 1829 m (6000 ft), some carburetors may require a special high altitude main jet. See your John Deere dealer.

If engine is hard to start or runs rough, check the TROUBLESHOOTING section of this manual.

Possible engine surging will occur at high throttle with transmission in neutral and mower engagement lever disengaged. This is a normal condition due to the emission control system.

If after performing the checks in the TROUBLESHOOTING section your engine is still not performing correctly, contact your John Deere dealer.

Replacing Fuel Filter

c CAUTION: Avoid injury! Fuel vapors are explosive and flammable:

· Do not smoke while handling fuel.

· Keep fuel away from flames or sparks.

· Shut off engine before servicing.

· Cool engine before servicing.

· Work in a well-ventilated area.

· Clean up spilled fuel immediately.


IMPORTANT: Avoid damage! When installing a new fuel filter, the filter arrow must be pointed in the direction of the fuel flow.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

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3. Turn fuel shutoff valve (A) to off position.

4. Slide hose clamps (B) away from fuel filter (C).

5. Place drain pan under hoses to catch any fuel that may be left in the hoses.

6. Disconnect hoses from fuel filter (C).

7. Install new fuel filter (C).

· Make sure fuel filter (C) is installed with arrow pointing in direction of fuel flow.

8. Connect hoses to new fuel filter (C).

9. Install hose clamps (B).