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V-Engine Service Manual

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V-Engine Service Manual V-ENGINE SERVICE MANUAL Table of Contents – Page 1 of 3 ABOUT THIS MANUAL SAFETY INFORMATION SPECIFICATIONS ENGINE SPECIFICATIONS ENGINE FASTENER TORQUE REQUIREMENTS CARBURETOR SPECIFICATIONS SPECIAL TOOL REQUIREMENTS SPECIAL TOOL REQUIREMENTS - REQUIRED SERVICE SUPPLIES TORO 2-CYCLE V ENGINE TOOL REQUIREMENTS TROUBLESHOOTING ENGINE WILL NOT START WHEN "COLD" ENGINE WILL START WHEN "COLD", BUT NOT WHEN "HOT" ENGINE WILL NOT PRODUCE SPARK ENGINE FLOODED WITH FUEL ENGINE HAS LOW COMPRESSION ENGINE LACKS POWER ENGINE SURGES ENGINE BACKFIRES ENGINE OVERHEATS ENGINE VIBRATES EXCESSIVELY ENGINE CRANKSHAFT WILL NOT TURN ENGINE PRODUCES MECHANICAL KNOCKING SOUND ENGINE PRE-IGNITES ENGINE SMOKES EXCESSIVELY ENGINE STALLS SPARK PLUG FOULED MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULE AIR FILTER - CLEANING SPARK PLUG SPARK PLUG GAP SPARK PLUG TORQUE EXHAUST SYSTEM - CLEANING REASSEMBLING PRIMER START CARBURETOR TROUBLESHOOTING - ENGINE STARTS HARD ENGINE RUNS RICH ENGINE RUNS LEAN FUEL LEAKS FROM CARBURETOR INTRODUCTION - IDENTIFICATION V-ENGINE SERVICE MANUAL Table of Contents – Page 2 of 3 PRIMER START CARBURETOR - Continued OPERATION GOVERNOR GOVERNOR ADJUSTMENT SERVICING - PRELIMINARY CHECK DISASSEMBLY CLEANING AND INSPECTION ASSEMBLY INSTALLATION PRESETTING THE GOVERNOR SERVICING THE AIR FILTER FUEL SYSTEM OPERATION - FUEL TANK FUEL CAP SERVICE - FUEL CAP TANK REMOVAL CLEANING TANK INSTALLATION FUEL STORAGE IGNITION SYSTEM TROUBLESHOOTING - PROCESS SPARK PLUG - OPERATION SERVICE CD PACK - ADVANTAGES OPERATION AIR GAP ADJUSTMENT REMOVAL/INSTALLATION FLYWHEEL - OPERATION REMOVAL INSTALLATION REWIND STARTER OPERATION RECOIL ASSEMBLY REPLACEMENT STARTER ROPE REPLACEMENT ENGINE ADVANTAGES/DESCRIPTION OPERATION SERVICE TIPS - CYLINDER/CRANKCASE HALVES OIL SEALS CORE PLUGS MUFFLER BAFFLE V-ENGINE SERVICE MANUAL Table of Contents – Page 3 of 3 ENGINE - Continued MUFFLER PLATE SCREWS EXHAUST PORTS CARBURETOR GASKETS REMOVAL DISASSEMBLY INSPECTION AND REPAIR REED VALVE SERVICE REASSEMBLY REINSTALLING EXTERNAL COMPONENTS PIVOTING ZONE START BRAKE SYSTEM PIVOTING ZONE START BRAKE - INTRODUCTION OPERATION DISASSEMBLY ASSEMBLY APPENDIX POWER HEAD - EXPLODED VIEW IGNITION AND EXHAUST - EXPLODED VIEW STARTER AND PRIMER START CARBURETOR - EXPLODED VIEW PRIMER START CARBURETOR ASSEMBLY - EXPLODED VIEW ABOUT THIS MANUAL Thismanual was written expressly for the Tor0 V Engine.The Tor0 Company has made every effortto make the informationin this manual complete and correct. This manual was written with the service' technicianin mind. The book is divided into two sections, Quick Reference information (specifications, troubleshooting, etc.) and servicing information (servicing procedures). We hope you find this manual a valuable additionto your service shop. If you have any questions or comments regarding this manual, please contact us at the following address: The Toro Company Consumer Service Department 81 11 Lyndale Avenue South Bloomington,MN 55420-1196 The Tor0 Company reserves the rightto change product specifications or this manual without notice. Copyright(R) 1995 The Tor0 Company All Rights Reserved Safety Information This safety symbol means WARNING or PERSONAL SAFETY INSTRUCTION - read the instruction becauseit has to do with your safety. Failure to comply with the instruction may resultin personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service and repairof the engine only. The Operator’s Manual will containsafety information onthe complete product powered by theTor0 2- Cycle V engine. Operator’s Manuals with complete instructions are available through: The Tor0 Company Publications Department 81 1 Lyndale Avenue South Bloomington, MN 55420-1196 U.S.A. Avoid unexpected starting of the Avoid spilling fuel and never smoke while engine.... working with any type of fuel. Always turn off the powered product and disconnect the spark plug before attempting Avoid accidental misuseof fuel. .. cleaning, adjustment or repair. Always store fuelin a properly labeled container designed for gasoline. Avoid lacerations and amputations... Stay clear of all moving parts when the Avoid injury due to inferior parts... engine is running. Treat all normally Use onlyTOR0 original parts to ensure that moving parts as if they were moving important safety criteria are met. whenever the engineis running or has the potential to start. Avoid injuryto bystanders... Always clear the area of bystanders before Avoid burns... starting or testing powered equipment. Do not touch the engine whileit is running or shortly afterit has been running. Avoid injury due to projectiles... Always clear the area of sticks, rocks, or Avoid falls... any other debris that could be picked up Do not operate the powered product on and thrown by the powered equipment. slippery surfaces orif footing is Keep all safety shieldsin place questionable. Avoid modifications... Avoid fires... Never alter or modify any part unlessit is a Wipe up any spilled fuel or oil immediately. factory approved procedure. Avoid asphyxiation... Avoid unsafe operation... Never operate an enginein a confined area Always test the safety systems after making without proper ventilation. adjustments or repairs on the machine. Avoid fires and explosions... Use a container designed for gasoline. QUICK REFERENCE SECTION Specifications .............................................. Special Tool Requirements. Tool Special ................................... Troubleshooting ............................................ Maintenance ............................................... SERVICE SECTION Primer Start Carburetor. ...................................... Fuelsystem ............................................... IgnitionSystem ............................................. ~~ Rewind Starter. ............................................. Engine .................................................... Pivoting Zone StartBrake. .................................... I Appendix .................................................. ~~ Reference Section Reference 1-1 Engine Specifications. 19 Engine Fastener Torque Requirements 1-4 Carburetor Specifications 1-4 Specifications Carburetor 1-2 Reference Section Engine Specifications I I Reference SectionReference 1-3 Bolt, Blade 81.6 N-m) Nut, Flywheel Screw, Air vane Screw, Carburetor mounting Screw, CD ignition pack 90 110 in lbs(10-12 N-m) Screw, Cylinder to crankcase 105 I 115in lbs (.I2I3 N-m Screws, Engine mounting 350-400in Ibs (39 45 N-m) Screw,Ground strap stop 15 25 in Ibs (1.7 2.8N-m) Screw, Muffler cover 150 190 in Ibs (I7 22 Nom)-. Screw, Muffler plate ~- 140 200 in Ibs (16 22 N-m) Screw,Reed* 10 13Ibs(1.1-1.5in N-m) 65 75in Ibs (7,3-8.4 N-m) Screw, Shroud 20 25 in Ibs (2.3 2.8N-m) *Use thread-locking compound See page2.2 Carburetor Specifications 1-4 Reference Section QUICK REFERENCE SECTION Specifications Special Tool Requirements. 2 Troubleshooting Maintenance SERVICE SECTION Primer Start Carburetor. Fuelsystem Ignition System Rewind Starter. Engine Pivoting Zone StartBrake. Appendix Reference Section 2-1 R EQUIRED SERVICE SUPPLIES SERVICE REQUIRED 2-2 Reference Section QUICKREFERENCE SECTION Specifications Special Tool Requirements. Troubleshooting 3 Maintenance SERVICE SECTION Primer Start Carburetor. Fuelsystem Ignition System Rewind Starter. Engine Pivoting Zone StartBrake. Appendix Reference Section 3-1 E NGINE WILL NOT START WHEN “COLD”WHEN START NOT WILLENGINE 3-3 ENGINE WILL START WHEN “COLD”, BUT NOT WHEN “HOT” 3-3 ENGINE WILL NOT PRODUCESPARK. 3-3 ENGINE BACKFIRES 3-5 ENGINE OVERHEATS. 3-5 ENGINE VIBRATES EXCESSIVELY. 3-5 ENGINE CRANKSHAFTWILL NOT TURN.. 3-5 SPARK PLUG FOULED. 3-7 3-2 Reference Section E N GINE WILL NOT START WHEN “COLD”WHEN START NOT WILL ENGINE Remedies Fill with clean,fresh, properly mixed, unleaded fuel Drain and flush tank andfloat bowl, fill tank with clean fresh unleaded, properly mixed fuel Clean and backflush fuel tank. Replace fuel tankif necessary Wash and re-oil air cleaner element Replacethe spark plug See “ENGINE WILL NOTSPARK PRODUCE table Check for loose blade Check See “ENGINEHAS LOW COMPRESSION table See “ENGINE FLOODED” WITH FUEL” table ENGINE WILL START WHEN “COLD”, BUT NOT WHEN “HOT” I S ee ‘ENGINE-FLOODEDSee FUEL”WITHtable fuelUse nomore than 10% ethanolblend See: ENGINE OVERHEATS table Clean bowl vent Reference Section 3-3 ENGINE FLOODED WITH FUEL Remedies Let unit sit, retry, or, remove spark plug, pull rope several times.. Reinstall plug. Try again. Adjust throttle cable Wash and re-oil cleaner element Replace sparkplug Clean carburetor, replaceparts failed Clean Clean ENGINE HAS LOW COMPRESSION Remedies Dirty plugged main fuel and/or Clean main fuel circuit andall air bleed circuits air bleed circuitsbleed air Check sealing surfaces, oil plugs Check filters and fuel line 3-4 Reference Section R eference Section Reference 3-5 ENGINEPRODUCES MECHANICAL KNOCKING SOUND Remedies Inspect and tighten bladebolt tocorrect torque Inspect and tightenflwheel nut to correct torque See“ENG!NE PRE-IGNITES’ table Inspectand repair and tighten-nuts to correct torque Tighten bolts Tighten ENGINE SMOKES EXCESSIVELY ENGINE STALLS Remedies Refill with fresh fuel-of the correct mixture Unload engine and-restart See “SPARK PLUG FOULED-table Replace fuel cap Inspect and repairto removeunwanted ground Clear ventof obstruction Clear debris from fins or causeof overheating Refill-with fresh, andproperly mixed, fuel 3-6 Reference Section SPARK PLUG
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