Form No. 3429-270 Rev A 1P65F-2 Service Manual Published: August 2019 1P65FC and 1P65FA engine specifications included © 2018—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision History Page 2 1P65F-2 Service Manual 3429-270 Rev A
Preface This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. We are hopeful that you will find this manual a valuable addition to your service shop.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S.
Table of Contents Preface ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
Preface Page 6 1P65F-2 Service Manual 3429-270 Rev A
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Think Safety First (continued) Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment.
Think Safety First (continued) Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–9 Equivalents and Conversions........................................................................................................... 2–14 U.S.
Specifications 1P65F–2 Engine Specifications Model 1P65F-2 Engine Name Toro Type Single Cylinder 4–stroke, Forced Air Cooled OHV Engine Bore X Stroke 65 mm x 48 mm Displacement 159 cc Compression Ratio 7.6 : 1 Lubrication Splash Starting Recoil/Electric Rotation Counter-Clockwise (from PTO Side) Transistorized Magneto Ignition Ignition System Air Cleaner Foam/Paper Fuel Type Unleaded Gasoline 87 Octane 10 % Ethanol Oil Capacity 18 oz (0.53 L) Dimension (L x W x H) 15 in. x 13.5 in.
1P65F–2 Engine Part Specifications (continued) Part Item Standard Service Limit Clearance (Cold) Intake 0.004-0.006 in. (0.10-0.15 mm) N/A Clearance (Cold) Exhaust 0.006-0.008 in. (0.15-0.20 mm) N/A Stem Diameter (Intake) 0.216 in. (5.48 mm) 0.209 in. (5.318 mm) Stem Diameter (Exhaust) 0.214 in. (5.44 mm) 0.208 in. (5.275 mm) Inside Diameter (Intake, Exhaust) 0.2165 in. (5.50 mm) 0.2193 in. (5.572 mm) Stem to Guide Clearance (Intake) 0.00039-0.00133 in. (0.01-0.034 mm) 0.00393 in. (0.
1P65F–2 Engine Torque Specifications (continued) Item Screw Thread Torque M4 bolt 16-26 in-lbs. (2-3 Nm) M5 bolt/nut 39-56 in-lbs. (4.5-6.5 Nm) M6 bolt/nut 70-105 in-lbs.
1P65FC Engine Part Specifications (continued) Part Item Standard Service Limit Small End Inside Diameter 0.513 in. (13.02 mm) 0.515 in. (13.07 mm) Large End Inside Diameter 1.024 in. (26.02 mm) 1.026 in. (26.07 mm) Large End to Crank Journal Clearance 0.0016-0.0025 in. (0.04-0.063 mm) 0.0047 in. (0.12 mm) Large End Side Clearance 0.0039-0.0275 in. (0.1-0.7 mm) 0.0433 in. (1.1 mm) Crank Pin Outside Diameter 1.022 in. (25.98 mm) 1.020 in. (25.92 mm) Clearance (Cold) Intake 0.004 in. (0.
1P65FC Engine Torque Specifications (continued) Item Screw Thread Torque Fuel Drain Screw M6 52–79 in-lbs. (6–9 Nm) Valve Cover Bolt M6 90 in-lbs. (10 Nm) Carburetor Mount Screw M8 52–79 in-lbs. (6–9 Nm) Spark Plug N/A 22 ft-lbs. (30 Nm) Governor Arm Pinch Nut M6 90 in-lbs. (10 Nm) Ignition and Charge Coil Bolts M6 90 in-lbs. (10 Nm) Electric Starter Motor Bolts M6 90 in-lbs. (10 Nm) M5 bolt/nut 54 in-lbs. (6 Nm) M6 bolt/nut 90 in-lbs. (10 Nm) M8 bolt/nut 228 in-lbs.
1P65FA Engine Part Specifications (continued) Part Item Standard Service Limit Skirt Outside Diameter 2.558 in. (64.985 mm) 2.553 in. (64.845 mm) Clearance to Cylinder 0.00059-0.00196 in. (0.015-0.05 mm) 0.0047 in. (0.12 mm) Piston Pin Bore Inside Diameter 0.512 in. (13.002 mm) 0.514 in. (13.048 mm) Piston - Pin Clearance 0.00007-0.0005 in. (0.002-0.014 mm) 0.00314 in. (0.08 mm) Outside Diameter 0.512 in. (13.0 mm) 0.510 in. (12.954 mm) End Gap (Top/Middle) 0.0078-0.0156 in. (0.2-0.
1P65FA Engine Torque Specifications (continued) Item Screw Thread Torque Cylinder Head Bolt M8 25 ft-lbs. (34 Nm) Connecting Rod Bolt M7 114 in-lbs. (13 Nm) Flywheel Nut M14 62 ft-lbs. (85 Nm) Rocker Arm Pivot Stud M8 22 ft-lbs. (30 Nm) Rocker Arm Lock Nut M6 120 in-lbs (14 Nm) Crankcase Cover Bolt M6 90 in-lbs. (10 Nm) Muffler Nuts M6 90 in-lbs. (10 Nm) Air Cleaner Nuts M6 72 in-lbs. (8 Nm) Recoil (Fan Cover Nut) M6 72 in-lbs. (8 Nm) Oil Drain Bolt M10 180 in-lbs.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply for all fasteners which do not have a specific requirement identified in the service manual.
Metric Bolts and Screws Figure 2 1. Class 8.8 Specifications and Maintenance: Torque Specifications 2. Page 2–10 Class 10.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studes & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) In-lb. In-lb.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb. N-cm in-lb. N-cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lbs. N-m ft-lbs. N-m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.5 38 ± 4 52 ± 5 54 ± 6 73 ± 8 M12 X 1.
SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb. 73 ± 12 in-lb. 5/16 - 18 UNC 215 ± 35 in-lb. 145 ± 20 in-lb. 1/2 - 13 UNC 75 ± 15 ft-lb. 50 ± 10 ft-lb. 3/8 - 16 UNC 35 ± 10 ft-lb. 18 ± 3 ft-lb. Wheel Bolts and Lug Nuts Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb. 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb. 108 ± 14 N-m M12 X 1.25 Class 8.8 80 ± 10 ft-lb. 108 ± 14 Nm M12 X 1.5 Class 8.
Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.272 5/32 0.15625 3.969 21/32 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Specifications and Maintenance: Torque Specifications Page 2–16 1P65F-2 Service Manual 3429-270 Rev A
Chapter 3 Troubleshooting Table of Contents General Troubleshooting .......................................................................................................................
GEARS The Systematic approach to defining, diagnosing and solving problems.
General Troubleshooting Problem Engine turns over but will not start Possible Cause Choke not closed Corrective Action 1. Check to see if the choke is fully closed at start up. 2. Check the thermal control, choke linkage, and air vane operation. 3. Make adjustments or replace components as necessary. Fuel delivery issue 1. Check fuel level in the tank, fuel filter, fuel lines, fuel tank venting, and carburetor. 2. Clean debris from the fuel system. 3. Replace damaged components as necessary.
General Troubleshooting (continued) Problem Engine hard starting/poor running Possible Cause Fuel quality Corrective Action 1. Check the fuel condition for age, octane, ethanol, percentage, water or other contaminates. 2. Flush the fuel system and fuel. Fuel delivery issue 1. Check the fuel level in the tank, fuel filter, fuel lines, fuel tank venting, and carburetor. 2. Clean debris from the fuel system. 3. Replace as necessary Spark plug 1.
General Troubleshooting (continued) Problem Engine doesn’t crank Possible Cause Electrical issues Corrective Action 1. Check the battery voltage, electrical connections, and the voltage to the starter motor. 2. Replace damaged components. 1. Bench test the starter motor. Starter motor 2. Replace as necessary. Engine overheats Cylinder Cooling fins 1. Check for debris build-up under the engine shroud. 2. Clean debris from the cooling fins. Oil 1.
Troubleshooting: General Troubleshooting Page 3–6 1P65F-2 Service Manual 3429-270 Rev A
Chapter 4 Engine Top End Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Recoil Replacement........................................................................................................................... 4–6 Flywheel Replacement.
General Information This chapter covers the disassembly, inspection, and reassembly of the recoil, flywheel, and crankcase breather assemblies.
Service and Repairs Engine Top End Assembly 1 Figure 3 1. 2. Acorn Nut Recoil Shroud Asm. 4. 5. Fan Shroud Shroud Stud 3.42 inch (86.9 mm) 3. Recoil Compression Spring 6. Shroud Stud 3.31 inch (84.
Engine Top End Assembly 2 Figure 4 1. 2. 3. Breather Cover Breather Gasket Cover Breather Valve 4. Oil Seal Engine Top End: Service and Repairs 5. 6. 7.
Engine Top End Assembly 3 Figure 5 1. Flange Nut 1P65F-2 Service Manual 3429-270 Rev A 2.
Recoil Replacement Recoil Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly. Figure 6 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine. Figure 7 3. Remove the shroud by lifting away from the engine. Recoil Inspection 1. Check the recoil dogs for excessive wear.
Recoil Inspection (continued) Figure 8 2. Verify the recoil dogs fully engage and disengage (fully seated) with the recoil hub. Recoil Installation 1. Install the shroud onto the engine. 2. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 9 3. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52—87 in-lbs. (6–10 Nm).
Recoil Installation (continued) Figure 10 Flywheel Replacement Flywheel Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly. Figure 11 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine.
Flywheel Removal (continued) Figure 12 3. Remove the shroud by lifting away from the engine. 4. Loosen the nut securing the crankshaft to the engine. 5. Unhook the spring from the brake mechanism. Figure 13 6. Place a pry bar under the flywheel to pry the flywheel upwards. Use a soft based hammer, loosen the flywheel assembly from the crankshaft, only striking the top of the nut to prevent crankshaft damage.
Flywheel Removal (continued) Figure 14 7. Remove the nut from the crankshaft. Remove the flywheel from the engine. Figure 15 Flywheel Inspection Inspect the keyway for damage.
Flywheel Inspection (continued) Figure 16 Flywheel Installation 1. Install the flywheel onto the crankcase. Figure 17 2. Install the nut securing the flywheel to the crankshaft. Torque nut to 59–66 ft-lbs. (80–90 Nm). 3. Hook the spring to the brake mechanism.
Flywheel Installation (continued) Figure 18 4. Install the shroud onto the engine. 5. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 19 6. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 in-lbs. (6–10 Nm).
Flywheel Installation (continued) Figure 20 Crankcase Breather System Replacement Crankcase Breather System Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly. Figure 21 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine.
Crankcase Breather System Removal (continued) Figure 22 3. Remove the shroud by lifting away from the engine. 4. Loosen the nut securing the crankshaft to the engine. 5. Unhook the spring from the brake mechanism. Figure 23 6. Place a pry bar under the flywheel, pry the flywheel upwards. Using a soft based hammer, loosen the flywheel assembly from crankshaft, only striking the top of the nut to prevent crankshaft damage.
Crankcase Breather System Removal (continued) Figure 24 7. Remove the nut from the crankshaft. Remove the flywheel from the engine. Figure 25 8. Remove the ground wire from the brake assembly.
Crankcase Breather System Removal (continued) Figure 26 9. Remove the 2 wires leading to the brake switch. Figure 27 10. Remove the 2 bolts securing the brake assembly to the crankcase.
Crankcase Breather System Removal (continued) Figure 28 11. Remove the bolt securing the breather assembly to the cover. Figure 29 12. Remove the cover from the breather assembly.
Crankcase Breather System Removal (continued) Figure 30 13. Remove the valve from the breather assembly. Figure 31 Crankcase Breather System Inspection 1. Inspect the valve seating surface for damage.
Crankcase Breather System Inspection (continued) Figure 32 2. Inspect the face of the valve for wear or damage. Figure 33 Crankcase Breather System Installation 1. Install the valve onto the breather assembly.
Crankcase Breather System Installation (continued) Figure 34 2. Install the cover to the breather assembly. Secure with a 10 mm bolt. Torque bolt to 90 in-lbs. (10 Nm). Figure 35 3. Install the 2 (10 mm) bolts securing the brake assembly to the crankcase. Torque bolts to 90 in-lbs. (10 Nm).
Crankcase Breather System Installation (continued) Figure 36 4. Install the 2 wires leading to the brake switch assembly. Figure 37 5. Install the ground wire to the brake assembly.
Crankcase Breather System Installation (continued) Figure 38 6. Install the flywheel onto the engine. Figure 39 7. Install the nut securing the flywheel to the crankshaft. Torque nut to 59–66 ft-lbs. (80–90 Nm). 8. Hook the spring to the brake mechanism.
Crankcase Breather System Installation (continued) Figure 40 9. Install the shroud onto the engine. 10. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 41 11. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 in-lbs. (6–10 Nm).
Crankcase Breather System Installation (continued) Figure 42 Engine Top End: Service and Repairs Page 4–24 1P65F-2 Service Manual 3429-270 Rev A
Chapter 5 Air Intake System Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Air Filter Replacement........................................................................................................................
General Information The Toro 1P65F-2 engine is equipped with a 2–stage filtration system. This chapter covers the disassembly, inspection, and assembly of the air intake system.
Service and Repairs Air Intake System Assembly Figure 43 1. 2. Air Cleaner Base Flange Nut 1P65F-2 Service Manual 3429-270 Rev A 3. 4.
Air Filter Replacement Air Filter Removal 1. Push down on the 2 air filter cover latch tabs. Figure 44 2. Hinge the air filter cover downward. Remove the cover from the air filter housing assembly. 3. Remove the air filter from the air filter housing. Air Filter Inspection 1. Check the air filter for damage or excessive dirt and debris. Figure 45 2. Remove the foam pre-filter from the air filter cover. Check for damage or excessive dirt and debris.
Air Filter Inspection (continued) Figure 46 Air Filter Installation 1. Install the air filter into the air filter housing. Figure 47 2. Install the cover to the air filter housing assembly. 3. Hinge the air filter cover upward and lock into place. Air Box Replacement Air Box Removal 1. Push down on the 2 air filter cover latch tabs.
Air Box Removal (continued) Figure 48 2. Hinge the air filter cover downward. Remove the cover from the air filter housing assembly. 3. Remove the air filter from the air filter housing. 4. Remove the 2 (10 mm) nuts securing the air filter housing to the engine. Figure 49 5. Remove the air filter housing from the engine. Air Box Inspection Inspect the O-ring on the back side (carburetor side) of the air filter housing for damage.
Air Box Inspection (continued) Figure 50 Air Box Installation 1. Install the air filter housing to the engine. Secure with 2 (10 mm) nuts securing the air filter housing to the engine. Torque nuts to 52–87 in-lbs. (6–10 Nm). Figure 51 2. Install the air filter into the air filter housing.
Air Box Installation (continued) Figure 52 3. Install the cover to the air filter housing assembly. 4.
Chapter 6 Fuel System Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Carbon Canister Replacement...........................................................................................................
General Information This chapter covers the disassembly, inspection, and assembly of the fuel system. The fuel system consists of a sealed fuel tank that is vented to the carburetor manifold through a carbon canister. The fuel is gravity fed to the carburetor through an in-line fuel filter to the carburetor float bowl. The fuel flow is controlled by the movement of the float inside the float bowl as the fuel level rises and falls.
Service and Repairs Fuel System Assembly 1 Figure 53 1. 2. Auto Choke Air Vane Choke Linkage 7. 8. Oil Seal Throttle Return Spring 3. Wire Harness Clip 9. Governor Rod 4. Throttle Control Plate 10. Governor Spring 5. 6. Governor Arm Hair Pin 11. 12.
Fuel System Assembly 2 Figure 54 1. Sealed Fuel Cap 2. 3. Fuel Tank Stud Bolt 9. 10. Intake Gasket Carburetor Spacer 4. 5. 6. Fuel Line Kit Thermal Control Thermal Choke Linkage 11. 12. 13. Carburetor Gasket Carburetor Insulator Carburetor 7. Throttle Lock 14. Carburetor Gasket Fuel System: Service and Repairs 8.
Carbon Canister Replacement Carbon Canister Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly. Figure 55 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine. Figure 56 3. Remove the fuel tank vent hose from the fitting on the fuel tank.
Carbon Canister Removal (continued) Figure 57 4. Remove the manifold vent hose from the intake manifold. Remove the carbon canister from the engine. Figure 58 Carbon Canister Test 1. Connect a hand vacuum pump to the hose attached to the “V” port on the carbon canister. 2. Place a thumb over the hose attached to the “P” port on the carbon canister. 3. Apply a vacuum with the hand pump. If the vacuum builds at the vacuum pump gauge, replace the carbon canister assembly.
Carbon Canister Inspection (continued) Figure 59 Carbon Canister Installation 1. Install the manifold vent hose onto the intake manifold. Figure 60 2. Install the fuel tank vent hose to the fitting on the fuel tank.
Carbon Canister Installation (continued) Figure 61 3. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 62 4. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 in-lbs. (6–10 Nm).
Carbon Canister Installation (continued) Figure 63 Fuel Filter and Hoses Replacement Fuel Filter and Hoses Removal 1. Drain the fuel tank. 2. Push down on the 2 air filter cover latch tabs. Figure 64 3. Hinge the air filter cover downward. Remove the cover from the air filter housing assembly. 4. Remove the air filter from the air filter housing. 5. Remove the 2 (10 mm) nuts securing the air filter housing to the engine.
Fuel Filter and Hoses Removal (continued) Figure 65 6. Remove the air filter housing from the engine. 7. Remove the fuel hose clamp at the carburetor. 8. Remove the fuel hose from the carburetor. Note: Use a rag to catch excess fuel from hose removal. Figure 66 9. Remove the fuel hose clamp at the fuel tank. 10. Remove the fuel hose from the fuel tank. 11. Remove the fuel filter from the fuel hose. Note: Replace the fuel filter and fuel hose as necessary.
Fuel Filter and Hoses Removal (continued) Figure 67 Fuel Filter and Hoses Inspection Check the fuel filter screen for debris. Fuel Filter and Hoses Installation 1. Install the fuel filter into the fuel tank fitting. Figure 68 2. Install the fuel hose to the fuel tank. Secure with the fuel hose clamp.
Fuel Filter and Hoses Installation (continued) Figure 69 3. Install the fuel hose to the carburetor. Secure with the fuel hose clamp. Figure 70 4. Install the air filter housing to the engine. 5. Install the air filter housing to the engine. Secure with 2 (10 mm) nuts securing the air filter housing to the engine. Torque nuts to 52–87 in-lbs. (6–10 Nm).
Fuel Filter and Hoses Installation (continued) Figure 71 6. Install the air filter into the air filter housing. Figure 72 7. Install the cover to the air filter housing assembly. 8. Hinge the air filter cover upward and lock into place. Carburetor Replacement Carburetor Removal 1. Push down on the 2 air filter cover latch tabs. 2. Hinge the air filter cover downward. Remove the cover from the air filter housing assembly. 3. Remove the air filter from the air filter housing. 4.
Carburetor Removal (continued) Figure 73 5. Remove the air filter housing from the engine. 6. Loosen the hose clamp on the fuel hose. 7. Remove the fuel hose from the carburetor. Figure 74 8. Remove the linkage connecting the air vein to the carburetor by pulling the air vein arm towards the breather hose. Lift the linkage upwards and remove from the air vein arm.
Carburetor Removal (continued) Figure 75 9. Remove the thermal control linkage from the carburetor by unhooking and sliding the linkage retainer outward. Figure 76 10. Remove the governor linkage from the governor arm by pivoting the arm towards the front of the engine for a wide open throttle. Then lift the governor linkage up and away from the carburetor.
Carburetor Removal (continued) Figure 77 11. Lift upwards on the governor linkage spring and away from the carburetor. 12. Slide the carburetor away from the engine. Figure 78 Carburetor Disassembly 1. Remove the 2 bolts (10 mm) securing the float bowl to carburetor body. Note: The center bolt is the float bowl mounting and the side bolt is the carburetor drain bolt.
Carburetor Disassembly (continued) Figure 79 2. Remove the float bowl from the carburetor body. Figure 80 3. Remove the float pin from the carburetor body.
Carburetor Disassembly (continued) Figure 81 4. Remove the float and needle from the carburetor body. Figure 82 5. Remove the main jet from the carburetor body.
Carburetor Disassembly (continued) Figure 83 Carburetor Inspection 1. Check for debris (dirt or metal shaving) or build-up of old fuel. 2. Verify passages are open and free from debris blockage. 3. Check for dirt or old fuel residue in the carburetor. Clean the carburetor body and parts in an ultra sonic cleaner before reassembly. 4. Check the tip of the float needle for grooves or wear. Carburetor Assembly 1. Install the main jet into the carburetor body. Figure 84 2.
Carburetor Assembly (continued) Figure 85 3. Install the float pin through the carburetor body and float. Figure 86 4. Install the float bowl onto the carburetor body.
Carburetor Assembly (continued) Figure 87 5. Install the 10 mm bolt securing the float bowl to carburetor body. Torque bolt to 52–79 in-lbs. (6–9 Nm). Figure 88 Pop Off Test 1. Install the needle into the float and onto the carburetor body. 2. Position the carburetor with the float up. 3. Install the pressure tester onto the inlet fitting on the carburetor.
Pop Off Test (continued) Figure 89 4. While pumping, observe the pressure increase. 5. Stop pumping, observe the pressure drop slightly, then stabilize as the float weight closes the needle and holds pressure. The pressure should not drop to zero. Carburetor Installation 1. Slide the carburetor into position on the engine. Figure 90 2. Install the governor linkage spring. 3. Install the governor linkage onto the governor arm.
Carburetor Installation (continued) Figure 91 4. Install the thermal control linkage to the carburetor by hooking the linkage retainer inward. Figure 92 5. Install the linkage connecting the air vane to the carburetor.
Carburetor Installation (continued) Figure 93 6. Install the fuel hose to the carburetor. Figure 94 7. Tighten the hose clamp on the fuel hose. 8. Install the air filter housing to the engine. Secure with 2 (10 mm) nuts securing the air filter housing to the engine. Torque nuts to 52–87 in-lbs. (6–10 Nm).
Carburetor Installation (continued) Figure 95 9. Install the air filter into the air filter housing. Figure 96 10. Install the cover to the air filter housing assembly. 11. Hinge the air filter cover upward and lock into place. Auto Choke System/Thermal Control Replacement Auto Choke System/Thermal Control Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly.
Auto Choke System/Thermal Control Removal (continued) Figure 97 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine. Figure 98 3. Remove the shroud by lifting away from the engine. 4. Remove the 2 (10 mm) nuts securing muffler to the cylinder head.
Auto Choke System/Thermal Control Removal (continued) Figure 99 5. Remove the muffler cover from the muffler. 6. Remove the 2 (7 mm) thermal control mounting bolts from the muffler. Figure 100 7. Remove the thermal control from the linkage.
Auto Choke System/Thermal Control Removal (continued) Figure 101 Auto Choke System/Thermal Control Inspection Verify the thermal control arm moves freely and returns to stop. Figure 102 Auto Choke System/Thermal Control Installation 1. Install the thermal control to the linkage.
Auto Choke System/Thermal Control Installation (continued) Figure 103 2. Install the 2 (7 mm) thermal control mounting bolts to the muffler. Torque mounting bolts to 54 in-lbs. (6 Nm). Figure 104 3. Install the muffler cover to the muffler. 4. Install the 2 (10 mm) nuts securing the muffler to the cylinder head. Torque nuts to 70–105 in-lbs. (8–12 Nm).
Auto Choke System/Thermal Control Installation (continued) Figure 105 5. Install the shroud onto the engine. 6. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 106 7. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 in-lbs. (6–10 Nm).
Auto Choke System/Thermal Control Installation (continued) Figure 107 Control Plate Replacement Control Plate Removal 1. Remove the spring from the governor arm. Note: Note the position of the spring. Figure 108 2. Remove the 10 mm bolt securing the control plate to the crankcase.
Control Plate Removal (continued) Figure 109 3. Remove the control plate from the crankcase. Figure 110 Control Plate Installation 1. Install the control plate onto the crankcase. 2. Secure the spring to the governor arm.
Control Plate Installation (continued) Figure 111 3. Install the bolt securing the control plate to the crankcase. Torque bolt to 90 in-lbs. (10 Nm).
Fuel System: Service and Repairs Page 6–34 1P65F-2 Service Manual 3429-270 Rev A
Chapter 7 Compression System Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Cylinder Head Replacement ..............................................................................................................
General Information This chapter covers the complete disassembly, inspection, adjustment, and assembly of the engine compression system. The 1P65F-2 engine is an overhead valve design. The camshaft is equipped with an automatic compression release and operates the valves through a push rod and rocker arm system.
Service and Repairs Compression System Assembly 1 Figure 113 1. 2. Valve Cover Valve Cover Gasket 7. 8. Intake Rocker Arm Asm. Spark Plug 3. Spring Valve Retainer 9. Valve Stem Seal 4. Valve Spring 10. Valve Set 5. 6. Exhaust Rocker Arm Asm. Complete Head Asm. 11.
Compression System Assembly 2 Figure 114 1. 2. 3. Push Rod Head Gasket Dowel Pin 6. 7. 8. Piston Piston Pin Valve Tappet 4. Piston Ring Set 9. Connecting Rod Asm. 5.
Compression System Assembly 3 Figure 115 1. 2. Muffler Shield Muffler Asm. 1P65F-2 Service Manual 3429-270 Rev A 3.
Cylinder Head Replacement Cylinder Head Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly. Figure 116 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine. Figure 117 3. Remove the shroud by lifting away from the engine. 4. Push down on the 2 air filter cover latch tabs.
Cylinder Head Removal (continued) Figure 118 5. Hinge the air filter cover downward. Remove the cover from the air filter housing assembly. 6. Remove the air filter from the air filter housing. 7. Remove the 2 (10 mm) nuts securing the air filter housing to the engine. Figure 119 8. Remove the air filter housing from the engine. 9. Loosen the hose clamp on the fuel hose. 10. Remove the fuel hose from the carburetor.
Cylinder Head Removal (continued) Figure 120 11. Remove the linkage connecting the air vein to the carburetor by pulling the air vein arm towards the breather hose. Lift the linkage upwards and remove from the air vein arm. Figure 121 12. Remove the thermal control linkage from the carburetor by unhooking and sliding the linkage retainer outward.
Cylinder Head Removal (continued) Figure 122 13. Remove the governor linkage from the governor arm by pivoting the arm towards the front of the engine, opening the throttle wide. Then lift the governor linkage up and away from the carburetor. Figure 123 14. Lift upwards on the governor linkage spring and away from the carburetor. 15. Slide the carburetor away from the engine.
Cylinder Head Removal (continued) Figure 124 16. Remove the 2 (10 mm) nuts securing muffler to the cylinder head. Figure 125 17. Remove the muffler cover from the muffler. 18. Remove the muffler and muffler gasket from the cylinder head. 19. Remove the spark plug wire from the spark plug.
Cylinder Head Removal (continued) Figure 126 20. Remove the spark plug from the cylinder head. Figure 127 21. Remove the 5 (10 mm) bolts securing the valve cover to the cylinder head.
Cylinder Head Removal (continued) Figure 128 22. Remove the valve cover from the cylinder head. Figure 129 23. Remove the circlip from the exhaust valve rocker arm pivot pin.
Cylinder Head Removal (continued) Figure 130 24. Remove the rocker arm pivot pin. Figure 131 25. Remove the rocker arm from the cylinder head.
Cylinder Head Removal (continued) Figure 132 26. Remove the 4 (12 mm) bolts securing the cylinder head to the crankcase. Figure 133 27. Remove the cylinder head from the crankcase.
Cylinder Head Removal (continued) Figure 134 Cylinder Head Disassembly 1. Push down on the valve retainer and slide towards the large end of the slot to release the retainer from the valve. Figure 135 2. Repeat for opposite valve. 3. Remove the circlip from the intake valve rocker arm pivot pin.
Cylinder Head Disassembly (continued) Figure 136 4. Remove the pivot pin and rocker arm from the cylinder head. Figure 137 Cylinder Head Cleaning Inspection 1. Remove the carbon deposits from the cylinder head. 2. Clean the cylinder head of any remaining gasket material; intake, exhaust, valve cover, and head gaskets. 3.
Cylinder Head Cleaning Inspection (continued) Figure 138 1. Spark Plug Threads 4. Exhaust Port 2. 3. Valve Seats Intake Port 5. Coolant Fins 4. Inspect the cylinder head for warpage using a straight edge and feeler gauge. Measure and compare to specifications: Service Limit: 0.002 in. 5. Inspect the intake and exhaust ports mounting surface for warpage. Cylinder Head Valve Seat Inspection 1. Thoroughly clean the cylinder head to remove carbon deposits. 2.
Valve Face Contact Test 1. Apply a light coat of Prussian Blue or erasable tipped marker ink to the valve face. 2. Insert the valve, lift the valve and snap closed against the seat several times. Note: Be sure the valve does not rotate on the seat. 3. Inspect the transferred making compound for any area of the seat that is not concentric. 4. Replace the cylinder head if any of the above items are found out of specification. Valve Guide Inspection 1.
Valve Spring (continued) Valve Spring Standard: 1.202 in. (30.5 mm) Service Limit: 1.141 in. (29.0 mm) Figure 141 2. Inspect for bent coils of the spring (spring should stand straight). Valve Mounting Components Clean and inspect all other valve mounting components including the spring retainers, keepers, and spring seats. Cylinder Head Assembly 1. Install the pivot pin and rocker arm to the cylinder head. Figure 142 2. Install the circlip to the intake valve rocker arm pivot pin.
Cylinder Head Assembly (continued) Figure 143 3. Repeat for opposite valve. 4. To secure the retainer to the valve, push down on the valve retainer and slide away from the large end of the slot. Figure 144 Cylinder Head Installation 1. Install the cylinder head to the crankcase.
Cylinder Head Installation (continued) Figure 145 2. Install the 4 (12 mm) bolts securing the cylinder head to the crankcase. Torque bolts to 22–26 ft-lbs. (30–36 Nm). Figure 146 3. Install the rocker arm to the cylinder head.
Cylinder Head Installation (continued) Figure 147 4. Install the rocker arm pivot pin. Figure 148 5. Install the circlip to the exhaust valve rocker arm pivot pin.
Cylinder Head Installation (continued) Figure 149 6. Install the valve cover to the cylinder head. Figure 150 7. Install the 5 (10 mm) bolts securing the valve cover to the cylinder head. Torque bolts to 72 in-lbs. (8 Nm).
Cylinder Head Installation (continued) Figure 151 8. Install the spark plug to the cylinder head. Figure 152 9. Install the spark plug wire to the spark plug. Torque the spark plug to 22 ft-lbs.(30 Nm).
Cylinder Head Installation (continued) Figure 153 10. Install the muffler and muffler gasket to the cylinder head. 11. Install the muffler cover to the muffler. 12. Install the 2 (10 mm) nuts securing the muffler to the cylinder head. Torque nuts to 70–105 in-lbs. (8–12 Nm). Figure 154 13. Slide the carburetor into position on the engine.
Cylinder Head Installation (continued) Figure 155 14. Install the governor linkage spring. 15. Install the governor linkage onto the governor arm. Figure 156 16. Install the thermal control linkage to the carburetor by hooking the linkage retainer inward.
Cylinder Head Installation (continued) Figure 157 17. Install the linkage connecting the air vein to the carburetor. Figure 158 18. Install the fuel hose to the carburetor.
Cylinder Head Installation (continued) Figure 159 19. Tighten the hose clamp on the fuel hose. 20. Install the air filter housing to the engine. Secure with 2 (10 mm) nuts securing the air filter housing to the engine. Torque nuts to 52–87 in-lbs. (6–10 Nm). Figure 160 21. Install the air filter into the air filter housing.
Cylinder Head Installation (continued) Figure 161 22. Install the cover to the air filter housing assembly. 23. Hinge the air filter cover upward and lock into place. 24. Install the shroud onto the engine. 25. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 162 26. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 in-lbs. (6–10 Nm).
Cylinder Head Installation (continued) Figure 163 Connecting Rod Replacement Connecting Rod Removal 1. Drain the oil. 2. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly. Figure 164 3. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine.
Connecting Rod Removal (continued) Figure 165 4. Remove the shroud by lifting away from the engine. 5. Loosen the nut securing the crankshaft to the engine. 6. Unhook the spring from the brake mechanism. Figure 166 7. Place a pry bar under the flywheel to pry the flywheel upwards. Use a soft based hammer, to loosen the flywheel assembly from the crankshaft, only striking the top of the nut to prevent crankshaft damage.
Connecting Rod Removal (continued) Figure 167 8. Remove the nut from the crankshaft. Remove the flywheel from the engine. Figure 168 9. Turn the motor upside down. 10. Remove the cylinder head assembly from the engine. 11. Remove the 7 (10 mm) bolts securing the sump cover to the crankcase.
Connecting Rod Removal (continued) Figure 169 12. Using a soft base hammer, tap the sump cover to remove from the crankcase. Figure 170 13. Remove the sump cover from the crankcase.
Connecting Rod Removal (continued) Figure 171 14. Remove the thrust washer from the crankshaft. Figure 172 15. Turn the crankshaft clockwise, match the timing marks between the camshaft and crankshaft.
Connecting Rod Removal (continued) Figure 173 16. Remove the camshaft from the crankcase. 17. Remove the 2 (10 mm) connecting rod cap bolts. Figure 174 18. Remove the connecting rod cap.
Connecting Rod Removal (continued) Figure 175 19. Remove the connecting rod and piston. Figure 176 Connecting Rod Inspection 1. Inspect the connecting rod and cap bearing surfaces for wear and scoring.
Connecting Rod Inspection (continued) Figure 177 2. Check the wrist pin bearing surface of the connecting rod for wear and scoring. Figure 178 Connecting Rod Installation 1. Install the connecting rod and piston.
Connecting Rod Installation (continued) Figure 179 2. Install the connecting rod cap. Figure 180 3. Install the 2 (10 mm) connecting rod cap bolts. Torque bolts to 108–132 in-lbs. (13–15 Nm).
Connecting Rod Installation (continued) Figure 181 4. Install the camshaft to the crankcase. 5. Verify the camshaft and crankshaft timing marks match. Figure 182 6. Install the thrust washer onto the crankshaft.
Connecting Rod Installation (continued) Figure 183 7. Install the sump cover to the crankcase. Secure the crankcase with 7 (10 mm) bolts. Torque the bolts to 70–105 in-lbs. (8–12 Nm). Figure 184 8. Turn the motor over. 9. Install the flywheel onto the engine.
Connecting Rod Installation (continued) Figure 185 10. Install the nut holding the flywheel to the crankshaft. Torque nut to 59–66 ft-lbs. (80–90 Nm). 11. Hook the spring to the brake mechanism. Figure 186 12. Install the shroud onto the engine. 13. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud.
Connecting Rod Installation (continued) Figure 187 14. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 in-lbs. (6–10 Nm). Figure 188 15. Add oil to the engine. Piston and Rings Assembly Replacement Piston and Rings Assembly Removal 1. Drain the oil. 2. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly.
Piston and Rings Assembly Removal (continued) Figure 189 3. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine. Figure 190 4. Remove the shroud by lifting away from the engine. 5. Push down on the 2 air filter cover latch tabs. 6. Hinge the air filter cover downward. Remove the cover from the air filter housing assembly. 7. Remove the air filter from the air filter housing. 8.
Piston and Rings Assembly Removal (continued) Figure 191 9. Remove the air filter housing from the engine. 10. Loosen the hose clamp on the fuel hose. 11. Remove the fuel hose from the carburetor. Figure 192 12. Remove the linkage connecting the air vein to the carburetor by pulling the air vein arm towards the breather hose. Lift the linkage upwards and remove from the air vein arm.
Piston and Rings Assembly Removal (continued) Figure 193 13. Remove the thermal control linkage from the carburetor by unhooking and sliding the linkage retainer outward. Figure 194 14. Remove the governor linkage from the governor arm by pivoting the arm towards the front of the engine, opening the throttle wide. Then lift the governor linkage up and away from the carburetor.
Piston and Rings Assembly Removal (continued) Figure 195 15. Lift upwards on the governor linkage spring and away from the carburetor. 16. Slide the carburetor away from the engine. Figure 196 17. Remove the 2 (10 mm) nuts securing muffler to the cylinder head.
Piston and Rings Assembly Removal (continued) Figure 197 18. Remove the muffler cover from the muffler. 19. Remove the muffler and muffler gasket from the cylinder head. 20. Remove the spark plug wire from the spark plug. Figure 198 21. Remove the spark plug from the cylinder head.
Piston and Rings Assembly Removal (continued) Figure 199 22. Remove the 5 (10 mm) bolts securing the valve cover to the cylinder head. Figure 200 23. Remove the valve cover from the cylinder head.
Piston and Rings Assembly Removal (continued) Figure 201 24. Remove the circlip from the exhaust valve rocker arm pivot pin. Figure 202 25. Remove the rocker arm pivot pin.
Piston and Rings Assembly Removal (continued) Figure 203 26. Remove the rocker arm from the cylinder head. Figure 204 27. Remove the 4 (12 mm) bolts securing the cylinder head to the crankcase.
Piston and Rings Assembly Removal (continued) Figure 205 28. Remove the cylinder head from the crankcase. Figure 206 29. Turn the motor upside down. 30. Remove the cylinder head assembly from the engine. 31. Remove the 7 (10 mm) bolts securing the sump cover to the crankcase.
Piston and Rings Assembly Removal (continued) Figure 207 32. Using a soft base hammer, tap the sump cover to remove from the crankcase. Figure 208 33. Remove the sump cover from the crankcase.
Piston and Rings Assembly Removal (continued) Figure 209 34. Remove the thrust washer from the crankshaft. Figure 210 35. Turn the crankshaft clockwise, match the timing marks between the camshaft and crankshaft.
Piston and Rings Assembly Removal (continued) Figure 211 36. Remove the camshaft from the crankcase. 37. Remove the 2 (10 mm) connecting rod cap bolts. Figure 212 38. Remove the connecting rod cap.
Piston and Rings Assembly Removal (continued) Figure 213 39. Turn the crankshaft until the piston is at the top of the stroke. Figure 214 40. Push on the connecting rod to push the piston out of the cylinder. Remove the piston from the engine. Piston and Rings Assembly Inspection 1. Inspect the piston for wear and scoring on the piston surface.
Piston and Rings Assembly Inspection (continued) Figure 215 2. Remove the piston rings from the piston. Note: Rings shown top to bottom, left to right. Figure 216 3. Inspect the rings for wear. End Gap (Top/Middle): 0.0078–0.0156 in. (0.2–0.4 mm) and 0.040 in. (1.0 mm) Width (Top/Middle): 0.0397 in. (1.0 mm) and 0.0342 in. (0.87 mm) Width (Oil Ring): 0.098 in. (2.5 mm) and 0.093 in. (2.37 mm) 4. Remove the wrist pin circlip from the piston. 5. Remove the wrist pin from the piston. 6.
Piston and Rings Assembly Inspection (continued) Service Limit: 2.552 in. (64.845 mm) 7. Measure the inside diameter of the piston. Sleeve Inside Diameter: 2.559 in. (65 mm) Service Limit: 2.565 in. (65.165 mm) 8. Measure piston to cylinder clearance. Clearance to Cylinder: 0.00059–0.00196 in. (0.015–0.05 mm). Piston and Rings Assembly Installation 1. Install the piston rings on the piston. 2. Install the piston into the cylinder. Figure 217 3.
Piston and Rings Assembly Installation (continued) 4. Install the connecting rod cap. Figure 219 5. Install the 2 (10 mm) connecting rod cap bolts. Torque bolts to 108–132 in-lbs. (13–15 Nm). Figure 220 6. Install the camshaft to the crankcase. 7. Verify the camshaft and crankshaft timing marks match.
Piston and Rings Assembly Installation (continued) Figure 221 8. Install the thrust washer onto the crankshaft.
Piston and Rings Assembly Installation (continued) 9. Install the sump cover to the crankcase. Secure the crankcase with 7 (10 mm) bolts. Torque the bolts to 70–105 in-lbs. (8–12 Nm). Figure 223 10. Install the cylinder head to the crankcase. Figure 224 11. Install the 4 (12 mm) bolts securing the cylinder head to the crankcase. Torque bolts to 22–26 ft-lbs. (30–36 Nm).
Piston and Rings Assembly Installation (continued) Figure 225 12. Install the rocker arm to the cylinder head. Figure 226 13. Install the rocker arm pivot pin.
Piston and Rings Assembly Installation (continued) Figure 227 14. Install the circlip to the exhaust valve rocker arm pivot pin. Figure 228 15. Install the valve cover to the cylinder head.
Piston and Rings Assembly Installation (continued) Figure 229 16. Install the 5 (10 mm) bolts securing the valve cover to the cylinder head. Torque bolts to 72 in-lbs. (8 Nm). Figure 230 17. Install the spark plug to the cylinder head.
Piston and Rings Assembly Installation (continued) Figure 231 18. Install the spark plug wire to the spark plug. Torque the spark plug to 22 ft-lbs.(30 Nm). Figure 232 19. Install the muffler and muffler gasket to the cylinder head. 20. Install the muffler cover to the muffler.
Piston and Rings Assembly Installation (continued) 21. Install the 2 (10 mm) nuts securing the muffler to the cylinder head. Torque nuts to 70–105 in-lbs. (8–12 Nm). Figure 233 22. Slide the carburetor into position on the engine. Figure 234 23. Install the governor linkage spring. 24. Install the governor linkage onto the governor arm.
Piston and Rings Assembly Installation (continued) Figure 235 25. Install the thermal control linkage to the carburetor by hooking the linkage retainer inward. Figure 236 26. Install the linkage connecting the air vein to the carburetor.
Piston and Rings Assembly Installation (continued) Figure 237 27. Install the fuel hose to the carburetor. Figure 238 28. Tighten the hose clamp on the fuel hose. 29. Install the air filter housing to the engine. Secure with 2 (10 mm) nuts securing the air filter housing to the engine. Torque nuts to 52–87 in-lbs. (6–10 Nm).
Piston and Rings Assembly Installation (continued) Figure 239 30. Install the air filter into the air filter housing. Figure 240 31. Install the cover to the air filter housing assembly. 32. Hinge the air filter cover upward and lock into place. 33. Install the shroud onto the engine. 34. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud.
Piston and Rings Assembly Installation (continued) Figure 241 35. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 in-lbs. (6–10 Nm). Figure 242 36. Turn the motor over. 37. Add oil to the engine. Valve Adjustment Valve Adjustment Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly.
Valve Adjustment Removal (continued) Figure 243 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine. Figure 244 3. Remove the shroud by lifting away from the engine. 4. Remove the spark plug wire from the spark plug.
Valve Adjustment Removal (continued) Figure 245 5. Remove the spark plug from the cylinder head. Figure 246 6. Remove the 5 (10 mm) bolts securing the valve cover to the cylinder head.
Valve Adjustment Removal (continued) Figure 247 7. Remove the valve cover from the cylinder head. Figure 248 8. Place the piston at the top of the compression stroke to check the piston’s location. 9. Place a wooden dowel in the spark plug hole and rotate the crankshaft until the piston is at the top of the compression stroke.
Valve Adjustment Removal (continued) Figure 249 10. Using a feeler gauge, check clearance between the rocker arm and the top of the valve stem for the intake and exhaust valves. Note: The left valve is the intake and the right valve is exhaust. Clearance for (Cold) Intake: 0.004-0.006 in. (0.10-0.15 mm) Clearance for (Cold) Exhaust: 0.006-0.008 in. (0.15-0.
Valve Adjustment Removal (continued) Figure 251 11. To make an adjustment, place a flat blade screwdriver in the slot of the adjusting screw. Loosen the lock nut using a 10 mm wrench. Turn the adjusting screw in or out to adjust the gap between the rocker arm and valve stem. When the clearance is correct, tighten the lock nut and recheck the clearance. Valve Adjustment Installation 1. Install the valve cover onto the cylinder head. 2.
Valve Adjustment Installation (continued) 3. Install the spark plug to the cylinder head. Torque the spark plug to 22 ft-lbs. (30 Nm) Figure 253 4. Install the spark plug wire to the spark plug. Figure 254 5. Install the shroud onto the engine. 6. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud.
Valve Adjustment Installation (continued) Figure 255 7. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 ft-lbs. (6–10 Nm).
Chapter 8 Electrical System Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Electric Starter Replacement .............................................................................................................
General Information This chapter covers the disassembly, inspection, testing, and assembly of the electrical system.
Service and Repairs Electrical System Assembly Figure 257 1. Ignition Coil Asm. 5. Brake Asm. 2. Starter Motor Harness 6. Brake Spring 3. Flywheel 7. Starter Motor 4.
Electric Starter Replacement Electric Starter Removal 1. Unplug the electric starter from the mower harness. Figure 258 2. Remove the 2 starter mounting bolts securing the starter to the engine. Figure 259 3. Remove the starter from the engine.
Electric Starter Removal (continued) Figure 260 Electric Starter Installation 1. Install the starter onto the engine. Figure 261 2. Loosely install the left hand mounting bolt securing the starter to the engine. 3. While installing the right hand mounting bolt, install the bolt through eyelet of the ground wire. Torque the mounting bolts to 90 in-lbs. (10 Nm).
Electric Starter Installation (continued) Figure 262 4. Plug the electric starter into the mower harness. Figure 263 Ignition Coils Replacement Ignition Coils Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly.
Ignition Coils Removal (continued) Figure 264 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine. Figure 265 3. Remove the shroud by lifting away from the engine. 4. Unplug the ground wire from the connector at the brake assembly.
Ignition Coils Removal (continued) Figure 266 5. Remove the spark plug wire from the spark plug. Figure 267 6. Remove the coil mounting bolt and shroud mounting stud from the coil.
Ignition Coils Removal (continued) Figure 268 7. Remove the ignition coil from the engine. Figure 269 Ignition Coil Resistance Test Primary 1. Place one lead on the coil connector. 2. Place one lead on the coil frame.
Ignition Coil Resistance Test (continued) Figure 270 3. The volt Ohm meter should read 1.3-1.7 Ohms. Secondary 1. Remove the spark plug cap from the high tension wire by holding the wire and unscrewing the cap by turning counter-clockwise. 2. Place one lead of the meter in the end of the high tension lead. Figure 271 3. Place the other lead on the coil frame. 4. The volt Ohm meter should read 5.4-6.2 Ohms. Ignition Coil Installation 1. Install the ignition coil onto the engine.
Ignition Coil Installation (continued) Figure 272 2. Install the coil mounting bolt and shroud mounting stud onto the coil. Torque the bolt and stud to 90 in-lbs. (10 Nm). Set air gap: 0.0157-0.007 in (0.4-0.2 mm) Figure 273 3. Install the spark plug wire to the spark plug.
Ignition Coil Installation (continued) Figure 274 4. Install the shroud onto the engine. 5. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 275 6. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 ft-lbs. (6–10 Nm).
Ignition Coil Installation (continued) Figure 276 Spark Plugs Replacement Spark Plug Removal 1. Remove the spark plug cap. Figure 277 2. Remove the spark plug from the cylinder head.
Spark Plug Removal (continued) Figure 278 Spark Plug Inspection 1. Inspect the spark plug condition for carbon or oil build-up. Replace as necessary. Figure 279 2. Check the spark plug gap. Gap: 0.30 in. (0.7–0.
Spark Plug Inspection (continued) Figure 280 Spark Plug Installation 1. Screw the spark plug into the cylinder head. Torque screw to 22 ft-lbs. (30 Nm). Figure 281 2. Install the spark plug cap.
Spark Plug Installation (continued) Figure 282 Charging System Replacement Charging System Removal 1. Remove the 3 (10 mm) acorn nuts securing the recoil assembly to the top of the engine. Remove the recoil assembly. Figure 283 2. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine.
Charging System Removal (continued) Figure 284 3. Remove the shroud by lifting away from the engine. 4. Drain the fuel tank. 5. Loosen the hose clamp on the fuel hose. 6. Remove the fuel hose from the fuel tank fitting. 7. Remove the 2 shroud mounting studs securing the fuel tank to the crankcase. Figure 285 8. Remove the 10 mm nut and washer from the fuel tank mounting stud.
Charging System Removal (continued) Figure 286 9. Remove the fuel tank from the engine. 10. Remove the 2 (10 mm) mounting bolts securing the charge coil to the crankcase. Figure 287 11. Remove the charge coil from the crankcase. Alternator Test 1. Make sure the battery is fully charged. 2. Place the positive test lead from the volt meter to the positive terminal on the mower battery. 3. Place the negative test lead from the volt meter to the negative test lead on the battery. 4. Start the engine.
Charging System Installation 1. Install the charge coil to the crankcase. 2. Install the 2 (10 mm) mounting bolts securing the charge coil to the crankcase. Torque bolts to 90 in-lbs. (10 Nm). Set air gap to: Air Gap: 0.0157 ± 3.007 in. (0.4–0.2 mm) Figure 288 3. Install the fuel tank to the engine. 4. Install the 10 mm nut and washer to the fuel tank mounting stud. Torque nut and washer to 90 in-lbs. (10 Nm). Figure 289 5. Install the 2 shroud mounting studs securing the fuel tank to the crankcase.
Charging System Installation (continued) Figure 290 6. Install the fuel hose to the fuel tank fitting. 7. Tighten the hose clamp on the fuel hose. 8. Add fuel to the fuel tank. 9. Install the shroud onto the engine. 10. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 291 11. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 ft-lbs. (6–10 Nm).
Charging System Installation (continued) Figure 292 1P65F-2 Service Manual 3429-270 Rev A Page 8–21 Electrical System: Service and Repairs
Electrical System: Service and Repairs Page 8–22 1P65F-2 Service Manual 3429-270 Rev A
Chapter 9 Engine Lower End Table of Contents General Information .............................................................................................................................. 9–2 Service and Repairs ............................................................................................................................. 9–3 Sump Cover Replacement .................................................................................................................
General Information This chapter covers the disassembly, inspection, and assembly of the crankshaft, camshaft, and governor system.
Service and Repairs Engine Lower End Assembly Figure 293 1. 2. 3. 4. Crankshaft Asm. Camshaft Asm. Dowel Pin Governor Gear Asm. 1P65F-2 Service Manual 3429-270 Rev A 5. 6. 7.
Sump Cover Replacement Sump Cover Removal 1. Drain the oil. 2. Turn the motor upside down. 3. Remove the 7 (10 mm) bolts securing the sump cover to the crankcase. Figure 294 4. Using a soft base hammer, tap the sump cover to remove from the crankcase. Figure 295 5. Remove the sump cover from the crankcase.
Sump Cover Removal (continued) Figure 296 Sump Cover Installation 1. Install the sump cover to the crankcase. Secure the crankcase with 7 (10 mm) bolts. Torque the bolts to 70–105 in-lbs. (8–12 Nm). Figure 297 2. Turn the motor over. 3. Add oil to the engine. Governor Assembly Replacement Governor Assembly Removal 1. Drain the oil.
Governor Assembly Removal (continued) 2. Turn the motor upside down. 3. Remove the 7 (10 mm) bolts securing the sump cover to the crankcase. Figure 298 4. Using a soft base hammer, tap the sump cover to remove from the crankcase. Figure 299 5. Remove the sump cover from the crankcase.
Governor Assembly Removal (continued) Figure 300 6. Remove the thrust washer from the crankshaft. Figure 301 7. Turn the crankshaft clockwise, match the timing marks between the camshaft and crankshaft.
Governor Assembly Removal (continued) Figure 302 8. Remove the camshaft from the crankcase. 9. Loosen the (10 mm) nut from the governor arm bolt. Figure 303 10. Remove the governor spring from the governor arm. Note the position of the governor spring.
Governor Assembly Removal (continued) Figure 304 11. Remove the governor arm from the governor shaft. Figure 305 12. Remove the hair pin from the governor shaft.
Governor Assembly Removal (continued) Figure 306 13. Slide the governor arm from the crankcase. Figure 307 14. Remove the (8 mm) bolt securing the governor gear to the sump cover.
Governor Assembly Removal (continued) Figure 308 15. Remove the governor gear from the sump cover. Figure 309 Governor Assembly Inspection 1. Inspect the fly weights for wear or damage.
Governor Assembly Inspection (continued) Figure 310 2. Remove the plunger and thrust washer. Inspect for wear or damage and verify the plunger moves freely on the governor gear shaft. Figure 311 3. Inspect the teeth for wear or damage.
Governor Assembly Inspection (continued) Figure 312 Governor Assembly Installation 1. Install the governor gear to the sump cover. Figure 313 2. Install the 8 mm bolt securing the governor gear to the sump cover.
Governor Assembly Installation (continued) Figure 314 3. Slide the governor arm to the crankcase. Figure 315 4. Install the hair pin to the governor shaft.
Governor Assembly Installation (continued) Figure 316 5. Install the governor arm to the governor shaft. Figure 317 6. Install the governor spring to the governor arm. Note the position of the governor spring.
Governor Assembly Installation (continued) Figure 318 7. Tighten the (10 mm) nut to the governor arm bolt. Torque nut to 90 in-lbs. (10 Nm). Figure 319 8. Install the camshaft to the crankcase. 9. Verify the camshaft and crankshaft timing marks match.
Governor Assembly Installation (continued) Figure 320 10. Install the thrust washer onto the crankshaft.
Governor Assembly Installation (continued) 11. Install the sump cover to the crankcase. Secure the crankcase with 7 (10 mm) bolts. Torque the bolts to 70–105 in-lbs. (8–12 Nm). Figure 322 12. Turn the motor over. 13. Zero the governor. Zeroing the Governor 1. Move the governor arm so the throttle plate at the carburetor is wide open. 2. Loosen the pinch bolt on the governor arm. 3. Using pliers, turn the governor shaft clockwise until it stops. 4. Tighten the pinch bolt.
Crankshaft Removal (continued) Figure 323 3. Remove the fuel tank vent hose from the hose retainer on the engine shroud. Move the carbon canister to the side of the engine. Figure 324 4. Remove the shroud by lifting away from the engine. 5. Loosen the nut securing the crankshaft to the engine. 6. Unhook the spring from the brake mechanism.
Crankshaft Removal (continued) Figure 325 7. Place a pry bar under the flywheel to pry the flywheel upwards. Use a soft based hammer, to loosen the flywheel assembly from crankshaft, only striking the top of the nut to prevent crankshaft damage. Figure 326 8. Remove the nut from the crankshaft. Remove the flywheel from the engine.
Crankshaft Removal (continued) Figure 327 9. Turn the motor upside down. 10. Remove the cylinder head assembly from the engine. 11. Remove the 7 (10 mm) bolts securing the sump cover to the crankcase. Figure 328 12. Using a soft base hammer, tap the sump cover to remove from the crankcase.
Crankshaft Removal (continued) Figure 329 13. Remove the sump cover from the crankcase. Figure 330 14. Remove the thrust washer from the crankshaft.
Crankshaft Removal (continued) Figure 331 15. Turn the crankshaft clockwise, match the timing marks between the camshaft and crankshaft. Figure 332 16. Remove the camshaft from the crankcase. 17. Remove the 2 (10 mm) connecting rod cap bolts.
Crankshaft Removal (continued) Figure 333 18. Remove the connecting rod cap. Figure 334 19. Remove the connecting rod and piston.
Crankshaft Removal (continued) Figure 335 20. Remove the flywheel key from the crankshaft. Figure 336 Crankshaft Inspection 1. Inspect the connecting rod journal and crankcase bearing surfaces for damage or scoring. 2. Check to specifications. Crankshaft Connecting Rod Journal Outside Diameter: 1.022 in. (25.98 mm) Service Limit: 1.020 in. (25.392 mm) Crankshaft Installation 1. Install the flywheel key to the crankshaft.
Crankshaft Installation (continued) Figure 337 2. Install the connecting rod and piston. Figure 338 3. Install the connecting rod cap.
Crankshaft Installation (continued) Figure 339 4. Install the 2 (10 mm) connecting rod cap bolts. Torque bolts to 108–132 in-lbs. (13–15 Nm). Figure 340 5. Install the camshaft to the crankcase. 6. Verify the camshaft and crankshaft timing marks match.
Crankshaft Installation (continued) Figure 341 7. Install the thrust washer onto the crankshaft.
Crankshaft Installation (continued) 8. Install the sump cover to the crankcase. Secure the crankcase with 7 (10 mm) bolts. Torque the bolts to 70–105 in-lbs. (8–12 Nm). Figure 343 9. Turn the motor over. 10. Install the flywheel onto the engine. Figure 344 11. Install the nut securing the crankshaft to the flywheel. Torque nut to 59–66 ft-lbs. (80–90 Nm). 12. Hook the spring to the brake mechanism.
Crankshaft Installation (continued) Figure 345 13. Install the shroud onto the engine. 14. Place the carbon canister into position on the engine. Install the fuel tank vent hose to the hose retainer on the engine shroud. Figure 346 15. Install the recoil assembly onto the engine. Secure with 3 (10 mm) acorn nuts. Torque acorn nuts to 52–87 ft-lbs. (6–10 Nm).
Crankshaft Installation (continued) Figure 347 16. Add oil to the engine. Camshaft Replacement Camshaft Removal 1. Drain the oil. 2. Turn the motor upside down. 3. Remove the 7 (10 mm) bolts securing the sump cover to the crankcase. Figure 348 4. Using a soft base hammer, tap the sump cover to remove from the crankcase.
Camshaft Removal (continued) Figure 349 5. Remove the sump cover from the crankcase. Figure 350 6. Remove the thrust washer from the crankshaft.
Camshaft Removal (continued) Figure 351 7. Turn the crankshaft clockwise, match the timing marks between the camshaft and crankshaft. Figure 352 8. Remove the camshaft from the crankcase. Camshaft Inspection 1. Inspect the cam lobes for wear.
Camshaft Inspection (continued) Figure 353 2. Inspect the automatic compression release for damage and functionality. Figure 354 3. Remove the tappets from the crankcase.
Camshaft Inspection (continued) Figure 355 4. Verify the tappets move freely in the crankcase. Inspect tappet faces for wear. Figure 356 Camshaft Installation 1. Install the camshaft to the crankcase. 2. Verify the camshaft and crankshaft timing marks match.
Camshaft Installation (continued) Figure 357 3. Install the thrust washer onto the crankshaft.
Camshaft Installation (continued) 4. Install the sump cover to the crankcase. Secure the crankcase with 7 (10 mm) bolts. Torque the bolts to 70–105 in-lbs. (8–12 Nm). Figure 359 5. Turn the motor over. 6. Add oil to the engine.
