TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL Table of Contents – Page 1 of 2 SPECIFICATIONS GENERAL INFORMATION OIL GASOLINE COOLING SYSTEM AIR CLEANER – GENERAL AIR CLEANER SERVICE TUNE-UP PROCEDURE OVERHAUL PROCEDURE CHECK-UP EQUIPMENT AFFECTING ENGINE OPERATION IGNITION CHECK IGNITION SPARK PLUG REMOVE FLYWHEEL INSPECT FLYWHEEL KEY, KEYWAYS, FLYWHEEL, AND CRANKSHAFT INSTALL FLYWHEEL SPECIFICATIONS CARBURETION CARBURETOR IDENTIFICATION SERVICE CARBURETOR WALBRO LMS GOVERNOR CONTROLS, CARBURETOR LINKA
TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL Table of Contents – Page 2 of 2 DISASSEMBLE REWIND STARTER ASSEMBLE REWIND STARTER ELECTRIC STARTER GENERAL INFORMATION TROUBLESHOOTING 12 VOLT STARTING SYSTEM TEST EQUIPMENT BATTERY STARTER ALTERNATOR ALTERNATOR SPECIFICATIONS EQUIPMENT TO TEST ALTERNATORS 1/2 AMP ALTERNATOR LUBRICATION EXTENDED OIL FILL AND DIPSTICK BREATHER REMOVE BREATHER INSTALL BREATHER VALVE REMOVE OIL PUMP INSPECT OIL PUMP INSTALL OIL PUMP INSTALL PUMP COVER INSTALL OIL FILTER ADAPTE
About This Manual This manual was written expressly for the Toro GTS 200 Overhead Valve Engine. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written with the service technician in mind. We hope that you find this manual a valuable addition to your service shop.
Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Pulley And Spring . . . . . . . . . . . . . . . . . . . . . Inspect Spring, Starter Housing and Pulley . . . . . . . . Assemble Rewind Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Pulley and Spring . . . . . . . . . . . . . . . . . . . . . . . Install Pawls and Retainer Assembly . . . . . . . . . . . . .
Specifications Basic model series . . . . . . . . . . . . . . . . . 123600 Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . 22 fl. oz. (.65 Liter) 26 fl. oz. (.78 Liter) with oil filter Armature air gap . . . . . . . . . . . . . . . . . . . .006/.014 in. 0.15/0.36mm Torque specifications Flywheel nut . . . . . . . . . . . . . . . . . . . 60 ft. lb. 81.0Nm Cylinder head . . . . . . . . . . . . . . . . . . 210 in. lb. 24.0Nm Connecting rod . . . . . . . . . . . . . . . . . 100 in. lb. 11.
Check Oil Level General Information Fill crankcase with SAE 30 oil until oil level reaches FULL mark on dipstick as shown in Figure 1. The maximum crankcase capacity is 22 ounces (0.65 Liter). On models equipped with an oil filter, the maximum crankcase capacity is 26 ounces (0.78 Liter). Use any high quality detergent oil having the American Petroleum Institute (API) “service classification”—SF, SG SH, or SJ. Contents Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Oil—Drain Plug Method 5. If replacing the oil filter (on models so equipped), do so at this time. 1. Run engine at least 5 minutes to warm the oil. Warm oil drains more easily and more of the contaminants are removed. 6. When oil is drained, return mower to upright position and add fresh oil to engine. Refer to Oil in this section. 2. Remove oil drain plug (Fig. 2). Drain oil into a pan. Approximate Crankcase Oil Capacity (Dry) Specifications Without oil filter . . . . . 22 oz. .
Gasoline DANGER Use clean, fresh, lead-free gasoline (including oxygenated or reformulated gasoline) with an octane rating of 87 or higher. To ensure freshness, purchase only the quantity of gasoline that can be used in 30 days. Using unleaded gasoline results in fewer combustion chamber deposits and longer spark plug life. POTENTIAL HAZARD • When fueling, under certain circumstances, a static charge can develop, igniting the gasoline.
This should be a regular maintenance operation, performed yearly or every 100 hours, whichever comes first and more often when dust or when airborne debris is present. 1 Fig. 5 – Static Screen 1 1. Static screen 2 m–3662 Fig. 7 – Remove Spark Plug Wire Prior to Service 1 1. Primer 2 2. Spark plug wire 2. Loosen two (2) knobs securing air cleaner cover to engine (Fig. 8). 1 2 Fig. 6 – Cylinder Fins and Ducting 1. Ducting ÔÔÔÔ ÔÔÔÔ 2.
Tune-Up Procedure By performing the following steps you will either be sure that the engine is functioning properly or will know what repairs should be made. These steps are also covered in the Overhaul Procedure and will normally be performed as a part of complete overhaul. Carbon deposits in combustion chamber should be removed every 100 to 300 hours of use (more often when run at steady loads), or whenever cylinder head is removed. Step No. 1. Remove air cleaner, check for proper servicing.
Overhaul Procedure The Overhaul Procedure which follows is intended to help you become accustomed to a systematic method of repairing Toro GTS 200 OHV engines. Naturally these steps could be rearranged in different order but efficiency is obtained when the repair operations are performed in the same sequence every time. The Overhaul Procedure can also be used as an index. For information on how to perform most operations listed, refer to the section number or operation.
Repairs Beginning Page Section Clean/replace parts as required Replace block or short block if cylinder is over allowable dimension Cylinder and Bearings 56 Replace valve guides – intake or exhaust, if required Compression 27 Reface valves and seats and lap, if required Compression 27 Replace ignition armature, if required Ignition 14 Replace throttle shaft bushings, if required Carburetion 18 Repair carburetor Carburetion 18 Replace rewind starter spring and rope (if so equipped) Rewi
Check-Up If spark does not occur, look for – 1. Shorted stop switch wire Most complaints concerning engine operation can be classified as one or a combination of the following: 2. Shorted stop switch 1. Will not start 3. Ignition armature failure 2. Hard starting 4. Improperly operating interlock system 3.
Hard Starting, or Will Not Start Power Loss 1. Check remote control assembly for proper adjustment. 1. Grass cuttings build-up under deck. 2. Check ignition system. 2. No lubrication in transmission or gear box. 3. Dull blade. Vibration 4. Excessive drive belt tension may cause excess bearing wear or seizure. 1. Cutter blade bent – Remove and replace. 2. Cutter blade out of balance – Remove and balance. Noise 3. Crankshaft bent – Replace. 1. BBC system problems (if so equipped). 4.
Ignition Contents Check Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check For Spark Miss . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Maintenance . . . . . . . . . . . . . . . . . . . . . . . Remove Ignition Armature . . . . . . . . . . . . . . . . . . . . . Remove Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Remove Flywheel The recommended spark plug is: 1. Remove blower housing. Spark Plug Type Brand Resistor Long Plug Champion RC12YC 2. Use flywheel holder to hold flywheel from turning, Fig. 13. 1 Note: In some areas, local law requires the use of a resistor spark plug to suppress ignition signals. If an engine was originally equipped with a resistor spark plug, be sure to use the same type of spark plug for replacement. Spark Plug Maintenance Set gap at .020” (0.51mm), Fig. 11.
Inspect Flywheel Key, Keyways, Flywheel, and Crankshaft 2 1 Inspect flywheel key for partial or complete shearing. If sheared, replace, Fig. 15. Flywheel should be inspected for cracks, burrs on taper or keyway, and distortion of keyway. Check taper of crankshaft for burrs, rust, oil, or other damage. Check cooling fan or flywheel for broken fins. If parts are damaged, replace with new parts. 1 2 Fig. 16 – Torquing Flywheel Fig. 15 – Inspect Flywheel Key 1. OK 1.
Adjust Ignition Armature Air Gap 3. See Table No. 1, Page 17 for armature air gap. Loosen mounting screw so magnet will pull armature down against thickness gauge. 1. Rotate flywheel until magnet is under armature laminations. 4. Torque both mounting screws to 25 in. lbs. (3.0Nm) Rotate flywheel to remove thickness gauge. 2. Place thickness gauge, Table No. 1, Page 17, between magnet and armature laminations, Fig. 18. 5. Install outer blower housing and screws and torque screws to 85 in. lbs., (10.
Carburetion Service Carburetor Walbro LMS Contents These carburetors have a fixed high speed main jet with non-adjustable idle mixture, Fig. 21. Carburetor Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Carburetor Walbro LMS . . . . . . . . . . . . . . . . . . . . . Remove Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassemble Carburetor . . . . . . . . . . . . . . . . . . . . . . .
Remove Carburetor 2 1 1. Move fuel line clamp and disconnect fuel line from carburetor. WARNING 3 CLOSE FUEL valve or plug fuel line to prevent fuel spillage. Do not use a screw to plug fuel line as this damages interior of hose. 2. Remove carburetor and rotate carburetor until governor link is free. 3. On current production engines, the control bracket is held on with three (3) screws, of which two (2) were removed to remove the carburetor, Fig. 23.
Carburetor Cleaning Recommendations 3. Lay throttle plate on shaft with numbers facing out and install screw, Fig. 27. Use a new patchlock screw, or use Loctite to secure screw in place. 1. Disassemble carburetor. 2. Remove all old gaskets, seals and sealing material. 2 3. Use commercial carburetor cleaning solvents to clean carburetor parts and body. 1 3 4. When cleaning non-metallic parts (plastic, nylon, Minlon, etc.), do not leave in commercial carburetor cleaner bath more than 15 minutes.
4. Place fiber washer over main jet and install main jet. Torque nut to 50 in. lbs. (6.0Nm), Fig. 29. 2 3 1 5 6 3 1 2 4 1 Fig. 31 – Installing Carburetor Fig. 29 – Installing Float, Hinge Pin and Inlet Needle 1. Float 2. Hinge pin 1 1. 2. 3. 4. 3. Inlet needle High Altitude Compensation Mounting screw Carburetor Carburetor control bracket Gasket 5. Current style, mounting hole 6. Early style Install Air Cleaner Note: If engine is operated at high altitudes, performance may decrease.
Governor Controls, Carburetor Linkage, and Flywheel Brake 2 3 1 Contents Remote Governor Controls . . . . . . . . . . . . . . . . . . . . . . . . . Remote Control Wire Travel . . . . . . . . . . . . . . . . . . . . Speed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Remote Controls . . . . . . . . . . . . . . . . . . . . . . . Flywheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove Flywheel Brake 7. Remove two screws from brake bracket and remove bracket, Fig. 38. 1. Disconnect spark plug lead from spark plug. 1 8 2. Remove static guard and fuel tank, Fig. 36. 2 1 3 3 6 2 3 2 5 Fig. 36 – Removing Static Guard and Fuel Tank 1. Static guard 2. Fuel tank 4 7 Fig. 38 – Removing Brake Bracket 3. Screw 1. 2. 3. 4. 3. Remove dipstick and oil fill tube, Fig. 37. Stop switch wire Screw Anchor Brake bracket 5. Starter interlock switch wires 6. Brake spring 7.
Governor and Carburetor Linkages Brake Adjustment WARNING Figures 40 and 41 show governor and carburetor linkages. TO PREVENT accidental starting, the spark plug wire must be removed from spark plug and grounded, after removing boot. Failure to do so can cause personal injury. 1 1. Using a torque wrench and socket to fit flywheel nut, turn flywheel clockwise with brake engaged. While turning at a steady rate, torque reading should be 30 in. lbs. (3.0Nm) or higher. 2.
Governor completely assembled machine. The RPM should be measured with the mower on a hard surface to eliminate cutting load on the blade. Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governed RPM Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Governor . . . . . . . . . . . . . .
3. Install crankcase cover or sump screws and torque screws in order of numbers cast on outside surface of sump to 110 in. lbs. (12.0Nm), Fig. 45. 2 1 Note: Screw at position four was factory coated with sealant. If sealant is missing, coat with a non-hardening sealant such as Permatex 2, or equivalent. 3 1 5 4 Fig. 44 – Removing Governor Lever 1. Governor lever nut 2. Governor link 3. Governor lever 4. Governor crank 5. Push nut Fig. 45 – Torque Sequence 1. Screw must have sealant 3.
Compression CAUTION Contents Test Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prepare Cylinder Head for Removal . . . . . . . . . . . . . . Remove Rocker Cover . . . . . . . . . . . . . . . . . . . . . . . . Remove Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . Remove Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Valve Guides . . . . . . . . . . . . . .
Remove Cylinder Head 1 2 Prepare Cylinder Head for Removal 3 Before cylinder head can be removed external parts such as air cleaner cover, fuel tank, oil fill tube and dipstick, blower housing with rewind starter, muffler guard and muffler, air cleaner, carburetor, carburetor control bracket assembly and carburetor adapter or intake manifold must be removed. ÓÓ ÓÓ Part No. 19413 Fig. 49 – Setting Tester 1. Inlet gauge set point 2. Outlet gauge needle Remove Rocker Cover 3.
Remove Valves 1. Thoroughly clean lapping compound from valve seat and valve face. 1. Place cylinder head on work surface. 2. Valve seat width should be as shown in Fig. 53. 2. Remove valve cap from valve stems, Fig. 52. 2 4 2 1 1 45° 3 Fig. 53 – Valve and Seat Dimensions 1. Margin 2. 1/32” (.79mm) fit for use 3. 1/64” (.38mm) discard 3. If seat is wider, a narrowing cutter should be used. If valve face is badly burned, the burned valve should be replaced. Fig. 52 – Removing Valves 1.
Install Valves Install Cylinder Head 1. Valve stems and guides must be free of foreign material and burrs or valve sticking will occur and valve stem seals will be damaged. Note: Do not use sealer of any kind on gaskets. 1. Coat threads of cylinder head screws with Briggs & Stratton Part #93963, Valve Guide Lubricant. 2. Lightly coat valve stems with Briggs & Stratton Part #93963, Valve Guide Lubricant, and install in valve guides. 2.
2. Install push rods through push rod guide making sure push rods are in valve tappets, Fig. 59. 4. Install screw assembly from Step 3 and turn screw in until there is zero clearance between valve cap and rocker arm. 5. Rotate crankshaft at least two (2) revolutions to be sure push rods operate rocker arms. Adjust Valve Clearance—Current Style Note: Check valve clearances while engine is cold. 1. Turn crankshaft until piston is at Top Dead Center (both valves closed) on compression stroke. 2.
Install Valve Cover 4. Loosen jam nut, Fig. 62. 1. Install valve cover with new gasket. Install four screws. and tighten screws to torque listed in Table No. 5, Page 32, in sequence shown in Fig. 65. 2 2. Install carburetor, exhaust manifold, air guides, shields and other parts removed from cylinder head. 4 3 1 2 1 Fig. 62 – Adjust Rocker Arm Clearance, Early Style 1. Feeler gauge 2. Jam nut 3 3. Rocker arm screw Fig. 65 – Valve Cover Torque Sequence 5.
Remove Blower Housing and Starter Rewind Starter Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Blower Housing and Starter . . . . . . . . . . . . . . . . . Disassemble Rewind Starter . . . . . . . . . . . . . . . . . . . . . . . . Remove Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Pulley And Spring . . . . . . . . . . . . . . . . . . . . .
3. Disconnect fuel line at carburetor and clamp fuel line. Remove three (3) screws holding fuel tank to blower housing and screw and spacer holding tank to cylinder, Fig. 69. 5. Remove four (4) screws, two (2) from front and two (2) from rear of blower housing, Fig. 71. Note: Rewind starters used on these engines are riveted to the blower housing. Replacement starters are supplied with screws and nuts to replace the rivets for mounting starter.
Remove Pulley And Spring Inspect Spring, Starter Housing and Pulley 1. Remove shoulder screw and retainer, Fig. 72. 1. Inspect pulley for wear, cracks, rough edges or burrs in pulley groove and wear on center hole, Fig. 74. 1 2 2 3 3 1 Fig. 74 – Inspecting Pulley 1. Edges 2. Center hole 3. Pulley groove 2. Replace pulley if damaged or worn. 3. Inspect spring for broken ends, kinks and burrs. Replace assembly if any of above conditions exists. 4.
Assemble Rewind Starter 2. Install retainer making sure that slots in retainer engage tabs on pulley, Fig. 79. Install Pulley and Spring 2 1. Lay starter housing on work bench. 2. Assemble starter pulley to center pivot post in housing, Fig. 76. 3 1 4 1 2 Fig. 79 – Installing Retainer and Screw Fig. 76 – Installing Pulley 1. Pulley 1. Slot 2. Torque screw to 70 in. lbs. (8.0Nm) 2. Center pivot post 3.
3. Insert unknotted end of rope through knot cavity and rope hole in pulley. 3. Tighten screw and then install three remaining screws. Install oil fill tube and dipstick. 4. Thread end of rope through starter housing eyelet and pull rope until knot is in rope cavity, Fig. 81. Note: Install fuel tank bracket with blower housing. After torquing blower housing screws install one (1) screw at top of fuel tank bracket to top of blower housing and torque screw to 85 in. lbs. (10.0Nm). 1 4.
Electric Starter When the starter switch is activated, the battery supplies power to the starter motor, cranking the engine. On 1999 and newer models, the brake switch must also be activated to power the starter. When the engine is running, the alternator recharges the battery. It will take approximately 15–20 minutes of running to replace the battery charge used to start the engine one time. Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Battery faulty or damaged. Tachometer E. Incorrect rotation due to reversed motor polarity or reverse battery connections – motor rotates counterclockwise viewed from pinion gear. A Trysit Sirometer (Tachometer) is available from your Briggs & Stratton source of supply. Use Briggs & Stratton Tool #19200. The Sirometer measures from 800 to 25,000 revolutions per minute (RPM), Fig. 87. 4. Starter Motor Spins, Will Not Stop A. Defective starter switch.
Battery 2. Fully charge battery with charger supplied with the mower. 3. Install battery on mower. Plug into wire harness. Handling Instructions 4. Slightly loosen battery plug and attach DC voltmeter. Reading should be around 12.5 VDC. CAUTION 5. Disconnect spark plug wire and turn switch to start. LIKE ALL batteries, these units contain corrosive fluids and toxic materials and should be handled with care. 6. Battery should maintain 9 volts or more while cranking engine.
Starter Check 12 Volt Starter Motor Check Starter Motor Drive and Clutch A performance test of starter motor may be made in the following manner. 1. When starter switch is activated, pinion gear should rise, engage flywheel ring gear, and crank engine. This should be observed. CAUTION GROUND SPARK plug wire using Briggs & Stratton Tool #19051 or #19368, Ignition Tester, before doing this test. Do not engage starter motor more than five seconds. 2.
3. A dirty or worn armature commutator. 5. Move wire inside connector. Meter should not change value. 4. A shorted, open or grounded armature. 6. Replace or repair wiring if there is no continuity or intermittent. Repeat for each wire in harness. A. Shorted armature (worn insulation, wires touching each other) will be indicated by slow speed and high current (amps). Disassemble Starter Motor B. Open armature (broken wire) may not turn (no current flow [amps]) or will have low RPM. CAUTION C.
3. Three (3) screws holding gear cover and gear itself may now be removed. 10. If brushes are worn to a length of 5/64” (2mm) or less, brushes should be replaced. 4. Lift clutch assembly and pinion gear off their respective shafts. 11. Check brush springs for proper tension (sufficient force to keep brush in firm contact with commutator). 5. Remove starter motor thru bolts, Fig. 97. Clean and Inspect Starter 2 1 1. Clean all dirt from armature, end cap, motor support, gears, etc. 3 2.
3. Place thrust washers on armature shaft in sequence shown. 17. Tap end cap edge lightly using a soft hammer to align bearings, Fig. 103. 4. Add gray plastic washers to obtain dimension shown in Fig. 100, inset. 2 1 5. Using care to ensure brushes clear commutator, slide armature shaft into end cap bearing. 6. Support armature shaft and slide it slowly into starter housing, as shown in Fig. 101. 3 1 2 3 Fig. 103 – Aligning End Cap Bearing 1. Drain hole 2. Tap edge of end cap 3. Soft hammer Fig.
Alternator Equipment to Test Alternators Contents The following equipment is recommended to test and repair alternators. Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment to Test Alternators . . . . . . . . . . . . . . . . . . . . . . . Digital Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 Amp Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Stator Air Gap 4. Attach RED test clip to output terminal, Fig. 108. 1 1. Stator air gap is 0.010” (.25mm). 2 2. Rotate flywheel until magnets are away from stator. 3. Loosen both stator mounting screws and move stator away from flywheel and tighten one screw. 4. Place a 0.010” (.25mm) thick gauge between stator and flywheel. 3 5. Turn flywheel until magnets are under stator. Loosen screw and let stator be pulled against flywheel magnet. 6. Torque mounting screws to 25 in. lbs. (2.8Nm). 7.
Lubrication 2 Contents 1 Extended Oil Fill and Dipstick . . . . . . . . . . . . . . . . . . . . . . Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Breather Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Pump Cover 1 (on models so equipped) 2 1. Install “O” ring in groove in sump, Fig. 115. Fig. 113 – Removing Oil Pump 1. Pump cover 2. “O” ring Inspect Oil Pump (on models so equipped) 1. Inspect surfaces of inner and outer rotors, pump housing, cover, and shaft for wear and scoring. Fig. 115 – Installing Pump Cover 2. Inspect pump housing and passages for debris. 2. Place pump cover on oil pump cavity and install three (3) screws. Torque screws to 35 in. lbs. (4.0Nm). 3. Clean if required.
Pistons, Rings, and Rods 3. Push piston and rod out through top of cylinder. Note: The GTS 200 engine uses oil drain slots in ring lands, Fig. 118. Contents Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . Remove Piston and Connecting Rod . . . . . . . . . . . . . . Remove Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . Check Piston Ring Groove Wear . . . . . . . . . . . . . . . . Check Piston Ring End Gap . . . . . . . . . . . . . . . . . . . .
Check Piston Ring Groove Wear 1 1. Clean carbon from top ring groove. 2. Place a NEW ring in groove, Fig. 120 and measure space between ring and ring land, Table No. 1, page 52. 1 2 Fig. 122 – Checking Rod Bearings 1. Crankpin bearing 2. Piston pin bearing Check Piston Pin and Piston Pin Bore 2 If piston pin is worn .0005” (.013mm) out of round or below reject size shown in Table 4, it should be replaced. Fig. 120 – Checking Ring Grooves 1. Piston If piston pin bore, Fig.
Install Connecting Rod and Piston 3. Insert piston pin from side opposite shoulder or installed lock until pin stops against lock or shoulder. 1. Thoroughly clean and then oil cylinder bore. 4. Install piston pin lock in groove at other end of piston pin. 2. Rotate crankshaft until crankpin journal is at bottom of stroke. 5. Be sure lock is firmly set in groove. Note: Some rods have the word “MAG” cast in the rod on the flywheel side.
5. Pull connecting rod against crankpin and install rod cap with match marks aligned, Fig. 129. 6. Cap should snap on when assembled correctly. Install rod screws. 7. Torque connecting rods screws, using Briggs & Stratton Tool #19197 or 19393, Torque Wrench to specifications listed in Table No. 5, page 52. Note: Failure to use a torque wrench can result in loose rods causing breakage, or deformed over tightened rods causing scoring. 8.
Crankshaft and Camshaft 7. With camshaft in this position, the valve tappets will remain clear of cam lobes. Lift out camshaft, Fig. 131. Contents 1 Remove Crankshaft and Camshaft . . . . . . . . . . . . . . . . . . . . Remove Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Compression Release . . . . . . . . . . . . . . . . . . . .
Inspect Camshaft Install Camshaft Inspect gear teeth for wear and nicks, Fig. 133. Camshaft, camshaft journals, and lobe rejection sizes are shown in Table No. 3, page 55. See Fig. 133 for other areas to be checked for wear and freedom of movement. Install camshaft, making sure tappets clear cam lobes. Timing marks must align, Fig. 135. 4 3 1 2 1 1 5 1 6 Fig. 133 – Camshaft Check Points 1. Mag journal 2. Intake 3. Cam lobe Fig. 135 – Aligning Timing Marks, Vertical Crankshaft 4. PTO journal 5.
Specification Tables Adjust Crankshaft End Play If end play is less than stated in Table No. 6, page 55, use additional gasket(s) to get proper end play, Fig. 137. 1 2 Table No. 1 Crankshaft Reject Sizes 3 Mag. Journal Crankpin Journal PTO Journal Eccentric .873” (22.17mm) 1.097” (27.86mm) 1.060” (26.92mm) – Table No. 2 Crankshaft Grinding Dimensions for Undersize Connecting Rods Fig. 137 – Adjusting Crankshaft End Play 1. Oil sump 2. Gaskets .015” (.38mm) 3. Cylinder .020” .
Cylinder and Bearings If the cylinder bore is more than .003” (.08mm) oversize, or .0015” (.04mm) out of round, it must be replaced. Contents Note: If cylinder bore is within specification and shows no sign of scoring or other damage, new piston rings may be installed providing cylinder bore is reconditioned using a rigid hone with finishing stones, to restore the proper cross hatch angle in the cylinder bore. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Plain or DU Bearings Table No. 1 Bearings should be replaced if scored or if plug gauge will enter. Try gauge at several locations in bearing, Fig. 140. Magneto Bearing Repair Tool Chart Briggs & Stratton Tools 1 Cylinder Support Bushing Driver Plug Gauge 19123 19124 19166 Table No. 2 PTO Bearing Repair Tool Chart Fig. 140 – Checking Bearing Cylinder Support Bushing Driver Plug Gauge N/A N/A 19375 1. Plug gauge Remove DU Magneto Bearing See gauge listing in Table No.
2. Press bearing to dimension shown in Table No. 7, page 58 and Fig. 144. 4 6 2 1 1 3 5 ÏÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏÏ ÏÏÏÏÏ ÎÎÎÎ ÏÏÏÏÏÏ ÏÏÏÏÏ ÎÎÎÎ ÏÏÏÏÏÏ ÏÏÏÏÏ ÎÎÎÎ ÎÎÎÎ 7 Fig. 146 – Torque Sequence 2 Specification Tables 3 Table No. 3 Seal Protectors Fig. 144 – Pressing Bearing 1. Bushing driver bearing 2. Bearing 3. Cylinder support Briggs & Stratton Tool # Color Crankshaft Journal Size 19334/5 Brown 1.062” (26.97mm) 3. Stake bearing as shown, Figs. 143 and 145. Table No.
Muffler 2 Contents 1 Remove Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install Muffler Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 59 59 60 60 1 Remove Exhaust System 1. Remove air filter cover, static guard, and fuel tank, Fig. 147. 1 Fig.
Install Muffler Install Muffler Guard 1. Coat muffler mounting screws with Valve Guide Lubricant, Briggs & Stratton Part #93963. 1. Lightly coat muffler guard mounting screws with Valve Guide Lubricant, Briggs & Stratton Part #93963. 2. Place new exhaust gasket on cylinder head and place muffler flange on gasket. 2. Place muffler guard over muffler and torque muffler guard to bracket screw to 85 in. lbs. (10.0Nm), Fig. 148. 3. Install two screws in muffler flange and torque to 85 in. lbs. (10.
