Installation Instructions

ManualsBrandsToro ManualsAttachments, Parts & AccessoriesToro 100-2863

E1999 The T

oro Company

8111 Lyndale Ave. South

Bloomington, MN 55420–1196

Printed in the USA

Form No. 3322-861

Model 100-2863

Kawasaki

Zone Start Engine Coversion Kit

For Toro Walk Power Lawn Mowers

Installation

Instructions

Loose

Parts

Note:

Use the following chart to identify the parts you will use to install the kit.

DESCRIPTION QTY. USE

Discharge Tunnel

Latch Plate

Discharge Door Assembly

Door Retainer

Self-tapping Screw – 1/4-10 x .60

Installing the new discharge tunnel and the

door assembly

Screw – 3/8-16 x 1.5

Replacing the engine

Engine Decal

Clamp 1

Installing the brake cable on the engine

Bolt 1

Throttle Control

Throttle Cable

E-Ring

Replacing the throttle cable

Engine Guard

Screw – 1/4-20 x 1.00

Installing the engine guard on the front of the

lawn mower

Attaching the guard to the lawn mower

Cable T

ie 4

Securing the cables to the deck (1)

Securing the brake cable to the right side of the

handle (2)

Installing the cables to the lower left side of the

handle (1)

raction Control Decal (Self-propelled models

only)

Replacing the decal

Screw – 3/8-16 x 1.00

Locknut – 3/8-16

Filling the holes left from removing the fuel tank

bracket

Summary of content (8 pages)

PAGE 1
Form No. 3322-861 Kawasaki Zone Start Engine Coversion Kit For Toro Walk Power Lawn Mowers Model 100-2863 Installation Instructions Loose Parts Note: Use the following chart to identify the parts you will use to install the kit. DESCRIPTION QTY. Discharge Tunnel 1 Latch Plate 1 Discharge Door Assembly 1 Door Retainer 1 Self-tapping Screw – 1/4-10 x .60 2 Screw – 3/8-16 x 1.
PAGE 2
Installation Instructions DESCRIPTION QTY. USE Square Key 3/16 x 1.25 (HP Models) or 3/16 x 0.50 (SP Models) 1 Installing the blade assembly Oil Drain Tube 1 Draining the engine oil Brake Cable 1 Replacing the brake cable Blade Retainer 1 Blade Spacer 1 Drive Pulley (SP Models only) 1 Before Installing Replacing the blade retainer and the drive pulley 3. Connect the wire to the spark plug. 4. Start the engine and let it run until it runs out of fuel. 5.
PAGE 3
Installation Instructions 1 4 2 2 3 1 Figure 2 1. Fuel line clamp 2. Fuel line 3 3. Tank bracket 4. Fuel tank 2. Remove the fuel tank from the tank bracket (Fig. 2). m-286 Figure 4 1. Cable clamp screw 2. Throttle cable 3. Remove the tank bracket. 3. Throttle lever 3 4. Install two screws and two locknuts to fill the holes left from removing the tank bracket. Disconnecting the Throttle Cable 1. Remove two self-tapping screws that secure the belt cover to the lawn mower deck (Fig. 3).
PAGE 4
Installation Instructions 4 1 3 11 10 2 7 6 4 9 8 5 Figure 6 1. Brake cable 2. Brake arm 3. Brake cable fitting 4. Brake assembly 3 2 1 2. Use a pliers to squeeze the tabs on the top and the bottom of the blade brake cable fitting, and slide the cable out of the brake assembly (Fig. 6). Self-propelled Models only 3. Cut the cable ties that secure the blade brake cable to the right side of the handle. 4. Remove the cable support, the screw, and the nut from the right side of the handle. Figure 7 1.
PAGE 5
Installation Instructions 2. Lift off the discharge tunnel assembly (Fig. 9). 1 3. Remove the spring bracket and the spring extension (Fig. 9). Note: Keep these items for the installation. 4. Discard the discharge tunnel assembly (Fig. 9). Conversion Kit Installation 2 Installing the New Discharge Tunnel Figure 8 1. Engine 2. Engine screw (3) Note: Figure 8 shows the GTS 150 engine. The GTS 200 engine is not shown. Removing the Discharge Tunnel Assembly 1.
PAGE 6
Installation Instructions 2 1 3 1 m-4678 Figure 11 2 m-4679 Figure 10 1. Engine 2. Engine screw (3) 1. Front quadrants 2. Hex head screw (4) 3. Engine guard 2. Install the new engine guard on the front of the lawn mower deck with four hex head screws as shown in Figure 11. Installing the Blade Assembly Installing the New Throttle Control Install the blade assembly in the reverse order of disassembly. Refer to Removing the Blade Assembly on page 4. 1.
PAGE 7
Installation Instructions 2. Remove the two hex head screws and two curved washers that secure the throttle control to the handle (Fig. 12). 1 2 5 4 Note: Keep the screws and washers. Discard the throttle control and the throttle cable. 3. Install the new throttle control using two hex head screws and two curved washers previously removed. 4. Connect the new throttle cable to the throttle control using a new E-ring. 5. Connect the brake cable or the traction cable, depending on the lawn mower.
PAGE 8
Installation Instructions Hand Push Models Only: A. Loosen the jam nut on the brake cable (Fig. 15). E. Pull down on the cable conduit until there is no slack in the wire. F. Tighten the nut. 1 G. Secure the blade brake cable to the right side of the handle with two cable ties. 2 Installing the Starter Rope in Rope Guide 3 Install the starter rope in the rope guide (Fig. 1).