Installation Instructions

ManualsBrandsToro ManualsAttachments, Parts & AccessoriesToro 100-2873

E1999 The T

oro Company

8111 Lyndale Ave. South

Bloomington, MN 55420–1196

Printed in the USA

Form No. 3322-863

Model 100-2873

Kawasaki BBC Engine Coversion Kit

For use with the 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

Filling the hole left from removing the fuel tank

bracket

Bolt 1

Throttle Control

Throttle Cable

Retainer

Replacing the throttle cable

Engine Guard

Screw – 1/4-20 x 1.0

Installing the engine guard on the lawn mower

housing

Cable T

ie 3

Installing the cables to the lower handle (1)

Securing the clutch and the throttle cables to

the lawn mower deck (1)

ying the throttle, traction, and clutch cables

together (1)

Control Panel Decal

Replacing the decal

Cable Clamp

Hex Head Screw – 5/16 16 x 1.0

Securing the clutch cable to the housing

Hex Locknut – 5/16 16

Summary of content (8 pages)

PAGE 1
Form No. 3322-863 Kawasaki BBC Engine Coversion Kit For use with the Toro Walk Power Lawn Mowers Model 100-2873 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. Oil Drain Tube 1 Draining the oil Screw– 5/16 18 x 0.75 1 Washer– 5/16 1 Securing the blade brake clutch (BBC) cover to the lawn mower housing Before Installing USE 5. Disconnect the wire from the spark plug. 6. Drain the engine oil (Refer to your operator’s manual for the procedure). POTENTIAL HAZARD • If you leave the wire on the spark plug, someone could accidentally start the engine.
PAGE 3
Installation Instructions 4 2 2 1 2 3 1 m-224 Figure 2 1. Fuel line clamp 2. Fuel line 3. Tank bracket 4. Fuel tank 2. Remove the fuel tank from the tank bracket (Fig. 2). 3. Remove the tank bracket. 4. Install a screw and a locknut to fill the hole left from removing the right side of the tank bracket. Figure 3 1. Belt cover 2. Self-tapping screw (2) 2. Loosen the cable clamp screw and disconnect the throttle cable from the throttle lever as shown in Figure 4.
PAGE 4
Installation Instructions Note: Figure 4 shows the GTS 150 engine only. 2. Loosen the tabs that secure the blade brake clutch shield to the lawn mower housing by loosening the nuts or bolts on the tabs (Fig. 5). Removing the Blade Assembly 1. Remove two blade nuts, the anti-scalp cup, the blade stiffener/accelerator, the blade, the locknut, and the blade spacer (Fig. 5). 4.
PAGE 5
Installation Instructions Removing the Discharge Tunnel Assembly 3. Remove the spring bracket and the spring extension (Fig. 7). 1. Remove two capscrews, two flat washers, two locknuts, a 1/2 in. hex head washer screw, and a 3/4 in. hex head washer screw that secure the discharge tunnel assembly to the lawn mower housing (Fig. 7). Note: Keep these items for the installation. 11 4. Discard the discharge tunnel assembly (Fig. 7).
PAGE 6
Installation Instructions 2. Install and tighten the three new engine screws (Fig. 8). Torque the engine screws to 250 to 400 in-lb (28 to 45 NSm). 2 3 1 1 m-4678 Figure 9 1. Front quadrants 2. Hex head screw (4) 2 3. Engine guard m-4679 Installing the New Throttle Control Figure 8 1. Engine 2. Engine screw (3) 1. Remove four Phillips head screws and four locknuts that secure the throttle control to the control panel (Fig. 10). 7 1 Installing the Blade Assembly 1.
PAGE 7
Installation Instructions 1 3. Install the new throttle control using four Phillips head screws and four locknuts previously removed. 4. Install the new throttle control retainer. Note: Make sure that the seal on the throttle cable is pushed down tight. 3 2 5. Connect the throttle cable to the speed control lever on the engine (Fig. 11). 1 2 5 4 Figure 12 1. Throttle cable 2. Blade brake clutch cable 1 6 11. Install the belt cover using the fasteners previously removed (Fig. 3). 2 3 Figure 11 1.
PAGE 8
Installation Instructions 2 3 1 1 4 Figure 13 1. Spring 2. Cable clamp screw 3. Cable conduit 4. Cable clamp 5. Locknut (on the underside of the deck) Figure 14 1. Decal location Note: Tighten the cable clamp screw only enough to allow the clutch cable to slide (Fig. 13). Before Starting the Engine 2. Pull the cable to remove the slack, but do not put tension on the spring (Fig. 13).