Exmark 127-9041 Service Manual

EXMARK V-TWIN AIR COOLED

ENGINE SERVICE MANUAL

P/N 127-9041 (708cc)

About this Manual

This service manual was written expressly for
Exmark service technicians. Exmark Mfg. Co. Inc.
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. An
electronic version of this service manual is available
on the Exmark Dealer Extranet. We are hopeful that
you will find this manual a valuable addition to your
service shop. If you have any questions or
comments regarding this manual, please contact us
at the following address:

Exmark Mfg. Co. Inc.

2101 Ashland Ave.
Beatrice, NE 68357
Customer Service All Call: 402-223-6375
e-mail - [e-mail]

NOTES:

Maintenance

Chapter 1 – General Service Information

1

Chapter 2 - Specifications

2

Chapter 3 - Engine Service and Maintenance

3

Chapter 4 – Engine Disassembly and Service

4

Chapter 5 - Electrical

5

– General Service Information

Safety
Safety Precautions
Service Rules

Engine Model / Serial Number Location

Torque Values

Engine Specifications

General Torque Specifications

Safety

Safety Information

Chapter 1

This symbol means WARNING or PERSONAL SAFETY INSTRUCTION – read the instruction because it has to do with
your safety. Failure to comply with the instruction may result in personal injury or even death.
This manual is intended as a service and repair manual only. The safety instructions provided herein are for
troubleshooting, service, and repair of the Toro engine. The Toro operator’s manual contains safety information and

operating tips for safe operating practices.

Avoid Unexpected Engine Start - Turn off engine and disconnect the spark plug before servicing engine.
Avoid Lacerations and Amputations - Stay clear of all moving parts while the engine is running.
Avoid Burns - Do not touch the engine, muffler, or other components which may increase in temperature during

operation, while the unit is running or shortly after it has been running.
Avoid Fires and Explosions - Avoid spilling fuel and never smoke while working with any type of fuel or lubricant. Wipe

up any spilled fuel or oil immediately. Never remove the fuel cap or add fuel when the engine is running. Always use
approved, labeled containers for storing or transporting fuel and lubricants.

Avoid Asphyxiation - Never operate an engine in a confined area without proper ventilation.
Avoid Injury From Batteries - 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 power equipment.
Avoid Injury Due To Projectiles - Always clear the area of sticks, rocks, or any other debris that could be picked up and

thrown by the power equipment.
Avoid Modifications - Never alter or modify any part unless it is a factory approved procedure.

Maintenance

WARNING

Explosive Fuel can cause
fires and severe burns.

Do not fill fuel tank while
engine is hot or running.

Gasoline is extremely flammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or flames.
Spilled fuel could ignite if it comes
in contact with hot parts or sparks
from ignition. Never use gasoline

WARNING

Accidental Starts can
cause severe injury or
death.

Disconnect and ground
spark plug lead(s) before
servicing.

Before working on engine or
equipment, disable engine as
follows: 1) Disconnect spark plug
lead(s). 2) Disconnect negative (–)
battery cable from battery.

CAUTION

Damaging Crankshaft
and Flywheel can cause
personal injury.

Using improper procedures can
lead to broken fragments. Broken
fragments could be thrown from
engine. Always observe and use
precautions and procedures when
installing flywheel.

WARNING

Hot Parts can cause
severe burns.

Do not touch engine
while operating or just
after stopping.

Never operate engine with heat
shields or guards removed.

WARNING

Rotating Parts can cause
severe injury.

Stay away while engine
is in operation.

Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never
operate engine with covers,
shrouds, or guards removed.

WARNING

Carbon Monoxide can
cause severe nausea,
fainting or death.

Avoid inhaling exhaust
fumes.

Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.

SAFETY PRECAUTIONS

WARNING: A hazard that could result in death, serious injury, or substantial property damage.
CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

CAUTION

Electrical Shock can
cause injury.

Do not touch wires while
engine is running.

Maintenance

WARNING

Before working on engine or equipment, disable engine as
follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.

Accidental Starts can cause severe injury or
death.

Disconnect and ground spark plug lead(s)
before servicing.

Engine
Model
& Serial
Number

1. Only use genuine Exmark parts and lubrication products.

2. Always install new gaskets, O-rings and seals when assembling engine.

3. Always torque fasteners to specification and in sequence.

4. Always lubricate friction components with clean engine oil or engine assembly lube
when assembling engine.

MAINTENANCE INSTRUCTIONS

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by an authorized Exmark dealer.

Service Rules

Engine Model / Serial Number Location

The engine model and serial number are stamped into the block, there will also be a label attached to
a new engine with this information on it as well.

XXX-XXXX XXXXXXXXXXX

Maintenance

No.

Process Description

Bolt Specification

Torque Range

1

Oil Drain Plug Assy.

Oil Drain Plug

20 Ft. Lbs.

26 N.m

2

Spark Plug

M14×1

21 Ft. Lbs.

28 N.m

3

Connecting Rod Cover

Hex Flange Bolt M6×35

9 Ft. Lbs.

12 N.m

4

Crankcase Cover Bolt

Hex Flange Bolt M8×55

21 Ft. Lbs.

28 N.m

5

Fuel Pump Assy.

Hex Flange Bolt M6×16

5 Ft. Lbs.

7 N.m

6

Breather Valve Assy.

Hex Flange Bolt M6×12

8 Ft. Lbs.

10 N.m

7

Cylinder Head
Hex Flange Bolt M10×1.25×70

38 Ft. Lbs.

52 N.m

Hex Flange Bolt M10×1.25×50

8

Push Rod Location Limit Plate

Valve Adjust Stud

22 Ft. Lbs.

30 N.m

9

Valve Lash Inspection（Q1）

Valve Lock Nut M6

10 Ft. Lbs.

14 N.m

10

Valve Cover

Hex Flange Bolt M6×25

8 Ft. Lbs.

10 N.m

11

Flywheel

Hex Flange Bolt M12×35

62 Ft. lbs.

82 N.m

12

Ignition Coil

Hex Flange Bolt M6×20

8 Ft. Lbs.

10 N.m

13

Electric Starter Motor

Hex Flange Bolt M8×80

20 Ft. Lbs.

26 N.m

14

Inlet Pipe
Hex Flange Bolt M6×35

8 Ft. lbs.

10 N.m

Stud Bolt M6×106

5 Ft. Lbs.

7 N.m

15

Air Box

Nut, Flange M6

6 Ft. Lbs.

8 N.m

16

Cooling Fan

Hex Flange Nut M8×20

15 Ft. Lbs.

22 N.m

17

Cooling Fan Cover

Hex Flange Nut M5×16

3 Ft. lbs.

4 N.m

18

Fan Shroud

Hex Flange Step Bolt 6×21.8-8×10.8

6 Ft. Lbs.

8 N.m

19

Shroud Comp

Hex Flange Step Bolt 6×16.8-8×5.8

8 Ft. Lbs.

10 N.m

20

Starter Shroud

Screw ST4.0×15

10 – 11 In. Lbs.

1 N.m

21

Charging Coil

Screw Inner Six Angle M6×25

8 Ft. Lbs.

10 N.m

22

Engine Shroud

Hex Flange Bolt M6×16

8 Ft. Lbs.

10 N.m

23

Breather Valve Cover

Hex Flange Bolt M6×16

8 Ft. lbs.

10 N.m

24

Ignition Coil

Hex Flange Bolt M6×20

8 Ft. Lbs.

10 N.m

25

Regulator

Hex Flange Bolt M6×16

5 Ft. Lbs.

7 N.m

26

Oil Drain Fitting

/

20 Ft. lbs.

26 N.m

27

Oil Pump Cover

Hex Flange Bolt M6×16

8 Ft. Lbs.

10 N.m

28

Oil Screen Cover

Hex Flange Bolt M6×16

8 Ft. Lbs.

10 N.m

29

Oil Tube Plate

Hex Flange Bolt M6×16

8 Ft. lbs.

10 N.m

30

Governor Throttle

Hex Flange Bolt M6×16

8 Ft. Lbs.

10 N.m

31

Governor Arm

Nut M6

8 Ft. Lbs.

10 N.m

32

Tube Clip

Hex Flange Bolt M6×16

5 Ft. Lbs.

7 N.m

33

Connector, Oil Filter

M20

30 Ft. Lbs.

42 N.m

Engine Model

Serial Number

1.1 Torque values

Note: For unspecified bolts and nuts listed, refer to the table of standard torque values.

Maintenance

34

Cylinder Head
Stud Bolt M8×39

11 Ft. Lbs.

14 N.m

Nut M8

13 Ft. Lbs.

17 N.m

35

Oil Filter

/

9 Ft. Lbs.

12 N.m

Part

Item

Standard

Service Limit

P/N 127-9041

P/N 127-9041

Engine

Ile speed

1800 RPM’s

+ or – 100 RPM’s

Operating RPM

3600 RPM’s

+ or – 50 RPM’s

Cylinder head

Warpage

0.0020” (0.05 mm)

Cylinder

Sleeve Taper / Out of Round

3.0315”-3.0319” (77 – 77.01 mm)

3.0354” (77.1 mm)

(Inside Diameter)

Piston

Skirt outside diameter

3.0301-3.0305” (76.965-76.975 mm)

3.0219” (76.755 mm)

Clearance to cylinder

0.00098-0.0017” (0.025-0.045 mm)

0.01000” (.255 mm)

Piston pin bore inside diameter

0.66937- 0.66961” (17.002-17.008 mm)

0.67402” (17.12 mm)

Piston – pin clearance

0..00016-0.00063” (0.004-0.016 mm)

0.0014” (0.029 mm)

Piston pin

Outside diameter

0.6689-0.6692” (16.992-16.998 mm)

0.6654” (16.9 mm)

Piston ring

Ring to Groove (Top and Middle

0.0008-0.0024” (0.02-0.06 mm)

0.0043” (0.11 mm)

End gap (top and middle )

0.0079-0.01578” (0.20-0.40 mm)

0.0177” (0.45 mm)

Width (top)

0.0382-0.0390” (0.97-0.99 mm)

0.0354” (0.9 mm)

Width (second)

0.0460-0.0469” (1.17-1.19 mm)

0.0433” (1.1 mm)

Width (oil ring)

0.0650-0.0728” (1.65-1.85 mm)

0.0630” (1.6 mm)

Connecting rod

Small end inside diameter

0.6695-0.670” (17.006-17.017 mm)

0.6712” (17.05 mm)

Big end inside diameter

1.575-1.576” (40.015-40.025 mm)

1.577” (40.065 mm)

Big end side clearance

0.0010-0.0031” (0.024-0.079 mm)

0.0051” (0.129 mm)

Crankshaft

Connecting Rod Journal Diameter

1.5735-1.5744” (39.966-39.991 mm)

1.555” (39.5 mm)

Valve

Clearance(cold) (intake)

0.004-0.006” (0.10-0.15 mm)

－

Clearance(cold) (exhaust)

0.006-0.008” (0.15-0.20 mm)

－

Stem diameter (intake)

0.258-0.259” (6.565-6.58 mm)

0.256” (6.515 mm)

Stem diameter (exhaust)

0.257-0.258” (6.545-6.56 mm)

0.258” (6.495 mm)

Valve guide

Inside diameter (intake, exhaust)

0.259-0.260” (6.6-6.615 mm)

0.262” (6.665 mm)

Stem to guide clearance (intake)

0.0008-0.0020” (0.02-0.05 mm)

0.006” (0.15 mm)

Stem to guide clearance exhaust)

0.0016-0.0027” (0.04-0.07 mm)

0.007” (0.17 mm)

Valve seat

Seat width

0.0027-0.0031” (0.7-0.8 mm)

0.051” (1.3 mm)

Valve spring

Free length

1.55-1.60” (39.5-40.5 mm)

1.535” (39 mm)

Cam shaft

Height (intake)

1.15-1.18” (29.95-30.05 mm)

1.17” (29.75 mm)

Height (exhaust)

1.15-1.18” (29.95-30.05 mm)

1.17” (29.75 mm)

Outside diameter (bearing)

0.628-0.629” (15.966-15.984 mm)

0.626” (15.916 mm)

1.2 Engine Specifications

Maintenance

Crankcase cover

Camshaft hole diameter

0.629-0.630” (16-16.018 mm)

0.633” (16.068 mm)

Crankshaft hole diameter

1.575-1.576” (40.009-40.025 mm)

1.578” 40.075 mm)

Spark plug

Gap

0.0027-0.0031” (0.7-0.8 mm)

－

Ignition coils

Resistance (primary)

(1.6-1.9Ω)

－

Resistance (secondary)

(6.27.1kΩ)

－

Gap to flywheel

0.015-0.016” (0.4±0.1 mm)

－

English Fastener Torque Recommendations for Standard Applications

Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel

Size Grade 2 Grade 5 Grade 8

Grade 2 or 5 Fasteners

Into Aluminum

Tightening Torque: N·m (in. lb.) ± 20%

8-32 2.3 (20) 2.8 (25) —

2.3 (20)

10-24 3.6 (32) 4.5 (40) —

3.6 (32)

10-32 3.6 (32) 4.5 (40) —

—

1/4-20 7.9 (70) 13.0 (115) 18.7 (165)

7.9 (70)

1/4-28 9.6 (85) 15.8 (140) 22.6 (200)

—

5/16-18 17.0 (150) 28.3 (250) 39.6 (350)

17.0 (150)

5/16-24 18.7 (165) 30.5 (270) —

—

3/8-16 29.4 (260) — —

—

3/8-24 33.9 (300) — —

—

Tightening Torque: N·m (ft. lb.) ± 20%

5/16-24 — — 40.7 (30)

—

3/8-16 — 47.5 (35) 67.8 (50)

—

3/8-24 — 54.2 (40) 81.4 (60)

—

7/16-14 47.5 (35) 74.6 (55) 108.5 (80)

—

7/16-20 61.0 (45) 101.7 (75) 142.5 (105)

—

1/2-13 67.8 (50) 108.5 (80) 155.9 (115)

—

1/2-20 94.9 (70) 142.4 (105) 223.7 (165)

—

9/16-12 101.7 (75) 169.5 (125) 237.3 (175)

—

9/16-18 135.6 (100) 223.7 (165) 311.9 (230)

—

5/8-11 149.5 (110) 244.1 (180) 352.6 (260)

—

5/8-18 189.8 (140) 311.9 (230) 447.5 (330)

—

3/4-10 199.3 (147) 332.2 (245) 474.6 (350)

—

3/4-16 271.2 (200) 440.7 (325) 637.3 (470)

—

Metric Fastener Torque Recommendations for Standard Applications

Property Class

Size

4.8 5.8

8.8 10.9 12.9

Noncritical

Fasteners

Into Aluminum

Tightening Torque: N·m (in. lb.) ± 10%

M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44)

2.0 (18)

M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86)

4.0 (35)

M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146)

6.8 (60)

M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360)

17.0 (150)

GENERAL TORQUE VALUES

Maintenance

Tightening Torque: N·m (ft. lb.) ± 10%

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60)

33.9 (25)

M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103)

61.0 (45)

M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162)

94.9 (70)

Torque Conversions
N·m = in. lb. x 0.113 in. lb. = N·m x 8.85
N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

Maintenance

2－1

2. Specifications

2.1 Specifications--------------------------------------------------2—2

2.2 Dimensional drawings----------------------------------------2—2

2.1 Specifications

2.2 Dimensional Drawings in Millimeters

Model

P/N 127-9041 - 708 CC

Type

OHV, V-twin –Air Cooled 4-Stroke

Idle speed

1800 ± 50 rpm

Bore X Stroke

3.03” x 2.99” (77×76mm)

Displacement(cc)

43.20 Cubic Inches (708 cc)

Compression Ratio

8.7 :1

Lubricating mode

Full pressure

Starting mode

Electric

Rotation

Counter Clockwise(from P.T.O. side)

Valve clearance

Intake valve：0.004” - 0.006” , Exhaust valve：0.006” – 0.008”

Spark plug clearance

0.0027” - 0.0031” (0.7~0.8mm)

Igniting mode

Transistorized Magneto Ignition

Air cleaner

Foam & paper

Fuel type

Unleaded gasoline, minimum 87 Octane

Oil capacity

2.1 Quarts (2.0 liters)

Dimension(L×W×H)

18.44” x 18.61” x 15.06” (468.4×472.7×382.7 mm)

Net weight

89.95 lbs. (40.8 kg)

2

Maintenance

2－2

Maintenance

2－3

Maintenance

2－4

Maintenance

3－1

3 Maintenance

3.1 Maintenance schedule-----------------------------------------3－2

3.2 Engine oil ------------------------------------------------------ 3－2

3.3 Air cleaner ------------------------------------------------------3－3

3.4 Spark plug ------------------------------------------------------3－4

3.5 Valve clearance ------------------------------------------------3－4

3.6 Carburetor ----------------------------------------------------- 3－5

3.7 Governor -----------------------------------------------------3－5

3

Maintenance

3－2

3.1 Maintenance Schedule

（1）Service more frequently when used in dusty condition areas.
（2）These items are to be maintained by designated dealers unless the user has special tools

and skills for maintenance.

3.2 Engine Oil

Drain the oil while the engine is warm to
assure rapid and complete draining.

1. Clean the area around the oil filler
cap/dipstick. Remove
the oil filler cap/dipstick.

2. Drain the engine oil into a suitable
container using one of the following
methods.

Oil Drain:

a. Unwind the tube from the cleat
b. Pull hose down from the fitting
c. Allow the oil to drain into a suitable container.
d. Replace hose fully

Maintenance schedule

Each
Use

First 1
month
or 5 hours

Every 3
months or
25 hours

Every 6
months or
50 hours

Every year
or 100
hours

Every 2
years or
200 hours

Engine oil
Oil level ●

Change

● ●

Air cleaner foam
element

Clean

●(1)

Change

●(1)

Air cleaner paper
element

Clean

●(1)

Change

●(1)

Oil Filter

Change

●

Fuel filter

Replace

Spark plug
Replace

●

Check-adjust

●(2)

Valve clearance

Check-adjust

●(2)

Combustion chamber

Clean

●(2)

Remove engine
shroud and clean

Compressed
Air

●

Fuel hose

Every 3 years (Replace sooner if necessary) (2)

OIL FILLER
CAP/DIPSTICK

DRAIN LINE

OIL FILTER