Toro 100-2863 Installation Instructions
Form No. 3322-861
Kawasaki
Zone Start Engine Coversion Kit
For Toro Walk Power Lawn Mowers
Model 100-2863
Loose
Note:
DESCRIPTION QTY. USE
Discharge Tunnel
Latch Plate
Discharge Door Assembly
Door Retainer
Self-tapping Screw – 1/4-10 x .60
Screw – 3/8-16 x 1.5
Engine Decal
Parts
Use the following chart to identify the parts you will use to install the kit.
1
1
1
1
2
3
1
Installing the new discharge tunnel and the
door assembly
Replacing the engine
Installation
Instructions
Clamp 1
Bolt 1
Throttle Control
Throttle Cable
E-Ring
Engine Guard
Screw – 1/4-20 x 1.00
Cable T
T
only)
Screw – 3/8-16 x 1.00
Locknut – 3/8-16
ie 4
raction Control Decal (Self-propelled models
Installing the brake cable on the engine
1
1
2
1
4
1
2
2
Replacing the throttle cable
Installing the engine guard on the front of the
lawn mower
Attaching the guard to the lawn mower
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)
Replacing the decal
Filling the holes left from removing the fuel tank
bracket
E1999 The T
8111 Lyndale Ave. South
Bloomington, MN 55420–1196
oro Company
All Rights Reserved
Printed in the USA
Installation Instructions
DESCRIPTION USEQTY.
Square Key 3/16 x 1.25 (HP Models) or
3/16 x 0.50 (SP Models)
Oil Drain T
Brake Cable
Blade Retainer
Blade Spacer
Drive Pulley (SP Models only)
Before
POTENTIAL
•
If you leave the wir
someone could accidentally start the engine.
WHA
•
Someone accidentally starting the engine can
seriously injur
HOW T
•
Disconnect the wir
you install the kit. Set the wir
does not accidentally contact the spark plug.
ube 1
Installing
HAZARD
e on the spark plug,
T CAN HAPPEN
e you or other bystanders.
O AVOID THE HAZARD
e fr
om the spark plug befor
e aside so that it
1
1
1
1
1
Installing the blade assembly
Draining the engine oil
Replacing the brake cable
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.
Disconnect the wire from the spark plug.
6.
Drain the engine oil (Refer to your operator’s manual
for the procedure).
Disassembly
Removing the Starter Rope
Remove
e
the starter rope from the rope guide (Fig. 1).
1.
Disconnect the wire from the spark plug.
POTENTIAL HAZARD
•
If gasoline is spilled on a hot engine, it could
ignite.
WHA
T CAN HAPPEN
•
Contact with burning gasoline could cause
serious personal injury
HOW T
•
2.
Note:
for draining the fuel.
O AVOID THE HAZARD
Drain the gasoline fr
Make sure that the engine is cool. Remove the cap
from the fuel tank and use a pump-type syphon to
drain the fuel into a clean, approved gasoline
container.
This is the only procedure that T
.
om a cold engine only
oro recommends
1
2
m–2705
Figure
1. Rope
.
Removing the Cable Ties
Cut
guide
the cable ties that hold the cables to the handle.
1
2.
Starter rope
Removing the Fuel Tank
1. Disconnect
the fuel line from the engine (Fig. 2).
2
Installation Instructions
4
2
3
1
1. Fuel
line clamp
2.
Fuel line
2. Remove
Figure
the fuel tank from the tank bracket
2
3. T
4.
ank bracket
Fuel tank
(Fig. 2).
3.
Remove the tank bracket.
4.
Install two screws and two locknuts to fill the holes
left from removing the tank bracket.
Disconnecting the Throttle Cable
1. Remove
cover to the lawn mower deck (Fig. 3). Set the cover
and the fasteners aside for the installation.
two self-tapping screws that secure the belt
1. Cable
2.
Throttle cable
1
1
clamp screw
3
2
4
2
Figure
4
3.
Throttle lever
3
m-286
1
2
2
m-224
1. Belt
cover
2. Loosen
Figure
the cable clamp screw and disconnect the
3
2.
Self-tapping screw (2)
throttle cable from the throttle lever (Fig. 4 or Fig. 5).
1. Cable
2.
Cable clamp
Figure
clamp screw
5
3.
Throttle cable
4.
Throttle arm
Disconnecting the Blade Brake Cable
1. Disconnect
(Fig. 6).
the blade brake cable from the brake arm
3
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