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

Installation Instructions

4

13

11

10

2

Figure

1. Brake

2.

2. Use

cable

Brake arm

a pliers to squeeze the tabs on the top and the

6

3.

Brake cable fitting

4.

Brake assembly

bottom of the blade brake cable fitting, and slide the
cable out of the brake assembly (Fig. 6).

Self-pr

opelled 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.

5.

Remove the blade brake cable from the cable support.

6.

Unhook the blade brake cable from the control bar
control lever

7.

Retain the cable support, the screw

.

, and the nut for

installing the new cable.

Removing the Blade Assembly

1. Remove

stiffener/accelerator
spacer
protector (Fig. 7).

the blade bolt, the lock washer, the blade

, the blade, the blade retainer

, and the square key

, and the crankshaft

, the

7
6

4

5

3

2
1

Figure

1. Blade

2.

3.

4. Blade

5.

6. Spacer

7.

Note:

square key

2.

bolt
Lock washer
Blade stif

Blade retainer

Square key

fener/accelerator

Discard the old blade retainer

.

Remove the crankshaft protector by removing three

7

8.

Self-tapping screw (3)

9.

Internal lock washer (3)

10.

Crankshaft protector

11.

Engine drive pulley
(self-propelled models
only)

, the spacer

self-tapping screws and three internal lock washers.

Note:

Keep all these items for the installation.

3.

Remove and discard the engine drive pulley
(self-propelled models only).

Removing the Old Engine

Remove
engine of
engine.

the three engine screws and carefully lift the

f the housing (Fig. 8). Discard the screws and the

9
8

, and the

4

Installation Instructions

1

2

Figure

1. Engine 2. Engine

Note:

Figure 8 shows the GTS 150 engine. The GTS 200

8

screw (3)

engine is not shown.

Removing the Discharge Tunnel
Assembly

1. Remove

locknuts, a 1/2 in. hex head washer screw
hex head washer screw that secure the dischar
assembly to the lawn mower housing (Fig. 9).

two capscrews, two flat washers, two

11

6

12

, and a 3/4 in.

ge tunnel

2. Lift of

3.

f the dischar

ge tunnel assembly (Fig. 9).

Remove the spring bracket and the spring extension
(Fig. 9).

Note:

Keep these items for the installation.

4.

Discard the dischar

Conversion

ge tunnel assembly (Fig. 9).

Kit Installation

Installing the New Discharge Tunnel

1. Position

deck. Align the holes in the dischar
holes in the lawn mower deck.

2.

Fasten the rear
dischar
capscrews, two flat washers, and two locknuts
previously removed.

3.

Fasten the front-right side of the dischar
the lawn mower deck using the 1/2 in. hex head
washer screw previously removed.

4.

Fasten the front-left corner of the dischar
the spring bracket to the lawn mower deck using the
3/4 in. hex head washer screw previously removed.

5.

Install the new dischar
with the new door retainer

the new dischar

ge tunnel on the lawn mower

ge tunnel with the

-left and the rear-right corners of the

ge tunnel to the lawn mower deck using two

ge tunnel to

ge tunnel and

ge door assembly and secure it

.

8

1

5

1. Discharge

2.

Capscrew (2)

3.

Flat washer (2)

4.

Locknut (2)

5.

Hex head washer screw
(1/2” long)

6.

Hex head washer screw
(3/4” long)

Note:

tunnel

Keep all these items for the installation.

7

Figure

9

9

10

2
3

4

7.

Spring bracket

8.

Spring extension

9.

Latch plate

10.

Self-tapping screw (2)

11.

Door retainer

12.

Discharge door assembly

6.

Install the new latch plate to the dischar

ge tunnel using

two new self-tapping screws.

7.

Hook one end of the spring extension through the hole
on the spring bracket and the other end onto the
dischar

ge door handle.

8.

Open and close the dischar
dischar

ge tunnel door closes when you release the

ge door to ensure that the

handle.

Installing the New Engine

1. Carefully

housing.
Install and tighten the three new engine screws

2.

(Fig. 10). T
(28 to
45 N

For Self–pr

3.

Install a new engine drive pulley

4.

Install the belt onto the pulley

set the new engine onto the lawn mower

orque the engine screws to 250 to 400 in-lb

Sm).

opelled Models

.

.

5

Installation Instructions

2

1

3

m-46792

Figure

1. Engine 2. Engine

10

screw (3)

Installing the Blade Assembly

Install

the blade assembly in the reverse order of
disassembly
page 4.

Note:

(Fig. 7).

Note:

tighten the mounting screws (Fig. 7). Insert a shim (a
business card works well) between the crankshaft
protector and the hub on the blade retainer
mounting screws and remove the shim.

. Refer to

Removing the Blade Assembly

Install a new blade retainer with a spacer and a key

When you install the crankshaft protector

. T

ighten the

, do not

on

1

m-4678

Figure 11

1. Front

2.

2. Install

quadrants

Hex head screw (4)

3.

Engine guard

the new engine guard on the front of the lawn
mower deck with four hex head screws as shown in
Figure 1

1.

Installing the New Throttle Control

1. Hand

Note:

Note:

Push Models Only

– Disconnect the brake and
throttle cables from the throttle control by removing
the E-rings (Fig. 12).

Discard the E-rings.

Self-pr

opelled Models Only - Disconnect the traction

and throttle cables from the throttle control by
removing the E-rings (Fig. 12).

Discard the E-rings.

Note: T

orque the blade bolt to 50 ft-lb (68 N

Installing the Engine Guard

1. Remove

(Fig. 1

four hex head screws from the front quadrants

1). Leave the quadrants in place.

m).

4

1. Throttle

2.

3.

4. E-ring

control

Brake cable (HP model)
T

raction cable (SP model)

Throttle cable

1

8

3

7

2

Figure

12

Hex head screw (2)

5.

6.

Curved washer (2)

7. Seal

8.

Bag support rod

6

5

6

6

Installation Instructions

2. Remove

the two hex head screws and two curved
washers that secure the throttle control to the handle
(Fig. 12).

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

6.

Route the cables behind the bag support rod.

7.

Connect the brake cable to the throttle control

.

(hand-push models only) or to the brake cable
(self–propelled models only) using a new E-ring.

8.

Connect the brake cable to the engine, leaving
approximately 1/4 in. of cable to extend beyond the
cable clamp (Fig. 14).

9.

Install the belt cover using the fasteners previously
removed (Fig. 3).

10.

Make sure that the seals on the cables are pushed down
tight (Fig. 12).

11.

Route the throttle cable across the top of the
transmission as shown in Figure 13.

2

1

5

4

6

1. Cable

2.

3.

2. Move

3.

clamp screw
Cable clamp
Throttle cable

the throttle to the

Align the hole of the speed control lever with the hole

1

Figure

14

4.

5.

6.

(F

AST) position.

3

2

Speed control lever
Blade brake cable
Base plate hole

in the base plate by inserting a 7/32-in. (6 mm)
diameter pin through both holes.

4.

Pull the throttle cable to remove the slack.

5. T

ighten the cable clamp screw

Restrain the throttle and brake cables to the lawn

6.

.

mower housing with a cable tie to prevent the cables
from contacting the gear box belt guide.

Do not secur

the cables tight against the housing.

e

1

2

1. Throttle

2.

Blade brake cable

Figure

cable

13

3.

Cable tie

Adjusting the Throttle Control

1. Connect

the engine (Fig. 14).

the throttle cable to the speed control lever on

7.

Install the new blade brake cable, cable clamp, and the
cable clamp screw to the engine (Fig. 14).

3

Adjusting the Blade Brake Cable

1. Check

the brake cable adjustment by moving the
control bar toward the handle until there is no slack in
the wire (Figs. 15 and 16).

Note:

Ensure that the gap between the brake lever and the

handle is 3/16 in. to 1/4 in.

2. T

o adjust the cable, do the following procedure:

7

Installation Instructions

Hand Push Models Only:

A.

Loosen the jam nut on the brake cable (Fig. 15).

1

2

3

4

5

6

Hand

Push Model

1. Handle

2.

Brake lever

3. 3/16”-1/4”

B. Insert

Figure

a 3/16 in. to 1/4 in. object between the brake

15

Cable adjuster

4.

5.

Jam nut

6.

Cable conduit

lever and the handle (Fig. 15).

483

E. Pull

down on the cable conduit until there is no

slack in the wire.

F. T

ighten the nut.

G.

Secure the blade brake cable to the right side of the
handle with two cable ties.

Installing the Starter Rope in Rope Guide

Install

the starter rope in the rope guide (Fig. 1).

Installing the New Cable Ties

Attach

the cables to the lower left side of the handle using

the new cable ties.

Self-pr

opelled Models Only:

the control bar with the new decal (Fig. 17).

Replace the old decal on

1

C. T

urn the cable adjuster on the brake cable until

there is no slack.

D. T

ighten the nut.

Self-pr

opelled Models Only:

A.

Insert the blade brake cable into the cable support.

B.

Assemble the cable support to the right side of the
handle.

C.

Hook the blade brake cable to the control bar lever

D.

Insert a 3/16 in. to 1/4 in. object between the brake

Do not tighten the locknut.

lever and the handle (Fig. 16).

1

2

3

4

16

3.

3/16 in. to 1/4 in.

4.

Cable bracket

Self-propelled

1. Handle
Brake lever

2.

Figure

Model

Figure

1. Decal

17

Installing the New Engine Decal

Install

the new decal on the engine as illustrated in

Fig. 18.

.

1

Figure

1. Decal

Before

For

location

Starting the Engine

information on how to fill the crankcase with oil,
fill the fuel tank with gasoline, and operate the engine,
r

efer to your

Kawasaki Engine Owner’s Manual

18

.

8