Toro 20040, 20486, 20487, 20488, 20786 Service Manual

...

TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL

Table of Contents – Page 1 of 2

SPECIFICATIONS

GENERAL INFORMATION OIL GASOLINE COOLING SYSTEM AIR CLEANER – GENERAL AIR CLEANER SERVICE TUNE-UP PROCEDURE OVERHAUL PROCEDURE CHECK-UP EQUIPMENT AFFECTING ENGINE OPERATION

IGNITION CHECK IGNITION SPARK PLUG REMOVE FLYWHEEL INSPECT FLYWHEEL KEY, KEYWAYS, FLYWHEEL, AND CRANKSHAFT INSTALL FLYWHEEL SPECIFICATIONS

CARBURETION CARBURETOR IDENTIFICATION SERVICE CARBURETOR WALBRO LMS

GOVERNOR CONTROLS, CARBURETOR LINKAGE, AND FLYWHEEL BRAKE REMOTE GOVERNOR CONTROLS FLYWHEEL BRAKE GOVERNOR ADJUSTMENTS GOVERNOR AND CARBURETOR LINKAGES

GOVERNOR GENERAL INFORMATION GOVERNED RPM LIMITS MECHANICAL GOVERNOR

COMPRESSION TEST COMPRESSION REMOVE CYLINDER HEAD VALVE SERVICE ASSEMBLE CYLINDER HEAD SPECIFICATION TABLES

REWIND STARTER GENERAL INFORMATION REMOVE BLOWER HOUSING AND STARTER

TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL

Table of Contents – Page 2 of 2

DISASSEMBLE REWIND STARTER ASSEMBLE REWIND STARTER

ELECTRIC STARTER GENERAL INFORMATION TROUBLESHOOTING 12 VOLT STARTING SYSTEM TEST EQUIPMENT BATTERY STARTER

ALTERNATOR ALTERNATOR SPECIFICATIONS EQUIPMENT TO TEST ALTERNATORS 1/2 AMP ALTERNATOR

LUBRICATION EXTENDED OIL FILL AND DIPSTICK BREATHER REMOVE BREATHER INSTALL BREATHER VALVE REMOVE OIL PUMP INSPECT OIL PUMP INSTALL OIL PUMP INSTALL PUMP COVER INSTALL OIL FILTER ADAPTER

PISTONS, RINGS, AND RODS PISTON AND CONNECTING ROD SPECIFICATION TABLES

CRANKSHAFT AND CAMSHAFT REMOVE CRANKSHAFT AND CAMSHAFT INSTALL CRANKSHAFT AND CAMSHAFT SPECIFICATION TABLES

CYLINDER AND BEARINGS CYLINDER PLAIN OR DUTM BEARINGS CRANKCASE SUMP SPECIFICATION TABLES

MUFFLER REMOVE EXHAUST SYSTEM INSPECT EXHAUST SYSTEM INSTALL MUFFLER INSTALL MUFFLER GUARD

About This Manual

This manual was written expressly for the Toro GTS 200 Overhead Valve Engine. The Toro Company has made every effort to make the information in this manual complete and correct.

This manual was written with the service technician in mind. We hope that you find this manual a valuable addition to your service shop. If you have questions or comments regarding this manual, please contact us at the following address:

The Toro Company Consumer Service Department 8111 Lyndale Avenue South Bloomington, MN 55420–1196

The Toro Company reserves the right to change product specifications or this manual without notice.

The Toro Company gratefully acknowledges the assistance of the Briggs & Stratton Corporation in the production of this manual.

The Toro Company – 1999

Bloomington, MN 55420 – U.S.A

VED

Contents

Specifications 4.

General Information5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Specifications5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Oil Level5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Oil5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Approximate Crankcase Oil Capacity (Dry)

Specifications 6 Gasoline 7

Cooling System7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner – General8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner Service8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

une-Up Procedure9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overhaul Procedure10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check-Up 12

Check Compression12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Ignition (Using Engine Starter)12. . . . . . . . . . . .

Check Carburetion12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Af

Hard Starting, or W Vibration 13

Power Loss13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise 13

Ignition 14

Check Ignition14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check For Spark Miss14. . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug Maintenance15. . . . . . . . . . . . . . . . . . . . . . .

Remove Ignition Armature15. . . . . . . . . . . . . . . . . . . . .

Remove Flywheel15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Flywheel Key

and Crankshaft16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Flywheel16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Flywheel16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Ignition Armature16. . . . . . . . . . . . . . . . . . . . . . .

Adjust Ignition Armature Air Gap17. . . . . . . . . . . . . . .

Specifications 17

Carburetion 18

Carburetor Identification18. . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Carburetor W

Remove Air Cleaner18. . . . . . . . . . . . . . . . . . . . . . . . . .

Remove Carburetor19. . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassemble Carburetor19. . . . . . . . . . . . . . . . . . . . . . .

Carburetor Cleaning Recommendations20. . . . . . . . . . .

Assemble Carburetor20. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Oil—Drain Plug Method6. . . . . . . . . . . .

Change Oil—Oil Fill T

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

fecting Engine Operation12. . . . . . . . . . . . . . .

ill Not Start13. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

, Keyways, Flywheel,

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

albro LMS18. . . . . . . . . . . . . . . . . . . . .

Install W

Install Throttle Shaft20. . . . . . . . . . . . . . . . . . . . . .

Install Inlet Needle Seat20. . . . . . . . . . . . . . . . . . .

elch Plug20. . . . . . . . . . . . . . . . . . . . . . . .

ube Method6. . . . . . . . . .

Install Inlet Needle and Float20. . . . . . . . . . . . . . .

High Altitude Compensation21. . . . . . . . . . . . . . .

Install Carburetor21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Air Cleaner21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Contr

and Flywheel Brake22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Governor Controls22. . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control W

Speed Regulation22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust Remote Controls22. . . . . . . . . . . . . . . . . . . . . . .

Flywheel Brake22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 22

Remove Flywheel Brake23. . . . . . . . . . . . . . . . . . . . . . .

Assemble Flywheel Brake23. . . . . . . . . . . . . . . . . . . . . .

Brake Adjustment24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Adjustments24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor and Carburetor Linkages24. . . . . . . . . . . . . . . . . . .

Governor 25

General Information25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governed RPM Limits25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical Governor25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassemble 25

Inspect Governor26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assemble Governor Crank26. . . . . . . . . . . . . . . . . . . . .

Install Crankcase Cover or Sump26. . . . . . . . . . . . . . . .

Adjust T

Seal Protectors26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compression 27

est Compression27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove Cylinder Head28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare Cylinder Head for Removal28. . . . . . . . . . . . . .

Remove Rocker Cover28. . . . . . . . . . . . . . . . . . . . . . . .

Remove Cylinder Head28. . . . . . . . . . . . . . . . . . . . . . . .

Remove V Inspect V

alve Service29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reface V

Assemble Cylinder Head29. . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Cylinder Head Plate and Rocker Arm Studs29. . Install V Install V

Install Cylinder Head30. . . . . . . . . . . . . . . . . . . . . . . . .

Install Rocker Arms—Current Style30. . . . . . . . . . . . . .

Install Rocker Arms—Early Style31. . . . . . . . . . . . . . .

Adjust V Adjust V Install V

Specification T

Rewind Starter33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove Blower Housing and Starter33. . . . . . . . . . . . . . . . .

Disassemble Rewind Starter34. . . . . . . . . . . . . . . . . . . . . . . .

ols, Carbur

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

op No Load RPM26. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

alves 29

alve Guides29. . . . . . . . . . . . . . . . . . . . . . . . . .

alves and Seats29. . . . . . . . . . . . . . . . . . . . . . .

alves 30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

alve Springs and Retainers30. . . . . . . . . . . . . . .

alve Clearance—Current Style31. . . . . . . . . . .

alve Clearance—Early Style31. . . . . . . . . . . . .

alve Cover32. . . . . . . . . . . . . . . . . . . . . . . . . . .

ables 32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

etor Linkage,

ire Travel 22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

Contents

GTS 200

Remove Rope34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Rope34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remove Pulley And Spring

Inspect Spring, Starter Housing and Pulley35. . . . . . . .

Assemble Rewind Starter36. . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Pulley and Spring36. . . . . . . . . . . . . . . . . . . . . . .

Install Pawls and Retainer Assembly36. . . . . . . . . . . . .

ind Spring and Install Rope36. . . . . . . . . . . . . . . . . . .

Install Rewind Starter on Blower Housing37. . . . . . . . .

Install Blower Housing and Rewind Starter37. . . . . . . .

Install Fuel T

Electric Starter38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

roubleshooting 12 V

est Equipment39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Multimeter39. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DC Shunt39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometer 39 Starter T

Other Equipment39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 40

Starter 41

Alternator 45

Alternator Specifications45. . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment to T

1/2 Amp Alternator45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 47

Extended Oil Fill and Dipstick47. . . . . . . . . . . . . . . . . . . . . .

Breather 47

Remove Breather47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Breather V

Remove Oil Pump47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Oil Pump48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling Instructions40. . . . . . . . . . . . . . . . . . . . . . . . .

First Aid40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Battery40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replace Battery T

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Starter Motor Drive and Clutch W

iring Diagrams41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check 12 V

Starter Motor Specifications41. . . . . . . . . . . . . . . . . . . .

roubleshoot Starter Motor41. . . . . . . . . . . . . . . . . . . . .

Check Brake Switch42. . . . . . . . . . . . . . . . . . . . . . . . . .

Check Brake Switch W

Disassemble Starter Motor42. . . . . . . . . . . . . . . . . . . . .

Clean and Inspect Starter43. . . . . . . . . . . . . . . . . . . . . . .

Assemble Starter Motor43. . . . . . . . . . . . . . . . . . . . . . .

Install Starter44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Multimeter45. . . . . . . . . . . . . . . . . . . . . . . . . . . .

est Alternator Output45. . . . . . . . . . . . . . . . . . . . . . . . .

Install Stator Studs46. . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust Stator Air Gap46. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ank 37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

olt Starting System38. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

est Bracket39. . . . . . . . . . . . . . . . . . . . . . . . . . .

erminal 40

olt Starter Motor41. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

est Alternators45. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

alve 47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .

iring 42

. . . . . . . . . . . . . . . . . . . .

Install Oil Pump48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Pump Cover48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Oil Filter Adapter48. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pistons, Rings, and Rods49. . . . . . . . . . . . . . . . . . . . . . . . . .

Piston and Connecting Rod49. . . . . . . . . . . . . . . . . . . . . . . . .

Remove Piston and Connecting Rod49. . . . . . . . . . . . . .

Remove Piston Rings49. . . . . . . . . . . . . . . . . . . . . . . . .

Check Piston Ring Groove W

Check Piston Ring End Gap50. . . . . . . . . . . . . . . . . . . .

Check Connecting Rod50. . . . . . . . . . . . . . . . . . . . . . . .

Check Piston Pin and Piston Pin Bore50. . . . . . . . . . . .

Assemble Piston and Connecting Rod50. . . . . . . . . . . .

Install Piston Rings On Piston51. . . . . . . . . . . . . . . . . . .

Compress Rings51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Connecting Rod and Piston51. . . . . . . . . . . . . . .

Specification T

Crankshaft and Camshaft53. . . . . . . . . . . . . . . . . . . . . . . . .

Remove Crankshaft and Camshaft53. . . . . . . . . . . . . . . . . . . .

Remove Crankshaft53. . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Crankshaft53. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Camshaft54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Compression Release54. . . . . . . . . . . . . . . . . . . .

Install Crankshaft and Camshaft54. . . . . . . . . . . . . . . . . . . . .

Install Crankshaft54. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Camshaft54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Crankcase Sump54. . . . . . . . . . . . . . . . . . . . . . . .

Adjust Crankshaft End Play

Specification T

Cylinder and Bearings56. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder 56

Inspection 56

Cylinder Finish (Cross Hatch)56. . . . . . . . . . . . . . . . . . .

Cylinder Cleaning56. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Plain or DU Bearings57. . . . . . . . . . . . . . . . . .

Check Camshaft Bearings57. . . . . . . . . . . . . . . . . . . . . .

Plain or DU Bearings57. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair W

Remove DU Magneto Bearing57. . . . . . . . . . . . . . . . .

Install Magneto DU Bushing57. . . . . . . . . . . . . . . . . .

Oil Seals58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Sump58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install 58

Specification T

Muffler 59

Remove Exhaust System59. . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Exhaust System59. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Muf Install Muf

ables 52

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ables 55

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

orn Aluminum Bearings57. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ables 58

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

fler 60

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

fler Guard60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ear 50

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

GTS 200

Contents

Specifications

Basic

model series

. . . . . . . . . . . . . . . .

123600.

Oil capacity

Armature air gap

Torque specifications

Flywheel nut

Cylinder head

Connecting

Crankcase

Valve

clearance

Intake

Exhaust .004/.008

Crankshaft

Stroke 2.040

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

rod

. . . . . . . . . . . . . . . .

cover or sump

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

22 fl. oz. (.65 Liter) 26

fl. oz. (.78 Liter) with oil filter

.006/.014 in.

0.15/0.36mm

60 ft. lb.

81.0Nm 210 in. lb.

24.0Nm 100 in. lb.

11.0Nm 1

10 in. lb.

12Nm

.004/.008 in.

0.10/0.20mm in.

0.10/0.20mm

in.

51.81mm

Standard

Journal

End play

Engine RPM (no load) Spark plug

Type Gap

crankpin journal

reject sizes

Magneto

Crankpin 1.097

PTO 1.065

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . . . . . . . . . . .

1.0983/1.0991 in.

27.897/27.917mm

.878 in.

22.30mm

in.

27.86mm

in.

27.05mm

.002/.033 in.

0.05/0.84mm

3,000 RPM  150

Champion RC12YC

0.020 in.

0.51mm

Specifications

GTS 200

General

Information

Contents

Oil 5.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Specifications5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Oil Level5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Oil5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Oil—Drain Plug Method6. . . . . . . . . . . .

Change Oil—Oil Fill T

Approximate Crankcase Oil Capacity (Dry)

Specifications 6 Gasoline 7

Cooling System7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner – General

Air Cleaner Service8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

une-Up Procedure9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overhaul Procedure10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check-Up 12

Equipment Af

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Compression12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Ignition (Using Engine Starter)12. . . . . . . . . . . .

Check Carburetion12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

fecting Engine Operation12. . . . . . . . . . . . . . .

Hard Starting, or W Vibration 13

Power Loss13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise 13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ill Not Start13. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ube Method6. . . . . . . . . .

Check Oil Level

Fill

crankcase with SAE 30 oil until oil level reaches FULL mark on dipstick as shown in Figure 1. The maximum crankcase capacity is 22 ounces (0.65 Liter). On models equipped with an oil filter 26 ounces (0.78 Liter). Use any high quality detergent oil having the American Petroleum Institute (API) “service classification”—SF

Before each use or every five hours, ensure oil level is between ADD and FULL marks on dipstick (Fig. 1). Add oil if

level is low

Position mower on level surface and clean around oil

dipstick.

Remove dipstick by rotating cap counterclockwise 1/4 turn

(Fig. 1).

3. W

clockwise 1/4 turn. Then remove dipstick and check level

of oil (Fig. 1). If level is low

level to FULL mark on dipstick.

FULL MARK BECAUSE ENGINE COULD BE

DAMAGED WHEN STARTED. POUR OIL SLOWL

Insert dipstick into oil fill tube and rotate cap clockwise

1/4 turn to lock (Fig. 1).

ipe dipstick and insert it into oil fill tube. Rotate cap

, the maximum crankcase capacity is

, SG SH, or SJ.

, add only enough oil to raise

DO NOT FILL ABOVE

Oil

Oil Specifications

Service classification . V

iscosity grade. . . . . . . .

Oil capacity. . . . . . . . . . . . 22 fl. oz. (.65 Liter)

Check oil. . . . . . . . . . . . . .

Change oil .

Change filter .

. . . . . . . . . . . .

. . . . . . . . . . on models so equipped,

. .

SF,

SG, SH, or SI

SAE

26 fl. oz. (.78 Liter) with filter before

each use or every five

hours. after

the first five hours; thereafter hours or every season.

every 100 operating hours or yearly

, every 50 operating

, whichever occurs first.

m–3845

Fig. 1

– Checking Oil Level

1. Oil

fill tube

2. Dipstick

ADD mark

FULL mark

Change Oil

Change change the oil every 50 operating hours or every season. More frequent oil changes are required when operating engine under a heavy load, or when used in dusty

Replace the oil filter (on models so equipped) every 100 hours or yearly

There are two methods of changing engine oil, the drain plug method and the oil fill tube method. Both work equally well.

the oil after the first 5 operating hours. Thereafter

, dirty

, or hot conditions.

, whichever occurs first.

GTS 200

General

Information

Change Oil—Drain Plug Method

1. Run

engine at least 5 minutes to warm the oil. W drains more easily and more of the contaminants are removed.

Remove oil drain plug (Fig. 2). Drain oil into a pan.

arm oil

5. If

replacing the oil filter (on models so equipped), do so at

this time.

When oil is drained, return mower to upright position and add fresh oil to engine. Refer to Oil in this section.

Approximate Crankcase Oil Capacity (Dry) Specifications

Fig. 2

– Drain Plug Location

1. Oil

drain plug

3. If

replacing the oil filter (on models so equipped), do so at

this time.

Install drain plug snugly

Remove dipstick and refill slowly with new oil of proper

service classification and viscosity grade.

Start and run engine at idle. Check for oil leaks.

Stop engine. Recheck oil level and add oil if required.

Change

1. Stop

Oil—Oil Fill T

ube Method

engine and wait for all moving parts to stop. Pull wire

f spark plug.

Remove grass bag. Drain gasoline from fuel tank.

Without

With oil filter

oil filter

. . . . . . .

. . . .

22 oz. .65

Liter

26 oz. .78

Liter

Change Oil Filter

(on models so equipped)

Change lightly oil filter gasket with fresh clean engine oil. Screw filter clockwise by hand until gasket contacts filter adapter 1/2 to 3/4 turn farther engine at idle for 30 seconds and stop engine. Recheck oil level and add oil if required. Restart engine and check for oil leaks, Fig. 4.

1. Install 2. Remove

filter every 100 hours. Before installing new filter

. Tighten

. Add fresh oil. Then, start and run

Fig. 4

– Remove and Install Oil Filter

Remove dipstick from oil fill tube and place a drain pan next to left side of mower

4. T

ip mower on its left side, allowing oil to drain into drain

pan (Fig. 3).

Fig. 3

1. Oil

fill tube

General

Information

Oil filter

m–3848

GTS 200

Gasoline

Use

clean, fresh, lead-free gasoline (including

reformulated

o ensure freshness, purchase only the quantity of gasoline

T that can be used in 30 days. Using unleaded gasoline results in fewer combustion chamber deposits and longer spark plug life.

Engines certified to comply with California and U.S. EP emission r

operate on regular unleaded gasoline, include EM and TWC (if so equipped) emission control systems, and do not include any user adjustable features.

IMPORTANT methanol, gasohol containing more than 10% ethanol, pr

emium gasoline, or white gas. Using these fuels can

damage the engine’

gasoline) with an octane rating of 87 or higher

egulations for ULGE engines

: Do not use methanol, gasoline containing

s fuel system.

DANGER

POTENTIAL HAZARD

•

In certain conditions gasoline is extr flammable and highly explosive.

WHA

T CAN HAPPEN

•

A fir

e or explosion fr

others, and cause pr

HOW T

•

• Stor

•

O AVOID THE HAZARD Use a funnel and fill the fuel tank outdoors, in an open ar any gasoline that spills. Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4” to 1/2” (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand. Never smoke when handling gasoline, and stay away fr fumes may be ignited by a spark.

keep it out of the r Never buy mor gasoline.

ea, when the engine is cold. W

om an open flame or wher

e gasoline in an appr

om gasoline can burn you,

operty damage.

oved container and

each of childr

e than a 30-day supply of

oxygenated or

are certified to

emely

ipe up

e gasoline

en.

DANGER

POTENTIAL HAZARD

•

When fueling, under certain cir static charge can develop, igniting the gasoline.

WHA

T CAN HAPPEN

•

A fir

e or explosion fr

and others and cause pr

HOW T

•

Use a fuel stabilizer/conditioner regularly during operation and storage. A stabilizer/conditioner cleans the engine during operation and prevents gum–like varnish deposits from forming in the engine during storage.

IMPORTANT stabilizer/conditioner alcohol base such as ethanol, methanol, or isopr

IMPORTANT filler neck. This space is for expansion of fuel. Do not fill the tank completely full.

O AVOID THE HAZARD Always place gasoline containers on the gr away from your vehicle befor Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge. When practical, r equipment fr the equipment with its wheels on the gr If this is not possible, then refuel such equipment on a truck or trailer from a portable container dispenser nozzle. If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Clean the area around the fuel tank cap. Remove the cap from the fuel tank. Using unleaded, regular gasoline, fill the tank to within 1/4

to 1/2 in. (6 to 13mm) from the top of the tank.

om the truck or trailer and r

, rather than fr

: Do not use fuel additives other than a fuel

: Do not fill the tank with gasoline into the

om gasoline can burn you

operty damage.

emove gas–power

om a gasoline

. Do not use fuel stabilizers with an

cumstances, a

ound

e filling.

efuel

ound.

opanol.

GTS 200

Install the fuel tank cap.

5. W

ipe up any spilled gasoline.

Cooling

Grass

particles, chaf especially after prolonged service in very dusty conditions or when cutting dry grass. Continued operation with a clogged cooling system can cause severe overheating and possible engine damage. Figures 5 and 6 show the areas to be cleaned.

System

f, or dirt can clog the air cooling system,

General Information

This

should be a regular maintenance operation, performed yearly or every 100 hours, whichever comes first and more often when dust or when airborne debris is present.

Fig. 5

– Static Screen

1. Static

screen

1 2

Fig. 7

– Remove Spark Plug W

1. Primer 2. Spark

ire Prior to Service

m–3662

plug wire

Fig. 6 – Cylinder Fins and Ducting

1. Ducting 2. Cylinder

Air

Cleaner – General

properly serviced air cleaner protects internal parts of the

engine from dust particles in the air

. If air cleaner instructions

fins

are not carefully followed, dirt and dust which should be collected in the air cleaner will be drawn into the engine and become a part of the oil film, which is very detrimental to engine life; dirt in the oil forms an abrasive mixture which wears moving parts instead of protecting them.

2. Loosen

(Fig. 8).

1. Knob

2. Cover

two (2) knobs securing air cleaner cover to engine

m–3664

Fig. 8

– Air Cleaner Service

3. Foam

pre–cleaner

Paper cartridge

Air

Cleaner Service

Normally,

clean the air cleaner pre–cleaner after every 25 operating hours or every season. Clean or replace the paper cartridge after every 100 hours or every season. More frequent cleaning is required when mower is operated in dusty or dirty conditions. Replace air cleaner parts, if very dirty

IMPORTANT elements; extr

Note: T

: Do not operate engine without air filter eme engine wear or damage will occur

ipping mower on wrong side to service underside of

mower may cause damage to air filters.

Stop engine and pull wire of

General

Information

f spark plug (Fig. 7).

3. Lift

cover of

Carefully remove pre–cleaner

f. Clean cover thoroughly

. If pre–cleaner is dirty

carefully wash it in a solution of liquid soap and warm water

. Rinse in clear water

. Allow to dry thoroughly before

using.

If paper cartridge is dirty it

gently

on a flat surface. If very dirty

IMPORTANT Do not use pr

Reinstall pre–cleaner over paper cartridge. Reinstall air

: Do not oil pr

essurized air to clean paper cartridge.

, clean the paper filter by tapping

, replace cartridge.

e–cleaner or paper cartridge.

cleaner cover and tighten securely in place with two (2) knobs.

GTS 200

Tune-Up

performing the following steps you will either be sure that the engine is functioning properly or will know what repairs should

be made. These steps are also covered in the Overhaul Procedure and will normally be performed as a part of complete overhaul. Carbon deposits in combustion chamber should be removed every 100 to 300 hours of use (more often when run at steady loads),

or whenever cylinder head is removed.

Procedure

Step No.

1. Remove

10.

11.

12.

13.

14.

15.

16.

Check oil level and drain oil. Remove blower housing, inspect rewind assembly Clean cooling fins and entire engine. Remove carburetor

necessary and assemble. Set initial adjustment. Inspect intake elbow or carburetor spacer for damaged gaskets. Check governor, linkage, and springs for damage, wear Clean fuel tank and lines. Remove flywheel. Check for oil seal leakage, both flywheel and PT Check armature coil. Inspect all wires for breaks and/or damaged insulation. Be sure lead wires do not touch

flywheel. Check stop switch and lead(s). Remove oil, debris, and nicks from flywheel and crankshaft tapers. Install flywheel and set air gap. Check for spark with Briggs & Stratton T Remove spark plug and cylinder head. Inspect valves for seating. Clean carbon from cylinder head and piston. Replace gaskets and install cylinder head. Tighten to specified torque. Adjust valve clearance. Set spark plug

gap or replace plug if necessary

air cleaner

, check for proper servicing. Replace if damaged or dirty

, disassemble, and inspect for wear or damage. W

, also check adjustment.

ash in solvent. Replace parts as

O sides. Check flywheel key

ool #19051 or #19368 ignition tester

17.

18.

19.

20.

21.

GTS 200

Replace gaskets and install carburetor Adjust remote control linkage and cable, if used, for correct operation. Check muf Replace oil and fuel. Run engine and adjust carburetor mixture and engine T

fler for restrictions or damage.

op No Load RPM.

General

Information

Overhaul

The

Overhaul Procedure which follows is intended to help you become accustomed to a systematic method of repairing T GTS 200 operations are performed in the same sequence every time.

The Overhaul Procedure can also be used as an index. For information on how to perform most operations listed, refer to the section number or operation.

Disassemble

Check

OHV engines. Naturally these steps could be rearranged in dif

compression

Procedure

ferent order but ef

Section

Compression 27

oro

ficiency is obtained when the repair

Beginning Page

Drain oil – Remove oil filter (when equipped) Air cleaner Fuel line, tank assembly and brackets, carburetor and linkage, carburetor

intake manifold or spacer Exhaust manifold, muf Disassemble carburetor Electric starter (12 V) Blower housing Breather and valve cover V

alves and springs, rocker arms, push rods, cylinder head and shields,

valve guides and seats Rewind starter Flywheel Ignition 14 Check crankshaft end play Remove burrs from crankshaft extension Crankcase cover or sump Mechanical governor parts Cam gear and tappets Connecting rod and piston

fler Muffler 59

Lubrication 47 General Information Carburetion 18

Carburetion 18 Electric Starter Lubrication 47 Compression 27

Rewind Starter

Crankshaft and Camshaft Crankshaft and Camshaft Crankshaft and Camshaft Governor 25 Crankshaft and Camshaft Pistons, Rings, and Rods

53 53 53

53 49

Crankshaft

Inspection Section

Inspect carburetor choke, throttle shaft, and bushings for wear and freedom of movement

Inspect and test ignition coil Crankshaft – inspect and check Oil pump – inspect and check, if so equipped Cylinder – check bore, main bearing Check piston, rings, connecting rod, and piston pin

General Information

Crankshaft and Camshaft

Carburetion 18

Ignition 14 Crankshaft and Camshaft Lubrication 47 Cylinder and Bearings Pistons, Rings, and Rods

Beginning Page

56 49

GTS 200

Beginning

Repairs Section

Clean/replace parts as required Replace block or short block if cylinder is over allowable dimension Cylinder and Bearings Replace valve guides – intake or exhaust, if required Reface valves and seats and lap, if required Replace ignition armature, if required Replace throttle shaft bushings, if required Repair carburetor Replace rewind starter spring and rope (if so equipped) Replace main bearings and seals, if required

Reassemble Section

Crankshaft Piston, piston pin, connecting rod, and rings T

appets, cam gear Oil pump, if so equipped Mechanical governor Crankcase cover or sump Breather Lubrication 47 Flywheel, starter cup, and fan Ignition armature assembly Adjust ignition armature to flywheel air gap Check spark Electric starter (12 V) V

alves, valve stem seals, springs, retainers, rocker arms Cylinder head and push rods Adjust valve clearance V

alve cover Spark plug – adjust gap to .020” Exhaust manifold, muf Intake manifold Carburetor and linkage and governor controls Governor Controls,

Check and adjust mechanical governor Blower housing and rewind starter Fuel filter Clean/replace and assemble air cleaner Fill crankcase with oil, fill with gas, start engine Adjust carburetor Set governor to obtain correct engine speed (remote controls) Spray paint engine parts and apply decals

, tank, and line

flers Muffler 59

Compression 27 Compression 27 Ignition 14 Carburetion 18 Carburetion 18 Rewind Starter Cylinder and Bearings

Crankshaft and Camshaft Pistons, Rings, and Rods Crankshaft and Camshaft Lubrication 47 Governor 25 Crankshaft and Camshaft

Ignition 14 Ignition 14 Ignition 14 Ignition 14 Electric Starter Compression 27 Compression 27 Compression 27 Compression 27 Ignition 14

Carburetion 18

Carburetor Linkage, and Flywheel Brake

Governor 25 Ignition 14 Carburetion 18 General Information General Information Carburetion 18 Governor 25

Page

33 56

Beginning Page

53 49 53

5 5

GTS 200

General Information

Check-Up

Most

complaints concerning engine operation can be

classified as one or a combination of the following:

1. W

ill not start

Hard starting

Lack of power

4. Vibration

5. Overheating

High oil consumption

Whe

n the c

aus

e o

f m

alfunctio

chec

k o

f th

e c

ompression

, p

check-up i

n a m

atter o determinin possibl

e c time. Th models subjec

e b

, w

t h

erforme

g the c

aus

asi

hil

eading.

f m

inutes. I

aus

e o

f futur

c c

heck-u

e any v

d i

n a s

e o

ariation

Check Compression

See

the section Compression for proper procedure.

If compression is poor

Loose spark plug

Loose cylinder head bolts

Blown head gasket

Burned valves, valve seats

5. Insuf

6. W

7. W

8. W

ficient valve clearance arped cylinder head or warped valve cover arped or worn valve stems and guides orn bore and/or rings

Broken connecting rod

Check Ignition (Using Engine Starter)

WARNING

n i

, i

gnition

ystemati

t i

s the q

f failure. Thi

e f

ailures

, w

p p

rocedur

, b

y m

, look for –

s n

ot readil

, and c

c m

uickes

hic

e i

odel

y a

arburetio

anner

, can u

t and s

s c

heck-u

h can b

s the same for all e

, will b

pparent

ures

t m

p will p

e c

orrecte

e s

how

n s

suall

n u

, p

erfor

m a

ystems. This

y b

e d

one

etho

d o

oin

t o

d a

t t

ngine

nder the

If spark does not occur

Shorted stop switch wire

Shorted stop switch

Ignition armature failure

Improperly operating interlock system

Note:

If engine runs but misses during operation, a quick check to determine if ignition is or is not at fault can be made by inserting the spark tester between the ignition cable and the spark plug. A spark miss will be readily seen. See the Ignition section.

, look for –

Check Carburetion

Before

making a carburetion check, be sure the fuel tank has an ample supply of fresh, clean gasoline. Be sure that the shut-of

f valve is open and fuel flows freely through fuel line and filter before starting engine. Inspect and adjust the needle valve. Check to see that the choke closes completely will not start, remove and inspect the spark plug.

If plug is wet, look for –

Over choking

Excessively rich fuel mixture

3. W

ater in fuel

Inlet needle stuck open

Clogged air cleaner

Fouled spark plug

If plug is dry

Leaking carburetor mounting gaskets

Gummy or dirty carburetor valve or fuel tank

Inlet needle stuck shut

Inoperative fuel pump (if so equipped)

A simple check to determine if the fuel is getting to the combustion chamber through the carburetor is to remove the spark plug and pour a small quantity of gasoline through the spark plug hole. Replace the plug. If the engine fires a few times and then stops, look for the same conditions as for a dry plug.

, look for -

, fuel filter

, fuel lines, shut-of

. If engine

SURE ther which might be ignited by the spark and cause a fir

e or explosion.

Attach a spark tester to spark plug wire and ground the other end of the tester to the engine block. W spark plug. Spin the flywheel with the engine starter jumps the ignition system is performing satisfactorily Ignition for additional information.

General Information

e is no fuel or fuel vapor pr

.166”

(4.20mm)

tester gap, you can assume the

esent,

arning: Do not remove

. If spark

. See the section

Equipment

Affecting Engine

Operation

What

appears to be a problem with engine operation, such as hard starting, vibration, etc., may be the fault of the mower rather than the engine itself. Listed are the most common ef

fects of equipment problems and what to look for as the

most common cause.

GTS 200

Hard Starting, or Will Not Start

Power Loss

1. Check

2. Chec

remote control assembly for proper adjustment.

k i

gnitio

n s

ystem.

Vibration

Cutter blade bent – Remove and replace.

Cutter blade out of balance – Remove and balance.

Crankshaft bent – Replace.

4. W

orn blade coupling – Replace if coupling allows blade to

shift, causing unbalance.

Mounting bolts loose – T

Mounting deck or plate cracked – Repair or replace.

Damaged belts or pulleys.

ighten.

1. Grass

cuttings build-up under deck. No lubrication in transmission or gear box. Dull blade. Excessive drive belt tension may cause excess bearing

wear or seizure.

Noise

BBC system problems (if so equipped).

No lubricant in transmission or gear box.

3. W

orn drive belts.

4. W

orn bearings.

GTS 200

General

Information

Ignition

Contents

Check Ignition14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check For Spark Miss14. . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug Maintenance15. . . . . . . . . . . . . . . . . . . . . . .

Remove Ignition Armature15. . . . . . . . . . . . . . . . . . . . .

Remove Flywheel15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspect Flywheel Key

and Crankshaft16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Flywheel

Install Flywheel16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Ignition Armature16. . . . . . . . . . . . . . . . . . . . . . .

Adjust Ignition Armature Air Gap17. . . . . . . . . . . . . . .

Specifications 17

, Keyways, Flywheel,

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig. 9

– Checking for Spark

1. Spark

plug wire

Check For Spark Miss

Spark tester Stratton T #19368

, Briggs &

ool #19051 or

WARNING

O PREVENT accidental starting, the spark plug

wir

e must be r

ounded, failur

injury.

emoved fr

e to do so can cause personal

om spark plug and

WARNING

DO NOT r ignition. A fir

emove spark plug when checking

e or explosion may occur

WARNING

YWHEEL KICKBACK can occur if the

flywheel key is shear occur.

Check

1. Connect

Operate starter and observe spark gap in tester jumps tester gap, ignition is good.

Ignition

spark plug wire to Spark T

ed and bodily injury may

ester

, Fig. 9.

. If spark

1. Install

1. Spark

2. Start

Briggs & Stratton T

Tester

, in series with spark plug lead and spark plug,

Fig. 10.

Fig. 10 – Running Check

plug lead

Spark tester Stratton T #19368

If spark jumps tester gap regularly problem is spark plug, compression, or fuel system.

, Briggs &

ool #19051 or

and run engine.

ool #19051 or #19368, Spark

Spark plug

, but miss continues,

Note: Note:

Ignition

Flywheel must rotate at 350 RPM, minimum. Spark will be observed.

GTS 200

Spark

The

Plug

recommended spark plug is:

Spark Plug Type Brand

Resistor Long Plug

Note:

In some areas, local law requires the use of a resistor

Champion

RC12YC

spark plug to suppress ignition signals. If an engine was originally equipped with a resistor spark plug, be sure to use the same type of spark plug for replacement.

Spark Plug Maintenance

Set

gap at .020” (0.51mm), Fig. 11. If electrodes are burned

away

, or porcelain is cracked or fouled, replace with a new

plug.

Note:

Do not use abrasive cleaning machines.

Remove

1. Remove

Use flywheel holder to hold flywheel from turning,

Flywheel

blower housing.

Fig. 13.

1. .020”

Fig. 11

(0.51mm) wire gauge

– Adjusting Spark Plug Gap

Remove Ignition Armature

1. Remove

Remove armature screws, disconnect stop wire, and lift of armature, Fig. 12.

blower housing.

Fig. 13

1. Flywheel

3. Use

socket and breaker bar to remove flywheel nut.

Note:

Remove ignition armature before removing

– Removing Flywheel Nut

holder Briggs & Stratton T

ool #19372

flywheel.

Thread flywheel nut onto crankshaft until top of nut is flush with crankshaft threads or slightly 1.5mm (1/16”) above end of threads.

Attach flywheel puller

6. T

urn puller screws into flywheel puller holes until screws

bottom.

7. T

urn lower nuts down until flywheel puller body rests

firmly on flywheel nut.

Then turn upper nuts down onto puller body

. T

urn both

nuts equally until flywheel pops loose, Fig. 14.

Fig. 12

1. Ignition

2. Screws

GTS 200

– Removing Ignition Armature

armature

Stop switch wire

4. Terminal

1. Flywheel

Fig. 14

nut

– Removing Flywheel

Briggs & Stratton T #19069 flywheel puller

ool

Ignition

Inspect

Flywheel Key

, Keyways,

Flywheel, and Crankshaft

Inspect

flywheel key for partial or complete shearing. If sheared, replace, Fig. 15. Flywheel should be inspected for cracks, burrs on taper or keyway, and distortion of keyway Check taper of crankshaft for burrs, rust, oil, or other damage. Check cooling fan or flywheel for broken fins. If parts are damaged, replace with new parts.

1 2

Fig. 15 – Inspect Flywheel Key

1. OK 2. Replace

Install

Flywheel

Install Flywheel

1. Clean

flywheel taper and crankshaft taper of all grease, oil

and dirt. Slide flywheel onto crankshaft and line up both keyways.

Insert flywheel key into both keyways.

Note:

DO NOT use a steel key under any circumstances.

WARNING

DO NOT use impact wr

Install starter cup, cooling fan, and flywheel nut or screw

Use flywheel holder to hold flywheel from turning, Fig. 16.

enches to install flywheel.

Fig. 16 – Torquing Flywheel

1. Briggs

& Stratton T

#19321,

flywheel holder or

Tool

# 19372 flywheel

strap wrench

ool

2. Cup

Install Ignition Armature

1. Install

2. T

stop switch wire on armature, Fig. 12, Page 15.

urn flywheel so magnet is away from armature.

Install armature and mounting screws, Fig. 17.

Note:

Mounting holes in armature are slotted.

Install flywheel nut or screw Use socket and torque wrench to tighten flywheel nut or

screw.

7. T

orque as listed in T

Ignition

able No. 1, Page 17.

Fig. 17

1. Ignition

4. Push

armature

armature away from flywheel as far as possible and

tighten one screw to hold armature in place.

– Installing Armature

2. T

ighten one screw

GTS 200

Adjust Ignition Armature Air Gap

1. Rotate

flywheel until magnet is under armature

laminations. Place thickness gauge, T

able No. 1, Page 17, between

magnet and armature laminations, Fig. 18.

3. See T

able No. 1, Page 17 for armature air gap. Loosen mounting screw so magnet will pull armature down against thickness gauge.

4. T

orque both mounting screws to 25 in. lbs.

(3.0Nm)

Rotate

flywheel to remove thickness gauge.

Install outer blower housing and screws and torque screws to 85 in. lbs., (10.0Nm),Fig. 19.

Fig. 18

1. Magnet

2. Turn

magnet away from

armature Armature down; gauge

3. stock in place

– Adjusting Armature Air Gap

Specifications

Armature

.006” – .012”

(0.15 – 0.30mm)

Air Gap

4. Turn

Roll out gauge

Flywheel Puller

Briggs & Stratton T

19069 19372

ool #

Fig. 19

1. Torque

Table No. 1

Flywheel Holder

Briggs & Stratton T

– Installing Outer Blower Housing

screws to 85 in. lbs.

ool #

Flywheel Nut Torque

60 ft. lbs.

(81.0Nm)

GTS 200

Ignition

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