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RESIDENTIAL PRODUCTS
WALK BEHIND MOWER
ENGINE SERVICE MANUAL
2012 and Prior LC1P65FA (159cc)
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About this Manual
This service manual was written expressly for Toro service technicians. The Toro Company
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 Toro Dealer Portal. 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:
The Toro Company
Residential and Landscape Contractor Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420
Page 3
Chapter 1 – General Service Information
1
Chapter 2 - Engine Service / Maintenance
2
Chapter 3 - Engine Disassembly and Service
3
Chapter 4 - Electrical
4
Page 4
NOTES:
Page 5
1
Chapter 1 – General Service Information
Safety 2
Service Rules 3
Engine Model / Serial Number Location 3
Engine Fastener Torque Specification 4
General Specifications 4
Engine Specifications 5
Troubleshooting 6
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Safety
Safety Information
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 mower and operator’s manuals contain
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.
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Service Rules
1. Only use genuine Toro 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.
Engine Model and
Serial Numbers
Engine Model
Serial Number
1
Engine Model / Serial Number Location
The engine model and serial number are stamped into the crankcase, near the fuel tank.
XXX-XXXX XXXXXXXXXXX
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Item
Fastener Size
Torque
Specification
Cylinder Head Bolts
M8
25 ft-lbs (34 Nm)
Connecting Rod Bolts
M7
9.5 ft-lbs (13 Nm)
Flywheel Nut
M14
62.5 ft-lbs (85 Nm)
Valve Adjust Lock Nut
M6
10 ft-lbs (14 Nm)
Pivot Arm Pivot Stud
M8
22 ft-lbs (30 Nm)
Crankcase Cover Bolt
M6
7.5 ft-lbs (10 Nm)
Muffler Nuts
M6
7.5 ft-lbs (10 Nm)
Air Cleaner Nuts
M6
6 ft-lbs (8 Nm)
Recoil (Fan Shroud) Nut
M6
6 ft-lbs (8 Nm)
Oil Drain Bolt
M10
15.5 ft-lbs (21 Nm)
Fuel Tank Bolts / Nuts
M6
7.5 ft-lbs (10 Nm)
Governor Arm Pinch Nut
M6
7.5 ft-lbs (10 Nm)
Spark Plug
-
22 ft-lbs (30 Nm)
Ignition and Charge Coil Bolts
M6
7.5 ft-lbs (10 Nm)
Electric Starter Motor Bolts
M6
7.5 ft-lbs (10 Nm)
Standard Torque Values
M5 Bolt / Nut
4.5 ft-lbs (6 Nm)
M6 Bolt / Nut
7.5 ft-lbs (10 Nm)
M8 Bolt / Nut
19 ft-lbs (26 Nm)
M10 Bolt / Nut
28 ft-lbs (38 Nm)
M12 Bolt / Nut
41 ft-lbs (55 Nm)
Model
1P65FA
Type
Single cylinder, 4-Stroke, Forced Air Cooling, OHV
Bore x Stroke (mm)
65×48
Displacement (cc)
159
Compression Ratio
8 :1
Lubrication
Splash
Starting
Recoil and Electric Start
Rotation
Counter-Clockwise (From P.T.O. Side)
Ignition System
Transistorized Magneto Ignition
Air Cleaner
Foam & Paper
Fuel Type
Unleaded Gasoline, 87 Octane
Oil Capacity
Max. Fill: 20 oz (0.59 l)
Dimensions (L×W×H)
371×338×356 (mm)
Dry Weight
26.4 lbs (12 kg)
Engine Fastener Torque Specifications
General Specifications
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Page 9
Engine Specifications
Part
Item
Standard
Service Limit
Engine
Operating RPM
2900 – 3100 RPM
－
Cylinder Head
Warpage
－
0.00393” (0.10 mm)
Cylinder
Sleeve Taper / Out of Round
(Inside Diameter)
2.559” (65.0 mm)
2.566” (65.165 mm)
Piston
Skirt Outside Diameter
2.558” (64.985 mm)
2.553” (64.845 mm)
Cylinder Clearance
0.00059 - 0.00196” (0.015-0.05 mm)
0.00472” (0.12 mm)
Piston Pin Bore Inside Diameter
0.5118” (13.002 mm)
0.5137” (13.048 mm)
Piston Pin Clearance
0.00007- 0.0005” (0.002-0.014 mm)
.00314“ (0.08 mm)
Piston Pin
Outside Diameter
0.5118” (13.0 mm)
0.51” (12.954 mm)
Piston Rings
Ring To Groove (Top and Middle)
0.00059 - 0.00177” (0.015-0.045 mm)
0.0059” (0.15 mm)
End Gap (Top and Middle)
0.0078 - 0.0157” (0.2-0.4 mm)
0.0393” (1.0 mm)
Width (Top and Middle)
0.059” (1.5 mm)
0.0539” (1.37 mm)
Width (Oil Ring)
0.0984” (2.5 mm)
0.0933” (2.37 mm)
Connecting Rod
Small End Inside Diameter
0.5125” (13.02 mm)
0.5145” (13.07 mm)
Big End Inside Diameter
1.0244” (26.02 mm)
1.0263” (26.07 mm)
Big End Oil Clearance
0.00157 - 0.00248” (0.04-0.063 mm)
0.0047” (0.12 mm)
Big End Side Clearance
0.00393 - 0.02755” (0.1-0.7 mm)
0.0433” (1.1 mm)
Crankshaft
Crackpin Outside Diameter
1.0228” (25.98 mm)
1.0204” (25.92 mm)
Valve
Clearance (cold) (Intake)
0.0039” (0.10 mm)
－
Clearance (cold) (Exhaust)
0.0059” (0.15 mm)
－
Stem Diameter (Intake)
0.2157” (5.48 mm)
0.2093” (5.318 mm)
Stem Diameter (Exhaust)
0.2141” (5.44 mm)
0.2076” (5.275 mm)
Valve Guides
Inside Diameter (Intake, Exhaust)
0.2165” (5.50 mm)
0.2193” (5.572 mm)
Stem to Guide Clearance (Intake)
.00039” - 0.0013” (0.01-0.034 mm)
.00393” (0.10 mm)
Stem to Guide Clearance (Exhaust)
0.0019 - 0.0027” (0.05-0.070 mm)
0.0047” (0.12 mm)
Valve Seat
Seat Width
0.0314” (0.8 mm)
0.0787” (2.0 mm)
Valve Spring
Free Length
1.2007” (30.5 mm)
1.1417” (29.0 mm)
Camshaft
Height (Intake)
1.0905” (27.7 mm)
1.0807” (27.45 mm)
Height (Exhaust)
1.0925“ (27.75 mm)
1.0826” (27.50 mm)
Journal (Bearing)
0.5505” (13.984 mm)
0.5478“ (13.916 mm)
Crankcase Cover
Camshaft Hole Diameter
0.5511” (14.0 mm)
0.553” (14.048 mm)
Crankshaft Hole Diameter
1.0” (25.4 mm)
1.00472” (25.52 mm)
Spark Plug
Gap
0.0275 - 0.0314” (0.7-0.8 mm)
－
Ignition Coil
Resistance (Primary)
1.1-1.6 Ω
－
Resistance (Secondary)
10.5 KΩ +/- 15%
－
Gap to Flywheel
.01” (0.254 mm)
－
1
NOTE: The only internal parts available for this engine are gaskets and seals.
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Troubleshooting
Hard Starting / Poor Running
- Incorrect Fuel (Level, Age, Octane, Ethanol Content)
- Fuel System Contamination and / or Carburetor Debris
- Incorrect Oil Level
- Spark Plug (Incorrect Gap, Fouled, Loose or Faulty)
- Air Filter Restriction
- Air Intake System Leaks
- Ignition Coil to Flywheel Gap Incorrect
- Weak / No Spark
- Auto Choke System (Improper Function)
- Choke / Air Vane Linkage
- Operating RPM Incorrect
- Governor Adjustment Incorrect
- Engine Valve Clearance out of Specification
- Low Compression or Excessive Leakdown
Overheating
- Incorrect Oil Level
- Cylinder Head Gasket Leak
- Debris Build-Up Restricting Air Flow
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2
Chapter 2 - Engine Service / Maintenance
Engine Oil Change Procedure 8
Air Cleaner Service 9
Spark Plug Service 10
Valve Clearance Inspection and Adjustment 11
Engine Governor – Zero Point Setting 11
Fuel Filter Replacement 12
Auto Choke System / Function 13
Auto Choke System View 14
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Engine Oil Change Procedure
1. Run engine to warm engine oil.
2. Remove spark plug cap from the spark plug.
NOTE: Ensure fuel system contains no fuel to prevent leakage when the mower is tipped onto its side.
3. Remove the dipstick.
4. Tip the mower onto side with the dipstick on the downward side. Drain the used oil through the oil fill tube
into a suitable container.
5. Return the mower to the operating position.
6. Add oil through the dipstick tube. Wipe the dipstick clean and insert it into the dipstick tube to check the oil
level.
NOTE: DO NOT screw the dipstick into the dipstick tube to check the oil level
NOTE: DO NOT overfill the engine oil
7. Fully Install the dipstick and hand tighten it securely.
8. Properly dispose of the used engine oil.
Engine Oil Capacity:
Max. Fill: 20 oz (0.59 l)
Engine Oil Type:
SAE 30 or 10W-30 detergent oil. API classification of SF,SG, SH, SJ, SL, or higher.
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2
Paper Element
Air Cleaner Base
Air Cleaner
Cover
Foam Element
Air Cleaner Service
1. Press the upper latch tabs and rotate the top of the cover outward to open and remove the cover.
2. Remove the paper air filter and the foam pre-filter.
3. Inspect the foam pre-filter, and replace it if damaged or excessively dirty.
4. Inspect the paper air filter.
NOTE: If the paper air filter is excessively dirty, damaged or is wet with oil or fuel, replace it.
5. Remove dirt from the air cleaner body and cover using a moist rag. Do not wipe dirt into the air duct.
6. If the foam pre-filter is reusable, clean it with warm soapy water. Thoroughly rinse and dry foam element.
7. Insert the foam pre-filter and the paper air filter into the air cleaner
8. Properly Install the cover and verify cover latch tabs are fully engaged.
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0.0275 - 0.0314”
(0.7-0.8 mm)
Spark Plug Service
NOTE: Spark plugs of the wrong size or incorrect heat range can cause severe engine damage.
High Voltage Ignition Systems can be Dangerous - Use Caution when Servicing Ignition Systems
1. Disconnect the spark plug cap and thoroughly clean the spark plug area.
2. Remove the spark plug from the engine.
3. Inspect the spark plug for excessively worn electrodes, chips or cracks in the insulator, or excessive
deposits.
4. Measure the electrode gap and adjust if necessary. Spark Plug Gap: 0.0275 - 0.0314” (0.7-0.8 mm)
5. Install spark plug and torque to specification - 22 ft-lbs (30 Nm).
6. Fully install the spark plug cap on the plug.
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2
Governor Arm
Shaft
Pinch Bolt Nut
Governor Arm
Valve Clearance Inspection and Adjustment
NOTE: Valve clearance inspection and adjustment must be done with the engine cold.
1. Rotate engine to TDC (top-dead-center) of the
compression stroke.
2. Remove the valve cover. Be sure both valves are
completely closed and the decompression arm is not
holding the valve open.
3. Measure the clearance between the rocker
arm and the valve stem with a feeler gauge.
Intake: 0.0039” (0.10 mm)
Exhaust: 0.0059” (0.15 mm)
4. To adjust valve clearance:
- Hold the rocker arm pivot and loosen the pivot lock
nut.
- Turn the rocker arm pivot to obtain the specified
clearance.
- Hold the rocker arm pivot and tighten the pivot lock nut to specification - 11 ft-lbs (15 Nm).
5. Recheck the clearance and readjust if necessary.
6. Inspect the valve cover gasket and replace if necessary. Install the valve cover and torque fasteners to
specification - 7.5 ft-lbs (10 Nm).
Engine Governor – Zero Point Setting
1. Loosen but do not remove the governor
arm pinch bolt and nut.
2. Move the governor arm to fully open
the throttle valve. Firmly hold
the governor arm in this position.
3. Rotate the governor arm shaft fully
clockwise and secure it in this position
with a pair of pliers.
4. Tighten the governor arm pinch bolt and nut to Specification - 7.5 ft-lbs (10 Nm).
5. Verify that the governor arm and throttle valve move freely. Verify engine RPM is within specification.
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Fuel Filter
A
Fuel Filter and Hose Replacement
- Fuel is Extremely Flammable - Use Extreme Caution When Servicing the Fuel System
1. Drain the fuel tank into an approved container.
NOTE: Ensure fuel system contains no fuel to prevent leak when the fuel filter is replaced.
2. If necessary, remove air filter cover and base as outlined in this manual.
3. Release the fuel filter / fuel hose clamps (A) and slide them away from fittings.
4. Remove the fuel filter / fuel hose asm. from the engine.
5. Install new fuel filter / hose asm. and hose clamps (A).
6. Re-fill tank with fresh fuel.
7. Verify hose routing and check for leaks.
8. Properly dispose of any unused fuel.
9. Reinstall air filter cover and base as outlined in this manual.
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1
2
2
Auto Choke System / Function
A. Governor Rod - Connected to the governor system
which controls the angle of the throttle plate and sets
engine operating RPM.
B. Thermal Spring Rod - Connected to the thermal
spring, which mounts on the muffler. The thermal spring
adjusts the choke plate angle as the engine temperature
changes.
C. Air Vane Rod - Connected to the air vane in the
blower housing which will fully open the choke plate at
full operating RPM at any engine temperature.
COLD START - Picture 1 illustrates the choke plate
position while starting a cold engine. The thermal spring
is cold, keeping the choke closed. The air vane is
inactive because the engine is not running.
HOT START - Picture 2 illustrates the maximum amount
the thermal spring can open the choke plate while the
engine is hot and not running.
FULL RPM - Picture 3 illustrates the maximum amount
the air vane can open the choke plate. When engine
RPM decreases, the choke will close, however if the
engine is hot, the thermal spring will prevent the choke
from fully closing.
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Auto Choke System View
Thermal Spring Asm.
(Mounts onto Muffler)
Thermal Spring
Choke Linkage
Choke Rod Lock
Air Vane
Choke Linkage
Air Vane
Washer
Screw
Image for Reference Only
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3
Chapter 3 - Engine Disassembly and Service
Engine Service – Upper End 16-26
Air Cleaner and Muffler Exploded View 16
Recoil Starter and Engine Cover Exploded View 17-18
Carburetor and Linkage Exploded View 19-20
Flywheel and Breather Exploded View and Service Info 21
Cylinder Head Exploded View and Service Info 22
Intake and Exhaust Valve Exploded View and Service Info 23
Valve Spring / Valve Seat / Cylinder Head Specifications 24
Valve Stem / Valve Guide Specifications 25
Valve Seat Reconditioning 26
Engine Service – Lower End 27-36
Crankcase / Governor Exploded View and Information 27-28
Crankshaft / Piston / Camshaft Exploded View and Info 29
Piston / Connecting Rod Exploded View and Information 30
Valve Timing 31
Crankshaft Bearing / Piston / Cylinder Specifications 32
Piston / Piston Ring Specifications 33
Piston Ring / Connecting Rod Specifications 34
Crankshaft Specifications 35
Camshaft Specifications 36
NOTE: The only internal parts available for this engine are gaskets and seals.
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Nut
Muffler
Shield
Muffler
Breather Tube
Exhaust
Gasket
Primer Asm
(International Only)
Air Cleaner Base
Intake Gasket
Cover
Foam
Element
Paper
Element
Nut
Engine Service – Upper End
Air Cleaner and Muffler Exploded View
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Page 21
Recoil Asm.
Nut
Fuel Cap Asm
Nut
Bolt
Washer
Fuel Tank
Bolt
Fuel Hose
Fuel Filter
Fuel Hose
Clamp
Screw
Engine Cover
3
Recoil Starter and Engine Cover Exploded View
17
Page 22
Set Screw
Ratchet Guide
Spring
Ratchet
Spring
Reel
Spring
Bushing
Recoil Asm. Cover
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3
Governor
Arm
Governor
Spring
Governor
Pinch Bolt
Throttle Return
Spring
Governor
Rod
Control Asm.
Bracket
Gasket
Insulator /
Heat Shield
Spacer
Gasket
Carburetor and Linkage Exploded View
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Carburetor Exploded View
Throttle Valve Asm.
Pilot Jet
O Ring
Float Valve Asm
Float
Main Jet and
Nozzle
Throttle Stop
Screw
Float Bowl
Float Bowl
Mounting Bolt
and Gasket
Drain Plug
and Gasket
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3
Key
Brake / Switch
Asm.
Flywheel Nut
63 ft-lbs (85 Nm)
Breather
Cover
Breather
Gasket
6 ft-lbs (8Nm)
Breather
Valve
7.5 ft-lbs (10Nm)
Shield
Flywheel and Breather Exploded View and Service Info
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Spark Plug
22 ft-lbs (36 Nm)
Cylinder Head Gasket
Valve Cover
7.5 ft-lbs
(10 Nm)
Valve Cover Gasket
Cylinder Head Bolt Torque Sequence:
1. Initially Torque the (4) Cylinder Head Bolts in a Crisscross Pattern to 10 ft-lbs (14 Nm).
2. Evenly Torque the (4) Cylinder Head Bolts in a Crisscross Pattern to 25 ft-lbs (34 Nm).
Cylinder Head Exploded View and Service Information
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3
Lock Nut
11 ft-lbs (15 Nm)
Rocker Arm Pivot
Rocker Arm
Rocker Arm Pivot Stud
22 ft-lbs (30 Nm)
Push Rods
Intake Valve
Exhaust Valve
Valve Spring
Valve Spring
Retainer
Push Rod
Guide
Intake and Exhaust Valve Exploded View and Service Information
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Standard
Service Limit
1.2007” (30.5 mm)
1.1417” (29.0 mm)
Standard
Service limit
0.0314” (0.8 mm)
0.0787” (2.0 mm)
Service Limit
0.00393” (0.10 mm)
STRAIGHT EDGE
FEELER GAUGE
Valve Spring Free Length Specification
NOTE: If this measurement is out of specification, complete engine
replacement is required. The only internal parts available for this engine are gaskets and seals.
Valve Seat Width Inspection
Remove carbon deposits from the combustion chamber. Inspect the valve
seats for pitting or other damage.
Valve Seat Width Specification:
Cylinder Head Warp Inspection
- Remove carbon deposits from the combustion
chamber.
- Clean off any gasket material from the
cylinder head surface.
- Check the spark plug hole and valve areas for cracks.
- Check the cylinder head for warpage with a straight
edge and a feeler gauge as shown.
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
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Standard
Service Limit
Intake
0.2157” (5.48 mm)
0.2093” (5.318 mm)
Exhaust
0.2141” (5.44 mm)
0.0047” (0.12 mm)
Standard
Service limit
0.2165” (5.50 mm)
0.2193” (5.572 mm)
Standard
Service limit
Intake
.00039” - 0.0013”
(0.01-0.034 mm)
.00393”
(0.10 mm)
Exhaust
0.0019 - 0.0027”
(0.05-0.070 mm)
0.0047”
(0.12 mm)
3
Valve Stem Inspection
Inspect each valve for face irregularities, bending
or abnormal wear.
Valve Stem Diameter Specification
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
Valve Guide Inspection
Ream the exhaust valve guide to remove any carbon deposits before
measuring.
Valve Guide ID Specification:
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
Valve Stem to Guide Clearance
Subtract each valve stem OD from the corresponding guide ID to
obtain the guide-to-stem clearance.
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
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Standard
Service Limit
0.0314”
(0.8 mm)
0.0787”
(2.0 mm)
CONTACT TOO LOW
CONTACT TOO HIGH
Valve Seat Reconditioning
1. Thoroughly clean the combustion chamber and valve seats to remove carbon deposits.
2. Apply a light coat of Prussian Blue or erasable felt-tipped marker ink to the valve faces.
3. Properly install valves, springs and keepers. Manually open the valves, then and snap them closed
against their seats several times. Be sure the valves do not rotate on the seat. Remove the valve
assemblies. The transferred marking compound will show any area of the seat that is not concentric.
4. Use a 45°cutter to remove enough material to produce a smooth and concentric seat. Follow the valve
seat cutter manufacture’s instructions. Turn the cutter clockwise, never counterclockwise. Continue to
turn the cutter as you lift it from the valve seat.
5. Use a 30°~32° and 60° cutter to narrow and adjust the valve seat so that it contacts the middle of the
valve face. The 30°~32° cutter removes material from the top edge. The 60° cutter removes material from
the bottom edge. Be sure that the width of the finished valve seat is within specification.
6. Lap valves in accordance with valve lapping kit instructions.
7. Clean valve and seat of all lapping compound.
Valve Seat Width
.
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3
Aux. Oil Drain
15.5 ft-lbs (21 Nm)
Sealing Washer
7.5 ft-lbs (10 Nm)
Governor
Holder
Gasket
Pin
Weight
Washer
Slider
Clip
Washer
Shaft
Governor
Holder
Governor Asm.
Rubber Oil
Baffle
Engine Service – Lower End
Crankcase / Governor Exploded View and Service Information
Governor Exploded Views
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Page 32
Crankcase Exploded View
Oil Seal
Crankcase /
Sump Cover
Crankcase / Sump Cover Bolt
Torque Sequence
7.5 ft-lbs (10 Nm)
1 2 3 4 5
6
7
Sump Cover Gasket
Oil Dip Stick
O Ring
Governor Arm Shaft
Governor Oil Seal
Governor Lock Pin
Oil Seal
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3
Crankshaft
Thrust Washer
Connecting Rod
Bolts
9.5 ft-lbs (13 Nm)
Bearing
Piston Asm.
Connecting Rod
Connecting Rod Cap
Valve Tappets
Cam Shaft
Oil Seal
Crankshaft / Piston / Camshaft Exploded View and Service Info
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Page 34
Piston Connecting Rod Exploded View and Service Information
Assembly:
Install Rings with Orientation Mark “UP”
Stagger the piston ring gap as shown:
Top Ring
Second Ring
Oil Ring
Piston
Mark
Top Ring
Second Ring
Oil Ring
Check, refer to
Piston Pin
Piston Pin Circlip:
Install the circlip gap in the
12:00 Position (circlip gap
facing up)
Connecting Rod Orientation
Align Long end of connecting rod
with piston orientation “triangle”
CLIP
CUT-OUT
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3
Timing Marks
Crankshaft
Camshaft
Valve Timing
Crankshaft Bearing Free Play
1. Clean the bearing in solvent and dry it.
2. Spin the bearing by hand and check for play.
Replace the bearing if it is noisy or has excessive free play.
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Crankshaft Bearing Free Play
Standard
Service Limit
0.5118”
(13.0 mm)
0.51”
(12.954 mm)
Standard
Service Limit
2.559”
(65.0 mm)
2.566”
(65.165 mm)
1. Clean the bearing in solvent and dry it.
2. Spin the bearing by hand and check for play.
Piston Pin Outside Diameter
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
Cylinder Taper and Out of Round
Inspect cylinder for taper and out of round with a bore gauge.
Measure in two different directions, front to back and side to side, on
three different levels (½”down from the top, middle and ½” up from the
bottom).
Cylinder Taper and Out of Round Specifications
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
32
Page 37
Standard
Service Limit
2.558”
(64.985 mm)
2.553”
(64.845 mm)
Standard
Service Limit
0.00059 - 0.00196”
(0.015-0.05 mm)
0.00472”
(0.12 mm)
Standard
Service Limit
Top/
Middle
0.00059 - 0.00177”
(0.015-0.045 mm)
0.0059”
(0.15 mm)
Standard
Service Limit
Top/
Middle
0.059”
(1.5 mm)
0.0539”
(1.37 mm)
Piston Skirt Outside Diameter
Measure the piston skirt outside diameter 10mm from the skirt base and
90°to piston pin hole.
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
Piston to Cylinder Clearance Specification
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
Piston Ring to Groove Clearance
NOTE: If this measurement is out of specification, complete engine
replacement is required. The only internal parts available for this engine are gaskets and seals.
Piston Ring Width
NOTE: If this measurement is out of specification, complete engine
replacement is required. The only internal parts available for this engine
are gaskets and seals.
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Standard
Service Limit
0.0078 - 0.0157”
(0.2-0.4 mm)
0.0393”
(1.0 mm)
Standard
Service Limit
0.5125”
(13.02 mm)
0.5145”
(13.07 mm)
Standard
Service Limit
1.0244”
(26.02 mm)
1.0263”
(26.07 mm)
Piston Ring End Gap
Use the piston to position the rings squarely 1” down from the
top of the cylinder.
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
Connecting Rod Small End ID
NOTE: If this measurement is out of specification, complete engine replacement
is required. The only internal parts available for this engine are gaskets and
seals.
Connecting Rod Big End ID
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
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Standard
Service Limit
1.0228”
(25.98 mm)
1.0204”
(25.92 mm)
Standard
Service Limit
0.00393 - 0.02755”
(0.1-0.7 mm)
0.0433”
(1.1 mm)
Standard
Service Limit
0.0015 – 0.0024”
(0.040-0.063 mm)
0.0047”
(0.120 mm)
Crankshaft pin OD
NOTE: If this measurement is out of specification, complete engine
replacement is required. The only internal parts available for this engine
are gaskets and seals.
Connecting Rod Big End Side Clearance
NOTE: If this measurement is out of specification, complete engine
replacement is required. The only internal parts available for this
engine are gaskets and seals.
Connecting Rod Big End Oil Clearance
1. Clean oil from the crankshaft and connecting rod.
2. Use plastic gauge style measuring tool in accordance to the
manufactures instructions to measure the oil clearance.
Connecting Rod Bolt Torque: 9.5 ft-lbs (13 Nm)
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
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Standard
Service Limit
Intake
1.0905”
(27.7 mm)
1.0807”
(27.45 mm)
Exhaust
1.0925“
(27.75 mm)
1.0826”
(27.50 mm)
Standard
Service Limit
0.5505”
(13.984 mm)
0.5478”
(13.916 mm)
Camshaft Lobe Specifications
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
Camshaft Journal OD
Check the camshaft bearing journal for scoring, wear or damage.
NOTE: Verify that the decompression mechanism moves freely.
NOTE: If this measurement is out of specification, complete engine replacement is required.
The only internal parts available for this engine are gaskets and seals.
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Page 41
4
Chapter 4 – Electrical System Information
Ignition / Charge Coil Gap Adjustment 38
Ignition Coil Resistance Inspection 38
Spark Testing 39
Electrical System Wiring 40
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Ignition / Charge Coil Gap
.01” (0.254 mm)
A - Primary Coil Resistance
1.1-1.6 Ω
B - Secondary Coil Resistance
10.5 KΩ +/- 15%
A
B
Ignition / Charge Coil Gap Adjustment
High Voltage Ignition Systems can be Dangerous - Use Caution when Servicing Ignition
Systems
1. Install the coil and lightly tighten the mounting bolts.
2. Rotate engine so the coil is aligned with the magnet portion of the flywheel.
3. Insert the feeler gauge between the flywheel and coil.
4. Adjust the coil gap at both side of the coil.
5. Torque the coil mounting bolts to specification – 7.5 ft-lbs (10 Nm).
Ignition Coil Resistance Inspection
Primary Coil
Place Ohm meter leads between the harness connection
lead and the exposed metal coil leg.
Secondary Coil
Place Ohm meter leads between exposed metal coil leg
and the spark plug terminal connection.
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Page 43
Spark Plug
4
Spark Testing
- Fuel is Extremely Flammable - Use Extreme Caution When Servicing the Fuel System
- High Voltage Ignition Systems can be Dangerous - Use Caution when Servicing Ignition Systems
1. Safely drain the fuel system and store fuel in an approved container.
2. Remove spark plug boot from the spark plug.
3. Remove the spark plug from the engine.
4. Connect the negative (-) electrode of the spark plug (threaded area) to ground (cylinder head cover).
5. Crank the engine and view the electrode gap. Spark should be present when engine is turning over.
6. Reinstall the spark plug and torque to specification - 22 ft-lbs (30 Nm).
7. Properly install the spark plug boot.
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E D B A C G F
F
Electrical System Wiring (Electric Start Shown)
A Ignition Coil
B Starter Motor
C Alternator
D Brake / Kill Switch
E Starter Interlock Switch
F To Chassis Harness
G To Ground
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NOTES:
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RESIDENTIAL PRODUCTS
Form Number: 492-9231
42
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