Toro 20314, 20323, 20374, 20383 Service Manual

RESIDENTIAL PRODUCTS

WALK BEHIND MOWER

ENGINE SERVICE MANUAL

2012 and Prior LC1P65FA (159cc)

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

Chapter 1 – General Service Information

Chapter 2 - Engine Service / Maintenance

Chapter 3 - Engine Disassembly and Service

Chapter 4 - Electrical

NOTES:

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

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.

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

Engine Model / Serial Number Location

The engine model and serial number are stamped into the crankcase, near the fuel tank.

XXX-XXXX XXXXXXXXXXX

Item

Fastener Size

Torque

Specification

Cylinder Head Bolts

25 ft-lbs (34 Nm)

Connecting Rod Bolts

9.5 ft-lbs (13 Nm)

Flywheel Nut

M14

62.5 ft-lbs (85 Nm)

Valve Adjust Lock Nut

10 ft-lbs (14 Nm)

Pivot Arm Pivot Stud

22 ft-lbs (30 Nm)

Crankcase Cover Bolt

7.5 ft-lbs (10 Nm)

Muffler Nuts

7.5 ft-lbs (10 Nm)

Air Cleaner Nuts

6 ft-lbs (8 Nm)

Recoil (Fan Shroud) Nut

6 ft-lbs (8 Nm)

Oil Drain Bolt

M10

15.5 ft-lbs (21 Nm)

Fuel Tank Bolts / Nuts

7.5 ft-lbs (10 Nm)

Governor Arm Pinch Nut

7.5 ft-lbs (10 Nm)

Spark Plug

22 ft-lbs (30 Nm)

Ignition and Charge Coil Bolts

7.5 ft-lbs (10 Nm)

Electric Starter Motor Bolts

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

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)

－

NOTE: The only internal parts available for this engine are gaskets and seals.

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

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

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.

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.

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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Toro 20314, 20323, 20374, 20383 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual