Toro 20441, 20442, 20708, 20709, 20710 Service Manual
...
V-ENGINE SERVICE MANUAL
Table of Contents – Page 1 of 3
ABOUT THIS MANUAL
SAFETY INFORMATION
SPECIFICATIONS
ENGINE SPECIFICAT IONS
ENGINE FASTENER TORQUE REQUIREMENTS
CARBURETOR SPECIFICATIONS
SPECIAL TOOL REQUIREMENTS
SPECIAL TOOL REQUIREMENTS - REQUIRED SERVICE SUPPLIES
TORO 2-CYCLE V ENGINE TOOL REQUIREMENTS
TROUBLESHOOTING
ENGINE WILL NOT START WHEN "COLD"
ENGINE WILL START WHEN "COLD", BUT NOT WHEN "HOT"
ENGINE WILL NOT PRODUCE SPARK
ENGINE FLOODED WITH FUEL
ENGINE HAS LOW COMPRESSION
ENGINE LACKS POWER
ENGINE SURGES
ENGINE BACKFIRES
ENGINE OVERHEATS
ENGINE VIBRATES EXCESSIVELY
ENGINE CRANKSHAFT WILL NOT TURN
ENGINE PRODUCES MECHANICAL KNOCKING SOUND
ENGINE PRE-IGNIT ES
ENGINE SMOKES EXCE SSI VE L Y
ENGINE STALLS
SPARK PLUG FOULED
MAINTENANCE
RECOMMENDED MAINTENANCE SCHEDUL E
AIR FILTER - CLEANING
SPARK PLUG
SPARK PLUG GAP
SPARK PLUG TORQUE
EXHAUST SYSTEM - CLEANING
REASSEMBLING
PRIMER START CARBURET O R
TROUBLESHOOTING - ENGINE STARTS HARD
ENGINE RUNS RICH
ENGINE RUNS LEAN
FUEL LEAKS FROM CARBURETOR
INTRODUCTION - IDENTIFICATION
V-ENGINE SERVICE MANUAL
Table of Contents – Page 2 of 3
PRIMER START CARBURETOR - Continued
OPERATION
GOVERNOR
GOVERNOR ADJUSTMENT
SERVICING - PRELIMINARY CHECK
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
INSTALLATION
PRESETTING THE GOVERNOR
SERVICING THE AIR FILTER
FUEL SYSTEM
OPERATION - FUEL TANK
FUEL CAP
SERVICE - FUEL CAP
TANK REMOVAL
CLEANING
TANK INSTALLATION
FUEL STORAGE
IGNITION SYSTEM
TROUBLESHOOTING - PROCESS
SPARK PLUG - OPERATION
SERVICE
CD PACK - ADVANTAGES
OPERATION
AIR GAP ADJUSTMENT
REMOVAL/INSTALLATION
FLYWHEEL - OPERATION
REMOVAL
INSTALLATION
REWIND STARTER
OPERATION
RECOIL ASSEMBLY REPLAC EM ENT
STARTER ROPE REPLACEMENT
ENGINE
ADVANTAGES/DESCRIPTION
OPERATION
SERVICE TIPS - CYLINDER/CRANKCASE HALVES
OIL SEALS
CORE PLUGS
MUFFLER BAFFLE
V-ENGINE SERVICE MANUAL
Table of Contents – Page 3 of 3
ENGINE - Continued
MUFFLER PLATE SCREWS
EXHAUST PORTS
CARBURETOR GASKETS
REMOVAL
DISASSEMBLY
INSPECTION AND REPAIR
REED VALVE SERVICE
REASSEMBLY
REINSTALLING EXTERNAL COMPONENTS
PIVOTING ZONE START BRAKE SYSTEM
PIVOTING ZONE START BRAKE - INTRODUCTION
OPERATION
DISASSEMBLY
ASSEMBLY
APPENDIX
POWER HEAD - EXPLODED VIEW
IGNITION AND EXHAUST - EXPLOD ED VIEW
STARTER AND PRIMER START CARBURETOR - EXPLODED VIEW
PRIMER START CARBURETOR ASSEMBLY - EXPLODED VIEW
ABOUT
THIS
MANUAL
This manual was written expressly for the Tor0
made every effort to make the information in this manual complete and correct.
This manual was written with the service' technician in mind. The book is divided
into two sections, Quick Reference information (specifications, troubleshooting, etc.)
and servicing information (servicing procedures).
We hope you find this manual a valuable addition to your service shop.
any questions or comments regarding this manual, please contact us at the
following address:
V
Engine. The Tor0 Company has
If
you have
The Toro Company
Consumer Service Department
81
11
Lyndale Avenue South
MN
Bloomington,
The Tor0 Company reserves the right to change product specifications or this
manual without notice.
55420-1
196
Copyright(R)
All
1995
The Tor0 Company
Rights
Reserved
Safety Information
This safety symbol means WARNING or PERSONAL SAFETY
-
INSTRUCTION
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 engine
only. The Operator’s Manual will contain safety information on the complete product
powered by the Tor0
2-
instructions are available through:
The Tor0 Company
Publications Department
81
1
Lyndale Avenue South
Bloomington, MN
read the instruction because it has to do with your
Cycle V engine. Operator’s Manuals with complete
55420-1
196
U.S.A.
Avoid unexpected starting of the
engine
Always turn
disconnect the spark plug before attempting
cleaning, adjustment or repair.
Avoid lacerations and amputations
Stay clear of all moving parts when the
engine is running. Treat all normally
moving parts as if they were moving
whenever the engine is running or has the
potential to start.
Avoid burns
Do
or shortly after it has been running.
Avoid falls
Do
slippery surfaces or
questionable.
Avoid fires
Wipe up any spilled fuel or oil immediately.
Avoid asphyxiation
Never operate an engine in a confined area
without proper ventilation.
....
off
the powered product and
...
...
not touch the engine while it is running
...
not operate the powered product on
if
footing is
...
...
Avoid spilling fuel and never smoke while
working with any type of fuel.
Avoid accidental misuse of fuel.
Always store fuel in a properly labeled
container designed for gasoline.
Avoid injury due to inferior parts
Use only TOR0 original parts to ensure that
important safety criteria are met.
Avoid injury
Always clear the area of bystanders before
starting or testing powered 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 powered equipment.
Keep all safety shields in place
Avoid modifications
Never alter or modify any part unless it is a
factory approved procedure.
Avoid unsafe operation
Always test the safety systems after making
adjustments or repairs on the machine.
to
bystanders
...
...
..
...
...
...
Avoid fires and explosions
Use a container designed for gasoline.
...
QUICK REFERENCE SECTION
Specifications
Special Tool Requirements.
Troubleshooting
Maintenance
..............................................
............................................
...............................................
SERVICE SECTION
Primer Start Carburetor.
Fuel system
...............................................
...................................
......................................
Ignition System
Rewind Starter.
Engine
Pivoting Zone Start Brake.
Appendix
....................................................
..................................................
.............................................
.............................................
~~
....................................
I
~~
Reference Section
1-1
Engine Specifications. 19
Engine Fastener Torque Requirements 1-4
Carburetor Specifications 1-4
1-2
Reference Section
Engine Specifications
I
I
Reference Section
1
-3
Bolt, Blade
Nut, Flywheel
Screw, Air vane
Screw, Carburetor mounting
81.6 N-m)
Screw, CD ignition pack
Screw, Cylinder to crankcase
Screws, Engine mounting
Screw, Ground strap stop
Screw, Muffler cover
Screw, Muffler plate
Screw, Reed*
Screw, Shroud
*Use thread-locking compound
See page
2.2
~-
Carburetor Specifications
90
110
in
lbs (10-12 N-m)
105
I
115
in
lbs
(.I2
350-400 in Ibs
15
25
in Ibs (1.7 2.8
150
190
140 200 in
10
13 in Ibs(1.1-1.5
65 75 in
20
25 in Ibs (2.3 2.8 N-m)
(39
in Ibs (I7 22 Nom)-.
Ibs
(16
Ibs
(7,3 -8.4 N-m)
I3
N-m
45 N-m)
N-m)
22 N-m)
N-m)
1-4
Reference Section
QUICK REFERENCE SECTION
Specifications
Special
Troubleshooting
Maintenance
Tool
Requirements.
SERVICE SECTION
Primer Start Carburetor.
Fuel system
Ignition System
2
Rewind Starter.
Engine
Pivoting Zone Start Brake.
Appendix
Reference
Section
2-1
REQUIRED SERVICE SUPPLIES
2-2
Reference
Section
QUICK REFERENCE SECTION
Specifications
Special
Troubleshooting
Maintenance
Tool
Requirements.
SERVICE SECTION
Primer Start Carburetor.
Fuel system
Ignition System
3
Rewind Starter.
Engine
Pivoting Zone Start Brake.
Appendix
Reference Section
3-1
ENGINE WILL NOT START WHEN “COLD”
3-3
ENGINE WILL START WHEN “COLD”, BUT NOT WHEN “HOT”
ENGINE WILL NOT PRODUCE SPARK.
ENGINE BACKFIRES
ENGINE OVERHEATS.
ENGINE VIBRATES EXCESSIVELY.
ENGINE CRANKSHAFT WILL NOT TURN..
SPARK PLUG FOULED.
3-3
3-3
3-5
3-5
3-5
3-5
3-7
3-2
Reference Section
ENGINE WILL NOT START WHEN “COLD”
Remedies
Fill with
Drain and flush tank and float bowl,
clean fresh unleaded, properly mixed fuel
Clean and backflush fuel tank. Replace fuel tank
necessary
Wash and re-oil air cleaner element
clean, fresh,
properly mixed, unleaded fuel
fill
tank with
if
Replace
See “ENGINE WILL NOT PRODUCE
Check for loose blade
Check
See “ENGINEHAS LOW COMPRESSION table
See “ENGINE
the spark
plug
FLOODED”
WITH FUEL” table
SPARK
table
ENGINE WILL START WHEN “COLD”, BUT NOT WHEN “HOT”
I
See ‘ENGINE-FLOODED WITH FUEL” table
10%
fuel Use no more than
See: ENGINE OVERHEATS table
Clean bowl vent
ethanol blend
Reference Section
3-3
ENGINE FLOODED WITH FUEL
Remedies
Let unit sit, retry, or, remove spark plug, pull rope
several times.. Reinstall plug. Try again.
Adjust
Wash and re-oil cleaner element
throttle
cable
Replace spark
Clean carburetor, replace failed parts
Clean
Clean
ENGINE HAS LOW COMPRESSION
plug
Dirty plugged main fuel and/or
air bleed circuits
3-4
Remedies
Clean main fuel circuit and all air bleed circuits
Check sealing surfaces, oil
plugs
Check filters and fuel line
Reference Section
Reference Section
3-5
ENGINE PRODUCES MECHANICAL KNOCKING SOUND
Remedies
Inspect and tighten blade bolt to correct torque
Inspect and tighten flwheel nut to correct torque
See
Inspect and repair and tighten-nuts to correct torque
Tighten bolts
ENGINE SMOKES EXCESSIVELY
“ENG!NE
PRE-IGNITES’ table
ENGINE STALLS
3-6
Remedies
Refill with fresh fuel-of the correct mixture
Unload engine and-restart
See “SPARK PLUG FOULED- table
Replace fuel cap
Inspect and repair to remove unwanted ground
Clear vent of obstruction
Clear debris from fins or cause of overheating
Refill-with fresh, and
Reference Section
properly
mixed, fuel
SPARK
PLUG
FOULED
possible
Incorrect spark plug
Carburetor running too rich
Clogged air cleaner element
Weakignition
Worn rings and/or cylinder
Use of leaded fuel
Fuel/oil mixture too rich
Wrong oil
Causes
~-
syslem
Use correct spark plug
Clean-!rebuild carburetor
or
Clean and re-oil element
Replace CD ignition pack
Rebuild engine or
Drain fuel tank and replace with fresh, unleaded
regular fuel, having the correct oil mixture
Drain fuel tank and
(32:
1
)
Use Tor0 2-Cycle, or
short block
fill
NMMA
replace
with fuel of correct mixture
certified ashless oil
Reference Section
3-7
QUICK REFERENCE SECTION
Specifications
Special Tool Requirements.
Troubleshooting
Maintenance
SERVICE SECTION
Primer Start Carburetor.
Fuel system
Ignition System
Rewind Starter.
Engine
e
Pivoting Zone Start Brake.
Appendix
Reference Section
4-1
AIR
FILTER
Cleaning
4-3
4-3
Spark
Exhaust system
Plug
Spark Plug Gap
Spark Plug Torque
Cleaning
Reassembling 4-7
4-4
4-5
4-5
4-5
4-5
4-2
Reference Section
RECOMMENDED MAINTENANCE SCHEDULE
25
50
100
Hours
Hours
Hours
item
Fasteners
Air filter
Spark plug
Housing
Self-propelled
Mechanism
Blade
Blade brake
Lubrication
Exhaust
Fuel system
Cooling system
ports
Comments
Check blade and engine mounting fasteners frequently.
Keep all nuts, bolts tight
25
Remove, and clean each mowing season or every
more frequently
if
operating conditions-
are
dusty.
necessary
Remove buildup- of grass clippings and-dlrt
Clean grass clippings and debris under drive belt and drive
belt cover
Sharpen or replace; maintain more frequently
~-
dulled quickly in rough. or sandy conditions
50
Check stopping time every
hours or at the start of each
mowing season. The blade must stop within
releasing the bail;
if
not, repair
or-replace
if
3
seconds of
Grease rear height adjuster brackets (self-propelled models
only)
Clean every
50
hours or at least once each mowing season
Check for leakage and/or deterioration of fuel hose; replace
necessary
Clean grass clippings, debris or dirt that clog the engine air
cooling fins;
do more often under dirty or high chaff
conditions.
hours:
edge is
if
FILTER
COVER
Reference Section
751.2.51
AIR
FILTER
Cleaning
Once every season, or every
filter housing and element.
under dusty conditions.
NOTES:
filter in place. Doing
cause excessive engine wear.
To
swing the cover to the side and unhook. Remove
the cover and air filter.
Do
not operate the engine without the air
so
remove the air filter, snap the cover latch open,
25
hours, clean the air
Do
so
more frequently
may damage the engine
or
4-3
AIR
FILTER
Cleaning (cont'd)
2.
Wash the air filter in dish or laundry
detergent. Squeeze the filter to remove
excess liquid and blot dry with a clean
paper towel or rag.
out the element
3.
Apply one tablespoon of SAE 1OW30, or
similar, oil to the air filter. Lightly squeeze
the filter until the oil is distributed evenly
throughout the filter. Blot lightly with a
clean paper towel or rag to remove excess
oil.
Reinstall the filter with the cleanest side
facing the carburetor.
NOTE:
in the air box and is not puckered (allowing
direct passage of air and dirt to carburetor).
(cont'd
NOTE:
or
damage
Be sure the filter is properly seated
Do
not wring
may
occur.
751.2.5130.801
Spark
Plug
A
spark plug that is dirty, pitted, carbon covered,
or has worn electrodes, may cause hard starting
and poor operation.
Clean or replace the spark plug once a season
25
or every
PLUG TYPE: Champion RJ12C
Remove the spark plug and clean
brush, removing carbon build up.
SANDBLAST.
damaged or worn electrodes. Replace if
necessary.
hours, whichever occurs first.
it
with a wire
DO
NOT
Check the plug for cracks,
Reference Section
751.2.5130.803
Spark Plug Gap
Set the spark plug gap to
Install the spark plug finger tight, then torque to 180
in Ibs (15
gasket are seated.
ft.
Ibs.) (20 Nm), or 1/4 turn after plug and
.035"
(.85mm).
Spark Plug Torque
0490
751.1
A4
WARNING: Disconnect the spark plug wire to
prevent accidentally starting the engine.
TOOLS
1.
REQUIRED:
1/2" drive
5/8"
socket
3/8"
(9mm) wooden dowel
Wearing heavy duty gloves hold the blade
while removing the bolt. Using the 1/2" drive
and
5/8"
secures the accelerator, blade and blade
retainer. Remove the accelerator, blade
and blade retainer.
Reference Section
Exhaust
socket, remove the blade bolt that
System
Cleaning
4-5
Exhaust
System
(cont'd)
Cleaning
2.
3.
(cont'd)
The small louvers in the muffler cover must
be open and free of debris. Clean if
necessary.
To remove the muffler cover, remove the
three bolts. Drop the cover down to inspect
the condition of the exhaust ports, etc.
4.
4-6
Pull the starter rope until the piston covers
the exhaust ports, this prevents carbon
from falling into the cylinder. Clean exhaust
3/8"
port area with the
dowel.
NOTE: Do not scratch the piston or allow
carbon to fall into the cylinder.
(9mm) wooden
Reference Section
751.1.0490.79
Reassembling
Insert the three bolts into the muffler cover 1.
and torque to 150-1
90
in Ibs (17-22 Nm).
751.1.O490.72
2. Check the condition
If
OK,
re-install the blade retainer.
3.
Re-install the blade and accelerator with the
7/16 20 blade bolt. Torque the bolt to 50
Ibs (68 Nm)
of
the key and keyway.
ft
Reference Section
4-7
QUICK REFERENCE SECTION
Specifications
Special
Troubleshooting
Maintenance
Tool
Requirements.
SERVICE SECTION
Primer Start Carburetor.
Fuel system
Ignition System
Rewind Starter.
Engine
Pivoting Zone Start Brake.
Appendix
Service
Section
5-1
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