Toro 31411, 31405, 31500, 31412, 31501 Service Manual

...

SINGLE STAGE SNOWTHROWER SERVICE MANUAL

Table Of Contents – Page 1 of 2

ENGINE APPLICATIONS

GENERAL INFORMATION GENERAL SAFETY INSTRUCTIONS IDENTIFICATION AND ORDERING MIXING INSTRUCTIONS FOR GASOLINE AND OIL PROPER FUEL AND OIL OFF SEASON STORAGE

CONTROLS/LOCATION AND OPERATION PRIMER CHOKE ON/OFF IGNITION SWITCH CHECKING THE IGNITION SWITCH VANE CONTROL - SNOW PUP - SNOWMASTER S-200 - S-620 CHUTE CONTROL CHUTE ROTATION AND DETENT SYSTEMS

ENGINE REMOVAL AND INSTALLAT I ON 1965 - 1985 MODELS, ENGINE REMOVAL 1965 - 1985 MODELS, ENGINE INSTALLATION POWERLITE, ENGINE REMOVAL POWERLITE, ENGINE INSTALLATION 20” CCR, ALL MODELS, ENGINE REMOVAL 20” CCR, ALL MODELS, ENGINE ASSEMBLY DRIVE SYSTEMS DRIVE SYSTEM (BELT) SNOWMASTER - S-200, S-620 BELT REPLACEMENT BELT/PULLEY ALIGNMENT ADJUSTING PULLEY ALIGNMENT ENGINE PULLEY REPLACEMENT ROTOR PULLEY REPLACEMENT IDLER ARM / IDLER PULLEY REPLACEMENT ASSEMBLY 20” CCR STYLE IDLER ARM CCR2000 IDLER ARM REMOVAL ROTOR BEARING/ ROTOR SHAFT REPLACEMENT DRIVE SYSTEM (CHAIN) SNOW PUP - S-140

ELECTRIC START SYSTEM INTRODUCTION CCR POWERLITE STARTER REMOVAL CCR 1000/TECUMSEH HSK 635 STARTER REMOVAL 20” CCR/R TEK STARTER REMOVAL SNOWMASTER 20”, 5200 – 5620/ TECUMSEH AH520 STARTER REMOVAL STARTER SWITCH WITH RECTIFIER TROUBLESHOOTING TROUBLESHOOTING CHECKING THE STARTER SWITCH STARTER SWITCH INSPECTION

SINGLE STAGE SNOWTHROWER SERVICE MANUAL

Table Of Contents – Page 2 of 2

MAINTENANCE WHEEL BRACKET REPLACEMENT (1975 AND OLDER MODELS) SCRAPER REPLACEMENT PADDLE REPLACEMENT - STRAIGHT PADDLE REPLACING ROTOR BLADES (CURVED ROTOR MODELS) VANE REPLACEMENT VANE CONTROL SERVICING ON 14” AND 21” SNOWTHROWERS FROM 1965-1967 VANE CONTROL SERVICING VANE CONTROL SERVICING: ALL 16” POWERLITE AND 20” SINGLE STAGE SNOWTHROWERS

TROUBLESHOOTING TROUBLESHOOTING TIPS - FAILURE TO START OLD FUEL SPARK PLUGS THE ENGINE RUNS BUT IT DOES NOT THROW SNOW

GAS POWER SHOVEL GENERAL INSTRUCTIONS PERSONAL SAFETY BEFORE OPERATING WHILE OPERATING MAINTENANCE AND STORAGE IDENTIFICATION AND ORDERING MIXING INSTRUCTIONS FOR GASOLINE AND OIL CONTROLS — LOCATION AND OPERATION PRIMER OPERATION CHOKE OPERATION TESTING THE SWITCH ENGINE OPERATING THEORY CARBURETOR ADJUSTMENT CARBURETOR SERVICE CARBURETOR ASSEMBLY ENGINE SERVICE CHECKING FOR SPARK COMPRESSION TEST ENGINE REMOVAL ENGINE SHORT BLOCK FLYWHEEL REMOVAL IGNITION TIMING/GOVERNOR DECARBONING THE EXHAUST PORT AND THE MUFFLER RECOIL STARTER SERVICING DRIVE SYSTEM REMOVING ROTOR REPLACE SCRAPER STORAGE MAINTENANCE RECORD

TORO

Single Stage

Snowthrower

Service Manual

PREFACE

ABOUT THIS MANUAL

This manual was written expressly for the Toro brand single stage snowthrowers. The Toro Company has made every effort to make the information in this manual complete and correct.

This manual was written with the assumption that the reader has basic mechanical and electrical knowledge and skills. The book contains material covering snowthrowers built by The Toro Company from 1965 through 2000, and will be specified for use on machines built after 2000 that are similar in design.

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 – 2000

Bloomington, MN 55420 – U.S.A.

TABLE OF CONTENTS

This book covers a variety of models built over several years. Look in the following Table Of Contents for the portion of the machine that you wish to work on. Within that section we will cover each of the systems used.

ENGINE APPLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

GENERAL INFORMATION

General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1

Identification And Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2

Mixing Instructions For Gasoline And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3

Proper Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3

Off Season Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5

CONTROLS/LOCATION AND OPERATION

Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3

On/off Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3

Checking The Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4

Vane Control - Snow Pup - Snowmaster S-200 - S-620 . . . . . . . . . . . . . . . . . . . . . .3 - 5

Chute Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5

Chute Rotation And Detent Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6

ENGINE REMOVAL AND INSTALLATION

1965 - 1985 Models, Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

1965 - 1985 Models, Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3

Powerlite, Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5

Powerlite, Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7

20” CCR, All Models, Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7

20” CCR, All Models, Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9

Single Stage Snowthrower Service Manual i

TABLE OF CONTENTS

DRIVE SYSTEMS

Drive System (Belt) Snowmaster - S-200, S-620 . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1

Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 14

Belt/Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 15

Adjusting Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 15

Engine Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 15

Rotor Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 16

Idler Arm / Idler Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 17

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 17

20” CCR Style Idler Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 17

CCR2000 Idler Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 17

Rotor Bearing/ Rotor Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 18

Drive System (Chain) Snow Pup - S-140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 19

ELECTRIC START SYSTEM

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1

CCR Powerlite Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1

CCR 1000/Tecumseh HSK 635 Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2

20” CCR/R Tek Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4

Snowmaster 20”, 5200 – 5620/ Tecumseh AH520 Starter Removal . . . . . . . . . . . . .6 - 6

Starter Switch With Rectifier Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 9

Checking The Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 10

Starter Switch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 10

ii Single Stage Snowthrower Service Manual

TABLE OF CONTENTS

MAINTENANCE

Wheel Bracket Replacement (1975 And Older Models) . . . . . . . . . . . . . . . . . . . . . .7 - 1

Scraper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1

Paddle Replacement - Straight Paddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 2

Replacing Rotor Blades (Curved Rotor Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 4

Vane Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6

Vane Control Servicing On 14” And 21” Snowthrowers From 1965-1967 . . . . . . . . .7 - 7

Vane Control Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 7

Vane Control Servicing: All 16” Powerlite And 20” Single Stage Snowthrowers . . . .7 - 8

TROUBLESHOOTING

Troubleshooting Tips - Failure To Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 1

Old Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 1

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 3

The Engine Runs But It Does Not Throw Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 3

GAS POWER SHOVEL

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 1

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 1

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 1

While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 1

Maintenance And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 2

Identification And Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 2

Mixing Instructions For Gasoline And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 3

Controls — Location And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 5

Single Stage Snowthrower Service Manual iii

TABLE OF CONTENTS

Primer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 6

Choke Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 6

Testing The Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 6

Engine Operating Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 7

Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 9

Carburetor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 10

Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 12

Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 14

Checking For Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 15

Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 16

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 16

Engine Short Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 17

Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 19

Ignition Timing/Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 19

Decarboning The Exhaust Port And The Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 20

Recoil Starter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 20

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 21

Removing Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 22

Replace Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 23

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 23

Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 28

iv Single Stage Snowthrower Service Manual

TABLE OF CONTENTS

ENGINES

Several different engines have been used on the single stage snowthrower product line. Refer to the chart beginning on page 1 - 1 to determine the engine manufacturer. Engine manuals may be obtained from the following sources.

Tecumseh Products Co. 900 North St. Grafton, WI 53024

Tecumseh Engine Models:

• AH520, AH600, HSK600

Toro Engines: Order the following service manuals through any Authorized Toro Service Dealer:

• Model 38350 Gas Power Shovel (the engine is covered in this book).

• Toro 47P series - Use Toro manual 492-0260.

• Toro R tek (E engine) series - Use Toro manual 492-0647.

Single Stage Snowthrower Service Manual v

THIS PAGE INTENTIONALLY LEFT BLANK

vi Single Stage Snowthrower Service Manual

ENGINE APPLICATIONS

Model # Model Name Width Years of Mfg Eng Mfg Eng Model Mix Ratio Max RPM Spark Plug * Gap (in.)

31405 Snow Pup 14” 1976-1977 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

31410 Snow Pup 14" 1966-1967 Tec. AH520 16:1 4300-4700 Champion

RJ18YC

31411 Snow Pup 14" 1968-1971 Tec. AH520 16:1 4100-4500 Champion

RJ18YC

31412 Snow Pup 14" 1972-1975 Tec. AH520 16:1 4300-4700 Champion

RJ18YC

31500 Snow Husky 21" 1966-1967 Tec. AH520 16:1 4300-4700 Champion

RJ18YC

31501 Snow Pup 21” 1968-1971 Tec. AH520 16:1 4300-4700 Champion

RJ18YC

31502 Snow Pup 21" 1972-1974 Tec. AH520 16:1 4300-4700 Champion

RJ18YC

31505 Snowmaster 20" 1975 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

31506 Snowmaster 20" 1976-1977 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

38014 Snowmaster 14” 1978 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

38020 Snowmaster 20" 1978 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

38030 Snowmaster 20" 1978 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

38100 S140 14" 1979-1981 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

38110C CR20 20" 1987-1990 Tec. AH600 32:1 4300-4500 Champion

RCJ8Y

38111C CR20 20" 1987 Tec. AH600 32:1 4300-4500 Champion

RCJ8Y

38115C CR20 20" 1987-1990 Tec. AH600 32:1 4300-4700 Champion

RCJ8Y

38116 CR20 20" 1988-1989 Tec. AH600 32:1 4300-4700 Champion

RCJ8Y

38116C CR20 20" 1987 Tec. AH600 32:1 4300-4700 Champion

RCJ8Y

38120 S200 20" 1979-1984 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

38130 S200 20" 1979-1981 Tec. AH520 32:1 4100-4500 Champion

RJ18YC

38162 S620 20" 1984-1991 Tec. AH600 32:1 4300-4700 Champion

RCJ8Y

38162C S620 20" 1984-1986 Tec. AH600 32:1 4300-4700 Champion

RCJ8Y

38165 S620 20" 1985-1991 Tec. AH600 32:1 4300-4700 Champion

RCJ8Y

38165C S620 20" 1986 Tec. AH600 32:1 4300-4700 Champion

RCJ8Y

38167C S620 20" 1986 Tec. AH600 32:1 4300-4700 Champion

RCJ8Y

38170 Powerlite 16" 1991-2000 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y

38171 Powerlite 16" 1992-1998 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y

38172 Powerlite 16" 2000 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y

.035

.030

.035

.030

Single Stage Snowthrower Service Manual 1 - 1

ENGINE APPLICATIONS

Model # Model Name Width Years of Mfg Eng Mfg Eng Model Mix Ratio Max RPM Spark Plug * Gap (in.)

38173 Powerlite 16" 2000 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y

38175 Powerlite 16" 1991-1999 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y

38176 Powerlite 16" 1992-1998 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y

38177 Powerlite 16" 1999 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y

38178 Powerlite 16" 1999 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y 38180 CCR2000 20" 1986-1996 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38180C CCR2000 20" 1987-1989 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38181 CCR2000 20" 1990-1996 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38182 Powerlite 16" 2000 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y 38183 Powerlite 16" 2000 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y 38185 CCR2000 20" 1987-1996 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38185C CCR2000 20" 1988-1998 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38186 CCR2000 20" 1990-1996 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38190 CCR1000 20" 1990-1996 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y 38191 CCR1000 20" 1992-1996 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y 38195 CCR1000 20" 1990-1996 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y 38196 CCR1000 20" 1992-1996 Tec. HSK600 50:1 4300-4700 Champion

RCJ8Y 38210 S140 14" 1979-1980 Tec. AH520 32:1 4100-4500 Champion

RJ18YC 38220 S200 20" 1979 Tec. AH520 32:1 4100-4500 Champion

RJ18YC 38225 S200 20" 1980 Tec. AH520 32:1 4100-4500 Champion

RJ18YC 38230 S200 20" 1979 Tec. AH520 32:1 4100-4500 Champion

RJ18YC 38232 S200 20" 1981-1985 Tec. AH520 32:1 4100-4500 Champion

RJ18YC 38235 S200 20" 1980-1983 Tec. AH520 32:1 4100-4500 Champion

RJ18YC 38242 S200 20" 1981-1983 Tec. AH520 32:1 4100-4500 Champion

RJ18YC 38252 S200 20" 1981 Tec. AH520 32:1 4100-4500 Champion

RJ18YC 38350 Gas Power Shovel 14" 1983-1985 Toro NA 32:1 7800-8800 Champion

RCJ8 38400 CCR1000 20" 1999-2000 Tec. HSK635 50:1 4300-4700 Champion

RCJ8Y 38405 CCR1000 20" 1999-2000 Tec. HSK635 50:1 4300-4700 Champion

RCJ8Y 38409 CCR2400 20" 1998-1999 Toro R tek 50:1 3450-3950 NGK BPMR4A .032 38410 CCR2400 20" 1997 Tec. HSK850 50:1 3550-3850 Champion

RCJ8Y 38411 CCR2400 20" 1997 Tec. HSK850 50:1 3550-3850 Champion

RCJ8Y 38412 CCR2400 20" 1998-1999 Toro R tek 50:1 3450-3950 NGK BPMR4A .032

.030

.035

.022

.030

1 - 2 Single Stage Snowthrower Service Manual

ENGINE APPLICATIONS

Model # Model Name Width Years of Mfg Eng Mfg Eng Model Mix Ratio Max RPM Spark Plug * Gap (in.)

38413 CCR2450 20" 2000 Toro R tek 50:1 3550-4050 NGK BPMR4A .032 38414 CCR2400 20" 1998-1999 Toro R tek 50:1 3450-3950 NGK BPMR4A .032 38415 CCR2400 20" 1997 Tec. HSK850 50:1 3550-3850 Champion

RCJ8Y

38416 CCR2400 20" 1997 Tec. HSK850 50:1 3550-3850 Champion

RCJ8Y 38417 CCR2400 20" 1998 Toro R tek 50:1 3450-3950 NGK BPMR4A .032 38418 CCR2400 20" 1999 Toro R tek 50:1 3450-3950 NGK BPMR4A .032 38419 CCR2450 20" 2000 Toro R tek 50:1 3550-4050 NGK BPMR4A .032 38420 CCR2500 20" 1997 Tec. HSK850 50:1 3550-3850 Champion

RCJ8Y 38421 CCR2500 20" 1997 Tec. HSK850 50:1 3550-3850 Champion

RCJ8Y 38422 CCR2500 20" 1998-1999 Toro R tek 50:1 3550-4050 NGK BPMR4A .032 38423 CCR2500 20" 1998 Toro R tek 50:1 3550-4050 NGK BPMR4A .032 38424 CCR2500 20" 1998-1999 Toro R tek 50:1 3550-4050 NGK BPMR4A .032 38425 CCR2500 20" 1997 Tec. HSK850 50:1 3550-3850 Champion

RCJ8Y 38426 CCR2500 20" 1997 Tec. HSK850 50:1 3550-3850 Champion

RCJ8Y 38427 CCR2500 20" 1998 Toro R tek 50:1 3550-4050 NGK BPMR4A .032 38428 CCR2450 20" 2000 Toro R tek 50:1 3550-4050 NGK BPMR4A .032 38429 CCR2450 20" 2000 Toro R tek 50:1 3550-4050 NGK BPMR4A .032 38430 CCR3000 20" 1997-1999 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38431 CCR3000 20" 1997-1998 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38432 CCR3000 20" 1999 Toro R tek 50:1 3650-4150 NGK BPMR4A .032 38433 CCR3000 20" 1999 Toro R tek 50:1 3650-4150 NGK BPMR4A .032 38435 CCR3000 20" 1997-1999 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38436 CCR3000 20" 1997-1998 Toro 47P** 50:1 3550-3850 NGK BPMR4A .032 38437 CCR3000 20" 1999 Toro R tek 50:1 3650-4150 NGK BPMR4A .032 38438 CCR3000 20" 1999 Toro R tek 50:1 3650-4150 NGK BPMR4A .032 38439 CCR3600 20" 2000 Toro R tek 50:1 3650-4150 NGK BPMR4A .032 38440 CCR3650 20" 2000 Toro R tek 50:1 3750-4250 NGK BPMR4A .032 38441 CCR3650 20" 2000 Toro R tek 50:1 3750-4250 NGK BPMR4A .032 38442 CCR3650 20" 2000 Toro R tek 50:1 3750-4250 NGK BPMR4A .032 38445 CCR3650 20" 2000 Toro R tek 50:1 3750-4250 NGK BPMR4A .032

.030

* RJ18YC replaces RJ18Y

Single Stage Snowthrower Service Manual 1 - 3

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1 - 4 Single Stage Snowthrower Service Manual

GENERAL INFORMATION

GENERAL SAFETY INSTRUCTIONS

This safety alert symbol means CAUTION

- PERSONAL SAFETY INSTRUCTION.

Read the instruction because it has to do with safety. Failure to comply with the instruction may result in personal injury.

Personal Safety

• Never allow children to operate the snowthrower. Adults should operate the snowthrower only after reading the owner’s manual and receiving proper instructions.

• Keep everyone, especially children and pets, away from the area of operation.

• Wear adequate winter clothing and footwear that will improve footing on slippery surfaces.

Before Operating

• Familiarize yourself with the controls. Know how to stop the engine and disengage controls quickly.

• Since fuel is highly flammable, handle it with care. Fill the fuel tank with a mixture of gasoline and oil before trying to start the engine.

• Use an approved fuel container for storing the gasoline/oil mixture. Store fuel outside unless it is stored in a fireproof cabinet.

• Fill fuel tank outdoors, not indoors. The fuel tank must not be filled when engine is running or when engine is hot.

• Install the gasoline container cap, fuel tank cap, and wipe up any spilled gasoline before starting the engine.

• Keep all shields and safety devices in place. If a shield or safety device is defective, make all repairs before operating the snowthrower. Also tighten all nuts, bolts, and screws.

During Operation

• Keep face, hands, feet, and other parts of your body or clothing away from concealed, moving, or rotating parts. Stay behind the handle while operating the snowthrower. STAY CLEAR OF DISCHARGE OPENING AT ALL TIMES.

• Do not attempt to make adjustments while engine is running.

• Use extreme caution when clearing snow from walk, road, or a gravel drive. Push down on the handle to raise skid and impeller blades to avoid picking up rocks and throwing them. Stay alert for hidden hazards and traffic on roads.

• Never direct discharge of the snowthrower at bystanders, glass enclosures, automobiles, trucks, and window wells. Keep children and pets away.

• If a solid object is hit or if the snowthrower vibrates abnormally, turn key to OFF so engine stops. Next, remove high tension wire from the spark plug; then check snowthrower for possible damage, an obstruction, or loose parts. Repair damage before starting and operating the snowthrower.

• Before adjusting, cleaning, repairing, or inspecting the snowthrower, and before unclogging the discharge guide, shut engine off and wait for all moving parts to stop. Next remove high tension wire from spark plug, and keep wire away from plug to prevent accidental starting.

• Use caution when operating snowthrower as the exhaust pipe is hot and could cause personal injury or damage to clothing.

Electric Start Safety Precautions

• Use the extension cord provided with the Electric Start (P.N. 28-9170) or any 16 gauge 2 or 3 wire cord.

• Do not plug the extension cord into the outlet while standing in water or when hands are wet.

• Do not use or connect the cord if gasoline has been spilled on it.

• Never operate the snowthrower without good visibility or light. Always maintain a secure footing and keep a firm grip on the handle when clearing snow: WALK, NEVER RUN. DO NOT USE SNOWTHROWER ON A ROOF.

• Do not run the engine indoors.

Single Stage Snowthrower Service Manual 2 - 1

• Always replace a damaged extension cord immediately.

• Authorized Toro Service Dealers are certified for electrical repairs and electrical servicing. Do not attempt to repair 110V products.

GENERAL INFORMATION

Storage During Snow Season

• When storing the snowthrower, REMOVE THE KEY FROM SWITCH. Store the key in a memorable place.

• Never leave gasoline in a snowthrower fuel tank when snowthrower is stored in a building where a flame or spark may be present. Allow the engine to cool before storing. Never store a snowthrower in the house or basement because of potential fire hazard.

• Before performing any maintenance or servicing to the snowthrower, turn key to OFF and wait for engine and all moving parts to stop. Remove the key switch and pull high tension wire from spark plug.

• Reinstall the fuel cap when the top cover is removed for maintenance procedures. Perform maintenance and use storage instructions described in this manual.

• Keep all nuts, bolts, and screws tight to assure snowthrower is in safe working condition. Be sure to check the rotor and the engine mounting bolts.

• ALWAYS USE TORO REPLACEMENT PARTS AND ACCESSORIES TO ASSURE SAFETY AND OPTIMUM PERFORMANCE. NEVER USE “WILL-FIT” REPLACEMENT PARTS AND ACCESSORIES.

14” and 21” Models

Figure 1 0217-001

Location: Right side of the square tubing on the main frame. Shroud will need removal to read.

20” Models

Figure 2 0217-002

Location: Right side of the impeller housing just ahead of the right wheel.

IDENTIFICATION AND ORDERING

IDENTIFICATION: All Toro Products, including single stage

snowthrowers, have two identification numbers: a model number and serial number. In any correspondence concerning your snowthrower, always supply the model and serial number, to assure the correct information or replacement parts are obtained. The two numbers are stamped on a decal, which are located in various places on the snowthrowers. The location will vary depending on the model and year the unit was manufactured. Please note the diagrams to determine the location of the model and serial number decal on your unit (Figure 1 through Figure 3).

Figure 3 0530-01

(A) Model and Serial Number Decal

2 - 2 Single Stage Snowthrower Service Manual

GENERAL INFORMATION

ORDERING: Toro parts are available through your

local Authorized Toro Service Dealer. NOTE: To find the nearest Authorized Toro Service

Dealer in your area, please consult your yellow pages under “lawn mowers” or “snowthrowers”.

Parts: To order replacement parts from an authorized TORO Dealer, the following information is needed:

1. Model and serial number of the snowthrower.

2. Description of the part(s) and quantity of part(s) desired. If a parts manual is being used, use the PART NUMBER and the description.

Manuals: Should a replacement owner’s manual or parts manual be needed, please send the complete model and serial number along with your name and address to:

The Toro Company 8111 Lyndale Avenue South Minneapolis, MN 55420 ATTN: Parts Department

MIXING INSTRUCTIONS FOR GASOLINE AND OIL

Safety Instructions

CAUTION

Gasoline is flammable and caution must be used when handling or storing it. Do not fill the fuel tank while snowthrower is running, while it is hot, or when it is in an enclosed area. Keep away from an open flame, an electrical spark, and DO NOT SMOKE while mixing fuel or filling the fuel tank. Fill the fuel tank to within 1/4 - 1/2 inch from top of the tank to provide space for expansion of fuel. Never fill the fuel tank to the top of filler neck. Always fill the fuel tank outdoors and use a funnel or spout to prevent spilling. Make sure to wipe up any spilled fuel before starting the engine.

Store gasoline in a clean, approved container, and keep the cap in place on the container. Keep gasoline in a cool, well ventilated place; never in the house. Never buy more than a 30 day supply of gasoline to assure volatility. Gasoline is intended to be used as a fuel for internal combustion engines; therefore, do not use gasoline for any other purpose. Since many children like the smell of gasoline, keep it out of their reach because the fumes are dangerous to inhale, as well as being explosive.

PROPER FUEL AND OIL

Three basic engine configurations have been used in this product group. Due to internal differences, there are three different fuel/oil mix ratios. See the charts on page 2 - 4 and 2 - 5 for the proper ratio for your model.

Mixing Procedures

Use the following procedures to assure the fuel is properly mixed:

1. Add 1 quart of unleaded REGULAR gasoline to a gasoline container.

2. If your snowthrower requires a 16:1 gas to oil ratio; pour one cup or 8 ounces of Toro 2-cycle engine oil into the gasoline container (Figure 4).

Single Stage Snowthrower Service Manual 2 - 3

GENERAL INFORMATION

3. If your unit requires a gasoline/oil ratio of 32:1, pour 1/2 cup or 4 ounces of TORO 2-cycle engine oil into the gasoline container (Figure 5).

CAUTION

4. If your snowthrower requires a 50:1 gas to oil ratio; pour 2.6 oz. of Toro 2-cycle oil into the gasoline container (Figure 6).

5. Shake the gasoline container vigorously so oil mixes with gasoline. Remember to install cap on gasoline container before shaking.

6. Add an additional 3 quarts of gasoline to the premixed gasoline. Fuel mixture is now ready to

use in your snowthrower.

Mix With One U.S. Gallon

Ratio Oil

16:1 8 oz. 32:1 4 oz. 50:1 2.6 oz.

16:1 RATIO MIX

Do not store the oil near an open flame or in an extremely warm environment as the oil is flammable.

IMPORTANT: If the fuel and Toro 2-cycle oil are not mixed at the correct ratio for your snowthrower, (either 16:1, 32:1, or 50:1) piston damage and other engine damage may occur. It is important that the fuel and oil be mixed at temperatures above 40° F to ensure complete mixing.

Note: To assure the fuel and oil mixes completely,

store your Toro 2-cycle Oil indoors, so it will be at room temperature (above 50° F).

Filling The Fuel Tank

IMPORTANT: Do not fill the fuel tank with gasoline that has not been mixed with Toro 2-cycle engine oil in the correct ratio for your snowthrower. Do not use gasoline additives, engine damage could result.

OIL (1 CUP OR 8 OZ.) (0.236 l)

GAS (1 U.S. QUART (0.946 l)

GASOLINE CONTAINER

OIL (1/2 CUP OR 4 OZ.) (0.118 l)

GAS (1 U.S. QUART (0.946 l)

GASOLINE CONTAINER

SHAKE CAN

Figure 4

32:1 RATIO MIX

SHAKE CAN

Figure 5

ADD MORE GAS (3 U.S. QUARTS) (2.84 l)

GASOLINE CONTAINER

ADD MORE GAS (3 U.S. QUARTS) (2.84 l)

GASOLINE CONTAINER

2 - 4 Single Stage Snowthrower Service Manual

GENERAL INFORMATION

50:1 RATIO MIX

OIL (1/3 CUP OR 2.6 OZ.) (0.079 l)

GAS (1 U.S. QUART (0.946 l)

GASOLINE CONTAINER

Figure 6

1. Mix the gasoline and oil in the correct ratio for your unit. Refer to “MIXING INSTRUCTIONS FOR GASOLINE AND OIL” on page 2 - 3.

2. Clean the area around snowthrower fuel tank cap so foreign matter does not get into the fuel tank. Remove the cap from the fuel tank.

3. Fill snowthrower fuel tank to within 1/4 - 1/2 inch from the top of the tank, not the filler neck.

4. Install the cap securely on snowthrower fuel tank.

Draining The Fuel Tank

ADD MORE GAS

SHAKE CAN

GASOLINE CONTAINER

2. Use the primer and choke and start the engine. It should run several minutes to consume the fuel in the carburetor and fuel line. When the engine stops, attempt to start it again. Use the primer and choke. The engine may start and stop 2 or 3 times. Repeat until you cannot start the engine.

Note: Draining the fuel tank and letting the unit run out of fuel is a critical servicing procedure when preparing your snowthrower for storage. Expending fuel from the engine will prevent gum-like varnish deposits from forming in the carburetor, fuel line, and fuel tank. Such deposits, if allowed to form, will cause starting problems the following season.

(3 U.S. QUARTS) (2.84 l)

CAUTION

Because the gasoline/oil mixture in the snowthrower fuel tank is explosive, the fuel mixture must be drained outdoors, away from fire and flame. Do not smoke while draining gasoline.

To assure safe servicing of your snowthrower, it is critical that the fuel tank be drained. To drain the fuel tank on your snowthrower, use the following procedure:

1. Use a pump type siphon to remove as much fuel from the tank as possible. Dispose of fuel properly. One method of disposing of left over fuel is to put it in the car. If you have a half tank of fuel in the car, a gallon or two of fuel mix will blend with the gas and have no effect. If the fuel is extremely old and does not smell like gasoline, we would not recommend its use in any engine. Contact your local authorities for disposal instructions.

OFF SEASON STORAGE

CAUTION

Because gasoline/oil mixture in the snowthrower fuel tank is explosive, the fuel mixture must be drained outdoors, away from fire and flame. Do not smoke while draining gasoline. If fuel mixture explodes, personal injury may result.

Properly preparing the machine for off season storage is the single most important thing that can be done to prevent problems. The summer heat will rapidly evaporate fuel in the tank and carburetor. Dried fuel in the carburetor can and often does plug the fuel passages and prevent starting the following snow season. We recommend the use of a petroleum based fuel stabilizer during the snow season. The stabilizer will help keep fuel fresh and assist with starting.

Single Stage Snowthrower Service Manual 2 - 5

GENERAL INFORMATION

1. Use a pump type siphon to remove as much fuel from the tank as possible. Dispose of fuel properly. One method of disposing of left over fuel is to put it in the car. If you have a half tank of fuel in the car, a gallon or two of fuel mix will blend with the gas and have no affect. If the fuel is extremely old and does not smell like gasoline, we would not recommend its use in any engine. Contact your local authorities for disposal instructions.

3. With the key off, slowly pull the starter rope until resistance is felt, release the starter rope.

4. Tighten loose nuts and bolts.

5. On the 14” models with chain drive (Snow Pup), remove the chain guard and lightly oil the chain with 30 wt. engine oil. Install the chain guard.

6. Store the machine in a clean dry area, cover if you wish. (DO NOT store any gasoline powered machine in the house, basement, or near any appliance that contains fire or flame.)

7. Remove the key and place in a memorable place.

2 - 6 Single Stage Snowthrower Service Manual

CONTROLS/LOCATION AND OPERATION

The primer and choke controls have been located in different areas throughout the years. Figure 7, Figure 8, Figure 9, and show the various locations.

Figure 7 0217-004

Figure 9 1854-28

(A) Choke (B) Primer

The ignition switch has been located in the same position on the control panel since introduction of the 1975 Snowmaster (Figure 8). Prior to 1975, the unit’s engine was stopped by depressing the spark plug kill lever. This lever was located below a translucent boot on the upper shroud. The lever would ground the spark to frame of the snowthrower when depressed (Figure 10). Press and hold until the engine stops completely.

Figure 8 0217-005

(A) Primer (B) Choke

Figure 10 0217-006

Single Stage Snowthrower Service Manual 3 - 1

CONTROLS/LOCATION AND OPERATION

PRIMER

The primer, used on most single stage snowthrowers, is designed to pump a small amount of fuel from the carburetor into the carburetor throat. This extra fuel mixture allows the engine to be started in cold temperatures.

The primer is operated by depressing the primer bulb with a finger, ensuring the finger covers the vent hole in the bulb. Depress the primer button, release, wait about 3 seconds, then depress the primer again. Repeat as often as needed. The pause in between primes allows time for the prime well in the carburetor to refill.

Operator priming instructions vary depending on the year your snowthrower was manufactured. On those units manufactured from 1972 and before, in a cold start application, the primer should be pressed approximately 10 times (Figure 11). The 1973 through 1977 single stage snowthrower primer should be pressed 5 times. Snowthrowers produced from 1978 through 1980, the primer should be pushed one to four times (Figure 8, Figure 11, or Figure 12). For temperatures above +20° F (-7° C) use one or two primes; below +20° F (-7° C) use three or four primes. For extremely cold temperatures below -10° F (-23° C) use five or six primes. For 1981 and newer models, depress the primer one or two times, with a pause in between. Additional primes may be necessary in colder temperatures.

Note: On early production, the diaphragm cover was vented, and on later production, the primer bulb incorporates the vent. Those models with a vented diaphragm cover require more primes.

Years

Figure 11 0217-007

Figure 12 0217-008

PRIMING CHART

Number of times primer is depressed

1965-1972 10 1973- 1977 5

1978- 1980 1981 - Up

3 - 2 Single Stage Snowthrower Service Manual

1-4 1-2

CONTROLS/LOCATION AND OPERATION

CHOKE

The carburetor choke control, or shutter, meters the amount of air passing into the engine. When starting the engine, the carburetor choke should be closed (Figure 13). If your snowthrower has either the choke cable, choke rod, or handle design to close the choke shutter, the cable, rod, or handle should be pulled out. If you have a single stage snowthrower manufactured in 1980, the choke control should be rotated clockwise to close the shutter, counterclockwise to open the shutter.

Figure 14 0217-010

Figure 13 0217-009

Closing the choke shutter allows air to enter the carburetor only through openings in and around the choke shutter (Figure 14). When the engine is cranked, a low pressure area is created in the engine and it extends into the carburetor. Since only a limited amount of air can enter this low pressure area because of the closed choke shutter, a greater amount of fuel is drawn through the fuel passages to fill the void. This creates the richer mixture needed for engine starting and restarting after the engine is warm.

After the engine starts, more air must pass into the engine. Therefore, after the engine is started, open the choke shutter to allow more air to pass into the engine. Again, to open the choke shutter on those models that have a choke cable, rod, or handle, push the choke control lever in. On 1980 snowthrowers, the choke control lever should be rotated counterclockwise.

THROTTLE: On Toro applications, the carburetor throttle is controlled by the governor only. Therefore, Toro single stage snowthrowers, are not equipped with an engine speed control for the operator.

ON/OFF IGNITION SWITCH

The ignition switch found on Toro single stage snowthrowers produced since 1975, allows the engine to be started when the key is in the ON position. Rotating the key to the OFF position will stop the engine by allowing magneto current to flow to ground (Figure 12).

Single Stage Snowthrower Service Manual 3 - 3

CONTROLS/LOCATION AND OPERATION

∞

CHECKING THE IGNITION SWITCH

The tools used to check for defective switches are a continuity tester/light or an ohmmeter (Figure 15). A continuity tester or ohmmeter, as the names imply, are used to test for a completed current flow in an electrical circuit. To test the ignition switch on your snowthrower:

Figure 15 0217-011

1. Remove the upper shroud.

CONTINUITY CHART FOR SWITCHING

Switch

OFF

Continuity Light

light off light on

Ohm Meter

Zero Ohms

Ohms

2. Slide the terminal connector off the ignition switch (Figure 16). With the key in the OFF position, place the continuity light or ohmmeter leads, one to each terminal on the ignition switch (Figure 17); the light or meter, depending on the instrument used, should show continuity. (The continuity light should be on or the ohmmeter needle should move to a zero ohms reading.) If not, the switch is defective and needs to be replaced.

Figure 17 0217-013

Now, turn the key to the ON position, the meter or light from the tester should not indicate continuity (Figure 18). (The continuity light, if being used, should be OFF. An ohmmeter should move close

to ∞.) If not, replace the switch.

Figure 16 0217-012

Figure 18 0217-015

3 - 4 Single Stage Snowthrower Service Manual

CONTROLS/LOCATION AND OPERATION

3. Slide the terminal connector back onto the ignition switch terminals (Figure 16).

4. Replace the upper shroud. Note: Toro single stage snowthrowers produced

between 1965 and 1975 did not utilize an ignition switch. These units were equipped with a translucent boot in the upper shroud. By depressing the boot on these models, the engine could be stopped (Figure 10). A small metal lever, which was attached to the frame, would ground the spark to the frame when depressed.

VANE CONTROL - SNOW PUP SNOWMASTER S-200 - S-620

The vane control, found on Toro single stage snowthrowers, directs the discharge of snow to the left, right, or straight forward (Figure 19).

Note: It is a good practice to set the vanes in a vertical position (place the vane control so the vanes are positioned straight forward), when your unit is not in use. This helps prevent the vanes from taking a permanent curved shape.

CHUTE CONTROL

All Powerlite and 20” CCR models use a chute to direct the snow (Figure 20). There are three methods to control the chute rotation. The crank style and two types of the lever style (Figure 21). However, the chute itself is basically the same.

Figure 20 2261-04

Figure 19 0217-016

Single Stage Snowthrower Service Manual 3 - 5

Figure 21 2261-01

CONTROLS/LOCATION AND OPERATION

The curved rotor is necessary to draw the snow towards the center, where the chute is (Figure 22). The upper part of the rotor housing is an inverted cone, which has two functions. This directs the snow towards the chute, and also serves to resist plugging.

Figure 22 1352-01

The discharge chute and deflector are not interchangeable from model to model (Figure 23). However, they are made from the same basic design. The deflector mounts on top of the chute and determines the height of the snow stream.

CHUTE ROTATION AND DETENT SYSTEMS

Powerlite Chute System

On Powerlite models, the chute attaches to a handle, which also is the base and contains detents which resemble gear teeth. The handle or base sets in a groove at the top of the rotor housing. The front of the housing is open to allow the handle to slip in. The front opening is closed by the addition of the chute retainer, which is held in place by four screws (Figure 24).

Figure 24 0310-01

Figure 23 1352-05

The bolts on either side of the deflector must be sufficiently tight to prevent the snow stream from causing the deflector to move.

(A) Discharge Chute (B) Rotor Housing (C) Chute Retainer (D) Chute Detent

(E) Detent Spring (F) Chute Handle (G) Chute Deflector (H) Screw (4)

3 - 6 Single Stage Snowthrower Service Manual

CONTROLS/LOCATION AND OPERATION

To keep the chute in the desired position, a spring loaded chute detent is located in the rear of the housing (Figure 25). As the chute is rotated manually, a ratchet sound indicates that the detent is working properly. As the handle, housing, and chute retainer are all made of plastic, no lubrication is necessary

Figure 25 1854-40

To access the chute assembly, remove the 4 screws holding the chute retainer to the housing and remove the chute retainer. The chute assembly can then be pulled forward and removed from the housing.

Figure 26 1854-12

Remove the 2 screws holding the nameplate to the chassis. Allow the nameplate to hang loose from the starter rope (the nameplate has 3 tabs that engage the upper shroud). Remove the two bolts and locknuts, one in each front corner of the shroud and 2 screws, one in each rear corner of the shroud (Figure 27 and Figure 28).

Reassembly is accomplished by installing the springs on the chute detent and installing the chute detent into the rotor housing. The chute assembly can be slid into place and the chute retainer installed (Figure 24).

20” CCR Manual Chute System

Some 20” CCR models were equipped with a manual chute system. As with the others, the component parts are all plastic to eliminate the need for lubrication and reduce icing.

On this version, the discharge chute attaches to the handle and chute ring. Three carriage head bolts and washers connect the parts. Below the upper shroud is the balance of the chute components.

To access the balance of the chute parts, remove the 3 carriage bolts and nuts at the base of the discharge chute (Figure 26). Remove the chute, deflector and handle. The upper shroud must now be removed. Remove the bolt in each front corner.

Figure 27 1352-03

Single Stage Snowthrower Service Manual 3 - 7

CONTROLS/LOCATION AND OPERATION

Reassembly is the reverse of disassembly. Note: The rounded heads of the carriage bolts must

be on the inside of the chute. The smooth head prevents snow from building up on the bolt head.

20” CCR Crank System

The third system, used on CCR2000 as well as the 2400, 2500 and 3600 series uses a crank that is mounted to the handle.

Rotating the handle turns a set of gears that engage a ring gear that the chute is mounted to. The gears are contained in a bracket located under the upper shroud.

Figure 28 1352-08

The chute ring gear rests on a support and is held in Remove the gas cap and lift the upper shroud off the machine. Replace the gas cap to prevent fuel spillage or dirt from entering the fuel system. Now you see the chute ring, the two chute ring retainers, and the detent arm and spring (Figure 29). To remove the chute ring, remove the 4 bolts and nuts that retain the left and right chute ring retainers.

place by two retainers. The chute retainers allow the

ring gear to rotate only.

To access the chute ring and gears:

1. Remove the 3 carriage head bolts and locknuts at the base of the chute and lift off the chute assembly.

Figure 29 1854-40

Note: The rear bolt in the left hand chute ring retainer

is also the pivot for the detent arm. This arm engages the notches in the chute ring to prevent unwanted rotation of the chute. With the four bolts removed, the retainers and chute ring will then lift off.

These parts are all plastic to eliminate the need for lubrication and resist icing.

2. Remove the 2 bolts and nuts that hold the chute crank rod bracket to the lower handle and draw the rod out of the upper shroud (Figure 30).

Figure 30 0309-22

(A) Crank Handle Grip (B) Chute Crank Support

3 - 8 Single Stage Snowthrower Service Manual

CONTROLS/LOCATION AND OPERATION

3. To remove the upper shroud, remove the two bolts and locknuts in the front corners of the shroud (Figure 31).

Figure 31

(A) Nameplate (B) Control Panel (C) Lower Shroud (D) Push Nut

(E) Chute Seal Retainer (F) Chute Seal (G) Upper Shroud (H) Gas Cap

6. The gears are held in the bracket by a shaft with a push nut on either end (Figure 32). To remove the shaft, remove one of the push nuts and pull the shaft out.

Figure 32 1854-19

(A) Shaft and Push Nut

7. To reassemble, reverse the process.

4. Remove 3 screws that hold the face plate to the control panel and let the face plate hang from the starter rope.

5. Remove the gas cap and lift the upper shroud, replace the gas cap. The chute ring and gears are now all exposed.

Note: When installing the chute, the rounded heads of the carriage bolts must be on the inside of the chute. The smooth head prevents snow from building up on the bolt head.

Single Stage Snowthrower Service Manual 3 - 9

CONTROLS/LOCATION AND OPERATION

Chute Seal

This system has a seal incorporated into the upper shroud (Figure 33). This is to prevent melted snow from seeping into the engine compartment. To replace the seal, remove the upper shroud in the same manner as accessing the chute gears. Turn the shroud over and remove the 8 pushnuts. (Cutting them with a side cutter is the best way to remove them.) Slide the seal and retainer off the mounting pegs and replace the seal and retainer. Install new pushnuts, using a socket to push them into place.

(A) Seal

Figure 33 1854-38

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