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

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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
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
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.
COPYRIGHT© – ALL RIGHTS RESERVED
The Toro Company – 2000
Bloomington, MN 55420 – U.S.A.
PREFACE
Single Stage Snowthrower Service Manual i
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
TABLE OF CONTENTS
ii Single Stage Snowthrower Service Manual
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
Single Stage Snowthrower Service Manual iii
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
TABLE OF CONTENTS
iv Single Stage Snowthrower Service Manual
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
Single Stage Snowthrower Service Manual v
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.
vi Single Stage Snowthrower Service Manual
THIS PAGE INTENTIONALLY LEFT BLANK
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.)
31405 Snow Pup 14” 1976-1977 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
31410 Snow Pup 14" 1966-1967 Tec. AH520 16:1 4300-4700 Champion
RJ18YC
.035
31411 Snow Pup 14" 1968-1971 Tec. AH520 16:1 4100-4500 Champion
RJ18YC
.035
31412 Snow Pup 14" 1972-1975 Tec. AH520 16:1 4300-4700 Champion
RJ18YC
.035
31500 Snow Husky 21" 1966-1967 Tec. AH520 16:1 4300-4700 Champion
RJ18YC
.035
31501 Snow Pup 21” 1968-1971 Tec. AH520 16:1 4300-4700 Champion
RJ18YC
.035
31502 Snow Pup 21" 1972-1974 Tec. AH520 16:1 4300-4700 Champion
RJ18YC
.035
31505 Snowmaster 20" 1975 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
31506 Snowmaster 20" 1976-1977 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38014 Snowmaster 14” 1978 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38020 Snowmaster 20" 1978 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38030 Snowmaster 20" 1978 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38100 S140 14" 1979-1981 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38110C CR20 20" 1987-1990 Tec. AH600 32:1 4300-4500 Champion
RCJ8Y
.030
38111C CR20 20" 1987 Tec. AH600 32:1 4300-4500 Champion
RCJ8Y
.030
38115C CR20 20" 1987-1990 Tec. AH600 32:1 4300-4700 Champion
RCJ8Y
.030
38116 CR20 20" 1988-1989 Tec. AH600 32:1 4300-4700 Champion
RCJ8Y
.030
38116C CR20 20" 1987 Tec. AH600 32:1 4300-4700 Champion
RCJ8Y
.030
38120 S200 20" 1979-1984 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38130 S200 20" 1979-1981 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38162 S620 20" 1984-1991 Tec. AH600 32:1 4300-4700 Champion
RCJ8Y
.030
38162C S620 20" 1984-1986 Tec. AH600 32:1 4300-4700 Champion
RCJ8Y
.030
38165 S620 20" 1985-1991 Tec. AH600 32:1 4300-4700 Champion
RCJ8Y
.030
38165C S620 20" 1986 Tec. AH600 32:1 4300-4700 Champion
RCJ8Y
.030
38167C S620 20" 1986 Tec. AH600 32:1 4300-4700 Champion
RCJ8Y
.030
38170 Powerlite 16" 1991-2000 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38171 Powerlite 16" 1992-1998 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38172 Powerlite 16" 2000 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
ENGINE APPLICATIONS
1 - 2 Single Stage Snowthrower Service Manual
38173 Powerlite 16" 2000 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38175 Powerlite 16" 1991-1999 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38176 Powerlite 16" 1992-1998 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38177 Powerlite 16" 1999 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38178 Powerlite 16" 1999 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
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
.030
38183 Powerlite 16" 2000 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
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
.030
38191 CCR1000 20" 1992-1996 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38195 CCR1000 20" 1990-1996 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38196 CCR1000 20" 1992-1996 Tec. HSK600 50:1 4300-4700 Champion
RCJ8Y
.030
38210 S140 14" 1979-1980 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38220 S200 20" 1979 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38225 S200 20" 1980 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38230 S200 20" 1979 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38232 S200 20" 1981-1985 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38235 S200 20" 1980-1983 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38242 S200 20" 1981-1983 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38252 S200 20" 1981 Tec. AH520 32:1 4100-4500 Champion
RJ18YC
.035
38350 Gas Power Shovel 14" 1983-1985 Toro NA 32:1 7800-8800 Champion
RCJ8
.022
38400 CCR1000 20" 1999-2000 Tec. HSK635 50:1 4300-4700 Champion
RCJ8Y
.030
38405 CCR1000 20" 1999-2000 Tec. HSK635 50:1 4300-4700 Champion
RCJ8Y
.030
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
.030
38411 CCR2400 20" 1997 Tec. HSK850 50:1 3550-3850 Champion
RCJ8Y
.030
38412 CCR2400 20" 1998-1999 Toro R tek 50:1 3450-3950 NGK BPMR4A .032
Model # Model Name Width Years of Mfg Eng Mfg Eng Model Mix Ratio Max RPM Spark Plug * Gap (in.)
Single Stage Snowthrower Service Manual 1 - 3
ENGINE APPLICATIONS
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
.030
38416 CCR2400 20" 1997 Tec. HSK850 50:1 3550-3850 Champion
RCJ8Y
.030
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
.030
38421 CCR2500 20" 1997 Tec. HSK850 50:1 3550-3850 Champion
RCJ8Y
.030
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
.030
38426 CCR2500 20" 1997 Tec. HSK850 50:1 3550-3850 Champion
RCJ8Y
.030
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
* RJ18YC replaces RJ18Y
Model # Model Name Width Years of Mfg Eng Mfg Eng Model Mix Ratio Max RPM Spark Plug * Gap (in.)
1 - 4 Single Stage Snowthrower Service Manual
THIS PAGE INTENTIONALLY LEFT BLANK
Single Stage Snowthrower Service Manual 2 - 1
GENERAL INFORMATION
GENERAL SAFETY INSTRUCTIONS
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
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.
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.
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.
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.
GENERAL INFORMATION
2 - 2 Single Stage Snowthrower Service Manual
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.
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).
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.
Figure 3 0530-01
(A) Model and Serial Number Decal
A
Single Stage Snowthrower Service Manual 2 - 3
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
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).
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.
CAUTION
GENERAL INFORMATION
2 - 4 Single Stage Snowthrower Service Manual
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).
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.
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.
Figure 4
Figure 5
Mix With One U.S. Gallon
Ratio Oil
16:1 8 oz.
32:1 4 oz.
50:1 2.6 oz.
Do not store the oil near an open flame or in an
extremely warm environment as the oil is
flammable.
CAUTION
OIL
(1 CUP OR 8 OZ.) (0.236 l)
GAS
(1 U.S. QUART (0.946 l)
GASOLINE CONTAINER
16:1 RATIO MIX
SHAKE
CAN
ADD
MORE
GAS
(3 U.S. QUARTS)
(2.84 l)
GASOLINE CONTAINER
OIL
(1/2 CUP OR 4 OZ.) (0.118 l)
GAS
(1 U.S. QUART (0.946 l)
GASOLINE CONTAINER
32:1 RATIO MIX
SHAKE
CAN
ADD
MORE
GAS
(3 U.S. QUARTS)
(2.84 l)
GASOLINE CONTAINER
Single Stage Snowthrower Service Manual 2 - 5
GENERAL INFORMATION
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
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.
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.
OFF SEASON STORAGE
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.
OIL
(1/3 CUP OR 2.6 OZ.) (0.079 l)
GAS
(1 U.S. QUART (0.946 l)
GASOLINE CONTAINER
50:1 RATIO MIX
SHAKE
CAN
ADD
MORE
GAS
(3 U.S. QUARTS)
(2.84 l)
GASOLINE CONTAINER
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.
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.
CAUTION
GENERAL INFORMATION
2 - 6 Single Stage Snowthrower Service Manual
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.
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.
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.
Single Stage Snowthrower Service Manual 3 - 1
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 8 0217-005
Figure 9 1854-28
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 10 0217-006
(A) Primer (B) Choke
A
B
(A) Choke (B) Primer
A
B
CONTROLS/LOCATION AND OPERATION
3 - 2 Single Stage Snowthrower Service Manual
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.
Figure 11 0217-007
Figure 12 0217-008
PRIMING CHART
Years
Number of times primer is
depressed
1965-1972 10
1973- 1977 5
1978- 1980
1-4
1981 - Up
1-2
Single Stage Snowthrower Service Manual 3 - 3
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 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.
Figure 14 0217-010
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).
CONTROLS/LOCATION AND OPERATION
3 - 4 Single Stage Snowthrower Service Manual
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.
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 16 0217-012
CONTINUITY CHART FOR SWITCHING
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 18 0217-015
Switch
ON
OFF
Continuity Light
light off
light on
Ohm Meter
Ohms
Zero Ohms
Single Stage Snowthrower Service Manual 3 - 5
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.
Figure 19 0217-016
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 21 2261-01
CONTROLS/LOCATION AND OPERATION
3 - 6 Single Stage Snowthrower Service Manual
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.
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.
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
(A) Discharge Chute
(B) Rotor Housing
(C) Chute Retainer
(D) Chute Detent
(E) Detent Spring
(F) Chute Handle
(G) Chute Deflector
(H) Screw (4)
A
B
C
D
E
F
G
H
Single Stage Snowthrower Service Manual 3 - 7
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.
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 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).
Figure 27 1352-03
CONTROLS/LOCATION AND OPERATION
3 - 8 Single Stage Snowthrower Service Manual
Figure 28 1352-08
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.
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.
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.
The chute ring gear rests on a support and is held in
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.
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
(C) Chute Crank Rod
(D) Spring
A
B
C
D
Single Stage Snowthrower Service Manual 3 - 9
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
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.
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
7. To reassemble, reverse the process.
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.
(A) Nameplate
(B) Control Panel
(C) Lower Shroud
(D) Push Nut
(E) Chute Seal Retainer
(F) Chute Seal
(G) Upper Shroud
(H) Gas Cap
A
B
C
D
E
F
G
H
(A) Shaft and Push Nut
A
CONTROLS/LOCATION AND OPERATION
3 - 10 Single Stage Snowthrower Service Manual
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.
Figure 33 1854-38
(A) Seal
A
A
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