Toro 74021, 74041, 74101, 74120, Y1-16OE01 Service Manual
...
ONAN TORO POWER PLUS P216V, 18V, 20V ENGINE - VERTICAL
Table of Contents – Page 1 of 2
SAFETY PRECAUT I O NS
GENERAL
PROTECT AGAINST MOVING PARTS
BATTERIES
FUEL SYSTEM
EXHAUST SYSTEM
EXHAUST GAS IS DEADLY!
COOLING SYSTEM
KEEP THE UNIT AND SURROUNDING AREA CLEAN
CAUTION
GENERAL INFORMATION
INTRODUCTION
ENGINE MODEL REFERENCE
SPECIFICATIONS
DIMENSIONS AND CLEARANCES
ASSEMBLY TORQUES
SPECIAL TOOLS
ENGINE TROUBLESHOOTING
OIL SYSTEM
CRANKCASE OIL
OIL FILTER CHANGE
CRANKCASE BREAT HER
PRESSURE LUBRICAT IO N
OIL PUMP
OIL BYPASS CHECK BALL
FUEL SYSTEM
CARBURETOR
CARBURETOR SPEED SETTINGS
CARBURETOR OVERHAUL
REMOVAL
DISASSEMBLY
CLEANING AND REPAIR
REASSEMBLY AN D INSTALLATION
PULSATING-DIAPHRAGM FUEL PUMP
FUEL PUMP TEST PROCEDURE
AIR CLEANER
GOVERNOR SENSITIVIT Y
ONAN TORO POWER PLUS P216V, 18V, 20V ENGINE - VERTICAL
Table of Contents – Page 2 of 2
IGNITION AND BATTERY CHARGING
IGNITION SYSTEM DESCRIPTION
IGNITION TIMING
CONTINUITY TEST
IGNITION COIL
SPARK PLUGS
BATTERY INSPECTION
BATTERY JUMP STARTING
FLYWHEEL ALTERNAT OR
ALTERNATOR OUTPUT TEST
STARTING SYSTEM
ELECTRIC STARTER
SERVICE
STARTER REMOVAL
STARTER DISASSEMBLY
STARTER ASSEMBLY
INSPECTION AND TESTING
STARTER MOUNTING
ENGINE DISASSEMBLY
DISASSEMBLY/ASSEMBLY
VALVE SYSTEM
TAPPETS
VALVE FACE AND SEAT GRINDING
FLYWHEEL
GEAR COVER
GOVERNOR CUP
TIMING GEARS
PISTONS AND CONNECTING RODS
CYLINDER BLOCK
CRANKSHAFT
BEARINGS
CRANKSHAFT ENDPLAY
CHECKING CONNECTING ROD BEARING CLEARANCE
OIL SEALS
PISTON ASSEMBLY
INSTALLATION OF PISTON IN CYLINDER
CYLINDER HEADS
Service
Manual
P216V,18V,2OV
Toro
Power
Plus
Engine
Tractors
1710
& Riding Mowers
Safety
It
is recommended that you read your engine manual and
become thoroughly acquainted with your equipment before
you start the engine.
severe personal injury or death.
severe personal injury or death.
Precautions
This symbol
diate hazards which will result in
This symbol refers
unsafe practice which can result In
if
used warns of imme-
lo
a hazard or
Fuel System
DO NOT
DO NOT smoke or use an open flame
engine or fuel tank. Internal combustion engine fuels are
highly flammable.
Fuel lines must be of steel piping, adequately secured.
and free from leaks. Piping at the engine should be
approved flexible line..
flexible lines as copper will work harden and become
brittle enough to break.
fill
fuel tanks while engine is running.
in
Do
not use copper piping for
the vicinity
of
the
This symbol refers
personal injury or product or properly damage.
Fuels, electrical equipment, batteries, exhaust gases and
moving parts present potential hazards that can result in
serious, personal injury. Take care in following these recommended procedures. All local, state and federal codes should
be consulted and complied with.
Use
of
this engine in aircraft can result in engine failure
and causes serious personal injury or death.
General
Provide appropriate fire extinguishers and install them in
convenient locations. Use an extinguisher rated ABC by
NFPA.
Make sure that all fasteners on the engine are secure and
accurately torqued. Keep guards in position over fans,
driving belts, etc.
If
it is necessary to make adjustments while the engine is
running, use extreme caution when close to hot exhausts,
moving parts. etc.
Protect Against Moving Parts
Do
not wear loose clothing in the vicinity
such as PTO shafts, flywheels, blowers, couplings, fans,
belts, etc.
unsafe practice which
This engine Is not designed or in-
tended for use in any type of aircraft.
lo
a hazard or
can result in
of
moving parts,
Be sure all fuel supplies have a positive shutoff valve.
Exhaust System
Exhaust products
toxic and can cause injury,
applications, especially those within
should be equipped with an exhaust system to discharge
gases to the outside atmosphere.
Do
not use exhaust gases to heat a compartment
Make sure that
Ensure that exhaust manifolds are secure and are not
warped by bolts unevenly torqued.
Gas
Exhaust
Exhaust gases contain carbon monoxide, a poisonous gas
that can cause unconsciousness and death.
and colorless gas formed during combustion
fuels. Symptoms
Dizziness
Headache
Weakness and Sleepiness
If
you experience any
immediately, shut down the unit and do not use until it has
been inspected.
The best protection against carbon monoxide inhalation
proper installation and regular, frequent inspections
complete exhaust system.
or appearance
immediately and have it inspected and repaired at once by a
competent mechanic.
is
of
any internal combustion engine are
or
death if inhaled.
a
confined area,
your
exhaust system
Deadly!
of
carbon monoxide poisoning are:
Vomiting
Muscular Twitching
Throbbing in Temples
of
these symptoms, get out into fresh air
If
of
you notice a change in the sound
exhaust system, shut the unit down
is
free
It
is an odorless
of
hydrocarbon
All
of
engine
leaks.
is
of
the
Keep your hands away from moving parts.
Batteries
Before starting work on the engine, disconnect batteries
of
to prevent inadvertent starting
DO NOT SMOKE while servicing batteries. Lead acid
batteries give
can be ignited by flame, electrical arcing or by smoking.
Verify battery polarity before connecting battery cables.
Connect negative cable last.
off
a highly explosive hydrogen gas which
the engine.
Cooling System
Coolants under pressure have a higher boiling Point than
water.
coolant temperature is above
engine
Keep the Unit and Surrounding Area Clean
Make sure that oily rags are not left on or near the engine.
Remove all unnecessary grease and oil from the unit
Accumulated grease and oil can cause overheating and
subsequent engine damage and present a potential fire
hazard.
DO
NOT open a radiator pressure cap when
212°F
is
running.
(l00°C)
or while
E-6
Table
of
Contents
TITLE
General Information
Specifications
Dimensions and Clearances
Assembly Torques and Special Tools
Engine Troubleshooting
Oil System
Fuel
System.
Ignition and Battery Charging
Engine Wiring Diagram.
Starting System..
Engine Disassembly
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PAGE
. l-1
.2-1
.3-1
.4-1
.5-1
.6-1
.7-1
.8-1
.8-7
.9-1
10-1
I
EXHAUST GAS
Exhaust gases from all fuels (including diesel, gasoline, liquid propane, natural
gas) contain carbon monoxide, an odorless and colorless gas. Carbon monoxide
is poisonous and can cause unconsciousness and death. Symptoms of carbon
monoxide poisoning can include:
Dizziness Throbbing in Temples
Nausea Muscular Twitching
Headache Vomiting
Weakness and Sleepiness Inability
IF
YOU
OR
ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT
INTO THE FRESH AIR IMMEDIATELY.
attention. Shut down the unit and do not operate until it has been inspected and
repaired.
Protection against carbon monoxide inhalation includes proper installation,
ventilation and regular, frequent visual and audible inspections of the complete
exhaust system.
IS
DEADLY!
to
Think Coherently
If
symptoms persist, seek medical
I
General
Information
INTRODUCTION
This manual deals with specific mechanical and electrical information needed by engine mechanics for
troubleshooting, servicing, repairing, or overhauling the
engine.
Use the separate PARTS MANUAL for parts identification
and for establishing their proper location on assemblies.
The PARTS MANUAL contains detailed exploded views
of each assembly and the individual piece part numbers
and their proper names for ordering replacement parts.
The illustrations and procedures presented in each
section apply
cleaner side of the engine is the front end. Right and left
sides are determined by viewing the engine from the
front. The No.
on the left.
If
a major repair or an overhaul is necessary, a competent
mechanic should either do the job
check the work of the mechanic assigned
ensure that all dimensions, clearances and torque
values are within the specified tolerances.
Use the table
separate engine system sections.
The troubleshooting guide is provided
reference for locating and correcting engine trouble.
The wiring diagram
nents are interconnected.
The disassembly section contains major overhaul
procedures for step by step removal, disassembly,
inspection, repair, and assembly
components.
to
the engines listed on the cover. The air
1
cylinder is on the right,
of
contents for a quick reference
shows
how the electrical compo-
No.
2
cylinder is
or
supervise and
to
the job
as
of
the engine
a quick
to
to
the
Use only Genuine
ensure quality and the best possible repair and overhaul
results. When ordering parts, always use the complete
model and spec number as well
shown on the nameplate.
ENGINE
Identify your model by referring
specification (spec letter) as shown on the unit nameplate. Always use these numbers and the engine serial
number when making reference
How
to
interpret MODEL and SPEC NO.
P
2 16
12
1.
Factory code for general identification of basic
engine series.
2.
Number of cylinders.
3.
BHP rating.
4.
Designation
5.
Engine duty cycle.
6.
Factory code for designated optional equipment,
any.
7.
Specification (spec letter) which advances with
factory production modifications.
Tom
Plower Plus replacement parts to
MODEL
V
3
(G
=
horizontal shaft,
as
the serial number
REFERENCE
to
'the model and
to
your engine.
/
10464
6
V
=
vertical shaft)
A
7
if
INCORRECT SERVICE
PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL
MUST
SERVICE.
BE
QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANICAL
OR
REPLACEMENTOF PARTS CAN RESULT IN SEVERE
Specifications
.
This manual contains
SPECIFICATION MEASURE P216V P218V P220V
Number
Bore
Stroke
Displacement
Compression Ratio
Power at
Oil Capacity Qts
Valve Clearance (Cold)
of
Cylinders
Rated Speed
Without Filter (litre)
Oil Filter Capacity
Intake in
(3600
rpm)
.
SI
metric equivalents that
U.S.
after the
UNIT OF SERIES
customary units
follow
of
measure.
immediately in parentheses
2
in
(mm)
in
(mm)
CU in
(cm³)
BHP
(kW)
3.250 3.250 3.250
(82.55) (82.55) (82.55)
2.625
(66.68)
43.3
(71
0)
6.5
to
1
16 18 20
(1 1.9) (1 3.4)
(73.03) (73.03)
7.0
1.7 1.7. 1.7
(1 .6)
Qts
(litre)
.3 .3 .3
(.3) (.3) (.3)
.005
2
2
2.875 2.875
47.7 47.7
(782)
to
1
(1
(782)
7.0
(1
4.9)
(1.6)
to
__-
.005 .005
1
Spark Plug Gap
Ignition Timing
Cylinder Compression psi
in
(mm)
BTC
(kPa)
.025
(.64) (.64) (.64)
20°
75
(517
to
to
115 75
793) 51
.025 .025
20° 20
to
7
115
to
793) (517
75
to
to
115
793)
2-
1
Dimensions
All
measurements given at room temperature
millimeter measurements in parentheses
and
of
.
Measurements are
Clearances
70°F (21 °C)
.
All
measurements are given in inches with approximate
for
standard size parts
.
DESCRIPTION
CYLINDER BLOCK
Cylinder Bore Diameter
Piston Clearance
Maximum Allowable
Taper
Out-of-Round
Top Main Bearing Bore
Top Main Bearing Inside Diameter (bearing installed)
Top Main Bearing Clearance
Bottom Main Bearing Bore
Bottom Main Bearings Inside
Bottom Main Bearing Clearance
Cam Bearing Bore
Cam Bearing Inside Diameter (bearing installed)
Cam Bearing Clearance
Intake Valve Seat Bore
Exhaust Valve Seat Bore
Tappet Bore Diameter
Tappet Clearance
CRANKSHAFT
Top Main Bearing
Bottom Main Bearing
Connecting Rod Journal Diameter
End Play
.................................................
Diameter (bearings installed)
Journal Diameter
Journal Diameter
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........
3.2490
0.0033
2.1 870
2.001
0.0024
2.1 840
1.9990
0.001
1.4995
1.3757
0.001
1.4395
1.1
890
0.7500
0.0020
1.9992 (50.78)
1.9972
1.6252
0.0060
5
0
5
(82.52)
(0.084)
(55.55)
(50.84)
(0.061)
(55.47)
(50.77)
(0.025)
(38.08)
(34.94)
(0.038)
(36.56)
(30.20)
(1 9.05)
(0.051
)
(50.73)
(41.28)
(0.1
52)
MAXIMUM
Inches
3.2500
0.0053
0.005
0.003
2.1 880
2.0040
0.0042
2.1 850
2.0020
0.0048
1
5005
1.3787
0.0030
1.4405
1.1 900
0.751 5
0.0040
2.0000
1.9980
1.6260
0.01 20
(mm)
(82.55)
(0.1
35)
(0.1
3)
(0.08)
(55.58)
(50.90)
(0.1
07)
(55.50)
(50.85)
(0.1
22)
(38.1
1)
(35.02)
(0.076)
(36.59)
(30.23)
(1
9.09)
(0.1 02)
(50.80)
(50.75)
(41.30)
(0.305)
CONNECTING
Large Bore Inside Diameter (rod bolts torqued)
Large Bore Clearance
Piston Pin Bore
Piston Pin Clearance
End Play
CAMSHAFT
Journal Diameter
Lobe Height
P216V. P218V Intake
P216V. P218V Exhaust
P220V Intake
P220V Exhaust
End
Play
ROD
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3-
1
1.6280
0.0020
0.6879
0.0002
0.0020
1.3740 (34.90)
0.01
10
(41.35)
(0.051)
(1
7.47)
(0.005)
(0.051)
(0.279)
1.6285
0.0033
0.6882
0.0007
0.0320
1.3745 (34.91)
1.1 370 (28.88)
1.1 570 (29.39)
1.1
670 (29.64)
1.1
570 (29.39)
0.0480 (1.219)
(41.36)
(0.084)
(1
7.48)
(0.01 8)
(0.81
3)
DESCRIPTION
(standard size)
pin
Measure 90° from
1
.187
below
top
Ring Groove Width
Top Groove
Middle Groove.
Bottom Groove.
Top Groove Clearance.
Pin Bore
Pin Clearance
PISTON PIN
Diameter
PISTON RINGS
End Gap
INTAKE VALVE
Stem Diameter
Face Angle
.....................................
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..........................................
...........................................
.................................
bore
of
piston.
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MINIMUM
Inches
3.2445
0.0800.
0.0800
0.1 880
0.0030
0.6877
0.00004
0.6875 (1 7.46) 0.6877 (1 7.47)
0.01
00
0.2795 (7.099) 0.2800 (7.1 12)
(mm)
(82.41)
(2.032)
(2.032)
(4.775)
(0.076)
(1 7.47)
(0.001)
(0.254) 0.0200 (0.508)
44
.
MAXIMUM
Inches
3.2462 (82.45)
0
0.081
.0.0810
.0.1890
0.0080
0.6882
0.00064
(mm)
(2.057)
(2.057)
(4.800)
(0.203)
(1 7.48)
(0.01 6)
INTAKE VALVE SEAT
Outside Diameter
Seat Width
Seat Angle
Stem Diameter
Face Angle
EXHAUST VALVE SEAT
Outside Diameter
Seat Width
Seat Angle
VALVE GUIDE
Intake Inside Diameter
Intake Stem to Guide Clearance
Exhaust Inside Diameter
Exhaust Stem to Guide Clearance..
TAPPET
Body Diameter.
VALVE SPRINGS
Free Length (approximate)
Valve Open Length
Valve Closed Length
Spring Load (valve open length)
Spring Load (valve closed length)
...............................................
..............................................
VALVE
..............................................
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1.4700 (37.34) 1.471
0.031
0.2780 (7.061) 0.2785 (7.074)
1.1 920
0.031
0.281
0.001
0.2805
0.0020
0.7475 (1 8.99) 0.7480
0
0
0
0
(0.787) 0.0470 (1.1 94)
(30.28)
(0.787)
(7.1 37)
(0.025)
(7.1 25)
(0.051)
1.600
1.055
1.346
55
Ib.
Ib.
25
45°
44
45°
-
1.1 930
0.0470
0.2820
0.0025
0.281
0.0035
(40.64)
(26.80)
(34.1 9)
(25 kg)
(11
kg)
0
5
(37.36)
(30.30)
(1.194)
(7.1 63)
(0.064)
(7.1
50)
(0.089)
(1 9.00)
GEAR BACKLASH
Timing Gear
Oil Pump Gear..
.............................................
.........................................
3-2
0.001
0.001
0
0
(0.025)
(0.025)
0.0050
0.0080
(0.1 27)
(0.203)
Assembly
The torque values given in Table 1 have been deter- Tighten all studs, nuts, and capscrews as required to
mined for specific applications. Standard torque values keep them from working loose. Refer to the
must not be used where those listed in Table 1 apply.
The engine assembly torques given here will assure
proper tightness without danger
threads must be clean and lubricated with new engine
oil before torquing.
Torques
of
stripping threads.
All
MANUAL
for
the location of washers and capscrews.
PARTS
DESCRIPTION
Gearcase Cover
Oil Base
Oil Base Cover (inner bolts).
Oil Base Cover (outer bolts).
Oil Cooler
Oil Pump
Hood Support Screws..
Starter Mounting Bolts
Connecting Rod Bolts..
Flywheel Capscrews
Valve Cover.
......................
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.
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....
TABLE
TORQUE
SPECIFICATION
Ft.-Lb. Nm
10-12 14-16
27-29 36-39
19-21 25-28
9-11 12-15
20-24
7-9 10-12
7-9
19-21 25-28
12-14
50-55
3-4 4-5
27-33
10-12
16-19
67-75
1.
DESCRIPTION
Cylinder Head Bolts (cold)
Asbestos Gasket
Graphoil Gasket..
Intake Manifold
Mounting Screws..
Exhaust Manifold
Mounting Screws..
/4"
Other 1
Nuts and Bolts
Other 5/16" Cylinder Block
Nuts and Bolts
Cylinder Block
............
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..........
..........
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TORQUE
SPECIFICATION
Ft.-Lb. Nm
16-1 8
14-1 6
6-10
9-11
7-9
8-10
22-24
19-22
8-14
12-15
10-12
11-14
Special
The following is a partial list of the special
from Onan. Use Onan tools whenever a repair or
overhaul is required. Refer to the
complete listing of tools available.
Valve Seat Driver
Valve Guide Driver
Oil Seal Guide and Driver
Combination Bearing Remover (Main and Cam)
Combination Bearing Driver (Main and Cam)
Flywheel Puller
Tools
tools
TOOL CATALOG
available
for a
Engine
Troubleshooting
5-
M-1686
1
Oil
System
CRANKCASE
Refer
to
Periodic Maintenance Schedule (located in the
Operator's Manual) for oil change interval.
in extremely'-dusty, high ambient, 'or low ambient
conditions, change oil more often.
Hotcrankcase oil can cause burns if
it comes in contact with skin.. Wear
protective clothing and keep fingers and hands clear
when draining oil.
Excess oil can cause high oil consumption, high operating temper-
atures, and oil foaming.
Run engine until thoroughly warm before draining oil.
Stop the engine, place a pan 'under the drain outlet and
remove the
drained, clean and replace the drain plug. Fill crankcase
with correct amount of oil. Refer
crankcase capacity. Use oils meeting the
fication SF, SF/CC, or SF/CD. Refer
the proper viscosity grade of oil
oils are recommended for severe duty use and at
temperatures above 32°F
consumption.
oil
drain plug. After the
Do
OIL
If
operating
not overfill crankcase.
oil
is
completely
to
SPEClFlCATlONS for
API
classi-
to
chart
to
determine
to
use. Straight weight
(0°C)
for minimum oil
Crankcase pressure can blow out hot
oil, which can cause severe personal
Do
injury.
Oil level should be to the FULL mark of the dipstick. Start
engine and run for a short time
around the drain plug.
Refer
Operator's Manual) for oil filter change interval.
operating in extremely dusty, high ambient, or low
ambient conditions, change oil filter more often.
not check oil while the engine
to
ENGINE
to
OIL
TEMPERATURE-
OIL
FILTER
Periodic Maintenenace Schedule (located in the
VISCOSITY
CHANGE
is
running.
check for oil leaks
CHART
If
FIGURE
1.
CRANKCASE
OIL
FILL
C-1000
Spin
off
oil
filter elementand discard it. Thoroughly clean
filter mounting surface and make sure new gasket is
inserted
gasket. Spin element down by hand until gasket just
touches mounting pad and then turn down an additional
112-314
With oil in crankcase, start engine and check for leaks
around filter element. Retighten only as much as
necessary
in
the element. Apply a thin film of clean oil to the
turn. Do not overtighten.
to
eliminate leaks; do not overtighten.
CRANKCASEBREATHER
The crankcase breather prevents pressure from building
It
up the crankcase
by removing moisture or gasoline vapors and other
harmful blow-by materials from the crankcase. These
vapors are routed
mixed with incoming air and burned in the combustion
chamber.
high oil consumption, rough idle, reduced engine power,
and
engine.
A
sticky breather valve can cause oil leaks,
a
rapid formation of sludge and varnish within the
Crankcase Breather Service
The crankcase breather does not require servicing.
Replace breather if it’s broken or cracked or
becomes pressurized as evidenced by
seals or excessive oil
also prevents oil contamination
to
the carburetor where they are
if
crankcase
oil
leaks at the
in
the air cleaner housing.
Oil
Bypass
The oil bypass check ball is located in the
gain access
removed. The check ball limits oil pressure
mum
temperatures
The check ball is non-adjustable and normally does not
need maintenance. Determine
correctly by inspecting as follows (Figure
1.
Remove internal retaining ring.
2.
Remove spring and check ball with a magnetic
3.
Determine proper operation by checking the spring
and check ball according
ments:
of
Check
to
about
Ball
the check ball the oil base cover must be
25
psi
(172
kPa) at normal operating
(250°F
oil temperature).
if
check ball is operating
to
the following measure-
2):
oil
to
base.
a maxi-
tool.
To
PRESSURE
All
engines use an oil pump
to
the engine parts. The oil supply collects in the oil
oil
base where
A
bypass valve is used
before removing oil base and always use a new gasket
when replacing the oil base.
Oil
Pump
The oil pump is mounted below the gear cover and is
driven by the crankshaft gear.
pump cover registers with a drilled passage
crankcase. Parallel passages distribute oil
and bottom main bearing and the oil bypass valve.
Circumferential grooves in the main bearings supply oil
to
connecting rod bearings through drilled passages
from each main journal.
front main bearing oil supply
bearing; rear cam bearing is splash lubricated.
Normal oil pressure should be
1500
temperature.
value, inspect oil system for faulty components.
it
is picked up by the oil pump pick-up cup.
rpm when the engine is at normal operating
If
pressure at
LUBRICATION
to
provide a constant flow of
to
control oil pressure. Drain oil
A
discharge passage in
to
the top
A
drilled passage connects the
to
the front camshaft
8
psi
(55
kPa) or higher at
1500
rpm drops below this
in
the
Check Ball Diameter.
Spring
Free Length
Load..
4.
Check the check ball seat and clean away- any
accumulation of metal particles which could cause
erratic check ball action. Verify the check ball seat is
not damaged.
5.
Clean spring and check ball in parts cleaning
solvent and install.
6.
A
new internal retaining ring must be installed with
the outside edges turned towards the top. Press in
until retaining ring outside edge is
(3.3 ± .3
OIL
BASE
...............
............
when compressed
mm) from top.
0.13±0.01”
(33±.3mm)
.....
.0.3125
.2.6 ± 0.2
to
RETAINING RING
inch
1.00
inch
Ibs
(11.6
0.5
inch
0.13 ± 0.01
(7.94
(25.4
±
(12.7
mm)
mm)
0.9
mm)
inch
N)
Check oil pump thoroughly for worn parts and replace
pump as an assembly
parts (pickup cup, pickup tube, gaskets, etc.) can be
replaced individually. Prime pump by oiling it before
installing.
if
parts are worn. Other component
6-2
FIGURE
2.
OIL BYPASS
CHECK
LS-1102
BALL
F’uel
System
..
..
_.i
..
.
CARBURETOR
All
carburetors have a fixed’main jet. An’optional fixed
main jet is avai1abI.e for altitude compensation above
5,000
feet.
The carburetor idle mixture was set for maximum
efficiency at the factory and should normally not
disfurbed.
If
adjustments seem necessary, first be sure
the ignition system is working properly and governor
sensitivity is properly adjusted.
The carburetor has a limited idle adjustment range
between stops of
adjusted within these limits; in
fl/8
turn. The screw should only be
to
lean the mixtuie, out
richen.
Overtightening the mixture adjustment
screw
Turn mixture adjustment screw in
will
cause carburetor damage.
only
until light
tension can be felt.
If
replacing idle mixture screw, turn in until lightly
seated, then turn sciew back out 1-1
limiter cap with the plastic
stop
/4
turns. Replace
approximately centered.
be
to
Carburetor
1. Start the engine and allow it
Speed
Settings
to
warm up thoroughly
“(at least 10 minutes).
Someequipment manufacturers may require higher
throttle stop speed and governor low speed rpm
settings. Refer to equipment manufacturer’s Operator’s Manual for .the correct rpm settings. When
.
rpm settings are not specified by
the
equipment
manufacturer, use the rpm settings listed in Steps
and
3.
2.
Move the engine speed control
to
the slow position.
Adjust the low speed adjustment screw on the
governor
so
the throttle stop screw on the carburetor
controls engine speed. Adjust the throttle stop
screw for
3.
Adjust the governor low speed stop for 11
idle.
4.
Move the engine speed control
1000
rpm idle (Figures 1 and
-..
_.
..
to
the fast position.
2).
Bend the high speed stop on the governor
engine. runs at the equipment manufacturer’s
recommended speed.
.-
00
so
2
rpm
the
FIGURE
HIGH
SPEED
STOP
GOVERNOR
1.
GOVERNOR SPEED ADJUSTMENT
ASSEMBLY
FS-1000-1
LIMITER
CAP-
FIGURE
2.
CARBURETOR ADJUSTMENTS
FS-1406.2
CARBURETOR
Carburetion problems
that
OVERHAUL
are not corrected
by
mixture
adjustments are usually a result of gummed-up fuel
passages or worn internal parts. The most effective
solution is a carburetor overhaul.
In general, overhauling a carburetor consists
of
disassembly, a thorough cleaning, and replacement of worn
parts. Carburetor overhaul kits are available.
General instructions for overhauling a carburetor are
given below. Carefully note the position of all parts while
removing
to
assure correct placement when reassemb-
ling. Read through all the instructions before beginning
for a better understanding of the procedures involved.
Carburetor components are shown in Figure
lgnition of fuel can
result
personal injury or death.
3.
in severe
Do
not
smoke or allow any spark, pilot light, or arcing eguipment near the fuel system.
Removal
1.
Remove air cleaner assembly.
2.
Disconnect throttle linkage, choke control, and fuel
line from carburetor.
3.
Remove carburetor from intake manifold.
ASSEMBLY
IDLE
ADJUSTMENT
NEEDLE
Disassembly
1.
Remove main jet and idle adjustment needle.
2.
Remove attaching screws and separate upper and
lower carburetor sections.
3.
Carefully note position of float assembly parts, then
pull out retaining pin and float assembly.
4.
Remove needle valve.
AND
LEVER
THROTTLE STOP CAP
SCREW
FIGURE
3.
CARBURETOR ASSEMBLY
FS-1440-4
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