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Super Recycler Lawn Mower

Toro Super Recycler Lawn Mower, 20-inch Mulching/Rear Bagging Lawn Mower, 20in Recycling/Rear Bagging Lawn Mower, 21in Heavy-Duty Recycler/Rear Bagger Lawn Mower, 22in Recycler Lawn Mower, 48cm Super Bagger Lawn Mower, 48cm Super Recycler Lawn Mower, 50cm Mulching/Rear Bagging Lawn Mower User manual

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FormNo.3429-270RevA
1P65F-2ServiceManual
Published:August2019
1P65FCand1P65FAenginespeciî‚¿cationsincluded
©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved
RevisionHistory
RevisionHistoryPage2
1P65F-2ServiceManual
3429-270RevA
Preface
ThisservicemanualwaswrittenexpresslyforToroservicetechnicians.TheT oroCompanyhasmade
everyefforttomaketheinformationinthismanualcompleteandcorrect.
Basicshopsafetyknowledgeandmechanical/electricalskillsareassumed.TheT ableofContentslists
thesystemsandtherelatedtopicscoveredinthismanual.
Wearehopefulthatyouwillî‚¿ndthismanualavaluableadditiontoyourserviceshop.Ifyouhaveany
questionsorcommentsregardingthismanual,pleasecontactusatthefollowingaddress:
TheToroCompany
RLC/SWSCustomerCareDepartment
8111LyndaleAvenueSouth
Bloomington,MN55420
TheT oroCompanyreservestherighttochangeproductspeciî‚¿cationsormakechangestothismanual
withoutnotice.
1P65F-2ServiceManual
Page3
Preface
3429-270RevA
ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
speciî‚¿cimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•Installingsafetyequipment(shields,guards,seatbelts,brakes,andR.O.P .S.
components)thatmayhavebeenremoved
•Dimensionsorsettingsthatmustbemaintainedforpropermachineoperation
•Aspecicfastenertighteningsequence
•Componentorientationthatmaynotbeobvious
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent
thanwhatisrecommendedintheStandardTorqueT ables.
FluidSpeciî‚¿cations
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
Preface
Page4
1P65F-2ServiceManual
3429-270RevA
TableofContents
Preface................................................................................................................3
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–9
Chapter3:Troubleshooting.............................................................................3–1
GeneralTroubleshooting..............................................................................3–3
Chapter4:EngineT opEnd..............................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–3
Chapter5:AirIntakeSystem...........................................................................5–1
GeneralInformation.....................................................................................5–2
ServiceandRepairs.....................................................................................5–3
Chapter6:FuelSystem...................................................................................6–1
GeneralInformation.....................................................................................6–2
ServiceandRepairs.....................................................................................6–3
Chapter7:CompressionSystem.....................................................................7–1
GeneralInformation.....................................................................................7–2
ServiceandRepairs.....................................................................................7–3
Chapter8:ElectricalSystem...........................................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
Chapter9:EngineLowerEnd..........................................................................9–1
GeneralInformation.....................................................................................9–2
ServiceandRepairs.....................................................................................9–3
1P65F-2ServiceManual
Page5
Preface
3429-270RevA
Preface
Page6
1P65F-2ServiceManual
3429-270RevA
Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
ThinkSafetyFirst...............................................................................................................................1–2
1P65F-2ServiceManual
Page1–1
Safety
3429-270RevA
SafetyInstructions
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldcauseseriouspermanentinjury,disability,or
death.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjuryand/ordamage
topropertyorequipment.
ThinkSafetyFirst
Avoidunexpectedstartingofengine…
Alwaysturnofftheengine,removetheignitionkeyanddisconnectthesparkplug
wire(s)beforecleaning,adjusting,orrepair.
Avoidlacerationsandamputations…
Stayclearofallmovingpartswhenevertheengineisrunning.Treatallnormally
movingpartsasiftheyweremovingwhenevertheengineisrunningorhas
thepotentialtostart.
Avoidburns…
Donottouchtheengine,mufer,orothercomponents,whichmaybehotduring
operation,whiletheunitisrunningorshortlyafterithasbeenrunning.
Avoidresandexplosions…
Useextremecareinhandlingfuel.Itisammableanditsvaporsareexplosive.
Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.Avoid
spillingfuelandneversmokewhileworkingwithanytypeoffuelorlubricant.
Wipeupanyspilledfueloroilimmediately.Neverremovethefuelcaporadd
fuelwhentheengineisrunning.Alwaysuseapproved,labeledcontainersfor
storingortransportingfuelandlubricants.Donotaddordrainfuelinanenclosed
space.Donotstorethemachineorfuelcontainerwherethereisanopename,
spark,orpilotlight,suchasonawaterheaterorotherappliance.
Avoidasphyxiation…
Donotoperateanengineinaconî‚¿nedareawithoutproperventilation.
Avoidinjuryfrombatteries…
Safety:SafetyInstructions
Page1–2
1P65F-2ServiceManual
3429-270RevA
ThinkSafetyFirst(continued)
Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,eyes
andclothing.Batterygasescanexplode.Keepcigarettes,sparksandames
awayfromthebattery.
Avoidinjuryduetoinferiorparts…
Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteriaaremet.
Avoidinjurytobystanders…
Alwayscleartheareaofbystandersbeforestartingortestingpowered
equipment.
Avoidinjuryduetoprojectiles…
Alwayscleartheareaofsticks,rocksoranyotherdebristhatcouldbepickedup
andthrownbythepoweredequipment.
Avoidmodications…
Neveralterormodifyanypartunlessitisafactoryapprovedprocedure.
Avoidunsafeoperation…
Alwaystestthesafetyinterlocksystemaftermakingadjustmentsorrepairson
themachine.RefertotheElectricalsectioninthismanualformoreinformation.
Avoidelectricalshock…
Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.They
canbesourcesofshock.De-energizethesystemifyouarehavingtodorepairs.
Iftestingelectricalcomponentsensureyouareworkinginadryenvironment.
HydraulicSystem...
Releaseallpressureinthehydraulicsystembeforeperforminganyworkon
thesystem.Keepyourbodyandhandsawayfrompin-holeleaksornozzles
thatejecthydraulicuidunderhighpressure.Donotuseyourhandstosearch
forleaks.Hydraulicuidescapingunderpressurecanhavesufcientforceto
penetratetheskinandcauseseriousinjury.Seekmedicalattentionrightawayif
hydraulicuidgetsintheskin.
PersonalProtectiveEquipment…
Useappropriatepersonalprotectiveequipment(PPE)forprotectingyourself
frompotentialhazardsintheenvironmentinwhichyouwillwork.Eachprocess
outlinedinthismanualmayneeddifferentPPEtoprotecttheserviceperson.
UsetheproperPPEforthetaskathand.
Tools…
Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatarebrokenorin
disrepair.Usethepropertoolfortheproperapplication.
Lifts,Hoists,andJacks…
Alllifts,hoists,andjacksshouldbeusedinaccordancewiththemanufacturer
information.Inspectlifts,hoists,andjackspriortouse.Donotoverloadlifts,
hoists,andjacks.Donotworkunderasuspendedload.Ensurechockblocks
areusedonequipmentthatcanmove.Useliftsorjacksandjackstandsthat
areratedtosupportthetotalweightofthemachineandanyattachments.Do
notrelyonjackstosupportthemachine.Ifyouareunsureoftheoperationof
anylifts,hoists,andjacksdonotuse.
FireExtinguishers…
Theproperclassofî‚¿reextinguishershouldbeusedincaseofî‚¿re.
1P65F-2ServiceManual
Page1–3
Safety:SafetyInstructions
3429-270RevA
ThinkSafetyFirst(continued)
ClassAextinguishersareforordinarycombustiblematerialssuchaspaper,
wood,cardboard,andmostplastics.Thenumericalratingonthesetypesof
extinguishersindicatestheamountofwateritholdsandtheamountofî‚¿reitcan
extinguish.Geometricsymbol(greentriangle).
ClassBresinvolveammableorcombustibleliquidssuchasgasoline,
kerosene,greaseandoil.ThenumericalratingforclassBextinguishers
indicatestheapproximatenumberofsquarefeetofî‚¿reitcanextinguish.
Geometricsymbol(redsquare).
ClassCî‚¿resinvolveelectricalequipment,suchasappliances,wiring,circuit
breakersandoutlets.NeverusewatertoextinguishclassCî‚¿res-theriskof
electricalshockisfartoogreat!ClassCextinguishersdonothaveanumerical
rating.TheCclassiî‚¿cationmeanstheextinguishingagentisnon-conductive.
Geometricsymbol(bluecircle).
ABC
î‚¿reextinguishersareadrychemicaltypeusedformultiplepurposes.Seeabove
informationfordescription.
Ensureî‚¿reextinguishersareserviceableandreplaceanythataredischargedor
outofinspectiondates.
Safety:SafetyInstructions
Page1–4
1P65F-2ServiceManual
3429-270RevA
Chapter2
Speciî‚¿cationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
TorqueSpecications...........................................................................................................................2–9
EquivalentsandConversions...........................................................................................................2–14
U.S.toMetricConversions..............................................................................................................2–15
1P65F-2ServiceManual
Page2–1
Speciî‚¿cationsandMaintenance
3429-270RevA
Speciî‚¿cations
1P65F–2EngineSpecications
Model1P65F-2
EngineNameToro
Type
SingleCylinder4–stroke,ForcedAirCooledOHVEngine
BoreXStroke
65mmx48mm
Displacement159cc
CompressionRatio
7.6:1
Lubrication
Splash
StartingRecoil/Electric
Rotation
Counter-Clockwise(fromPTOSide)
IgnitionSystem
TransistorizedMagnetoIgnition
AirCleanerFoam/Paper
FuelType
UnleadedGasoline87Octane10%Ethanol
OilCapacity18oz(0.53L)
Dimension(LxWxH)15in.x13.5in.x10in.(38.10x34.29x25.40cm)
Weight
31lbs.(14.06kg)
Operating(top)RPM
3000±100RPM
1P65F–2EnginePartSpecications
PartItem
StandardServiceLimit
CylinderHead
Warpage
N/A0.004in.(0.10mm)
CylinderSleeve(InsideDiameter)2.559in.(65mm)2.565in.(65.165mm)
SkirtOutsideDiameter2.558in.(64.985mm)2.552in.(64.845mm)
ClearancetoCylinder
0.00059-0.00196in.
(0.015-0.05mm)
N/A
PistonPinBoreInside
Diameter
0.512in.(13.002mm)0.514in.(13.048mm)
Piston
Piston-PinClearance
0.00008-0.00055in.
(0.002-0.014mm)
0.00314in.(0.08mm)
OutsideDiameter0.512in.(13.0mm)0.510in.(12.954mm)
PistonPin
SideClearance(Top/Middle)
0.00056-0.00177in.
(.015-0.045mm)
0.0059in.(0.15mm)
EndGap(Top/Middle)
0.0078-0.0156in.(0.2-0.4
mm)
0.040in.(1.0mm)
Width(T op/Middle)0.0397in.(1.0mm)0.0342in.(0.87mm)
PistonRing
Width(OilRing)0.098in.(2.5mm)0.093in.(2.37mm)
SmallEndInsideDiameter0.513in.(13.02mm)0.515in.(13.07mm)
BigEndInsideDiameter
1.024in.(26.02mm)1.026in.(26.07mm)
LargeEndtoCrankJournal
Clearance
0.0016-0.0025in.
(0.04-0.063mm)
0.0047in.(0.12mm)
ConnectingRod
LargeEndSideClearance
0.0039-0.0275in.(0.1-0.7
mm)
0.0433in.(1.1mm)
CrankshaftCrankPinOutsideDiameter1.022in.(25.98mm)1.020in.(25.92mm)
Speciî‚¿cationsandMaintenance:Speciî‚¿cations
Page2–2
1P65F-2ServiceManual
3429-270RevA
1P65F–2EnginePartSpecications(continued)
PartItem
StandardServiceLimit
Clearance(Cold)Intake
0.004-0.006in.(0.10-0.15
mm)
N/A
Clearance(Cold)Exhaust
0.006-0.008in.(0.15-0.20
mm)
N/A
StemDiameter(Intake)0.216in.(5.48mm)0.209in.(5.318mm)
Valve
StemDiameter(Exhaust)0.214in.(5.44mm)0.208in.(5.275mm)
InsideDiameter(Intake,
Exhaust)
0.2165in.(5.50mm)0.2193in.(5.572mm)
StemtoGuideClearance
(Intake)
0.00039-0.00133in.
(0.01-0.034mm)
0.00393in.(0.10mm)
ValveGuide
StemtoGuideClearance
(Exhaust)
0.00196-0.00275in.
(0.05-0.070mm)
0.0047in.(0.12mm)
ValveSeatSeatWidth0.0315in.(0.8mm)0.0787in.(2.0mm)
ValveSpring
FreeLength
1.202in.(30.5mm)1.141in.(29.0mm)
Height(Intake)1.091in.(27.72mm)1.080in.(27.45mm)
Height(Exhaust)1.093in.(27.78mm)1.0826in.(27.50mm) Camshaft
OutsideDiameter(Bearing)0.550in.(13.984mm)0.547in.(13.916mm)
CamshaftHoleDiameter0.551in.(14.0mm)0.553in.(14.048mm)
CrankcaseCover
CrankshaftHoleDiameter1.000in.(25.4mm)1.004in.(25.52mm)
SparkPlugGap
NGKBPR6HS/Champion
RL87YC
Gap0.030in.(0.7-0.8mm)
Resistance(Primary)
1.3-1.7ohms
N/A
Resistance(Secondary)
5.4-6.2ohms
N/A
IgniterCoils
GaptoFlywheel
0.0157±0.007in.(0.4-0.2
mm)
N/A
1P65F–2EngineTorqueSpecications
Item
ScrewThread
Torque
CylinderHeadBolt
M8
22-26ft-lbs.(30-36Nm)
ConnectingRodBolt
M7
108-132in-lbs.(13-15Nm)
FlywheelNut
M14(specialnut)59-66ft-lbs.(80-90Nm)
PivotAdjustingNut
M5(specialnut)52-87in-lbs.(6-10Nm)
CrankcaseCoverBolt
M6
70-105in-lbs.(8-12Nm)
MuferNut
M6
70-105in-lbs.(8-12Nm)
AirCleanerNut
M6
52-87in-lbs.(6-10Nm)
Recoil(FanCoverNut)
M6
52-87in-lbs.(6-10Nm)
OilDrainBolt
M10
13-18ft-lbs.(18-25Nm)
FuelTankBolt/Nut
M6
13-18ft-lbs.(18-25Nm)
GovernorArmPinchNut
M6
70-105in-lbs.(8-12Nm)
CarburetorBowlMountScrew
M8
52–79ft-lbs.(6-9Nm)
FuelDrainScrew
M6
52-79in-lbs.(6-9Nm)
ValveCoverBolt
M6
90in-lbs.(10Nm)
1P65F-2ServiceManual
Page2–3
Speciî‚¿cationsandMaintenance:Speciî‚¿cations
3429-270RevA
1P65F–2EngineTorqueSpecications(continued)
Item
ScrewThread
Torque
M4bolt
16-26in-lbs.(2-3Nm)
M5bolt/nut39-56in-lbs.(4.5-6.5Nm) StandardTorqueValue
M6bolt/nut70-105in-lbs.(8-12Nm)
1P65FCEngineSpeciî‚¿cations
Model
1P65FC
EngineNameToro
Type
SingleCylinder4-Stroke,ForcedAirCooledOHVEngine
BoreXStroke
65mmx48mm
Displacement159cc
CompressionRatio
8to1
Lubrication
Splash
StartingRecoil/Electric
Rotation
Counter-Clockwise(fromPTOSide)
IgnitionSystem
TransistorizedMagnetoIgnition
AirCleanerFoam/Paper
FuelType
UnleadedGasolineMinimum87Octane10%Ethanol
OilCapacityMaxFill20oz(0.59L)
Dimension(LxWxH)15in.x13.5in.x14in.(38.10x24.29x35.56cm)
Weight
26.4lbs.(11.97kg)
Operating(Top)RPM
3000±100RPM
1P65FCEnginePartSpeciî‚¿cations
PartItem
StandardServiceLimit
CylinderHead
Warpage
N/A0.004in.(0.10mm)
Cylinder
SleeveT aper/OutofRound
(InsideDiameter)
2.559in.(65mm)2.566in.(65.165mm)
SkirtOutsideDiameter2.558in.(64.985mm)2.552in.(67.845mm)
ClearancetoCylinder
0.00059-0.00196in.
(0.015-0.05mm)
0.0047in.(0.12mm)
PistonPinBoreInside
Diameter
N/A0.514in.(13.048mm)
Piston
Piston-PinClearance
0.00007-0.0005in.
(0.002-0.014mm)
0.00314in.(0.08mm)
OutsideDiameter0.512in.(13.0mm)0.510in.(12.954mm)
PistonPin
SideClearance
0.00059-0.00177in.
(.015-0.045mm)
0.0059in.(0.15mm)
EndGap(Top/Middle)
0.0078-0.0157in.(0.2-0.4
mm)
0.040in.(1.0mm)
Width(T op/Middle)0.0393in.(1.0mm)0.0342in.(0.87mm)
PistonRing
Width(OilRing)0.098in.(2.5mm)0.093in.(2.37mm)
Speciî‚¿cationsandMaintenance:Speciî‚¿cations
Page2–4
1P65F-2ServiceManual
3429-270RevA
1P65FCEnginePartSpeciî‚¿cations(continued)
PartItem
StandardServiceLimit
SmallEndInsideDiameter0.513in.(13.02mm)0.515in.(13.07mm)
LargeEndInsideDiameter
1.024in.(26.02mm)1.026in.(26.07mm)
LargeEndtoCrankJournal
Clearance
0.0016-0.0025in.
(0.04-0.063mm)
0.0047in.(0.12mm)
ConnectingRod
LargeEndSideClearance
0.0039-0.0275in.(0.1-0.7
mm)
0.0433in.(1.1mm)
CrankshaftCrankPinOutsideDiameter1.022in.(25.98mm)1.020in.(25.92mm)
Clearance(Cold)Intake0.004in.(0.10mm)N/A
Clearance(Cold)Exhaust0.006in.(0.15mm)N/A
StemDiameter(Intake)0.216in.(5.48mm)0.209in.(5.318mm)
Valve
StemDiameter(Exhaust)0.214in.(5.44mm)0.208in.(5.275mm)
InsideDiameter(Intake,
Exhaust)
0.2165in.(5.50mm)0.2193in.(5.572mm)
StemtoGuideClearance
(Intake)
0.00039-0.00133in.
(0.01-0.034mm)
0.00393in.(0.10mm)
Valveguide
StemtoGuideClearance
(Exhaust)
0.0019-0.0027in.
(0.05-0.070mm)
0.0047in.(0.12mm)
ValveSeatSeatWidth0.0314in.(0.8mm)0.0787in.(2.0mm)
ValveSpring
FreeLength
1.2007in.(30.5mm)1.1417in.(29.0mm)
Height(Intake)1.0905in.(27.72mm)1.0807in.(27.45mm)
Height(Exhaust)1.0937in.(27.78mm)1.0826in.(27.50mm) CamShaft
OutsideDiameter(Bearing)0.550in.(13.984mm)0.548in.(13.916mm)
CamshaftHoleDiameter0.551in.(14.0mm)0.553in.(14.048mm)
CrankcaseCover
CrankshaftHoleDiameter1.000in.(25.4mm)1.005in.(25.52mm)
SparkPlugGap
NGKBPR6HS/Champion
RL87YC
Gap0.030in.(0.7-0.8mm)
Resistance(Primary)
1.1-1.6ohms
N/A
Resistance(Secondary)10.5Kohms±15%N/A IgniterCoils
GaptoFlywheel0.010in.(0.254mm)N/A
1P65FCEngineTorqueSpeciî‚¿cations
Item
ScrewThread
Torque
CylinderHeadBolt
M8
25ft-lbs.(34Nm)
ConnectingRodBolt
M7
114in-lbs(13Nm)
FlywheelNutM14
62ft-lbs.(85Nm)
RockerArmAdjustingNutM6
120in-lbs.(14Nm)
CrankcaseCoverBolt
M6
90in-lbs.(10Nm)
MuferNut
M6
90in-lbs.(10Nm)
AirCleanerNut
M6
72in-lbs.(8Nm)
Recoil(FanShroud)Nut
M6
72in-lbs.(8Nm)
OilDrainBolt
M10
186in-lbs.(21Nm)
FuelTankBolt/Nut
M6
90in-lbs.(10Nm)
1P65F-2ServiceManual
Page2–5
Speciî‚¿cationsandMaintenance:Speciî‚¿cations
3429-270RevA
1P65FCEngineTorqueSpeciî‚¿cations(continued)
Item
ScrewThread
Torque
FuelDrainScrew
M6
52–79in-lbs.(6–9Nm)
ValveCoverBolt
M6
90in-lbs.(10Nm)
CarburetorMountScrew
M8
52–79in-lbs.(6–9Nm)
SparkPlugN/A22ft-lbs.(30Nm)
GovernorArmPinchNut
M6
90in-lbs.(10Nm)
IgnitionandChargeCoilBolts
M6
90in-lbs.(10Nm)
ElectricStarterMotorBolts
M6
90in-lbs.(10Nm)
M5bolt/nut54in-lbs.(6Nm)
M6bolt/nut90in-lbs.(10Nm)
M8bolt/nut228in-lbs.(26Nm)
M10bolt/nut28ft-lbs.(38Nm)
StandardTorqueValue
M12bolt/nut41ft-lbs.(55Nm)
1P65FAEngineSpeciî‚¿cations
Model1P65FA
EngineNameToro
Type
SingleCylinder4-Stroke,ForcedAirCooledOHVEngine
BoreXStroke
65mmx48mm
Displacement159cc
CompressionRatio
8to1
Lubrication
Splash
StartingRecoil/Electric
Rotation
Counter-Clockwise(fromPTOSide)
IgnitionSystem
TransistorizedMagnetoIgnition
AirCleanerFoam/Paper
FuelType
UnleadedGasolineMinimum87Octane10%Ethanol
OilCapacityMaxFill20oz(0.59L)
Dimension(LxWxH)15x13.5x14in.(38.10x34.29x35.56cm)
Weight
26.4lbs.(11.97kg)
Operating(Top)RPM
3000±100RPM
Idlespeed2200±150RPM
1P65FAEnginePartSpeciî‚¿cations
Part
Item
StandardServiceLimit
CylinderHead
Warpage
N/A0.004in.(0.10mm)
CylinderOutofRoundSleeve(InsideDiameter)2.559in.(65mm)2.566in.(65.165mm)
Speciî‚¿cationsandMaintenance:Speciî‚¿cations
Page2–6
1P65F-2ServiceManual
3429-270RevA
1P65FAEnginePartSpeciî‚¿cations(continued)
Part
Item
StandardServiceLimit
SkirtOutsideDiameter2.558in.(64.985mm)2.553in.(64.845mm)
ClearancetoCylinder
0.00059-0.00196in.
(0.015-0.05mm)
0.0047in.(0.12mm)
PistonPinBoreInside
Diameter
0.512in.(13.002mm)0.514in.(13.048mm)
Piston
Piston-PinClearance
0.00007-0.0005in.
(0.002-0.014mm)
0.00314in.(0.08mm)
PistonPin
OutsideDiameter0.512in.(13.0mm)0.510in.(12.954mm)
EndGap(Top/Middle)
0.0078-0.0156in.(0.2-0.4
mm)
0.040in.(1.0mm)
Width(T op/Middle)0.0590in.(1.5mm)0.0539in.(1.37mm)
PistonRing
Width(OilRing)0.098in.(2.5mm)0.093in.(2.37mm)
SmallEndInsideDiameter0.513in.(13.02mm)0.515in.(13.07mm)
LargeEndInsideDiameter
1.024in.(26.02mm)1.026in.(26.07mm)
LargeEndtoCrankJournal
Clearance
0.0016-0.0025in.
(0.04-0.063mm)
0.0047in.(0.12mm)
ConnectingRod
LargeEndSideClearance
0.0039-0.0275in.(0.1-0.7
mm)
0.0433in.(1.1mm)
CrankshaftCrankPinOutsideDiameter1.023in.(25.98mm)1.020in.(25.92mm)
Clearance(Cold)Intake
0.004-0.006in.(0.10-0.15
mm)
N/A
Clearance(Cold)Exhaust
0.006-0.008in.(0.15-0.20
mm)
N/A
StemDiameter(Intake)0.216in.(5.48mm)0.209in.(5.318mm)
Valve
StemDiameter(Exhaust)0.214in.(5.44mm)0.208in.(5.275mm)
InsideDiameter(Intake,
Exhaust)
0.2165in.(5.50mm)0.2193in.(5.572mm)
StemtoGuideClearance
(Intake)
0.00039-0.00133in.
(0.01-0.034mm)
0.00393in.(0.10mm)
ValveGuide
StemtoGuideClearance
(Exhaust)
0.00196-0.00275in.
(0.05-0.070mm)
0.0047in.(0.12mm)
ValveSeatSeatWidth0.0315in.(0.8mm)0.0787in.(2.0mm)
ValveSpring
FreeLength
1.200in.(30.5mm)1.142in.(29.0mm)
Height(Intake)1.091in.(27.7mm)1.081in.(27.45mm)
Height(Exhaust)1.093in.(27.75mm)1.0826in.(27.50mm) CamShaft
OutsideDiameter(Bearing)0.550in.(13.984mm)0.548in.(13.916mm)
CamshaftHoleDiameter0.551in.(14.0mm)0.553in.(14.048mm)
CrankcaseCover
CrankshaftHoleDiameter1.000in.(25.4mm)1.005in.(25.52mm)
SparkPlug
Gap
NGKBPR6HS/Champion
RL87YC
Gap0.030in.(0.7-0.8mm)
Resistance(Primary)
1.1-1.6ohms
N/A
Resistance(Secondary)10.5Kohms±15%N/A IgniterCoils
GaptoFlywheel0.010in.(0.254mm)N/A
1P65FAEngineTorqueSpeciî‚¿cations
1P65F-2ServiceManual
Page2–7
Speciî‚¿cationsandMaintenance:Speciî‚¿cations
3429-270RevA
1P65FAEngineTorqueSpeciî‚¿cations(continued)
Item
ScrewThread
Torque
CylinderHeadBolt
M8
25ft-lbs.(34Nm)
ConnectingRodBolt
M7
114in-lbs.(13Nm)
FlywheelNutM14
62ft-lbs.(85Nm)
RockerArmPivotStud
M8
22ft-lbs.(30Nm)
RockerArmLockNutM6
120in-lbs(14Nm)
CrankcaseCoverBolt
M6
90in-lbs.(10Nm)
MuferNuts
M6
90in-lbs.(10Nm)
AirCleanerNuts
M6
72in-lbs.(8Nm)
Recoil(FanCoverNut)
M6
72in-lbs.(8Nm)
OilDrainBolt
M10
180in-lbs.(21Nm)
FuelTankBolt/Nut
M6
90in-lbs.(10Nm)
FuelDrainScrew
M6
52–79in-lbs.(6–9Nm)
ValveCoverbolt
M6
90in-lbs.(10Nm)
CarburetorBowlMountScrew
M8
52–79in-lbs.(6–9Nm)
SparkPlugN/A22ft-lbs.(30Nm)
GovernorArmPinchNut
M6
90in-lbs.(10Nm)
IgnitionandChargeCoilBolts
M6
90in-lbs.(10Nm)
ElectricStarterMotorBolts
M6
90in-lbs.(10Nm)
M5bolt/nut54in-lbs.(6Nm)
M6bolt/nut90in-lbs.(10Nm)
M8bolt/nut228in-lbs.(26Nm)
M10bolt/nut28ft-lbs.(38Nm)
StandardTorqueValue
M12bolt/nut41ft-lbs.(55Nm)
Speciî‚¿cationsandMaintenance:Speciî‚¿cations
Page2–8
1P65F-2ServiceManual
3429-270RevA
TorqueSpeciî‚¿cations
Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For
criticalapplications,asdeterminedbyToro,eithertherecommendedtorqueora
torquethatisuniquetotheapplicationisclearlyidentiî‚¿edandspeciî‚¿edinthe
servicemanual.
Thesetorquespeciî‚¿cationsfortheinstallationandtighteningoffastenersshall
applyforallfastenerswhichdonothaveaspeciî‚¿crequirementidentiî‚¿edin
theservicemanual.Thefollowingfactorsshallbeconsideredwhenapplying
torque:cleanlinessofthefastener,useofathreadsealant(Loctite),degreeof
lubricationonthefastener,presenceofaprevailingtorquefeature,hardness
ofthesurfaceunderneathofthefastener’shead,orsimilarconditionwhich
affectstheinstallation.
Asnotedinthefollowingtables,torquevaluesshouldbereducedby25%for
lubricatedfastenerstoachievethesimilarstressasadryfastener.T orquevalues
mayalsohavetobereducedwhenthefasteneristhreadedintoaluminumor
brass.Thespeciî‚¿ctorquevalueshouldbedeterminedbasedonthealuminum
orbrassmaterialstrength,fastenersize,lengthofthreadengagement,etc.
Thestandardmethodofverifyingtorqueshallbeperformedbymarkingalineon
thefastener(headornut)andmatingpart,thenbackofffastener1/4ofaturn.
Measurethetorquerequiredtotightenthefasteneruntilthelinesmatchup.
FastenerIdentiî‚¿cation
InchSeriesBoltsandScrews
Figure1
1.Grade13.Grade8
2.Grade5
1P65F-2ServiceManual
Page2–9
Speciî‚¿cationsandMaintenance:TorqueSpeciî‚¿cations
3429-270RevA
MetricBoltsandScrews
Figure2
1.Class8.82.Class10.9
Speciî‚¿cationsandMaintenance:TorqueSpeciî‚¿cations
Page2–10
1P65F-2ServiceManual
3429-270RevA
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