Exmark 127-9041 Service Manual Download Page 1 | Manualshive

Page: 1 / 47

Exmark 127-9041 Service Manual Download Page 1

EXMARK V-TWIN AIR COOLED

ENGINE SERVICE MANUAL

P/N 127-9041 (708cc)

1
2
3
...
»

Summary of Contents for 127-9041

Page 1: ...EXMARK V TWIN AIR COOLED ENGINE SERVICE MANUAL P N 127 9041 708cc...

Page 2: ...Contents lists the systems and the related topics covered in this manual An electronic version of this service manual is available on the Exmark Dealer Extranet We are hopeful that you will find this...

Page 3: ...running Avoid Fires and Explosions Avoid spilling fuel and never smoke while working with any type of fuel or lubricant Wipe up any spilled fuel or oil immediately Never remove the fuel cap or add fu...

Page 4: ...engine Always observe and use precautions and procedures when installing flywheel WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engi...

Page 5: ...individual however warranty repairs must be performed by an authorized Exmark dealer Service Rules Engine Model Serial Number Location The engine model and serial number are stamped into the block the...

Page 6: ...s 26 N m 14 Inlet Pipe Hex Flange Bolt M6 35 8 Ft lbs 10 N m Stud Bolt M6 106 5 Ft Lbs 7 N m 15 Air Box Nut Flange M6 6 Ft Lbs 8 N m 16 Cooling Fan Hex Flange Nut M8 20 15 Ft Lbs 22 N m 17 Cooling Fan...

Page 7: ...dth second 0 0460 0 0469 1 17 1 19 mm 0 0433 1 1 mm Width oil ring 0 0650 0 0728 1 65 1 85 mm 0 0630 1 6 mm Connecting rod Small end inside diameter 0 6695 0 670 17 006 17 017 mm 0 6712 17 05 mm Big e...

Page 8: ...17 0 150 28 3 250 39 6 350 17 0 150 5 16 24 18 7 165 30 5 270 3 8 16 29 4 260 3 8 24 33 9 300 Tightening Torque N m ft lb 20 5 16 24 40 7 30 3 8 16 47 5 35 67 8 50 3 8 24 54 2 40 81 4 60 7 16 14 47 5...

Page 9: ...1 7 16 27 1 20 47 5 35 66 4 49 81 4 60 33 9 25 M12 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 M14 58 3 43 76 4 56 131 5 97 184 4 136 219 7 162 94 9 70 Torque Conversions N m in lb x 0 113 in l...

Page 10: ...c Inches 708 cc Compression Ratio 8 7 1 Lubricating mode Full pressure Starting mode Electric Rotation Counter Clockwise from P T O side Valve clearance Intake valve 0 004 0 006 Exhaust valve 0 006 0...

Page 11: ...Maintenance 2 2...

Page 12: ...Maintenance 2 3...

Page 13: ...Maintenance 2 4...

Page 14: ...Maintenance 3 1 3 Maintenance 3 1 Maintenance schedule 3 2 3 2 Engine oil 3 2 3 3 Air cleaner 3 3 3 4 Spark plug 3 4 3 5 Valve clearance 3 4 3 6 Carburetor 3 5 3 7 Governor 3 5 3...

Page 15: ...in a Unwind the tube from the cleat b Pull hose down from the fitting c Allow the oil to drain into a suitable container d Replace hose fully Maintenance schedule Each Use First 1 month or 5 hours Eve...

Page 16: ...to the oil filler tube Remove the oil filler cap dipstick and check the oil level Bring the level to the upper mark on the dipstick after running the engine recheck the oil level and adjust if necessa...

Page 17: ...to brush off the dirt Brushing will force dirt into the filter fibers 5 Use a damp rag to wipe any dirt from the inside of the air cleaner base and cover Be careful not to allow dirt into the duct le...

Page 18: ...2 turn after the spark plug seats 18 22 ft lbs NOTICE A loose spark plug can become hot enough to damage the engine Over tightening a spark plug can damage the threads in the engine 6 Install the spar...

Page 19: ...0 rpm 3 7 Governor 1 Loosen the governor arm pinch bolt nut but do not remove it 2 Move the governor arm anti clockwise to fully open the throttle and hold it in this position 3 Rotate the governor ar...

Page 20: ...Air cleaner 4 2 4 2 Engine cover 4 3 4 3 Control lever 4 4 4 4 Air Intake 4 5 4 5 Carburetor 4 5 4 6 Ignition coil 4 6 4 7 Flywheel breather 4 7 4 8 Cylinder head valves 4 8 4 9 Crankcase cover govern...

Page 21: ...Maintenance 4 2 4 1 Air Cleaner...

Page 22: ...Maintenance 4 3 4 2 Engine Cover...

Page 23: ...Maintenance 4 4 4 3 Control Lever Removal Installation...

Page 24: ...Maintenance 4 5 4 4 Air Intake...

Page 25: ...Process Description Bolt Specification Torque Range N m In lb 1 Solenoid Valve M12 6 9 53 1 79 6 2 Fuel Cup Screw M4 1 5 2 0 13 3 17 7 3 Fuel Plug Flange Bolt M6 6 9 53 1 79 6 4 Pin Float Screw M3 1 8...

Page 26: ...contact with iron core of coil and measure the primary coil resistance Primary coil resistance 1 6 1 9 Secondary coil Put the tester terminal and removed spark plug cap s high tension cord to contact...

Page 27: ...Disassembly Do not hit the flywheel with a hammer Remove with a commercially available puller Avoid the magnet section when attaching the puller Reassembly Make certain there are no metal objects stuc...

Page 28: ...Maintenance 4 9 4 8 Cylinder Head Valves Removal Installation Remove the following 1 engine cover 2 carburetor 3 Shroud Comp Cylinder Head Right...

Page 29: ...oval Installation Loosen and tighten Bolt Cylinder Head in a crisscross pattern in 2 3 steps Before installation remove any carbon deposits from the combustion chamber and inspect the valve seats Meas...

Page 30: ...Maintenance 4 11 Disassembly Reassembly Inspection Cylinder Head Right...

Page 31: ...lace the spring if they shorter than the service limit Valve Seat Width Remove carbon deposits from the combustion chamber Inspection the valve seats for pitting or other damage Measure the valve seat...

Page 32: ...e limit Valve Guide ID Ream the exhaust valve guide to remove any carbon deposits before measuring Measure and record each valve guide ID Standard Service limit 0 259 0 260 0 262 Stem to Guide Clearan...

Page 33: ...e combustion chambers and valve seats to remove carbon deposits 2 Apply a light coat of Prussian Blue or erasable felt tipped marker ink to the valve faces 3 Insert the valve and then lift them and sn...

Page 34: ...erasable felt tipped marker ink to the valve faces 4 Insert the valves and then lift them and snap them closed against their seats several times Be sure the valve does not rotate on the seat The seati...

Page 35: ...Maintenance 4 16 4 9 Crankcase Cover Governor Disassembly Reassembly Governor NOTICE Check that the governor moves smoothly...

Page 36: ...Maintenance 4 17 Crankcase cover...

Page 37: ...Maintenance 4 18 4 10 Crankshaft Piston Camshaft Remove installation...

Page 38: ...he piston to piston pin hole with 120 degree Top ring The second ring Oil ring Piston Sign Top ring The second ring Oil ring Check refer to Piston pin Piston ring clip Assembly Put the one end into th...

Page 39: ...Maintenance 4 20 Piston Pin OD Model Standard Service limit LC2P77F 0 6689 0 6692 0 6653...

Page 40: ...0318 Y 3 0315 3 0318 3 0354 3 0354 Piston Skirt Outside Diameter Measure and record the piston skirt outside diameter at the 10mm from piston skirt maximum lower side making 90 to piston pin hole Mod...

Page 41: ...to position the ring so it will not be cocked in the cylinder bore Connecting Rod Small End ID Model Standard Service limit 708 CC 0 6695 0 6699 0 6712 Connecting Rod Large End ID Original size Model...

Page 42: ...tic gauge 4 If the clearance exceeds the service limit replace the connecting rod and recheck the clearance After using new connecting rod the clearance still exceeds the service limit lap the neck jo...

Page 43: ...24 Chapter 5 Electrical System Information Ignition Coil Gap Adjustment 1 Ignition Coil Resistance Inspection 1 Spark Testing 2 Fuel Solenoid 2 Charging System Specifications 3 AC Output Test 3 DC Ou...

Page 44: ...t the feeler gauge between the flywheel and coil 7 Adjust the ignition coil gap at both sides of the coil 8 Sufficiently tighten the mounting bolts Ignition Coil Resistance Inspection Primary Coil Pla...

Page 45: ...ark plug from the engine 3 Connect the negative electrode of the spark plug threaded area to ground cylinder head cover 4 Crank the engine and view the electrode gap Spark should be present when engin...

Page 46: ...ngine running at 3600 RPM output should be no less than 14 volts AC 7 NOTE The battery MUST be in good condition to perform this test Charge Coil s Air Gap Measure Between the Magnet Area of the Flywh...

Page 47: ...test leadinto1OAreceptacle in meter 2 Insert BLACK test lead into COM receptacle in meter 3 Rotate selector to A DC AMPS position 4 Attach RED test lead clip 1 to DC output pin 6 in connector 4 Fig 16...

Reviews:

No comments