Tecumseh VLV Technician'S Handbook Download Page 1

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This handbook covers VLV40 - 675.

Other illustrated Tecumseh 2 and 4-Cycle Engine and

Transmission handbooks, booklets and wall charts are

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www.TecumsehPower.com

T E C H N I C I A N ' S H A N D B O O K

TECUMSEH

Form No. 695578 Rev. 6/02

Litho in U.S.A.

ENGINES

TRANSMISSIONS

Tecumseh Products Company

Engine & Transmission Group

900 North Street

Grafton, WI 53024

Phone: 262-377-2700

FAX: 262-377-4485

Tecumseh Europa S.p.A.

Strada delle Cacce, 99

10135 Torino, Italy

Tel. 011 39 11 391-8411

Telefax 011 39 11 3910031

ENGINES

TRANSMISSIONS

www.TecumsehPower.com

VLV
(Vector)
4-CYCLE
ENGINES

Summary of Contents for VLV

Page 1: ...ehPower com T E C H N I C I A N S H A N D B O O K TECUMSEH Form No 695578 Rev 6 02 Litho in U S A ENGINES TRANSMISSIONS Tecumseh Products Company Engine Transmission Group 900 North Street Grafton WI...

Page 2: ...gine it is your responsibility to read this Operator s Manual Follow these basic rules for your personal safety Keep this manual handy at all times for future reference Read it carefully and familiari...

Page 3: ...6 Engine Speed 1 6 Engine Stopping Mechanism 1 6 Seasonal Storage 1 7 Fuel System 1 7 Method 1 1 7 Method 2 1 7 Oil 1 7 Lubricating Cylinder Bore 1 7 Quick Maintenance Chart 1 7 4 Cycle Engine Theory...

Page 4: ...1 5 3 Method 2 5 3 Stopping the Engine 5 3 To Start Engine 5 3 Wiring Diagrams 5 4 Battery 5 4 Brake Pad Replacement 5 4 Brake Control Lever Replacement 5 5 Control Switch 5 5 Checking Control Switch...

Page 5: ...s 11 2 Chapter 12 Oil Seal Service and Mounting Flange 12 1 Oil Seal Service 12 1 Seal Replacement 12 1 Chapter 13 Troubleshooting 13 1 Table 1 4 Cycle Engine Troubleshooting Chart 13 2 Table 2 Carbur...

Page 6: ...o do so can result in serious injury or death Call Tecumseh Products Company at 1 800 558 5402 if you have any questions NEVER store engine with fuel in fuel tank inside a building with potential sour...

Page 7: ......

Page 8: ...o do so can result in serious injury or death Call Tecumseh Products Company at 1 800 558 5402 if you have any questions NEVER store engine with fuel in fuel tank inside a building with potential sour...

Page 9: ...nufacture 2002 39 The last 3 digits of date code represent the calendar the 39th day of 2002 D represents the shift and line on which the engine was built at the factory Emitted engines that meet the...

Page 10: ...on number stamped on the engine blower housing Carburetor and starter breakdowns are found in the chapters referring to their repair NOTE If the short block has been replaced an identification tag for...

Page 11: ...16 18 x 1 1 2 52 Spark Plug Champion RJ 17LM or equivalent 53 Spring Valve 54 Cap Valve spring 55 Gasket Valve cover 56 Cover Valve spring box 57 Screw 10 24 x 1 2 58 Stud Carburetor mounting 59 Link...

Page 12: ...llow it to cool before refueling 2 Be sure engine is outdoors and in a well ventilated area 3 Clean area around fuel fill cap and remove fuel fill cap See Figure 2 4 Using an approved red GASOLINE con...

Page 13: ...ecking and Changing Oil To avoid engine damage it is important to Check oil level after every 5 operating hours when engine is warm and before each use Change oil after first 2 operating hours and eve...

Page 14: ...cleaner to remove and replace it NOTE DO NOT put oil on or clean paper filter Air Cleaner Assembly Tabs Cover Flange Slot Paper Filter Resistor Spark Plug 030 0 76mm Gap Electrodes Porcelain Carbureto...

Page 15: ...fires empty fuel tank by running engine until it stops from lack of fuel DO NOT attempt to pour fuel from engine 2 Drain remaining fuel from carburetor by pressing up on bowl drain if present Oil Chan...

Page 16: ...he intake charge back down the in take pipe This eliminates unburned fuel going out the exhaust during normal compression relief cycle typically used on the exhaust valve 1 Intake 2 Compression Power...

Page 17: ...E Do not put oil on or clean a paper filter Be sure to clean base and cover thoroughly before installing new paper filter DO NOT run engine without complete air cleaner installed on engine Doing so ma...

Page 18: ...e hinge is assembled properly 9 Swing cover up and tighten cover screw Do not over tighten 2 Swing cover down and remove from hinge B 3 Pull foam pre filter out of air cleaner body if equipped with pr...

Page 19: ...elch Plug Idle Mixture Well 39 32 25 25A 38 37 36 29 47 26 30 27 1 5 7 6 6 7 5 1 47 29 31 31 General Proper Carburetion Function is dependent on clean fresh fuel and a well maintained air cleaner syst...

Page 20: ...to check the cross holes on the body of the nozzle and the main orifice in the bottom of the nozzle Compressed air can pierce the skin and cause injury DO Not use your hand to check for leaks or to de...

Page 21: ...the inlet seat goes into the float bowl first Use care when installing inlet seat into float bowl Failure to do so may result in scratching the inlet bore 13 Install a new inlet seat into the float b...

Page 22: ...el b Pry plug out of position NOTE 18 Drop the main nozzle spring into the main nozzle well in the float bowl Put a small amount of oil on the main nozzle O ring and push the nozzle into the main nozz...

Page 23: ...shutter that sticks 6 Install the throttle shaft and shutter 7 Verify the scribe mark on the shutter is in the 12 o clock position New Welch Plug Flat End Punch Same Diameter of Plug NOTE To rebuild...

Page 24: ...tor 13 Press the new bulb and the new retainer into position using a deep reach socket as shown 14 Install the air cleaner body over the carburetor NOTE The VLV models use a closed loop breather syste...

Page 25: ...t through an idler gear as shown below VLV Type II Type I TYPE II governors do not use governor retainer clips The spool is retained by a raised upset on the shaft Wear eye protection and verify setup...

Page 26: ...t the speed control lever Long Bend Short Bend Governor Spring Twist Counterclockwise to Disconnect Governor Adjustment 1 Verify engine is stopped 2 Loosen the screw holding the governor clamp and lev...

Page 27: ...ring and cover are held together by the bosses in the pulley Assembly and Inspection 1 Reverse the above listed procedure keeping in mind that the starter dogs with the dog springs must snap back to t...

Page 28: ...ey cavity while aligning the outside spring hook into the deep notch in the pulley 3 Push the spring cover in until seated 4 Apply a small amount of lithium grease to the inner bore of the center shaf...

Page 29: ...asher cupped over retainer spring 9 Washer metal 10 Retainer ring 11 Thrust washer metal 12 Washer plastic 13 Lock nuts 14 Cap assembly drive end 15 Armature 16 Housing 17 End cap and brush card assem...

Page 30: ...Brush Assembly Armature Check If commutator bars are glazed or dirty they can be turned down in a lathe While rotating hold a strip of 00 sandpaper lightly on the commutator moving it back and forth...

Page 31: ...om carburetor NOTE The throttle linkage is routed around starter while the gov ernor spring is routed through the end cap prongs 4 Tighten nuts on starter bolts see Specifications 5 Place blower housi...

Page 32: ...695578 NOTES 4 6...

Page 33: ...Diecast Aluminum Flywheel The second and most popular style of flywheel is diecast aluminum The aluminum flywheel features a replaceable plastic fan NOTE If the engine is equipped with an electric sta...

Page 34: ...ing so may result in flywheel breakage Never use a pry bar with any type of curve on the end Doing so may result in Breather cover damage F O R Installation 1 Inspect brake pad to be free of dirt oil...

Page 35: ...g system WILL NOT RECHARGE a dead battery This system is designed to maintain the charge Before storage and again in spring the battery should be charged with the O E M supplied charger Stopping the E...

Page 36: ...ator Lead Battery Check battery per manufacturer s recommendations The charging system on the engine maintains the battery during normal use When battery is low use the 120 volt auxiliary charger usua...

Page 37: ...t close the switch before the starter can be engaged Disconnect battery from circuit before making check Engines equipped with an electric starter have a control switch that is attached to the brake l...

Page 38: ...mination Screws Alternator Coil Ignition Coil Lamination Screw Troubleshooting Electric Start Engines The following is a list of possible problems and causes Dead Battery Extended storage without char...

Page 39: ...transferred through the switch SCR to a transformer where the voltage is increased from 200 volts to 25 000 volts This voltage is transferred by means of the high tension lead to the spark plug where...

Page 40: ...5 Nm Recheck gap setting to make certain there is proper clearance between the magnets and laminations Ignition Timing The flywheel key is what times the ignition for the engine If this key is partia...

Page 41: ...gger ring gaps 6 When installing new rings deglaze cylinder wall using a commercially available deglazing tool 7 Use a ring expander to remove and replace rings Do not spread the piston rings too wide...

Page 42: ...rd toward the mechanic when installed in an engine A new piston can be installed on the connecting rod in either direction If the old piston is reused install the piston to the connecting rod so that...

Page 43: ...t stone to obtain a good cross hatch pattern for proper ring seating Clean cylinder with soap and water and dry thoroughly Replace piston and piston rings with correct oversize parts as indicated in p...

Page 44: ...he crankpin at top dead center the timing mark should be in the 2 30 position NOTE Timing marks on crankshaft gear and camshaft gear must be aligned for proper valve timing Camshaft Removal Align timi...

Page 45: ...eck for plugged mist hole From Camshaft Oil Passage Main Bearing Lube Hole Oil Mist Hole Spray Mist Hole Breather Oil Return Hole Oil Drain Hole Oil Pump An eccentric on the camshaft works the plunger...

Page 46: ...ng so may result in leakage Condensed oil vapors are returned to the crankcase by means of the oil return hole The oil return hole is opened and closed in the cylinder by the piston The breather filte...

Page 47: ...ground handle with care to pre vent damage to the ground faces Do not use valves with undersized margins Doing so may result in a valve that does not seat normally burns easily and can also lead to v...

Page 48: ...gh the spring The valve spring cap should sit around the valve lifter exposed end Use extreme care when servicing any springs Wear the appropriate safety equipment These springs may be highly compress...

Page 49: ...tapping them out with a screwdriver or punch from the inside To remove a seal with the crankshaft in the engine insert a screwdriver between the seal and the crankshaft and pry the seal out Seal Repla...

Page 50: ...ic starter does not crank engine See 12 volt starter troubleshooting chart Loose or defective ignition wiring Check ignition wiring for shorts or grounds repair if necessary Incorrect timing Flywheel...

Page 51: ...k valve spring Replace valve spring Air cleaner fouled Service air cleaner Remedy and Reference Cause Engine Misses Under Load Table 1 4 Cycle Engine Troubleshooting Chart Continued Engine Lacks Power...

Page 52: ...tall new rings and check land clearance and correct as necessary Cylinder wall worn or glazed allowing oil to Bore cylinder for oversized piston rings bypass rings into combustion chamber Piston fit u...

Page 53: ...king Replace cover gasket Damaged or worn oil seals on end of crankshaft Replace seals Breather mechanism loose or gaskets leaking Install new gaskets and tighten securely Breather mechanism installed...

Page 54: ...ausing siphon affect 19 Check for warp air filter box causing prime charge loss 20 Air leak at idle welch plug reseal with nail polish 21 Air leak at intake cross over pipe check using spray carbureto...

Page 55: ...n over Replace flywheel if necessary Brushes sticking Free brushes Replace worn brushes and those which have come in contact with grease and oil Open or shorted armature Replace armature Shorted open...

Page 56: ...aulty electrical Correct connections Dirty or oily commutator Clean and dress commutator Brushes binding in holders Free up brushes Replace worn brushes and those which have come in contact with greas...

Page 57: ...996 mm 1 0230 25 984 mm 1 0230 25 984 mm Crankshaft Magneto Main Brg Dia 1 0242 26 014 mm 1 0242 26 014 mm 1 0237 26 001 mm 1 0237 26 001 mm Crankshaft P T O Main Brg Dia 1 0242 26 014 mm 1 0242 26 0...

Page 58: ...Nut Cast Iron 500 600 56 5 67 8 Housing to Baffle 35 45 4 0 5 1 Carburetor Stud to Cylinder 50 75 5 7 8 5 A C Hex Nut to Stud 35 45 4 0 5 1 Control Face Plate to Baffle 20 35 2 3 3 9 Starter Top Moun...

Page 59: ...ures for the 800 801 and 820 transaxles Specialty Troubleshooting Booklets Instruc tional Guide 692738 Assists in the use and understanding of the Tecumseh Master Parts Manual Illustrates time saving...

Page 60: ...Flywheel Puller 670169 670292 670294 670293 670324 670323 670334 670333 670320 670324 670297 Air gap Gauge 0125 670321 Air gap Gauge 030 670315A Valve Spring Compressor For OVM OVXL 120 125 OHV 11 17...

Page 61: ...169 VIBRATION TACHOMETER No 670156 Vibration tachometer No 670339 E 5 Socket No 670283 Valve Guide Reamer TORX DRIVERS Torx 8 670334 Torx 10 670333 Torx 15 670323 Torx 20 670324 Torx 25 670319 Torx 30...

Page 62: ...02507B 143 976602 VLV66 502508B 143 976604 VLV66 502505B 143 976604 VLV66 502509B 143 976608 VLV66 502511B 143 976610 VLV66 502512B 143 976612 VLV66 502513D 143 986008 VLV60 502055D 143 986516 VLV65 5...

Page 63: ...375 3 8 391 25 64 406 13 32 422 27 64 438 7 16 453 29 64 469 15 32 484 31 64 50 1 2 516 33 64 531 17 32 547 35 64 563 9 16 578 37 64 594 19 32 609 39 64 625 5 8 641 41 64 656 21 32 672 43 64 688 11 16...

Page 64: ...695578 NOTES 16 3...

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