Toro 1P65F-2 Service Manual Download Page 15

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1P65FC Engine Part Specifications (continued)

Part

Item

Standard

Service Limit

Small End Inside Diameter

0.513 in. (13.02 mm)

0.515 in. (13.07 mm)

Large End Inside Diameter

1.024 in. (26.02 mm)

1.026 in. (26.07 mm)

Large End to Crank Journal

Clearance

0.0016-0.0025 in.

(0.04-0.063 mm)

0.0047 in. (0.12 mm)

Connecting Rod

Large End Side Clearance

0.0039-0.0275 in. (0.1-0.7

mm)

0.0433 in. (1.1 mm)

Crankshaft

Crank Pin Outside Diameter

1.022 in. (25.98 mm)

1.020 in. (25.92 mm)

Clearance (Cold) Intake

0.004 in. (0.10 mm)

N/A

Clearance (Cold) Exhaust

0.006 in. (0.15 mm)

N/A

Stem Diameter (Intake)

0.216 in. (5.48 mm)

0.209 in. (5.318 mm)

Valve

Stem Diameter (Exhaust)

0.214 in. (5.44 mm)

0.208 in. (5.275 mm)

Inside Diameter (Intake,

Exhaust)

0.2165 in. (5.50 mm)

0.2193 in. (5.572 mm)

Stem to Guide Clearance

(Intake)

0.00039-0.00133 in.

(0.01-0.034 mm)

0.00393 in. (0.10 mm)

Valve guide

Stem to Guide Clearance

(Exhaust)

0.0019-0.0027 in.

(0.05-0.070 mm)

0.0047 in. (0.12 mm)

Valve Seat

Seat Width

0.0314 in. (0.8 mm)

0.0787 in. (2.0 mm)

Valve Spring

Free Length

1.2007 in. (30.5 mm)

1.1417 in. (29.0 mm)

Height (Intake)

1.0905 in. (27.72 mm)

1.0807 in. (27.45 mm)

Height (Exhaust)

1.0937 in. (27.78 mm)

1.0826 in. (27.50 mm)

Cam Shaft

Outside Diameter (Bearing)

0.550 in. (13.984 mm)

0.548 in. (13.916 mm)

Camshaft Hole Diameter

0.551 in. (14.0 mm)

0.553 in. (14.048 mm)

Crankcase Cover

Crankshaft Hole Diameter

1.000 in. (25.4 mm)

1.005 in. (25.52 mm)

Spark Plug

Gap

NGK BPR6HS/Champion

RL87YC

Gap 0.030 in. (0.7-0.8 mm)

Resistance (Primary)

1.1-1.6 ohms

N/A

Resistance (Secondary)

10.5 K ohms ± 15%

N/A

Igniter Coils

Gap to Flywheel

0.010 in. (0.254 mm)

N/A

1P65FC Engine Torque Specifications

Item

Screw Thread

Torque

Cylinder Head Bolt

25 ft-lbs. (34 Nm)

Connecting Rod Bolt

114 in-lbs (13 Nm)

Flywheel Nut

M14

62 ft-lbs. (85 Nm)

Rocker Arm Adjusting Nut

120 in-lbs. (14 Nm)

Crankcase Cover Bolt

90 in-lbs. (10 Nm)

Muffler Nut

90 in-lbs. (10 Nm)

Air Cleaner Nut

72 in-lbs. (8 Nm)

Recoil (Fan Shroud) Nut

72 in-lbs. (8 Nm)

Oil Drain Bolt

M10

186 in-lbs. (21 Nm)

Fuel Tank Bolt/Nut

90 in-lbs. (10 Nm)

1P65F-2 Service Manual

Page 2–5

Specifications and Maintenance: Specifications

3429-270 Rev A

Summary of Contents for 1P65F-2

Page 1: ... 2 Service Manual Published August 2019 1P65FC and 1P65FA engine specifications included 2018 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Rights Reserved ...

Page 2: ...Revision History Revision History Page 2 1P65F 2 Service Manual 3429 270 Rev A ...

Page 3: ...the related topics covered in this manual We are hopeful that you will find this manual a valuable addition to your service shop If you have any questions or comments regarding this manual please contact us at the following address The Toro Company RLC SWS Customer Care Department 8111 Lyndale Avenue South Bloomington MN 55420 The Toro Company reserves the right to change product specifications or...

Page 4: ...stener tightening sequence Component orientation that may not be obvious Critical Torque This icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tables Fluid Specifications This icon is used to highlight fluid specifications and capacities that are less common and may not appear on the machine service decal or in the machine O...

Page 5: ... 2 Service and Repairs 4 3 Chapter 5 Air Intake System 5 1 General Information 5 2 Service and Repairs 5 3 Chapter 6 Fuel System 6 1 General Information 6 2 Service and Repairs 6 3 Chapter 7 Compression System 7 1 General Information 7 2 Service and Repairs 7 3 Chapter 8 Electrical System 8 1 General Information 8 2 Service and Repairs 8 3 Chapter 9 Engine Lower End 9 1 General Information 9 2 Ser...

Page 6: ...Preface Page 6 1P65F 2 Service Manual 3429 270 Rev A ...

Page 7: ...Chapter 1 Safety Table of Contents Safety Instructions 1 2 Think Safety First 1 2 1P65F 2 Service Manual Page 1 1 Safety 3429 270 Rev A ...

Page 8: ...normally moving parts as if they were moving whenever the engine is running or has the potential to start Avoid burns Do not touch the engine muffler or other components which may be hot during operation while the unit is running or shortly after it has been running Avoid fires and explosions Use extreme care in handling fuel It is flammable and its vapors are explosive Extinguish all cigarettes c...

Page 9: ...away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use your hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury Seek medical attention right away if hydraulic fluid gets in the skin Personal Protective Equipment Use appropriate personal protective equipment PPE for protecti...

Page 10: ... feet of fire it can extinguish Geometric symbol red square Class C fires involve electrical equipment such as appliances wiring circuit breakers and outlets Never use water to extinguish class C fires the risk of electrical shock is far too great Class C extinguishers do not have a numerical rating The C classification means the extinguishing agent is non conductive Geometric symbol blue circle A...

Page 11: ...ns and Maintenance Table of Contents Specifications 2 2 Torque Specifications 2 9 Equivalents and Conversions 2 14 U S to Metric Conversions 2 15 1P65F 2 Service Manual Page 2 1 Specifications and Maintenance 3429 270 Rev A ...

Page 12: ... 845 mm Clearance to Cylinder 0 00059 0 00196 in 0 015 0 05 mm N A Piston Pin Bore Inside Diameter 0 512 in 13 002 mm 0 514 in 13 048 mm Piston Piston Pin Clearance 0 00008 0 00055 in 0 002 0 014 mm 0 00314 in 0 08 mm Outside Diameter 0 512 in 13 0 mm 0 510 in 12 954 mm Piston Pin Side Clearance Top Middle 0 00056 0 00177 in 015 0 045 mm 0 0059 in 0 15 mm End Gap Top Middle 0 0078 0 0156 in 0 2 0 ...

Page 13: ... mm 0 553 in 14 048 mm Crankcase Cover Crankshaft Hole Diameter 1 000 in 25 4 mm 1 004 in 25 52 mm Spark Plug Gap NGK BPR6HS Champion RL87YC Gap 0 030 in 0 7 0 8 mm Resistance Primary 1 3 1 7 ohms N A Resistance Secondary 5 4 6 2 ohms N A Igniter Coils Gap to Flywheel 0 0157 0 007 in 0 4 0 2 mm N A 1P65F 2 Engine Torque Specifications Item Screw Thread Torque Cylinder Head Bolt M8 22 26 ft lbs 30 ...

Page 14: ...26 4 lbs 11 97 kg Operating Top RPM 3000 100 RPM 1P65FC Engine Part Specifications Part Item Standard Service Limit Cylinder Head Warpage N A 0 004 in 0 10 mm Cylinder Sleeve Taper Out of Round Inside Diameter 2 559 in 65 mm 2 566 in 65 165 mm Skirt Outside Diameter 2 558 in 64 985 mm 2 552 in 67 845 mm Clearance to Cylinder 0 00059 0 00196 in 0 015 0 05 mm 0 0047 in 0 12 mm Piston Pin Bore Inside...

Page 15: ...4 in 0 8 mm 0 0787 in 2 0 mm Valve Spring Free Length 1 2007 in 30 5 mm 1 1417 in 29 0 mm Height Intake 1 0905 in 27 72 mm 1 0807 in 27 45 mm Height Exhaust 1 0937 in 27 78 mm 1 0826 in 27 50 mm Cam Shaft Outside Diameter Bearing 0 550 in 13 984 mm 0 548 in 13 916 mm Camshaft Hole Diameter 0 551 in 14 0 mm 0 553 in 14 048 mm Crankcase Cover Crankshaft Hole Diameter 1 000 in 25 4 mm 1 005 in 25 52 ...

Page 16: ...gle Cylinder 4 Stroke Forced Air Cooled OHV Engine Bore X Stroke 65 mm x 48 mm Displacement 159 cc Compression Ratio 8 to 1 Lubrication Splash Starting Recoil Electric Rotation Counter Clockwise from PTO Side Ignition System Transistorized Magneto Ignition Air Cleaner Foam Paper Fuel Type Unleaded Gasoline Minimum 87 Octane 10 Ethanol Oil Capacity Max Fill 20 oz 0 59 L Dimension L x W x H 15 x 13 ...

Page 17: ...04 0 006 in 0 10 0 15 mm N A Clearance Cold Exhaust 0 006 0 008 in 0 15 0 20 mm N A Stem Diameter Intake 0 216 in 5 48 mm 0 209 in 5 318 mm Valve Stem Diameter Exhaust 0 214 in 5 44 mm 0 208 in 5 275 mm Inside Diameter Intake Exhaust 0 2165 in 5 50 mm 0 2193 in 5 572 mm Stem to Guide Clearance Intake 0 00039 0 00133 in 0 01 0 034 mm 0 00393 in 0 10 mm Valve Guide Stem to Guide Clearance Exhaust 0 ...

Page 18: ... Bolt M10 180 in lbs 21 Nm Fuel Tank Bolt Nut M6 90 in lbs 10 Nm Fuel Drain Screw M6 52 79 in lbs 6 9 Nm Valve Cover bolt M6 90 in lbs 10 Nm Carburetor Bowl Mount Screw M8 52 79 in lbs 6 9 Nm Spark Plug N A 22 ft lbs 30 Nm Governor Arm Pinch Nut M6 90 in lbs 10 Nm Ignition and Charge Coil Bolts M6 90 in lbs 10 Nm Electric Starter Motor Bolts M6 90 in lbs 10 Nm M5 bolt nut 54 in lbs 6 Nm M6 bolt nu...

Page 19: ...rneath of the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass m...

Page 20: ...Metric Bolts and Screws Figure 2 1 Class 8 8 2 Class 10 9 Specifications and Maintenance Torque Specifications Page 2 10 1P65F 2 Service Manual 3429 270 Rev A ...

Page 21: ... 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93 12 140 20 190 27 265 27 359 37 375 38 508 52 3 4 16 UNF 115 15 165 25 224 34 300 30 407 41 420 43 5...

Page 22: ...duce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material st...

Page 23: ... No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb 3 8 16 UNC 200 100 in lb Hole size material strength material thickness and finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners Conversion Factors in lb X 11 2985 N cm ft lb X 1 3558 N m N cm X 0 08851 in lb N cm X 0 73776 ft lb Thread Cutting Screws Zinc P...

Page 24: ...3 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 541 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 ...

Page 25: ...46 Cubic Feet Cubic Meters 0 02832 Volume Cubic Inches Cubic Centimeters 16 39 Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Weight Ounces Grams 28 3495 Pressure Pounds Square Inch Kilopascal 6 895 Foot Pounds Newton Meters 1 356 Foot Pounds Kilogram Meters 0 1383 Work Inch Pounds Kilogram Centimeters 1 152144 Quarts Liters 0 9463 Liquid Volume Gallons Liters 3 785 Liquid Flows Gallons Min...

Page 26: ...Specifications and Maintenance Torque Specifications Page 2 16 1P65F 2 Service Manual 3429 270 Rev A ...

Page 27: ...Chapter 3 Troubleshooting Table of Contents General Troubleshooting 3 3 1P65F 2 Service Manual Page 3 1 Troubleshooting 3429 270 Rev A ...

Page 28: ...is E Narrow down the focus of the problem Assess Performance Ensure you have all the necessary tools for testing Test all potential causes of the failure A Reevaluate and create new hypotheses if necessary Repair R Return the unit to service by repairing rebuilding or replacing Solution Confirmation Did the issue go away Was the root cause of the issue correctly repaired S Are there any other new ...

Page 29: ...l quality 1 Check the fuel condition for age octane ethanol percentage water or other contaminates 2 Flush the fuel system 3 Replace the fuel Weak or no spark 1 Check to verify the spark plug cap is installed correctly ignition coil air gap spark plug and spark plug gap 2 Adjust the ignition coil air gap 3 Replace damaged components Engine turns over but will not start Insufficient compression 1 P...

Page 30: ... verify the air filter isn t clogged or damaged 2 Replace as necessary Ignition coil 1 Perform a spark test 2 Check the ignition coil air gap 3 Adjust ignition coil air gap or replace coil as necessary Choke function 1 Check the choke is closing on start up and opening after the engine is running 2 Check the thermal control choke linkage and air vane operation 3 Make adjustments or replace compone...

Page 31: ...r 2 Replace as necessary Cylinder Cooling fins 1 Check for debris build up under the engine shroud 2 Clean debris from the cooling fins Oil 1 Check the oil level oil condition and correct oil viscosity 2 Change the oil using the correct viscosity Engine overheats Engine gasket leaking 1 Check the head gasket for leaking 2 Check for warped cylinder head 3 Replace head gasket as necessary 1P65F 2 Se...

Page 32: ...Troubleshooting General Troubleshooting Page 3 6 1P65F 2 Service Manual 3429 270 Rev A ...

Page 33: ...End Table of Contents General Information 4 2 Service and Repairs 4 3 Recoil Replacement 4 6 Flywheel Replacement 4 8 Crankcase Breather System Replacement 4 13 1P65F 2 Service Manual Page 4 1 Engine Top End 3429 270 Rev A ...

Page 34: ...nformation This chapter covers the disassembly inspection and reassembly of the recoil flywheel and crankcase breather assemblies Engine Top End General Information Page 4 2 1P65F 2 Service Manual 3429 270 Rev A ...

Page 35: ...ssembly 1 Figure 3 1 Acorn Nut 4 Fan Shroud 2 Recoil Shroud Asm 5 Shroud Stud 3 42 inch 86 9 mm 3 Recoil Compression Spring 6 Shroud Stud 3 31 inch 84 0 mm 1P65F 2 Service Manual Page 4 3 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 36: ...bly 2 Figure 4 1 Breather Cover 5 Crankcase 2 Breather Gasket Cover 6 Breather Tube 3 Breather Valve 7 Dipstick and Fill Tube Kit 4 Oil Seal Engine Top End Service and Repairs Page 4 4 1P65F 2 Service Manual 3429 270 Rev A ...

Page 37: ...Engine Top End Assembly 3 Figure 5 1 Flange Nut 2 Flywheel 1P65F 2 Service Manual Page 4 5 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 38: ...bly Figure 6 2 Remove the fuel tank vent hose from the hose retainer on the engine shroud Move the carbon canister to the side of the engine Figure 7 3 Remove the shroud by lifting away from the engine Recoil Inspection 1 Check the recoil dogs for excessive wear Engine Top End Service and Repairs Page 4 6 1P65F 2 Service Manual 3429 270 Rev A ...

Page 39: ...roud onto the engine 2 Place the carbon canister into position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Figure 9 3 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 in lbs 6 10 Nm 1P65F 2 Service Manual Page 4 7 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 40: ... nuts securing the recoil assembly to the top of the engine Remove the recoil assembly Figure 11 2 Remove the fuel tank vent hose from the hose retainer on the engine shroud Move the carbon canister to the side of the engine Engine Top End Service and Repairs Page 4 8 1P65F 2 Service Manual 3429 270 Rev A ...

Page 41: ...gine 5 Unhook the spring from the brake mechanism Figure 13 6 Place a pry bar under the flywheel to pry the flywheel upwards Use a soft based hammer loosen the flywheel assembly from the crankshaft only striking the top of the nut to prevent crankshaft damage 1P65F 2 Service Manual Page 4 9 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 42: ...d Figure 14 7 Remove the nut from the crankshaft Remove the flywheel from the engine Figure 15 Flywheel Inspection Inspect the keyway for damage Engine Top End Service and Repairs Page 4 10 1P65F 2 Service Manual 3429 270 Rev A ...

Page 43: ...nstall the flywheel onto the crankcase Figure 17 2 Install the nut securing the flywheel to the crankshaft Torque nut to 59 66 ft lbs 80 90 Nm 3 Hook the spring to the brake mechanism 1P65F 2 Service Manual Page 4 11 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 44: ...to position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Figure 19 6 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 in lbs 6 10 Nm Engine Top End Service and Repairs Page 4 12 1P65F 2 Service Manual 3429 270 Rev A ...

Page 45: ...the 3 10 mm acorn nuts securing the recoil assembly to the top of the engine Remove the recoil assembly Figure 21 2 Remove the fuel tank vent hose from the hose retainer on the engine shroud Move the carbon canister to the side of the engine 1P65F 2 Service Manual Page 4 13 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 46: ... to the engine 5 Unhook the spring from the brake mechanism Figure 23 6 Place a pry bar under the flywheel pry the flywheel upwards Using a soft based hammer loosen the flywheel assembly from crankshaft only striking the top of the nut to prevent crankshaft damage Engine Top End Service and Repairs Page 4 14 1P65F 2 Service Manual 3429 270 Rev A ...

Page 47: ... continued Figure 24 7 Remove the nut from the crankshaft Remove the flywheel from the engine Figure 25 8 Remove the ground wire from the brake assembly 1P65F 2 Service Manual Page 4 15 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 48: ...val continued Figure 26 9 Remove the 2 wires leading to the brake switch Figure 27 10 Remove the 2 bolts securing the brake assembly to the crankcase Engine Top End Service and Repairs Page 4 16 1P65F 2 Service Manual 3429 270 Rev A ...

Page 49: ...emoval continued Figure 28 11 Remove the bolt securing the breather assembly to the cover Figure 29 12 Remove the cover from the breather assembly 1P65F 2 Service Manual Page 4 17 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 50: ...inued Figure 30 13 Remove the valve from the breather assembly Figure 31 Crankcase Breather System Inspection 1 Inspect the valve seating surface for damage Engine Top End Service and Repairs Page 4 18 1P65F 2 Service Manual 3429 270 Rev A ...

Page 51: ...nued Figure 32 2 Inspect the face of the valve for wear or damage Figure 33 Crankcase Breather System Installation 1 Install the valve onto the breather assembly 1P65F 2 Service Manual Page 4 19 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 52: ... to the breather assembly Secure with a 10 mm bolt Torque bolt to 90 in lbs 10 Nm Figure 35 3 Install the 2 10 mm bolts securing the brake assembly to the crankcase Torque bolts to 90 in lbs 10 Nm Engine Top End Service and Repairs Page 4 20 1P65F 2 Service Manual 3429 270 Rev A ...

Page 53: ...stallation continued Figure 36 4 Install the 2 wires leading to the brake switch assembly Figure 37 5 Install the ground wire to the brake assembly 1P65F 2 Service Manual Page 4 21 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 54: ...nstall the flywheel onto the engine Figure 39 7 Install the nut securing the flywheel to the crankshaft Torque nut to 59 66 ft lbs 80 90 Nm 8 Hook the spring to the brake mechanism Engine Top End Service and Repairs Page 4 22 1P65F 2 Service Manual 3429 270 Rev A ...

Page 55: ...ister into position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Figure 41 11 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 in lbs 6 10 Nm 1P65F 2 Service Manual Page 4 23 Engine Top End Service and Repairs 3429 270 Rev A ...

Page 56: ...Crankcase Breather System Installation continued Figure 42 Engine Top End Service and Repairs Page 4 24 1P65F 2 Service Manual 3429 270 Rev A ...

Page 57: ...ter 5 Air Intake System Table of Contents General Information 5 2 Service and Repairs 5 3 Air Filter Replacement 5 4 Air Box Replacement 5 5 1P65F 2 Service Manual Page 5 1 Air Intake System 3429 270 Rev A ...

Page 58: ... 1P65F 2 engine is equipped with a 2 stage filtration system This chapter covers the disassembly inspection and assembly of the air intake system Air Intake System General Information Page 5 2 1P65F 2 Service Manual 3429 270 Rev A ...

Page 59: ... Repairs Air Intake System Assembly Figure 43 1 Air Cleaner Base 3 Air Filter and Prefilter Kit 2 Flange Nut 4 Air Cleaner Cover 1P65F 2 Service Manual Page 5 3 Air Intake System Service and Repairs 3429 270 Rev A ...

Page 60: ...he air filter housing assembly 3 Remove the air filter from the air filter housing Air Filter Inspection 1 Check the air filter for damage or excessive dirt and debris Figure 45 2 Remove the foam pre filter from the air filter cover Check for damage or excessive dirt and debris Air Intake System Service and Repairs Page 5 4 1P65F 2 Service Manual 3429 270 Rev A ...

Page 61: ...filter housing Figure 47 2 Install the cover to the air filter housing assembly 3 Hinge the air filter cover upward and lock into place Air Box Replacement Air Box Removal 1 Push down on the 2 air filter cover latch tabs 1P65F 2 Service Manual Page 5 5 Air Intake System Service and Repairs 3429 270 Rev A ...

Page 62: ...r from the air filter housing 4 Remove the 2 10 mm nuts securing the air filter housing to the engine Figure 49 5 Remove the air filter housing from the engine Air Box Inspection Inspect the O ring on the back side carburetor side of the air filter housing for damage Air Intake System Service and Repairs Page 5 6 1P65F 2 Service Manual 3429 270 Rev A ...

Page 63: ...lter housing to the engine Secure with 2 10 mm nuts securing the air filter housing to the engine Torque nuts to 52 87 in lbs 6 10 Nm Figure 51 2 Install the air filter into the air filter housing 1P65F 2 Service Manual Page 5 7 Air Intake System Service and Repairs 3429 270 Rev A ...

Page 64: ...ion continued Figure 52 3 Install the cover to the air filter housing assembly 4 Hinge the air filter cover upward and lock into place Air Intake System Service and Repairs Page 5 8 1P65F 2 Service Manual 3429 270 Rev A ...

Page 65: ...2 Service and Repairs 6 3 Carbon Canister Replacement 6 5 Fuel Filter and Hoses Replacement 6 9 Carburetor Replacement 6 13 Auto Choke System Thermal Control Replacement 6 25 Control Plate Replacement 6 31 1P65F 2 Service Manual Page 6 1 Fuel System 3429 270 Rev A ...

Page 66: ... vented to the carburetor manifold through a carbon canister The fuel is gravity fed to the carburetor through an in line fuel filter to the carburetor float bowl The fuel flow is controlled by the movement of the float inside the float bowl as the fuel level rises and falls Fuel System General Information Page 6 2 1P65F 2 Service Manual 3429 270 Rev A ...

Page 67: ...e 7 Oil Seal 2 Choke Linkage 8 Throttle Return Spring 3 Wire Harness Clip 9 Governor Rod 4 Throttle Control Plate 10 Governor Spring 5 Governor Arm 11 Governor Arm Bolt 6 Hair Pin 12 Governor Arm 1P65F 2 Service Manual Page 6 3 Fuel System Service and Repairs 3429 270 Rev A ...

Page 68: ...ank 9 Intake Gasket 3 Stud Bolt 10 Carburetor Spacer 4 Fuel Line Kit 11 Carburetor Gasket 5 Thermal Control 12 Carburetor Insulator 6 Thermal Choke Linkage 13 Carburetor 7 Throttle Lock 14 Carburetor Gasket Fuel System Service and Repairs Page 6 4 1P65F 2 Service Manual 3429 270 Rev A ...

Page 69: ...he engine Remove the recoil assembly Figure 55 2 Remove the fuel tank vent hose from the hose retainer on the engine shroud Move the carbon canister to the side of the engine Figure 56 3 Remove the fuel tank vent hose from the fitting on the fuel tank 1P65F 2 Service Manual Page 6 5 Fuel System Service and Repairs 3429 270 Rev A ...

Page 70: ...er 2 Place a thumb over the hose attached to the P port on the carbon canister 3 Apply a vacuum with the hand pump If the vacuum builds at the vacuum pump gauge replace the carbon canister assembly Carbon Canister Inspection The fittings on the carbon canister are marked The T is the longer hose leading to the fuel tank fitting The P is the shorter hose leading to intake manifold Fuel System Servi...

Page 71: ... 59 Carbon Canister Installation 1 Install the manifold vent hose onto the intake manifold Figure 60 2 Install the fuel tank vent hose to the fitting on the fuel tank 1P65F 2 Service Manual Page 6 7 Fuel System Service and Repairs 3429 270 Rev A ...

Page 72: ...el tank vent hose to the hose retainer on the engine shroud Figure 62 4 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 in lbs 6 10 Nm Fuel System Service and Repairs Page 6 8 1P65F 2 Service Manual 3429 270 Rev A ...

Page 73: ...own on the 2 air filter cover latch tabs Figure 64 3 Hinge the air filter cover downward Remove the cover from the air filter housing assembly 4 Remove the air filter from the air filter housing 5 Remove the 2 10 mm nuts securing the air filter housing to the engine 1P65F 2 Service Manual Page 6 9 Fuel System Service and Repairs 3429 270 Rev A ...

Page 74: ...el hose from the carburetor Note Use a rag to catch excess fuel from hose removal Figure 66 9 Remove the fuel hose clamp at the fuel tank 10 Remove the fuel hose from the fuel tank 11 Remove the fuel filter from the fuel hose Note Replace the fuel filter and fuel hose as necessary Fuel System Service and Repairs Page 6 10 1P65F 2 Service Manual 3429 270 Rev A ...

Page 75: ...ck the fuel filter screen for debris Fuel Filter and Hoses Installation 1 Install the fuel filter into the fuel tank fitting Figure 68 2 Install the fuel hose to the fuel tank Secure with the fuel hose clamp 1P65F 2 Service Manual Page 6 11 Fuel System Service and Repairs 3429 270 Rev A ...

Page 76: ...the fuel hose clamp Figure 70 4 Install the air filter housing to the engine 5 Install the air filter housing to the engine Secure with 2 10 mm nuts securing the air filter housing to the engine Torque nuts to 52 87 in lbs 6 10 Nm Fuel System Service and Repairs Page 6 12 1P65F 2 Service Manual 3429 270 Rev A ...

Page 77: ...d and lock into place Carburetor Replacement Carburetor Removal 1 Push down on the 2 air filter cover latch tabs 2 Hinge the air filter cover downward Remove the cover from the air filter housing assembly 3 Remove the air filter from the air filter housing 4 Remove the 2 10 mm nuts securing the air filter housing to the engine 1P65F 2 Service Manual Page 6 13 Fuel System Service and Repairs 3429 2...

Page 78: ... fuel hose 7 Remove the fuel hose from the carburetor Figure 74 8 Remove the linkage connecting the air vein to the carburetor by pulling the air vein arm towards the breather hose Lift the linkage upwards and remove from the air vein arm Fuel System Service and Repairs Page 6 14 1P65F 2 Service Manual 3429 270 Rev A ...

Page 79: ...iding the linkage retainer outward Figure 76 10 Remove the governor linkage from the governor arm by pivoting the arm towards the front of the engine for a wide open throttle Then lift the governor linkage up and away from the carburetor 1P65F 2 Service Manual Page 6 15 Fuel System Service and Repairs 3429 270 Rev A ...

Page 80: ...Slide the carburetor away from the engine Figure 78 Carburetor Disassembly 1 Remove the 2 bolts 10 mm securing the float bowl to carburetor body Note The center bolt is the float bowl mounting and the side bolt is the carburetor drain bolt Fuel System Service and Repairs Page 6 16 1P65F 2 Service Manual 3429 270 Rev A ...

Page 81: ...assembly continued Figure 79 2 Remove the float bowl from the carburetor body Figure 80 3 Remove the float pin from the carburetor body 1P65F 2 Service Manual Page 6 17 Fuel System Service and Repairs 3429 270 Rev A ...

Page 82: ...sembly continued Figure 81 4 Remove the float and needle from the carburetor body Figure 82 5 Remove the main jet from the carburetor body Fuel System Service and Repairs Page 6 18 1P65F 2 Service Manual 3429 270 Rev A ...

Page 83: ...rt or old fuel residue in the carburetor Clean the carburetor body and parts in an ultra sonic cleaner before reassembly 4 Check the tip of the float needle for grooves or wear Carburetor Assembly 1 Install the main jet into the carburetor body Figure 84 2 Install the needle into the float and onto to the carburetor body 1P65F 2 Service Manual Page 6 19 Fuel System Service and Repairs 3429 270 Rev...

Page 84: ...continued Figure 85 3 Install the float pin through the carburetor body and float Figure 86 4 Install the float bowl onto the carburetor body Fuel System Service and Repairs Page 6 20 1P65F 2 Service Manual 3429 270 Rev A ...

Page 85: ...ue bolt to 52 79 in lbs 6 9 Nm Figure 88 Pop Off Test 1 Install the needle into the float and onto the carburetor body 2 Position the carburetor with the float up 3 Install the pressure tester onto the inlet fitting on the carburetor 1P65F 2 Service Manual Page 6 21 Fuel System Service and Repairs 3429 270 Rev A ...

Page 86: ... the float weight closes the needle and holds pressure The pressure should not drop to zero Carburetor Installation 1 Slide the carburetor into position on the engine Figure 90 2 Install the governor linkage spring 3 Install the governor linkage onto the governor arm Fuel System Service and Repairs Page 6 22 1P65F 2 Service Manual 3429 270 Rev A ...

Page 87: ... Install the thermal control linkage to the carburetor by hooking the linkage retainer inward Figure 92 5 Install the linkage connecting the air vane to the carburetor 1P65F 2 Service Manual Page 6 23 Fuel System Service and Repairs 3429 270 Rev A ...

Page 88: ... Figure 94 7 Tighten the hose clamp on the fuel hose 8 Install the air filter housing to the engine Secure with 2 10 mm nuts securing the air filter housing to the engine Torque nuts to 52 87 in lbs 6 10 Nm Fuel System Service and Repairs Page 6 24 1P65F 2 Service Manual 3429 270 Rev A ...

Page 89: ...sing assembly 11 Hinge the air filter cover upward and lock into place Auto Choke System Thermal Control Replacement Auto Choke System Thermal Control Removal 1 Remove the 3 10 mm acorn nuts securing the recoil assembly to the top of the engine Remove the recoil assembly 1P65F 2 Service Manual Page 6 25 Fuel System Service and Repairs 3429 270 Rev A ...

Page 90: ...om the hose retainer on the engine shroud Move the carbon canister to the side of the engine Figure 98 3 Remove the shroud by lifting away from the engine 4 Remove the 2 10 mm nuts securing muffler to the cylinder head Fuel System Service and Repairs Page 6 26 1P65F 2 Service Manual 3429 270 Rev A ...

Page 91: ...gure 99 5 Remove the muffler cover from the muffler 6 Remove the 2 7 mm thermal control mounting bolts from the muffler Figure 100 7 Remove the thermal control from the linkage 1P65F 2 Service Manual Page 6 27 Fuel System Service and Repairs 3429 270 Rev A ...

Page 92: ...stem Thermal Control Inspection Verify the thermal control arm moves freely and returns to stop Figure 102 Auto Choke System Thermal Control Installation 1 Install the thermal control to the linkage Fuel System Service and Repairs Page 6 28 1P65F 2 Service Manual 3429 270 Rev A ...

Page 93: ...ounting bolts to the muffler Torque mounting bolts to 54 in lbs 6 Nm Figure 104 3 Install the muffler cover to the muffler 4 Install the 2 10 mm nuts securing the muffler to the cylinder head Torque nuts to 70 105 in lbs 8 12 Nm 1P65F 2 Service Manual Page 6 29 Fuel System Service and Repairs 3429 270 Rev A ...

Page 94: ...on canister into position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Figure 106 7 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 in lbs 6 10 Nm Fuel System Service and Repairs Page 6 30 1P65F 2 Service Manual 3429 270 Rev A ...

Page 95: ...Plate Replacement Control Plate Removal 1 Remove the spring from the governor arm Note Note the position of the spring Figure 108 2 Remove the 10 mm bolt securing the control plate to the crankcase 1P65F 2 Service Manual Page 6 31 Fuel System Service and Repairs 3429 270 Rev A ...

Page 96: ...emove the control plate from the crankcase Figure 110 Control Plate Installation 1 Install the control plate onto the crankcase 2 Secure the spring to the governor arm Fuel System Service and Repairs Page 6 32 1P65F 2 Service Manual 3429 270 Rev A ...

Page 97: ...nstallation continued Figure 111 3 Install the bolt securing the control plate to the crankcase Torque bolt to 90 in lbs 10 Nm Figure 112 1P65F 2 Service Manual Page 6 33 Fuel System Service and Repairs 3429 270 Rev A ...

Page 98: ...Fuel System Service and Repairs Page 6 34 1P65F 2 Service Manual 3429 270 Rev A ...

Page 99: ...nts General Information 7 2 Service and Repairs 7 3 Cylinder Head Replacement 7 6 Connecting Rod Replacement 7 30 Piston and Rings Assembly Replacement 7 42 Valve Adjustment 7 69 1P65F 2 Service Manual Page 7 1 Compression System 3429 270 Rev A ...

Page 100: ...bly of the engine compression system The 1P65F 2 engine is an overhead valve design The camshaft is equipped with an automatic compression release and operates the valves through a push rod and rocker arm system Compression System General Information Page 7 2 1P65F 2 Service Manual 3429 270 Rev A ...

Page 101: ... 7 Intake Rocker Arm Asm 2 Valve Cover Gasket 8 Spark Plug 3 Spring Valve Retainer 9 Valve Stem Seal 4 Valve Spring 10 Valve Set 5 Exhaust Rocker Arm Asm 11 Exhaust Stud 6 Complete Head Asm 1P65F 2 Service Manual Page 7 3 Compression System Service and Repairs 3429 270 Rev A ...

Page 102: ... 2 Figure 114 1 Push Rod 6 Piston 2 Head Gasket 7 Piston Pin 3 Dowel Pin 8 Valve Tappet 4 Piston Ring Set 9 Connecting Rod Asm 5 Wrist Pin Clip Compression System Service and Repairs Page 7 4 1P65F 2 Service Manual 3429 270 Rev A ...

Page 103: ...Compression System Assembly 3 Figure 115 1 Muffler Shield 3 Exhaust Gasket 2 Muffler Asm 1P65F 2 Service Manual Page 7 5 Compression System Service and Repairs 3429 270 Rev A ...

Page 104: ...oil assembly Figure 116 2 Remove the fuel tank vent hose from the hose retainer on the engine shroud Move the carbon canister to the side of the engine Figure 117 3 Remove the shroud by lifting away from the engine 4 Push down on the 2 air filter cover latch tabs Compression System Service and Repairs Page 7 6 1P65F 2 Service Manual 3429 270 Rev A ...

Page 105: ... the air filter from the air filter housing 7 Remove the 2 10 mm nuts securing the air filter housing to the engine Figure 119 8 Remove the air filter housing from the engine 9 Loosen the hose clamp on the fuel hose 10 Remove the fuel hose from the carburetor 1P65F 2 Service Manual Page 7 7 Compression System Service and Repairs 3429 270 Rev A ...

Page 106: ...ling the air vein arm towards the breather hose Lift the linkage upwards and remove from the air vein arm Figure 121 12 Remove the thermal control linkage from the carburetor by unhooking and sliding the linkage retainer outward Compression System Service and Repairs Page 7 8 1P65F 2 Service Manual 3429 270 Rev A ...

Page 107: ...e front of the engine opening the throttle wide Then lift the governor linkage up and away from the carburetor Figure 123 14 Lift upwards on the governor linkage spring and away from the carburetor 15 Slide the carburetor away from the engine 1P65F 2 Service Manual Page 7 9 Compression System Service and Repairs 3429 270 Rev A ...

Page 108: ...ffler to the cylinder head Figure 125 17 Remove the muffler cover from the muffler 18 Remove the muffler and muffler gasket from the cylinder head 19 Remove the spark plug wire from the spark plug Compression System Service and Repairs Page 7 10 1P65F 2 Service Manual 3429 270 Rev A ...

Page 109: ...d Figure 126 20 Remove the spark plug from the cylinder head Figure 127 21 Remove the 5 10 mm bolts securing the valve cover to the cylinder head 1P65F 2 Service Manual Page 7 11 Compression System Service and Repairs 3429 270 Rev A ...

Page 110: ...nued Figure 128 22 Remove the valve cover from the cylinder head Figure 129 23 Remove the circlip from the exhaust valve rocker arm pivot pin Compression System Service and Repairs Page 7 12 1P65F 2 Service Manual 3429 270 Rev A ...

Page 111: ...ad Removal continued Figure 130 24 Remove the rocker arm pivot pin Figure 131 25 Remove the rocker arm from the cylinder head 1P65F 2 Service Manual Page 7 13 Compression System Service and Repairs 3429 270 Rev A ...

Page 112: ...ed Figure 132 26 Remove the 4 12 mm bolts securing the cylinder head to the crankcase Figure 133 27 Remove the cylinder head from the crankcase Compression System Service and Repairs Page 7 14 1P65F 2 Service Manual 3429 270 Rev A ...

Page 113: ... valve retainer and slide towards the large end of the slot to release the retainer from the valve Figure 135 2 Repeat for opposite valve 3 Remove the circlip from the intake valve rocker arm pivot pin 1P65F 2 Service Manual Page 7 15 Compression System Service and Repairs 3429 270 Rev A ...

Page 114: ...Cleaning Inspection 1 Remove the carbon deposits from the cylinder head 2 Clean the cylinder head of any remaining gasket material intake exhaust valve cover and head gaskets 3 Inspect the cylinder head for cracks specifically around the following Compression System Service and Repairs Page 7 16 1P65F 2 Service Manual 3429 270 Rev A ...

Page 115: ...mit 0 002 in 5 Inspect the intake and exhaust ports mounting surface for warpage Cylinder Head Valve Seat Inspection 1 Thoroughly clean the cylinder head to remove carbon deposits 2 Inspect the valve seats for loose seat proper valve face contact and proper seat width Standard 0 028 0 030 in Service Limit 0 040 in Figure 139 3 Repeat the inspection for all valves and seats 1P65F 2 Service Manual P...

Page 116: ...rd 0 2598 0 2604 in 6 60 6 615 mm Service Limit 0 2624 in 6 665 mm 2 Replace the cylinder head if any of the above items are found to be out of specification Valve Inspection 1 Clean carbon from the valve Figure 140 2 Inspect the valve stem for pitting wear or bent Compare to standard Intake Standard 0 216 in 5 48 mm Intake Service Limit 0 209 in 5 318 mm Exhaust Standard 0 214 in 5 44 mm Exhaust ...

Page 117: ...ve Mounting Components Clean and inspect all other valve mounting components including the spring retainers keepers and spring seats Cylinder Head Assembly 1 Install the pivot pin and rocker arm to the cylinder head Figure 142 2 Install the circlip to the intake valve rocker arm pivot pin 1P65F 2 Service Manual Page 7 19 Compression System Service and Repairs 3429 270 Rev A ...

Page 118: ...ecure the retainer to the valve push down on the valve retainer and slide away from the large end of the slot Figure 144 Cylinder Head Installation 1 Install the cylinder head to the crankcase Compression System Service and Repairs Page 7 20 1P65F 2 Service Manual 3429 270 Rev A ...

Page 119: ...Install the 4 12 mm bolts securing the cylinder head to the crankcase Torque bolts to 22 26 ft lbs 30 36 Nm Figure 146 3 Install the rocker arm to the cylinder head 1P65F 2 Service Manual Page 7 21 Compression System Service and Repairs 3429 270 Rev A ...

Page 120: ...ation continued Figure 147 4 Install the rocker arm pivot pin Figure 148 5 Install the circlip to the exhaust valve rocker arm pivot pin Compression System Service and Repairs Page 7 22 1P65F 2 Service Manual 3429 270 Rev A ...

Page 121: ...6 Install the valve cover to the cylinder head Figure 150 7 Install the 5 10 mm bolts securing the valve cover to the cylinder head Torque bolts to 72 in lbs 8 Nm 1P65F 2 Service Manual Page 7 23 Compression System Service and Repairs 3429 270 Rev A ...

Page 122: ...gure 151 8 Install the spark plug to the cylinder head Figure 152 9 Install the spark plug wire to the spark plug Torque the spark plug to 22 ft lbs 30 Nm Compression System Service and Repairs Page 7 24 1P65F 2 Service Manual 3429 270 Rev A ...

Page 123: ... head 11 Install the muffler cover to the muffler 12 Install the 2 10 mm nuts securing the muffler to the cylinder head Torque nuts to 70 105 in lbs 8 12 Nm Figure 154 13 Slide the carburetor into position on the engine 1P65F 2 Service Manual Page 7 25 Compression System Service and Repairs 3429 270 Rev A ...

Page 124: ...ernor linkage spring 15 Install the governor linkage onto the governor arm Figure 156 16 Install the thermal control linkage to the carburetor by hooking the linkage retainer inward Compression System Service and Repairs Page 7 26 1P65F 2 Service Manual 3429 270 Rev A ...

Page 125: ... continued Figure 157 17 Install the linkage connecting the air vein to the carburetor Figure 158 18 Install the fuel hose to the carburetor 1P65F 2 Service Manual Page 7 27 Compression System Service and Repairs 3429 270 Rev A ...

Page 126: ...all the air filter housing to the engine Secure with 2 10 mm nuts securing the air filter housing to the engine Torque nuts to 52 87 in lbs 6 10 Nm Figure 160 21 Install the air filter into the air filter housing Compression System Service and Repairs Page 7 28 1P65F 2 Service Manual 3429 270 Rev A ...

Page 127: ...he shroud onto the engine 25 Place the carbon canister into position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Figure 162 26 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 in lbs 6 10 Nm 1P65F 2 Service Manual Page 7 29 Compression System Service and Repairs 3429 270 Rev A ...

Page 128: ...e 3 10 mm acorn nuts securing the recoil assembly to the top of the engine Remove the recoil assembly Figure 164 3 Remove the fuel tank vent hose from the hose retainer on the engine shroud Move the carbon canister to the side of the engine Compression System Service and Repairs Page 7 30 1P65F 2 Service Manual 3429 270 Rev A ...

Page 129: ...ine 6 Unhook the spring from the brake mechanism Figure 166 7 Place a pry bar under the flywheel to pry the flywheel upwards Use a soft based hammer to loosen the flywheel assembly from the crankshaft only striking the top of the nut to prevent crankshaft damage 1P65F 2 Service Manual Page 7 31 Compression System Service and Repairs 3429 270 Rev A ...

Page 130: ...emove the flywheel from the engine Figure 168 9 Turn the motor upside down 10 Remove the cylinder head assembly from the engine 11 Remove the 7 10 mm bolts securing the sump cover to the crankcase Compression System Service and Repairs Page 7 32 1P65F 2 Service Manual 3429 270 Rev A ...

Page 131: ...ed Figure 169 12 Using a soft base hammer tap the sump cover to remove from the crankcase Figure 170 13 Remove the sump cover from the crankcase 1P65F 2 Service Manual Page 7 33 Compression System Service and Repairs 3429 270 Rev A ...

Page 132: ...171 14 Remove the thrust washer from the crankshaft Figure 172 15 Turn the crankshaft clockwise match the timing marks between the camshaft and crankshaft Compression System Service and Repairs Page 7 34 1P65F 2 Service Manual 3429 270 Rev A ...

Page 133: ...d Figure 173 16 Remove the camshaft from the crankcase 17 Remove the 2 10 mm connecting rod cap bolts Figure 174 18 Remove the connecting rod cap 1P65F 2 Service Manual Page 7 35 Compression System Service and Repairs 3429 270 Rev A ...

Page 134: ...175 19 Remove the connecting rod and piston Figure 176 Connecting Rod Inspection 1 Inspect the connecting rod and cap bearing surfaces for wear and scoring Compression System Service and Repairs Page 7 36 1P65F 2 Service Manual 3429 270 Rev A ...

Page 135: ... 2 Check the wrist pin bearing surface of the connecting rod for wear and scoring Figure 178 Connecting Rod Installation 1 Install the connecting rod and piston 1P65F 2 Service Manual Page 7 37 Compression System Service and Repairs 3429 270 Rev A ...

Page 136: ...inued Figure 179 2 Install the connecting rod cap Figure 180 3 Install the 2 10 mm connecting rod cap bolts Torque bolts to 108 132 in lbs 13 15 Nm Compression System Service and Repairs Page 7 38 1P65F 2 Service Manual 3429 270 Rev A ...

Page 137: ... 181 4 Install the camshaft to the crankcase 5 Verify the camshaft and crankshaft timing marks match Figure 182 6 Install the thrust washer onto the crankshaft 1P65F 2 Service Manual Page 7 39 Compression System Service and Repairs 3429 270 Rev A ...

Page 138: ...mp cover to the crankcase Secure the crankcase with 7 10 mm bolts Torque the bolts to 70 105 in lbs 8 12 Nm Figure 184 8 Turn the motor over 9 Install the flywheel onto the engine Compression System Service and Repairs Page 7 40 1P65F 2 Service Manual 3429 270 Rev A ...

Page 139: ...6 ft lbs 80 90 Nm 11 Hook the spring to the brake mechanism Figure 186 12 Install the shroud onto the engine 13 Place the carbon canister into position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud 1P65F 2 Service Manual Page 7 41 Compression System Service and Repairs 3429 270 Rev A ...

Page 140: ...to 52 87 in lbs 6 10 Nm Figure 188 15 Add oil to the engine Piston and Rings Assembly Replacement Piston and Rings Assembly Removal 1 Drain the oil 2 Remove the 3 10 mm acorn nuts securing the recoil assembly to the top of the engine Remove the recoil assembly Compression System Service and Repairs Page 7 42 1P65F 2 Service Manual 3429 270 Rev A ...

Page 141: ...move the shroud by lifting away from the engine 5 Push down on the 2 air filter cover latch tabs 6 Hinge the air filter cover downward Remove the cover from the air filter housing assembly 7 Remove the air filter from the air filter housing 8 Remove the 2 10 mm nuts securing the air filter housing to the engine 1P65F 2 Service Manual Page 7 43 Compression System Service and Repairs 3429 270 Rev A ...

Page 142: ... the fuel hose 11 Remove the fuel hose from the carburetor Figure 192 12 Remove the linkage connecting the air vein to the carburetor by pulling the air vein arm towards the breather hose Lift the linkage upwards and remove from the air vein arm Compression System Service and Repairs Page 7 44 1P65F 2 Service Manual 3429 270 Rev A ...

Page 143: ...d sliding the linkage retainer outward Figure 194 14 Remove the governor linkage from the governor arm by pivoting the arm towards the front of the engine opening the throttle wide Then lift the governor linkage up and away from the carburetor 1P65F 2 Service Manual Page 7 45 Compression System Service and Repairs 3429 270 Rev A ...

Page 144: ...ds on the governor linkage spring and away from the carburetor 16 Slide the carburetor away from the engine Figure 196 17 Remove the 2 10 mm nuts securing muffler to the cylinder head Compression System Service and Repairs Page 7 46 1P65F 2 Service Manual 3429 270 Rev A ...

Page 145: ...ver from the muffler 19 Remove the muffler and muffler gasket from the cylinder head 20 Remove the spark plug wire from the spark plug Figure 198 21 Remove the spark plug from the cylinder head 1P65F 2 Service Manual Page 7 47 Compression System Service and Repairs 3429 270 Rev A ...

Page 146: ...tinued Figure 199 22 Remove the 5 10 mm bolts securing the valve cover to the cylinder head Figure 200 23 Remove the valve cover from the cylinder head Compression System Service and Repairs Page 7 48 1P65F 2 Service Manual 3429 270 Rev A ...

Page 147: ...Removal continued Figure 201 24 Remove the circlip from the exhaust valve rocker arm pivot pin Figure 202 25 Remove the rocker arm pivot pin 1P65F 2 Service Manual Page 7 49 Compression System Service and Repairs 3429 270 Rev A ...

Page 148: ...ontinued Figure 203 26 Remove the rocker arm from the cylinder head Figure 204 27 Remove the 4 12 mm bolts securing the cylinder head to the crankcase Compression System Service and Repairs Page 7 50 1P65F 2 Service Manual 3429 270 Rev A ...

Page 149: ...er head from the crankcase Figure 206 29 Turn the motor upside down 30 Remove the cylinder head assembly from the engine 31 Remove the 7 10 mm bolts securing the sump cover to the crankcase 1P65F 2 Service Manual Page 7 51 Compression System Service and Repairs 3429 270 Rev A ...

Page 150: ...ontinued Figure 207 32 Using a soft base hammer tap the sump cover to remove from the crankcase Figure 208 33 Remove the sump cover from the crankcase Compression System Service and Repairs Page 7 52 1P65F 2 Service Manual 3429 270 Rev A ...

Page 151: ...igure 209 34 Remove the thrust washer from the crankshaft Figure 210 35 Turn the crankshaft clockwise match the timing marks between the camshaft and crankshaft 1P65F 2 Service Manual Page 7 53 Compression System Service and Repairs 3429 270 Rev A ...

Page 152: ...ntinued Figure 211 36 Remove the camshaft from the crankcase 37 Remove the 2 10 mm connecting rod cap bolts Figure 212 38 Remove the connecting rod cap Compression System Service and Repairs Page 7 54 1P65F 2 Service Manual 3429 270 Rev A ...

Page 153: ... the stroke Figure 214 40 Push on the connecting rod to push the piston out of the cylinder Remove the piston from the engine Piston and Rings Assembly Inspection 1 Inspect the piston for wear and scoring on the piston surface 1P65F 2 Service Manual Page 7 55 Compression System Service and Repairs 3429 270 Rev A ...

Page 154: ...8 0 0156 in 0 2 0 4 mm and 0 040 in 1 0 mm Width Top Middle 0 0397 in 1 0 mm and 0 0342 in 0 87 mm Width Oil Ring 0 098 in 2 5 mm and 0 093 in 2 37 mm 4 Remove the wrist pin circlip from the piston 5 Remove the wrist pin from the piston 6 Measure the outside diameter of the piston Skirt Outside Diameter 2 558 in 64 985 mm Compression System Service and Repairs Page 7 56 1P65F 2 Service Manual 3429...

Page 155: ... mm 8 Measure piston to cylinder clearance Clearance to Cylinder 0 00059 0 00196 in 0 015 0 05 mm Piston and Rings Assembly Installation 1 Install the piston rings on the piston 2 Install the piston into the cylinder Figure 217 3 Turn the crankshaft until the piston is at the top of the stroke Figure 218 1P65F 2 Service Manual Page 7 57 Compression System Service and Repairs 3429 270 Rev A ...

Page 156: ...re 219 5 Install the 2 10 mm connecting rod cap bolts Torque bolts to 108 132 in lbs 13 15 Nm Figure 220 6 Install the camshaft to the crankcase 7 Verify the camshaft and crankshaft timing marks match Compression System Service and Repairs Page 7 58 1P65F 2 Service Manual 3429 270 Rev A ...

Page 157: ...ston and Rings Assembly Installation continued Figure 221 8 Install the thrust washer onto the crankshaft Figure 222 1P65F 2 Service Manual Page 7 59 Compression System Service and Repairs 3429 270 Rev A ...

Page 158: ... 10 mm bolts Torque the bolts to 70 105 in lbs 8 12 Nm Figure 223 10 Install the cylinder head to the crankcase Figure 224 11 Install the 4 12 mm bolts securing the cylinder head to the crankcase Torque bolts to 22 26 ft lbs 30 36 Nm Compression System Service and Repairs Page 7 60 1P65F 2 Service Manual 3429 270 Rev A ...

Page 159: ...sembly Installation continued Figure 225 12 Install the rocker arm to the cylinder head Figure 226 13 Install the rocker arm pivot pin 1P65F 2 Service Manual Page 7 61 Compression System Service and Repairs 3429 270 Rev A ...

Page 160: ...tion continued Figure 227 14 Install the circlip to the exhaust valve rocker arm pivot pin Figure 228 15 Install the valve cover to the cylinder head Compression System Service and Repairs Page 7 62 1P65F 2 Service Manual 3429 270 Rev A ...

Page 161: ...e 229 16 Install the 5 10 mm bolts securing the valve cover to the cylinder head Torque bolts to 72 in lbs 8 Nm Figure 230 17 Install the spark plug to the cylinder head 1P65F 2 Service Manual Page 7 63 Compression System Service and Repairs 3429 270 Rev A ...

Page 162: ...park plug wire to the spark plug Torque the spark plug to 22 ft lbs 30 Nm Figure 232 19 Install the muffler and muffler gasket to the cylinder head 20 Install the muffler cover to the muffler Compression System Service and Repairs Page 7 64 1P65F 2 Service Manual 3429 270 Rev A ...

Page 163: ... cylinder head Torque nuts to 70 105 in lbs 8 12 Nm Figure 233 22 Slide the carburetor into position on the engine Figure 234 23 Install the governor linkage spring 24 Install the governor linkage onto the governor arm 1P65F 2 Service Manual Page 7 65 Compression System Service and Repairs 3429 270 Rev A ...

Page 164: ...5 25 Install the thermal control linkage to the carburetor by hooking the linkage retainer inward Figure 236 26 Install the linkage connecting the air vein to the carburetor Compression System Service and Repairs Page 7 66 1P65F 2 Service Manual 3429 270 Rev A ...

Page 165: ...etor Figure 238 28 Tighten the hose clamp on the fuel hose 29 Install the air filter housing to the engine Secure with 2 10 mm nuts securing the air filter housing to the engine Torque nuts to 52 87 in lbs 6 10 Nm 1P65F 2 Service Manual Page 7 67 Compression System Service and Repairs 3429 270 Rev A ...

Page 166: ...to the air filter housing assembly 32 Hinge the air filter cover upward and lock into place 33 Install the shroud onto the engine 34 Place the carbon canister into position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Compression System Service and Repairs Page 7 68 1P65F 2 Service Manual 3429 270 Rev A ...

Page 167: ...orque acorn nuts to 52 87 in lbs 6 10 Nm Figure 242 36 Turn the motor over 37 Add oil to the engine Valve Adjustment Valve Adjustment Removal 1 Remove the 3 10 mm acorn nuts securing the recoil assembly to the top of the engine Remove the recoil assembly 1P65F 2 Service Manual Page 7 69 Compression System Service and Repairs 3429 270 Rev A ...

Page 168: ...he hose retainer on the engine shroud Move the carbon canister to the side of the engine Figure 244 3 Remove the shroud by lifting away from the engine 4 Remove the spark plug wire from the spark plug Compression System Service and Repairs Page 7 70 1P65F 2 Service Manual 3429 270 Rev A ...

Page 169: ...ued Figure 245 5 Remove the spark plug from the cylinder head Figure 246 6 Remove the 5 10 mm bolts securing the valve cover to the cylinder head 1P65F 2 Service Manual Page 7 71 Compression System Service and Repairs 3429 270 Rev A ...

Page 170: ...8 8 Place the piston at the top of the compression stroke to check the piston s location 9 Place a wooden dowel in the spark plug hole and rotate the crankshaft until the piston is at the top of the compression stroke Compression System Service and Repairs Page 7 72 1P65F 2 Service Manual 3429 270 Rev A ...

Page 171: ...of the valve stem for the intake and exhaust valves Note The left valve is the intake and the right valve is exhaust Clearance for Cold Intake 0 004 0 006 in 0 10 0 15 mm Clearance for Cold Exhaust 0 006 0 008 in 0 15 0 20 mm Figure 250 1P65F 2 Service Manual Page 7 73 Compression System Service and Repairs 3429 270 Rev A ...

Page 172: ...adjust the gap between the rocker arm and valve stem When the clearance is correct tighten the lock nut and recheck the clearance Valve Adjustment Installation 1 Install the valve cover onto the cylinder head 2 Install the 5 10 mm bolts securing the valve cover to the cylinder head Torque bolts to 57 87 ft lbs 6 10 Nm Figure 252 Compression System Service and Repairs Page 7 74 1P65F 2 Service Manu...

Page 173: ...Nm Figure 253 4 Install the spark plug wire to the spark plug Figure 254 5 Install the shroud onto the engine 6 Place the carbon canister into position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud 1P65F 2 Service Manual Page 7 75 Compression System Service and Repairs 3429 270 Rev A ...

Page 174: ...tinued Figure 255 7 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 ft lbs 6 10 Nm Figure 256 Compression System Service and Repairs Page 7 76 1P65F 2 Service Manual 3429 270 Rev A ...

Page 175: ...ents General Information 8 2 Service and Repairs 8 3 Electric Starter Replacement 8 4 Ignition Coils Replacement 8 6 Spark Plugs Replacement 8 13 Charging System Replacement 8 16 1P65F 2 Service Manual Page 8 1 Electrical System 3429 270 Rev A ...

Page 176: ...General Information This chapter covers the disassembly inspection testing and assembly of the electrical system Electrical System General Information Page 8 2 1P65F 2 Service Manual 3429 270 Rev A ...

Page 177: ...ical System Assembly Figure 257 1 Ignition Coil Asm 5 Brake Asm 2 Starter Motor Harness 6 Brake Spring 3 Flywheel 7 Starter Motor 4 Alternator 1P65F 2 Service Manual Page 8 3 Electrical System Service and Repairs 3429 270 Rev A ...

Page 178: ...g the electric starter from the mower harness Figure 258 2 Remove the 2 starter mounting bolts securing the starter to the engine Figure 259 3 Remove the starter from the engine Electrical System Service and Repairs Page 8 4 1P65F 2 Service Manual 3429 270 Rev A ...

Page 179: ...gure 261 2 Loosely install the left hand mounting bolt securing the starter to the engine 3 While installing the right hand mounting bolt install the bolt through eyelet of the ground wire Torque the mounting bolts to 90 in lbs 10 Nm 1P65F 2 Service Manual Page 8 5 Electrical System Service and Repairs 3429 270 Rev A ...

Page 180: ...into the mower harness Figure 263 Ignition Coils Replacement Ignition Coils Removal 1 Remove the 3 10 mm acorn nuts securing the recoil assembly to the top of the engine Remove the recoil assembly Electrical System Service and Repairs Page 8 6 1P65F 2 Service Manual 3429 270 Rev A ...

Page 181: ...etainer on the engine shroud Move the carbon canister to the side of the engine Figure 265 3 Remove the shroud by lifting away from the engine 4 Unplug the ground wire from the connector at the brake assembly 1P65F 2 Service Manual Page 8 7 Electrical System Service and Repairs 3429 270 Rev A ...

Page 182: ...ued Figure 266 5 Remove the spark plug wire from the spark plug Figure 267 6 Remove the coil mounting bolt and shroud mounting stud from the coil Electrical System Service and Repairs Page 8 8 1P65F 2 Service Manual 3429 270 Rev A ...

Page 183: ...Remove the ignition coil from the engine Figure 269 Ignition Coil Resistance Test Primary 1 Place one lead on the coil connector 2 Place one lead on the coil frame 1P65F 2 Service Manual Page 8 9 Electrical System Service and Repairs 3429 270 Rev A ...

Page 184: ... wire and unscrewing the cap by turning counter clockwise 2 Place one lead of the meter in the end of the high tension lead Figure 271 3 Place the other lead on the coil frame 4 The volt Ohm meter should read 5 4 6 2 Ohms Ignition Coil Installation 1 Install the ignition coil onto the engine Electrical System Service and Repairs Page 8 10 1P65F 2 Service Manual 3429 270 Rev A ...

Page 185: ...ng bolt and shroud mounting stud onto the coil Torque the bolt and stud to 90 in lbs 10 Nm Set air gap 0 0157 0 007 in 0 4 0 2 mm Figure 273 3 Install the spark plug wire to the spark plug 1P65F 2 Service Manual Page 8 11 Electrical System Service and Repairs 3429 270 Rev A ...

Page 186: ...nto position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Figure 275 6 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 ft lbs 6 10 Nm Electrical System Service and Repairs Page 8 12 1P65F 2 Service Manual 3429 270 Rev A ...

Page 187: ...tinued Figure 276 Spark Plugs Replacement Spark Plug Removal 1 Remove the spark plug cap Figure 277 2 Remove the spark plug from the cylinder head 1P65F 2 Service Manual Page 8 13 Electrical System Service and Repairs 3429 270 Rev A ...

Page 188: ... Plug Inspection 1 Inspect the spark plug condition for carbon or oil build up Replace as necessary Figure 279 2 Check the spark plug gap Gap 0 30 in 0 7 0 8 mm Electrical System Service and Repairs Page 8 14 1P65F 2 Service Manual 3429 270 Rev A ...

Page 189: ...gure 280 Spark Plug Installation 1 Screw the spark plug into the cylinder head Torque screw to 22 ft lbs 30 Nm Figure 281 2 Install the spark plug cap 1P65F 2 Service Manual Page 8 15 Electrical System Service and Repairs 3429 270 Rev A ...

Page 190: ...m acorn nuts securing the recoil assembly to the top of the engine Remove the recoil assembly Figure 283 2 Remove the fuel tank vent hose from the hose retainer on the engine shroud Move the carbon canister to the side of the engine Electrical System Service and Repairs Page 8 16 1P65F 2 Service Manual 3429 270 Rev A ...

Page 191: ...sen the hose clamp on the fuel hose 6 Remove the fuel hose from the fuel tank fitting 7 Remove the 2 shroud mounting studs securing the fuel tank to the crankcase Figure 285 8 Remove the 10 mm nut and washer from the fuel tank mounting stud 1P65F 2 Service Manual Page 8 17 Electrical System Service and Repairs 3429 270 Rev A ...

Page 192: ...lternator Test 1 Make sure the battery is fully charged 2 Place the positive test lead from the volt meter to the positive terminal on the mower battery 3 Place the negative test lead from the volt meter to the negative test lead on the battery 4 Start the engine Check the battery voltage Voltage specification should be 13 2 16 2 VDC Electrical System Service and Repairs Page 8 18 1P65F 2 Service ...

Page 193: ...r Gap 0 0157 3 007 in 0 4 0 2 mm Figure 288 3 Install the fuel tank to the engine 4 Install the 10 mm nut and washer to the fuel tank mounting stud Torque nut and washer to 90 in lbs 10 Nm Figure 289 5 Install the 2 shroud mounting studs securing the fuel tank to the crankcase Torque studs to 70 105 in lbs 8 12 Nm 1P65F 2 Service Manual Page 8 19 Electrical System Service and Repairs 3429 270 Rev ...

Page 194: ...ll the shroud onto the engine 10 Place the carbon canister into position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Figure 291 11 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 ft lbs 6 10 Nm Electrical System Service and Repairs Page 8 20 1P65F 2 Service Manual 3429 270 Rev A ...

Page 195: ...Charging System Installation continued Figure 292 1P65F 2 Service Manual Page 8 21 Electrical System Service and Repairs 3429 270 Rev A ...

Page 196: ...Electrical System Service and Repairs Page 8 22 1P65F 2 Service Manual 3429 270 Rev A ...

Page 197: ... Contents General Information 9 2 Service and Repairs 9 3 Sump Cover Replacement 9 4 Governor Assembly Replacement 9 5 Crankshaft Replacement 9 18 Camshaft Replacement 9 31 1P65F 2 Service Manual Page 9 1 Engine Lower End 3429 270 Rev A ...

Page 198: ...ral Information This chapter covers the disassembly inspection and assembly of the crankshaft camshaft and governor system Engine Lower End General Information Page 9 2 1P65F 2 Service Manual 3429 270 Rev A ...

Page 199: ... Lower End Assembly Figure 293 1 Crankshaft Asm 5 Case Gasket Cover 2 Camshaft Asm 6 Crankcase Cover 3 Dowel Pin 7 Oil Seal 4 Governor Gear Asm 1P65F 2 Service Manual Page 9 3 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 200: ... Remove the 7 10 mm bolts securing the sump cover to the crankcase Figure 294 4 Using a soft base hammer tap the sump cover to remove from the crankcase Figure 295 5 Remove the sump cover from the crankcase Engine Lower End Service and Repairs Page 9 4 1P65F 2 Service Manual 3429 270 Rev A ...

Page 201: ...nkcase Secure the crankcase with 7 10 mm bolts Torque the bolts to 70 105 in lbs 8 12 Nm Figure 297 2 Turn the motor over 3 Add oil to the engine Governor Assembly Replacement Governor Assembly Removal 1 Drain the oil 1P65F 2 Service Manual Page 9 5 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 202: ... 7 10 mm bolts securing the sump cover to the crankcase Figure 298 4 Using a soft base hammer tap the sump cover to remove from the crankcase Figure 299 5 Remove the sump cover from the crankcase Engine Lower End Service and Repairs Page 9 6 1P65F 2 Service Manual 3429 270 Rev A ...

Page 203: ...ure 300 6 Remove the thrust washer from the crankshaft Figure 301 7 Turn the crankshaft clockwise match the timing marks between the camshaft and crankshaft 1P65F 2 Service Manual Page 9 7 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 204: ...mshaft from the crankcase 9 Loosen the 10 mm nut from the governor arm bolt Figure 303 10 Remove the governor spring from the governor arm Note the position of the governor spring Engine Lower End Service and Repairs Page 9 8 1P65F 2 Service Manual 3429 270 Rev A ...

Page 205: ...emoval continued Figure 304 11 Remove the governor arm from the governor shaft Figure 305 12 Remove the hair pin from the governor shaft 1P65F 2 Service Manual Page 9 9 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 206: ...ontinued Figure 306 13 Slide the governor arm from the crankcase Figure 307 14 Remove the 8 mm bolt securing the governor gear to the sump cover Engine Lower End Service and Repairs Page 9 10 1P65F 2 Service Manual 3429 270 Rev A ...

Page 207: ...nued Figure 308 15 Remove the governor gear from the sump cover Figure 309 Governor Assembly Inspection 1 Inspect the fly weights for wear or damage 1P65F 2 Service Manual Page 9 11 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 208: ...ve the plunger and thrust washer Inspect for wear or damage and verify the plunger moves freely on the governor gear shaft Figure 311 3 Inspect the teeth for wear or damage Engine Lower End Service and Repairs Page 9 12 1P65F 2 Service Manual 3429 270 Rev A ...

Page 209: ... 312 Governor Assembly Installation 1 Install the governor gear to the sump cover Figure 313 2 Install the 8 mm bolt securing the governor gear to the sump cover 1P65F 2 Service Manual Page 9 13 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 210: ...y Installation continued Figure 314 3 Slide the governor arm to the crankcase Figure 315 4 Install the hair pin to the governor shaft Engine Lower End Service and Repairs Page 9 14 1P65F 2 Service Manual 3429 270 Rev A ...

Page 211: ...gure 316 5 Install the governor arm to the governor shaft Figure 317 6 Install the governor spring to the governor arm Note the position of the governor spring 1P65F 2 Service Manual Page 9 15 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 212: ...n the 10 mm nut to the governor arm bolt Torque nut to 90 in lbs 10 Nm Figure 319 8 Install the camshaft to the crankcase 9 Verify the camshaft and crankshaft timing marks match Engine Lower End Service and Repairs Page 9 16 1P65F 2 Service Manual 3429 270 Rev A ...

Page 213: ...Governor Assembly Installation continued Figure 320 10 Install the thrust washer onto the crankshaft Figure 321 1P65F 2 Service Manual Page 9 17 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 214: ...governor arm so the throttle plate at the carburetor is wide open 2 Loosen the pinch bolt on the governor arm 3 Using pliers turn the governor shaft clockwise until it stops 4 Tighten the pinch bolt Crankshaft Replacement Crankshaft Removal 1 Drain the oil 2 Remove the 3 10 mm acorn nuts securing the recoil assembly to the top of the engine Remove the recoil assembly Engine Lower End Service and R...

Page 215: ...ne shroud Move the carbon canister to the side of the engine Figure 324 4 Remove the shroud by lifting away from the engine 5 Loosen the nut securing the crankshaft to the engine 6 Unhook the spring from the brake mechanism 1P65F 2 Service Manual Page 9 19 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 216: ...s Use a soft based hammer to loosen the flywheel assembly from crankshaft only striking the top of the nut to prevent crankshaft damage Figure 326 8 Remove the nut from the crankshaft Remove the flywheel from the engine Engine Lower End Service and Repairs Page 9 20 1P65F 2 Service Manual 3429 270 Rev A ...

Page 217: ...he cylinder head assembly from the engine 11 Remove the 7 10 mm bolts securing the sump cover to the crankcase Figure 328 12 Using a soft base hammer tap the sump cover to remove from the crankcase 1P65F 2 Service Manual Page 9 21 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 218: ...moval continued Figure 329 13 Remove the sump cover from the crankcase Figure 330 14 Remove the thrust washer from the crankshaft Engine Lower End Service and Repairs Page 9 22 1P65F 2 Service Manual 3429 270 Rev A ...

Page 219: ...shaft clockwise match the timing marks between the camshaft and crankshaft Figure 332 16 Remove the camshaft from the crankcase 17 Remove the 2 10 mm connecting rod cap bolts 1P65F 2 Service Manual Page 9 23 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 220: ...nkshaft Removal continued Figure 333 18 Remove the connecting rod cap Figure 334 19 Remove the connecting rod and piston Engine Lower End Service and Repairs Page 9 24 1P65F 2 Service Manual 3429 270 Rev A ...

Page 221: ...rod journal and crankcase bearing surfaces for damage or scoring 2 Check to specifications Crankshaft Connecting Rod Journal Outside Diameter 1 022 in 25 98 mm Service Limit 1 020 in 25 392 mm Crankshaft Installation 1 Install the flywheel key to the crankshaft 1P65F 2 Service Manual Page 9 25 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 222: ...haft Installation continued Figure 337 2 Install the connecting rod and piston Figure 338 3 Install the connecting rod cap Engine Lower End Service and Repairs Page 9 26 1P65F 2 Service Manual 3429 270 Rev A ...

Page 223: ...10 mm connecting rod cap bolts Torque bolts to 108 132 in lbs 13 15 Nm Figure 340 5 Install the camshaft to the crankcase 6 Verify the camshaft and crankshaft timing marks match 1P65F 2 Service Manual Page 9 27 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 224: ...Crankshaft Installation continued Figure 341 7 Install the thrust washer onto the crankshaft Figure 342 Engine Lower End Service and Repairs Page 9 28 1P65F 2 Service Manual 3429 270 Rev A ...

Page 225: ...s to 70 105 in lbs 8 12 Nm Figure 343 9 Turn the motor over 10 Install the flywheel onto the engine Figure 344 11 Install the nut securing the crankshaft to the flywheel Torque nut to 59 66 ft lbs 80 90 Nm 12 Hook the spring to the brake mechanism 1P65F 2 Service Manual Page 9 29 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 226: ...to position on the engine Install the fuel tank vent hose to the hose retainer on the engine shroud Figure 346 15 Install the recoil assembly onto the engine Secure with 3 10 mm acorn nuts Torque acorn nuts to 52 87 ft lbs 6 10 Nm Engine Lower End Service and Repairs Page 9 30 1P65F 2 Service Manual 3429 270 Rev A ...

Page 227: ...haft Removal 1 Drain the oil 2 Turn the motor upside down 3 Remove the 7 10 mm bolts securing the sump cover to the crankcase Figure 348 4 Using a soft base hammer tap the sump cover to remove from the crankcase 1P65F 2 Service Manual Page 9 31 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 228: ...moval continued Figure 349 5 Remove the sump cover from the crankcase Figure 350 6 Remove the thrust washer from the crankshaft Engine Lower End Service and Repairs Page 9 32 1P65F 2 Service Manual 3429 270 Rev A ...

Page 229: ...t clockwise match the timing marks between the camshaft and crankshaft Figure 352 8 Remove the camshaft from the crankcase Camshaft Inspection 1 Inspect the cam lobes for wear 1P65F 2 Service Manual Page 9 33 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 230: ...inued Figure 353 2 Inspect the automatic compression release for damage and functionality Figure 354 3 Remove the tappets from the crankcase Engine Lower End Service and Repairs Page 9 34 1P65F 2 Service Manual 3429 270 Rev A ...

Page 231: ... freely in the crankcase Inspect tappet faces for wear Figure 356 Camshaft Installation 1 Install the camshaft to the crankcase 2 Verify the camshaft and crankshaft timing marks match 1P65F 2 Service Manual Page 9 35 Engine Lower End Service and Repairs 3429 270 Rev A ...

Page 232: ...Camshaft Installation continued Figure 357 3 Install the thrust washer onto the crankshaft Figure 358 Engine Lower End Service and Repairs Page 9 36 1P65F 2 Service Manual 3429 270 Rev A ...

Page 233: ...mp cover to the crankcase Secure the crankcase with 7 10 mm bolts Torque the bolts to 70 105 in lbs 8 12 Nm Figure 359 5 Turn the motor over 6 Add oil to the engine 1P65F 2 Service Manual Page 9 37 Engine Lower End Service and Repairs 3429 270 Rev A ...

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