Toro LC1P65FC Service Manual Download

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WALK BEHIND MOWER

ENGINE SERVICE MANUAL

LC1P65FC (159cc)

RESIDENTIAL PRODUCTS

Summary of Contents for LC1P65FC

Page 1: ...WALK BEHIND MOWER ENGINE SERVICE MANUAL LC1P65FC 159cc RESIDENTIAL PRODUCTS...

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

Page 3: ...Chapter 1 General Service Information 1 Chapter 2 Engine Service Maintenance 2 Chapter 3 Engine Disassembly and Service 3 Chapter 4 Electrical 4...

Page 4: ...NOTES...

Page 5: ...pter 1 General Service Information Safety 2 Service Rules 3 Engine Model Serial Number Location 3 Engine Fastener Torque Specification 4 General Specifications 4 Engine Specifications 5 Troubleshootin...

Page 6: ...unning 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 fuel...

Page 7: ...XX 1 Only use genuine Toro parts and lubrication products 2 Always install new gaskets O rings and seals when assembling engine 3 Always torque fasteners to specification and in sequence 4 Always lubr...

Page 8: ...Spark Plug 22 ft lbs 30 Nm Ignition and Charge Coil Bolts M6 7 5 ft lbs 10 Nm Electric Starter Motor Bolts M6 7 5 ft lbs 10 Nm Standard Torque Values M5 Bolt Nut 4 5 ft lbs 6 Nm M6 Bolt Nut 7 5 ft lb...

Page 9: ...047 0 12 mm Big End Side Clearance 0 00393 0 02755 0 1 0 7 mm 0 0433 1 1 mm Crankshaft Crackpin Outside Diameter 1 0228 25 98 mm 1 0204 25 92 mm Valve Clearance cold Intake 0 00393 0 10 mm Clearance c...

Page 10: ...or Faulty Air Filter Restriction Air Intake System Leaks Ignition Coil to Flywheel Gap Incorrect Weak No Spark Auto Choke System Improper Function Choke Air Vane Linkage Operating RPM Incorrect Gover...

Page 11: ...ngine Oil Change Procedure 8 Air Cleaner Service 9 Spark Plug Service 10 Valve Clearance Inspection and Adjustment 11 Engine Governor Zero Point Setting 11 Fuel Filter Replacement 12 Auto Choke System...

Page 12: ...nto a suitable container 5 Return the mower to the operating position 6 Add oil through the dipstick tube Wipe the dipstick clean an insert it into the dipstick tube to check the oil level NOTE DO NOT...

Page 13: ...air filter is excessively dirty damaged or is wet with oil or fuel replace it 5 Remove dirt from the air cleaner body and cover using a moist rag Do not wipe dirt into the air duct 6 If the foam pre f...

Page 14: ...g boot and thoroughly clean the spark plug area 2 Remove the spark plug from the engine 3 Inspect the spark plug for excessively worn electrodes chips or cracks in the insulator or excessive deposits...

Page 15: ...ghten the lock nut to specification 11 ft lbs 15 Nm 5 Recheck the clearance and readjust if necessary 6 Inspect the valve cover gasket and replace if necessary Install the valve cover and torque faste...

Page 16: ...ilter is replaced 2 If necessary remove air filter cover and base as outlined in this manual 3 Release the fuel filter fuel hose clamps A and remove the hose from the fittings 4 Remove the fuel filter...

Page 17: ...ke plate at full operating RPM at any engine temperature COLD START Picture 1 illustrates the choke plate position while starting a cold engine The thermal spring is cold keeping the choke closed The...

Page 18: ...14 Auto Choke System View Thermal Spring Asm Mounts onto Muffler Thermal Spring Choke Linkage Choke Rod Lock Air Vane Choke Linkage Air Vane Washer Screw...

Page 19: ...linder Head Specifications 24 Valve Stem Valve Guide Specifications 25 Valve Seat Reconditioning 26 Engine Service Lower End 27 36 Crankcase Governor Exploded View and Information 27 28 Crankshaft Pis...

Page 20: ...16 Engine Service Upper End Air Cleaner and Muffler Exploded View Muffler Shield Muffler Exhaust Gasket Cover Foam Element Paper Element Nut Air Cleaner Base Nut...

Page 21: ...17 Recoil Starter and Engine Cover Exploded View Screw Engine Cover Nut Recoil Asm Fuel Cap Asm Fuel Tank Nut Washer Bolt Fuel Hose Clamp 3...

Page 22: ...18 Set Screw Ratchet Guide Spring Ratchet Spring Reel Spring Bushing Recoil Asm Cover...

Page 23: ...19 Carburetor and Linkage Exploded View Control Asm Bracket Governor Spring Governor Rod Throttle Return Spring Governor Arm Spacer Gasket Insulator Heat Shield Gasket 3 Governor Pinch Bolt...

Page 24: ...20 Carburetor Exploded View Throttle Valve Asm Pilot Jet O Ring Float Valve Asm Float Main Jet and Nozzle Throttle Stop Screw Float Bowl Float Bowl Mounting Bolt and Gasket Drain Plug and Gasket...

Page 25: ...21 Flywheel Breather Exploded View and Service Info 3 Flywheel Nut 63 ft lbs 85 Nm 6 ft lbs 8Nm Breather Cover Breather Gasket Breather Valve Brake Switch Asm Key Shield...

Page 26: ...Nm Cylinder Head Gasket Valve Cover Gasket Valve Cover 7 5 ft lbs 10 Nm Cylinder Head Bolt Torque Sequence 1 Initially Torque the 4 Cylinder Head Bolts in a Crisscross Pattern to 10 ft lbs 14 Nm 2 Eve...

Page 27: ...oded View and Service Information 3 Push Rods Valve Valve Valve Spring Valve Spring Retainer Rocker Arm Exhaust Rocker Arm Intake Lock Nut 11 ft lbs 15 Nm Rocker Arm Pivot Shaft Retaining Clip Valve L...

Page 28: ...age Valve Seat Width Specification Standard Service Limit 0 0314 0 8 mm 0 0787 2 0 mm Cylinder Head Warp Inspection Remove carbon deposits from the combustion chamber Clean off any gasket material fro...

Page 29: ...fore measuring Valve Guide ID Specification Standard Service Limit 0 2165 5 50 mm 0 2193 5 572 mm NOTE If this measurement is out of specification complete engine replacement is required The only inte...

Page 30: ...oncentric seat Follow the valve seat cutter manufacture s instructions Turn the cutter clockwise never counterclockwise Continue to turn the cutter as you lift it from the valve seat 5 Use a 30 32 and...

Page 31: ...se Governor Exploded View and Service Information Governor Exploded Views 3 Aux Oil Drain 15 5 ft lbs 21 Nm Sealing Washer 7 5 ft lbs 10 Nm Governor Holder Gasket Pin Weight Washer Slider Clip Washer...

Page 32: ...loded View Oil Seal Crankcase Sump Cover Crankcase Sump Cover Bolt Torque Sequence 7 5 ft lbs 10 Nm 1 2 3 4 5 6 7 Sump Cover Gasket Oil Dip Stick O Ring Governor Arm Shaft Governor Oil Seal Governor L...

Page 33: ...nkshaft Piston Camshaft Exploded View and Service Info 3 Crankshaft Thrust Washer Connecting Rod Bolts 9 5 ft lbs 13 Nm Bearing Piston Asm Connecting Rod Connecting Rod Cap Valve Tappets Cam Shaft Oil...

Page 34: ...g Oil Ring Check refer to Assembly Install Rings with Orientation Mark UP Stagger the piston ring gap as shown Top Ring Second Ring Oil Ring Piston Mark Top Ring Second Ring Oil Ring Check refer to Pi...

Page 35: ...Crankshaft Bearing Free Play 1 Clean the bearing in solvent and dry it 2 Spin the bearing by hand and check for play Replace the bearing if it is noisy or has excessive free play 3 Timing Marks Crank...

Page 36: ...s available for this engine are gaskets and seals Cylinder Taper and Out of Round Inspect cylinder for taper and out of round with a bore gauge Measure in two different directions front to back and si...

Page 37: ...s measurement is out of specification complete engine replacement is required The only internal parts available for this engine are gaskets and seals Piston Ring to Groove Clearance Standard Service L...

Page 38: ...re gaskets and seals Connecting Rod Small End ID Standard Service Limit 0 5125 13 02 mm 0 5145 13 07 mm NOTE If this measurement is out of specification complete engine replacement is required The onl...

Page 39: ...complete engine replacement is required The only internal parts available for this engine are gaskets and seals Connecting Rod Big End Oil Clearance Clean oil from the crankshaft and connecting rod Us...

Page 40: ...only internal parts available for this engine are gaskets and seals Camshaft Journal OD Standard Service Limit 0 5505 13 984 mm 0 5478 13 916 mm Check the camshaft bearing journal for scoring wear or...

Page 41: ...37 Chapter 4 Electrical System Information Ignition Charge Coil Gap Adjustment 38 Ignition Coil Resistance Inspection 38 Spark Testing 39 Electrical System Wiring 40 4...

Page 42: ...een the flywheel and coil 4 Adjust the coil gap at both side of the coil 5 Torque the coil mounting bolts to specification 7 5 ft lbs 10 Nm Ignition Coil Resistance Inspection Primary Coil Place Ohm m...

Page 43: ...uel in an approved container 2 Remove spark plug boot from the spark plug 3 Remove the spark plug from the engine 4 Connect the negative electrode of the spark plug threaded area to ground cylinder he...

Page 44: ...40 Electrical System Wiring Electric Start Shown A Ignition Coil B Starter Motor C Alternator D Brake Kill Switch E Starter Interlock Switch F To Chassis Harness G To Ground E D B A C G F F...

Page 45: ...41 NOTES...

Page 46: ...42 RESIDENTIAL PRODUCTS Form Number 492 9232...

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