Toro Prior LC1P65FA Service Manual
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Toro Prior LC1P65FA Service Manual

Toro Prior LC1P65FA Service Manual

Walk behind mower engine
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RESIDENTIAL PRODUCTS
WALK BEHIND MOWER
ENGINE SERVICE MANUAL
2012 and Prior LC1P65FA (159cc)

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Summary of Contents for Toro Prior LC1P65FA

  • Page 1 RESIDENTIAL PRODUCTS WALK BEHIND MOWER ENGINE SERVICE MANUAL 2012 and Prior LC1P65FA (159cc)
  • Page 2 An electronic version of this service manual is available on the Toro Dealer Portal. 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...
  • Page 3 Chapter 1 – General Service Information Chapter 2 - Engine Service / Maintenance Chapter 3 - Engine Disassembly and Service Chapter 4 - Electrical...
  • Page 4 NOTES:...

  • Page 5: Table Of Contents

    Chapter 1 – General Service Information Safety Service Rules Engine Model / Serial Number Location Engine Fastener Torque Specification General Specifications Engine Specifications Troubleshooting...

  • Page 6: Safety

    This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Toro engine. The Toro mower and operator’s manuals contain safety information and operating tips for safe operating practices.

  • Page 7: Service Rules

    Service Rules 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 lubricate friction components with clean engine oil or engine assembly lube when assembling engine.

  • Page 8: Engine Fastener Torque Specification

    Engine Fastener Torque Specifications Torque Item Fastener Size Specification Cylinder Head Bolts 25 ft-lbs (34 Nm) Connecting Rod Bolts 9.5 ft-lbs (13 Nm) Flywheel Nut 62.5 ft-lbs (85 Nm) Valve Adjust Lock Nut 10 ft-lbs (14 Nm) Pivot Arm Pivot Stud 22 ft-lbs (30 Nm) Crankcase Cover Bolt 7.5 ft-lbs (10 Nm)

  • Page 9: Engine Specifications

    Engine Specifications Part Item Standard Service Limit 2900 – 3100 RPM － Engine Operating RPM － 0.00393” (0.10 mm) Cylinder Head Warpage Sleeve Taper / Out of Round 2.559” (65.0 mm) 2.566” (65.165 mm) Cylinder (Inside Diameter) 2.558” (64.985 mm) 2.553”...

  • Page 10: Troubleshooting

    Troubleshooting Hard Starting / Poor Running - Incorrect Fuel (Level, Age, Octane, Ethanol Content) - Fuel System Contamination and / or Carburetor Debris - Incorrect Oil Level - Spark Plug (Incorrect Gap, Fouled, Loose or Faulty) - Air Filter Restriction - Air Intake System Leaks - Ignition Coil to Flywheel Gap Incorrect - Weak / No Spark...
  • Page 11 Chapter 2 - Engine Service / Maintenance Engine Oil Change Procedure Air Cleaner Service Spark Plug Service Valve Clearance Inspection and Adjustment Engine Governor – Zero Point Setting Fuel Filter Replacement Auto Choke System / Function Auto Choke System View...

  • Page 12: Engine Oil Change Procedure

    Engine Oil Change Procedure 1. Run engine to warm engine oil. 2. Remove spark plug cap from the spark plug. NOTE: Ensure fuel system contains no fuel to prevent leakage when the mower is tipped onto its side. 3. Remove the dipstick. 4.

  • Page 13: Air Cleaner Service

    Air Cleaner Service 1. Press the upper latch tabs and rotate the top of the cover outward to open and remove the cover. 2. Remove the paper air filter and the foam pre-filter. 3. Inspect the foam pre-filter, and replace it if damaged or excessively dirty. 4.

  • Page 14: Spark Plug Service

    Spark Plug Service NOTE: Spark plugs of the wrong size or incorrect heat range can cause severe engine damage. High Voltage Ignition Systems can be Dangerous - Use Caution when Servicing Ignition Systems 1. Disconnect the spark plug cap and thoroughly clean the spark plug area. 2.

  • Page 15: Valve Clearance Inspection And Adjustment

    Valve Clearance Inspection and Adjustment NOTE: Valve clearance inspection and adjustment must be done with the engine cold 1. Rotate engine to TDC (top-dead-center) of the compression stroke. 2. Remove the valve cover. Be sure both valves are completely closed and the decompression arm is not holding the valve open.

  • Page 16: Fuel Filter Replacement

    Fuel Filter and Hose Replacement - Fuel is Extremely Flammable - Use Extreme Caution When Servicing the Fuel System 1. Drain the fuel tank into an approved container. NOTE: Ensure fuel system contains no fuel to prevent leak when the fuel filter is replaced. 2.

  • Page 17: Auto Choke System / Function

    Auto Choke System / Function A. Governor Rod - Connected to the governor system which controls the angle of the throttle plate and sets engine operating RPM. B. Thermal Spring Rod - Connected to the thermal spring, which mounts on the muffler. The thermal spring adjusts the choke plate angle as the engine temperature changes.

  • Page 18: Auto Choke System View

    Auto Choke System View Washer Screw Air Vane Thermal Spring Asm (Mounts onto Muffler) Thermal Spring Choke Linkage Air Vane Choke Rod Lock Choke Linkage Image for Reference Only...
  • Page 19 Chapter 3 - Engine Disassembly and Service Engine Service – Upper End 16-26 Air Cleaner and Muffler Exploded View Recoil Starter and Engine Cover Exploded View 17-18 Carburetor and Linkage Exploded View 19-20 Flywheel and Breather Exploded View and Service Info Cylinder Head Exploded View and Service Info Intake and Exhaust Valve Exploded View and Service Info Valve Spring / Valve Seat / Cylinder Head Specifications...

  • Page 20: Engine Service - Upper End

    Engine Service – Upper End Air Cleaner and Muffler Exploded View Muffler Shield Muffler Exhaust Gasket Breather Tube Intake Gasket Air Cleaner Base Primer Asm (International Only) Paper Element Foam Element Cover...

  • Page 21: Recoil Starter And Engine Cover Exploded View

    Recoil Starter and Engine Cover Exploded View Screw Engine Cover Recoil Asm. Fuel Cap Asm Bolt Washer Fuel Tank Bolt Fuel Hose Fuel Filter Fuel Hose Clamp...
  • Page 22 Recoil Asm. Cover Bushing Spring Reel Spring Ratchet Spring Ratchet Guide Set Screw...

  • Page 23: Carburetor And Linkage Exploded View

    Carburetor and Linkage Exploded View Control Asm. Bracket Governor Governor Governor Throttle Return Spring Spring Governor Gasket Pinch Bolt Gasket Spacer Insulator / Heat Shield...
  • Page 24 Carburetor Exploded View Throttle Valve Asm. Pilot Jet O Ring Throttle Stop Screw Main Jet and Nozzle Float Valve Asm Float Float Bowl Drain Plug and Gasket Float Bowl Mounting Bolt and Gasket...

  • Page 25: Flywheel And Breather Exploded View And Service Info

    Flywheel and Breather Exploded View and Service Info Flywheel Nut 63 ft-lbs (85 Nm) 6 ft-lbs (8Nm) Breather Cover Shield 7.5 ft-lbs (10Nm) Breather Gasket Breather Valve Brake / Switch Asm.

  • Page 26: Cylinder Head Exploded View And Service Info

    Cylinder Head Exploded View and Service Information Cylinder Head Gasket Spark Plug 22 ft-lbs (36 Nm) 7.5 ft-lbs (10 Nm) Valve Cover Gasket Valve Cover Cylinder Head Bolt Torque Sequence: 1. Initially Torque the (4) Cylinder Head Bolts in a Crisscross Pattern to 10 ft-lbs (14 Nm). 2.

  • Page 27: Intake And Exhaust Valve Exploded View And Service Info

    Intake and Exhaust Valve Exploded View and Service Information Rocker Arm Pivot Stud Push Rods 22 ft-lbs (30 Nm) Rocker Arm Lock Nut 11 ft-lbs (15 Nm) Intake Valve Push Rod Guide Rocker Arm Pivot Exhaust Valve Valve Spring Valve Spring Retainer...

  • Page 28: Valve Spring / Valve Seat / Cylinder Head Specifications

    Valve Spring Free Length Specification Standard Service Limit 1.2007” (30.5 mm) 1.1417” (29.0 mm) NOTE: If this measurement is out of specification, complete engine replacement is required. The only internal parts available for this engine are gaskets and seals. Valve Seat Width Inspection Remove carbon deposits from the combustion chamber.

  • Page 29: Valve Stem / Valve Guide Specifications

    Valve Stem Inspection Inspect each valve for face irregularities, bending or abnormal wear. Valve Stem Diameter Specification Standard Service Limit 0.2157” (5.48 mm) 0.2093” (5.318 mm) Intake 0.2141” (5.44 mm) 0.0047” (0.12 mm) Exhaust NOTE: If this measurement is out of specification, complete engine replacement is required. The only internal parts available for this engine are gaskets and seals.

  • Page 30: Valve Seat Reconditioning

    Valve Seat Reconditioning 1. Thoroughly clean the combustion chamber and valve seats to remove carbon deposits. 2. Apply a light coat of Prussian Blue or erasable felt-tipped marker ink to the valve faces. 3. Properly install valves, springs and keepers. Manually open the valves, then and snap them closed against their seats several times.

  • Page 31: Engine Service - Lower End

    Engine Service – Lower End Crankcase / Governor Exploded View and Service Information Governor Exploded Views Governor Asm. 7.5 ft-lbs (10 Nm) Gasket Aux. Oil Drain 15.5 ft-lbs (21 Nm) Rubber Oil Baffle Governor Holder Sealing Washer Washer Slider Shaft Clip Weight Washer...
  • Page 32 Crankcase Exploded View Oil Dip Stick Oil Seal Governor Arm Shaft Governor Lock Pin Governor Oil Seal O Ring Sump Cover Gasket Crankcase / Sump Cover Oil Seal Crankcase / Sump Cover Bolt Torque Sequence 7.5 ft-lbs (10 Nm)

  • Page 33: Crankshaft / Piston / Camshaft Exploded View And Info

    Crankshaft / Piston / Camshaft Exploded View and Service Info Oil Seal Bearing Cam Shaft Valve Tappets Piston Asm. Connecting Rod Bolts 9.5 ft-lbs (13 Nm) Connecting Rod Connecting Rod Cap Crankshaft Thrust Washer...

  • Page 34: Piston / Connecting Rod Exploded View And Information

    Piston Connecting Rod Exploded View and Service Information Assembly: Mark Install Rings with Orientation Mark “UP” Stagger the piston ring gap as shown: Top Ring Second Ring Top Ring Oil Ring Second Ring Oil Ring Check, refer to Piston Piston Pin Piston Pin Circlip: Install the circlip gap in the 12:00 Position (circlip gap...

  • Page 35: Valve Timing

    Valve Timing Crankshaft Timing Marks 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. Camshaft...

  • Page 36: Crankshaft Bearing / Piston / Cylinder Specifications

    Crankshaft Bearing Free Play 1. Clean the bearing in solvent and dry it. 2. Spin the bearing by hand and check for play. Piston Pin Outside Diameter Standard Service Limit 0.5118” 0.51” (13.0 mm) (12.954 mm) NOTE: If this measurement is out of specification, complete engine replacement is required. The only internal parts available for this engine are gaskets and seals.

  • Page 37: Piston / Piston Ring Specifications

    Piston Skirt Outside Diameter Measure the piston skirt outside diameter 10mm from the skirt base and 90°to piston pin hole. Standard Service Limit 2.558” 2.553” (64.985 mm) (64.845 mm) NOTE: If this measurement is out of specification, complete engine replacement is required. The only internal parts available for this engine are gaskets and seals.

  • Page 38: Piston Ring / Connecting Rod Specifications

    Piston Ring End Gap Standard Service Limit 0.0078 - 0.0157” 0.0393” (0.2-0.4 mm) (1.0 mm) Use the piston to position the rings squarely 1” down from the top of the cylinder. NOTE: If this measurement is out of specification, complete engine replacement is required. The only internal parts available for this engine are gaskets and seals.

  • Page 39: Crankshaft Specifications

    Crankshaft pin OD Standard Service Limit 1.0228” 1.0204” (25.98 mm) (25.92 mm) NOTE: If this measurement is out of specification, complete engine replacement is required. The only internal parts available for this engine are gaskets and seals. Connecting Rod Big End Side Clearance Standard Service Limit 0.0433”...

  • Page 40: Camshaft Specifications

    Camshaft Lobe Specifications Standard Service Limit 1.0905” 1.0807” Intake (27.7 mm) (27.45 mm) 1.0925“ 1.0826” Exhaust (27.75 mm) (27.50 mm) NOTE: If this measurement is out of specification, complete engine replacement is required. The only internal parts available for this engine are gaskets and seals. Camshaft Journal OD Standard Service Limit...
  • Page 41 Chapter 4 – Electrical System Information Ignition / Charge Coil Gap Adjustment Ignition Coil Resistance Inspection Spark Testing Electrical System Wiring...
  • Page 42 Ignition / Charge Coil Gap Adjustment High Voltage Ignition Systems can be Dangerous - Use Caution when Servicing Ignition Systems 1. Install the coil and lightly tighten the mounting bolts. 2. Rotate engine so the coil is aligned with the magnet portion of the flywheel. 3.
  • Page 43 Spark Testing - Fuel is Extremely Flammable - Use Extreme Caution When Servicing the Fuel System - High Voltage Ignition Systems can be Dangerous - Use Caution when Servicing Ignition Systems 1. Safely drain the fuel system and store fuel in an approved container. 2.
  • Page 44 Electrical System Wiring (Electric Start Shown) Ignition Coil Starter Motor Alternator Brake / Kill Switch Starter Interlock Switch To Chassis Harness To Ground...
  • Page 45 NOTES:...
  • Page 46 RESIDENTIAL PRODUCTS Form Number: 492-9231...

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159cc

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