Toro 1P65F-2 Service Manual
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Toro 1P65F-2 Service Manual

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© 2018—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
1P65F-2 Service Manual
Published: August 2019
1P65FC and 1P65FA engine specifications included
Form No. 3429-270 Rev A
Contact us at www.Toro.com.
Original Instructions (EN)
All Rights Reserved

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Summary of Contents for Toro 1P65F-2

  • Page 1 Form No. 3429-270 Rev A 1P65F-2 Service Manual Published: August 2019 1P65FC and 1P65FA engine specifications included © 2018—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision History Page 2 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 3 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 make changes to this manual without notice. 1P65F-2 Service Manual Page 3 Preface...
  • Page 4 Operator’s Manual. Note: Refer to the service decal on the machine and the machine Operator’s Manual for commonly used fluid specifications and capacities. Preface Page 4 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 5 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 Service and Repairs ..................9–3 1P65F-2 Service Manual Page 5 Preface 3429-270 Rev A...
  • 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 Avoid asphyxiation… Do not operate an engine in a confined area without proper ventilation. Avoid injury from batteries… Safety: Safety Instructions Page 1–2 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 9 If you are unsure of the operation of any lifts, hoists, and jacks do not use. Fire Extinguishers… The proper class of fire extinguisher should be used in case of fire. 1P65F-2 Service Manual Page 1–3 Safety: Safety Instructions 3429-270 Rev A...
  • Page 10 See above information for description. Ensure fire extinguishers are serviceable and replace any that are discharged or out of inspection dates. Safety: Safety Instructions Page 1–4 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 11 Chapter 2 Specifications 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 0.0047 in. (0.12 mm) (0.04-0.063 mm) Clearance 0.0039-0.0275 in. (0.1-0.7 Large End Side Clearance 0.0433 in. (1.1 mm) Crankshaft Crank Pin Outside Diameter 1.022 in. (25.98 mm) 1.020 in. (25.92 mm) Specifications and Maintenance: Specifications Page 2–2 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 13 Governor Arm Pinch Nut 70-105 in-lbs. (8-12 Nm) Carburetor Bowl Mount Screw 52–79 ft-lbs. (6-9 Nm) Fuel Drain Screw 52-79 in-lbs. (6-9 Nm) Valve Cover Bolt 90 in-lbs. (10 Nm) 1P65F-2 Service Manual Page 2–3 Specifications and Maintenance: Specifications 3429-270 Rev A...
  • Page 14 End Gap (Top/Middle) 0.040 in. (1.0 mm) Piston Ring Width (Top/Middle) 0.0393 in. (1.0 mm) 0.0342 in. (0.87 mm) Width (Oil Ring) 0.098 in. (2.5 mm) 0.093 in. (2.37 mm) Specifications and Maintenance: Specifications Page 2–4 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 15 Air Cleaner Nut 72 in-lbs. (8 Nm) Recoil (Fan Shroud) Nut 72 in-lbs. (8 Nm) Oil Drain Bolt 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...
  • Page 16 1P65FA Engine Part Specifications Part Item Standard Service Limit Cylinder Head Warpage 0.004 in. (0.10 mm) Cylinder Out of Round Sleeve (Inside Diameter) 2.559 in. (65 mm) 2.566 in. (65.165 mm) Specifications and Maintenance: Specifications Page 2–6 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 17 Gap 0.030 in. ( 0.7-0.8 mm) RL87YC Resistance (Primary) 1.1-1.6 ohms Igniter Coils Resistance (Secondary) 10.5 K ohms ± 15% Gap to Flywheel 0.010 in. (0.254 mm) 1P65FA Engine Torque Specifications 1P65F-2 Service Manual Page 2–7 Specifications and Maintenance: Specifications 3429-270 Rev A...
  • Page 18 54 in-lbs. (6 Nm) M6 bolt/nut 90 in-lbs. (10 Nm) Standard Torque Value M8 bolt/nut 228 in-lbs. (26 Nm) M10 bolt/nut 28 ft-lbs. (38 Nm) M12 bolt/nut 41 ft-lbs. (55 Nm) Specifications and Maintenance: Specifications Page 2–8 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 19 Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
  • Page 20 Metric Bolts and Screws Figure 2 Class 8.8 Class 10.9 Specifications and Maintenance: Torque Specifications Page 2–10 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 21 The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately ± 10% of the nominal torque value. Thin nuts include jam nuts. 1P65F-2 Service Manual Page 2–11 Specifications and Maintenance: Torque Specifications...
  • Page 22 The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts. Specifications and Maintenance: Torque Specifications Page 2–12 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 23 85 ± 15 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. 1P65F-2 Service Manual Page 2–13 Specifications and Maintenance: Torque Specifications 3429-270 Rev A...
  • Page 24 24.209 15/32 0.46875 11.906 31/32 0.96875 24.606 31/64 0.484375 12.303 63/64 0.984375 25.003 0.5000 12.700 1.000 25.400 1 mm = 0.03937 in. 0.001 in. = 0.0254 mm Specifications and Maintenance: Torque Specifications Page 2–14 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 25 Inch-Pounds Kilogram-Centimeters 1.152144 Quarts Liters 0.9463 Liquid Volume Gallons Liters 3.785 Liquid Flows Gallons/Minute Liters/Minute 3.785 1. Subtract by 32° Temperature Fahrenheit Celsius 2. Multiply by 5/9 1P65F-2 Service Manual Page 2–15 Specifications and Maintenance: Torque Specifications 3429-270 Rev A...
  • 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 • 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 • Are there any other new symptoms Troubleshooting: General Troubleshooting Page 3–2 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 29 Insufficient compression 1. Perform a leak down test. 2. Check for worn cylinder, valve(s) not seating, valve clearance, and head gasket. 3. Adjust the valve clearance. 4. Replace damaged components. 1P65F-2 Service Manual Page 3–3 Troubleshooting: General Troubleshooting 3429-270 Rev A...
  • Page 30 1. Perform a leak down test 2. Check the valve clearance, valves not seating, worn cylinder, and head gasket leaking. 3. Adjust the valve clearance. 4. Replace damaged components. Troubleshooting: General Troubleshooting Page 3–4 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 31 2. Change the oil using the correct viscosity. Engine gasket leaking 1. Check the head gasket for leaking. 2. Check for warped cylinder head. 3. Replace head gasket as necessary. 1P65F-2 Service Manual Page 3–5 Troubleshooting: General Troubleshooting 3429-270 Rev A...
  • Page 32 Troubleshooting: General Troubleshooting Page 3–6 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 33 Chapter 4 Engine Top 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 General Information 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 Engine Top End Assembly 1 Figure 3 Acorn Nut Fan Shroud Recoil Shroud Asm. Shroud Stud 3.42 inch (86.9 mm) Recoil Compression Spring 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 Engine Top End Assembly 2 Figure 4 Breather Cover Crankcase Breather Tube Breather Gasket Cover Breather Valve Dipstick and Fill Tube Kit 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 Flange Nut Flywheel 1P65F-2 Service Manual Page 4–5 Engine Top End: Service and Repairs 3429-270 Rev A...
  • Page 38 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 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 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 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...
  • Page 42 Flywheel Removal (continued) 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 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 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 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 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 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 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 Crankcase Breather System Removal (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 Crankcase Breather System Removal (continued) 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 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 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 Crankcase Breather System Installation (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 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 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 Chapter 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 General Information The Toro 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 Service and Repairs Air Intake System Assembly Figure 43 Air Cleaner Base Air Filter and Prefilter Kit Flange Nut Air Cleaner Cover 1P65F-2 Service Manual Page 5–3 Air Intake System: Service and Repairs 3429-270 Rev A...
  • Page 60 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 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 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 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 Air Box Installation (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 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 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 Auto Choke Air Vane Oil Seal Choke Linkage Throttle Return Spring Wire Harness Clip Governor Rod Throttle Control Plate Governor Spring Governor Arm Governor Arm Bolt Hair Pin Governor Arm 1P65F-2 Service Manual Page 6–3 Fuel System: Service and Repairs 3429-270 Rev A...
  • Page 68 19 cc Carbon Canister Fuel Tank Intake Gasket Stud Bolt Carburetor Spacer Fuel Line Kit Carburetor Gasket Thermal Control Carburetor Insulator Thermal Choke Linkage Carburetor Throttle Lock Carburetor Gasket Fuel System: Service and Repairs Page 6–4 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 69 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 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: Service and Repairs Page 6–6 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 71 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 3. Install the fuel 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 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 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 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 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 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 3429-270 Rev A...
  • Page 78 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 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...
  • Page 80 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 Carburetor Disassembly (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 Carburetor Disassembly (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 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 A...
  • Page 84 Carburetor Assembly (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 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...
  • Page 86 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 4. 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 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 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 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 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 Auto Choke System/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 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 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 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 3. Remove 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 Control Plate Installation (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 Table of Contents 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 General Information This chapter covers the complete disassembly, inspection, adjustment, and assembly 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.
  • Page 101 Intake Rocker Arm Asm. Valve Cover Gasket Spark Plug Spring Valve Retainer Valve Stem Seal Valve Spring Valve Set Exhaust Rocker Arm Asm. Exhaust Stud Complete Head Asm. 1P65F-2 Service Manual Page 7–3 Compression System: Service and Repairs 3429-270 Rev A...
  • Page 102 Compression System Assembly 2 Figure 114 Push Rod Piston Head Gasket Piston Pin Dowel Pin Valve Tappet Piston Ring Set Connecting Rod Asm. 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 Muffler Shield Exhaust Gasket Muffler Asm. 1P65F-2 Service Manual Page 7–5 Compression System: Service and Repairs 3429-270 Rev A...
  • Page 104 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 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 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 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 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 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 Cylinder Head Removal (continued) 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 Cylinder Head 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 Cylinder Head Removal (continued) 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 1. Push down on the 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 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 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 Page 7–17 Compression System: Service and Repairs 3429-270 Rev A...
  • Page 116 4. Replace the valve if encounter any of the items above. 5. Repeat inspection for all valves. Valve Spring 1. Inspect the free length of the valve spring. Compression System: Service and Repairs Page 7–18 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 117 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 4. To secure 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 2. 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 Cylinder Head Installation (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 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 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 14. Install the governor 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 Cylinder Head Installation (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 20. 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). 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 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 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 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...
  • Page 130 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 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 Connecting Rod Removal (continued) Figure 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 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 Figure 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 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 Figure 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 7. Install the sump 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 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...
  • Page 140 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 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 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 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...
  • Page 144 15. Lift upwards 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 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 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 Piston and Rings Assembly 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 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 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 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 Piston and Rings Assembly Removal (continued) Figure 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 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 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 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 3429-270 Rev A...
  • Page 155 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 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 Piston 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. 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 Piston and Rings Assembly 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 Piston and Rings Assembly Installation (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 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 18. Install the spark 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 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 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 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...
  • Page 166 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 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 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 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. 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 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 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 Manual 3429-270 Rev A...
  • Page 173 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...
  • Page 174 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 Table of Contents 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 Service and Repairs Electrical System Assembly Figure 257 Ignition Coil Asm. Brake Asm. Starter Motor Harness Brake Spring Flywheel Starter Motor Alternator 1P65F-2 Service Manual Page 8–3 Electrical System: Service and Repairs 3429-270 Rev A...
  • Page 178 1. Unplug 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 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...
  • Page 180 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 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 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 7. 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 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 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 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 Ignition Coil Installation (continued) 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 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 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 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 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...
  • Page 192 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 Manual 3429-270 Rev A...
  • Page 193 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 A...
  • Page 194 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 Table of 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 General 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 Service and Repairs Engine Lower End Assembly Figure 293 Crankshaft Asm. Case Gasket Cover Camshaft Asm. Crankcase Cover Dowel Pin Oil Seal Governor Gear Asm. 1P65F-2 Service Manual Page 9–3 Engine Lower End: Service and Repairs 3429-270 Rev A...
  • Page 200 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 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 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 Figure 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 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 Governor Assembly Removal (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 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 Governor Assembly Removal (continued) 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 2. Remove 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 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 Governor Assembly 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 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 7. Tighten 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 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 Repairs Page 9–18 1P65F-2 Service Manual 3429-270 Rev A...
  • Page 215 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 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 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...
  • Page 218 Crankshaft Removal (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 15. Turn the crankshaft 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 Crankshaft 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 2. Check to specifications. Crankshaft Connecting Rod Journal Outside Diameter: 1.022 in. (25.98 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 Crankshaft 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 4. Install the 2 (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 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 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 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...
  • Page 228 Camshaft Removal (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 7. Turn the crankshaft 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 Camshaft Inspection (continued) 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 4. Verify the tappets move 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 4. Install the sump 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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