Engine Removal; Engine Disassembly And Repair; Recoil Starter Repair - Toro GTS 120 Service Manual

IV. ENGINE REMOVAL, DISASSEMBLY
REPAIR INSTRUCTIONS
ENGINE REMOVAL
To remove the engine from the mower the air
cleaner housing, recoil assembly and fuel tank
must first be removed to disconnect the control
cables. Remove the retaining capscrew, lock-
washer, blade, blade adapter and self-propel
components below the mower deck from the
engine crankshaft. Remove the four capscrews
that retain the engine to the mower chassis and
remove the engine from the mower. The engine
can then be placed in a support fixture for repair.
Most common repairs, however, can be accom-
plished with the engine in place on the mower
chassis. Use the following procedures to dis-
assemble the engine on the mower chassis:
ENGINE DISASSEMBLY AND REPAIR
1. Remove the high tension wire from the spark
plug and drain the fuel from the fuel tank.
A
CAUTION: The gasoline in
the fuel tank is explosive.
Always drain
or fill tank outdoors,
away from fire and flame. Do not
smoke when fuel vapors are present.
2. Remove the four retaining capscrews from
the recoil starter and lift the starter from the
engine. Disconnect the recoil rope from the
rope handle stop for ease of handling.
A. Remove the center capscrew from the
recoil assembly and lift off the pawl re-.
tainer. Remove the center spring, pawl
and pawl spring. Lift the rope pulley
assembly from the recoil housing and
remove the recoil spring and retainer
(Figure 4-1).
B. Replace all worn or damaged parts before
reassembling. Reassemble the recoil
starter in reverse order. Use Threebond
#1342 or Loctite #242 on the threads of
the center capscrew during reassembly
and torque to 80-90Kg-Cm (70-1 10 in-lb).
On installation there should be sufficient
spring pretension to hold the recoil rope
taut in the rope pulley.
RECOIL STARTER REPAIR
NOTE: Place a small amount of #2 grease on the
recoil spring to prevent rust and corrosion.
ASSEMBLY AND
i S
Center Spring Pawl Spring
Pawl Retainer-
Center Spring Pawl Spring
/-
Pawl Retainer-
Figure 4-1
3.
Disconnect the fuel line from the carburetor.
Remove the fuel tank by lifting it from the
mounting tabs of the blower housing.
4. Remove the capscrew, two nuts and lock
washers which retain the muffler and remove
the muffler from the engine. The heat shield
may also be removed from the muffler. Dis-
card the muffler gasket and remove any
gasket material remaining on the engine or
muffler.
5. Lift the retaining tabs of the air cleaner cover
and remove the cover and filter element.
Remove the capscrew, and two locknuts
retaining the air cleaner housing and lift the
housing from the engine.
6. Remove the remaining three capscrews from
the blower housing and lift the blower hous-
ing from the engine.
7. Cage the spring activated engine brake by
compressing and retaining the control bar
against the operating handle. Remove the
capscrew holding the ignition switch and
brake assembly in place. Disconnect the
ignition switch from the electrical lead and
remove the switch from the brake assembly.
Slowly lower the control bar to disengage
the brake. The brake assembly may now be
disconnected from the control cable for
repair.
8. Use a starter cup wrench as shown in the
Special Tools List to hold the starter cup
while loosening the flywheel nut. Hold the
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IV- 1