Toro A 31 Two Cycle Engine Service Manual

A-31 ENGINE SERVICE MANUAL Table of Contents ­ Page 1 of 1 GENERAL INFORMATION GENERAL SPECIFICATIONS TORQUE SPECIFICATIONS SAFETY WARNINGS AND NOTES OPERATION AND MAINTENANCE TROUBLESHOOTING ENGINE FAILS TO START ENGINE STARVES ON ACCELERATION ENGINE IS HARD TO START ENGINE STALLS ENGINE FIRES INTERMITTENTLY ENGINE DOES NOT PRODUCE MAXIMUM POWER CARBURETOR FLOODS ENGINE STOPS AFTER RUNNING BRIEFLY ENGINE WILL NOT IDLE ENGINE BACKFIRES OR MISFIRES ENGINE WILL NOT ACCELERATE ENGINE LACKS POWER OR STOPS DURING OPERATION DISASSEMBLY, INSPECTION, & REPAIR TYPICAL DISASSEMBLY SEQUENCE DISASSEMBLE MAJOR COMPONENTS DISASSEMBLE ENGINE REASSEMBLY TYPICAL ASSEMBLY SEQUENCE ENGINE REASSEMBLY INSTALL MAJOR COMPONENTS GENERAL INFORMATION General Information .

1 Troubleshooting 2 3 Disassembly, Inspection and Repair . Reassembly 4 1-1 GENERAL INFORMATION Table Of Contents 1 General Specifications . 1-3 Engine 1-3 Fuel And Lubrication . 1-3 Ignition 1-3 Torque Specifications 1-4 Air Filter 1-4 Carburetor 1-4 Carburetor Mount/Reed Plate 1-4 Clutch . 1-4 Crankcase And Cylinder . 1-5 Flex Drive Housing (Boom) 1-5 Flywheel . 1-5 Ignition Module 1-5 Ignition Switch 1-6 Muffler 1-6 Starter/Starter Housing 1-6 Safety Warnings and Notes . 1-7 Operation and Maintenance . 1-8 Product Identification Numbers 1-8 Fuel Recommendations . 1-8 Fuel and Oil Mixing Instructions . 1-9 Starting/Stopping Instructions 1-9 Service/Maintenance Instructions 1-11 Storage Instructions . 1-14 Special Tools . 1-15 1-2 GENERAL INFORMATION General Specifications Engine Item Engine Type Displacement Bore Stroke Average Compression Piston Ring Width Piston Ring End Gap Piston Ring Side Clearance Air-cooled, 2-Cycle 1.9 cu. in. (31 cc) 1.37 in. (34.80 mm) 1.25 in. (31.75 mm) 90-120 lbs. (41-55 kg) 0.046 in. (1.16 mm) 0.085 in. (2.159 mm) 0.005 in. max (0.127 mm) 1 Fuel And Lubrication Item Lubrication Fuel/Oil Ratio Approx. Fuel Tank Capacity Fuel/Oil Mixture 32:1 18 oz (530 ml) Ignition Item Ignition Type Ignition Module Air Gap Spark Plug Type Spark Plug Gap C.D. Electronic Ignition 0.010-0.015 in. (0.254-0.381 mm) Champion® DJ8J 0.025 in (0.635 mm) 1-3 GENERAL INFORMATION Torque Specifications 1 Air Filter Item Air Filter Cover Mounting Screws 15-25 in·lb (1.7-2.8 N·m) Carburetor Item Carburetor/Choke Plate Mounting Screws Throttle Wire Swivel Screw 35-40 in·lb (3.9-4.5 N·m) 9-12 in·lb (1.0-1.4 N·m) Carburetor Mount/Reed Plate Item Carburetor Mount/Reed Plate Mounting Screws Reed Valve/Reed Backup Plate Mounting Screw(s) 60-65 in·lb (6.8-7.3 N·m) 15-20 in·lb (1.7-2.3 N·m) Clutch Item Clutch Cover Mounting Screws Clutch Drum Screw Clutch Rotor 35-40 in·lb (3.9-4.5 N·m) 38-44 in·lb (4.3-5.0 N·m) 150-160 in·lb (16.9-18 N·m) 1-4 GENERAL INFORMATION Crankcase And Cylinder Item Crankcase (Cylinder) Mounting Screws Crankcase Cover Mounting Screws Fan Shroud Mounting Screws Spark Plug 110-120 in·lb (12.4-13.5 N·m) 67 in·lb (7.5 N·m) 110-120 in·lb (12.4-13.5 N·m) 190-210 in·lb (21.4-23.6 N·m) 1 Flex Drive Housing (Boom) Item Boom Clamp Nut Anti-rotation Screw 70-80 in·lb (7.9-9.0 N·m) 15-20 in·lb (1.7-2.3 N·m) Flywheel Item Flywheel Mounting/Square Drive Nut (Non-clutch Models) Flywheel Mounting/Crankshaft Extension Nut (Blowers) 150-160 in·lb (16.9-18 N·m) 150-160 in·lb (16.9-18 N·m) Ignition Module Item Ignition Module Mounting Screws 28-35 in·lb (3.2-3.9 N·m) 1-5 GENERAL INFORMATION Ignition Switch 1 Item Slide Switch Contact To Switch Cover Screw Slide Switch Contact To Starter Housing Screw Stop Switch Lead To Starter Housing Screw Toggle Switch Nut 7-12 in·lb (0.8-1.4 N·m) 10-15 in·lb (1.1-1.7 N·m) 10-15 in·lb (1.1-1.7 N·m) 25-35 in·lb (2.8-3.9 N·m) Muffler Item Muffler Exhaust Tube Screws Muffler Heat Shield Screw Muffler Mounting Screws Serial Numbers Prior to 809000000 Serial Number 809000000 and Greater 15-25 in·lb (1.7-2.8 N·m) 15-25 in·lb (1.7-2.8 N·m) 56 in·lb (6.3 N·m) 80-90 in·lb (9.0-10.1 N·m) Starter/Starter Housing Item Shroud Extension/Engine Stand Screw Starter Housing Screws Starter Pulley Retainer Screw(s) Handle Bracket Screws (Cultivators) 25-35 in·lb (2.8-3.9 N·m) 35-40 in·lb (4.1-4.5 N·m) 20-30 in·lb (2.3-3.4 N·m) 35-40 in·lb (4.1-4.5 N·m) 1-6 GENERAL INFORMATION SAFETY WARNINGS AND NOTES The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols and the explanations with them, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures. WARNING: For Your Safety! WARNING: Explosive Fuel! Gasoline may be present in the fuel tank, carburetor, fuel lines, or crankcase. Gasoline is extremely flammable and its vapors can explode if ignited. Keep sparks, flames, and other sources of ignition away from the engine. Do not smoke while servicing the engine. Never use gasoline as a cleaning agent. Store gasoline only in approved containers, in wellventilated, unoccupied buildings, away from sparks, flames, or other sources of ignition. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Do not smoke while handling gasoline or filling the fuel tank. WARNING: Cracked or Broken Cooling Fins Are A Hazard! Be careful not to crack or break any cooling fins. They could fly off during operation. If cooling fins are cracked or broken, replace the flywheel. 1 Highlights instructions which failure to obey can result in personal injury. NOTE: Advises of information which maybe useful while performing maintenance or repair of the equipment. Also highlights instructions which failure to obey can result in damage to parts or equipment. WARNING: Spring Under Tension! The rope starter on these engines contains a flat wire spring that is under tension. Wear eye and hand protection when replacing worn or broken spring, in case it should uncoil as it is handled. Allow spring tension to be completely relieved and make sure pulley disengages from spring before removing the pulley retainer(s), pulley, and starter spring from housing. WARNING: Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. WARNING: Hot Surfaces! The muffler, cylinder, crankcase, trimmer cutting head, and other engine surfaces get extremely hot from operation. These surfaces remain hot for a short period of time after the engine is stopped. To prevent severe burns, allow the engine to cool completely before servicing. 1-7 GENERAL INFORMATION OPERATION AND MAINTENANCE Fuel Recommendations WARNING: Explosive Fuel! 1 PRODUCT IDENTIFICATION NUMBERS When ordering parts, or in any communication involving an engine or product, always give the: · Model Number, and · Serial Number These numbers are located on a decal (or decals) affixed to the unit (Figure 1-1). The identification decal(s) will be located on the engine, metal boom, or plastic housing. The actual location will vary depending on the type of product. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well-ventilated, unoccupied buildings, away from sparks or flames. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Do not smoke while handling gasoline. Never use gasoline as a cleaning agent. NOTE: READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO START OR OPERATE THIS UNIT. Using old oil or fuel, or improperly mixing the oil and fuel can cause engine damage. This type of damage will void the engine warranty. Recommended Oil Type Toro 2-cycle oil is recommended for use in these engines (Figure 1-2). If another brand of 2-cycle oil is used, use a high quality oil that is formulated for small 2-cycle air-cooled engines. Figure 1-1A. Product Identification Plate. 2.6078.001 Figure1-2. Recommended Oil Type. Recommended Fuel Type Use clean, fresh, regular grade unleaded gasoline. 1.0762.005 Figure 1-1B. Product Identification Plate. NOTE: Alcohol blended fuel absorbs moisture (water). As little as 1% moisture in the fuel can cause fuel and oil to separate and form acids when stored. 1-8 GENERAL INFORMATION If these types of fuel must be used, use fresh fuel (less than 60 days old) and mix according to the instructions in this section. Use Of Blended Fuels If you choose to use a blended fuel or its use is unavoidable, the following precautions are recommended. 1. Always use fresh fuel mixed according to the instructions in this section. 2. Use the special additive Alcohol Protector® (by Gold Eagle) or equivalent to inhibit corrosion and reduce oil/fuel separation (mix as directed). 3. Always agitate the fuel mix before fueling unit. 2. Add 4-oz. (118 ml) of Toro 2-cycle engine oil.

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