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From inside (document excerpt):
R-TEK/DURAFORCE (E) ENGINE SERVICE MANUAL Table of Contents Page 1 of 1 PREFACE SAFETY SPECIFICATIONS SPECIAL TOOLS TROUBLESHOOTING MAINTENANCE CARBURETOR FUEL SYSTEM IGNITION SYSTEM REWIND STARTER ENGINE PIVOTING ZONE START BRAKE ELECTRIC START SYSTEM (120 VOLT) ELECTRIC START SYSTEM (12 VOLT) PREFACE ABOUT THIS MANUAL This manual was written expressly for the E series engines. There are two engines in this series. One is piston ported (R tek) and the other is a reed valve (DuraForce). As these engines are of the same family, they will both be covered here.
Where there are differences between the two versions, a heading will state which engine is being discussed. We have made every effort to make this information complete and correct. We hope that you find this manual a valuable addition to your service shop. If you have questions or comments regarding this manual, please contact us at the following address: The Toro Company Consumer Service Department 8111 Lyndale Ave. So. Minneapolis, MN 55420-1196 The Toro Company reserves the right to change product specifications or this manual without notice. TABLE OF CONTENTS TABLE OF CONTENTS SAFETY . 1 SPECIFICATIONS . 2 Engine Specifications (All dimensions are for a new engine) . .2 Engine Fastener Torque Requirements 3 Standard Torques .4 Carburetor Specifications . .4 SPECIAL TOOL REQUIREMENTS 5 TROUBLESHOOTING .6 Engine Will Not Start When “Cold ” 6 Engine Will Start When “Cold “, But Not When “Hot ” .6 Engine Will Not Produce Spark .7 Engine Flooded With Fuel .7 Engine Has Low Compression . .7 Engine Lacks Power .8 Engine Surges . .8 Engine Backfires . .8 Engine Overheats .9 Engine Vibrates Excessively .9 Engine Crankshaft Will Not Turn . .9 Engine Produces Mechanical Knocking Sound .9 Engine Pre-Ignites . .10 Engine Smokes Excessively (Smoke is light colored, engine runs well) .10 Engine Smokes Excessively (Smoke is dark, engine runs poorly) .10 Engine Stalls . .11 Spark Plug Fouled . .11 MAINTENANCE .13 Recommended Maintenance Schedule . .13 Air Filter (Mower Only) .14 Spark Plug . .14 Cleaning the Exhaust System (Lawn Mower) .15 Cleaning the Exhaust System (Snowthrower) .16 Reassembling Exhaust System (Mower Only) .16 i TABLE OF CONTENTS CARBURETOR . 17 Identification .17 Theory of Operation .17 Troubleshooting . .18 Preliminary Check . .19 Removal of DuraForce Carburetor . .20 Removal of R tek Carburetor . .20 Disassembly .21 Cleaning and Inspection . .23 Assembly .23 Installation . .25 Governor Theory .26 Reed Valve Engine (DuraForce Engines Only) . .26 Piston Ported Engine (R tek Engines Only) .26 Presetting the Governor (DuraForce Engines Only) 26 Servicing the Air Filter (DuraForce Engines Only) . .27 FUEL SYSTEM .29 Operation .29 Fuel Cap Service .29 Cleaning . .29 IGNITION SYSTEM . .31 Troubleshooting . .31 Testing .31 Spark Plug Operation . .31 Spark Plug Service . .32 CD Pack Operation .32 CD Pack Air Gap Adjustment . .33 CD Pack Removal/Installation .33 Flywheel Operation .34 Flywheel Removal . .34 Flywheel Installation .35 ii TABLE OF CONTENTS REWIND STARTER . .37 Operation .37 Removal and Disassembly . .37 Reassembly .37 ENGINE .39 General Information .39 Theory of Operation .39 Reed Valve Engine . .39 Piston Ported Engine . .40 Both Piston Ported and Reed Valve Engines . .40 Service Tips .41 Disassembly .41 Inspection and Repair .42 Reed Valve Service (DuraForce Engines Only) . .43 Reassembly .44 Reinstalling External Components . .45 Crankshaft Seal Replacement .46 PIVOTING ZONE START BRAKE .47 Introduction .47 Operation .47 Disassembly .48 Assembly . 49 ELECTRIC START SYSTEM (120 VOLT) .51 Troubleshooting . .51 Introduction .51 Starter Removal . 51 Starter Disassembly .52 Starter Assembly .52 Starter Installation . .52 iii TABLE OF CONTENTS ELECTRIC START SYSTEM (12 VOLT) . .53 Troubleshooting . .53 Introduction .53 Starter Removal . .53 Starter Testing .54 Starter Disassembly .54 Starter Assembly .55 Starter Installation . .55 Alternator Introduction .56 Alternator Output Testing .57 Alternator Air Gap Adjustment .57 Alternator Resistance Check . .57 Cup Assembly Test .57 iv SAFETY SAFETY INFORMATION General This safety symbol means WARNING or PERSONAL SAFETY INSTRUCTION – read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the engine only. The individual Operator’s manual will contain safety information on the complete product powered by the E series engine. Operator’s manuals with complete instructions are available through: Lawn-Boy Corporation / The Toro Company Parts Department 8111 Lyndale Avenue South Bloomington, MN 55420 U.S.A. Safety Tips Avoid unexpected starting of engine.
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