Toro 159cc, Service Manual

Page 1: ...WALK BEHIND MOWER ENGINE SERVICE MANUAL 2012 and Prior LC1P65FA 159cc RESIDENTIAL PRODUCTS ...

Page 2: ...Contents lists the systems and the related topics covered in this manual 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 manual please contact us at the following address The Toro Company Residential and Landscape Contractor...

Page 3: ...Chapter 1 General Service Information 1 Chapter 2 Engine Service Maintenance 2 Chapter 3 Engine Disassembly and Service 3 Chapter 4 Electrical 4 ...

Page 4: ...NOTES ...

Page 5: ...apter 1 General Service Information Safety 2 Service Rules 3 Engine Model Serial Number Location 3 Engine Fastener Torque Specification 4 General Specifications 4 Engine Specifications 5 Troubleshooting 6 1 ...

Page 6: ...running Avoid Fires and Explosions Avoid spilling fuel and never smoke while working with any type of fuel or lubricant Wipe up any spilled fuel or oil immediately Never remove the fuel cap or add fuel when the engine is running Always use approved labeled containers for storing or transporting fuel and lubricants Avoid Asphyxiation Never operate an engine in a confined area without proper ventila...

Page 7: ...XXX 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 Engine Model and Serial Numbers Engine Model Serial Number 1 ...

Page 8: ...ut M6 7 5 ft lbs 10 Nm Spark Plug 22 ft lbs 30 Nm Ignition and Charge Coil Bolts M6 7 5 ft lbs 10 Nm Electric Starter Motor Bolts M6 7 5 ft lbs 10 Nm Standard Torque Values M5 Bolt Nut 4 5 ft lbs 6 Nm M6 Bolt Nut 7 5 ft lbs 10 Nm M8 Bolt Nut 19 ft lbs 26 Nm M10 Bolt Nut 28 ft lbs 38 Nm M12 Bolt Nut 41 ft lbs 55 Nm Model 1P65FA Type Single cylinder 4 Stroke Forced Air Cooling OHV Bore x Stroke mm 6...

Page 9: ...0047 0 12 mm Big End Side Clearance 0 00393 0 02755 0 1 0 7 mm 0 0433 1 1 mm Crankshaft Crackpin Outside Diameter 1 0228 25 98 mm 1 0204 25 92 mm Valve Clearance cold Intake 0 0039 0 10 mm Clearance cold Exhaust 0 0059 0 15 mm Stem Diameter Intake 0 2157 5 48 mm 0 2093 5 318 mm Stem Diameter Exhaust 0 2141 5 44 mm 0 2076 5 275 mm Valve Guides Inside Diameter Intake Exhaust 0 2165 5 50 mm 0 2193 5 ...

Page 10: ...e or Faulty Air Filter Restriction Air Intake System Leaks Ignition Coil to Flywheel Gap Incorrect Weak No Spark Auto Choke System Improper Function Choke Air Vane Linkage Operating RPM Incorrect Governor Adjustment Incorrect Engine Valve Clearance out of Specification Low Compression or Excessive Leakdown Overheating Incorrect Oil Level Cylinder Head Gasket Leak Debris Build Up Restricting Air Fl...

Page 11: ...Engine Oil Change Procedure 8 Air Cleaner Service 9 Spark Plug Service 10 Valve Clearance Inspection and Adjustment 11 Engine Governor Zero Point Setting 11 Fuel Filter Replacement 12 Auto Choke System Function 13 Auto Choke System View 14 2 ...

Page 12: ...into a suitable container 5 Return the mower to the operating position 6 Add oil through the dipstick tube Wipe the dipstick clean and insert it into the dipstick tube to check the oil level NOTE DO NOT screw the dipstick into the dipstick tube to check the oil level NOTE DO NOT overfill the engine oil 7 Fully Install the dipstick and hand tighten it securely 8 Properly dispose of the used engine ...

Page 13: ... air filter is excessively dirty damaged or is wet with oil or fuel replace it 5 Remove dirt from the air cleaner body and cover using a moist rag Do not wipe dirt into the air duct 6 If the foam pre filter is reusable clean it with warm soapy water Thoroughly rinse and dry foam element 7 Insert the foam pre filter and the paper air filter into the air cleaner 8 Properly Install the cover and veri...

Page 14: ...lug cap and thoroughly clean the spark plug area 2 Remove the spark plug from the engine 3 Inspect the spark plug for excessively worn electrodes chips or cracks in the insulator or excessive deposits 4 Measure the electrode gap and adjust if necessary Spark Plug Gap 0 0275 0 0314 0 7 0 8 mm 5 Install spark plug and torque to specification 22 ft lbs 30 Nm 6 Fully install the spark plug cap on the ...

Page 15: ...ocker arm pivot and tighten the pivot lock nut to specification 11 ft lbs 15 Nm 5 Recheck the clearance and readjust if necessary 6 Inspect the valve cover gasket and replace if necessary Install the valve cover and torque fasteners to specification 7 5 ft lbs 10 Nm Engine Governor Zero Point Setting 1 Loosen but do not remove the governor arm pinch bolt and nut 2 Move the governor arm to fully op...

Page 16: ...d 2 If necessary remove air filter cover and base as outlined in this manual 3 Release the fuel filter fuel hose clamps A and slide them away from fittings 4 Remove the fuel filter fuel hose asm from the engine 5 Install new fuel filter hose asm and hose clamps A 6 Re fill tank with fresh fuel 7 Verify hose routing and check for leaks 8 Properly dispose of any unused fuel 9 Reinstall air filter co...

Page 17: ...oke plate at full operating RPM at any engine temperature COLD START Picture 1 illustrates the choke plate position while starting a cold engine The thermal spring is cold keeping the choke closed The air vane is inactive because the engine is not running HOT START Picture 2 illustrates the maximum amount the thermal spring can open the choke plate while the engine is hot and not running FULL RPM ...

Page 18: ...14 Auto Choke System View Image for Reference Only Thermal Spring Asm Mounts onto Muffler Thermal Spring Choke Linkage Choke Rod Lock Air Vane Choke Linkage Air Vane Washer Screw ...

Page 19: ...lve Seat Cylinder Head Specifications 24 Valve Stem Valve Guide Specifications 25 Valve Seat Reconditioning 26 Engine Service Lower End 27 36 Crankcase Governor Exploded View and Information 27 28 Crankshaft Piston Camshaft Exploded View and Info 29 Piston Connecting Rod Exploded View and Information 30 Valve Timing 31 Crankshaft Bearing Piston Cylinder Specifications 32 Piston Piston Ring Specifi...

Page 20: ... Service Upper End Air Cleaner and Muffler Exploded View Nut Muffler Shield Muffler Breather Tube Exhaust Gasket Primer Asm International Only Air Cleaner Base Intake Gasket Cover Foam Element Paper Element Nut ...

Page 21: ...17 Recoil Starter and Engine Cover Exploded View Recoil Asm Nut Fuel Cap Asm Nut Bolt Washer Fuel Tank Bolt Fuel Hose Fuel Filter Fuel Hose Clamp Screw Engine Cover 3 ...

Page 22: ...18 Set Screw Ratchet Guide Spring Ratchet Spring Reel Spring Bushing Recoil Asm Cover ...

Page 23: ...19 Carburetor and Linkage Exploded View 3 Governor Arm Governor Spring Governor Pinch Bolt Throttle Return Spring Governor Rod Control Asm Bracket Rod Gasket Insulator Heat Shield Spacer Gasket ...

Page 24: ...20 Carburetor Exploded View Throttle Valve Asm Pilot Jet O Ring Float Valve Asm Float Main Jet and Nozzle Throttle Stop Screw Float Bowl Float Bowl Mounting Bolt and Gasket Drain Plug and Gasket ...

Page 25: ...21 Flywheel and Breather Exploded View and Service Info 3 Key Brake Switch Asm Flywheel Nut 63 ft lbs 85 Nm Breather Cover Breather Gasket 6 ft lbs 8Nm Breather Valve 7 5 ft lbs 10Nm Shield ...

Page 26: ... Nm Cylinder Head Gasket Valve Cover 7 5 ft lbs 10 Nm Valve Cover Gasket Cylinder Head Bolt Torque Sequence 1 Initially Torque the 4 Cylinder Head Bolts in a Crisscross Pattern to 10 ft lbs 14 Nm 2 Evenly Torque the 4 Cylinder Head Bolts in a Crisscross Pattern to 25 ft lbs 34 Nm ...

Page 27: ...Valve Exploded View and Service Information 3 Lock Nut 11 ft lbs 15 Nm Rocker Arm Pivot Rocker Arm Rocker Arm Pivot Stud 22 ft lbs 30 Nm Push Rods Intake Valve Exhaust Valve Valve Spring Valve Spring Retainer Push Rod Guide ...

Page 28: ...mage Valve Seat Width Specification Standard Service limit 0 0314 0 8 mm 0 0787 2 0 mm Cylinder Head Warp Inspection Remove carbon deposits from the combustion chamber Clean off any gasket material from the cylinder head surface Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and a feeler gauge as shown Service Limit 0 00393 0 10 mm NOT...

Page 29: ...efore measuring Valve Guide ID Specification Standard Service limit 0 2165 5 50 mm 0 2193 5 572 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 Stem to Guide Clearance Subtract each valve stem OD from the corresponding guide ID to obtain the guide to stem clearance Standard Ser...

Page 30: ...enough material to produce a smooth and concentric seat Follow the valve seat cutter manufacture s instructions Turn the cutter clockwise never counterclockwise Continue to turn the cutter as you lift it from the valve seat 5 Use a 30 32 and 60 cutter to narrow and adjust the valve seat so that it contacts the middle of the valve face The 30 32 cutter removes material from the top edge The 60 cutt...

Page 31: ...nor Exploded View and Service Information Governor Exploded Views 3 Aux Oil Drain 15 5 ft lbs 21 Nm Sealing Washer 7 5 ft lbs 10 Nm Governor Holder Gasket Pin Weight Washer Slider Clip Washer Shaft Governor Holder Governor Asm Rubber Oil Baffle ...

Page 32: ...ploded View Oil Seal Crankcase Sump Cover Crankcase Sump Cover Bolt Torque Sequence 7 5 ft lbs 10 Nm 1 2 3 4 5 6 7 Sump Cover Gasket Oil Dip Stick O Ring Governor Arm Shaft Governor Oil Seal Governor Lock Pin Oil Seal ...

Page 33: ...ankshaft Piston Camshaft Exploded View and Service Info 3 Crankshaft Thrust Washer Connecting Rod Bolts 9 5 ft lbs 13 Nm Bearing Piston Asm Connecting Rod Connecting Rod Cap Valve Tappets Cam Shaft Oil Seal ...

Page 34: ... the piston ring gap as shown Top Ring Second Ring Oil Ring Piston Mark Top Ring Second Ring Oil Ring Check refer to Piston Pin Piston Pin Circlip Install the circlip gap in the 12 00 Position circlip gap facing up Connecting Rod Orientation Align Long end of connecting rod with piston orientation triangle CLIP CUT OUT ...

Page 35: ...g 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 3 Timing Marks Crankshaft Camshaft ...

Page 36: ...this engine are gaskets and seals Cylinder Taper and Out of Round Inspect cylinder for taper and out of round with a bore gauge Measure in two different directions front to back and side to side on three different levels down from the top middle and up from the bottom Cylinder Taper and Out of Round Specifications Standard Service Limit 2 559 65 0 mm 2 566 65 165 mm NOTE If this measurement is out...

Page 37: ...his measurement is out of specification complete engine replacement is required The only internal parts available for this engine are gaskets and seals Piston Ring to Groove Clearance Standard Service Limit Top Middle 0 00059 0 00177 0 015 0 045 mm 0 0059 0 15 mm NOTE If this measurement is out of specification complete engine replacement is required The only internal parts available for this engi...

Page 38: ...are gaskets and seals Connecting Rod Small End ID Standard Service Limit 0 5125 13 02 mm 0 5145 13 07 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 ID Standard Service Limit 1 0244 26 02 mm 1 0263 26 07 mm NOTE If this measurement is out of specification comp...

Page 39: ...complete engine replacement is required The only internal parts available for this engine are gaskets and seals Connecting Rod Big End Oil Clearance 1 Clean oil from the crankshaft and connecting rod 2 Use plastic gauge style measuring tool in accordance to the manufactures instructions to measure the oil clearance Connecting Rod Bolt Torque 9 5 ft lbs 13 Nm NOTE If this measurement is out of spec...

Page 40: ... only internal parts available for this engine are gaskets and seals Camshaft Journal OD Standard Service Limit 0 5505 13 984 mm 0 5478 13 916 mm Check the camshaft bearing journal for scoring wear or damage NOTE Verify that the decompression mechanism moves freely NOTE If this measurement is out of specification complete engine replacement is required The only internal parts available for this en...

Page 41: ...37 Chapter 4 Electrical System Information Ignition Charge Coil Gap Adjustment 38 Ignition Coil Resistance Inspection 38 Spark Testing 39 Electrical System Wiring 40 4 ...

Page 42: ...en the flywheel and coil 4 Adjust the coil gap at both side of the coil 5 Torque the coil mounting bolts to specification 7 5 ft lbs 10 Nm Ignition Coil Resistance Inspection Primary Coil Place Ohm meter leads between the harness connection lead and the exposed metal coil leg Secondary Coil Place Ohm meter leads between exposed metal coil leg and the spark plug terminal connection Ignition Charge ...

Page 43: ...fuel in an approved container 2 Remove spark plug boot from the spark plug 3 Remove the spark plug from the engine 4 Connect the negative electrode of the spark plug threaded area to ground cylinder head cover 5 Crank the engine and view the electrode gap Spark should be present when engine is turning over 6 Reinstall the spark plug and torque to specification 22 ft lbs 30 Nm 7 Properly install th...

Page 44: ...40 Electrical System Wiring Electric Start Shown A Ignition Coil B Starter Motor C Alternator D Brake Kill Switch E Starter Interlock Switch F To Chassis Harness G To Ground E D B A C G F F ...

Page 45: ...41 NOTES ...

Page 46: ...42 RESIDENTIAL PRODUCTS Form Number 492 9231 ...