SINGLE STAGE SNOW ENGINE SERVICE MANUAL
Contents
1. M6 Bolt Nut M8 Bolt Nut M10 Bolt Nut M12 Bolt Nut 17 ft lbs 23 Nm 8 5 ft lbs 12 Nm 25 ft lbs 34 Nm 8 5 ft lbs 12 Nm 11 ft lbs 15 Nm 22 ft lbs 30 Nm 7 ft lbs 10 Nm 22 ft lbs 30 Nm 7 ft lbs 10 Nm 7 ft lbs 10 Nm 50 ft lbs 70 Nm 7 ft lbs 10 Nm 7 ft lbs 10 Nm 7 ft lbs 10 Nm 22 ft lbs 30 Nm 7 ft lbs 10 Nm 4 5 ft lbs 6 Nm 7 5 ft lbs 10 Nm 19 ft lbs 26 Nm 28 ft lbs 38 Nm 41 ft lbs 55 Nm General Specifications OHV Single Cylinder Four Stroke Forced Air Cooling Engine Specifications Pat em Specifieation es a EE S Valve Clearance NOTE The only internal parts available for this engine are gaskets and seals Troubleshooting Hard Starting Poor Running Incorrect Fuel Level Age Octane Ethanol Content Fuel System Contamination and or Debris in Carburetor Incorrect Oil Level Spark Plug Incorrect Gap Fouled Loose or Faulty Air Intake System Leaks Ignition Coil to Flywheel Gap Incorrect Weak No Spark Choke Function 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 Flow Chapter 2 Engine Service Maintenance 2 Engine Oil Change Procedure 8 Spark Plug Service 9 Valve Clearance Inspection and Adjustment2. Fuel Tank Mounting A Fuel is Extremely Flammable Use Extreme Caution When Servicing Fuel System Fuel Tank Mounting Hardware 7 ft lbs 10 Nm Fuel Tank Mounting Hardware 7 ft lbs 10 Nm Fuel Filter P anii en DR Fuel Tank Fitting Heater Box Exploded View 7 ft lbs 10 Nm Key Switch Ta Note Verify primer hose is not kinked or pinched upon heater box installation Carburetor Governor Mounting Exploded View Governor Arm 7 ft lbs 10 Nm Governor Spring Carburetor Asm Clip Gasket Carburetor Exploded View a Choke Lever Stop Screw Carburetor Bod Are y i Choke Plate Main Jet Needle Asm Gasket 7 ft lbs 10 Nm gt 2 gt D D Q x LL T lt O OC Shroud and Recoil Asm 7 ft lbs 10 Nm yf Cd DV a JH dd Y 4 LA EN i LA S H 4 f Ne 7 ft lbs 10 Nm 6 o 5 oc lt Set Screw Guide a call EO VAUT P D VS O C lt O ep 19 Starter Flywheel Coil Exploded View Blower Shroud Electric Start Starter Asm Blower Shroud Recoil Start 8 7 ft lbs 10 Nm ua Flywheel Cup Ignition Coil Asm Side Plate 7 ft lbs 10 Nm Fan Flywheel Nut 50 ft lbs 70 Nm Starter Removal 1 Remove recoil and shroud asm 2 Remove flywheel with an appropriate puller 3
3. Ensure fuel system contains no fuel to prevent leak when the fuel filter is replaced Release the fuel hose clamps A and slide them away from the carburetor and fuel tank fittings Remove the fuel filter hose asm from the engine Unscrew the fuel tank drain fitting B from the fuel tank Install a new fuel tank fitting B Install new fuel filter fuel hose asm and clamps A Re fill tank with fresh fuel Verify hose routing and check for leaks Properly dispose of any unused fuel 12 Chapter 3 Engine Disassembly and Service El Engine Service Upper End 14 24 Muffler Heat Shield Exploded View 14 Fuel Tank Mounting 15 Heater Box Exploded View 16 Carburetor Governor Mounting 17 Carburetor Exploded View 18 Recoil Asm Exploded View 19 Starter Flywheel Coil Exploded View 20 Cylinder Head Exploded View and Service Information 21 Cylinder Head Valves Exploded View and Service Information 22 Valve Seat Width Inspection Cylinder Head Warp Inspection 23 Valve Seat Reconditioning 24 Engine Service Lower End 25 28 Crankcase Exploded View and Service Information 25 Governor Exploded View 26 Piston Connecting Rod Exploded View and Service Information 27 Valve Timing 28 NOTE The only internal parts available for this engine are gaskets and seals Engine Service Upper End Muffler Heat Shield Exploded View Self Tapping Screws Muffler Shield Muffler Gasket 27 ft lbs 30 Nm
4. Remove the fasteners securing the starter motor to the engine and remove starter asm 20 Cylinder Head Exploded View and Service Information Spark Plug 22 ft lbs 30 Nm el Gasket Cylinder Head 7 ft lbs 10 Nm Breather Tube 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 21 Cylinder Head Valves Exploded View and Service Information Valve Spring Exhaust Valve Push Rod 7 ft lbs 10 Nm i Intake Valve Valve Lash Lock Nut Retainer Guide Plate 11 ft lbs 15 Nm 22 Valve Seat Width Inspection Remove carbon deposits from the combustion chamber Inspect the valve seats for pitting or other damage 0 0315 0 0394 0 0787 0 8 1 0 mm 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 0 00393 0 10 mm STRAIGHT EDGE 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 25 Valve Seat Reconditioning 1 Thoroughl
5. 10 Engine Governor Zero Point Setting 11 Engine RPM Adjustment 11 Fuel Filter Replacement 12 Engine Oil Change Procedure 1 Run engine to warm engine oil 2 Remove the ignition key NOTE Ensure fuel system contains no fuel to prevent leak when engine is tipped 3 Position oil drain pan under oil drain plug 4 Remove the oil fill check cap 5 Remove the oil drain plug If necessary replace drain plug gasket 6 Tip engine slightly backwards if necessary to completely drain the engine oil 7 Install the oil drain plug torque to 17 ft lbs 23 Nm 8 Add oil through the oil check fill hole Wipe the dipstick clean and insert it into the dipstick hole NOTE DO NOT fully install screw in the dipstick to check the oil 9 Remove the dipstick and check the oil level Add oil if needed until the proper oil level is reached NOTE DO NOT overfill the engine oil 10 Fully install and tighten the dipstick 11 Properly dispose of the used engine oil Engine Oil Capacity 12 oz 0 35 Engine Oil Type API classification of SF SG SH SJ SL or higher Or oc 104 40 86 30 68 s 20 P 50 10 n 32 2 0 2 14 10 gt 4 o 20 22 30 Spark Plug Service 2 NOTE Spark plugs of the wrong size or incorrect heat range can cause severe engine damage A High Voltage Ignition Systems can be Dangerous Use Caution when Servicing Ignition Systems 1 Disconnect the spark plug boot and thorough
6. RESIDENTIAL PRODUCTS SINGLE STAGE SNOW ENGINE SERVICE MANUAL LC154FS LC154FDS 87cc About this Manual This service manual was written expressly for Toro service technicians The Toro Company has made every effort to make the information in this manual complete and correct Basic shop safety knowledge and mechanical electrical skills are assumed The Table of 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 Service Training Department 8111 Lyndale Avenue South Bloomington MN 55420 Chapter 1 General Service Information Chapter 2 Engine Service Maintenance Chapter 3 Engine Disassembly and Service Chapter 4 Electrical NOTES Chapter 1 General Service Information ER Safety Service Rules Engine Model Serial Number Location Engine Fastener Torque Specification General Specifications Engine Specifications Troubleshooting Ooch W W N Safety Safety Information This 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 per
7. ea of bystanders before starting or testing power equipment Avoid Injury Due To Projectiles Always clear the area of sticks rocks or any other debris that could be picked up and thrown by the power equipment Avoid Modifications Never alter or modify any part unless it is a factory approved procedure Service Rules ER 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 Serial Number Location 2010 2011 The engine model and serial number are stamped into the crankcase near the electric starter mounting position on the side of the engine towards the front of machine shown below 2012 The engine model and serial number are stamped into the crankcase near the rear of the machine Engine Model and Serial Numbers XXX XXXX XXXXXXXXXXX Engine Model Serial Number Engine Fastener Torque Specifications Torque Specification Oil Drain Plug Connecting Rod Bolts Cylinder Head Bolt Crankcase Cover Bolts Valve Lash Lock Nut Rocker Arm Studs Valve Cover Bolts Spark Plug Cylinder Head Cover Bolts Heater Box Nuts Flywheel Nut Ignition Coil Bolts Governor Arm Nut Starter Bolts Muffler Hex Nuts Fuel Tank bolts Standard Torque Values M5 Bolt Nut
8. ing Rod 12 Nm Oil Splash Spoon Point Down to Match Piston Arrow Piston Asm Triangular Mark to Face Down 25 Bearing Governor Shaft Governor Governor Exploded View Clip Weight Slider Governor Gear Washer Washer Pa Pin Governor Shaft Clip 26 Piston Connecting Rod Exploded View and Service Information El Second Ring Gap Piston Rotation Arrow Install Piston Ring Markings UP S Top Ring Gap Oil Rings Stagger Scraper Rings 150 210 from the Oil Ring Connecting Rod Piston Pin Piston Pin Clip Oil Splash Spoon Point Down to UV Match Piston Arrow Triangular Mark to Face DOWN Towards Push Rods t Clip Gap Piston Cut out 27 Valve Timing Crankshaft Timing Marks e 28 Chapter 4 Electrical System Information a Ignition Coil Gap Adjustment 30 Ignition Coil Resistance Inspection 31 Spark Testing 31 29 Ignition Coil Gap Adjustment A High Voltage Ignition Systems can be Dangerous Use Caution when Servicing Ignition Systems Install the ignition coil and lightly tighten the ignition coil mounting bolts Rotate engine so ignition coil is aligned with the magnet portion of the flywheel Adjust the ignition coil gap at both side of the coil 4 2 3 Insert the feeler gauge between the flywheel and coil 4 5 Torque the ignition coil fasteners to specification 7 ft lbs 10 Nm Ignitio
9. ly clean the spark plug area 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 Measure the electrode gap and adjust if necessary Spark Plug Gap 0 0275 0 0314 0 7 0 8 mm Install spark plug and torque to specification 22 ft lbs 30 Nm Fully install the spark plug boot onto the spark plug d 0 0275 0 0314 0 7 0 8 mm Spark Plug n Valve Clearance Inspection and Adjustment NOTE Valve clearance inspection and adjustment must be done with the engine cold 1 NOTE Be sure feeler gauge blade is not opening the valve while measuring valve clearance Rotate Engine to TDC top dead center of the compression stroke Remove the valve cover Be sure both valves are completely closed and the decompression arm is not holding the valve open Measure the clearance between the rocker Valve Stem arm and the valve stem with a feeler gauge Intake 0 0059 0 15 mm Exhaust 0 0078 0 20 mm To adjust valve clearance Hold adjustment bolt and loosen the lock nut Lock Nut Turn adjustment bolt to obtain the specified clearance Hold the adjustment bolt and tighten the lock nut to specification 11 ft lbs 15 Nm Image For Reference Only Recheck the clearance and readjust if necessary Inspect the valve cover gasket and replace if necessary Install the cylinder head cover and torque faste
10. n Coil Ignition Coil 30 Ignition Coil Resistance Inspection Primary Coil Place Ohm meter leads between the harness connection lead and the exposed metal coil leg A Primary Coil Resistance 1 0 1 6 O Secondary Coil Place Ohm meter leads between exposed metal coil leg and the spark plug terminal connection B Secondary Coil Resistance 15 KO 15 Spark Testing A Fuel is Extremely Flammable Use Extreme Caution When Servicing the Fuel System High Voltage Ignition Systems can be Dangerous Use Caution when Servicing Ignition Systems Remove spark plug boot from the spark plug Remove the spark plug from the engine Connect the negative electrode of the spark plug threaded area to ground cylinder head cover Crank the engine and view the electrode gap Spark should be present when engine is turning over Reinstall the spark plug and torque to specification 22 ft lbs 30 Nm Properly install the spark plug boot CF ee ee es 31 RESIDENTIAL PRODUCTS Form Number 492 9233
11. ners to specification 7 5 ft lbs 10 Nm Valve Cover Feeler Gauge do 10 o i iO ak OP OY EE Engine Governor Zero Point Setting 2 1 Remove the 3 fuel tank mounting fasteners to gain access to the governor asm Fuel tank removal is not necessary Loosen but do not remove the governor pinch nut A Move the governor arm B towards the carburetor to fully open the throttle valve Firmly hold the governor arm in this position Rotate the governor arm shaft C fully clockwise and secure it in this position with a pair of pliers Tighten the governor arm pinch bolt and nut to specification 7 5 ft lbs 10 Nm Verify that the governor arm and throttle valve move freely Install fuel tank mounting fasteners and torque to specification 7 ft lbs 10 Nm Start and warm engine Verify the engine operating RPM is set between 4350 4650 RPM em a LO DE OD ACI Y i dE mm DC cradle Dv ETERN POPAN Pag Engine RPM Adjustment e I pe Properly set the governor zero point as shown in this manual Start and warm engine Attached an appropriate tachometer to the engine Adjust engine RPM by turning the High Speed Setting Screw D located on the engine shroud Engine Operating RPM 4350 4650 RPM 11 Fuel Filter and Hose Replacement A Fuel is Extremely Flammable Use Extreme Caution When Servicing Fuel System 1 Properly drain the fuel tank into an approved container NOTE
12. sonal 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 Toro engine The Toro operator s manual contains safety information and operating tips for safe operating practices Avoid Unexpected Engine Start Turn off engine and disconnect the spark plug before servicing engine Avoid Lacerations and Amputations Stay clear of all moving parts while the engine is running Avoid Burns Do not touch the engine muffler or other components which may increase in temperature during operation while the unit is running or shortly after it has been 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 ventilation Avoid Injury From Batteries Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Battery gases can explode Keep cigarettes sparks and flames away from the battery Avoid Injury Due To Inferior Parts Use only original equipment parts to ensure that important safety criteria are met Avoid Injury To Bystanders Always clear the ar
13. y clean the combustion chamber and valve seats to remove carbon deposits 2 Apply a light coat of Prussian Blue or erasable felt tipped marker ink to the valve faces 3 Properly install valves springs and keepers Manually open the valves then and snap them closed against their seats several times Be sure the valves do not rotate on the seat Remove the valve assemblies The transferred marking compound will show any area of the seat that is not concentric 4 Use a 45 utter to remove 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 cutter removes material from the bottom edge Be sure that the width of the finished valve seat is within specification 6 Lap valves in accordance with valve lapping kit instructions 7 Clean valve and seat of all lapping compound Valve Seat Width 0 0315 0 0394 0 0787 0 8 1 0 mm 2 0 mm CONTACT TOO HIGH NN CONTACT TOO LOW wk 24 Engine Service Lower End Crankcase Exploded View and Service Information 8 5 ft lbs 12 Nm Seal Bearing Gasket Crankshaft Camshaft 8 5 ft lbs Connect
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