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Toro GTS 200 Service Manual

Overhead valve engine
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TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL
Table of Contents – Page 1 of 2
SPECIFICATIONS
GENERAL INFORMATION
OIL
GASOLINE
COOLING SYSTEM
AIR CLEANER – GENERAL
AIR CLEANER SERVICE
TUNE-UP PROCEDURE
OVERHAUL PROCEDURE
CHECK-UP
EQUIPMENT AFFECTING ENGINE OPERATION
IGNITION
CHECK IGNITION
SPARK PLUG
REMOVE FLYWHEEL
INSPECT FLYWHEEL KEY, KEYWAYS, FLYWHEEL, AND CRANKSHAFT
INSTALL FLYWHEEL
SPECIFICATIONS
CARBURETION
CARBURETOR IDENTIFICATION
SERVICE CARBURETOR WALBRO LMS
GOVERNOR CONTROLS, CARBURETOR LINKAGE, AND FLYWHEEL BRAKE
REMOTE GOVERNOR CONTROLS
FLYWHEEL BRAKE
GOVERNOR ADJUSTMENTS
GOVERNOR AND CARBURETOR LINKAGES
GOVERNOR
GENERAL INFORMATION
GOVERNED RPM LIMITS
MECHANICAL GOVERNOR
COMPRESSION
TEST COMPRESSION
REMOVE CYLINDER HEAD
VALVE SERVICE
ASSEMBLE CYLINDER HEAD
SPECIFICATION TABLES
REWIND STARTER
GENERAL INFORMATION
REMOVE BLOWER HOUSING AND STARTER

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Summary of Contents for Toro GTS 200

  • Page 1 TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL Table of Contents – Page 1 of 2 SPECIFICATIONS GENERAL INFORMATION GASOLINE COOLING SYSTEM AIR CLEANER – GENERAL AIR CLEANER SERVICE TUNE-UP PROCEDURE OVERHAUL PROCEDURE CHECK-UP EQUIPMENT AFFECTING ENGINE OPERATION IGNITION CHECK IGNITION...

  • Page 2: Piston And Connecting Rod

    TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL Table of Contents – Page 2 of 2 DISASSEMBLE REWIND STARTER ASSEMBLE REWIND STARTER ELECTRIC STARTER GENERAL INFORMATION TROUBLESHOOTING 12 VOLT STARTING SYSTEM TEST EQUIPMENT BATTERY STARTER ALTERNATOR ALTERNATOR SPECIFICATIONS EQUIPMENT TO TEST ALTERNATORS...

  • Page 3: About This Manual

    About This Manual This manual was written expressly for the Toro GTS 200 Overhead Valve Engine. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written with the service technician in mind. We hope that you find this manual a valuable addition to your service shop.
  • Page 4 ......Install Inlet Needle Seat ....GTS 200 Contents...

  • Page 5: Table Of Contents

    ....... . Inspect Oil Pump ....... . . GTS 200 Contents...
  • Page 6 ......Champion RC12YC ......0.020 in. 0.51mm GTS 200 Specifications...

  • Page 7: Check Oil Level

    Replace the oil filter (on models so equipped) every 100 hours or yearly, whichever occurs first. There are two methods of changing engine oil, the drain plug method and the oil fill tube method. Both work equally well. GTS 200 General Information...

  • Page 8: Change Oil—Oil Fill Tube Method

    3. Remove dipstick from oil fill tube and place a drain pan next to left side of mower. 4. Tip mower on its left side, allowing oil to drain into drain pan (Fig. 3). m–3848 Fig. 3 1. Oil fill tube 2. Oil filter GTS 200 General Information...

  • Page 9: Cooling System

    Continued operation with a clogged cooling system can cause severe overheating and possible engine damage. Figures 5 and 6 show the areas to be cleaned. GTS 200 General Information...

  • Page 10: Air Cleaner Service

    6. Reinstall pre–cleaner over paper cartridge. Reinstall air 1. Stop engine and pull wire off spark plug (Fig. 7). cleaner cover and tighten securely in place with two (2) knobs. GTS 200 General Information...
  • Page 11 Replace gaskets and install carburetor Adjust remote control linkage and cable, if used, for correct operation. Check muffler for restrictions or damage. Replace oil and fuel. Run engine and adjust carburetor mixture and engine Top No Load RPM. GTS 200 General Information...

  • Page 12: Overhaul Procedure

    The Overhaul Procedure which follows is intended to help you become accustomed to a systematic method of repairing Toro GTS 200 OHV engines. Naturally these steps could be rearranged in different order but efficiency is obtained when the repair operations are performed in the same sequence every time.
  • Page 13 Clean/replace and assemble air cleaner General Information Fill crankcase with oil, fill with gas, start engine General Information Adjust carburetor Carburetion Set governor to obtain correct engine speed (remote controls) Governor Spray paint engine parts and apply decals GTS 200 General Information...

  • Page 14: Check Carburetion

    166” (4.20mm) tester gap, you can assume the most common cause. ignition system is performing satisfactorily. See the section Ignition for additional information. GTS 200 General Information...

  • Page 15: Power Loss

    2. No lubricant in transmission or gear box. 5. Mounting bolts loose – Tighten. 3. Worn drive belts. 6. Mounting deck or plate cracked – Repair or replace. 4. Worn bearings. 7. Damaged belts or pulleys. GTS 200 General Information...
  • Page 16 2. Operate starter and observe spark gap in tester. If spark jumps tester gap, ignition is good. Note: Flywheel must rotate at 350 RPM, minimum. Note: Spark will be observed. GTS 200 Ignition...
  • Page 17 Fig. 14. Fig. 12 – Removing Ignition Armature Fig. 14 – Removing Flywheel 1. Ignition armature 3. Stop switch wire 1. Flywheel nut 2. Briggs & Stratton Tool 2. Screws 4. Terminal #19069 flywheel puller GTS 200 Ignition...
  • Page 18 7. Torque as listed in Table No. 1, Page 17. Fig. 17 – Installing Armature 1. Ignition armature 2. Tighten one screw 4. Push armature away from flywheel as far as possible and tighten one screw to hold armature in place. GTS 200 Ignition...
  • Page 19 Specifications Table No. 1 Flywheel Puller Flywheel Holder Armature Air Gap Flywheel Nut Torque Briggs & Stratton Tool # Briggs & Stratton Tool # .006” – .012” 19069 19372 60 ft. lbs. (0.15 – 0.30mm) (81.0Nm) GTS 200 Ignition...

  • Page 20: Carburetor Identification

    TO PREVENT accidental starting when servicing Fig. 22 – Removing Air Cleaner engine or equipment, always remove spark plug 1. 2 screws 4. Cartridge wire from spark plug and prevent wire from 2. Cover 5. Base contacting spark plug. 3. Pre-cleaner GTS 200 Carburetion...

  • Page 21: Remove Carburetor

    2. Remove float bowl and bowl gasket from carburetor. 1. Choke plate and shaft 4. Welch plug 3. Remove float hinge pin, float and inlet needle, Fig. 24. 2. Idle speed screw 5. 5/32” punch 3. Throttle shaft 6. Throttle plate screw GTS 200 Carburetion...
  • Page 22 2. Insert float hinge pin and center pin between float pin 1. Install throttle shaft and foam washer. bosses. Float height is non-adjustable. 2. Turn shaft until flat is facing out. 3. Install rubber gasket on carburetor and lay float bowl on body. GTS 200 Carburetion...

  • Page 23: High Altitude Compensation

    1. Install breather tube on air cleaner primer base and position decrease. If poor performance is experienced refer to the base with new gasket on carburetor mounting surface. proper Toro parts manual for replacement high altitude main jet. 2. Install air cleaner primer base with two (2) screws into carburetor.

  • Page 24: Flywheel Brake

    The flywheel brake is part of the safety control system required for this engine. The flywheel brake MUST stop the engine within three seconds, while running at FAST speed position, when the operator releases the equipment safety control. Governor Controls, Carburetor Linkage, GTS 200 and Flywheel Brake...
  • Page 25 5. Install fuel tank and static guard. 5. Disconnect spring from brake anchor. 6. Disconnect stop switch wire from stop switch. If engine is equipped with electric starter, disconnect both wires from starter interlock switch. Governor Controls, Carburetor Linkage, GTS 200 and Flywheel Brake...

  • Page 26: Governor Adjustments

    3. Rotate the governor lever to the right until it stops. Hold and tighten the governor lever nut. To adjust top no load RPM, see page 26. Refer to page 26 for specific procedures for governor adjustments. Governor Controls, Carburetor Linkage, GTS 200 and Flywheel Brake...

  • Page 27: General Information

    ....... tachometer. Toro rotary mowers should be set to run at 3,000 RPM 150, General Information which will produce blade tip speeds of 19,000 feet per minute.

  • Page 28: Install Crankcase Cover Or Sump

    19334/5 vertical crankshaft engines. Color ..... . Brown Crankshaft Journal Size ..1.062” (26.97mm) GTS 200 Governor...
  • Page 29 6. Pull regulator lock nut out and turn adjustment knob counterclockwise as far as it will go, Fig. 48. Note: The crankshaft must be held with the piston at top dead center to eliminate any chance of rotation. GTS 200 Compression...
  • Page 30 If reading does not Fig. 51 – Removing Cylinder Head ponents. change, look for problems 1. Cylinder head screws 2. Cylinder head beginning with component that appeared to leak the most air. Re-test after re- pair. GTS 200 Compression...

  • Page 31: Assemble Cylinder Head

    1. Screw: torque to 80 in. lbs. (9.0Nm) lapped in using Briggs & Stratton Tool #19258, Valve Lapping Tool, and Briggs & Stratton Part #94150, Valve Lapping Compound, to assure a good seal between the valve face and the seat. GTS 200 Compression...

  • Page 32: Install Cylinder Head

    (15.0Nm), Fig. 58. fully engaged in valve stem groove, Fig. 56. Fig. 58 – Installing Rocker Arm Studs Fig. 56 – Installing Valve Retainers 1. Rocker arm stud: torque to 130 in. lbs. (15.0Nm) 1. Valve retainer GTS 200 Compression...
  • Page 33 3. Turn crankshaft clockwise (flywheel end), while watching through rocker arm. screwdriver or rod, past Top Dead Center until piston is 3. Install jam nut of end of rocker arm screw and run nut up 1/4” (6mm) down. on threads half way. GTS 200 Compression...

  • Page 34: Install Valve Cover

    24.0 Table No. 4 Valve Clearances Intake Exhaust .004–.008 .004–.008 (.10-.20mm) (.10-.20mm) Table No. 5 Valve Cover Torques Fig. 64 – Locking Jam Nut In. Lb. (Nm) 1. Torque jam nut 85 in. lbs. (10Nm) (10.0) GTS 200 Compression...
  • Page 35 3. Foam pre–cleaner 2. Cover 4. Paper cartridge 2. Remove four (4) screws from rewind cover, Fig. 68. Remove cover. Fig. 68 – Removing Blower Housing Cover 1. Screw Fig. 66 – Rewind Starter, Exploded View GTS 200 Rewind Starter...

  • Page 36: Remove Rope

    Fig. 70 – Removing Oil Fill Tube Table No. 1 1. Screws (2) 3. Dipstick and oil fill tube 2. Blower housing and Rewind Starter Rope Specifications rewind starter Length Rope Size Rope Size Inches Meters 88–5/8 2.25 GTS 200 Rewind Starter...

  • Page 37: Remove Pulley And Spring

    THE STARTER spring is still under tension when the rope has been removed and the pulley has no spring tension against it. Wear eye protection to prevent eye injury when installing or removing starter pulley and spring. GTS 200 Rewind Starter...

  • Page 38: Assemble Rewind Starter

    2. Pulley rope hole 4. Clockwise 2. Then rotate pulley clockwise until rope hole in pulley is in Fig. 78 – Installing Pawls line with starter housing eyelet and hold pulley, Fig. 80. 1. Posts 2. Pawls GTS 200 Rewind Starter...

  • Page 39: Install Rewind Starter On Blower Housing

    85 in. lbs. (9.6Nm) 4. Torque lower tank mounting screw to 45 in. lbs. (5.0Nm), Fig. 83. Note: 21” commercial mowers use a remote fuel tank. Fig. 82 – Installing Blower Housing 1. Tighten first 2. Tighten second GTS 200 Rewind Starter...

  • Page 40: Electric Starter

    C. Faulty electrical connection (battery circuit). General Information D. Dirty or worn starter motor commutator, bearing, weak The Toro GTS 200 electric start system consists of a 12V magnets, etc. battery, starter motor, switch, and alternator. In addition, the E. Worn brushes or weak brush springs.

  • Page 41: Test Equipment

    Other Equipment A growler or armature tester (checks armature for continuity, shorts and opens) is available from an Automobile Diagnostic Service supplier. A known good 12 volt battery is required when testing 12 volt starting systems. GTS 200 Electric Starter...

  • Page 42: Battery

    Take whites of eggs. Do not Replace Battery Terminal induce vomiting. Toro Part #49–8141 is a replacement plug with two solderless connectors (Fig. 91). It can be used when the plug or lead wires between the plug and battery are damaged.

  • Page 43: Starter

    Wiring Diagrams Fig. 94 – Testing Starter Motor with Digital The following wiring diagrams (Fig. 93) show the two systems Multimeter used with the GTS 200 engine. 1. Red test lead 3. Briggs & Stratton Tool #19200 2. Black test lead 4.

  • Page 44: Check Brake Switch

    3. Connect one meter test lead to end of one wire inside connector and other test lead to second connector terminal for the same wire. 2. Remove “E” retaining ring and pinion gear. 4. Meter should read low or no resistance. GTS 200 Electric Starter...

  • Page 45: Clean And Inspect Starter

    Fig. 100 – Armature Assembly to End Cap 5/64” (2mm) 1. Gray plastic washers 4. .176” (4.47mm) thick fiber washer 2. Armature Fig. 99 – Checking Brushes 5. .030” (.76mm) thick steel 3. Brush spreader washer 1. Brushes GTS 200 Electric Starter...

  • Page 46: Install Starter

    16. Install washer, gasket and cover, Fig. 102. Fig. 104 – Installing Starter 1. Wire clip 3. Lug 2. Torque screws to 4. Alternator wire(s) 140 in. lbs. (16.0Nm) Fig. 102 – Lubricating Gears 1. Apply lubricant here 2. Oil felt washer GTS 200 Electric Starter...

  • Page 47: Alternator

    1. Insert RED test lead into 10 A receptacle in meter. tween output connector and battery. 2. Insert BLACK test lead into COM receptacle in meter. Damaged battery (shorted battery cells). 3. Rotate selector to (DC amps) position. Damaged alternator magnets. Defective stator. GTS 200 Alternator...

  • Page 48: Install Stator Studs

    2. 25 in. lbs. (2.8Nm) 8. If stator air gap is within specification and there is low or no output, replace stator. Install Stator Studs If stator studs were removed, install and torque to 30 in. lbs (3.4Nm), Fig. 109. GTS 200 Alternator...

  • Page 49: Lubrication

    ......Extended Oil Fill and Dipstick Fig. 111 – Removing Breather and Breather The GTS 200 uses a plastic extended oil fill tube and a quarter Passage Cover turn screw-on-dipstick.

  • Page 50: Inspect Oil Pump

    4. Place “O” ring in groove in cover, Fig. 114. Fig. 116 – Oil Filter Adapter 1. Filter 2. Adapter Fig. 114 – Installing Oil Pump 1. Outer rotor 4. “O” ring 2. Groove 5. Inner rotor 3. Cover GTS 200 Lubrication...

  • Page 51: Pistons, Rings, And Rods

    Pistons, Rings, and 3. Push piston and rod out through top of cylinder. Note: The GTS 200 engine uses oil drain slots in ring Rods lands, Fig. 118. Contents Piston and Connecting Rod ......

  • Page 52: Check Piston Ring Groove Wear

    Fig. 123 – Checking Piston Pin Bore 1. Piston pin bore Assemble Piston and Connecting Rod Note: Pistons on the GTS 200 engine have a shoulder stop on one side of piston and use only one (1) piston pin lock. Î Î...

  • Page 53: Install Piston Rings On Piston

    4. Tighten compressor until piston cannot be turned in compressor. 5. Then loosen compressor until piston can be turned with slight resistance. Note: Do not attempt to install piston and ring assembly without ring compressor. GTS 200 Pistons, Rings, and Rods...

  • Page 54: Specification Tables

    Connecting Rod Screw Torque Center Comp. Comp. Control Torque Ring Ring Ring In. Lbs. .020” .030” .035” (.51mm) (.76mm) (.89mm) (11.3) Table No. 3 Connecting Rod Rejects Crankpin Piston Pin Bearing Bearing 1.102” .627” (27.98mm) (15.93mm) GTS 200 Pistons, Rings, and Rods...

  • Page 55: Remove Crankshaft And Camshaft

    Check timing gears for chipped or cracked teeth and keyway for wear. Replace timing gear, if damaged. If timing gear is 6. Rotate crankshaft until timing marks are aligned. chipped or cracked, also check camshaft for damage. GTS 200 Crankshaft and Camshaft...

  • Page 56: Inspect Camshaft

    5. Install connecting rod on crankshaft, page 51. with a non-hardening sealant such as Permatex 2, or 6. Install slip fit timing gear (if removed) with inner chamfer equivalent. toward crankpin. This assures timing mark will be visible. GTS 200 Crankshaft and Camshaft...

  • Page 57: Adjust Crankshaft End Play

    Table No. 4 Seal Protectors Briggs & Crankshaft Color Stratton Tool # Journal Size 1.062” 19334/5 Brown (26.97mm) Table No. 5 Crankcase Sump Torque n. Lbs. (12.0) Table No. 6 Crankshaft End Play .002”–.028” .002 .028 (.05mm–.86mm) GTS 200 Crankshaft and Camshaft...

  • Page 58: Cylinder And Bearings

    Cylinder Crosshatching aids proper lubrication. GTS 200 OHV engines use aluminum alloy plain bearings as part of the cylinder material. Inspection Always inspect cylinder after engine has been disassembled.

  • Page 59: Check Plain Or Du Bearings

    Place pilot guide bushing in bearing opposite of bearing to be repaired. Have flange of bushing on inside of 1. Split in bearing crankcase. Replace sump if sump crankshaft bearing is worn or damaged. GTS 200 Cylinder and Bearings...

  • Page 60: Oil Seals

    Table No. 8 1. For adjustment procedure for crankshaft end play see Crankcase Sump Torque Crankshaft and Camshaft, page 55. In. Lbs. 2. Torque crankcase cover screws in sequence shown in Fig. 146. (12.0) GTS 200 Cylinder and Bearings...

  • Page 61: Remove Exhaust System

    Check muffler for split seams, loose internal parts, or cracked welds. Replace any damaged parts with new Original Equipment Parts. 3. Remove dipstick and oil fill tube. 4. Remove blower housing and rewind starter, Fig. 149. GTS 200 Muffler...

  • Page 62: Install Muffler

    1. Screw: torque to 85 in. lbs (10.0Nm) 4. Install screw in muffler bracket to cylinder head and torque to 85 in. lbs. (10.0Nm), Fig. 151. 5. Install screw in muffler to cylinder bracket and torque to 85 in. lbs. (10.0Nm). GTS 200 Muffler...

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