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GGP SV200 Workshop Manual

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Summary of Contents for GGP SV200

  • Page 1 SV200 SV200ES R200 R200ES...
  • Page 2 • • • • • • • • SERVICE MANUAL Rel. 2.0 - 4/2007 The manufacturer reserves the right to make all the necessary technical or commercial improvements to its products, so there may be some differences between the series of engines and the contents of this manual. However the basic specifications and different operating procedures will remain the same.

  • Page 3: Table Of Contents

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 •••• from INDEX 1 / 1 page MAIN CHAPTERS tightening torques, expendable materials and spare parts available. 1. Rules and procedures for Service Centres This chapter covers all the main aspects of the 4.
  • Page 4 INTRODUCTION The purpose of this manual is to help Service The manual refers to the following symbols: Centres service, disassemble and repair SV200 engines. Each page of this manual states the following infor- Warns of operations that should be carried...

  • Page 5: Rules And Procedures For Service Centres

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2005 1.1. •••• from RULES AND PROCEDURES FOR SERVICE CENTRES 1 / 1 page 1.1 RULES AND PROCEDURES FOR SERVICE CENTRES C) Fault notification A) Guarantee validity The manufacturer should be informed of all The warranty is supplied under the terms, pro- faults that recur frequently;...

  • Page 6: General And Safety Regulations

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2005 2.1. •••• from GENERAL AND SAFETY REGULATIONS 1 / 1 page 2.1 GENERAL AND SAFETY REGULATIONS As well as following the usual accident prevention regulations that apply to most repair shops, we rec-...
  • Page 7 <= ...BACK... <= SERVICE MANUAL SV200 R200 2005 3.1. •••• from TECHNICAL DATA AND SPECIFICATIONS 1 / 3 page A) Identification Magneto flywheel fixing nut (41) ..45-50 Nm Breather plate fixing screws (51) ..8-10 Nm 6.10 Screws for engine fastening (3) ..20-28 Nm All the engines have a 6.10 Cover-sump union screws (6) ..

  • Page 8: Engine Tuning

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2005 4.1. •••• from ENGINE TUNING AND TESTING 1 / 1 page 4.1 ENGINE TUNING AND TESTING – adjusting minimum and maximum speeds [u 6.4 6.5]; – inspecting the condition of the spark plug and A) Operating guidelines ignition cable;...

  • Page 9: Troubleshooting

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 5.1. •••• from TROUBLESHOOTING 1 / 7 page A) The engine does not start Probable cause Comment Solution Lawnmower problems The engine brake cable is The cable control does not activate the coil earth...
  • Page 10 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 5.1. •••• from TROUBLESHOOTING 2 / 7 page The starter motor turns but cannot start the engine due to: Battery insufficiently If the machine's battery is insufficiently charged, Check and recharge charged...
  • Page 11 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 5.1. •••• from TROUBLESHOOTING 3 / 7 page Intake problems Air filter is clogged up The clogged filter can thicken the mixture flood- Check and clean the ing the engine air filter [u 6.3.A]...
  • Page 12 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 5.1. •••• from TROUBLESHOOTING 4 / 7 page D) The engine starts but does not run Probable cause Comment Solution Supply problems The tank cap has a clogged The clogged breather pipe in the tank stops the...
  • Page 13 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 5.1. •••• from TROUBLESHOOTING 5 / 7 page Insufficient pressure The piston rings can wear out due to the pas- Replace the rings sage of dust or overheating caused by the lack [u 6.10.C]...
  • Page 14 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 5.1. •••• from TROUBLESHOOTING 6 / 7 page G) The engine overreved Probable cause Comment Solution Carburation problems Governor blocked The breakage of the internal device counter- Check the entire weights does not allow opening of the butterfly governor system to be opposed.
  • Page 15 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 5.1. •••• from TROUBLESHOOTING 7 / 7 page K) The engine does not stop within 3 seconds after it has turned off Probable cause Comment Solution Problems with the stopping system Faulty or no clutch lining...

  • Page 16: Servicing Procedures

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.1. •••• from TANK AND SUPPLY 1 / 3 page 6.1 TANK AND SUPPLY GENERAL INFORMATION The supply system consists of a petrol tank con- nected to the carburettor by a pipe. A mesh filter on the bottom of the tank stops deposits and impurities from reaching the carburettor.
  • Page 17 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.1. •••• from TANK AND SUPPLY 2 / 3 page To reassemble, reverse the order of the previous operations. Remount the starting system 6.2.A]. WARNING! Check that the petrol pipe (4) is intact and secured correctly before pouring in new fuel.
  • Page 18 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.1. •••• from TANK AND SUPPLY 3 / 3 page – the air passages (24) inside the cap are not clogged; – the sponge (23) is not crushed or broken. NOTE Always replace the entire cap if the gasket or...
  • Page 19 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.2. •••• from STARTING SYSTEM 1 / 2 page 6.2 STARTING SYSTEM GENERAL INFORMATION The starting system consists of a cable wound onto a pulley and consists of a rope wound onto a pulley.
  • Page 20 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.2. •••• from STARTING SYSTEM 2 / 2 page 14 Pass one end of the cable (4) (Ø 4.5 mm - length 2.40 m) through the ventilation grille into the hole in the pulley (3) and make a knot so that it cannot escape.

  • Page 21: Intake System

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.3. •••• from INTAKE SYSTEM 1 / 1 page 6.3 INTAKE SYSTEM GENERAL INFORMATION The intake system uses an air filter which is directly connected to the carburettor by means of a mani- fold which conveys the air/petrol mixture towards the induction valve.

  • Page 22: Carburation

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.4. •••• from CARBURATION 1 / 3 page 6.4 CARBURATION GENERAL INFORMATION The carburettor has a float with a fixed jet and a “CHOKE” control. The carburettor can malfunction in the following ways: •...
  • Page 23 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.4. •••• from CARBURATION 2 / 3 page Completely pull out the carburettor (6) to allow the tie-rod (10) to be disconnected from the starter butterfly lever (11) and remove the car- burettor.

  • Page 24: Minimum Speed (Slow)

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.4. •••• from CARBURATION 3 / 3 page B) Replacing the carburettor – Follow steps 1 - 2 -3 - 4 - 10 of the procedure described in point “A”. C) Adjusting minimum speed...

  • Page 25: Carburettor Governor System

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.5. •••• from GOVERNOR SYSTEM OF THE CARBURETTOR 1 / 3 page 6.5 GOVERNOR SYSTEM OF THE CARBURETTOR GENERAL INFORMATION The carburettor governor system uses a rod linkage fitted on a support fixed to the left-hand side of the...
  • Page 26 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.5. •••• from GOVERNOR SYSTEM OF THE CARBURETTOR 2 / 3 page B) Adjusting maximum speed 11 Check that the throttle cable is adjusted cor- rectly 6.5.A]. 12 Let the engine heat up for a few minutes then set the throttle control to “FAST”.

  • Page 27: Governor Support Fixing Screws (35) . 8-10 Nm

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.5. •••• from GOVERNOR SYSTEM OF THE CARBURETTOR 3 / 3 page 23 Disconnect the air butterfly tie-rod (34) and unscrew the two screws (35) fixing the support (36) to the engine.

  • Page 28: Ignition System

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.6. •••• from IGNITION SYSTEM 1 / 3 page 6.6 IGNITION SYSTEM GENERAL INFORMATION The ignition system has a flywheel with an electron- ic coil which supplies high voltage to the spark plug.
  • Page 29 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.6. •••• from IGNITION SYSTEM 2 / 3 page and to earth on the engine (5). Activate the starter and see in the instrument if the spark jumps. If the test has a positive result, clean the elec- trodes (2) with compressed air and adjust the distance to 0.6-0.8 mm.

  • Page 30: Spark Plug Tightening Torque (1)

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.6. •••• from IGNITION SYSTEM 3 / 3 page 19 Carry out a spark test as described in point “A”: – If the spark jumps = the coil functions cor- rectly, so if the system malfunctions, it is due to the earth microswitch or relative cable 6.7.B];...

  • Page 31: Turning Off And Stopping The Engine

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.7. •••• from TURNING OFF AND STOPPING THE ENGINE 1 / 3 page 6.7 TURNING OFF AND STOPPING THE ENGINE GENERAL INFORMATION The engine is turned off and stopped by releasing a lever on the lawnmower.
  • Page 32 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.7. •••• from TURNING OFF AND STOPPING THE ENGINE 2 / 3 page Check that the wire (2) runs freely inside the sheath (1) when you move the lever. Check that the end of the wire (2) is slightly loose when you release the lawnmower lever.
  • Page 33 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.7. •••• from TURNING OFF AND STOPPING THE ENGINE 3 / 3 page D) Replacing the system for turning off and stopping the engine 31 Remove the flywheel 6.9.E]. 32 Disconnect the brake wire (21) from the lever (22).

  • Page 34: Exhaust System

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.8. •••• from EXHAUST SYSTEM 1 / 1 page 6.8 EXHAUST SYSTEM GENERAL INFORMATION The exhaust system consists of a muffler installed on the cylinder together with a gasket, a spacer and a heatproof baffle.
  • Page 35 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.9. •••• from ENGINE BLOCK – External operations 1 / 7 page 6.9 ENGINE BLOCK – External operations GENERAL INFORMATION This chapter covers the checking, adjustment and replacement operations of components that do not require the engine being removed from the lawn- mower to which it is fitted.
  • Page 36 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.9. •••• from ENGINE BLOCK – External operations 2 / 7 page 13 Use a 0.10 mm feeler gauge (13) to check the gap between the rocker arm and the tip of the valve stem;...
  • Page 37 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.9. •••• from ENGINE BLOCK – External operations 3 / 7 page 30 Turn the flywheel manually to move the piston and clean inside the cylinder (26). 31 When mounting: – the gasket (25) must always be replaced;...
  • Page 38 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.9. •••• from ENGINE BLOCK – External operations 4 / 7 page NOTE - The valve seats must be ground by hand, using a special grinding tool with an angle of 45°.
  • Page 39 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.9. •••• from ENGINE BLOCK – External operations 5 / 7 page – apply a film of oil on the valve stems before inserting them in their respective housings; – ensure the correct position of the inlet valve and the exhaust valve, marked, respectively, with «IN»...
  • Page 40 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.9. •••• from ENGINE BLOCK – External operations 6 / 7 page F) Checking the oil breather 71 Remove the magneto flywheel 6.9.E]. 72 Unscrew the three screws (51) fixing the closing plate (52).

  • Page 41: Magneto Flywheel Fixing Nut (41)

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.9. •••• from ENGINE BLOCK – External operations 7 / 7 page H) Replacing the lower compression ring of the engine shaft (sump side) NOTE - This operation must be performed by...
  • Page 42 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.10. •••• from ENGINE BLOCK – Overhauling internal parts 1 / 7 page 6.10 ENGINE BLOCK – Overhauling internal parts GENERAL INFORMATION All operations for dismantling and replacing internal engine components require the engine to be removed from the lawnmower.
  • Page 43 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.10. •••• from ENGINE BLOCK – Overhauling internal parts 2 / 7 page – ensure that the two centring pins (8) are cor- rectly inserted; – always replace the compression ring (9) from the sump side 6.9.H].
  • Page 44 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.10. •••• from ENGINE BLOCK – Overhauling internal parts 3 / 7 page 27 When assembling the new group, care must be taken over the correct positioning of one scraper washer (30) under the sliding pin (27) and the other (31) on the opposite side.
  • Page 45 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.10. •••• from ENGINE BLOCK – Overhauling internal parts 4 / 7 page 45 Remove the camshaft 6.10.B]. 46 Dismantle the connecting rod (42) cap (41), fixed with two screws (43). 47 Push the connecting rod (42) so as to cause the piston (44) to come out of the cylinder (45).
  • Page 46 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.10. •••• from ENGINE BLOCK – Overhauling internal parts 5 / 7 page 52 To check the wear in the piston ring housings, fit a new ring and measure the residual space with a feeler gauge (49).
  • Page 47 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.10. •••• from ENGINE BLOCK – Overhauling internal parts 6 / 7 page 58 To check the alignment between the manifolds and the protruding part of the shaft, place the engine shaft on two prismatic guides (53) and,...

  • Page 48: Piston Ring Removal Expander

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.10. •••• from ENGINE BLOCK – Overhauling internal parts 7 / 7 page 64 Assemble the engine shaft (52) and the con- necting rod cap (41) with the relative screws (43), taking care not to reverse the cap assem- bly direction.

  • Page 49: Electrical Starting System And Recharge

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.11. - ELECTRICAL STARTING SYSTEM •••• from AND RECHARGE ALTERNATOR 1 / 4 page 6.11 ELECTRICAL STARTING SYSTEM AND RECHARGE ALTERNATOR GENERAL INFORMATION The electrical starting system consists of a motor powered by a 12 Volt battery (fitted to the machine).
  • Page 50 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.11. - ELECTRICAL STARTING SYSTEM •••• from AND RECHARGE ALTERNATOR 2 / 4 page – remove the dirt with a jet of compressed air; – apply an unlocking spray and repeat the pin- ion movement;...
  • Page 51 <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.11. - ELECTRICAL STARTING SYSTEM •••• from AND RECHARGE ALTERNATOR 3 / 4 page 24 Check the condition of the brushes (24) and rel- ative springs (25). 25 Extract the rotor (26) and make the electrical...

  • Page 52: Ammeter Clamp

    <= ...BACK... <= SERVICE MANUAL SV200 R200 2007 6.11. - ELECTRICAL STARTING SYSTEM •••• from AND RECHARGE ALTERNATOR 4 / 4 page If different values are registered, make the checks described below and, if a satisfactory result is not obtained, the alternator must be replaced.

This manual is also suitable for:

Sv200esR200R200es

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