<p>TECHNICAL MANUAL Litho in U.S.A John Deere Worldwide Commercial and Consumer Equipment Division GX70, GX75, GX85, SX85 GX95, SRX75 and SRX95 Riding Mowers TM1491 (JULY99) Replaces TM1491 (01JAN97) INTRODUCTION This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: Table of Contents General Diagnostic Information Specifications Electrical Wiring Harness Legend Component Location System Schematic Wiring Harness Troubleshooting Chart Theory of Operation Diagnostics Tests & Adjustments Repair Note: Depending on the particular section or system being covered, not all of the above groups may be used. Each section will be identified with a symbol rather than a number. The groups and pages within a section will be consecutively numbered. We appreciate your input on this manual. To help, there are postage paid post cards included at the back. If you find any errors or want to comment on the layout of the manual please fill out one of the cards and mail it back to us. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT 1999 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division Horicon, WI All rights reserved Previous Editions COPYRIGHT 1997, 1992, 1991, 1990, 1989, and 1988 7/12/99 Information Specifications and Engine Electrical Steering Brakes Safety Miscellaneous Power Train Attachments 1 - 1 SAFETY RECOGNIZE SAFETY INFORMATION This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe servicing practices. Understand Signal Words A signal wordDANGER, WARNING, or CAUTION is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement. HANDLE FLUIDS SAFELYAVOID FIRES Be Prepared for Emergencies When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. 1 - 2 6/29/99 SAFETY USE CARE IN HANDLING AND SERVICING BATTERIES Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16C (60F). Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Using proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 1015 minutes. 4. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. USE CARE AROUND HIGH- PRESSURE FLUID LINES Avoid High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid injury from escaping fluid under pressure by stopping the engine and relieving pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. 6/29/99 1 - 3 SAFETY USE SAFE SERVICE PROCEDURES Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Service Machines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. Park Machine Safely Before working on the machine: 1. Lower all equipment to the ground. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a "DO NOT OPERATE" tag in operator station. Support Machine Properly and Use Proper Lifting Equipment If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual. Work in Clean Area Before starting a job: 1. Clean work area and machine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts. 1 - 4 6/29/99 SAFETY Using HighPressure Washers Directing pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle. Illuminate Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. Work in Ventilated Area Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. WARNING: California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area. SERVICE TIRES SAFELY Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts. 6/29/99 1 - 5 SAFETY AVOID INJURY FROM ROTATING BLADES, AUGERS AND PTO SHAFTS Keep hands and feet away while machine is running. Shut off power to service, lubricate, or remove mower blades, augers, or PTO shafts. SERVICE COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off machine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields. 1 - 6 6/29/99 SPECIFICATIONS AND INFORMATION CONTENTS Page CONTENTS 7/12/99 2 - 1 SPECIFICATIONS AND INFORMATION SPECIFICATIONSGX70/GX75 AND SRX75 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONSGX95 AND SRX75/SRX95 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIFICATIONSGX85/SX85 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . 5 METRIC FASTENER TORQUE VALUEGRADE 7 . . . . . . . . . . . . . . . . 6 INCH FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 O-RING SEAL SERVICE RECOMMENDATIONS FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE . . . . . . . . . . . . . . . . . . . 8 FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE. . . . . . . . . . . . . . . . . 9 O-RING FACE SEAL FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 O-RING BOSS FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GASOLINE SPECIFICATIONS 4CYCLE ENGINESNORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4CYCLE ENGINESEUROPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 OIL AND LUBRICANT SPECIFICATIONS 4CYCLE GASOLINE ENGINE OILNORTH AMERICA (KAWASAKI ENGINES) . 13 4CYCLE GASOLINE ENGINE OILEUROPE (KAWASAKI ENGINES) . . . . . . . . 13 4CYCLE GASOLINE ENGINE OILNORTH AMERICA (BRIGGS & STRATTON ENGINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4CYCLE GASOLINE ENGINE OILEUROPE (BRIGGS & STRATTON ENGINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 BREAKIN 4-CYCLE GASOLINE ENGINE OILNORTH AMERICA . . . . . . . . . . . 15 BREAKIN 4-CYCLE GASOLINE ENGINE OILEUROPE . . . . . . . . . . . . . . . . . . . 16 GEAR TRANSMISSION GREASENORTH AMERICA . . . . . . . . . . . . . . . . . . . . . 17 GEAR TRANSMISSION GREASEEUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ANTI-CORROSION GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 GREASENORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 GREASE EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2 - 2 SPECIFICATIONSGX70/GX75 AND SRX75 SPECIFICATIONS AND INFORMATION SPECIFICATIONSGX70/GX75 AND SRX75 GENERAL SPECIFICATIONS Engine: Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere "K" Series Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FC290V Starting System: GX70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil GX75 and SRX75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Crankcase Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 L (1.16 U.S. qt) Electrical System: Type GX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Type GX75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt Battery Size GX70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A Battery Size GX75 and SRX75 . . . . . . . . . . . . . 160 Cold Cranking Amps at18C (0F) Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Amp Fuel System: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravity Fed Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 L (1.1 U.S. gal) Drive Train: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Transaxle Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Travel Speeds at Full Engine RPM: Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08.7 km/h (05.4 mph) 1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 km/h (1.1 mph) 2nd Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 km/h (2.2 mph) 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 km/h (3.3 mph) 4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 km/h (4.2 mph) 5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 km/h (5.0 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 km/h (1.9 mph) Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spur Gear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disk Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sector and Pinion Tires: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 x 4.005 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 x 6.508 Overall Dimensions: Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060 mm (42 in.) Minimum Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 mm (3.74 in.) Overall Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1570 mm (62 in.) Overall Width: W/O Deck (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694 mm (27.3 in.) W/O Deck (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 780 mm (30.7 in.) W/Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 790 mm (31.1 in.) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 mm (39.76 in.) Weight GX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 kg (315 lb) Weight GX75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 kg (340 lb) 7/19/99 7/19/99 SPECIFICATIONS AND INFORMATION SPECIFICATIONSGX95 AND SRX75/SRX95 SPECIFICATIONSGX95 AND SRX75/SRX95 GENERAL SPECIFICATIONS Engine: Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere "K" Series Model SRX75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FC290V Models GX95 and SRX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB460V Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Crankcase Capacity: SRX75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 L (1.16 U.S. qt) GX95 and SRX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 L (1.48 U.S. qt) Electrical System: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt Battery Size. . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Cold Cranking Amps at 18C (0F) Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Amp Fuel System: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Fuel Delivery: SRX75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravity Fed SRX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Fuel Tank Capacity SRX75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 L (0.91 U.S. gal) GX95 and SRX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 L (1.6 U.S. gal) Drive Train: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Transaxle Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Travel Speeds at Full Engine RPM: Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 km/h (05 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 km/h (2.2 mph) Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disk Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sector and Pinion Tires: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 x 4.005 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 x 6.508 Overall Dimensions: Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060 mm (42 in.) Minimum Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 mm (3.74 in.) Overall Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1570 mm (62 in.) Overall Width: W/O Deck (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694 mm (27.3 in.) W/O Deck (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 780 mm (30.7 in.) W/Deck SRX75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 790 mm (31.1 in.) W/Deck GX95 and SRX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040 mm (40.9 in.) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 mm (39.76 in.) Weight: SRX75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167 kg (367 lbs) GX95 and SRX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 kg (431 lbs) 2 - 3 2 - 4 SPECIFICATIONSGX85/SX85 SPECIFICATIONS AND INFORMATION SPECIFICATIONSGX85/SX85 GENERAL SPECIFICATIONS Engine: Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton "Diamond I/C" Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28M707 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Crankcase Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 L (1.48 U.S. qt) Electrical System: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt Battery Size. . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Cold Cranking Amps at 18C (0F) Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Amp Fuel System: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Fuel Tank Capacity: GX85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L (1.1 U.S. gal) SX85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 L (0.91 U.S. gal) Drive Train: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Transaxle Number of Speeds GX85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Number of Speeds SX85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Travel Speeds at Full Engine RPM: Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 km/h (05 mph) 1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 km/h (1.1 mph) 2nd Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 km/h (2.2 mph) 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 km/h (3.3 mph) 4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 km/h (4.2 mph) 5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 km/h (5.0 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 km/h (1.9 mph) Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spur Gear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disk Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sector & Pinion Tires: Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 x 4.005 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 x 6.508 Overall Dimensions: Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060 mm (42 in.) Minimum Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 mm (3.74 in.) Overall Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1570 mm (62 in.) Overall Width: W/O Deck (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694 mm (27.3 in.) W/O Deck (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 780 mm (30.7 in.) W/Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 790 mm (31.1 in.) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 mm (39.76 in.) Weight: GX85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 kg (340 lb) SX85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 kg (370 lb) 7/19/99 SPECIFICATIONS AND INFORMATION METRIC FASTENER TORQUE VALUES METRIC FASTENER TORQUE VALUES Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5 M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35 M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70 M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109 M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300 M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410 M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580 M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800 M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000 M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500 M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000 M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500 TS1163 4.8 8.8 9.8 10.9 12.9 5 10 12Property Class and Head Markings Property Class and Nut Markings 4.8 4.8 55 8.8 8.8 9.8 9.8 10.9 10.9 12.9 12.9 12.9 12 12 10 10 10 1010 DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a 10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same class. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. "Dry" means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication. Reference: JDSG200. 7/19/99 2 - 5 METRIC FASTENER TORQUE VALUEGRADE 7 SPECIFICATIONS AND INFORMATION METRIC FASTENER TORQUE VALUEGRADE 7 Size Steel or Gray Iron Torque Aluminum Torque Nm lb-ft Nm lb-ft M6 11 8 8 6 M8 24 18 19 14 M10 52 38 41 30 M12 88 65 70 52 M14 138 102 111 82 M16 224 165 179 132 2 - 6 7/19/99 SPECIFICATIONS AND INFORMATION INCH FASTENER TORQUE VALUES INCH FASTENER TORQUE VALUES Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft 1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5 5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26 3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46 7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75 1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115 9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160 5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225 3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400 7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650 1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975 1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350 1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950 1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550 1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 TS1162 1 or 2b 2 5 5.1 5.2 5 8 8.2 8 No Marks No Marks SAE Grade and Nut Markings SAE Grade and Head Markings DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a 10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. "Dry" means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication. b "Grade 2" applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. "Grade 1" applies for hex cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length. Reference: JDSG200. 7/19/99 2 - 7 O-RING SEAL SERVICE RECOMMENDATIONS SPECIFICATIONS AND INFORMATION O-RING SEAL SERVICE RECOMMENDATIONS FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE NOTE: Torque tolerance is + 15 minus 20%. Nominal Tube O.D./Hose I.D. Face Seal Tube/Hose End O-ring Stud Ends Metric Tube O.D. Inch Tube O.D. Thread Size Tube Nut/ Swivel Nut Torque Bulkhead Locknut Torque Thread Size Straight Fitting or Locknut Torque mm Dash Size in. mm in. Nm lb-ft Nm lb-ft in. Nm lb-ft -3 0.188 4.76 3/8-24 8 6 6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9 8 -5 0.312 7.94 1/2-20 16 12 10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18 12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34 16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46 -12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75 22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90 25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105 32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140 38 -24 1.50 38.10 2-12 217 160 217 160 1-7/8-12 217 160 Stud End Tube Nut Swivel Nut Locknut Tube Nut Stud End Stud Straight and Tube Nut Bulkhead Union and Bulkhead Lucknut 90 Swivel Elbow and Tube Nut 90 Adjustable Stud Elbow 2 - 8 7/19/99 SPECIFICATIONS AND INFORMATION O-RING SEAL SERVICE RECOMMENDATIONS FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE NOTE: Torque tolerance is + 15 minus 20%. Nominal Tube O.D./Hose I.D. Face Seal Tube/Hose End O-ring Stud Ends, Straight Fitting or Locknut Metric Tube O.D. Inch Tube O.D. Thread Size Hex Size Tube Nut/ Swivel Nut Torque Bulkhead Locknut Torque Thread Size Hex Size Steel or Gray Iron Torque Aluminum Torque mm Dash Size in. mm in. mm Nm lb-ft Nm lb-ft mm mm Nm lb-ft Nm lb-ft 6 -4 0.250 6.35 9/16-18 17 16 12 12 9 M12X1.5 17 21 15.5 9 6.6 8 -5 0.312 7.94 M14X1.5 19 33 24 15 11 10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16X1.5 22 41 30 18 13 12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18X1.5 24 50 37 21 15 16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1.5 27 69 51 28 21 -12 0.750 19.05 1-3/16-12 36 102 75 102 75 M27X2 32 102 75 46 34 22 -14 0.875 22.22 1-3/16-12 36 102 75 102 75 M30X2 36 25 -16 1.000 25.40 1-7/16-12 41 142 105 142 105 M33X2 41 158 116 71 52 28 M38X2 46 176 130 79 58 32 -20 1.25 31.75 1-11/16-12 50 190 140 190 140 M42X2 50 190 140 85 63 38 -24 1.50 38.10 2-12 60 217 160 217 160 M48X2 55 217 160 98 72 Stud End Tube Nut Stud Straight and Tube Nut Bulkhead Union and Bulkhead Lucknut Swivel Nut Locknut Tube Nut Stud End 90 Swivel Elbow and Tube Nut 90 Adjustable Stud Elbow Groove For Metric Identification Groove For Metric Identification 7/19/99 2 - 9 O-RING SEAL SERVICE RECOMMENDATIONS SPECIFICATIONS AND INFORMATION O-RING FACE SEAL FITTINGS 1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. 4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. 5. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 6. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fitting. Do not allow hoses to twist when tightening fittings. O-RING BOSS FITTINGS 1. Inspect boss O-ring boss seat. It must be free of dirt and defects. If repeated leaks occur, inspect for defects with a magnifying glass. Some raised defects can be removed with a slip stone. 2. Put hydraulic oil or petroleum jelly on the O-ring. Place electrical tape over the threads to protect O- ring from nicks. Slide O-ring over the tape and into the groove of fitting. Remove tape. . 3. For angle fittings, loosen special nut and push special washer against threads so O-ring can be installed into the groove of fitting. 4. Turn fitting into the boss by hand until special washer or washer face (straight fitting) contacts boss face and O-ring is squeezed into its seat. 5. To position angle fittings, turn the fitting counter- clockwise a maximum of one turn. 6. Tighten straight fittings to torque value shown on chart. For angle fittings, tighten the special nut to value shown in the chart while holding body of fitting with a wrench. Sealing Surface O-ring Sealing Surface Groove O-ring STRAIGHT FITTING OR SPECIAL NUT TORQUE Thread Size Torquea a. Torque tolerance is 10 percent. Number of Flatsb b. To be used if a torque wrench cannot be used. After tightening fitting by hand, put a mark on nut or boss; then tighten special nut or straight fitting the number of flats shown. Nm lb-ft 3/8-24 UNF 8 (6) 2 7/16-20 UNF 12 (9) 2 1/2-20 UNF 16 (12) 2 9/16-18 UNF 24 (18) 2 3/4-16 UNF 46 (34) 2 7/8-14 UNF 62 (46) 1-1/2 1-1/16-12 UN 102 (75) 1 1-3/16-12 UN 122 (90) 1 1-5/16-12 UN 142 (105) 3/4 1-5/8-12 UN 190 (140) 3/4 1-7/8-12 UN 217 (160) 1/2 Special Nut Special Washer Angle Fitting 2 - 10 7/19/99 SPECIFICATIONS AND INFORMATION GASOLINE SPECIFICATIONS GASOLINE SPECIFICATIONS 4CYCLE ENGINESNORTH AMERICA c CAUTION Gasoline is HIGHLY FLAMMABLE, handle it with care. DO NOT refuel machine while: indoors, always fill gas tank outdoors machine is near an open flame or sparks engine is running, STOP engine engine is hot, allow it to cool sufficiently first smoking Help prevent fires: fill gas tank to bottom of filler neck only be sure fill cap is tight after fueling clean up any gas spills IMMEDIATELY keep machine clean and in good repairfree of excess grease, oil, debris, and faulty or damaged parts any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter NO STATIC ELECTRIC DISCHARGE NO SMOKING NO HOT ENGINE STOP ENGINE NO OPEN FLAME OR SPARK To avoid engine damage: DO NOT mix oil with gasoline ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher fill gas tank at the end of each day's operation to help prevent condensation from forming inside a partially filled tank keep up with specified service intervals Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: the ethyl or grain alcohol blends DO NOT exceed 10% by volume or methyl tertiary butyl ether (MTBE) blends DO NOT exceed 15% by volume IMPORTANT: DO NOT use METHANOL gasolines because METHANOL is harmful to the environment and to your health. GASOLINE STORAGE IMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked ("UNLEADED GASOLINE") POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container. c WARNING California Proposition 65 Warning: Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 7/19/99 2 - 11 GASOLINE SPECIFICATIONS SPECIFICATIONS AND INFORMATION 4CYCLE ENGINESEUROPE c CAUTION Gasoline is HIGHLY FLAMMABLE, handle it with care. DO NOT refuel machine while: indoors, always fill gas tank outdoors machine is near an open flame or sparks engine is running, STOP engine engine is hot, allow it to cool sufficiently first smoking Help prevent fires: fill gas tank to bottom of filler neck only be sure fill cap is tight after fueling clean up any gas spills IMMEDIATELY keep machine clean and in good repairfree of excess grease, oil, debris, and faulty or damaged parts any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter NO STATIC ELECTRIC DISCHARGE NO SMOKING NO HOT ENGINE STOP ENGINE NO OPEN FLAME OR SPARK To avoid engine damage: DO NOT mix oil with gasoline ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher fill gas tank at the end of each day's operation to help prevent condensation from forming inside a partially filled tank keep up with specified service intervals Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: the ethyl or grain alcohol blends DO NOT exceed 10% by volume or methyl tertiary butyl ether (MTBE) blends DO NOT exceed 15% by volume IMPORTANT: DO NOT use METHANOL gasolines because METHANOL is harmful to the environment and to your health. GASOLINE STORAGE IMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked ("UNLEADED GASOLINE") POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container. 2 - 12 7/19/99 SPECIFICATIONS AND INFORMATION OIL AND LUBRICANT SPECIFICATIONS OIL AND LUBRICANT SPECIFICATIONS 4CYCLE GASOLINE ENGINE OIL NORTH AMERICA (KAWASAKI ENGINES) Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. The following John Deere oils are PREFERRED: PLUS4SAE 10W-40 TORQGARD SUPREMESAE 5W-30 The following John Deere oils are also recommended, based on their specified temperature range: TURFGARDSAE 10W-30 PLUS4SAE 10W-30 TORQGARD SUPREMESAE 30 Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: SAE 10W-40API Service Classification SG or higher SAE 5W-30API Service Classification SG or higher SAE 10W-30API Service Classification SG or higher SAE 30API Service Classification SC or higher 4CYCLE GASOLINE ENGINE OIL EUROPE (KAWASAKI ENGINES) Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. The following John Deere oils are PREFERRED: TORQGARD SUPREMESAE 10W-40 UNIGARDSAE 10W-40 TORQGARD SUPREMESAE 5W-30 UNIGARDSAE 5W-30 The following John Deere oils are also recommended, based on their specified temperature range: TORQGARD SUPREMESAE 10W-30 UNIGARDSAE 10W-30 TORQGARD SUPREMESAE 30 UNIGARDSAE 30 Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: CCMC Specification G4 or higher AIR TEMPERATURE SAE 10W-40M58275 SAE 5W-30PREFERRED SAE 10W-30SAE 30AIR TEMPERATURE SAE 10W-40M58275 SAE 5W-30PREFERRED SAE 10W-30SAE 30 7/19/99 2 - 13 OIL AND LUBRICANT SPECIFICATIONS SPECIFICATIONS AND INFORMATION 4CYCLE GASOLINE ENGINE OIL NORTH AMERICA (BRIGGS & STRATTON ENGINES) Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. The following John Deere oils are PREFERRED: TORQGARD SUPREMESAE 30 TORQGARD SUPREMESAE 5W-30 The following John Deere oils are also recommended, based on their specified temperature range TURFGARDSAE 10W-30 PLUS4SAE 10W-30 Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: SAE 30API Service Classification SC or higher SAE 5W-30API Service Classification SG or higher SAE 10W-30API Service Classification SG or higher 4CYCLE GASOLINE ENGINE OIL EUROPE (BRIGGS & STRATTON ENGINES) Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. The following John Deere oils are PREFERRED: TORQGARD SUPREMESAE 30 UNIGARDSAE 30 TORQGARD SUPREMESAE 5W-30 UNIGARDSAE 5W-30 The following John Deere oils are also recommended, based on their specified temperature range: TORQGARD SUPREMESAE 10W-30 UNIGARDSAE 10W-30 Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: CCMC Specification G4 or higher AIR TEMPERATURE SAE 30M58275 SAE 5W-30PREFERRED SAE 10W-30AIR TEMPERATURE SAE 30M58275 SAE 5W-30PREFERRED SAE 10W-30 2 - 14 7/19/99 SPECIFICATIONS AND INFORMATION OIL AND LUBRICANT SPECIFICATIONS BREAKIN 4-CYCLE GASOLINE ENGINE OILNORTH AMERICA IMPORTANT: ONLY use a quality break-in oil in rebuilt or remanufactured engines for the first 5 hours (maximum) of operation. DO NOT use oils with heavier viscosity weights than SAE 5W-30 or oils meeting specifications API SG or SH, these oils will not allow rebuilt or remanufactured engines to break-in properly. The following John Deere oil is PREFERRED: BREAKIN ENGINE OIL John Deere BREAKIN ENGINE OIL is formulated with special additives for aluminum and cast iron type engines to allow the power cylinder components (pistons, rings, and liners as well) to "wear-in" while protecting other engine components, valve train and gears, from abnormal wear. Engine rebuild instructions should be followed closely to determine if special requirements are necessary. John Deere BREAKIN ENGINE OIL is also recommended for non-John Deere engines, both aluminum and cast iron types. The following John Deere oil is also recommended as a break-in engine oil: TORQGARD SUPREMESAE 5W-30 If the above recommended John Deere oils are not available, use a break-in engine oil meeting the following specification during the first 5 hours (maximum) of operation: SAE 5W-30API Service Classification SE or higher IMPORTANT: After the break-in period, use the John Deere oil that is recommended for this engine. M58275 BREAK-IN OILAIR TEMPERATURE PREFERRED SAE 5W-30 7/19/99 2 - 15 OIL AND LUBRICANT SPECIFICATIONS SPECIFICATIONS AND INFORMATION BREAKIN 4-CYCLE GASOLINE ENGINE OILEUROPE IMPORTANT: ONLY use a quality break-in oil in rebuilt or remanufactured engines for the first 5 hours (maximum) of operation. DO NOT use oils with heavier viscosity weights than SAE 5W-30 or oils meeting CCMC Specification G5these oils will not allow rebuilt or remanufactured engines to break-in properly. The following John Deere oil is PREFERRED: BREAKIN ENGINE OIL John Deere BREAKIN ENGINE OIL is formulated with special additives for aluminum and cast iron type engines to allow the power cylinder components (pistons, rings, and liners as well) to "wear-in" while protecting other engine components, valve train and gears, from abnormal wear. Engine rebuild instructions should be followed closely to determine if special requirements are necessary. John Deere BREAKIN ENGINE OIL is also recommended for non-John Deere engines, both aluminum and cast iron types. The following John Deere oil is also recommended as a break-in engine oil: TORQGARD SUPREMESAE 5W-30 If the above recommended John Deere oils are not available, use a break-in engine oil meeting the following specification during the first 5 hours (maximum) of operation: SAE 5W-30CCMC Specification G4 or higher IMPORTANT: After the break-in period, use the John Deere oil that is specified for this engine. GEAR TRANSMISSION GREASE NORTH AMERICA Use the following gear grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature gear transmission failure. IMPORTANT: ONLY use a quality gear grease in this transmission. DO NOT mix any other greases in this transmission. DO NOT use any BIOGREASE in this transmission. The following John Deere gear grease is PREFERRED: NON-CLAY HIGH-TEMPERATURE EP GREASEJDM J13E4, NLGI Grade 2 Other gear greases may be used if above recommended John Deere gear grease is not available, provided they meet one of the following specification: John Deere Standard JDM J13E4, NLGI Grade 2 M58275 BREAK-IN OILAIR TEMPERATURE PREFERRED SAE 5W-30 2 - 16 7/19/99 SPECIFICATIONS AND INFORMATION OIL AND LUBRICANT SPECIFICATIONS GEAR TRANSMISSION GREASE EUROPE Use the following gear grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature gear transmission failure. IMPORTANT: ONLY use a quality gear grease in this transmission. DO NOT mix any other greases in this transmission. DO NOT use any BIOGREASE in this transmission. The following John Deere gear grease is PREFERRED: GREASEGARDJDM J13E4, NLGI Grade 2 Other gear greases may be used if above recommended John Deere gear grease is not available, provided they meet the following specification: John Deere Standard JDM J13E4, NLGI Grade 2 JDM J13E4M58275 AIR TEMPERATURE NLGI Grade 2JDM J13E4NLGI Grade 2M58275 AIR TEMPERATURE 7/19/99 2 - 17 OIL AND LUBRICANT SPECIFICATIONS SPECIFICATIONS AND INFORMATION ANTI-CORROSION GREASE SPECIFICATIONS This anti-corrosion grease is formulated to provide the best protection against absorbing moisture, which is one of the major causes of corrosion. This grease is also superior in its resistance to separation and migration. The following anti-corrosion grease is PREFERRED: DuBois MPG-2 Multi-Purpose Polymer GreaseM79292 Other greases may be used if they meet or exceed the following specifications: John Deere Standard JDM J13A2, NLGI Grade 1 GREASENORTH AMERICA Use the following grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature failures. IMPORTANT: ONLY use a quality grease in this application. DO NOT mix any other greases in this application. DO NOT use any BIOGREASE in this application. The following John Deere grease is PREFERRED: NON-CLAY HIGH-TEMPERATURE EP GREASEJDM J13E4, NLGI Grade 2 Other greases may be used if above preferred John Deere grease is not available, provided they meet the following specification: John Deere Standard JDM J13E4, NLGI Grade 2 JDM J13A2NLGI Grade 1M58275 AIR TEMPERATURE JDM J13E4M58275 AIR TEMPERATURE NLGI Grade 2 2 - 18 7/19/99 SPECIFICATIONS AND INFORMATION OIL AND LUBRICANT SPECIFICATIONS GREASE EUROPE Use the following grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature failures. IMPORTANT: ONLY use a quality grease in this application. DO NOT mix any other greases in this application. DO NOT use any BIOGREASE in this application. The following John Deere grease is PREFERRED: GREASEGARDJDM J13E4, NLGI Grade 2 Other greases may be used if above preferred John Deere grease is not available, provided they meet the following specification: John Deere Standard JDM J13E4, NLGI Grade 2 ALTERNATIVE LUBRICANTS Conditions in certain geographical areas outside the United States and Canada may require different lubricant recommendations than the ones printed in this technical manual or the operator's manual. Consult with your John Deere Dealer, or Sales Branch, to obtain the alternative lubricant recommendations. IMPORTANT: Use of alternative lubricants could cause reduced life of the component. If alternative lubricants are to be used, it is recommended that the factory fill be thoroughly removed before switching to any alternative lubricant. SYNTHETIC LUBRICANTS Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry classification and/or military specification) as shown in this manual. The recommended air temperature limits and service or lubricant change intervals should be maintained as shown in the operator's manual. Avoid mixing different brands, grades, or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. LUBRICANT STORAGE All machines operate at top efficiency only when clean lubricants are used. Use clean storage containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides. Make sure all containers are properly marked as to their contents. Dispose of all old, used containers and their contents properly. MIXING OF LUBRICANTS In general, avoid mixing different brands or types of lubricants. Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements. Mixing different lubricants can interfere with the proper functioning of these additives and lubricant properties which will downgrade their intended specified performance. JDM J13E4M58275 AIR TEMPERATURE NLGI Grade 2 7/19/99 2 - 19 OIL AND LUBRICANT SPECIFICATIONS SPECIFICATIONS AND INFORMATION OIL FILTERS IMPORTANT: Filtration of oils is critical to proper lubrication performance. Always change filters regularly. The following John Deere oil filters are PREFERRED: AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL FILTERS Most John Deere filters contain pressure relief and anti-drainback valves for better engine protection. Other oil filters may be used if above recommended John Deere oil filters are not available, provided they meet the following specification: ASTB Tested In Accordance With SAE J806 NOTES 2 - 20 7/19/99 ENGINE CONTENTS Page CONTENTS 7/13/99 ENGINE SPECIFICATIONSFC290V ENGINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPECIFICATIONSFB460V ENGINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPECIFICATIONSBRIGGS & STRATTON ENGINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ENGINE COMPONENT LOCATION"K" SERIES FC290V. . . . . . . . . 15 ENGINE COMPONENT LOCATION"K" SERIES FB460V. . . . . . . . . 16 THEORY OF OPERATION"K" SERIES FC290V GOVERNOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 COMPRESSION RELEASE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 LUBRICATION SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CRANKCASE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FUEL/AIR SUPPLY SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 THEORY OF OPERATION"K" SERIES FB460V GOVERNOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 LUBRICATION SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FUEL/AIR SUPPLY SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ENGINE SYSTEM DIAGNOSIS"K" SERIES FC290V WILL NOT START OR STARTS HARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 WILL NOT STAY RUNNING OR RUNS ROUGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ENGINE PULLS OVER HARD OR RECOIL SNAPS BACK . . . . . . . . . . . . . . . . . . . 32 BLACK SMOKE AT START OR DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . 34 BLUE SMOKE AT START OR DURING OPERATION. . . . . . . . . . . . . . . . . . . . . . . . 36 EXCESSIVE OIL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ENGINE SURGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 UNEVEN OR UNCONTROLLED RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 LOW POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3 - 1 CONTENTS CONTINUED ENGINE 3 - 2 Page ENGINE SYSTEM DIAGNOSIS"K" SERIES FB460V WILL NOT START OR STARTS HARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 WILL NOT STAY RUNNING OR RUNS ROUGH . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ENGINE SPINS OVER HARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 BLACK SMOKE AT START OR DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . 52 BLUE SMOKE AT START OR DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . 54 EXCESSIVE OIL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 ENGINE SURGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 BACKFIRES AT SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 UNEVEN OR UNCONTROLLED RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 LOW POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 ENGINE SYSTEM DIAGNOSISBRIGGS & STRATTON ENGINE WILL NOT START AND HARD TO START, KICKBACK . . . . . . . . . . . . . . 66 LACK OF POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 EXCESSIVE OIL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 TESTS AND ADJUSTMENTS"K" SERIES FC290V (GX70/GX75/SRX75) COMPRESSION AND CYLINDER LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 72 CRANKCASE VACUUM TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 CARBURETOR SLOW IDLE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 73 GOVERNOR AND FAST IDLE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . 73 THROTTLE CABLE AND CHOKE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 74 VALVE CLEARANCE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 74 COMPRESSION RELEASE OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 TESTS AND ADJUSTMENTS"K" SERIES FB460V (GX95/SRX95) COMPRESSION AND CYLINDER LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 76 CRANKCASE VACUUM TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 CARBURETOR SLOW IDLE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 77 GOVERNOR AND FAST IDLE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . 77 THROTTLE CABLE AND CHOKE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 78 VALVE CLEARANCE TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 78 FUEL PUMP PRESSURE AND FLOW TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 OIL PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 TESTS AND ADJUSTMENTSBRIGGS & STRATTON (GX85/SX85) CARBURETOR ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 FUEL PUMP PRESSURE AND FLOW TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 7/13/99 7/13/99 ENGINE CONTENTS CONTINUED Page FUEL AND AIR REPAIRGX70/GX75/SRX75 CARBURETORREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 FUEL FILTERREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 FUEL SHUT-OFF VALVEREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 FUEL TANK AND LINESREMOVAL/INSPECTION/INSTALLATION . . . . . . . . . . . 84 THROTTLE CONTROL LEVER AND CABLEREPLACEMENT. . . . . . . . . . . . . . . 84 AIR CLEANER ASSEMBLYREMOVAL/INSTALLATION/INSPECTION . . . . . . . . . 85 BREATHER ASSEMBLYREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 85 FUEL AND AIR REPAIRGX85/SX85 AIR CLEANER ASSEMBLY REMOVAL/INSPECTION/INSTALLATION . . . . . . . . 86 THROTTLE CONTROL LEVER AND CABLE ASSEMBLY FOR GX85 (S. N. M0GX85X0850001096966) AND SX85 (S. N. M0SX85X085001095909) REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 THROTTLE CONTROL LEVER AND CABLE ASSEMBLY FOR GX85 (S.N. M0GX85X0096966) AND SX85 (S. N. M0SX85X095909) REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 CARBURETORREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 FUEL PUMPREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 FUEL PUMPDISASSEMBLY/INSPECTION/ASSEMBLY. . . . . . . . . . . . . . . . . . . . 93 FUEL FILTERREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 BREATHER ASSEMBLYREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 95 FUEL AND AIR REPAIRGX95/SRX95 FUEL TANKREMOVAL/INSPECTION/INSTALLATION . . . . . . . . . . . . . . . . . . . . . 96 FUEL HOSESREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 AIR CLEANER ASSEMBLYREMOVAL/INSPECTION/INSTALLATION . . . . . . . . . 96 CARBURETORREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 FUEL PUMPREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 FUEL PUMPDISASSEMBLY/INSPECTION/ASSEMBLY. . . . . . . . . . . . . . . . . . . . 98 FUEL FILTERREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 THROTTLE CONTROL LEVER AND CABLEREPLACEMENT. . . . . . . . . . . . . . . 99 FUEL TANK AND LINES (GX95)REMOVAL/INSPECTION/INSTALLATION . . . . . 99 THROTTLE CONTROL LEVER AND CABLE (GX95)REPLACEMENT . . . . . . . . 99 BREATHERREMOVAL/INSPECTION/NSTALLATION . . . . . . . . . . . . . . . . . . . . . 100 CARBURETORDISASSEMBLY/CLEANING/INSPECTION/ASSEMBLY. . . . . . . 102 3 - 3 CONTENTS CONTINUED ENGINE 3 - 4 Page CARBURETOR REPAIR FC290V CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 FB460V CARBURETOR (WITHOUT FUEL SHUT-OFF SOLENOID) . . . . . . . . . . 104 FB460V CARBURETOR (WITH FUEL SHUTOFF SOLENOID) . . . . . . . . . . . . . . 105 CARBURETOR (BRIGGS & STRATTON)DISASSEMBLY . . . . . . . . . . . . . . . . . 106 CARBURETORCLEANING/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 CARBURETOR (BRIGGS & STRATTON)ASSEMBLY . . . . . . . . . . . . . . . . . . . . 108 FC290V (GX70/GX75/SRX75) ENGINEREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 MUFFLER AND SHIELDREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . 111 BLOWER HOUSING (RECOIL STARTER)REMOVAL/INSTALLATION . . . . . . . 112 BLOWER HOUSING (ELECTRIC STARTER)REMOVAL/INSTALLATION . . . . . 112 FLYWHEELREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 ROCKER ARM ASSEMBLYREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . 113 ROCKER ARM ASSEMBLYINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 CYLINDER HEADREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 114 VALVES AND SPRINGSREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . 114 STEM SEALS AND SPRINGSINSPECTION/REPLACEMENT . . . . . . . . . . . . . 115 CYLINDER HEADINSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 VALVE GUIDESINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 VALVE GUIDE BUSHINGSREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 VALVE SEATSRECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 CHECK VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 CRANKCASE COVERREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 117 CRANKCASE COVEROIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 117 CAMSHAFTREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 CAMSHAFTINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 CAMSHAFT PLAIN BEARINGSINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 118 AUTOMATIC COMPRESSION RELEASE (A.C.R.)INSPECTION . . . . . . . . . . . 119 TAPPETSREMOVAL/INSPECTION/INSTALLATION . . . . . . . . . . . . . . . . . . . . . 119 CAMSHAFT AXIAL PLAYADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 PISTON AND CONNECTING RODREMOVAL/INSTALLATION . . . . . . . . . . . . . 120 PISTON AND CONNECTING RODDISASSEMBLY/INSPECTION/ASSEMBLY 120 PISTONINSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 CONNECTING RODINSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 PISTON RINGSREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 CHECK PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 RECIPROCATING BALANCERREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . 123 RECIPROCATING BALANCERDISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . 123 BALANCER ASSEMBLYINSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 BALANCER BUSHINGSREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 CRANKSHAFTREMOVAL/INSPECTION/INSTALLATION . . . . . . . . . . . . . . . . . 124 CRANKSHAFT PLAIN BEARINGINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 125 CRANKSHAFT BALL BEARINGINSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 125 CRANKSHAFTALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 7/13/99 7/13/99 ENGINE CONTENTS CONTINUED Page CRANKSHAFT END PLAYMEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 CRANKSHAFT END PLAYADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 CYLINDER BLOCKINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 REBORE CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 OIL SLINGERINSPECTION/REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 128 OIL FILTER MANIFOLDREMOVAL/INSPECTION/INSTALLATION. . . . . . . . . . . 128 GOVERNOR ASSEMBLYREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . 128 GOVERNOR SHAFTINSPECTION/REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 129 RECOIL STARTERDISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 RECOIL STARTERINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 SPRINGREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 RECOIL STARTERASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 FB460V (GX95/SRX95) ENGINEREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 MUFFLER AND SHIELD (SRX95)REMOVAL/INSTALLATION . . . . . . . . . . . . . . 133 MUFFLER AND SHIELD (GX95)REMOVAL/INSTALLATION . . . . . . . . . . . . . . . 133 BLOWER HOUSING (RECOIL START)REMOVAL/INSTALLATION . . . . . . . . . . 134 BLOWER HOUSING (ELECTRIC START)REMOVAL/INSTALLATION . . . . . . . . 134 FLYWHEEL SCREENADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 FLYWHEELREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 BREATHERREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 CYLINDER HEADREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 CYLINDER HEADINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 VALVES AND SPRINGSREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 136 VALVE SPRINGS AND GUIDESINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 136 VALVE GUIDE BUSHINGSREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 RECONDITION VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 CHECK VALVE-TO-TAPPET CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 CRANKCASE COVERREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 138 CAMSHAFTREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 CAMSHAFTINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 CAMSHAFT PLAIN BEARINGSINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 139 TAPPETSREMOVAL/INSPECTION/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 140 PISTON AND CONNECTING RODREMOVAL/INSTALLATION . . . . . . . . . . . . . 140 PISTON AND CONNECTING RODDISASSEMBLY/INSPECTION/ASSEMBLY . 140 PISTON RINGSREMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 CHECK PISTON RING END GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 PISTONINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 CONNECTING RODINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 CRANKSHAFTREMOVAL/INSPECTION/INSTALLATION. . . . . . . . . . . . . . . . . . 142 RECIPROCATING BALANCERREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . 143 RECIPROCATING BALANCERDISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . 144 BALANCER ASSEMBLYINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 BALANCER BUSHINGSREPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 3 - 5 CONTENTS CONTINUED ENGINE 3 - 6 Page FB460V (GX95 AND SRX95) CRANKSHAFT PLAIN BEARINGINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 145 CRANKSHAFT BALL BEARINGINSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 145 CRANKSHAFTALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 CRANKSHAFT END PLAYMEASUREMENT/ADJUSTMENT . . . . . . . . . . . . . . 146 OIL SEALSINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 CYLINDER BLOCK STUDSREPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 147 CYLINDER BLOCKINSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 REBORE CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 OIL PUMPDISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 OIL PUMPINSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 OIL FILTER MANIFOLDREMOVAL/INSPECTION/INSTALLATION . . . . . . . . . . 149 GOVERNOR ASSEMBLYREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . 150 GOVERNOR SHAFTINSPECTION/REPLACEMENT. . . . . . . . . . . . . . . . . . . . . 150 BENCH TEST SOLENOID DRIVE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 TEST SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 CHECK STARTER ARMATURE ROTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 TEST STARTER ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 TEST FIELD COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 BRIGGS & STRATTON (GX85/SX85) ENGINEREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 MUFFLER AND SHIELDREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . 154 BLOWER HOUSINGREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 154 CYLINDER HEAD AND VALVESREMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 REFACE VALVES AND SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 TAPPET CLEARANCECHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 155 CYLINDER HEAD AND VALVESINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 156 SERVICE VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 SERVICE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 FLYWHEELREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 CRANKCASE COVERREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 159 GOVERNOR ASSEMBLYREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . 159 CAMSHAFT AND TAPPETSREMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . 159 CRANKSHAFT AND COUNTERBALANCE ASSEMBLYREMOVAL . . . . . . . . . 160 CRANKSHAFT AND COUNTERBALANCEINSPECTION . . . . . . . . . . . . . . . . . 160 CRANKSHAFT AND COUNTERBALANCE ASSEMBLYINSTALLATION. . . . . . 160 PISTONREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 PISTONINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 MEASURE AND RECONDITION CYLINDER BORE. . . . . . . . . . . . . . . . . . . . . . . 163 MAGNETO AND CRANKCASE COVER BEARINGSREPLACEMENT . . . . . . . 163 REBUSH MAGNETO BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 TEST STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 MOTOR REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 7/13/99 6/29/99 ENGINE SPECIFICATIONSFC290V SPECIFICATIONSFC290V ENGINE APPLICATIONS GX70/GX75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FC290V-BS10 SRX75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FC290V-CS10 TEST AND ADJUSTMENT SPECIFICATIONS Engine: Crankcase Vacuum (Minimum at Operating Temp.) . . . . . . . . . . . . . . 7.0 cm (2.8 in.) of Water Movement Fuel/Air System: Carburetor Slow Idle Mixture Screw Initial Setting . . . .Lightly Seat, then 1-1/2 Turn Out Slow Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 75 rpm Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 50 rpm REPAIR SPECIFICATIONS Fuel and Air Systems Breather: Maximum Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Blower Housing and Flywheel: Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm (63 lb-ft) Minimum Flywheel Screen Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.) Cylinder Head and Valves: Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Rocker Arm: Minimum Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.94 mm (0.509 in.) Maximum Bearing ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.07 mm (0.515 in.) Push Rod: Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Intake Pushrod Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.313 mm (0.2092 in.) (Wear Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.048 mm (0.1987 in.) Exhaust Pushrod Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.388 mm (0.2121 in.) (Wear Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.118 mm (0.2015 in.) 3 - 7 3 - 8 SPECIFICATIONSFC290V ENGINE Valves and Springs: Minimum Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.00 mm (1.220 in.) Valve Guide ID (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.000 mm (0.2756 in.) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.015 mm (0.2762 in.) Intake Valve Stem OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.960 mm (0.2740 in.) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.975 mm (0.2746 in.) Intake Valve-to-Guide Clearance (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.0010 in.) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.055 mm (0.0022 in.) Exhaust Valve Stem OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.950 mm (0.2736 in.) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.965 mm (0.0026 in.) Exhaust Valve-to-Guide Clearance (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 mm (0.0014 in.) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.065 mm (0.0026 in.) Intake Valve Lift (W/Clearance set at 0.00) . . . . . . . . . . . . . . . . . . 6.923 mm(0.2726 in.) (Wear Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.578 mm(0.2590 in.) Exhaust Valve Lift (W/Clearance set at 0.00) . . . . . . . . . . . . . . . . 7.021 mm (0.2764 in.) (Wear Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.670 mm (0.2626 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . 0.501.10 mm (0.0200.043 in.) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.020 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Cylinder Head: Cylinder Head Flatness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Cap Screw Torque in Sequence (Lubricated) Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm (159 lb-in.) Final Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm (18 lb-ft) Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.) Crankcase Cover: Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 L (1.16 qt) Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.) Camshaft: Minimum End Journal OD PTO Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.92 mm (0.548 in.) Flywheel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.92 mm (0.627 in.) Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.08 mm (1.066 in.) Maximum Bearing ID Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.06 mm (0.632 in.) Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.05 mm (0.553 in.) Reciprocating Balancer Link Rod Minimum Journal OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.86 mm (1.845 in.) Maximum Small End ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.06 mm (0.475 in.) Maximum Large End ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.12 mm (0.855 in.) Bushing Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.040 in.) 6/29/99 6/29/99 ENGINE SPECIFICATIONSFC290V Balancer Weight: Maximum Bearing ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.027 in.) Support Shaft: Minimum Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.93 mm (1.021 in.) Support Shaft Assembly Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Nm (65 lb-in.) Piston: Maximum Ring Groove Clearance Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.) Oil Control Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.19 mm (0.007 in.) Minimum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Maximum Ring End Gap Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.71 mm (0.028 in.) Oil Ring Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.047 in.) Minimum Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.98 mm (0.747 in.) Maximum Pin Bore ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.03 mm (0.749 in.) Maximum Piston-to-Piston Pin Clearance. . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Piston OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.8577.87 mm (3.06493.0657 in.) Piston-to-Cylinder Bore Clearance . . . . . . . . . . 0.1100.142 mm (0.00430.0056 in.) Connecting Rod: Maximum Crankshaft Bearing ID . . . . . . . . . . . . . . . . . . . . . . . . . . 35.57 mm (1.400 in.) Maximum Piston Pin Bearing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.06 mm (0.750 in.) Maximum Connecting Rod-to-Piston Pin Clearance. . . . . . . . . . . . . 0.08 mm (0.003 in.) Maximum Connecting Rod-to-Crankpin Clearance. . . . . . . . . . . . . . 0.14 mm (0.006 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.) Crankshaft: Minimum PTO Side Journal OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.92 mm (1.178 in.) Minimum Connecting Rod Journal OD . . . . . . . . . . . . . . . . . . . . . . 35.43 mm (1.395 in.) Maximum Crankcase Cover Plain Bearing ID . . . . . . . . . . . . . . . . . 30.13 mm (1.186 in.) Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090.22 mm (0.0040.009 in.) Cylinder Bore: Standard Cylinder Bore ID . . . . . . . . . . . . . . . . . . 77.9878.00 mm (3.0703.071 in.) Maximum Cylinder Bore ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.07 mm (3.074 in.) Rebore Cylinder: Oversize Diameter 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.2178.23 mm (3.0793.080 in.) 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.4678.48 mm (3.0893.090 in.) 0.75 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.7178.73 mm (3.0993.100 in.) Ignition Module: Ignition Coil Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) 3 - 9 3 - 10 SPECIFICATIONSFB460V ENGINE SPECIFICATIONSFB460V ENGINE APPLICATIONS GX95 and SRX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB460V-BS25 TEST AND ADJUSTMENT SPECIFICATIONS Engine: Oil Pressure (Minimum at 1250 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . 240 kPa (35 psi) Crankcase Vacuum (Minimum at Operating Temp.) . . . . . . . . . . . . . . . 25 cm (9.8 in.) of Water Movement Fuel/Air System: Fuel Pump Minimum Fuel Flow. . . . . . . . . . . . . . . . . . . . 90 mL (3.15 oz.) in 10 seconds Carburetor Slow Idle Mixture Screw Initial Setting . . . .Lightly Seat, then 1-1/8 Turn Out Slow Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 75 rpm Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 50 rpm REPAIR SPECIFICATIONS Blower Housing and Flywheel: Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft) Flywheel Screen Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (0.0390.118 in.) Cylinder Head: Maximum Cylinder Head Warp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.015 in.) Cap Screw Torque in Sequence (Lubricated) Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (17 lb-ft) Final Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm (27 lb-ft) Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm (18 lb-ft) Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . 0.100.16 mm (0.0040.006 in.) Valves and Springs: Minimum Spring Free Length Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 mm (1.710 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 mm (1.540 in.) Maximum Valve Guide ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.08 mm (0.318 in.) Valve Guide Bushing Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mm (1.178 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Valve Seating Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 mm (0.050 in.) Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.020 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 6/29/99 6/29/99 ENGINE SPECIFICATIONSFB460V Crankcase Cover: Oil Capacity With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (1.69 qt) Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 L (1.48 qt) Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.) Camshaft: Minimum End Journal OD PTO Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.91 mm (0.784 in.) Magneto Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.91 mm (0.627 in.) Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.40 mm (1.395 in.) Maximum Bearing ID Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.07 mm (0.633 in.) Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.07 mm (0.790 in.) Reciprocating Balancer: Link Rod Minimum Journal OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.95 mm (2.124 in.) Maximum Small End ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.60 mm (0.475 in.) Maximum Large End ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.12 mm (2.132 in.) Bushing Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Balancer Weight: Maximum Bearing ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.027 in.) Support Shaft: Minimum Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.93 mm (1.021 in.) Support Shaft Assembly Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Nm (65 lb-in.) Piston: Maximum Ring Groove Clearance Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.) Oil Control Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.19 mm (0.007 in.) Minimum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Maximum Ring End Gap Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 cm (0.028 in.) Oil Ring Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.047 in.) Minimum Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.98 mm (0.827 in.) Maximum Pin Bore ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.03 mm (0.829 in.) Maximum Piston-to-Piston Pin Clearance. . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Piston OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.8188.83 mm (3.49913.4999 in.) Piston-to-Cylinder Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . 0.156 mm (0.0061 in.) Connecting Rod: Maximum Crankshaft Bearing ID . . . . . . . . . . . . . . . . . . . . . . . . . . 37.02 mm (1.459 in.) Maximum Piston Pin Bearing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.01 mm (0.829 in.) Maximum Connecting Rod-to-Piston Pin Clearance. . . . . . . . . . . . . 0.03 mm (0.001 in.) Maximum Connecting Rod-to-Crankpin Clearance. . . . . . . . . . . . . . 0.09 mm (0.004 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.) 3 - 11 3 - 12 SPECIFICATIONSFB460V ENGINE Crankshaft: Minimum PTO Side Journal OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.91 mm (1.374 in.) Minimum Connecting Rod Journal OD . . . . . . . . . . . . . . . . . . . . . . 36.95 mm (1.455 in.) Maximum Crankcase Cover Plain Bearing ID . . . . . . . . . . . . . . . . . 35.06 mm (1.380 in.) Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090.22 mm (0.0040.009 in.) PTO Side Oil Seal: Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Cylinder Block: Crankcase/Block Stud Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Nm (27 lb-ft) Cylinder Bore: Standard Cylinder Bore ID . . . . . . . . . . . . . . . . . . 88.9089.00 mm (3.5003.504 in.) Maximum Cylinder Bore ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.06 mm (3.506 in.) Maximum Out-of-Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.063 mm (0.0025 in.) Maximum Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.076 mm (0.003 in.) Rebore Cylinder: Oversize Diameter 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.2189.23 mm (3.5123.513 in.) 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.4689.48 mm (3.5223.523 in.) 0.75 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.7189.73 mm (3.5323.533 in.) Oil Pump: Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . 1723 Nm (150204 lb-in.) Minimum Rotor Shaft ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.63 mm (0.497 in.) Maximum Rotor Shaft Bearing ID . . . . . . . . . . . . . . . . . . . . . . . . . . 12.76 mm (0.502 in.) Outer Rotor Minimum thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.92 mm (0.470 in.) Minimum OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.90 mm (1.139 in.) Outer Rotor Bearing Maximum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14 mm (0.478 in.) Maximum ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.15 mm (1.148 in.) Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . 19.00 mm (0.750 in.) Ignition Module: Ignition Coil Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) 6/29/99 6/29/99 ENGINE SPECIFICATIONSBRIGGS & STRATTON SPECIFICATIONSBRIGGS & STRATTON ENGINE APPLICATIONS GX85 and SX85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton TEST AND ADJUSTMENT SPECIFICATIONS Engine: Oil Pressure (Minimum at 1250 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 kPa (0.5 psi) Fuel/Air System: Fuel Pump Minimum Fuel Flow. . . . . . . . . . . . . . . . . . . . 90 mL (3.15 oz.) in 15 seconds Carburetor Slow Idle Mixture Screw Initial Setting . . . .Lightly Seat, then 1-1/2 Turn Out Slow Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15501850 rpm Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31503450 rpm REPAIR SPECIFICATIONS Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft) Engine Drive Sheave Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 73 Nm (54 lb-ft) Engine-to-Frame Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Nm (35 lb-ft) Carburetor Mounting Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Nm (66 lb-in.) Muffler Mounting Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 Nm (137 lb-in.) Starter Mounting Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm (137 lb-in.) Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Nm (124 lb-in.) Cylinder Head Cap Screw Torque (Lubricated). . . . . . . . . . . . . . . . . 19 Nm (168 lb-in.) Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Nm (168 lb-in.) Crankcase Sump Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . 22.6 Nm (200 lb-in.) Oil Capacity: With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (3.38 pt) Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 L (2.96 pt) Valves: Valve Seat and Face Angle (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Valve Seat and Face Angle (Exhaust). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Valve Seating Width (Min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 mm (0.031 in.) Valve Seating Width (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 mm (3/64 in.) Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Greater Than 0.40 mm (1/64 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Intake Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.130.18 mm (0.0050.007 in.) Exhaust Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.230.28 (0.0090.011 in.) Exhaust Guide ID . . . . . . . . . . . . . . . . . . . . . . . 7.9387.963 mm (0.31250.3135 in.) Intake Guide ID . . . . . . . . . . . . . . . . . . . . . . . . . 7.9127.938 mm (0.31150.3125 in.) Intake and Exhaust Valve Stem Dia. . . . . . . . . . . . 7.8487.874 mm (0.3090.310 in.) 3 - 13 3 - 14 SPECIFICATIONSBRIGGS & STRATTON ENGINE Camshaft: Minimum Journal OD (Rejection Size) . . . . . . . . . . . . . . . . . . . . . . 12.65 mm (0.498 in.) Maximum Bearing ID (Rejection Size) . . . . . . . . . . . . . . . . . . . . . . 12.80 mm (0.504 in.) PTO Bearing ID (Standard Size) . . . . . . . . . . . . . . 12.7312.75 mm (0.5010.502 in.) Lobe Height (Rejection Size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.08 mm (1.184 in.) Counterbalance: Eccentric (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.93 mm (2.202 in.) Bearing (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.18 mm (2.212 in.) Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nm (115 lb-in.) Piston: Ring-to-Land Clearance (Rejection) . . . . . . . . . . . . . . . . . . . . . . . 0.317 mm (0.0125 in.) Ring End Gap Top and Center (Rejection) . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Ring End Gap Oil Control (Reject) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.89 mm (0.035 in.) Piston Pin ID Reject Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.307 mm (0.7995 in.) Piston Pin Bearing ID Rejection Size. . . . . . . . . . . . . . . . . . . . . . 20.409 mm (0.8035 in.) Max. Bore Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.313 mm (3.4375 in.) Upper Bore OD Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1.6825 in.) Upper Crankshaft Seal Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1.691 in.) Connecting Rod: Crankpin Bearing ID Reject Size. . . . . . . . . . . . . . . . . . . . . . . . . . . 31.80 mm (1.252 in.) Crankpin Bearing ID Standard Size. . . . . . . . 31.75031.763 mm (1.25001.2505 in.) Piston Pin Bearing ID Reject Size. . . . . . . . . . . . . . . . . . . . . . . . . . 20.37 mm (0.802 in.) Piston Pin Bearing ID Standard Size. . . . . . . 20.33520.350 mm (0.80060.8012 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.91 Nm (185 lb-in.) Undersize Connecting Rod Crankpin Grinding Dimensions: Crankpin Diameter . . . . . . . . . . . . . . . . . . . . 31.22431.214 mm (1.22931.2289 in.) Fillet Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.303.05 mm (0.1300.120 in.) Crankshaft Throw . . . . . . . . . . . . . . . . . . . . . 33.38833.287 mm (1.31451.3105 in.) Crankshaft: Main Bearing ID (Magneto Side) Rejection Size . . . . . . . . . . . . . . 35.13 mm (1.383 in.) Main Bearing ID (PTO Side) Rejection Size . . . . . . . . . . . . . . . . . . 35.26 mm (1.388 in.) Minimum Connecting Rod Journal OD Rejection Size.. . . . . . . . . . 31.67 mm (1.247 in.) Journal OD (Magneto and PTO Side) Rejection Size . . . . . . . . . . 34.95 mm (1.376 in.) End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0510.762 mm (0.0020.030 in.) Ignition Module: Ignition Coil Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) 6/29/99 ENGINE ENGINE COMPONENT LOCATION"K" SERIES FC290V ENGINE COMPONENT LOCATION"K" SERIES FC290V M49460 Valve Piston Connecting Rod Crankshaft Balancer Balancer Pin Connecting Rod Rocker Arm Cylinder Head Pushrod Tappet Camshaft Blower Housing Fins Flywheel W/Fan Cooling Fan 6/29/99 3 - 15 ENGINE COMPONENT LOCATION"K" SERIES FB460V ENGINE ENGINE COMPONENT LOCATION"K" SERIES FB460V M49623 Flywheel W/Fan Crankshaft Fins Blower Housing Crankshaft Journal Piston Valves Cylinder Head Block Tappets Camshaft Balancer Pin Balancer Balancer Connecting Rod Cooling Fan 3 - 16 6/29/99 ENGINE THEORY OF OPERATION"K" SERIES FC290V THEORY OF OPERATION"K" SERIES FC290V GOVERNOR OPERATION M49461 Linkage Throttle Lever Carburetor Camshaft Gear Flyweights Governor Gear Shaft Throttle Cable Spool Lever Spring Governor Control Panel Theory of Operation: The governor system senses the engine rpms by the position of the flyweights. These flyweights are rotated by the governor gear that is driven by the camshaft gear. The flyweights press against spool that rotates the shaft and lever. This lever is connected to the throttle lever of the carburetor by linkage. As engine rpms increase, the movement of the flyweights tries to close the throttle valve. This movement is opposed by a spring at the control panel. The tension of this spring can be changed by changing the position of the throttle cable. As the throttle is advanced, the tension of the spring is increased and the governed rpms increase. The maximum rpm is controlled by a stop on the control panel. As the load on the engine increases, the rpms will drop. This allows the spring to pull on the linkage and open the throttle valve that increases the power and raises the rpms. When the load decreases, the rpms increase, which causes the flyweights to move the linkage and close the throttle valve. The power is lowered and the rpms drop. The chosen rpm is maintained by the balancing of the forces of the flyweights and the spring. 6/29/99 3 - 17 THEORY OF OPERATION"K" SERIES FC290V ENGINE COMPRESSION RELEASE OPERATION M49467 Push Rod Exhaust Valve Tappet Tab Camshaft Gear Weight Spring Camshaft Theory of Operation: The compression release on this engine consists of a release tab, weight and spring that are mounted on gear of the camshaft The release tab holds the exhaust valve tappet and push rod off its seat during a portion of the compression stroke. The release tab is connected to the weight and the spring holds the weight in at low rpms. As the engine starts and the rpms increase, the weight overcomes the spring and moves out. As it moves out, the release tab moves in until it clears the valve tappet. The exhaust valve seats properly and full compression is obtained. Valve lash is important for correct operation. Too much lash and compression will be high; too little and compression will be low. 3 - 18 6/29/99 ENGINE THEORY OF OPERATION"K" SERIES FC290V LUBRICATION SYSTEM OPERATION M49468 Paddles Balancer Balancer Pin Crankshaft Camshaft Breather Tappets Head Rocker Arms Valves Piston Connecting Rod Journal Main Bearings Balancer Connecting Rods Oil Slinger Passage Gear Theory of Operation: The lubrication of the internal components of the engine is from splashed oil or oil-laden air. The piston, connecting rod journal, crankshaft main bearings, balancer rods and balancer pin are lubricated by splashed oil. Oil is splashed around the crankcase by the paddles on the oil slinger gear. The slinger gear is driven by the governor gear. During operation, the air in the crankcase becomes very oily. This air travels out the breather passage into the head. This oil/air mixture lubricates the rocker arms and valves. Lubrication of the camshaft and tappets is by splash. 6/29/99 3 - 19 THEORY OF OPERATION"K" SERIES FC290V ENGINE CRANKCASE OPERATION M49469 Breather Passage Head Maze Tube Reed Valve Oil Laden Air Return Hole Theory of Operation: The breather consists of a reed valve that controls the flow of air out of and into the crankcase. As the piston moves in during power and intake strokes, the volume in the crankcase decreases. To prevent a build-up of pressure, oil-laden air is allowed to freely flow out through the breather passage, past the reed valve into the head. In the head some of the oil separates from the air and returns to the crankcase through the return hole. The air then passes into the maze. In the maze more oil separates from the air and also returns through the return hole. The air then passes through a tube which connects to the air cleaner housing of the carburetor. The air is routed to burn oil vapors and keep them out of the atmosphere. As the crankshaft continues to rotate and the piston goes out for compression or exhaust strokes, the volume in the crankcase increases and the air that was let out tries to get back in. But the reed valve is now closed and the return hole is below the level of the oil in the crankcase so only a small amount of air can get back in through the return hole. A vacuum is created. 3 - 20 6/29/99 ENGINE THEORY OF OPERATION"K" SERIES FC290V FUEL/AIR SUPPLY SYSTEM OPERATION M49480 Tank Cap Fuel Tank Fuel Pick Up Valve Fuel Filter Air Filter Carburetor Fuel Line Function: Under a variety of conditions, supplies the correct amount of fuel and air to the engine to allow it to run. Theory of Operation: The fuel supply for this engine is a gravity-feed type. Fuel flows from the tank through the fuel filter and fuel shutoff valve to the carburetor where it is metered to supply the correct amount for the various operating conditions. The vent for the fuel tank is a notch in the threads of the fuel tank cap. The air supply is drawn into the air filter housing through the air filter elements. This filter is a two-stage design consisting of a paper element and a foam element. The air inlet to the filter housing is connected to the engine fan shroud so the air supplied to the carburetor is controlled by the engine cooling fan. Any blockage of the air flow on the fins of the engine will alter the air supply to the carburetor and can change engine performance and operation. 6/29/99 3 - 21 THEORY OF OPERATION"K" SERIES FB460V ENGINE THEORY OF OPERATION"K" SERIES FB460V GOVERNOR OPERATION M49624 Linkage Lever Spring Governor Control Panel Spool Shaft Throttle Cable Flyweights Governor Gear Camshaft Gear Carburetor Throttle Lever Theory of Operation: The governor system senses engine rpms by the position of the flyweights. These flyweights are rotated by the governor gear that is driven by the camshaft gear. The flyweights press against spool that rotates the shaft and lever. This lever is connected to the throttle lever of the carburetor by linkage. As engine rpms increase, the movement of the flyweights tries to close the throttle valve. This movement is opposed by spring at the control panel. The tension of this spring can be changed by changing the position of the throttle cable. As the throttle is advanced, the tension of the spring is increased and the governed rpms increase. The maximum rpm is controlled by a stop on the control panel. As the load on the engine increases, the rpms will drop. This allows the spring to pull on the linkage and open the throttle valve that increases the power and raises the rpms. When the load decreases, the rpms increase causes the flyweights to move the linkage and close the throttle valve. The power is lowered and the rpms drop. The chosen rpm is maintained by the balancing of the forces of the flyweights and the spring. 3 - 22 6/29/99 Thank you very much for your reading. Please Click Here Then Get More Information. </p>