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TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL Table of Contents – Page 1 of 2 SPECIFICATIONS GENERAL INFORMATION GASOLINE COOLING SYSTEM AIR CLEANER – GENERAL AIR CLEANER SERVICE TUNE-UP PROCEDURE OVERHAUL PROCEDURE CHECK-UP EQUIPMENT AFFECTING ENGINE OPERATION IGNITION CHECK IGNITION...
TORO GTS 200 OVERHEAD VALVE ENGINE SERVICE MANUAL Table of Contents – Page 2 of 2 DISASSEMBLE REWIND STARTER ASSEMBLE REWIND STARTER ELECTRIC STARTER GENERAL INFORMATION TROUBLESHOOTING 12 VOLT STARTING SYSTEM TEST EQUIPMENT BATTERY STARTER ALTERNATOR ALTERNATOR SPECIFICATIONS EQUIPMENT TO TEST ALTERNATORS...
About This Manual This manual was written expressly for the Toro GTS 200 Overhead Valve Engine. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written with the service technician in mind. We hope that you find this manual a valuable addition to your service shop.
Replace the oil filter (on models so equipped) every 100 hours or yearly, whichever occurs first. There are two methods of changing engine oil, the drain plug method and the oil fill tube method. Both work equally well. GTS 200 General Information...
3. Remove dipstick from oil fill tube and place a drain pan next to left side of mower. 4. Tip mower on its left side, allowing oil to drain into drain pan (Fig. 3). m–3848 Fig. 3 1. Oil fill tube 2. Oil filter GTS 200 General Information...
Continued operation with a clogged cooling system can cause severe overheating and possible engine damage. Figures 5 and 6 show the areas to be cleaned. GTS 200 General Information...
6. Reinstall pre–cleaner over paper cartridge. Reinstall air 1. Stop engine and pull wire off spark plug (Fig. 7). cleaner cover and tighten securely in place with two (2) knobs. GTS 200 General Information...
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Replace gaskets and install carburetor Adjust remote control linkage and cable, if used, for correct operation. Check muffler for restrictions or damage. Replace oil and fuel. Run engine and adjust carburetor mixture and engine Top No Load RPM. GTS 200 General Information...
The Overhaul Procedure which follows is intended to help you become accustomed to a systematic method of repairing Toro GTS 200 OHV engines. Naturally these steps could be rearranged in different order but efficiency is obtained when the repair operations are performed in the same sequence every time.
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Clean/replace and assemble air cleaner General Information Fill crankcase with oil, fill with gas, start engine General Information Adjust carburetor Carburetion Set governor to obtain correct engine speed (remote controls) Governor Spray paint engine parts and apply decals GTS 200 General Information...
166” (4.20mm) tester gap, you can assume the most common cause. ignition system is performing satisfactorily. See the section Ignition for additional information. GTS 200 General Information...
2. No lubricant in transmission or gear box. 5. Mounting bolts loose – Tighten. 3. Worn drive belts. 6. Mounting deck or plate cracked – Repair or replace. 4. Worn bearings. 7. Damaged belts or pulleys. GTS 200 General Information...
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2. Operate starter and observe spark gap in tester. If spark jumps tester gap, ignition is good. Note: Flywheel must rotate at 350 RPM, minimum. Note: Spark will be observed. GTS 200 Ignition...
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7. Torque as listed in Table No. 1, Page 17. Fig. 17 – Installing Armature 1. Ignition armature 2. Tighten one screw 4. Push armature away from flywheel as far as possible and tighten one screw to hold armature in place. GTS 200 Ignition...
2. Remove float bowl and bowl gasket from carburetor. 1. Choke plate and shaft 4. Welch plug 3. Remove float hinge pin, float and inlet needle, Fig. 24. 2. Idle speed screw 5. 5/32” punch 3. Throttle shaft 6. Throttle plate screw GTS 200 Carburetion...
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2. Insert float hinge pin and center pin between float pin 1. Install throttle shaft and foam washer. bosses. Float height is non-adjustable. 2. Turn shaft until flat is facing out. 3. Install rubber gasket on carburetor and lay float bowl on body. GTS 200 Carburetion...
1. Install breather tube on air cleaner primer base and position decrease. If poor performance is experienced refer to the base with new gasket on carburetor mounting surface. proper Toro parts manual for replacement high altitude main jet. 2. Install air cleaner primer base with two (2) screws into carburetor.
The flywheel brake is part of the safety control system required for this engine. The flywheel brake MUST stop the engine within three seconds, while running at FAST speed position, when the operator releases the equipment safety control. Governor Controls, Carburetor Linkage, GTS 200 and Flywheel Brake...
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5. Install fuel tank and static guard. 5. Disconnect spring from brake anchor. 6. Disconnect stop switch wire from stop switch. If engine is equipped with electric starter, disconnect both wires from starter interlock switch. Governor Controls, Carburetor Linkage, GTS 200 and Flywheel Brake...
3. Rotate the governor lever to the right until it stops. Hold and tighten the governor lever nut. To adjust top no load RPM, see page 26. Refer to page 26 for specific procedures for governor adjustments. Governor Controls, Carburetor Linkage, GTS 200 and Flywheel Brake...
....... tachometer. Toro rotary mowers should be set to run at 3,000 RPM 150, General Information which will produce blade tip speeds of 19,000 feet per minute.
19334/5 vertical crankshaft engines. Color ..... . Brown Crankshaft Journal Size ..1.062” (26.97mm) GTS 200 Governor...
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6. Pull regulator lock nut out and turn adjustment knob counterclockwise as far as it will go, Fig. 48. Note: The crankshaft must be held with the piston at top dead center to eliminate any chance of rotation. GTS 200 Compression...
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If reading does not Fig. 51 – Removing Cylinder Head ponents. change, look for problems 1. Cylinder head screws 2. Cylinder head beginning with component that appeared to leak the most air. Re-test after re- pair. GTS 200 Compression...
1. Screw: torque to 80 in. lbs. (9.0Nm) lapped in using Briggs & Stratton Tool #19258, Valve Lapping Tool, and Briggs & Stratton Part #94150, Valve Lapping Compound, to assure a good seal between the valve face and the seat. GTS 200 Compression...
(15.0Nm), Fig. 58. fully engaged in valve stem groove, Fig. 56. Fig. 58 – Installing Rocker Arm Studs Fig. 56 – Installing Valve Retainers 1. Rocker arm stud: torque to 130 in. lbs. (15.0Nm) 1. Valve retainer GTS 200 Compression...
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3. Turn crankshaft clockwise (flywheel end), while watching through rocker arm. screwdriver or rod, past Top Dead Center until piston is 3. Install jam nut of end of rocker arm screw and run nut up 1/4” (6mm) down. on threads half way. GTS 200 Compression...
THE STARTER spring is still under tension when the rope has been removed and the pulley has no spring tension against it. Wear eye protection to prevent eye injury when installing or removing starter pulley and spring. GTS 200 Rewind Starter...
2. Pulley rope hole 4. Clockwise 2. Then rotate pulley clockwise until rope hole in pulley is in Fig. 78 – Installing Pawls line with starter housing eyelet and hold pulley, Fig. 80. 1. Posts 2. Pawls GTS 200 Rewind Starter...
C. Faulty electrical connection (battery circuit). General Information D. Dirty or worn starter motor commutator, bearing, weak The Toro GTS 200 electric start system consists of a 12V magnets, etc. battery, starter motor, switch, and alternator. In addition, the E. Worn brushes or weak brush springs.
Other Equipment A growler or armature tester (checks armature for continuity, shorts and opens) is available from an Automobile Diagnostic Service supplier. A known good 12 volt battery is required when testing 12 volt starting systems. GTS 200 Electric Starter...
Take whites of eggs. Do not Replace Battery Terminal induce vomiting. Toro Part #49–8141 is a replacement plug with two solderless connectors (Fig. 91). It can be used when the plug or lead wires between the plug and battery are damaged.
Wiring Diagrams Fig. 94 – Testing Starter Motor with Digital The following wiring diagrams (Fig. 93) show the two systems Multimeter used with the GTS 200 engine. 1. Red test lead 3. Briggs & Stratton Tool #19200 2. Black test lead 4.
3. Connect one meter test lead to end of one wire inside connector and other test lead to second connector terminal for the same wire. 2. Remove “E” retaining ring and pinion gear. 4. Meter should read low or no resistance. GTS 200 Electric Starter...
1. Insert RED test lead into 10 A receptacle in meter. tween output connector and battery. 2. Insert BLACK test lead into COM receptacle in meter. Damaged battery (shorted battery cells). 3. Rotate selector to (DC amps) position. Damaged alternator magnets. Defective stator. GTS 200 Alternator...
2. 25 in. lbs. (2.8Nm) 8. If stator air gap is within specification and there is low or no output, replace stator. Install Stator Studs If stator studs were removed, install and torque to 30 in. lbs (3.4Nm), Fig. 109. GTS 200 Alternator...
......Extended Oil Fill and Dipstick Fig. 111 – Removing Breather and Breather The GTS 200 uses a plastic extended oil fill tube and a quarter Passage Cover turn screw-on-dipstick.
Pistons, Rings, and 3. Push piston and rod out through top of cylinder. Note: The GTS 200 engine uses oil drain slots in ring Rods lands, Fig. 118. Contents Piston and Connecting Rod ......
Fig. 123 – Checking Piston Pin Bore 1. Piston pin bore Assemble Piston and Connecting Rod Note: Pistons on the GTS 200 engine have a shoulder stop on one side of piston and use only one (1) piston pin lock. Î Î...
4. Tighten compressor until piston cannot be turned in compressor. 5. Then loosen compressor until piston can be turned with slight resistance. Note: Do not attempt to install piston and ring assembly without ring compressor. GTS 200 Pistons, Rings, and Rods...
Connecting Rod Screw Torque Center Comp. Comp. Control Torque Ring Ring Ring In. Lbs. .020” .030” .035” (.51mm) (.76mm) (.89mm) (11.3) Table No. 3 Connecting Rod Rejects Crankpin Piston Pin Bearing Bearing 1.102” .627” (27.98mm) (15.93mm) GTS 200 Pistons, Rings, and Rods...
Check timing gears for chipped or cracked teeth and keyway for wear. Replace timing gear, if damaged. If timing gear is 6. Rotate crankshaft until timing marks are aligned. chipped or cracked, also check camshaft for damage. GTS 200 Crankshaft and Camshaft...
5. Install connecting rod on crankshaft, page 51. with a non-hardening sealant such as Permatex 2, or 6. Install slip fit timing gear (if removed) with inner chamfer equivalent. toward crankpin. This assures timing mark will be visible. GTS 200 Crankshaft and Camshaft...
Cylinder Crosshatching aids proper lubrication. GTS 200 OHV engines use aluminum alloy plain bearings as part of the cylinder material. Inspection Always inspect cylinder after engine has been disassembled.
Place pilot guide bushing in bearing opposite of bearing to be repaired. Have flange of bushing on inside of 1. Split in bearing crankcase. Replace sump if sump crankshaft bearing is worn or damaged. GTS 200 Cylinder and Bearings...
Table No. 8 1. For adjustment procedure for crankshaft end play see Crankcase Sump Torque Crankshaft and Camshaft, page 55. In. Lbs. 2. Torque crankcase cover screws in sequence shown in Fig. 146. (12.0) GTS 200 Cylinder and Bearings...
Check muffler for split seams, loose internal parts, or cracked welds. Replace any damaged parts with new Original Equipment Parts. 3. Remove dipstick and oil fill tube. 4. Remove blower housing and rewind starter, Fig. 149. GTS 200 Muffler...
1. Screw: torque to 85 in. lbs (10.0Nm) 4. Install screw in muffler bracket to cylinder head and torque to 85 in. lbs. (10.0Nm), Fig. 151. 5. Install screw in muffler to cylinder bracket and torque to 85 in. lbs. (10.0Nm). GTS 200 Muffler...