MAINTENANCE AND REPAIR INSTRUCTIONS

CHECKING THE OIL LEVEL

WARNING: To prevent extensive engine wear and damage to the unit, always maintain the proper oil level in the crankcase. Never operate the unit with the oil level below the bottom of the dipstick.

The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil before each use:

1.Stop the engine and allow oil to drain into the crankcase.

2.Place the unit on a flat, level surface to get a proper oil level reading.

3.Keep dirt, grass clippings and other debris out of the engine. Clean the area around the oil fill plug/dipstick before removing it.

4.Remove the oil fill plug/dipstick and wipe off oil. Reinsert it all the way back in.

5.Remove the oil fill plug/dipstick and check the oil level. Oil should be up to the top of the dipstick (Fig. 22).

O-Ring

Oil Fill Plug/Dipstick

Full

Add 1.4-1.5 Oz.

(41-44 ml)

Top of

Dipstick

Fig. 22

Oil Fill

Plug/Dipstick

Oil Fill Hole

Clean Air Filter

Air Filter Cover

The condition of the air filter is important to the operation of the

 

unit. A dirty air filter will restrict air flow. This is often mistaken for

 

an out of adjustment carburetor. Check the condition of the air

 

filter before adjusting the idle speed screw. Refer to Air Filter

 

Maintenance.

 

Adjust Idle Speed Screw

 

WARNING: To avoid serious personal injury,

 

always turn the unit off and allow it to cool

Cover Hinge

before you clean or service it.

Fig. 31

 

If, after checking the fuel and cleaning the air filter, the engine still will not idle, adjust the idle speed screw as follows:

1.Start the engine and let it run at a high idle for a minute to warm up. Refer to Starting/Stopping Instructions.

2.Release the throttle trigger and let the engine idle. If the engine stops, insert a small phillips or flat blade screwdriver into the hole in the air filter/muffler cover (Fig. 32). Turn the idle speed screw in, clockwise, 1/8 of a turn at a time (as needed) until the engine idles smoothly.

NOTE: The cutting attachment should not rotate when the engine idles.

3. If the cutting attachment rotates when the engine idles,

Idle Ajustment Screw

6. If the level is low, add a small amount of oil to the oil fill

Fig. 23

hole and recheck (Fig. 23). Repeat this procedure until the oil level reaches the top of the dipstick.

NOTE: Do not overfill the unit.

NOTE: Make sure the O-ring is in place on the oil fill plug/dipstick when checking and changing the oil (Fig. 22).

CHANGING THE OIL

CAUTION: Wear gloves to prevent injury

turn the idle speed screw counterclockwise 1/8 of a turn at a time (as needed), to reduce idle speed.

Checking the fuel, cleaning the air filter, and adjusting the idle speed should solve most engine problems. If not and all of the following are true:

• the engine will not idle

• the engine hesitates or stalls on acceleration

• there is a loss of engine power

Have the carburetor adjusted by an authorized service dealer.

when handling the unit.

ROCKER ARM CLEARANCE

Fig. 32

Fig. 24

WARNING: To avoid serious personal injury,

Remove

Remove Screws

Screws

Engine

always turn the unit off and allow it to cool

 

For a new engine, change the oil after the first 10 hours of operation. Change the oil while the engine is still warm. The oil will flow freely and carry away more impurities.

1.Unplug spark plug boot to prevent accidental starting.

2. Remove the oil fill plug/dipstick.

Fill Level

before you clean or service it.

Cover

 

This requires disassembly of the engine. If you feel unsure or unqualified to perform this, take the unit to an authorized service center.

3. Pour the oil out of the oil fill hole and into a container by tipping the unit to a vertical position (Fig. 24). Allow ample time for complete drainage.

4.Wipe up any oil residue on the unit and clean up any oil that may have spilled. Dispose of the oil according to Federal, State and local regulations.

5.Refill the crankcase with 3.04 fluid ounce (90 ml) of SAE 30 SF, SG, SH oil.

NOTE: Use the bottle and spout saved from initial use to measure the correct amount of oil. The top of the label on the bottle measures approximately 3.4 ounces (100 ml) (Fig. 25). Check the level with the dipstick. If the level is low, add a small amount of oil and recheck. Do not overfill (Fig. 25).

6.Replace the oil fill plug/dipstick.

7.Reconnect the spark plug boot.

AIR FILTER MAINTENANCE

WARNING: To avoid serious personal injury, always turn the unit off and allow it to cool before you clean or service it.

Cleaning the Air Filter

Clean and re-oil the air filter every 10 hours of operation. It is an important item to maintain. Failure to maintain your air filter properly can result in poor performance or can cause permanent damage to your engine.

1.Open the air filter cover. Push the tab on the left side of the cover inward. Then pull the air filter cover out and to the right (Fig. 26).

NOTE: It may be necessary to remove the fuel cap to completely remove the air filter cover.

2.Remove the air filter (Fig. 26).

3.Wash the filter in detergent and water (Fig. 27). Rinse the filter thoroughly and allow it to dry.

4.Apply enough clean SAE 30 motor oil to lightly coat the filter (Fig. 28).

5.Squeeze the filter to spread and remove excess oil (Fig. 29).

6.Replace the filter (Fig. 30).

Fig. 25

Air Filter

Air Filter Cover

Tab

Fig. 26

Fig. 27

Fig. 28

NOTE: Inspect the valve to rocker arm clearance with a feeler gauge after the first 10 hours of operation and then every 25 hours of operation thereafter.

•The engine must be cold when checking or adjusting the valve clearance.

•This task should be performed inside in a clean, dust free area.

1.Remove the five (5) screws on back of the engine cover with a Flat-head or T-20 Torx screwdriver (Fig. 33).

2.Remove the screw behind the engine cover with a Flat- head or T-25 Torx screwdriver (Fig. 34).

3.Disconnect the spark plug wire.

4.Clean dirt from around the spark plug. Remove the spark plug from the cylinder head by turning a 5/8 in. socket counterclockwise.

5.Remove the engine cover (Fig. 33 & 34).

6.Clean dirt from around the rocker arm cover. Remove the screw holding the rocker arm cover with a large flat blade screwdriver or Torx T-25 bit (Fig. 35). Remove the rocker arm cover and gasket.

7.Pull the starter rope slowly to bring the piston to the top of its travel, (known as top dead center). Check that:

•The piston is at the top of its travel while looking in the spark plug hole (Fig. 36)

•Both rocker arms move freely, and both valves are closed If these statements are not true, repeat this step.

8.Slide the feeler gauge between the rocker arm and the valve return spring. Measure the clearance between the valve stem and rocker arm (Fig. 37). Measure both the intake and exhaust valves.

The recommended clearance for both intake and exhaust is .003

–.006 in. (.076 – 0.152 mm). Use a standard automotive .005 in. (0.127 mm) feeler gauge. The feeler gauge should slide between the rocker arm and valve stem with a slight amount of resistance, without binding. Figure 38 and 39 show how to measure the clearance.

9.If the clearance is not within specification:

a. Turn the adjusting nut using a 5/16 inch (8 mm) wrench or nut driver (Fig. 37).

Muffler

Fig. 33

Screw

Fig. 34

Rocker Arm Cover

Spark Plug Hole

Fig. 35

Adjusting Nuts

Rocker Arms

INTAKE

 

EXHAUST

Feeler

 

Gauge

 

 

Fig. 36

Exhaust

Exhaust

Adjusting Nut

Rocker Arm

 

Feeler

NOTE: If the unit is operated without the air filter, you will VOID the warranty.

•To increase clearance, turn the adjusting nut counterclockwise.

Gauge

7. Reinstall the air filter cover. Position the hooks on the right side of the air filter cover into the slots at the right side of the back plate (Fig. 31, no.1).

8. Swing the cover to the left until the tab on the air filter cover snaps into place in the slot on the back plate (Fig. 31, no. 2).

CARBURETOR ADJUSTMENT

 

The idle speed of the engine is adjustable. An idle adjustment screw

 

is reached though a hole in the top of the engine cover (Fig. 32).

Fig. 29

NOTE:

Careless adjustments can seriously damage your

Back Plate

 

unit. An authorized service dealer should make

 

 

carburetor adjustments.

Slots

Check Fuel

 

 

 

Old fuel is usually the reason for improper unit performance. Drain and refill the tank with fresh fuel prior to making any adjustments. Refer to Oil and Fuel Information.

Fig. 30

 

• To decrease clearance, turn the adjusting nut clockwise.

0.003–0.006 in.

 

b. Recheck both clearances, and adjust as necessary.

(0.076–0.152 mm)

 

10.

Reinstall the rocker arm cover using a new gasket. Torque

 

 

 

the screw to 20–30 in•lb (2.2–3.4 N•m).

Intake Valve

Exhaust Valve

11.

Reinstall the engine cover. Check alignment of the cover

Stem

Stem

 

before tightening the screws. Tighten screws.

Fig. 37

 

12.Check the spark plug and reinstall. See Replacing the Spark Plug.

13.Replace the spark plug wire.

REPLACING THE SPARK PLUG

WARNING: To avoid serious personal injury, always turn the unit off and allow it to cool before you clean or service it.

Use a replacement part number 791-180852Bspark plug. The correct air gap is 0.025 in. (0.635 mm.). Remove the plug after every 25 hours of operation and check its condition.

1.Stop the engine and allow it to cool. Grasp the plug wire firmly and pull the cap from the spark plug.

2.Clean dirt from around the spark plug. Remove the spark plug from the cylinder head by turning a 5/8 in. socket counterclockwise.

6