Form No. 3439-732 Rev A G210 Engine Service Manual Published: December 2020 © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision History Page 2 G210 Engine Service Manual 3439-732 Rev A
Preface This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. We are hopeful that you will find this manual a valuable addition to your service shop.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S.
Table of Contents Preface ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
Preface Page 6 G210 Engine Service Manual 3439-732 Rev A
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Think Safety First (continued) Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment.
Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–5 Equivalents and Conversions........................................................................................................... 2–10 U.S.
Specifications G210FS-1 & G210FDS-1, G210FS-2 & G210FDS-2, and G210FS-4 & G210FDS-4 Engine Specifications Model G210FS-1 & G210FDS-1 G210FS-2 & G210FDS-2 Engine Name Toro Snow Engine Type OHV Single Cylinder, Four Stroke, Forced Air Cooling Bore X Stroke 70 × 55 mm (2.76 x 2.17 inch) Displacement 212 cc Compression Ratio 8.5 : 1 Lubrication Splash Starting Recoil/Electric Start Rotation Counter-Clockwise (from P.T.O.
G210F (D) S-1, S-2, & S-4 Engine Part Specifications (continued) Rod Journal 30.16 mm (1.18740 inch) 30.1 mm (1.18503 inch) Clearance (Cold) (Intake) 0.13-0.17 mm (0.005-0.007 inch) N/A Clearance (Cold) (Exhaust) 0.18-0.22 mm (0.007-0.009 inch) N/A Stem Diameter (Intake) 5.480 mm (0.2157 inch) 5.318 mm (0.2094 inch) Stem Diameter (Exhaust) 5.440 mm (0.2142 inch) 5.275 mm (0.2077 inch) Inside Diameter (Intake, Exhaust) 5.500 mm (0.2165 inch) 5.572 mm (0.
G210 Engine Fastener Torque Specifications (continued) Fuel Filter N/A 2.0 N • m (18 in-lb) Recoil Mount Bolt M6 10 N • m (89 in-lb) Electric Start Switch Mount Screw M4 1.4 N • m (12 in-lb) Valve Cover Bolt M6 10 N • m (89 in-lb) Electric Starter Motor Bolt M6 10 N • m (89 in-lb) Spark Plug N/A 29 N • m (21 ft-lb) Shroud Mount Bolt or Nut M6 10 N • m (89 in-lb) Carburetor Bowl Screw M8 7.5 N • m (66 in-lb) Fuel Drain Screw M6 7.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply for all fasteners which do not have a specific requirement identified in the service manual.
Metric Bolts and Screws g272209 Figure 2 1. Class 8.8 Specifications and Maintenance: Torque Specifications 2. Page 2–6 Class 10.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studes & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) in-lb in-lb N • cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 30 18 ± 2 30 ± 5 339 ± 56 1/4-20 UNC 48 ± 7 53 ± 7 1/4-28 UNF 53 ± 7 5/16-18 UNC 5/16-24 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolt
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb N • cm in-lb N • cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lb N • m ft-lb N • m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.5 38 ± 4 52 ± 5 54 ± 6 73 ± 8 M12 X 1.
SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N • m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N • m M12 X 1.25 Class 8.8 80 ± 10 ft-lb 108 ± 14 N •m M12 X 1.5 Class 8.
Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.272 5/32 0.15625 3.969 21/32 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Specifications and Maintenance: Torque Specifications Page 2–12 G210 Engine Service Manual 3439-732 Rev A
Chapter 3 Troubleshooting Table of Contents General Troubleshooting ....................................................................................................................... 3–3 Engine Model/Serial Number Location ................................................................................................
GEARS The Systematic approach to defining, diagnosing and solving problems.
General Troubleshooting Problem Engine does not start, hard start, or running poorly Possible Cause Choke function Corrective Action 1. Verify the choke is fully closed. 2. Check that the lever moves the choke butterfly open and close. 3. Replace components as necessary. Fuel delivery issue 1. Verify fuel shut off is in ON position. 2. Check the fuel level in the tank, fuel filter, fuel lines, fuel tank venting, and carburetor. 3. Check for ice blocking the filter, lines, or in bowl of carburetor. 4.
General Troubleshooting (continued) Problem Engine does not start, hard start, or running poorly (continued) Possible Cause Insufficient compression Corrective Action 1. Perform a leak down test. 2. Check cylinder for wear. 3. Check for valve(s) not seating. 4. Check the valve clearance. 5. Check the head gasket or intake gasket for leaking. 6. Adjust the valve clearance. 7. Replace damaged components as necessary.
General Troubleshooting (continued) Problem Engine runs but misses Possible Cause Fuel quality Corrective Action 1. Check the fuel condition: age, octane, ethanol percentage, water/ice or other contaminants. 2. Flush the fuel system, replace fuel with known good fuel. 3. Replace the fuel filter. 4. Consider using Toro Fuel Treatment. Fuel delivery issue 1. Verify the fuel shut off is in the ON position. 2. Check the fuel level, fuel filter, fuel lines, fuel tank venting, and carburetor. 3.
General Troubleshooting (continued) Problem Engine runs but misses (continued) Possible Cause Insufficient compression Corrective Action 1. Perform a leak down test. 2. Check the cylinder for wear. 3. Check for valve(s) not seating. 4. Check the valve clearance. 5. Check the head gasket or intake gasket for leaking. 6. Adjust the valve clearance. 7. Replace damaged components as necessary. Engine does not crank Engine overheated 1. See engine overheating troubleshooting table section. Recoil issue 1.
General Troubleshooting (continued) Problem Engine is oil leaking from the breather hose Possible Cause Oil Corrective Action 1. Check if the oil is overfilled or contaminated. 2. Check the oil viscosity. 3. Change the oil using correct viscosity. See the product Operator’s Manual for oil changing procedures. Breather hose 1. Check if the breather hose is open. 2. Check the breather hose routing. 3. Replace damaged components as necessary. Excessive crankcase pressure 1. Perform a leak down test. 2.
General Troubleshooting (continued) Problem Engine overheats Possible Cause Flywheel fan Corrective Action 1. Check the flywheel fan for damage. 2. Replace damaged components as necessary. Cylinder cooling fins 1. Check for debris build up under the engine shroud. 2. Clear debris from under the shrouds and between cooling fins 3. Replace damaged components as necessary. Oil 1. Check if the oil level is low or contaminated. 2. Check the oil viscosity. 3. Change the oil using correct viscosity.
General Troubleshooting (continued) Problem Engine Surges at Top No Load RPM Possible Cause Fuel delivery issue Corrective Action 1. Hold the throttle shaft to keep engine at RPM. If the engine shuts off, see the corrective actions below. 2. Verify the fuel shut off is in the ON position. 3. Check the fuel level, fuel filter, fuel lines, fuel tank venting, and carburetor. 4. Check the ice blocking filter, lines and bowl in the carburetor for damage. 5. Verify the fuel tank cap is venting. 6.
Engine Model/Serial Number Location The engine model and serial numbers are engraved into the crankcase. At the time of production, there is a disposable paper tag located on the engine block, above the oil drain. The engine model number is located in the top row. g339493 Figure 3 The engine serial number is located in the bottom row. The first 4 digits represent the date the engine was manufactured. The first 2 digits represent the year and the following 2 digits represent the month.
Chapter 4 Starter System Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Recoil Replacement...........................................................................................................................
General Information This Starter System chapter covers the removal, inspection, and installation of the recoil assembly. There are two different orientations of the recoil for the different engine variations.
Service and Repairs Recoil Starter Assembly g322269 Figure 5 1.
Recoil Replacement Recoil Removal 1. Remove the 4 (M6 x 8) screws and 4 (M6) washers securing the recoil starter assembly to the blower shroud. g322365 Figure 6 2. Remove the recoil starter assembly from the blower shroud. g322362 Figure 7 Recoil Inspection 1. Inspect the starter cup for burrs, nicks, or if out of round. Replace the starter cup if damaged.
Recoil Inspection (continued) g322366 Figure 8 2. Inspect the rope for fraying or wear. Replace the recoil starter assembly if damaged. 3. Inspect the starter pawl engagement. Hold the recoil in one hand and pull the rope with the other hand. Ensure both of the pawls smoothly extend fully to the stops. g322361 Figure 9 4. Pull the rope all the way out of the recoil assembly and slowly let it rewind while watching the rope pulley for smooth return.
Recoil Inspection (continued) g322359 Figure 10 Recoil Installation 1. Rotate the recoil assembly to match the chassis application.
Recoil Installation (continued) G210–2 g326031 Figure 12 G210–4 g326032 Figure 13 2. Install the 4 (M8 x 8) screws and 4 (M6) washers securing the recoil starter assembly to the blower shroud. Torque the screws in an alternating pattern to 10 N • m (89 in-lb).
Recoil Installation (continued) 3. Test the recoil function by pulling the rope several times as if going to start the engine.
Chapter 5 Fuel System Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Carburetor Replacement....................................................................................................................
General Information The Fuel System chapter includes the removal and installation of the carburetor, heater box, primer assembly, and two variations of the fuel line. One of the fuel lines has a fuel shut off valve.
Service and Repairs Carburetor Assembly g324209 Figure 15 1. 2. Intake Stud Carburetor Gasket 3. 4. Carburetor Insulator Throttle Return Spring 9. 10. Primer Bulb Primer Hose 5. 6. Fuel Hose Carburetor Gasket 11. 12. Carburetor Gasket Heater Box G210 Engine Service Manual 3439-732 Rev A 7. 8.
G210–1 Fuel Line Assembly g326209 Figure 16 1. Fuel Cap 5. Fuel Valve 2. Fuel Tank 6. Fuel Hose (80 mm) 3. Fuel Filter 7. Carburetor Assembly 4.
G210–2 & G210–4 Fuel Line Assembly g326210 Figure 17 1. Fuel Cap 4. Fuel Hose 2. Fuel Tank 5. Carburetor Assembly 3.
Carburetor Replacement Carburetor Removal 1. Drain the fuel into a suitable container. 2. Remove the muffler guard from the engine block. Refer to the product Service Manual for the muffler guard removal procedures. 3. Remove the 2 (M6) flange nuts securing the heater box to the intake studs. g323684 Figure 18 4. Disconnect the 2 wires from the back of the key switch. g323698 Figure 19 5. Slide the primer hose clamp away from the primer assembly. Remove the primer hose from the primer bulb base.
Carburetor Removal (continued) g323701 Figure 20 1. 2. Primer Hose Clamp Primer Hose 6. Position the choke lever in the middle of the heater box slot. g323685 Figure 21 7. Slide and remove the heater box from the intake studs. 8. Remove the metal carburetor gasket from the intake studs.
Carburetor Removal (continued) g323683 Figure 22 9. Slide the fuel hose clamp away from the carburetor. Remove the fuel hose from the carburetor. g323693 Figure 23 1. Fuel Hose 2. Fuel Hose Clamp 10. Slide the primer hose clamp away from the carburetor. Remove the primer hose from the carburetor. 11. Slide the carburetor partially away from the engine block. Rotate the throttle shaft to open the throttle and unhook the governor rod and throttle return spring from the carburetor throttle shaft.
Carburetor Removal (continued) g324196 Figure 24 1. Governor Rod 2. Throttle Return Spring 12. Slide and remove the carburetor from the intake studs. 13. Remove the electrical harness and fuel hose from the insulator gasket holders. g323689 Figure 25 14. Remove the carburetor gasket, insulator, and carburetor gasket from the intake studs.
Carburetor Removal (continued) g323695 Figure 26 1. 2. Carburetor Gasket Insulator 3. Carburetor Gasket Carburetor Disassembly 1. Remove the bowl drain and gasket from the carburetor. Drain the fuel into a suitable container. g323687 Figure 27 2. Remove the float bowl screw and gasket securing the float bowl to the carburetor. Remove the float bowl from the carburetor.
Carburetor Disassembly (continued) g323691 Figure 28 3. Remove the float bowl gasket from the carburetor. g323688 Figure 29 4. Slide and remove the float hinge pin securing the float to the carburetor. Remove the float from the carburetor.
Carburetor Disassembly (continued) g324193 Figure 30 1. Float 2. Hinge Pin 5. Remove the needle from the float. 6. Using a narrow tipped flat blade screwdriver, remove the main jet and nozzle from the carburetor body. g323700 Figure 31 1. Nozzle 2. Jet 7. Using a flat blade screwdriver, remove the idle speed screw.
Carburetor Disassembly (continued) g323696 Figure 32 8. Remove the pilot jet from the carburetor. Note: Do not twist or turn the pilot jet when removing the pilot jet. Damage to the o-rings will occur. g323697 Figure 33 9. Remove the screw securing the choke lever to the carburetor. Remove the choke lever from the carburetor.
Carburetor Disassembly (continued) g323690 Figure 34 Carburetor Inspection 1. Inspect the carburetor and removed components prior to cleaning. Inspect the following components for damage and replace as necessary. • Jets and nozzles • Float • Air inlet circuit • Bowl vent circuit 2. Using an ultrasonic cleaner, clean the carburetor body and the removed components. 3. Rinse all of the parts with warm water to remove the cleaner residue. 4. Using compressed air, dry all of the parts. 5.
Carburetor Inspection (continued) g340112 Figure 35 • Pilot circuit g340111 Figure 36 • Main circuit G210 Engine Service Manual 3439-732 Rev A Page 5–15 Fuel System: Service and Repairs
Carburetor Inspection (continued) g340109 Figure 37 • Bowl vent circuit g340108 Figure 38 • Transfer ports near the throttle vents Fuel System: Service and Repairs Page 5–16 G210 Engine Service Manual 3439-732 Rev A
Carburetor Inspection (continued) g333351 Figure 39 • Pilot jet cavity g340110 Figure 40 8. Inspect the carburetor throttle shaft and choke shaft. Verify the parts move freely and their discs do not rub on the carburetor throat. If rubbing exists, loosen the screw and rotate the disc to gain clearance, retighten the screw. If unable to adjust, replace the carburetor assembly. 9. Inspect the carburetor body for corrosion or pitting. If corrosion or pitting is found, replace the carburetor assembly.
Carburetor Assembly (continued) 1. Use a new carburetor rebuild kit. g326029 Figure 41 2. Install the choke lever to the carburetor. Install the screw securing the choke lever to the carburetor. g323690 Figure 42 3. Lightly apply engine oil to both of the pilot jet o-rings. Align the flats of the pilot jet with the flats of the carburetor. Install the pilot jet. Note: Do not twist the pilot jet while installing.
Carburetor Assembly (continued) g323697 Figure 43 4. Install the idle speed screw into the carburetor next to the throttle shaft. Tighten until the head of the screw is centered over the pilot jet. g339520 Figure 44 5. Install the nozzle into the carburetor by placing the double rings last.
Carburetor Assembly (continued) g324195 Figure 45 6. Using a flat blade screwdriver, install the main jet securing the nozzle to the carburetor. g324194 Figure 46 7. Install the needle and spring onto the float.
Carburetor Assembly (continued) g339519 Figure 47 8. Install the float with a needle in the carburetor. Install the float hinge pin securing the float to the carburetor. g324193 Figure 48 1. Float 2. Hinge Pin 9. Install the new float bowl gasket into the carburetor.
Carburetor Assembly (continued) g323688 Figure 49 10. Install the float bowl onto the carburetor. 11. Install the new gasket and screw securing the float bowl onto the carburetor. Torque the screw to 7 N • m (66 in-lb). g323691 Figure 50 12. Install the new gasket and drain screw onto the float bowl. Torque the screw to 7 N • m (66 in-lb).
Carburetor Assembly (continued) g323687 Figure 51 Carburetor Pop Off Test 1. 2. 3. 4. With carburetor removed, position with float bowl upwards. Using a hand pressure tester, apply pressure to the fuel inlet. While pumping, observe the pressure increase. Stop pumping, observe the pressure drop slightly, then stabilize as the float weight closes the needle and holds pressure. The pressure should not drop to zero.
Carburetor Installation 1. Install the new carburetor gasket, insulator, and new carburetor gasket onto the intake studs. Note: Ensure the carburetor gaskets and insulator are positioned correctly on the intake studs. g323695 Figure 53 1. 2. Carburetor Gasket Insulator 3. Carburetor Gasket 2. Route the electrical harness and fuel hose through the insulator gasket holders. g323689 Figure 54 3. Slide the carburetor partially onto the intake studs. 4.
Carburetor Installation (continued) g324196 Figure 55 1. Governor Rod 2. Throttle Return Spring 5. Install the primer hose onto the carburetor, secure with the primer hose clamp. 6. Install the fuel hose onto the inlet fitting of carburetor, secure with the fuel hose clamp. g323693 Figure 56 1. Fuel Hose 2. Fuel Hose Clamp 7. Install the metal carburetor gasket onto the intake studs. Note: Ensure the metal carburetor gasket is positioned correctly on the intake studs.
Carburetor Installation (continued) g323683 Figure 57 8. Rotate the choke lever to partial choke and slide the heater box partially onto the intake studs and over choke lever. g323685 Figure 58 9. Install the primer hose onto the primer bulb base, secure with the primer hose clamp.
Carburetor Installation (continued) g323701 Figure 59 1. 2. Primer Hose Clamp Primer Hose 10. Connect the 2 wires to the key switch terminals. Note: Verify the wires are not crossed. g323698 Figure 60 11. Fully slide the heater box onto the intake studs. Install the 2 (M6) flange nuts securing the heater box to the intake studs.
Carburetor Installation (continued) g323684 Figure 61 12. Install the muffler guard onto the cylinder head. Refer to the product Service Manual for the muffler guard installation procedures. Carburetor Test 1. Add fuel to the fuel tank and verify no fuel leaks exist. 2. Verify engine oil is at a proper level. 3. Start the engine and let it get to operating temperature. Verify Top No Load RPM. Specifications (page 2–2) 4. G210–1 engine models only, use a tachometer to verify the engine idle speed RPM.
G210–1 Fuel Line Removal (continued) 2. Remove the muffler guard from the engine block. Refer to the product Service Manual for the muffler guard removal procedures. 3. Remove the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank removal procedures. 4. Remove the 2 (M6) flange nuts securing the heater box to the intake studs. g323684 Figure 63 5. Disconnect the 2 wires from the back of the key switch. g323698 Figure 64 6.
G210–1 Fuel Line Removal (continued) g323701 Figure 65 1. 2. Primer Hose Clamp Primer Hose 7. Position the choke lever in the middle of the heater box slot. g323685 Figure 66 8. Slide and remove the heater box from the intake studs. 9. Slide the fuel hose clamp away from the carburetor. Remove the fuel hose from the carburetor.
G210–1 Fuel Line Removal (continued) g323693 Figure 67 1. Fuel Hose 2. Fuel Hose Clamp 10. Remove the cap from the fuel valve knob. 11. Remove the screw (M4 x 18) securing the fuel valve knob to the control panel. Remove the fuel valve knob from the fuel valve.
G210–1 Fuel Line Removal (continued) g326084 Figure 69 12. Remove the 2 (M6) acorn nuts securing the control panel to the engine block. Note: If the studs loosen from the engine block, use a box wrench on the inside of the control panel to hold the studs from turning while removing the acorn nuts. g326078 Figure 70 13. Engine equipped with an electric starter only, remove the electric starter switch box bracket from the RH blower mount stud. 14. Remove the control panel from the blower shroud. 15.
G210–1 Fuel Line Removal (continued) g326080 Figure 71 16. Remove the (M6) flange nut securing the fuel shutoff valve to the control panel. Remove the fuel shutoff valve with the hoses from the control panel. g326079 Figure 72 17. Slide the 2 clamps away from the fuel shutoff valve. Remove the fuel hoses from the inlet and outlet barbs.
G210–1 Fuel Line Removal (continued) g326082 Figure 73 1. 2. Outlet Barb Inlet Barb G210–1 Fuel Line Inspection 1. Verify the fuel valve rotates freely. Use compressed air to verify there is no blockage through the fuel valve. Inspect the fuel valve barbs for cracks or corrosion. Replace the fuel valve if not it is not functioning or is damaged. 2. If reusing the fuel hoses, inspect the fuel hoses for blockage, cracks, or deterioration. Replace the fuel hoses if damaged. 3.
G210–1 Fuel Line Installation (continued) g326144 Figure 75 3. Install the fuel shutoff valve onto the control plate, secure with a (M6) flange nut. g326143 Figure 76 4. Install the short fuel hose onto the inlet fitting of carburetor, secure with a clamp.
G210–1 Fuel Line Installation (continued) g323693 Figure 77 1. Fuel Hose 2. Fuel Hose Clamp 5. Verify the 2 (M6 x 89) mount studs are securely fastened to the engine block. If necessary, torque the mount studs to 10 N • m (89 in-lb). g326145 Figure 78 6. Install the control plate onto the mount studs. 7. Engine equipped with an electric starter only, install the electric starter switch box bracket onto the RH blower mount stud. 8.
G210–1 Fuel Line Installation (continued) g326078 Figure 79 g326142 Figure 80 1. Ground Wire 9. Engines equipped with an electric starter only, install the electric starter switch box bracket to the blower shroud, secure with a (M6) acorn nut. 10. Install the fuel knob onto the fuel valve. Install the screw (M4 x 8) securing the fuel knob to the fuel valve. Torque the screw to 2 N • m (18 in-lb). Install the cap onto the fuel knob.
G210–1 Fuel Line Installation (continued) g326081 Figure 81 11. Install the throttle control knob onto the speed control assembly. g325572 Figure 82 12. Verify the metal carburetor gasket is positioned correctly on the intake studs.
G210–1 Fuel Line Installation (continued) g323683 Figure 83 13. Slide the choke lever to partial choke. Slide the heater box partially onto intake studs and over choke lever. g323685 Figure 84 14. Install the primer hose onto the primer bulb base,secure with the primer hose clamp.
G210–1 Fuel Line Installation (continued) g323701 Figure 85 1. 2. Primer Hose Clamp Primer Hose 15. Connect the 2 wires to the key switch terminals. Note: Verify the wires are not crossed. g323698 Figure 86 16. Fully slide the heater box onto the intake studs. Install the 2 (M6) flange nuts securing the heater box to the intake studs.
G210–1 Fuel Line Installation (continued) g323684 Figure 87 17. Install the fuel tank onto the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 18. Install the muffler guard onto the cylinder head. Refer to the product Service Manual for the muffler guard installation procedures. G210–1 Fuel Line Test 1. Verify no fuel leaks exist. 2. Test the speed control assembly by starting the engine and sliding the throttle to full stroke.
G210–2 & G210–4 Fuel Line Removal (continued) g323698 Figure 89 5. Slide the primer hose clamp away from the primer assembly. Remove the primer hose from the primer bulb base. g323701 Figure 90 1. 2. Primer Hose Clamp Primer Hose 6. Position the choke lever in the middle of the heater box slot.
G210–2 & G210–4 Fuel Line Removal (continued) g323685 Figure 91 7. Slide and remove the heater box from the intake studs. 8. Slide the fuel hose clamp away from the carburetor and remove the fuel hose from the carburetor. g323693 Figure 92 1. Fuel Hose 2. Fuel Hose Clamp 9. Remove the clamps from both ends of the fuel hose and remove the fuel hose from the engine block.
G210–2 & G210–4 Fuel Line Removal (continued) g326156 Figure 93 1. Fuel Hose to Carburetor Clamp 2. Fuel Hose to Fuel Filter Fitting Clamp G210–2 & G210–4 Fuel Line Inspection 1. Verify the fuel valve rotates freely. Use compressed air to verify there is no blockage through the valve. Inspect the valve barbs for cracks or corrosion. Replace the valve if it is not functioning or is damaged. 2. If reusing the fuel hose, inspect the fuel hose for blockage, cracks, or deterioration.
G210–2 & G210–4 Fuel Line Installation (continued) 3. Verify the metal carburetor gasket is positioned correctly on the intake studs. g323683 Figure 95 4. Slide the choke lever to partial choke. Slide the heater box partially onto the intake studs and over choke lever. g323685 Figure 96 5. Install the primer hose onto the primer bulb base, secure with a clamp.
G210–2 & G210–4 Fuel Line Installation (continued) g323701 Figure 97 1. 2. Clamp Primer Hose 6. Connect the 2 wires to the key switch terminals. Note: Verify the wires are not crossed. g323698 Figure 98 7. Fully slide the heater box onto the intake studs. Install the 2 (M6) flange nuts securing the heater box to the intake studs. Torque the nuts to 10 N • m (89 in-lb).
G210–2 & G210–4 Fuel Line Installation (continued) g323684 Figure 99 8. Install the fuel tank onto the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 9. Install the muffler guard onto the cylinder head. Refer to the product Service Manual for the muffler guard installation procedures. G210–2 & G210–4 Fuel Line Test 1. Verify no fuel leaks exist. 2. Test run the engine. 3. Using a tachometer, verify the engine speed is to specification.
Primer Assembly Removal (continued) g323701 Figure 100 1. 2. Primer Hose Clamp Primer Hose 3. Squeeze the retaining tangs together. Remove the primer assembly from the heater box. Primer Assembly Installation 1. Install the primer assembly into the heater box. 2. Install the primer hose onto the primer bulb base, secure with a clamp. g323701 Figure 101 1. 2. Clamp Primer Hose 3. Install the muffler guard onto the cylinder head.
Chapter 6 Governor Controls Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Speed Control Assembly Replacement (G210–1, G210–2, & G210–4)..............................................
General Information The Governor Controls chapter covers the removal, inspection, and installation of the engine speed control assembly, linkage, and the governor arm. It also includes sections on how to set Top No Load RPM and how to Zero the Governor. The G210-2 and G210-4 are constant RPM engines whereas the G210-1 has a throttle control that allows engine to operate at a fast or slow speed. The throttle control also shuts off the engine.
Service and Repairs G210–1 Speed Control Assembly g325024 Figure 102 1. 2. Governor Arm Governor Spring 5. 6. Governor Shaft Speed Control Assembly 3. 4. Governor Arm Bolt Throttle Return Spring 7. 8.
G210–2 & G210–4 Speed Control Assembly g325025 Figure 103 1. 2. Governor Arm Bolt Governor Arm 5. 6. Governor Shaft Speed Control Assembly 3. Governor Spring 7. Governor Rod 4.
Speed Control Assembly Replacement (G210–1, G210–2, & G210–4) G210–1 Speed Control Assembly Removal 1. Drain the fuel into a suitable container. 2. Remove the muffler guard from the engine block. Refer to the product Service Manual for the muffler guard removal procedures. 3. Remove the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank removal procedures. 4. Pull and remove the throttle control knob from the speed control assembly. g333166 Figure 104 5.
G210–1 Speed Control Assembly Removal (continued) g325570 Figure 106 7. Unhook the governor spring from the speed control assembly and governor arm. g325569 Figure 107 8. Remove the speed control assembly from the engine block. G210–1 Speed Control Assembly Installation 1. Install the ground wire to the stop switch.
G210–1 Speed Control Assembly Installation (continued) g325570 Figure 108 2. Connect the governor spring to the specified hole in the governor arm and speed control assembly. g325569 Figure 109 3. Position the speed control assembly to the blower shroud by inserting the lever through the slot. Install the 2 (M6 x 10) screws securing the speed control assembly to the blower shroud. Torque the screws to 10 N • m (89 in-lb).
G210–1 Speed Control Assembly Installation (continued) g325571 Figure 110 4. Install the throttle control knob onto the speed control assembly. g325572 Figure 111 5. Install the fuel tank to the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 6. Install the muffler guard to the engine block. Refer to the product Service Manual for the muffler guard installation procedures. 7. Refill the fuel. G210–1 Speed Control Assembly Test 1.
G210–1 Speed Control Assembly Test (continued) 4. Using a tachometer, verify the engine idle speed RPM. Specifications (page 2–2) G210–2 & G210–4 Speed Control Assembly Removal 1. Drain the fuel into a suitable container. 2. Remove the muffler guard for the engine block. Refer to the product Service Manual for the muffler guard removal procedures. 3. Remove the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank removal procedures. 4.
G210–2 & G210–4 Speed Control Assembly Installation (continued) g325573 Figure 114 2. Install the 2 (M6 x 10) screws securing the speed control assembly to the engine block. g325574 Figure 115 3. Install the fuel tank to the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 4. Install the muffler guard to the engine block. Refer to the product Service Manual for the muffler guard installation procedures. 5. Refill the fuel.
Governor Arm Replacement (G210–1, G210–2, & G210–4) G210–1 Governor Arm Removal 1. Drain the fuel into a suitable container. 2. Remove the muffler guard from the engine block. Refer to the product Service Manual for the muffler guard removal procedures. 3. Remove the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank removal procedures. 4. Unhook the governor spring from the governor arm. g325633 Figure 116 5.
G210–1 Governor Arm Removal (continued) g325634 Figure 118 1. Governor Rod 2. Throttle Return Spring 7. Remove the governor arm from the engine block. Note: The clamping bolt and nut may fall out of the arm once the governor arm is removed. G210–1 Governor Arm Installation 1. Connect the governor rod and throttle return spring to the governor arm. g325634 Figure 119 1. Governor Rod 2. Throttle Return Spring 2.
G210–1 Governor Arm Installation (continued) g325632 Figure 120 3. Connect the governor spring to the governor arm and speed control assembly. g325633 Figure 121 4. Zero the governor. Zeroing the Governor (page 6–16) 5. Install the fuel tank to the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 6. Install the muffler guard to the engine block. Refer to the product Service Manual for the muffler guard installation procedures. 7. Set Top No Load RPM.
G210–2 & G210–4 Governor Arm Removal (continued) 4. Unhook the governor spring from the governor arm. g325636 Figure 122 5. Loosen the (M6) flange nut secured to the governor arm bolt and slide the governor arm off of governor shaft. Note: A small flat bladed screwdriver can be used to pry the clamp open to allow arm to lift up more easily. g325635 Figure 123 6. Unhook the governor rod and throttle return spring from the governor arm.
G210–2 & G210–4 Governor Arm Removal (continued) g325637 Figure 124 1. Governor Rod 2. Throttle Return Spring 7. Remove the governor arm from the engine block. Note: The clamping bolt and nut may fall out of the arm once the governor arm is removed. G210–2 & G210–4 Governor Arm Installation 1. Connect the governor rod and throttle return spring to the governor arm. g325637 Figure 125 1. Governor Rod 2. Throttle Return Spring 2.
G210–2 & G210–4 Governor Arm Installation (continued) g325635 Figure 126 3. Connect the governor spring to the governor arm and speed control assembly. g325636 Figure 127 4. Zero the governor. Zeroing the Governor (page 6–16) 5. Install the fuel tank to the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 6. Install the muffler guard to the engine block. Refer to the product Service Manual for the muffler guard installation procedures. 7.
Zeroing the Governor (continued) g325733 Figure 128 g325732 Figure 129 4. Ensure the governor shaft is completely through the governor arm clamp. Rotate the governor shaft clockwise and hold while tightening the (M6) flange nut. Torque the nut to 10 N • m (89 in-lb). Note: Verify there is an air gap between each side of the clamp. If overtightened and the gap is closed, replace the governor arm.
Zeroing the Governor (continued) g339523 Figure 130 g339524 Figure 131 5. Verify the throttle control linkage is free to move by rotating the governor arm. 6. Install the fuel tank to the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 7. Refill the fuel. 8. Start and run engine to verify governor arm and throttle shaft move freely. Top No Load RPM 1. Using a tachometer, verify Top No Load RPM. Specifications (page 2–2). 2.
Top No Load RPM (continued) Engine Model Image G210–1 g325734 Figure 132 G210–2 & G210–4 g325735 Figure 133 3. Test run the engine to verify Top No Load RPM.
Governor Controls: Service and Repairs Page 6–20 G210 Engine Service Manual 3439-732 Rev A
Chapter 7 Compression System Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Cylinder Head Replacement (G210–1, G210–2, & G210–4) .............................................................. 7–6 Piston and Connecting Rod Replacement......
General Information The Compression System chapter includes detailed steps for two assemblies. The Cylinder Head Assembly section includes the removal and installation of the head assembly and the complete head rebuild with valve reconditioning and adjustment steps (valve seat cutting, valve face angles, and valve spring height). The Piston and Connecting Rod Assembly section includes the removal and installation of the piston and connecting rod.
Service and Repairs G210–1, G210–2, & G210–4 Cylinder Head and Piston Assembly 1 g328799 Figure 134 1. 2. Valve Rotator Valve Spring Retainer 13. 14. Push Rod Guide Plate Valve Tappet 3. Valve Spring 15. Push Rod 4. 5. Exhaust Valve Intake Valve 16. 17. Valve Cover Cylinder Head Gasket 6. 7. 8. Valve Stem Seal Valve Set Rocker Arm Nut 18. 19. 20. Breather Tube Valve Cover Gasket Connecting Rod Assembly 9. 10. 11. Rocker Pivot Nut Rocker Arm Rocker Stud 21. 22. 23.
G210–1 Cylinder Head Assembly 2 g328800 Figure 135 1. Baffle Compression System: Service and Repairs 2.
G210–2 & G210–4 Cylinder Head Assembly 2 g328801 Figure 136 1. Speed Control Assembly G210 Engine Service Manual 3439-732 Rev A 2.
Cylinder Head Replacement (G210–1, G210–2, & G210–4) G210–1 Cylinder Head Removal 1. Drain the fuel into suitable container. 2. Remove the muffler from the cylinder head. Refer to the product Service Manual for the muffler removal procedure. 3. Remove the carburetor from the cylinder head. Carburetor Removal (page 5–6) 4. Remove the spark plug wire from the spark plug. 5. Remove the 2 (M6 x 10) screws securing the baffle to the cylinder head and engine block. g327606 Figure 137 6.
G210–1 Cylinder Head Removal (continued) g327610 Figure 138 8. Remove the lower shroud from the engine block. 9. Remove the 4 (M6 x 16) screws securing the valve cover to the cylinder head. 10. Remove the valve cover from the cylinder head. Remove and discard the valve cover gasket. 11. Place the piston at the top of the compression stroke. Note: Insert a wooden dowel into the spark plug hole to verify the piston is at the top of the compression stroke. 12.
G210–1 Cylinder Head Removal (continued) g327607 Figure 140 g327608 Figure 141 15. Remove the 2 push rods from the engine block.
G210–1 Cylinder Head Removal (continued) g327611 Figure 142 CAUTION Do not use a metal scraper or wire brush to remove head gasket remnants from the cylinder head or engine block. Doing so may damage the cylinder head or engine block. 16. Using a wood or plastic scraper, remove the head gasket from the cylinder head and the engine block. G210–1 Cylinder Head Inspection 1. Inspect the spark plug threads for damage. Replace the spark plug if damaged. 2. Remove carbon deposits from the cylinder head. 3.
G210–1 Cylinder Head Inspection (continued) g327663 Figure 143 1. Straight Edge 2. Feeler Gauge 5. Inspect the pushrods. Replace the pushrods if they are bent or worn. G210–1 Cylinder Head Disassembly 1. While holding the exhaust pivot nut with a wrench, remove the exhaust rocker arm nut from the rocker arm mounting stud. Repeat on the intake side of the cylinder head. g338830 Figure 144 2. Remove the exhaust pivot nut and exhaust rocker arm. Repeat on the intake side of the cylinder head.
G210–1 Cylinder Head Disassembly (continued) g338831 Figure 145 4. Place the cylinder head with the valve side facing downwards on a shop rag. 5. Using a valve spring compressor, compress the exhaust valve spring and exhaust. Remove the valve spring from the cylinder head. Repeat on the intake side of the cylinder head. Note: Keep the exhaust and intake parts separated. 6. Remove the remaining valve components. Note: Keep the exhaust and intake components separated.
G210–1 Cylinder Head Rocker Arm Components Inspection 1. Clean and inspect the rocker arm nuts, pivot nuts, rocker arms, and valve rotators for damage. Replace the rocker arm assembly if components are damaged. 2. Inspect the rocker arm mounting studs for damage. Replace the rocker arm assembly if the rocker arm mounting studs are damaged. 3. Clean and inspect the guide plate. Replace if cracked, worn, or bent. G210–1 Cylinder Head Valve Seat Inspection 1.
G210–1 Valve Inspection 1. Clean the carbon from the valves. 2. Inspect the valve stems for pitting, wear, or if bent. 3. Measure and verify the valve stem diameter is to specification. Stem Diameter Standard Service Limit Intake 5.480 mm (0.2157 inch) 5.318 mm (0.2094 inch) Exhaust 5.440 mm (0.2142 inch) 5.275 (0.2077 inch) g338827 Figure 148 4. Inspect the valve face for pitting, wear, or corrosion. 5. Replace the valve set if either valve is out of specification or damaged. 6.
G210–1 Valve Seat Reconditioning 1. Using a 45–46º cutter, remove enough material to produce a smooth, concentric seat. Follow the valve seat cutter manufacturer’s instructions. Note: Always turn the cutter clockwise. Continue to turn the cutter while lifting from the valve seat. g338833 Figure 150 2. Using 30–32º and 60º cutter, narrow and adjust the valve seat. The valve should contact the middle of the valve face. Ensure the width of the finished valve is to specification. Standard: 0.8 mm (0.
G210–1 Valve Lapping (continued) g338828 Figure 151 3. Apply a light coat of valve grind compound to the valve face. 4. Insert the valve into the matching valve guide. 5. Rotate the valve on the seat with the valve-lapping tool until the valve face and valve seat have smooth surfaces. 6. Repeat lapping on the other valve. 7. Use hot soapy water to remove the grinding compound from the entire cylinder head and all of the valves. 8.
G210–1 Cylinder Head Assembly (continued) g339528 Figure 152 4. Lubricate both valve stems with engine oil. 5. Install the intake and exhaust valves into the cylinder head. Note: Exhaust valve has a slightly smaller valve head. g339540 Figure 153 1. Intake Valve 2. Exhaust Valve 6. Install the valve springs and valve spring retainers. 7. Verify the notch in the valve stem is fully seated in the middle of the valve spring retainer. 8. Install the valve rotators onto the end of each valve stem.
G210–1 Cylinder Head Assembly (continued) g338831 Figure 154 9. Install the exhaust rocker arm onto the exhaust rocker arm stud. Position the rocker arm so the ball socket is over the push rod installation site. Repeat on the intake side of the cylinder head. 10. Thread the exhaust pivot nut onto the exhaust rocker arm stud until the nut contacts the rocker arm. Repeat on the intake side of the cylinder head. 11. Install the exhaust rocker arm nut onto the exhaust rocker arm stud.
G210–1 Cylinder Head Installation (continued) • Torque all of the screws to 11.3 N • m (100 in-lb) • Torque all of the screws to 22.6 N • m (200 in-lb) • Torque all of the screws to 33.9 N • m (300 in-lb) g327614 Figure 156 4. Install the 2 push rods and align the rocker arms over the push rods. If necessary, loosen the rocker lock nuts or push down on the valve spring to position the rocker arms over the push rods. Verify the 2 valve rotators are installed on each valve stem.
G210–1 Cylinder Head Installation (continued) g334746 Figure 158 5. Place the piston at the top of the compression stroke. Note: Insert a wooden dowel into the spark plug hole to verify the piston is at the top of the compression stroke. 6. Using a flat feeler gauge, check the intake and exhaust valve clearances. • To adjust the valve clearance, loosen the lock nut while holding the adjuster nut. Loosen the adjuster nut to increase the clearance or tighten the adjuster nut to decrease the clearance.
G210–1 Cylinder Head Installation (continued) g327613 Figure 159 7. Verify the rocker arms are free to rock. 8. Rotate the engine two revolutions to verify the valve train opens and closes for all four strokes. Note: The engine has ACR which opens the exhaust valve partially for a short time on compression stroke. 9. Install the new valve cover gasket to the cylinder head. 10. Install the valve cover onto the cylinder head. Install the 4 (M6 x 16) screws securing the valve cover to the cylinder head.
G210–1 Cylinder Head Installation (continued) g327610 Figure 160 12. Install the baffle onto the engine block. Install the 2 (M6 x 10) screws securing the baffle to the engine block. Torque the screws to 10 N • m (89 in-lb). g327606 Figure 161 13. Route the spark plug wire under the breather hose and install the spark plug wire to the spark plug. 14. Install the carburetor onto the cylinder head. Carburetor Installation (page 5–24) 15. Install the muffler onto the cylinder head.
G210–1 Cylinder Head Test 1. Start the engine and test the operation of the engine. 2. Using a tachometer, verify the engine is operating at the correct RPM. Specifications (page 2–2) G210–2 & G210–4 Cylinder Head Removal 1. Drain the fuel into a suitable container. 2. Remove the muffler from the cylinder head. Refer to the product Service Manual for the muffler removal procedure. 3. Remove the carburetor from the cylinder head. Carburetor Removal (page 5–6) 4.
G210–2 & G210–4 Cylinder Head Removal (continued) g327610 Figure 163 7. Remove the lower shroud from the engine block. 8. Remove the 4 (M6 x 16) screws securing the valve cover to the cylinder head. 9. Remove the valve cover from the cylinder head. Remove and discard the valve cover gasket. 10. Place the piston at the top of the compression stroke. Note: Insert a wooden dowel into the spark plug hole to verify the piston is at the top of the compression stroke. 11.
G210–2 & G210–4 Cylinder Head Removal (continued) g327607 Figure 165 g327608 Figure 166 14. Remove the 2 push rods from the engine block.
G210–2 & G210–4 Cylinder Head Removal (continued) g327611 Figure 167 CAUTION Do not use a metal scraper or wire brush to remove head gasket remnants from the cylinder head or engine block. Doing so may damage the cylinder head or engine block. 15. Using a wood or plastic scraper, remove the head gasket from the cylinder head and the engine block. G210–2 & G210–4 Cylinder Head Inspection 1. Inspect the spark plug threads for damage. Replace the spark plug if damaged. 2.
G210–2 & G210–4 Cylinder Head Inspection (continued) g327663 Figure 168 1. Straight Edge 2. Feeler Gauge G210–2 & G210–4 Cylinder Head Disassembly 1. While holding the exhaust pivot nut with a wrench, remove the exhaust rocker arm nut from the rocker arm mounting stud. Repeat on the intake side of the cylinder head. g338830 Figure 169 2. Remove the exhaust pivot nut and exhaust rocker arm. Repeat on the intake side of the cylinder head. Note: Keep the exhaust and intake parts separated. 3.
G210–2 & G210–4 Cylinder Head Disassembly (continued) g338831 Figure 170 4. Place the cylinder head with the valve side facing downwards on a shop rag. 5. Using a valve spring compressor, compress the exhaust valve spring and exhaust. Remove the valve spring from the cylinder head. Repeat on the intake side of the cylinder head. Note: Keep the exhaust and intake parts separated. 6. Remove the remaining valve components. Note: Keep the exhaust and intake components separated.
G210–2 & G210–4 Cylinder Head Rocker Arm Components Inspection 1. Clean and inspect the rocker arm nuts, pivot nuts, rocker arms, and valve rotators for damage. Replace the rocker arm assembly if components are damaged. 2. Inspect the rocker arm mounting studs for damage. Replace the rocker arm assembly if the rocker arm mounting studs are damaged. 3. Clean and inspect the guide plate. Replace the guide plate if cracked, worn, or bent. G210–2 & G210–4 Cylinder Head Valve Seat Inspection 1.
G210–2 & G210–4 Valve Guide Inspection (continued) Service Limit: 5.572 mm (0.2194 inch) G210–2 & G210–4 Valve Inspection 1. Clean the carbon from the valves. 2. Inspect the valve stem for pitting, wear, or if bent. 3. Measure and verify the valve stem diameter is to specification. Stem Diameter Standard Service Limit Intake 5.480 mm (0.2157 inch) 5.318 mm (0.2094 inch) Exhaust 5.440 mm (0.2142 inch) 5.275 (0.2077 inch) g338827 Figure 173 4.
G210–2 & G210–4 Valve Spring Inspection (continued) g338829 Figure 174 2. Inspect the valve spring for bent coils (the spring should stand straight). 3. Clean and inspect the spring retainers. Replace if damaged. G210–2 & G210–4 Valve Seat Reconditioning 1. Using a 45–46º cutter, remove enough material to produce a smooth, concentric seat. Follow the valve seat cutter manufacturer’s instructions. Note: Always turn the cutter clockwise. Continue to turn the cutter while lifting from the valve seat.
G210–2 & G210–4 Valve Lapping 1. Perform the valve lapping if any of the following were performed: • New valve • Reground valve • Valve seat was reconditioned 2. Using a hand valve-lapping tool, attach the suction cup to the end of the valve. g338828 Figure 176 3. Apply a light coat of valve grind compound to the valve face. 4. Insert the valve into the matching valve guide. 5. Rotate the valve on the seat with the valve-lapping tool until the valve face and valve seat have smooth surfaces. 6.
G210–2 & G210–4 Cylinder Head Assembly (continued) g339528 Figure 177 4. Lubricate both of the valve stems with engine oil. 5. Install the intake and exhaust valves into the cylinder head. Note: Exhaust valve has a slightly smaller valve head. g339540 Figure 178 1. Intake Valve 2. Exhaust Valve 6. Install the valve springs and valve spring retainers. 7. Verify the notch in the valve stem is fully seated in the middle of the valve spring retainer. 8.
G210–2 & G210–4 Cylinder Head Assembly (continued) g338831 Figure 179 9. Install the exhaust rocker arm onto the exhaust rocker arm stud. Position the rocker arm so the ball socket is over the push rod installation site. Repeat on the intake side of the cylinder head. 10. Thread the exhaust pivot nut onto the exhaust rocker arm stud until the nut contacts the rocker arm. Repeat on the intake side of the cylinder head. 11. Install the exhaust rocker arm nut onto the exhaust rocker arm stud.
G210–2 & G210–4 Cylinder Head Installation (continued) • Torque all of the screws to 11.3 N • m (100 in-lb) • Torque all of the screws to 22.6 N • m (200 in-lb) • Torque all of the screws to 33.9 N • m (300 in-lb) g327614 Figure 181 4. Install the 2 push rods. Align the rocker arms over the push rods. If necessary, loosen rocker lock nuts or push down on valve spring to position the rocker arms over the push rods. Verify the 2 valve rotators are installed on each valve stem.
G210–2 & G210–4 Cylinder Head Installation (continued) g334746 Figure 183 5. Place the piston at the top of the compression stroke. Note: Insert a wooden dowel into the spark plug hole to verify the piston is at the top of the compression stroke. 6. Using a flat feeler gauge, check the intake and exhaust valve clearances. • To adjust the valve clearance, loosen the lock nut while holding the adjuster nut.
G210–2 & G210–4 Cylinder Head Installation (continued) g327613 Figure 184 7. Verify the rocker arms are free to rock. 8. Rotate the engine 2 revolutions to verify the valve train opens and closes for all 4 strokes. Note: The engine has ACR which opens the exhaust valve partially for a short time on compression stroke. 9. Install the new valve cover gasket to the cylinder head. 10. Install the valve cover to the cylinder head. Install the 4 (M6 x 16) screws securing the valve cover to the cylinder head.
G210–2 & G210–4 Cylinder Head Installation (continued) g327610 Figure 185 12. Install the 2 (M6 x 10) screws securing the speed control assembly to the engine block. Torque the 2 screws to 10 N • m (89 in-lb). g340494 Figure 186 13. Route the spark plug wire under the breather hose. Install the spark plug wire to the spark plug. 14. Install the carburetor onto the cylinder head. Carburetor Installation (page 5–24) 15. Install the muffler onto the cylinder.
G210–2 & G210–4 Cylinder Head Test (continued) 2. Using a tachometer, verify the engine is operating at the correct RPM. Specifications (page 2–2) Piston and Connecting Rod Replacement Piston and Connecting Rod Removal 1. Drain the oil and fuel into a suitable container. 2. G210–1 engine models only, remove the G210–1 cylinder head. G210–1 Cylinder Head Removal (page 7–6) 3. G210–2 & G210–4 engine models only, remove the G210–2 & G210–4 cylinder head. G210–1 Cylinder Head Removal (page 7–6) 4.
Piston and Connecting Rod Removal (continued) CAUTION Do not use a metal scraper to remove the gasket. Doing so may damage the aluminum surface. 7. Using a wooden tool or liquid gasket remover, remove the remaining crankcase cover gasket from the crankcase cover and crankcase. 8. Remove and discard the oil seal from the crankcase cover. 9. Rotate the crankshaft until the timing marks are aligned. g331668 Figure 189 10. Remove the camshaft from the crankcase. 11.
Piston and Connecting Rod Removal (continued) g332955 Figure 190 g332956 Figure 191 12. Remove the 2 bolts securing the connecting rod cap to the connecting rod. Remove the connecting rod cap.
Piston and Connecting Rod Removal (continued) g338328 Figure 192 13. Rotate the crankshaft to push the piston and connecting rod assembly toward Top Center. 14. Slide and remove the connecting rod and piston from the cylinder. 15. Install the connecting rod cap to the connecting rod. Loosely install the 2 bolts. Note: This protects the bearing surface of the connecting rod if being reused. g338341 Figure 193 Piston and Connecting Rod Disassembly 1. Remove the piston clips from each side of the piston.
Piston and Connecting Rod Disassembly (continued) g338327 Figure 194 2. Remove the piston pin from the piston and connecting rod. Note: The piston pin is not a press fit into the piston or connecting rod. g338326 Figure 195 3. Slide the connecting rod out of the piston. 4. Remove the 2 bolts securing the connecting rod cap to the connecting rod. 5. Remove each piston ring from the dome end of the piston. Start with the top ring, followed by the middle ring, and then the 3 piece oil ring.
Piston and Connecting Rod Disassembly (continued) g338343 Figure 196 1. Top Ring 2. Middle Ring 3. Oil Ring Piston and Connecting Rod Inspection 1. Inspect the cylinder bore for damage. Replace the engine if the cylinder bore is damaged or out of specification. • Inspect the cylinder bore for surface wear, pitting, or scratches. • Inspect the cylinder taper and cylinder out of round. • Measure and verify the cylinder bore is to specification. Standard: 70 mm (2.7559 inch) Service Limit: 70.
Piston and Connecting Rod Inspection (continued) • Inspect both ends of the connecting rod for scuffs, pitting, or scoring. 3. Clean the end of the piston pin. Measure and verify the inside diameter of the piston pin end is to specification. Standard: 18.0 mm (0.70866 inch) Service Limit: 17.954 mm (0.70685 inch) g338336 Figure 198 4. Measure and verify the inside diameter of the crankshaft end is to specification. Standard: 30.22 mm (1.18976 inch) Service Limit: 30.246 mm (1.
Piston and Connecting Rod Inspection (continued) Standard: 0.1–0.7 mm (0.0039–0.00276 inch) Service Limit: 1.1 mm (0.04331 inch) g338339 Figure 200 6. Inspect the oil clearance (radial) of the large end of the connecting rod. • Clean the oil from the crankshaft rod journal and thrust side. • Install a piece of plastic gauge on the crankshaft rod journal. Install the connecting rod and match the cap/rod marks. Install the 2 bolts securing the connecting rod cap to the crankshaft.
Piston and Connecting Rod Inspection (continued) • If the clearance of the plastic gauge is greater than the service limit, replace the connecting rod and recheck the clearance with the new connecting rod. If the clearance still exceeds the service limit, replace the crankshaft and repeat the procedure to check the clearances of the new crankshaft. 7. Clean the piston to remove carbon and debris from the piston dome and ring lands. 8. Inspect the piston for damage. If damaged, replace the piston assembly.
Piston and Connecting Rod Inspection (continued) clearance. If the clearance is still not to specification, replace the engine assembly. Standard: 0.015–0.05 mm (0.000591–0.001969 inch) Service Limit: 0.12 mm (0.0047 inch) 12. Measure and verify the piston pin is to specification. If the piston pin is not to specification, replace the piston pin. Standard: 18.0 mm (0.70866 inch) Service Limit: 17.954 mm (0.70685 inch) g338333 Figure 204 13. Inspect the piston pin clips for damage.
Piston and Connecting Rod Inspection (continued) g338335 Figure 206 Piston Ring Thickness Ring Standard Service Limit Width (Top) 1.2 mm (0.04724 inch) 1.07 mm (0.04213 inch) Width (Middle) 1.2 mm (0.04724 inch) 1.07 mm (0.04213 inch) • Measure and verify the piston ring end gap is to specification. Standard: 0.2–0.4 mm (0.0079–0.0157 inch) Service Limit: 1.0 mm (0.0394 inch) Piston and Connecting Rod Assembly 1. Install each piston ring onto the dome end of the piston.
Piston and Connecting Rod Assembly (continued) 2. Stagger the ring gaps approximately 120º apart. 3. Install a piston pin clip into the piston so that the gap of the piston pin does not match the opening in the piston skirt g338329 Figure 208 4. Rotate the piston so the piston pin clip is facing downward. 5. Install the connecting rod cap onto the connecting rod and loosely secure with 2 bolts. Ensure the connecting rod cap and connecting rod marks are matched up. g338325 Figure 209 6.
Piston and Connect Rod Installation 1. Remove the 2 bolts securing the connecting rod cap to the connecting rod. Remove the connecting rod cap. 2. Lightly oil the piston, piston rings, cylinder walls, and crankshaft journal. 3. Using a ring compressor, insert the piston assembly into the cylinder with the piston dome triangle mark pointing downwards. 4. Push the piston into the bore until the connecting rod is at the crankshaft journal. g338344 Figure 210 5.
Piston and Connect Rod Installation (continued) g338328 Figure 211 7. Verify the piston is installed with the triangle on the piston dome pointing downwards. g338342 Figure 212 8. Verify the crankshaft and piston move by rotating the crankshaft 2 revolutions. 9. Apply engine oil to both of the entirety of the valve tappets. 10. Install the intake and exhaust valve tappets into the crankcase. Note: The intake is closest to the side cover and the exhaust is closest to the flywheel.
Piston and Connect Rod Installation (continued) g332955 Figure 213 11. Apply engine oil to the entire camshaft and install the camshaft into the crankcase matching the timing marks on the crankshaft gear. g331668 Figure 214 12. Install the 2 dowel pins into the crankcase.
Piston and Connect Rod Installation (continued) g331671 Figure 215 13. Install the new crankcase cover gasket onto the crankcase. 14. If ball bearing was removed, apply a light coat of engine oil on the outside diameter of the ball bearing. Support the crank case cover around the opening and press the ball bearing into the cover until bottomed out against the shoulder of the cover. Note: The ball bearing has a press-fit tolerance to the side cover and should not fit loosely in the crankcase cover. 15.
Piston and Connect Rod Installation (continued) g331673 Figure 216 17. Apply a light coat of engine oil onto the oil seal. Install the oil seal into the crankcase cover until just below flush. Note: Install the oil seal with the lipped side facing inward. g331669 Figure 217 18. G210–1 engine models only, install the G210–1 cylinder head. G210–1 Cylinder Head Installation (page 7–17) 19. G210–2 & G210–4 engine models only, install the G210–2 & G210–4 cylinder head.
Chapter 8 Electrical Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Flywheel Replacement (G210–1, G210–2, & G210–4) ......................................................................
General Information The Electrical chapter contains steps to remove, inspect, and install the flywheel, ignition coil & harness, key switch, and throttle turn off switch (G210-1 only). It also has steps for removal and installation of all components that need to be removed to access these electrical components.
Service and Repairs G210–1 Electrical System Assembly 1 g330761 Figure 218 1. Engine Stop Switch 5. Ignition Coil Assembly 2. Flywheel 6. Key Switch 3. Fan 7. Key 4.
G210–1 Electrical System Assembly 2 g330762 Figure 219 1. 2. Blower Shroud Control Panel Electrical: Service and Repairs 3.
G210–2 & G210–4 Electric System Assembly 1 g330763 Figure 220 1. Flywheel 4. Ignition Coil Assembly 2. Fan 5. Key Switch 3. Starter Cup 6.
G210–2 & G210–4 Electrical System Assembly 2 g330764 Figure 221 1. Blower Shroud Electrical: Service and Repairs 2.
Flywheel Replacement (G210–1, G210–2, & G210–4) G210–1 Flywheel Removal 1. Drain the fuel into a suitable container. 2. Pull and remove the throttle control knob from the speed control assembly. g333166 Figure 222 3. Remove the muffler guard from the engine block. Refer to the product Service Manual for the muffler guard removal procedures. 4. Remove the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank removal procedures. 5.
G210–1 Flywheel Removal (continued) g323698 Figure 224 7. Slide the primer hose clamp away from the primer assembly and remove the primer hose from the primer bulb base. g323701 Figure 225 1. 2. Primer Hose Clamp Primer Hose 8. Position the choke lever in the middle of the heater box slot.
G210–1 Flywheel Removal (continued) g323685 Figure 226 9. Slide and remove the heater box from the intake studs. 10. Slide the fuel hose clamp away from the carburetor. g323693 Figure 227 1. Fuel Hose 2. Fuel Hose Clamp 11. Remove the fuel hose from the carburetor. 12. Remove the fuel hose clamp from the fuel hose. 13. Remove the cap from the fuel valve knob.
G210–1 Flywheel Removal (continued) g330766 Figure 228 14. Remove the screw (M4 x 18) securing the fuel valve knob to the control panel. Remove the fuel valve knob from the fuel valve. g326084 Figure 229 15. Engines equipped with an electric starter only, remove the electric starter switch box bracket from the RH blower mount stud. 16. Remove the 2 (M6) acorn nuts securing the control panel to the blower shroud.
G210–1 Flywheel Removal (continued) g326078 Figure 230 17. Remove the control panel from the blower shroud. 18. Guide the short fuel hose through the rubber block. Remove the control panel with the fuel valve and hoses attached. g326080 Figure 231 19. Remove the 2 (M6 x 10) screws securing the speed control assembly to the blower shroud.
G210–1 Flywheel Removal (continued) g325571 Figure 232 20. Remove the 2 (M6 x 89) mount studs securing the blower shroud to the engine block. g339596 Figure 233 21. Remove the 2 (M6 x 12) screws securing the bottom blower shroud to the engine block.
G210–1 Flywheel Removal (continued) g339595 Figure 234 22. Remove the blower shroud with the recoil assembly attached. Note: Tip the blower shroud so the upper part of the blower shroud goes under the governor rod. 23. Remove the 2 (M6 x 25) screws securing the ignition coil assembly to the engine block. Move the ignition coil assembly away from the flywheel, towards the carburetor. g340492 Figure 235 24. Using a strap wrench to keep the flywheel and crankshaft from turning, remove the (M14 x 1.
G210–1 Flywheel Removal (continued) g340493 Figure 236 25. Remove the fan from the flywheel. 26. To loosen the flywheel, install the flange nut until flush with the end of the crankshaft. Pry up under the flywheel while using a plastic hammer to hit the end of the crankshaft. Note: If the flywheel does not come loose after 1 or 2 hits, rotate the flywheel to align the flywheel key to where prying. g333067 Figure 237 27. Remove the flange nut and flywheel from the engine block.
G210–1 Flywheel Removal (continued) g328427 Figure 238 28. Using a side cutter, remove the flywheel key. g328425 Figure 239 G210–1 Flywheel Inspection 1. Inspect the starter cup for burrs, nicks, cracks, anchor post damage, or if out of round. Replace the starter cup if damaged. 2. Inspect the fan for cracks, breakage, or anchor tab damage. Replace the flywheel fan if damaged. 3. Inspect the flywheel for cracks, breakage, or damage. Replace the flywheel if damaged. 4.
G210–1 Flywheel Installation 1. Clean the taper of the crankshaft and flywheel inside diameter to remove all the grease and oil. 2. Install the flywheel key into the slot on the crankshaft taper. Note: The long flat of the flywheel key should be parallel to the length of the crankshaft. g328425 Figure 240 g330765 Figure 241 1. 2. Correct Incorrect 3. Install the flywheel onto the crankshaft by aligning the keyway of the flywheel with the key in the crankshaft. 4.
G210–1 Flywheel Installation (continued) g328424 Figure 242 6. Using a strap wrench to keep the flywheel and crankshaft from turning, install the (M6) flange nut to the crankshaft. Torque the nut to 85 N • m (63 ft-lb). Note: Do not lubricate the crankshaft or threads of flange nut. 7. Loosely install the 2 (M6 x 25) screws securing the ignition coil to the engine block. Slide the ignition coil to the end of the slot away from the flywheel and tighten the screws. g340492 Figure 243 8.
G210–1 Flywheel Installation (continued) • Rotate the flywheel to align the magnets to both legs of the ignition coil. Insert the feeler gauge between the flywheel and coil legs. • Loosen both screws allowing the coil to pinch the feeler gauge to the magnets. • Tighten the 2 screws and remove the feeler gauge. • Verify the air gap is to specification. g339646 Figure 244 9. Insert the top of the blower shroud under the governor rod. 10. Install the blower shroud onto the engine block. 11.
G210–1 Flywheel Installation (continued) g339596 Figure 246 13. Route the stop switch wire between the left stud and top of the blower shroud. 14. Torque the lower blower shroud screws to 10 N • m (89 in-lb). 15. Torque the 2 mount studs to 10 N • m (89 in-lb). 16. Route the short fuel hose through the rubber block and the longer fuel hose toward the fuel tank. g326080 Figure 247 17. Install the clamp onto the short fuel hose located near the carburetor. 18.
G210–1 Flywheel Installation (continued) g323693 Figure 248 1. Fuel Hose 2. Fuel Hose Clamp 19. Install the control panel onto the mount studs. Install the 2 (M6) acorn nuts securing the control panel to the engine block. Torque the acorn nuts to 10 N • m (89 in-lb). Note: Verify the fuel hoses are not kinked or pinched. Verify ground wire is routed between the blower shroud and mount studs.
G210–1 Flywheel Installation (continued) g326142 Figure 250 1. Ground Wire 20. Engines equipped with an electric starter only, install the electric starter switch box bracket to the blower shroud, retain with an (M6) acorn nut. 21. Install the fuel valve knob on the fuel valve, retain with a screw (M4 x 18). Torque the screw to 2 N • m (18 in-lb). Install the cap onto the fuel valve knob. g326081 Figure 251 22. Install the speed control assembly onto the blower shroud.
G210–1 Flywheel Installation (continued) g325571 Figure 252 23. Install the throttle control knob to the speed control assembly. g325572 Figure 253 24. Verify the metal carburetor gasket is positioned correctly on the intake studs.
G210–1 Flywheel Installation (continued) g323683 Figure 254 25. Slide the choke lever to partial choke. Install the heater box partially onto the intake studs and over the choke lever. g323685 Figure 255 26. Install the primer hose onto the primer bulb base and secure with the primer hose clamp.
G210–1 Flywheel Installation (continued) g323701 Figure 256 1. 2. Primer Hose Clamp Primer Hose 27. Connect the 2 wires to the key switch terminals. Note: Ensure the wires are not crossed. g323698 Figure 257 28. Fully slide the heater box onto the intake studs. Install the 2 (M6) flange nuts securing the heater box to the intake studs. Torque the nuts to 10 N • m (89 in-lb).
G210–1 Flywheel Installation (continued) g323684 Figure 258 29. Install the fuel tank onto the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 30. Install the muffler guard onto the cylinder head. Refer to the product Service Manual for the muffler guard installation procedures. G210–1 Flywheel Test 1. Start the engine and test the operation of the engine. 2. Test the throttle control by sliding the throttle full stroke. 3.
G210–2 & G210–4 Flywheel Removal (continued) 2. Engines equipped with an electric starter only, remove the bolt securing the electric starter switch box bracket to the blower shroud. Remove the electric starter switch box bracket. 3. Remove the control panel from the blower shroud. 4. Remove the 2 (M6 x 89) mount studs securing the blower shroud to the engine block. g328138 Figure 260 5. Remove the 2 (M6 x 12) screws securing the bottom of the blower shroud to the engine block. g328137 Figure 261 6.
G210–2 & G210–4 Flywheel Removal (continued) g328136 Figure 262 8. Using a strap wrench to keep the flywheel and crankshaft from turning, remove the (M14 x 1.5) flange nut securing the starter cup to the flywheel. Remove the starter cup from the fan. g328426 Figure 263 9. Remove the fan from the flywheel. 10. To loosen the flywheel, install the flange nut until flush with the end of the crankshaft. Pry up under the flywheel while using a plastic hammer to hit the end of the crankshaft.
G210–2 & G210–4 Flywheel Removal (continued) g340732 Figure 264 11. Remove the flange nut and flywheel from the engine block. g328427 Figure 265 12. Using a side cutter, remove the flywheel key.
G210–2 & G210–4 Flywheel Removal (continued) g328425 Figure 266 G210–2 & G210–4 Flywheel Inspection 1. Inspect the starter cup for burrs, nicks, cracks, anchor post damage, or if out of round. Replace the starter cup if damaged. 2. Inspect the fan for cracks, breakage, or anchor tab damage. Replace the flywheel fan if damaged. 3. Inspect the flywheel for cracks, breakage, or damage. Replace the flywheel if damaged. 4. Inspect the crankshaft threads and keyway for damage.
G210–2 & G210–4 Flywheel Installation (continued) g328425 Figure 267 g330765 Figure 268 1. 2. Correct Incorrect 3. Install the flywheel onto the crankshaft by aligning the keyway of the flywheel with the key in the crankshaft. 4. Match up the 3 alignment tabs to the holes in the flywheel and install the fan on the flywheel . 5. Match up the alignment tab of the starter cup to the hole in the flywheel.
G210–2 & G210–4 Flywheel Installation (continued) g328424 Figure 269 6. Using a strap wrench to keep the flywheel and crankshaft from turning, install the (M6) flange nut to the crankshaft. Torque the nut to 85 N • m (63 ft-lb). Note: Do not lubricate the crankshaft or threads of the flange nut. 7. Loosely install the 2 (M6 x 25) screws securing the ignition coil to the engine block. Slide the ignition coil to the end of the slot away from flywheel and tighten the screws. g328136 Figure 270 8.
G210–2 & G210–4 Flywheel Installation (continued) • Rotate the flywheel to align the magnets to both legs of the ignition coil. Insert the feeler gauge between the flywheel and coil legs. • Loosen both screws allowing the coil to pinch the feeler gauge to the magnets. • Tighten the 2 screws and remove the feeler gauge. • Verify the air gap is to specification. g339646 Figure 271 9. Insert the top of the blower shroud under the governor rod. 10. Install the blower shroud onto the engine block. 11.
G210–2 & G210–4 Flywheel Installation (continued) 12. Loosely install the 2 (M6 x 89) mount studs securing the top of the blower shroud to the engine block. g328138 Figure 273 13. Torque the lower blower shroud screws to 10 N • m (89 in-lb). 14. Torque the 2 mount studs to 10 N • m (89 in-lb). 15. Install the control panel onto the mount studs. 16. Engines equipped with an electric starter only, install the electric starter switch box bracket onto the RH blower mount stud. 17.
G210–2 & G210–4 Flywheel Test 1. Start the engine and test the operation of the engine. 2. Using a tachometer, verify the engine is operating at the correct RPM. Specifications (page 2–2) Ignition Coil Replacement (G210–1, G210–2, & G210–4) G210–1 Ignition Coil Removal 1. Drain the fuel into a suitable container. 2. Pull and remove the throttle control knob from the speed control assembly. g333166 Figure 275 3. Remove the muffler guard from the engine block.
G210–1 Ignition Coil Removal (continued) 6. Disconnect the 2 wires from the back of the key switch. g323698 Figure 277 7. Slide the primer hose clamp away from the primer assembly. Remove the primer hose from the primer bulb base. g323701 Figure 278 1. 2. Primer Hose Clamp Primer Hose 8. Position the choke lever in the middle of the heater box slot.
G210–1 Ignition Coil Removal (continued) g323685 Figure 279 9. Slide and remove the heater box from the intake studs. 10. Slide the fuel hose clamp away from the carburetor. g323693 Figure 280 1. Fuel Hose 2. Fuel Hose Clamp 11. Remove the fuel hose from the carburetor. 12. Remove the fuel hose clamp from the fuel hose. 13. Remove the cap from the fuel valve knob.
G210–1 Ignition Coil Removal (continued) g330766 Figure 281 1. Cap 14. Remove the (M4 x 18) screw securing the fuel valve knob to the control panel. Remove the fuel valve knob from the fuel valve. g326084 Figure 282 15. Remove the 2 (M6) acorn nuts securing the control panel to the blower shroud.
G210–1 Ignition Coil Removal (continued) g326078 Figure 283 16. Engines equipped with an electric starter only, remove the electric starter switch box bracket from the RH blower mount stud. 17. Remove the control panel from the blower shroud. 18. Guide the short fuel hose through the rubber block. Remove the control panel with the fuel valve and hoses attached. g326080 Figure 284 19. Remove the 2 (M6 x 10) screws securing the speed control assembly to the blower shroud.
G210–1 Ignition Coil Removal (continued) g325571 Figure 285 20. Remove the 2 (M6 x 89) mount studs securing the blower shroud to the engine block. g339596 Figure 286 21. Remove the 2 (M6 x 12) screws securing the bottom of the blower shroud to the engine block.
G210–1 Ignition Coil Removal (continued) g339595 Figure 287 22. Remove the blower shroud with the recoil assembly attached. Note: Tip the blower shroud so the upper part of the blower shroud goes under the governor rod. 23. Remove the 2 (M6 x 25) screws securing the ignition coil assembly to the engine block. g340492 Figure 288 24. Remove the spark plug wire from the spark plug. 25. Remove the wires from the stop switch on the heater box. 26.
G210–1 Ignition Coil Removal (continued) g340731 Figure 289 27. Remove the stop wire connected to the throttle control switch. 28. Remove the ignition coil from the engine block. g340733 Figure 290 G210–1 Ignition Coil Test 1. Using a digital volt ohm meter (set to ohms), place one lead on the ignition coil spade connector and the other lead on the ignition coil frame. Verify the primary circuit resistance is to specification. Primary Circuit Resistance: 1.0–1.
G210–1 Ignition Coil Test (continued) g340717 Figure 291 2. Using a digital volt ohm meter (set to ohms), place one lead inside the spark plug connector and the other lead on the ignition coil frame. Verify the secondary circuit resistance is to specification. Secondary Circuit Resistance: 5.1–6.1 Ω g340718 Figure 292 G210–1 Ignition Coil Installation 1. Weave the wire harness under the fuel line and over the top of the carburetor insulator gasket. Route the spark plug wire under the breather hose.
G210–1 Ignition Coil Installation (continued) g340731 Figure 293 2. Route and connect the stop wire to the throttle control switch. 3. Loosely install the 2 (M6 x 25) screws securing the ignition coil to the engine block. Slide the ignition coil to the end of the slot away from the flywheel and tighten the screws. g340492 Figure 294 4. Using a non-metallic feeler gauge, adjust the air gap between the ignition coil and the flywheel to 0.4 mm (0.016 inch). Torque the screws 10 N • m (89 in-lb).
G210–1 Ignition Coil Installation (continued) g339646 Figure 295 5. Insert the top of the blower shroud under the governor rod. 6. Install the blower shroud onto the engine block. 7. Loosely install the 2 (M6 x 12) screws securing the bottom of the blower shroud to the engine block. g339595 Figure 296 8. Loosely install the 2 (M6 x 89) mount studs securing the top of the blower shroud to the engine block.
G210–1 Ignition Coil Installation (continued) g339596 Figure 297 9. Route the stop switch wire between the left stud and top of the blower shroud. 10. Torque the lower blower shroud screws to 10 N • m (89 in-lb). 11. Torque the mount studs to 10 N • m (89 in-lb). 12. Route the short fuel hose through the rubber block and the longer fuel hose toward the fuel tank. g326080 Figure 298 13. Install the clamp onto the fuel hose located near the carburetor. 14.
G210–1 Ignition Coil Installation (continued) g323693 Figure 299 1. Fuel Hose 2. Fuel Hose Clamp 15. Install the control panel onto the mount studs. 16. Engines equipped with an electric starter only, install the electric starter switch box bracket onto the RH blower mount stud. 17. Install the 2 (M6) acorn nuts securing the control panel to the engine block. Torque the nuts to 10 N • m (89 in-lb). Note: Verify the fuel hoses are not kinked or pinched.
G210–1 Ignition Coil Installation (continued) g326142 Figure 301 1. Ground Wire 18. Install the fuel valve knob on the fuel valve, retain with a screw (M4 x 18). Torque the screw to 2 N • m (18 in-lb). Install the cap onto the fuel valve knob. g326081 Figure 302 19. Install the speed control assembly onto the blower shroud. Install the 2 (M6 x 10) screws securing the speed control assembly to the blower shroud. Torque the screws to 10 N • m (89 in-lb).
G210–1 Ignition Coil Installation (continued) g325571 Figure 303 20. Install the throttle control knob to the speed control assembly. g325572 Figure 304 21. Verify the metal carburetor gasket is positioned correctly on the intake studs.
G210–1 Ignition Coil Installation (continued) g323683 Figure 305 22. Slide the choke lever to partial choke. Install the heater box partially onto intake studs and over choke lever. g323685 Figure 306 23. Install the primer hose onto the primer bulb base, secure with the primer hose clamp.
G210–1 Ignition Coil Installation (continued) g323701 Figure 307 1. 2. Primer Hose Clamp Primer Hose 24. Connect the 2 wires to the key switch terminals. Note: Verify the wires are not crossed. g323698 Figure 308 25. Fully slide the heater box onto the intake studs. Install the 2 (M6) flange nuts securing the heater box to the intake studs. Torque the nuts to 10 N • m (89 in-lb).
G210–1 Ignition Coil Installation (continued) g323684 Figure 309 26. Install the fuel tank onto the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 27. Install the muffler guard onto the cylinder head. Refer to the product Service Manual for the muffler guard installation procedures. 28. Install the spark plug boot onto the spark plug.
G210–2 & G210–4 Ignition Coil Removal (continued) g323698 Figure 311 4. Slide the primer hose clamp away from primer assembly. Remove the primer hose from the primer bulb base. g323701 Figure 312 1. 2. Primer Hose Clamp Primer Hose 5. Position the choke lever in the middle of the heater box slot.
G210–2 & G210–4 Ignition Coil Removal (continued) g323685 Figure 313 6. Slide and remove the heater box from the intake studs. 7. Remove the 2 (M6) acorn nuts securing the control panel to the blower shroud. g328134 Figure 314 8. Engines equipped with an electric starter only, remove the electric starter switch box bracket from the RH blower mount stud. 9. Remove the control panel from the blower shroud. 10. Remove the 2 (M6 x 89) mount studs securing the blower shroud to the engine block.
G210–2 & G210–4 Ignition Coil Removal (continued) g326145 Figure 315 11. Remove the 2 (M6 x 12) screws securing the bottom of the blower shroud to the engine block. g328137 Figure 316 12. Remove the blower shroud with the recoil assembly attached. Note: Tip the blower shroud so the upper part of the blower shroud goes under the governor rod. 13. Remove the 2 (M6 x 25) screws securing the ignition coil assembly to the engine block.
G210–2 & G210–4 Ignition Coil Removal (continued) g328136 Figure 317 14. Remove the spark plug wire from the spark plug. 15. Remove the wires from the stop switch on the heater air box. 16. Remove the wire harness from the carburetor insulator gasket. 17. Remove the ignition coil from the engine block. g328135 Figure 318 G210–2 & G210–4 Ignition Coil Test 1. Using a digital volt ohm meter (set to ohms), place one lead on the ignition coil spade connector and the other lead on the ignition coil frame.
G210–2 & G210–4 Ignition Coil Test (continued) g340717 Figure 319 2. Using a digital volt ohm meter (set to ohms), place one lead inside the spark plug connector and the other lead on the ignition coil frame. Verify the secondary circuit resistance is to specification. Secondary Circuit Resistance: 5.1–6.1 Ω g340718 Figure 320 G210–2 & G210–4 Ignition Coil Installation 1. Weave the wire harness under the fuel line and over the top of the carburetor insulator gasket.
G210–2 & G210–4 Ignition Coil Installation (continued) g328139 Figure 321 2. Loosely install the 2 (M6 x 25) screws securing the ignition coil to the engine block. Slide the ignition coil to the end of the slot away from the flywheel and tighten the screws. g328136 Figure 322 3. Using a non-metallic feeler gauge, adjust the air gap between the ignition coil and the flywheel to 0.4 mm (0.016 inch). Torque the screws 10 N • m (89 in-lb).
G210–2 & G210–4 Ignition Coil Installation (continued) g339646 Figure 323 4. Insert the top of the blower shroud under the governor rod. 5. Install the blower shroud onto the engine block. 6. Loosely install the 2 (M6 x 12) screws securing the bottom of the blower shroud to the engine block. g328137 Figure 324 7. Loosely install the 2 (M6 x 89) mount studs securing the top of the blower shroud to the engine block.
G210–2 & G210–4 Ignition Coil Installation (continued) g326145 Figure 325 8. Torque the lower blower shroud screws to 10 N • m (89 in-lb). 9. Torque the mount studs to 10 N • m (89 in-lb). 10. Install the control panel onto the mount studs. 11. Engines equipped with an electric starter only, install the electric starter switch box bracket onto the RH blower mount stud. 12. Install the 2 (M6) acorn nuts securing the control panel to the engine block. Torque the nuts to 10 N • m (89 in-lb).
G210–2 & G210–4 Ignition Coil Installation (continued) g323683 Figure 327 14. Slide the choke lever to partial choke. Install the heater box partially onto intake studs and over choke lever. g323685 Figure 328 15. Install the primer hose onto the primer bulb base, secure with the primer hose clamp.
G210–2 & G210–4 Ignition Coil Installation (continued) g323701 Figure 329 1. 2. Primer Hose Clamp Primer Hose 16. Connect the 2 wires to the key switch terminals. Note: Verify the wires are not crossed. g323698 Figure 330 17. Fully slide the heater box onto the intake studs. Install the 2 (M6) flange nuts securing the heater box to the intake studs. Torque the nuts to 10 N • m (89 in-lb).
G210–2 & G210–4 Ignition Coil Installation (continued) g323684 Figure 331 18. Install the muffler guard onto the cylinder head. Refer to the product Service Manual for the muffler guard installation procedures. 19. Install the spark plug boot onto the spark plug. Note: Verify the spark plug wire is positioned correctly into the carburetor insulator gasket and routed under the breather hose. Key Switch Replacement Key Switch Removal 1. Remove the key from the key switch. g339647 Figure 332 2.
Key Switch Removal (continued) g323698 Figure 333 4. Squeeze and slide the key switch from the heater box. Key Switch Installation 1. Install the key switch into the heater box. 2. Connect the 2 wires to the back of the key switch terminals Note: Verify the wires are not crossed. g323698 Figure 334 3. Install the muffler guard onto the cylinder head. Refer to the product Service Manual for the muffler guard installation procedures. 4. Install the key into the key switch.
Key Switch Installation (continued) g339647 Figure 335 Key Switch Test 1. Start the engine. 2. Remove the key to stop the engine and verify the key switch function. G210–1 Stop Switch Replacement G210–1 Stop Switch Removal 1. Drain the fuel into a suitable container. 2. Remove the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank removal procedures. 3. Remove the (M4 x 10) screw securing the stop switch to the speed control assembly. g330206 Figure 336 4.
G210–1 Stop Switch Removal (continued) g330208 Figure 337 5. Remove the stop switch from the speed control assembly. g330207 Figure 338 G210–1 Stop Switch Installation 1. Install the stop switch wire to the stop switch.
G210–1 Stop Switch Installation (continued) g330208 Figure 339 2. Match the pin on the bottom of the stop switch to the hole in the speed control assembly. 3. Install the (M4 x 10) screw securing the stop switch to the speed control assembly. g330206 Figure 340 4. Install the fuel tank onto the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 5. Refill the fuel. G210–1 Stop Switch Test 1. Start the engine. 2.
Chapter 9 Engine Lower End Table of Contents General Information .............................................................................................................................. 9–2 Service and Repairs ............................................................................................................................. 9–3 Crankcase Cover Replacement ......................................................................................................... 9–6 Camshaft Replacement ......
General Information The Engine Lower End chapter contains steps to remove, inspect, and install the internal components of the crankcase and components mounted to the crankcase. The components include the crankshaft, bearings & seals, camshaft & followers, governor shaft & governor gear assembly, and crankcase cover & oil drain pipe.
Service and Repairs G210–1 Crankcase Cover Assembly g331498 Figure 341 1. Oil Dipstick 2. Drain Plug 7. Crankcase 3. 4. 5. Crankcase Cover Crankcase Cover Gasket Crankshaft 8. 9. Camshaft Oil Drain Tube G210 Engine Service Manual 3439-732 Rev A 6.
G210–2 Crankcase Cover Assembly g331499 Figure 342 1. Oil Dipstick 2. Drain Plug 7. Crankcase 3. 4. 5. Crankcase Cover Crankcase Cover Gasket Crankshaft 8. 9. Camshaft Oil Drain Tube Engine Lower End: Service and Repairs 6.
G210–4 Crankcase Cover Assembly g331500 Figure 343 1. Crankcase Cover 5. Woodruff Key 2. 3. Crankcase Cover Gasket Oil Dipstick 6. 7. Crankcase Camshaft 4.
Crankcase Cover Replacement Crankcase Cover Removal 1. Drain the oil into a suitable container. 2. Clean the crankshaft of rust and debris. 3. Place the piston at the top of the compression stroke. Note: Insert a wooden dowel into the spark plug hole to verify the piston is at the top of the compression stroke. 4. Remove the 6 (M8 x 32) screws securing the crankcase cover to the crankcase. g331674 Figure 344 5.
Crankcase Cover Removal (continued) CAUTION Do not use a metal scraper to remove the gasket. Doing so may damage the aluminum surface. 8. Using a wooden tool or liquid gasket remover, remove the crankcase cover gasket from the crankcase cover and crankcase. 9. Remove and discard the oil seal from the crankcase cover. Crankcase Cover Inspection 1. Clean and inspect both the crankcase cover and crankcase surfaces for nicks and deep scratches. 2. Inspect the crankcase cover for cracks or warpage.
Crankcase Cover Installation (continued) g331671 Figure 347 4. Install the new crankcase cover gasket over the dowels and onto the crankcase. 5. Lightly apply engine oil to the outside diameter of the ball bearing. Support the crankcase cover around the opening and press the bearing into the cover until bottomed out against the shoulder of the cover. Note: The ball bearing has a press-fit tolerance to the side cover and should not fit loosely in the crankcase cover. 6.
Crankcase Cover Installation (continued) g331673 Figure 348 8. Apply a light coat of engine oil onto the oil seal. Install the oil seal into the crankcase cover until just below flush. Note: Install the oil seal with the lip side facing inward. g331669 Figure 349 9. Refill the oil. Crankcase Cover Test 1. Test run the engine and verify no oil leaks exist. Camshaft Replacement Camshaft Removal 1. Drain the oil into a suitable container. 2.
Camshaft Removal (continued) 3. Remove the valve cover from the cylinder head. Remove and discard the valve cover gasket. 4. Place the piston at the top of the compression stroke. Note: Insert a wooden dowel into the spark plug hole to verify the piston is at the top of the compression stroke. 5. Move the rocker arms to the side and remove the push rods. g327612 Figure 350 6. Clean the crankshaft of rust and debris. 7. Remove the 6 (M8 x 32) screws securing the crankcase cover to the crankcase.
Camshaft Removal (continued) g331672 Figure 352 CAUTION Do not use a metal scraper to remove the gasket. Doing so may damage the aluminum surface. 10. Using a wooden tool or liquid gasket remover, remove the remaining crankcase cover gasket from the crankcase cover and crankcase. 11. Remove and discard the oil seal from the crankcase cover. 12. Rotate the crankshaft until the timing marks are aligned. g331668 Figure 353 13. Remove the camshaft from the crankcase.
Camshaft Removal (continued) g340489 Figure 354 14. Mark the intake and exhaust valve tappets using a permanent marker. Remove the 2 valve tappets from the crankcase. Note: The intake is closest to the crankcase cover and exhaust is closest to the flywheel.
Camshaft Removal (continued) g332956 Figure 356 Camshaft Inspection 1. Verify the automatic compression release (ACR) is free to move. 2. Inspect the cam gear teeth for damage. Replace the camshaft if damaged. 3. Verify both of the cam lobes are to specification. If not to specification, replace the camshaft. Intake Lobe Standard: 27.70 mm (1.0.9055 inches) Intake Lobe Service Limit: 27.45 mm (1.08071 inches) Exhaust Lobe Standard: 27.75 mm (1.09252 inches) Exhaust Lobe Service Limit: 27.50 mm (1.
Camshaft Inspection (continued) Standard: 13.984 mm (0.55055 inch) Service Limit: 13.916 mm (0.54787 inch) g338941 Figure 358 5. Inspect the crankcase cover. Crankcase Cover Inspection (page 9–7) 6. Verify the camshaft bearing in the crankcase cover is to specification. Replace crankcase cover if out of specification. Standard: 14 mm (0.55118 inch) Service Limit: 14.048 mm (0.55307 inch) 7. Inspect the push rods. If the push rods are bent or worn, replace the push rods. 8.
Camshaft Installation (continued) g332955 Figure 359 3. Apply engine oil to the entire camshaft. Install the camshaft into the crankcase matching the timing marks on the crankshaft gear. g331668 Figure 360 4. Install the 2 dowel pins into the crankcase.
Camshaft Installation (continued) g331671 Figure 361 5. Install the new crankcase cover gasket onto the crankcase. 6. If ball bearing was removed, apply a light coat of engine oil on the outside diameter of the ball bearing. Support the crank case cover around the opening and press the ball bearing into the cover until bottomed out against the shoulder of the cover. Note: The ball bearing has a press-fit tolerance to the side cover and should not fit loosely in the crankcase cover. 7.
Camshaft Installation (continued) g331673 Figure 362 9. Apply a light coat of engine oil onto the oil seal. Install the oil seal into the crankcase cover until just below flush. Note: Install the oil seal with the lipped side facing inward. g331669 Figure 363 10. Install the 2 push rods and align the rocker arms over the push rods. If necessary, loosen the rocker lock nuts or push down on the valve spring to position the rocker arms over the push rods.
Camshaft Installation (continued) g327612 Figure 364 g334746 Figure 365 11. Place the piston at the top of the compression stroke. Note: Insert a wooden dowel into the spark plug hole to verify the piston is at the top of the compression stroke. 12. Using a flat feeler gauge, check the intake and exhaust valve clearances. • To adjust the valve clearance, loosen the lock nut while holding the adjuster nut.
Camshaft Installation (continued) Intake Valve Clearance: 0.13–1.17 mm (0.005–0.007 inch) Exhaust Valve Clearance: 0.18–0.22 mm (0.007–0.009 inch) g327613 Figure 366 13. Verify the rocker arms are free to rock. 14. Rotate the engine 2 revolutions to verify the valve train opens and closes for all 4 strokes. Note: The engine has ACR opens the exhaust valve partially for a short time on compression stroke. 15. Install the new valve cover gasket to the cylinder head. 16.
Crankshaft Removal (continued) g333029 Figure 367 7. Rotate the crankshaft to push the piston and rod to Top Center. 8. Rotate the crankshaft to move the end of the rod away from the crankshaft. g333032 Figure 368 9. Slide and remove the crankshaft from crankcase. Note: G210–1, G210–2, and G210–4 engine models have different versions crankshafts.
Crankshaft Removal (continued) g340489 Figure 369 10. Remove the oil seal from the outside of the crankcase and discard. g334871 Figure 370 11. Remove the ball bearing from the crankcase. Note: The ball bearing has a press-fit tolerance to the crankcase and should not fit loosely.
Crankshaft Removal (continued) g334870 Figure 371 Crankshaft Inspection 1. Inspect the 3 crankshaft bearing surfaces for wear, pits, or other damage. Replace the crankshaft if damaged. 2. Measure and verify the crankshaft rod journal is to specification. Replace the crankshaft if not to specification. Standard: 30.16 mm (1.18740 inch) Service Limit: 30.1 mm (118503 inch) g333033 Figure 372 3. Inspect the timing gear teeth for damage. Replace the crankshaft if the timing gear teeth are damaged. 4.
Crankshaft Installation (continued) 2. Apply a light coat of engine oil to the outside diameter of the ball bearing. Support the crankcase housing around the opening and press the ball bearing into the crankcase until bottomed out against the shoulder of the crankcase. g334870 Figure 373 3. Clean the 3 crankshaft journals and lightly coat with engine oil. 4. Install the crankshaft by slowly sliding the crankshaft through the ball bearing on the flywheel side of the crankcase. 5.
Crankshaft Installation (continued) g333030 Figure 375 7. Loosely install the 2 connecting rod bolts securing the connecting rod cap to the journal. Torque the bolts alternating pattern in the specification order below. • 5 N • m (44 in-lb) • 10 N • m (88 in-lb) • 14 N • m (124 in-lb). g338328 Figure 376 8. Install the camshaft onto the engine block. Camshaft Installation (page 9–14) 9. Apply a light coat of engine oil to the inner diameter of the oil seal.
Crankshaft Installation (continued) g334871 Figure 377 10. G210–1 engine models only, install the G210–1 flywheel. G210–1 Flywheel Installation (page 8–16) 11. G210–2 & G210–4 engine models only, install the G210–2 & G210–4 flywheel. G210–2 & G210–4 Flywheel Installation (page 8–29) 12. Refill the oil. Crankshaft Test 1. Test run the engine and verify no oil leaks exist. Oil Drain Replacement (G210–1, G210–2, & G210–4) G210–1 & G210–2 Oil Drain Removal 1. Remove the (M10 x 1.
G210–1 & G210–2 Oil Drain Removal (continued) 2. Remove the (M10 x 1.25) screw and washer from the engine block. g336027 Figure 379 3. Remove the oil drain tube and washer from engine block. g336016 Figure 380 G210–1 & G210–2 Oil Drain Inspection 1. Clean and inspect the cylinder block threads and surrounding cylinder casting for damage. Replace the engine if damaged. 2. Clean and inspect the oil drain tube and the threads on both ends. Replace the oil drain tube if damaged. 3.
G210–1 & G210–2 Oil Drain Installation 1. Apply pipe thread sealant suitable for high temperatures to the oil drain tube threads. 2. Install the washer onto the oil drain tube. Install the oil drain tube into the engine block. Torque the oil drain tube to 22 N • m (195 in-lb). g336016 Figure 381 3. Install the (M10 x 1.25) screw and washer onto the oil drain tube. Torque the screw to 22 N • m (195 in-lb). g336013 Figure 382 4. Install the (M10 x 1.25) screw and washer onto the engine block. 5.
G210–4 Oil Drain Removal 1. Remove the (M10 x 1.25) screw and washer from each side of the engine block. g336014 Figure 383 2. Drain the oil into a suitable container. G210–4 Oil Drain Inspection 1. Clean and inspect the screws for damage. Replace if damaged. 2. Clean and inspect the washers for damage. Replace if damaged. G210–4 Oil Drain Installation 1. Install the (M10 x 1.25) screw and washer onto each side of the engine block. Torque the screw to 22 N • m (195 in-lb). g336014 Figure 384 2.
Governor Gear Assembly Replacement (G210–1, G210–2, & G210–4) G210–1 Governor Gear Assembly Removal 1. Drain the fuel and oil into a suitable container. 2. Remove the G210–1 flywheel. G210–1 Flywheel Removal (page 8–7) 3. Unhook the governor spring from the governor arm and speed control assembly. g325633 Figure 385 4. Loosen the (M6) flange nut secured to the governor arm bolt. Remove the governor arm off of the governor shaft.
G210–1 Governor Gear Assembly Removal (continued) g337344 Figure 387 6. Remove the crankcase cover from the engine block. Crankcase Cover Removal (page 9–6) 7. Rotate the crankshaft to access the governor gear assembly. 8. Rotate the governor shaft away from the governor spool. Note: Do not rotate the crankshaft. Damage to the governor shaft may occur. g337343 Figure 388 9. Place a shop towel inside the crankcase to catch the governor gear assembly. 10.
G210–1 Governor Gear Assembly Removal (continued) g337341 Figure 389 12. Remove the shop towel and governor gear assembly. Note: There are 2 types of governor gear assemblies. One with a plastic spool and one with a metal spool.
G210–1 Governor Gear Assembly Removal (continued) g337340 Figure 391 G210–1 Governor Gear Assembly Inspection 1. Clean and inspect the hole in the crankcase where the governor gear assembly was installed. If damage exists, replace the engine. 2. If installing a used governor gear assembly, inspect the components below. If any components are damaged, obtain a new governor gear assembly. • Inspect the gear teeth for wear or damage. • Inspect the center bore if worn or loose on shaft.
G210–1 Governor Gear Assembly Installation (continued) g337342 Figure 392 6. Place the governor gear assembly into the crankcase and verify the teeth of the governor gear assembly mesh with the crankshaft gear. 7. Press the governor gear assembly into the crankcase. Verify the clearance between the washer and the crankcase is 0.05–0.35 mm (0.002–0.013 inch). 8. If installing the plastic spool, install the washer and plastic spool on the governor gear shaft. 9.
G210–1 Governor Gear Assembly Installation (continued) g337344 Figure 394 12. Remove the spark plug from cylinder head and rotate the crankshaft 360º to verify the governor gear assembly rotates freely. 13. Verify the camshaft timing mark is matched up to the crankshaft timing mark. g331668 Figure 395 14. Install the spark plug into cylinder head. Torque the spark plug to 29 N • m (21 ft-lb). 15. Install the crankcase cover. Crankcase Cover Installation (page 9–7) 16.
G210–1 Governor Gear Assembly Installation (continued) g325632 Figure 396 17. Connect the governor spring to the governor arm and speed control assembly. g325633 Figure 397 18. Zero the governor. Zeroing the Governor (page 6–16) 19. Install the G210–1 flywheel. G210–1 Flywheel Installation (page 8–16) 20. Refill the fuel and oil. 21. Set Top No Load RPM. Top No Load RPM (page 6–18) G210–1 Governor Gear Assembly Test 1. Start and run the engine to verify Top No Load RPM. Specifications (page 2–2) 2.
G210–2 & G210–4 Governor Gear Assembly Removal (continued) 2. Remove the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank removal procedures. 3. Unhook the governor spring from the governor arm. g325636 Figure 398 4. Loosen the (M6) flange nut secured to the governor arm bolt. Slide the governor arm off of the governor shaft. Note: A small flat bladed screwdriver can be used to pry the clamp open to allow arm to lift up more easily g325635 Figure 399 5.
G210–2 & G210–4 Governor Gear Assembly Removal (continued) g337344 Figure 400 6. Remove the G210–2 & G210–4 flywheel. G210–2 & G210–4 Flywheel Removal (page 8–25) 7. Remove the crankcase cover from the engine block. Crankcase Cover Removal (page 9–6) 8. Rotate the crankshaft to access the governor gear assembly. 9. Rotate the governor shaft away from the governor spool. Note: Do not rotate the crankshaft. Damage to the governor shaft may occur. g337343 Figure 401 10.
G210–2 & G210–4 Governor Gear Assembly Removal (continued) g337341 Figure 402 13. Remove the shop towel and governor gear assembly. Note: There are 2 types of governor gear assemblies. One with a plastic spool and one with a metal spool.
G210–2 & G210–4 Governor Gear Assembly Removal (continued) g337340 Figure 404 G210–2 & G210–4 Governor Gear Assembly Inspection 1. Clean and inspect the hole in the crankcase where the governor gear assembly was installed. If damage exists, replace the engine. 2. If installing a used governor gear assembly, inspect the components below. If any components are damaged, obtain a new governor gear assembly. • Inspect the gear teeth for wear or damage. • Inspect the center bore if worn or loose on shaft.
G210–2 & G210–4 Governor Gear Assembly Installation (continued) g337342 Figure 405 6. Place the governor gear assembly into the crankcase and verify the teeth of the governor gear assembly are mesh with the crankshaft gear. 7. Press the governor gear assembly into the crankcase. Verify the clearance between the washer and the crankcase is 0.05–0.35 mm (0.002–0.013 inch). 8. If installing the plastic spool, install the washer and plastic spool on the governor gear shaft. 9.
G210–2 & G210–4 Governor Gear Assembly Installation (continued) g337344 Figure 407 12. Remove the spark plug from cylinder head and rotate the crankshaft 360º to verify the governor gear assembly rotates freely. 13. Verify the camshaft timing mark is matched up to the crankshaft timing mark. g331668 Figure 408 14. Install the crankcase cover. Crankcase Cover Installation (page 9–7) 15. Install the spark plug into cylinder head. Torque the spark plug to 29 N • m (21 ft-lb). 16.
G210–2 & G210–4 Governor Gear Assembly Installation (continued) g325635 Figure 409 17. Connect the governor spring to the governor arm and speed control assembly. g325636 Figure 410 18. Zero the governor. Zeroing the Governor (page 6–16) 19. Install the G210–2 & G210–4 flywheel. G210–2 & G210–4 Flywheel Installation (page 8–29) 20. Install the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 21. Refill the fuel and oil. 22.
Governor Shaft Replacement (G210–1, G210–2, & G210–4) G210–1 Governor Shaft Removal 1. Drain the fuel and oil into a suitable container. 2. Remove the crankshaft from the engine block. Crankshaft Removal (page 9–19) 3. Remove the fuel tank from the engine block. Refer to the product Service Manual for the fuel tank removal procedures. 4. Unhook the governor spring from the governor arm. g325633 Figure 411 5. Loosen the (M6) flange nut secured to the governor arm bolt.
G210–1 Governor Shaft Removal (continued) g337344 Figure 413 7. Remove the governor shaft and washer from the inside of the crankcase. g340491 Figure 414 G210–1 Governor Shaft Inspection 1. Clean and inspect the hole in the crankcase where the governor shaft is installed. If damaged, replace the engine. 2. Clean and inspect the governor shaft for damage. If damaged or worn, replace the governor shaft. 3. Clean and inspect the washer. If damaged or worn, replace the washer. 4. Inspect the hair clip.
G210–1 Governor Shaft Installation (continued) 2. Install the splined end of the governor shaft through the hole in the crankcase. Position the governor shaft so the lever makes contact with the governor spool. 3. Install the hair pin on the governor shaft with the open end of the hair pin pointing towards the flywheel. g337344 Figure 415 4. Install the crankshaft onto the engine block. Crankshaft Installation (page 9–22) 5.
G210–1 Governor Shaft Installation (continued) g325633 Figure 417 7. Zero the governor. Zeroing the Governor (page 6–16) 8. Refill the fuel and oil. 9. Set Top No Load RPM. Top No Load RPM (page 6–18) G210–1 Governor Shaft Test 1. Start and run the engine to verify Top No Load RPM. Specifications (page 2–2) 2. Verify no oil leaks exist. G210–2 & G210–4 Governor Shaft Removal 1. Drain the fuel and oil into a suitable container. 2. Remove the crankshaft from the engine block.
G210–2 & G210–4 Governor Shaft Removal (continued) 5. Loosen the (M6) flange nut secured to the governor arm bolt. Remove the governor arm from the governor shaft. Note: A small flat bladed screwdriver can be used to pry the clamp open to allow arm to lift up more easily. g325635 Figure 419 6. While holding the spline of the governor shaft, remove the hairpin from the governor shaft. g337344 Figure 420 7. Remove the governor shaft and washer from the inside of the crankcase.
G210–2 & G210–4 Governor Shaft Removal (continued) g340491 Figure 421 G210–2 & G210–4 Governor Shaft Inspection 1. Clean and inspect the hole in the crankcase where the governor shaft is installed. If damaged, replace the engine. 2. Clean and inspect the governor shaft for damage. If damaged or worn, replace the governor shaft. 3. Clean and inspect the washer. If damaged or worn, replace the washer. 4. Inspect the hair clip.
G210–2 & G210–4 Governor Shaft Installation (continued) g337344 Figure 422 4. Install the crankshaft onto the engine block. Crankshaft Installation (page 9–22) 5. Align the governor bolt and (M6) flange nut so that the bolt head is captured by the governor arm. Slide the governor arm over the governor shaft protruding from top of engine block. Loosely install the flange nut. g325635 Figure 423 6. Connect the governor spring to the governor arm and speed control assembly.
G210–2 & G210–4 Governor Shaft Installation (continued) g325636 Figure 424 7. Zero the governor. Zeroing the Governor (page 6–16) 8. Install the fuel tank onto the engine block. Refer to the product Service Manual for the fuel tank installation procedures. 9. Refill the fuel and oil. 10. Set Top No Load RPM. Top No Load RPM (page 6–18) G210–2 & G210–4 Governor Shaft Test 1. Start and run the engine to verify Top No Load RPM. Specifications (page 2–2) 2. Verify no oil leaks exist.
