Tecumseh HSK840 User manual

This manual covers the following models:
TVS, TVXL, HXL, HSK 840 - 850
Other illustrated Tecumseh 2-Cycle Engine, 4-Cycle Engine
and Transmission manuals; booklets; and wall charts are
available through Tecumseh.
For complete listing write or call
T E C H N I C I A N ' S H A N D B O O K
TECUMSEH
HSK/HXL840 - 850
TVS/TVXL840
2-Cycle Engines
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TABLE OF CONTENTS
Page
ENGINE IDENTIFICATION AND CARE
IDENTIFICATION ................................................................................................................. .................. 1
INTERPRETATION OF MODEL NUMBER ............................................................................................ 1
FUELS .................................................................................................................................................... 1
ENGINE OIL ........................................................................................................................................... 1
FUEL/OIL MIX ......................................................................................................................................... 1
STORAGE .............................................................................................................................................. 2
TUNE-UP PROCEDURE ........................................................................................................................ 2
EXHAUST PORT CLEANING................................................................................................................. 2
AIR CLEANER
AIR CLEANER .................................................................................................................... .................... 3
POLYURETHANE-TYPE AIR CLEANER ............................................................................................... 3
PAPER TYPE AIR CLEANER ......................................................................................................... ....... 3
KLEEN-AIRE® CANISTER STYLE DUEL STAGE AIR CLEANER ......................................................... 3
2 CYCLE THEORY OF OPERATION
OPERATION OF HSK, HXL840-850 MODELS ...................................................................................... 4
OPERATION OF TVS, TVXL840 ............................................................................................................ 4
TERMS ................................................................................................................................................... 4
EXHAUST OR SCAVENGE PHASE ...................................................................................................... 4
PORTS .................................................................................................................................................... 4
LUBRICATION ........................................................................................................................................ 4
REED VALVE ......................................................................................................................................... 4
CARBURETION
CARBURETOR IDENTIFICATION ....................................................................................................... .. 5
SERIES I OPERATION........................................................................................................................... 5
SERIES VI OPERATION ........................................................................................................................ 5 - 6
SERVICING THE CARBURETOR - SERIES VI
REBUILDING THE CARBURETOR...................................................................................................... .. 7 - 8
TROUBLESHOOTING CARBURETION SERIES VI
TABLE OF PROBLEMS AND CORRECTIONS ..................................................................................... 9
SERVICING THE CARBURETOR - SERIES I
SERVICE ........................................................................................................................ ........................ 10
SERVICE CARBURETOR PRE-SETS AND ADJUSTMENTS
PRE-SETS AND ADJUSTMENTS ....................................................................................................... ... 11
FINAL ADJUSTMENTS .......................................................................................................................... 11
TROUBLESHOOTING CARBURETION SERIES I
TABLE OF PROBLEMS AND CORRECTIONS ..................................................................................... 12
PISTON AND RINGS
840 - 850 MODELS............................................................................................................... .................. 13
E.G.R. TUBE - SERVICE AND INSTALLATION (TVS/TVXL 840 ONLY)
PORT PLUG REINSTALLATION....................................................................................................... ..... 14
ANTI-PUDDLING METER HOLE SCREEN
REPLACEMENT OF SCREEN ............................................................................................................... 15
SELF-ENERGIZING BRAKE SYSTEM
DISASSEMBLY OF THE BRAKE SYSTEM ........................................................................................... 16
REASSEMBLY OF THE BRAKE SYSTEM ............................................................................................ 16 - 17
GOVERNOR LINKAGE AND ADJUSTMENT
LINKAGE LOCATION ............................................................................................................... .............. 18
GOVERNOR ADJUSTMENT .................................................................................................................. 18
GOVERNOR FOLLOWER ARM AND SHAFT ASSEMBLY ................................................................... 18
GOVERNOR LINKAGE AND ADJUSTMENT - HXL/HSK840 - 850
CONTROLS ............................................................................................................................................ 19
REWIND STARTER
TYPE I ..................................................................................................................................................... 20
TYPE II .................................................................................................................................................... 20
840 - 850 DISASSEMBLY
MODEL 840-850 DISASSEMBLY ...................................................................................................... .... 21
EXHAUST PORT CLEANING................................................................................................................. 22 - 25
TVS & TVXL 840 REASSEMBLY
840 HORIZONTAL AND VERTICAL REASSEMBLY ............................................................................. 26 - 30
TORQUE SPECIFICATIONS
TORQUE LIMITS FOR REASSEMBLY .................................................................................................. 31
ENGINE SPECIFICATIONS
TOLERANCES IN THE ENGINES...................................................................................................... .... 32
TRAINING AIDS AND TOOLS
LISTING OF SPECIAL TRAINING AIDS AND TOOLS .......................................................................... 33 - 34
C Tecumseh Products Company
1996
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1
ENGINE IDENTIFICATION AND CARE
IDENTIFICATION
Tecumseh engine Models 840 - 850, specification, and
serial number or date of manufacture (D.O.M.) are
stamped into the blower housing, or located on a decal
on the engine in locations as shown.
Make sure that gasoline and oil are stored in clean,
covered, rust free containers. Dirt in fuel can clog small
ports and passages in the carburetor. Use fresh gasoline
only. Gasoline standing for long periods of time develop
a gum that will result in fouled spark plugs, clogged fuel
lines, carburetors and fuel screens. Using fuel that is
not fresh will cause engines to be hard starting,
especially in cold temperatures.
Clean gas cap, tank and fuel container spout when filling
fuel tank, to assure that dirt will not get into fuel system.
If gasohol is used, special care is required when the
engine is to be stored for extended periods.
ENGINE OIL. Use Clean, high quality 2 CYCLE OIL.
NMMA TC-WII, or TC-W3.
FUEL/OIL MIX. Follow fuel and engine oil requirements
listed in the Owners Manual. Disregard conflicting
instructions found on oil containers. The fuel/oil mix for
all 840-850s is 50:1.
NOTE: Sears Craftsman models use a 40:1 mix which
is acceptable.
NOTE: ALWAYS DOUBLE THE AMOUNT OF OIL
FOR THE FIRST GALLON OF MIX FOR ENGINE
BREAK IN.
To assure thorough mixing of oil and gasoline, fill
container with gasoline to one quarter full, add oil as
recommended, shake container vigorously and then add
remainder of gasoline. Do not mix directly in engine
or equipment fuel tank.
Some models will have a Mix-Rite cup attached to the
under side of the air cleaner cover to assure proper fuel/
oil mixture.
The mixing chart below should be used for proper fuel
and oil mix ratio.
FUEL MIX CHART Mixture 50:1
U.S. S.I. (METRIC)
Gas Oil To Be Added Petrol Oil To Be Added
1 Gal. 2-1/2 oz. 4 Liters 80 ml
2 Gal. 5 oz. 8 Liters 160 ml
5 Gal. 13 oz. 20 Liters 400 ml
NOTE: Beginning with the 1998 Snowblower season,
Horizontal Snow King®engines will have Emission
Compliance information on the identification decal.
Interpretation of Model Number
The letter designations in a model number indicate the
basic type of engine. This is followed by the specification
number and date of manufacture.
HXL - Horizontal Extra Life
HSK - Horizontal Snow King®
TVS - Tecumseh Vertical Style
840/850 - Base engine model
SPECIFICATION NUMBER
Specification number used to locate correct parts.
5215C is the serial number or D.O.M. (Date of
Manufacture)
5is the last digit in the year of manufacture
(1995).
215 indicates the calendar day of that year
(215th day or August 3, 1995).
Crepresents the line and shift on which the
engine was built at the factory.
FUELS. Tecumseh Products Company strongly
recommends the use of fresh, clean, UNLEADED
regular gasoline in all Tecumseh Engines. Unleaded
gasoline burns cleaner, extends engine life and
promotes good starting by reducing the build up of
carbon deposits. Premium gas or gasohol containing
no more than 10% ethanol can be used if unleaded fuel
is not available.
NOTE: NEVER USE GASOLINE CONTAINING
METHANOL, GASOHOL CONTAINING MORE THAN
10% ETHANOL, UNLEADED REGULAR GASOLINE
CONTAINING MORE THAN 15% M.T.B.E. OR ETBE,
GASOLINE ADDITIVES, OR WHITE GAS BECAUSE
ENGINE/FUEL SYSTEM DAMAGE COULD RESULT.
NOTE: In countries where unleaded gasoline is not
available, regular gas can be used.
FUEL: REGULAR UNLEADED
FUEL/OIL MIX 50:1
TVXL840 8405F (E)
5018B
TVS/TVXL ENGINE
IDENTIFICATION
HXL/HSK ENGINE
IDENTIFICATION
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2
Make sure fuel tank, fuel filters and fuel lines are
clean. Reinstall carburetor, replacing any worn or
damaged governor springs or linkage. Make proper
governor adjustment. Adjustments are found in the
manual under governor linkage and adjustment and
engine reassembly.
4. Replace with correct spark plug.
5. Make sure all ignition wires are properly routed, so
they will not rub on flywheel. Inspect all ignition wires
for abrasion or damage. Remove flywheel and
check flywheel key, reinstall flywheel, torque
flywheel nut to specifications. Set air gap between
solid state module and flywheel at .0125'. Air gap
gauge, part no. 670297 may be used.
6. The engine must be firmly mounted to the associated
equipment. On rotary lawnmowers, make sure blade
is properly balanced and correctly torqued. See
dissassembly section for flywheel removal and air
gap setting procedure.
7. Make sure all remote linkage is properly adjusted
for proper operation.
8. Fill tank with proper fuel/oil mix.
9. Run the engine, allow it to warm up 5 minutes, then
adjust carburetor and set R.P.M. according to
Tecumsehs recommendations.
Snow King®engines should be run in outdoor
temperatures for engine adjustments.
EXHAUST PORT CLEANING. The exhaust ports
should be cleaned after each seventy-five (75) to one
hundred (100) hours of use.
Before cleaning the ports place the piston in the Bottom
Dead Center position. Then clean the ports using a
pointed 3/8' diameter wooden dowel or similar tool. Be
sure not to scratch the port area. Also remember to
remove all the loose carbon particles from the engine.
COMPRESSION
RELEASE HOLE
STORAGE:
NEVER STORE ENGINE WITH FUEL IN TANK
INDOORS OR IN ENCLOSED, POORLY
VENTILATED ENCLOSURES WHERE FUEL
FUMES MAY REACH AN OPEN FLAME, SPARK
OR PILOT LIGHT AS ON A FURNACE, WATER
HEATER, CLOTHES DRYER, ETC.
If engine is to be stored over 30 days, prepare for storage
as follows:
1. Remove all gasoline from fuel tank to prevent gum
deposits from forming in tank and other fuel system
components, causing possible malfunction of the
engine.
DRAIN FUEL INTO APPROVED CONTAINER
OUTDOORS, AWAY FROM OPEN FLAMES.
Run engine until fuel tank is empty and engine stops
due to lack of fuel.
Fuel stabilizer (such as STA-BIL) is an acceptable
alternative in minimizing the formation of fuel gum
deposits during storage. Add stabilizer to fuel in fuel
tank or storage container. Always follow mix ratio
found on stabilizer container. Run engine at least
10 minutes after adding stabilizer to allow it to reach
carburetor.
If gasohol has been used, complete preceding
instructions and then add a small amount, one pint
or less, of unleaded regular automotive gasoline
properly mixed with the specified lubricating oil and
run the engine until the fuel tank is empty and the
engine stops due to lack of fuel.
2. Pull starter handle slowly until resistance is felt due
to compression pressure, then stop. Release starter
tension slowly to prevent engine from reversing due
to compression pressure. This position will close
both the intake and exhaust ports to prevent
corrosion of the piston and the cylinder bore.
3. Clean unit by removing any dirt from exterior of the
engine and equipment.
TUNE-UP PROCEDURE. The following is a minor tune-
up procedure. Repair procedures for this engine and
its components are listed in this manual if the engine
does not perform to satisfaction after tune-up is
performed.
CAUTION: Remove spark plug wire before doing
any service work on engine.
1. Service or replace air cleaner as necessary.
NOTE: Snow King®engines do not use an air filter
due to the clean operating environment and to
prevent filter freeze-up.
2. Remove blower housing, clean all dirt, grass or
debris from air intake screen, cylinder cooling fins,
and carburetor governor levers and linkage.
3. Remove carburetor, clean and install a carburetor
kit, make adjustment presets where needed. Presets
are found in the carburetor section of this manual.
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3
AIR CLEANER
AIR CLEANER. Service the air cleaner frequently to
prevent clogging of the element & screen and to prevent
dust and dirt from entering the engine. Dust by- passing
an improper or damaged air filter can quickly damage
an engine. Always make certain covers and air cleaner
connections are tightly sealed to prevent entry of dirt.
NOTE: SNOW KING MODELS DO NOT HAVE AIR
FILTERS DUE TO THE CLEAN ENVIRONMENT THEY
OPERATE IN AND TO PREVENT AIR CLEANER
FREEZE UP.
If a loss of power occurs, inspect the air filter for clogging
before making any adjustments.
NOTE: Use factory recommended parts only.
POLYURETHANE-TYPE AIR CLEANER. This
serviceable air cleaner utilizes a polyurethane element
which will clog with use. The element should be cleaned
and serviced in the following manner.
Wash element in a detergent and water solution and
squeeze (dont twist) until all dirt is removed. Rinse
thoroughly.
Wrap in clean cloth and squeeze (dont twist) until
completely dry.
Clean air cleaner body and cover. Dry thoroughly.
Re-oil element by applying generous quantity of engine
oil to all sides. Squeeze vigorously to distribute oil and
to remove excess oil.
When reassembling polyurethane type air cleaners,
replace in the same order as pictured above.
Flocked screen elements may be cleaned by blowing
compressed air through the screen from the back side.
If screen can not be cleaned with this procedure, it
should be replaced with a new screen.
NOTE: Polyurethane type filters will lose effectiveness
if stored for extended periods of time, due to oil migration
out of the filter. Re-oil filter as necessary.
PAPER TYPE AIR CLEANER. The paper type air
cleaners found on some HXL, TVS and TVXL840-850's
should be replaced once a year or more often in
extremely dirty or dusty conditions.
DO NOT ATTEMPT TO CLEAN OR OIL PAPER
FILTER'S.
NEVER RUN THE ENGINE WITHOUT THE
COMPLETE AIR CLEANER INSTALLED ON THE
ENGINE IF SO EQUIPPED.
KLEEN-AIRE®CANISTER STYLE DUAL STAGE AIR
CLEANER. This air cleaner consists of a paper type
element with a polyurethane pre-cleaner around it. For
servicing the assembly see instructions under Paper
Type Air Cleaner and Polyurethane Type Air Cleaner.
Be sure to clean base and cover thoroughly before
installing new paper filter.
NOTE: When installing a new foam pre-cleaner always
turn it inside out before installing around the paper
element to prevent gaps between paper element and
pre-cleaner.
*NOTE*: Tecumseh has changed the cannister filter
cartridge to remove the nut/seal assembly. If you receive
a new filter with a rubber seal that is tight around the
stud, follow the instruction sheet included regarding NOT
RE-USING THE NUT.
PAPER
ELEMENT
FOAM
ELEMENT
COVER
WING NUT
FLOCKED SCREEN
SCREEN
(OPTIONAL - TVS ONLY)
COVER
MIX RITE CUP
POSITION
(If equipped)
POLYURETHANE
ELEMENT
PAPER ELEMENT
(TVXL ONLY)
AIR CLEANER
BODY
EARLY
PRODUCTION
NUT WITH SEAL
(SEE NOTE*)
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4
OPERATION OF HSK, HXL840-850 MODELS.
A low pressure area is created in the crankcase as the
piston moves upward to compress the air / fuel mixture
in the cylinder. Then the piston moves far enough to
uncover the intake port, the air / fuel mixture from the
carburetor flows into the engine crankcase due to higher
pressure atmospheric air. Just before the piston reaches
top dead center (TDC), the spark plug ignites the
air / fuel mixture in the cylinder.
The expanding combustion gases force the piston down.
The downward piston travel causes a pressure buildup
in the crankcase. The piston uncovers the exhaust port
first followed by the transfer ports. The exhaust flows
out the exhaust port while the pressurized air / fuel
mixture enters the cylinder from the crankcase through
the transfer ports. As the piston travels upward the
sequence is repeated.
OPERATION OF TVS, TVXL840
This model uses a loop scavenge system with a reed
valve.
The following illustrates the loop scavenge design which
uses a vacuum-pressure activated reed valve. Here the
ports are located on three sides of the cylinder; the intake
ports are on two sides opposite each other, and the
exhaust ports are illustrated by the three holes just above
the head of the piston.
As the mixture flows into the combustion chamber
through the transfer ports, it collides and is directed to
the top of the combustion chamber looping when it
strikes the cylinder head, thus forcing all spent gases
out through the open exhaust ports.
TERMS. Listed are common terms often referred to on
2-cycle engines.
EXHAUST or SCAVENGE PHASE. The burned gases
must be cleared out of the combustion chamber and
replaced by a fresh charge of fuel-air mixture through
the intake ports. The exhaust passes out through the
exhaust ports into the outside air.
PORTS. Openings in the cylinder allow gases to pass
into and out of the combustion chamber. The ports are
opened or closed by the upward and downward
movement of the piston.
EXHAUST PORTS. Allow the burned gases to pass out
of the combustion chamber.
THIRD PORT (Sometimes called piston port). A third
port is for entry of the fuel-air and oil mixture to the
crankcase. From the crankcase the fuel-air mixture
enters the combustion chamber through the intake ports.
The third port is controlled by the piston skirt.
LUBRICATION. Tecumseh 2-cycle engines are
lubricated by a gas oil mix. The correct mix ratio of oil
and gas combines with air in the venturi and enters the
crankcase. During engine operation the oil clings to all
the internal moving parts for lubrication.
NOTE: ALWAYS MIX AT OUR RECOMMENDED
RATIO AND USE ONLY CERTIFIED OILS OR
WARRANTY IS VOID.
REED VALVE. A reed valve is activated by crankcase
pressure or vacuum. A decrease in crankcase pressure
opens the valve allowing the fuel air and oil mixture to
enter the crankcase. Increased crankcase pressure
closes the valve, preventing escape of the fuel-air and
oil mixture back through the carburetor.
4.3.
2.
1.
2 CYCLE THEORY OF OPERATION
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5
CARBURETION
CARBURETOR IDENTIFICATION
Tecumseh carburetors are identified by a model number
and code date stamped on the carburetor as illustrated.
When servicing carburetors the model and date code
number of the carburetor will be found on the carburetor
body. It is a recommended procedure to use the engine
model and specification number for looking up repair
parts. However, if they are not available, the carburetor
model number may be used for the proper carburetor
repair parts. Cross reference the carburetor model
number into a service part number using the Master
Parts Manual or Microfiche and look up the required
parts.
ALTERNATE LOCATION FOR
MANUFACTURING NUMBER THROTTLE
SHUTTER
IDLE AIR
BLEED MAINAIR
BLEED
CHOKE
SHUTTER
INLET NEEDLE
AND SEAT
FLOAT
MAIN ADJUSTMENT
IDLE
ADJUSTMENT
MAIN NOZZLE
NOTE: EITHER JET MAY BE FIXED TYPE. (NON- ADJUSTABLE)
SERIES I OPERATION. The HSK and HXL840-850
models use a Series ( I ) carburetor. (Fixed speed
models have no idle circuit with a fixed main jet.)
Variable speed engines use a full circuit Series I which
has an idle fuel circuit (as shown above).
SERIES VI OPERATION. This carburetor is a high bred
of the dual system carburetor. It is equipped with a primer
for easy starting and has a fixed main and idle circuit.
Fuel fills the prime well in the bowl nut to the level
maintained by the float. Pushing the primer button 3-5
times will provide the rich mixture required to start a
cold engine. It takes about 3 seconds for the prime well
to refill after each prime.
If the engine is used under cool weather conditions, the
number of primes should be increased.
NOTE: All Emissionized engines will be equipped with
fixed jet carburetors.
MANUFACTURING
NUMBER
CARBURETOR
DATE CODE
The TVS or TVXL840 engines use a Series VI
carburetor. The Series VI has a fixed high speed and a
fixed idle system.
IDLE MIXTURE
SCREW
HSK - HXL CARB
TVS - TVXL CARB
MAIN
MIXTURE
SCREW
SERIES VI SERIES I
VENTED
PRIMER
BULB
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6
When the engine starts and runs, the fuel level in the
bowl and prime well stabilizes, then air from the air bleed
and fuel from the main jet is pulled up the main nozzle
for engine operation.
CAUTION: Do not exceed equipment manufacturers
recommended RPM. Excessive RPM will cause the
carburetor fuel mixture to lean out and the engine may
overheat and eventually fail.
At Idle or Low Load running, the fuel will be drawn up
the fixed idle passage in the carb.
MAIN
NOZZLE
AIR BLEED
MAIN JET
FIXED
IDLE
PASSAGE
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7
SERVICING THE CARBURETOR - SERIES VI
To service the Series VI carburetor follow the procedure
listed in this section of the manual.
NOTE: Left handed fixed jets are used on TVS/TVXL840
models only.
Remove the bowl nut. The bowl nut on this carburetor
has LEFT HANDED threads. This can be identified by
the letter L preceding the numbering on the bowl nut.
Also, the head of the bowl nut is notched. This is the
same identification used in many industries for left
handed nuts.
If the bowl nut is turned the wrong way, it will break off
in the center leg where the fuel pick up passages are
drilled. If this happens, a screwdriver will fit into the bowl
nut which then may be turned out in the proper direction.
Remove the throttle plate and shaft with the dust seal
and spring.
Remove the inlet seat using a hook made from a paper
clip or a No. 4 crochet hook.
Soak the carburetor body and bowl nut in a commercial
cleaner no longer than 30 minutes. Is is not necessary
to remove the fuel fitting when soaking the carburetor.
All passages may be probed with soft tag wire and blown
out with compressed air to open plugged or restricted
passages.
REBUILDING THE CARBURETOR
Place the inlet needle and spring clip onto the float and
set in place. The long end of the spring clip must point
towards the air cleaner end of the carburetor. This will
ensure that the inlet needle will drop and raise in a
straight line.
Replace the seat into the carburetor body. The side of
the seat with the groove in, goes into the carburetor
body so that the smooth side can be seen. Place a small
drop of oil onto the seat and press it in with a flat punch
or a point plunger until it seats. Be careful not to scratch
the polished inlet bore.
LEFT HANDED MARKINGS
LONG END
OF CLIP
CLIP
OPEN END
OF CLIP
3/32"
INSERT GROOVE
DOWN
SEAT
5/32" FLAT PUNCH
PRESS IN UNTIL
SEAT RESTS ON
BODY SHOULDER
HOOK END
After the carburetor has been removed from the engine,
remove the primer bulb. Using a needle nose pliers,
grasp the primer bulb and roll the primer bulb out.
CAUTION: Wear safety glasses or goggles while
removing the retaining ring that holds the primer
bulb in place.
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8
This carburetor uses a dampening spring on the float.
The short leg hooks onto the carburetor body and the
longer end points towards the choke end.
Install the throttle shaft and shutter. The scribe mark on
the shutter is in the twelve oclock position. Any other
position may cause the throttle to stick. Use a new
throttle shutter screw to insure that the screw does not
come loose during running. A new dust seal should also
be used on the throttle shaft.
Place the primer bulb with the retainer ring into a 3/4'
deep reach socket. Press down until seated. NOTE: An
improper seat will cause poor priming.
Install a new bowl O ring. Place the bowl onto the
carburetor with the flat area of the bowl over the hinge
pin and running parallel to the hinge pin. Insert the bowl
nut with the fiber washer between the bowl and the nut.
Remember this is a left handed bowl nut.
POINTS TOWARD
THE CHOKE END
SCRIBE MARK AT THE
12 O'CLOCK LOCATION
FLOAT
INLET NEEDLE
AND SEAT
ADJUSTING TAB
FLOAT HINGE
AND AXLE
All Tecumseh carburetors with an adjustable float
require the correct float height to achieve the proper
operation and easy engine starts. To check the float
setting, hold the carburetor in an upside down position.
Remove the bowl nut, float bowl, and "O" ring. Place an
11/64" diameter drill bit across the top of the carburetor
casting on the opposite side and parallel to the float
hinge pin. The float must just touch the drill bit when the
bit is flush with the edge of the float. If the float is too
high or too low, adjust the height by bending the tab
accordingly. If the required adjustment is minor, the tab
adjustment may be made without removing the float and
carefully inserting a small bladed screwdriver to bend
the tab.
11/64
VENTED
PRIMER
FLOAT
SETTING
TECUMSEH PRODUCTS
MADE IN
U.S.A.
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9
TROUBLESHOOTING CARBURETION
SERIES VI
IDLE AIR BLEED
FIXED IDLE PASSAGE LEFT HANDED BOWL NUT
MAIN JET
MAIN NOZZLE AIR BLEED
MAIN NOZZLE
TROUBLE CORRECTIONS
Carburetor out of adjustment .................................... 3, 4, 11, 15
Engine will not start ................................................... 1, 2, 3, 4, 5, 8, 10, 11, 13, 16, 18, 19
Engine will not accelerate ......................................... 2, 3, 4, 5, 8, 11, 15, 18
Engine hunts (at idle or high speed) ......................... 3, 4, 8, 9, 10, 11, 15, 16, 18
Engine will not idle..................................................... 3, 4, 8, 9, 10, 11, 14, 15, 16, 18
Engine lacks power at high speed ............................ 2, 3, 4, 7, 8, 11, 15, 16, 18, 19
Carburetor floods....................................................... 4, 7, 13, 16, 17, 18
Carburetor leaks ........................................................ 4, 6, 7, 13, 14, 18
Engine overspeeds ................................................... 8, 9, 10, 11, 14, 15
Idle speed is excessive ............................................. 8, 9, 10, 11, 14, 15
Engine starves for fuel at high speed (leans out) ..... 1, 3, 4, 5, 11, 12, 13, 14, 16
Performance unsatisfactory after being serviced ..... ALL
1. Fill tank with fuel.
2. Check ignition, spark plug and compression.
3. Clean air cleaner service as required.
4. Dirt or restriction in fuel system clean tank and fuel
strainers, and filter, check for kinks or sharp bends.
5. Check for stale fuel or water in fuel fill with fresh
fuel/oil mixture of correct ratio.
6. Examine fuel line and pick-up for sealing at fittings.
7. Check and clean atmospheric vent holes.
8. Examine throttle shaft for binding or excessive play
-remove all dirt or paint, replace shaft.
9. Examine throttle return spring for operation.
10. Check position of throttle plate.
11. Adjust control cable or linkage to assure carburetor
control.
12. Clean carburetor after removing all metallic parts
that are serviceable. Trace all passages.
13. Check inlet needle and seat for condition and proper
installation.
14. Check sealing of gaskets and O rings.
15. Adjust governor linkage.
16. Adjust float setting.
17. Check float shaft for wear and float for leaks or dents.
18. Is carburetor operating on excessive angle?
19. Check primer bulb for damage.
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10
PRY OUT PLUG
TWELVE O'CLOCK
POSITION
FLAT
DOWN
CHOKE PLATE
The following covers variations from the Series VI
carburetors.
The Series ( I ) carburetor is used on summer and winter
versions of the horizontal 840 thru 850 Series, and is
equipped with a choke to be positioned as shown.
The throttle plate on the Series ( I ) is set in place at the
12 o'clock position. ALWAYS USE SERVICE SCREWS
IF YOU HAVE REMOVED EITHER THE CHOKE OR
THROTTLE SHUTTER. TECUMSEH SCREWS ARE
EQUIPPED WITH DRY LOCTITE ADHESIVE.
WELCH PLUG
TO BE
REMOVED
PIERCE PLUG WITH TIP
ABOUT 1/8" WIDE
SMALL CHISEL
SMALL CHISEL
DO NOT ALLOW
CHISEL POINT TO
STRIKE CARBURETOR
BODY OR CHANNEL
REDUCER
WELCH
PLUG
REMOVED
Clean all passages out with soft tag wire. To do a proper
cleaning job welch plugs should be removed to expose
drilled passages, if equipped. To remove welch plug,
sharpen a small chisel to a sharp wedge point. Drive
the chisel into the welch plug, push down on chisel and
pry plug out of position.
NOTE: Snow KIng®engines have a primer tube on the
carburetor. Make sure this passage is open and replace
the hose when servicing.
FLAT END PUNCH
NEW WELCH PLUG SAME OR LARGER
DIAMETER OF
PLUG
To install a new welch plug after cleaning, place welch
plug into rmixing well with raised portion up. With a punch
equal to the size of the plug, merely flatten the plug. Do
not dent or drive the center plug below the top surface
of the carburetor. To insure sealing use, nail polish
around the plug.
If float sticking occurs due to deposits, or when the fuel
tank is filled for the first time, this condition can be quickly
corrected by loosening the carburetor bowl nut one full
turn. Turn the bowl 1/4 inch in either direction, then return
the bowl to its original position and tighten the bowl nut.
SERVICING THE CARBURETOR
SERIES I
FIXED IDLE JET MAY HAVE A
TAMPER RESISTANT CAP.
EXTERNAL
ATMOSPHERIC
VENT
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11
SERVICE
CARBURETOR PRE-SETS AND ADJUSTMENT
All models with float-type
carburetors
Engine Model Main Pre-set Idle Pre-set
1-1/2 turn 1 turn
Tecumseh Carburetors
NOTE: Some carburetors have fixed main and idle jets. The absence of the adjusting screw indicates a fixed jet
and no adjustment is necessary.
Before adjusting any mixture screws the necessary carburetor presets should be made. Check for the proper
governor adjustments (see governor adjustment section). Identify the correct carburetor model to find locations of
the high and low speed adjustment screws. Check the throttle control bracket for proper adjustment allowing a full
choke shutter position. (see "Speed Controls and Linkage"). Check to see if the normal maintenance procedures
have been performed (oil changed, fresh fuel, air filter replaced or clean). Consult microfiche card #30 to find the
correct R.P.M. settings for the engine. RPM specifications can also be found on Plus One or Parts Smart computer
programs. Start the engine and allow it to warm to operating temperature. The carburetor can now be adjusted.
Final Adjustments
Start the engine and allow it to warm up to normal operating temperature (3 - 5 minutes). Set the speed control to
the HIGH or FAST position, then turn the main mixture adjustment screw in (clockwise) slowly until the engine
begins to run erratic (lean). Note the position of the screw. Now, turn the screw out (counterclockwise) until the
engine begins to run erratic (rich). Turn the screw in (clockwise) midway between these two positions. This will be
the best setting.
Set the speed control to the IDLE or SLOW position. Adjust the idle mixture screw following the same procedure
used to adjust the main mixture adjustment screw.
Identify the location of both HIGH and LOW speed adjustment screws, then identify the recommended HIGH and
LOW R.P.M. setting according to microfiche card # 30 and adjust carburetor accordingly.
Pre-sets and Adjustments If Equipped.
Turn both the main and idle mixture adjusting screws in
(clockwise) until finger tight.
NOTE: OVERTIGHTENING WILL DAMAGE THE
TAPER PORTION OF THE NEEDLE.
Now back the mixture screws out (counterclockwise) to
obtain the pre-set figure in the chart shown at right.
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14. Check position of choke and throttle plates.
15. Adjust control cable or linkage to assure full choke
and carburetor control.
16. Clean carburetor after removing all non-metallic
parts that are serviceable. Trace all passages.
17. Check inlet needle and seat for condition and proper
installation.
18. Check sealing of welch plugs, cups, plugs and
gaskets.
19. Adjust governor linkage.
20. Adjust float setting.
21. Check float shaft for wear and float for leaks or
dents.
22. Check seal for fuel drain or bowl gasket.
23. Is carburetor operating at excessive angle?
TROUBLESHOOTING CARBURETION SERIES I
TROUBLE CORRECTIONS
Carburetor out of adjustment ................................. 3, 4, 11, 12, 13, 15, 19
Engine will not start ................................................ 1, 2, 3, 4, 5, 6, 8, 9, 10, 11, 12, 14, 15, 16, 17, 19, 20, 23
Engine will not accelerate ...................................... 2, 3, 4, 5, 11, 12, 15, 19, 23
Engine hunts (at idle or high speed) ...................... 3, 4, 8, 9, 10, 11, 12, 14, 19, 20, 23
Engine will not idle ................................................. 3, 4, 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 23
Engine lacks power at high speed ......................... 2, 3, 4, 7, 8, 10, 11, 12, 15, 18, 19, 20, 23
Carburetor floods ................................................... 4, 7, 17, 20, 21
Carburetor leaks..................................................... 4, 6, 7, 10, 17, 18, 22, 23
Engine overspeeds ................................................ 8, 9, 13, 14, 15, 18, 19
Idle speed is excessive .......................................... 8, 9, 13, 14, 15, 18, 19
Choke does not open fully ..................................... 8, 9, 14, 15
Engine starves for fuel at high speed (leans out).. 1, 3, 4, 5, 6, 10, 11, 15, 16, 17, 18, 20
Carburetor runs rich with main adjustment ........... 7, 11, 17, 18, 20
needle shut off
Performance unsatisfactory after being serviced .. ALL
1. Open fuel shut off valve at fuel tank fill tank with
fuel.
2. Check ignition, spark plug and compression.
3. Clean air cleaner service as required.
4. Dirt or restriction in fuel system clean tank and fuel
strainers, check for kinks or sharp bends.
5. Check for stale fuel or water in fuel fill with fresh
fuel/oil mixture of correct ratio.
6. Examine fuel line and pick-up for sealing at fittings.
7. Check and clean atmospheric vent holes.
8. Examine throttle and choke shafts for binding or
excessive play remove all dirt or paint, replace shaft.
9. Examine throttle and choke return springs for
operation.
10. Examine idle and main mixture adjustment screws
and O rings for cracks or damage.
11. Adjust main mixture adjustment screw. Check to see
that it is the correct screw.
12. Adjust idle mixture adjustment screw. Check to see
that it is the correct screw.
13. Adjust idle speed screw.
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13
HALF
KEYSTONE
RING
PISTON AND RINGS
Their are various types of piston and ring sets used in
840-850 models, and should not be interchanged.
The piston and ring sets on some 840-850's are of a
standard type construction. Either ring may be placed
in either ring groove of the piston.
Some 840-850 models use a half keystone upper ring.
The ring groove in the piston and on the ring have a
distinctive taper to them. The ring must be placed in the
top ring groove with the long beveled side towards the
dome of the piston as shown.
NOTE: Piston ring end gaps should be staggered upon
installation.
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NOTE: HXL, HSK840 thru 850 models do not use the
E.G.R. system.
An E.G.R. (Exhaust Gas Recirculation) tube is placed
in the block of the TVS/TVXL840 engine and extends
into the outer chamber of the muffler.
A controlled amount of exhaust gas is drawn into the
crankcase of the engine to aid in the movement of the
air/fuel mixture to the combustion chamber.
However, if for any reason the plug should come out of
the engine, it can be reinstalled. Clean the block and
the port plug with lacquer thinner or comparable product
so that it is free of all oil.
Using a small, thin center punch or large scribe, stake
the port plug in 12 evenly spaced positions.
Use 5 minute epoxy and fill in around the outer diameter
of the plug. This will ensure you have no air leaks.
Allow epoxy to cure for 24 hours before using engine.
Install the E.G.R. tube in to the proper depth by using
service tool number 670318.
PORT PLUG REINSTALLATION
The large transfer port plug's on all 840 series engines
are pressed into the block and should not have to be
removed.
E.G.R. TUBE
SERVICE & INSTALLATION
TVS / TVXL 840 ONLY
E.G.R. PASSAGE
It is a good idea when decarbonizing the exhaust ports,
check the E.G.R. passage as well.
The E.G.R. tube is a hardened steel roll pin. To remove
the tube, grasp it with a vise grip and rotate in the
direction that will collapse the tube and allow it to be
removed.
It is best to clean this passage when the piston is out of
the bore to eliminate any possible damage to the piston
or bore. Use any non-metallic material and clean the
E.G.R. port in the cylinder.
12
3
6
12
9
4
5
10 11
7
8
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15
ANTI-PUDDLING METER HOLE SCREEN
NOTE: This section applies to TVS, TVXL840's only.
TVS / TVXL840 engines built since 1/1/87, serial
numbers 7001 and thereafter, have a screen pressed
into the cavity below the anti-puddling meter hole.
This screen is a precautionary measure against abuses
such as contaminated fuel or in some instances
customers removing air cleaner elements allowing
contaminants to enter the crankcase. Engines built prior
to 1/1/87 can also have a screen installed. Part No.
430233 can be installed using the following procedure.
1. Disassemble engine so the piston, rod and
crankshaft assembly can be removed.
3. Insert the screen past the governor lever into the
tapered cavity with brass ring up. Use a small punch
or scribe to seat the screen squarely. Be careful
not to bend or poke a hole in the screen.
4. With the screen in place, take a 1/4' roll pin punch,
place it on top of the screen and tap until the screen
is seated securely in the hole.
5. Reassemble the engine as stated in that section of
this book. Engines built after 1/1/87 (serial numbers
7001 and beyond) have a screen installed in
production.
REPLACEMENT OF SCREEN
If the anti-puddling meter hole screen becomes clogged
with debris, a wire hook can be used to remove the
screen. The same procedure as outlined in this section
should be followed for reinstallation of the new screen.
2. After removing the crankshaft assembly, clean the
antipuddling meter hole with a soft tag wire. Probe
the hole several times to assure proper cleaning.
The hole is located between the shelf and PTO end
of the block directly under the governor lever.
CAVITY IN WHICH
THE ANTI-PUDDLING
METER HOLE
IS LOCATED
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16
SELF-ENERGIZING BRAKE SYSTEM
TVS/TVLX840 Models
These are the components of the self-energizing brake
system.
DISASSEMBLY OF THE BRAKE SYSTEM.
1. Disconnect the grounding wire from the shorting clip.
2. Press the shorting clip out of the brake bracket.
3. Unhook the return spring from the brake bracket.
4. Align the hole in the brake pad lever to the hole in
the bracket and hold in this position with a small
punch.
5. Remove the control lever pivot screw.
6. Disconnect the control link from brake pad lever.
Remove punch.
7. Remove brake pad lever pivot screw.
8. Turn the brake spring so the small arm (on the
bottom) clears the notch in the brake pad lever.
REASSEMBLY OF THE BRAKE SYSTEM.
1. Position brake spring on brake pad lever with small
extension of spring into notch on pad arm.
2. Assemble the brake pad lever and spring assembly
to the bracket with the pivot screw. Position the long
extension from the brake spring into the notch on
the bracket.
3. Position the control lever in the brake bracket.
BRAKE BRACKET
BRAKE CONTROL
LEVER
RETURN
SPRING
BRAKE PAD LEVER SMALL ARM
NOTCH
BRAKE SPRING
SMALL ARM
BRAKE SPRING
LONG ARM
NOTCH IN BRACKET
BRAKE PAD PIVOT
SCREW
ALIGNMENT
PUNCH
BRAKE PAD
LEVER
CONTROL
LINK
CONTROL
LINK
BRAKE PAD
BRAKE PAD
LEVER
CONTROL LEVER
PIVOT SCREW
BRAKE PAD
LEVER PIVOT
SCREW
SHORTING CLIP
BRAKE CONTROL
LEVER
BRAKE BRACKET
SMALL END
LARGE END
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4. Align the hole in the brake pad lever to the hole in
the bracket with a small punch.
5. With the short side up, slide the control link through
the slotted hole of the control lever. Place opposite
end of link into slotted hole of brake pad lever short
side up.
6. Slide control link to its proper position in the control
lever.
7. Position control lever and pivot screw.
8. Tighten both pivot screws, and remove alignment
punch.
CAUTION: Secure the screws with red Loctite. DO
NOT over torque or the brake pad will be distorted.
Then a new pad and lever assembly will be required.
9. Place large end of return spring in hole of control
lever, short end of spring on the notch in the brake
bracket.
10. Reposition shorting clip and attach grounding wire.
BRAKE BRACKET
BRAKE CONTROL
LEVER
SMALL END
LARGE END
RETURN
SPRING
ALIGNMENT PIN
CONTROL LINK
CONTROL LEVER
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18
GOVERNOR LINKAGE, AND ADJUSTMENT
LINKAGE LOCATION. To aid in the proper reassembly
of the governor linkage, mark the linkage locations.
GOVERNOR FOLLOWER ARM AND SHAFT
ASSEMBLY. The governor following lever and governor
shaft can be serviced by removing the two screws in
the following lever and shaft. Reassemble the following
lever and governor shaft so that curved end of the
following lever points toward the P.T.O. end of the
engine.
New service screws should be used when the old screws
are removed. The new service screws have a dry
adhesive applied to them to prevent them from coming
loose. This is the same screw that is used on the choke
and throttle plates in the carburetor.
GOVERNOR SHAFT SEAL. The governor shaft seal
may be pressed in until it seats in the boss of the block.
Care should be used when this seal is replaced, forcing
the seal to far into the block will distort the seal and
cause it not to seal the governor shaft.
GOVERNOR FOLLOWER ARM
HOLDING
SCREW
GOVERNOR ADJUSTMENT. To adjust the governor,
move the throttle to the wide open position. Loosen the
holding screw, turn the slotted governor shaft clockwise
as far as it will go without forcing it. Then tighten the
holding screw.
HIGH SPEED
ADJUSTMENT
IDLE SPEED ADJUSTMENT
STATIC GOVERNOR
ADJUSTMENT SCREW
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