Toro 100-2863 User manual

E1999 The T oro Company
8111 Lyndale Ave. South
Bloomington, MN 55420–1196 All Rights Reserved
Printed in the USA
Form No. 3322-861
Model 100-2863
Kawasaki Zone Start Engine Coversion Kit
For Toro Walk Power Lawn Mowers
Installation
Instructions
Loose Parts
Note: Use the following chart to identify the parts you will use to install the kit.
DESCRIPTION QTY. USE
Discharge Tunnel
Latch Plate
Discharge Door Assembly
Door Retainer
Self-tapping Screw – 1/4-10 x .60
1
1
1
1
2
Installing the new discharge tunnel and the
door assembly
Screw – 3/8-16 x 1.5 3 Replacing the engine
Engine Decal 1
Clamp 1 Installing the brake cable on the engine
Bolt 1
Throttle Control
Throttle Cable
E-Ring
1
1
2
Replacing the throttle cable
Engine Guard
Screw – 1/4-20 x 1.00
1
4
Installing the engine guard on the front of the
lawn mower
Attaching the guard to the lawn mower
Cable T ie 4
Securing the cables to the deck (1)
Securing the brake cable to the right side of the
handle (2)
Installing the cables to the lower left side of the
handle (1)
T raction Control Decal (Self-propelled models
only) 1
Replacing the decal
Screw – 3/8-16 x 1.00
Locknut – 3/8-16
2
2
Filling the holes left from removing the fuel tank
bracket

Installation Instructions
2
DESCRIPTION USEQTY.
Square Key 3/16 x 1.25 (HP Models) or
3/16 x 0.50 (SP Models)
1 Installing the blade assembly
Oil Drain T ube 1 Draining the engine oil
Brake Cable 1 Replacing the brake cable
Blade Retainer
Blade Spacer
Drive Pulley (SP Models only)
1
1
1
Replacing the blade retainer and the drive
pulley
Before Installing
POTENTIAL HAZARD
• If you leave the wir e on the spark plug,
someone could accidentally start the engine.
WHA T CAN HAPPEN
• Someone accidentally starting the engine can
seriously injur e you or other bystanders.
HOW T O A V OID THE HAZARD
• Disconnect the wir e fr om the spark plug befor e
you install the kit. Set the wir e aside so that it
does not accidentally contact the spark plug.
1. Disconnect the wire from the spark plug.
POTENTIAL HAZARD
• If gasoline is spilled on a hot engine, it could
ignite.
WHA T CAN HAPPEN
• Contact with burning gasoline could cause
serious personal injury .
HOW T O A V OID THE HAZARD
• Drain the gasoline fr om a cold engine only .
2. Make sure that the engine is cool. Remove the cap
from the fuel tank and use a pump-type syphon to
drain the fuel into a clean, approved gasoline
container.
Note:
This is the only procedure that T oro recommends
for draining the fuel.
3. Connect the wire to the spark plug.
4. Start the engine and let it run until it runs out of fuel.
5. Disconnect the wire from the spark plug.
6. Drain the engine oil (Refer to your operator ’ s manual
for the procedure).
Disassembly
Removing the Starter Rope
Remove the starter rope from the rope guide (Fig. 1).
2
m–2705
1
Figure 1
1. Rope guide 2. Starter rope
Removing the Cable Ties
Cut the cable ties that hold the cables to the handle.
Removing the Fuel Tank
1. Disconnect the fuel line from the engine (Fig. 2).

Installation Instructions
3
1
32
4
Figure 2
1. Fuel line clamp
2. Fuel line
3. T ank bracket
4. Fuel tank
2. Remove the fuel tank from the tank bracket
(Fig. 2).
3. Remove the tank bracket.
4. Install two screws and two locknuts to fill the holes
left from removing the tank bracket.
Disconnecting the Throttle Cable
1. Remove two self-tapping screws that secure the belt
cover to the lawn mower deck (Fig. 3). Set the cover
and the fasteners aside for the installation.
m-224
2
12
Figure 3
1. Belt cover 2. Self-tapping screw (2)
2. Loosen the cable clamp screw and disconnect the
throttle cable from the throttle lever (Fig. 4 or Fig. 5).
m-286
2
3
1
Figure
4
1. Cable clamp screw
2. Throttle cable
3. Throttle lever
12
3
4
Figure 5
1. Cable clamp screw
2. Cable clamp
3. Throttle cable
4. Throttle arm
Disconnecting the Blade Brake Cable
1. Disconnect the blade brake cable from the brake arm
(Fig. 6).

Installation Instructions
4
2
13 4
Figure 6
1. Brake cable
2. Brake arm
3. Brake cable fitting
4. Brake assembly
2. Use a pliers to squeeze the tabs on the top and the
bottom of the blade brake cable fitting, and slide the
cable out of the brake assembly (Fig. 6).
Self-pr opelled Models only
3. Cut the cable ties that secure the blade brake cable to
the right side of the handle.
4. Remove the cable support, the screw , and the nut from
the right side of the handle.
5. Remove the blade brake cable from the cable support.
6. Unhook the blade brake cable from the control bar
control lever .
7. Retain the cable support, the screw , and the nut for
installing the new cable.
Removing the Blade Assembly
1. Remove the blade bolt, the lock washer, the blade
stiffener/accelerator , the blade, the blade retainer , the
spacer , and the square key , and the crankshaft
protector (Fig. 7).
1
2
3
45
6
7
8
9
10
11
Figure 7
1. Blade bolt
2. Lock washer
3. Blade stif fener/accelerator
4. Blade
5.
Blade retainer
6. Spacer
7.
Square key
8. Self-tapping screw (3)
9. Internal lock washer (3)
10. Crankshaft protector
11. Engine drive pulley
(self-propelled models
only)
Note: Discard the old blade retainer , the spacer , and the
square key .
2. Remove the crankshaft protector by removing three
self-tapping screws and three internal lock washers.
Note: Keep all these items for the installation.
3. Remove and discard the engine drive pulley
(self-propelled models only).
Removing the Old Engine
Remove the three engine screws and carefully lift the
engine of f the housing (Fig. 8). Discard the screws and the
engine.

Installation Instructions
5
1
2
Figure 8
1. Engine 2. Engine screw (3)
Note: Figure 8 shows the GTS 150 engine. The GTS 200
engine is not shown.
Removing the Discharge Tunnel
Assembly
1. Remove two capscrews, two flat washers, two
locknuts, a 1/2 in. hex head washer screw , and a 3/4 in.
hex head washer screw that secure the dischar ge tunnel
assembly to the lawn mower housing (Fig. 9).
2
3
4
5
6
18
7
9
10
12
11
Figure 9
1. Discharge tunnel
2. Capscrew (2)
3. Flat washer (2)
4. Locknut (2)
5. Hex head washer screw
(1/2” long)
6. Hex head washer screw
(3/4” long)
7. Spring bracket
8. Spring extension
9. Latch plate
10. Self-tapping screw (2)
11. Door retainer
12. Discharge door assembly
Note: Keep all these items for the installation.
2. Lift of f the dischar ge tunnel assembly (Fig. 9).
3. Remove the spring bracket and the spring extension
(Fig. 9).
Note: Keep these items for the installation.
4. Discard the dischar ge tunnel assembly (Fig. 9).
Conversion Kit Installation
Installing the New Discharge Tunnel
1. Position the new dischar ge tunnel on the lawn mower
deck. Align the holes in the dischar ge tunnel with the
holes in the lawn mower deck.
2. Fasten the rear -left and the rear-right corners of the
dischar ge tunnel to the lawn mower deck using two
capscrews, two flat washers, and two locknuts
previously removed.
3. Fasten the front-right side of the dischar ge tunnel to
the lawn mower deck using the 1/2 in. hex head
washer screw previously removed.
4. Fasten the front-left corner of the dischar ge tunnel and
the spring bracket to the lawn mower deck using the
3/4 in. hex head washer screw previously removed.
5. Install the new dischar ge door assembly and secure it
with the new door retainer .
6.
Install the new latch plate to the dischar ge tunnel using
two new self-tapping screws.
7. Hook one end of the spring extension through the hole
on the spring bracket and the other end onto the
dischar ge door handle.
8. Open and close the dischar ge door to ensure that the
dischar ge tunnel door closes when you release the
handle.
Installing the New Engine
1. Carefully set the new engine onto the lawn mower
housing.
2.
Install and tighten the three new engine screws
(Fig. 10). T orque the engine screws to 250 to 400 in-lb
(28 to
45 N Sm).
For Self–pr opelled Models
3. Install a new engine drive pulley .
4. Install the belt onto the pulley .

Installation Instructions
6
m-46792
1
Figure
10
1. Engine 2. Engine screw (3)
Installing the Blade Assembly
Install the blade assembly in the reverse order of
disassembly . Refer to Removing the Blade Assembly on
page 4.
Note: Install a new blade retainer with a spacer and a key
(Fig. 7).
Note: When you install the crankshaft protector , do not
tighten the mounting screws (Fig. 7). Insert a shim (a
business card works well) between the crankshaft
protector and the hub on the blade retainer . T ighten the
mounting screws and remove the shim.
Note: T orque the blade bolt to 50 ft-lb (68 N m).
Installing the Engine Guard
1. Remove four hex head screws from the front quadrants
(Fig. 1 1). Leave the quadrants in place.
m-4678
1
23
Figure 1 1
1. Front quadrants
2. Hex head screw (4)
3. Engine guard
2. Install the new engine guard on the front of the lawn
mower deck with four hex head screws as shown in
Figure 1 1.
Installing the New Throttle Control
1. Hand Push Models Only – Disconnect the brake and
throttle cables from the throttle control by removing
the E-rings (Fig. 12).
Note: Discard the E-rings.
Self-pr opelled Models Only - Disconnect the traction
and throttle cables from the throttle control by
removing the E-rings (Fig. 12).
Note: Discard the E-rings.
1
4
5
6
6
7
2
3
8
Figure
12
1. Throttle control
2. Brake cable (HP model)
T raction cable (SP model)
3. Throttle cable
4. E-ring
5.
Hex head screw (2)
6. Curved washer (2)
7. Seal
8.
Bag support rod

Installation Instructions
7
2. Remove the two hex head screws and two curved
washers that secure the throttle control to the handle
(Fig. 12).
Note: Keep the screws and washers. Discard the throttle
control and the throttle cable.
3. Install the new throttle control using two hex head
screws and two curved washers previously removed.
4. Connect the new throttle cable to the throttle control
using a new E-ring.
5. Connect the brake cable or the traction cable,
depending on the lawn mower .
6. Route the cables behind the bag support rod.
7. Connect the brake cable to the throttle control
(hand-push models only) or to the brake cable
(self–propelled models only) using a new E-ring.
8. Connect the brake cable to the engine, leaving
approximately 1/4 in. of cable to extend beyond the
cable clamp (Fig. 14).
9. Install the belt cover using the fasteners previously
removed (Fig. 3).
10. Make sure that the seals on the cables are pushed down
tight (Fig. 12).
11. Route the throttle cable across the top of the
transmission as shown in Figure 13.
2
1
3
Figure 13
1. Throttle cable
2. Blade brake cable
3. Cable tie
Adjusting the Throttle Control
1. Connect the throttle cable to the speed control lever on
the engine (Fig. 14).
1
1
2
23
5
6
4
Figure 14
1. Cable clamp screw
2. Cable clamp
3. Throttle cable
4. Speed control lever
5. Blade brake cable
6. Base plate hole
2. Move the throttle to the (F AST) position.
3. Align the hole of the speed control lever with the hole
in the base plate by inserting a 7/32-in. (6 mm)
diameter pin through both holes.
4. Pull the throttle cable to remove the slack.
5. T ighten the cable clamp screw .
6.
Restrain the throttle and brake cables to the lawn
mower housing with a cable tie to prevent the cables
from contacting the gear box belt guide. Do not secur e
the cables tight against the housing.
7. Install the new blade brake cable, cable clamp, and the
cable clamp screw to the engine (Fig. 14).
Adjusting the Blade Brake Cable
1. Check the brake cable adjustment by moving the
control bar toward the handle until there is no slack in
the wire (Figs. 15 and 16).
Note: Ensure that the gap between the brake lever and the
handle is 3/16 in. to 1/4 in.
2. T o adjust the cable, do the following procedure:

Installation Instructions
8
Hand Push Models Only:
A. Loosen the jam nut on the brake cable (Fig. 15).
483
1
2
3
4
5
6
Figure 15
Hand Push Model
1. Handle
2.
Brake lever
3. 3/16”-1/4”
4.
Cable adjuster
5. Jam nut
6. Cable conduit
B. Insert a 3/16 in. to 1/4 in. object between the brake
lever and the handle (Fig. 15).
C. T urn the cable adjuster on the brake cable until
there is no slack.
D. T ighten the nut.
Self-pr opelled Models Only:
A. Insert the blade brake cable into the cable support.
B. Assemble the cable support to the right side of the
handle.
Do not tighten the locknut.
C. Hook the blade brake cable to the control bar lever .
D.
Insert a 3/16 in. to 1/4 in. object between the brake
lever and the handle (Fig. 16).
1
24
3
Figure
16
Self-propelled Model
1. Handle
2.
Brake lever
3. 3/16 in. to 1/4 in.
4. Cable bracket
E. Pull down on the cable conduit until there is no
slack in the wire.
F. T ighten the nut.
G. Secure the blade brake cable to the right side of the
handle with two cable ties.
Installing the Starter Rope in Rope Guide
Install the starter rope in the rope guide (Fig. 1).
Installing the New Cable Ties
Attach the cables to the lower left side of the handle using
the new cable ties.
Self-pr opelled Models Only: Replace the old decal on
the control bar with the new decal (Fig. 17).
1
Figure 17
1. Decal
Installing the New Engine Decal
Install the new decal on the engine as illustrated in
Fig. 18.
1
Figure 18
1. Decal location
Before Starting the Engine
For information on how to fill the crankcase with oil,
fill the fuel tank with gasoline, and operate the engine,
r efer to your Kawasaki Engine Owner ’ s Manual .