Toro PROLINE 165 MID-SIZE User manual

FORM NO. 3315-525 Rev. A
The Toro Company  1993
MODEL NO. 30165-390001 & UP OPERATOR'S
MANUAL
PROLINE 165 MIDSIZE
TRACTION UNIT
To assure maximum safety, optimum performance,
and to gain knowledge of the product, it is essential
that you or any other operator of the machine read
and understand the contents of this manual before
the engine is ever started. Pay particular attention to
the SAFETY INSTRUCTIONS highlighted by this
symbol 
The safety alert symbol means CAUTION, WARN
ING or DANGER  personal safety instruction. Fail
ure to comply with the instruction may result in per
sonal injury.

2
FOREWORD
The Proline mid size mowers have advanced concepts in engineering, design and safety; and if maintained proper
ly, will give excellent service.
Since this is a high-quality product, Toro is concerned about the future use of the machine and safety of the user.
Therefore, read this manual to familiarize yourself with proper set-up, operation and maintenance instructions. The
major sections of the manual are:
1. Safety Instructions 3. Before Operating 5. Maintenance
2. Set-up Instructions 4. Operation
Certain information in this manual is emphasized. DANGER, WARNING and CAUTION identify personal safety re
lated information. IMPORTANT identifies mechanical information demanding special attention. Be sure to read this
directive because it deals with the possibility of damaging a part or parts of the machine. NOTE identifies general
information worthy of special attention.
TABLE OF CONTENTS
Page Page
SAFETY INSTRUCTIONS 2. . . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 4. . . . . . . . .
SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOOSE PARTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SET-UP INSTRUCTIONS 5. . . . . . . . . . . . . . . . . . . . .
BEFORE OPERATING 8. . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING INSTRUCTIONS 9. . . . . . . . . . . . . . . . . .
MAINTENANCE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease Wheels 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease Transmission Couplers 10. . . . . . . . . . . . .
Servicing Air Cleaner 10. . . . . . . . . . . . . . . . . . . . . .
Changing Crankcase Oil 11. . . . . . . . . . . . . . . . . . .
Fuel Filter Replacement 11. . . . . . . . . . . . . . . . . . .
Replacing Spark Plug 12. . . . . . . . . . . . . . . . . . . . .
Adjusting Throttle-Choke Control 12. . . . . . . . . .
Adjusting Carburetor 13. . . . . . . . . . . . . . . . . . . . . .
Adjusting and Replacing Traction Belt 13. . . . . . .
Adjusting Clutch 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Adjustment 14. . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt Replacement 14. . . . . . . . . . . . . . . . . . .
Cleaning Cooling System 14. . . . . . . . . . . . . . . . . .
WIRING SCHEMATIC 15. . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION AND ORDERING 15. . . . . . . . . . . .
THE TORO PROMISE Back Cover. . . . . . . . . . . . . . . .
SAFETY INSTRUCTIONS
The safety alert symbol means
CAUTION, WARNING or DAN
GER  personal safety in
struction". Read and under
stand the instruction because
it has to do with safety. Failure to comply with
the instruction may result in personal injury.
Hazard control and accident prevention are depen
dent upon the awareness, concern, and proper
training of the personnel involved in the operation,
transport, maintenance, and storage of the ma
chine. Improper use or maintenance of the machine
can result in injury or death. To reduce the potential
for injury or death, comply with the following safety
instructions.
WARNING: Engine exhaust contains carbon monox
ide which is an odorless, deadly poison. Carbon mon
oxide is also known to the State of California to cause
birth defects. Do not run engine indoors or in an en
closed area.
BEFORE OPERATING
1. Read and understand the contents of this Opera
tor's Manual before operating the machine. Become
familiar with all controls and know how to stop quickly.
A free replacement manual is available by sending
complete Model and Serial Number to:
The Toro Company
8111 Lyndale Avenue South
Bloomington, Minnesota 55420-1196
2. Never allow children to operate the machine. Do
not allow adults to operate machine without proper in
struction. Only trained operators who have read this
manual should operate this machine.
3. Never operate the machine when under the influ
ence of drugs or alcohol.
4. Before attempting to start engine, shift into neutral
and lock parking brake.
5. Remove all debris or other objects that might be
picked up and thrown by the cutter blades. Keep all by
standers away from the mowing area.
6. Do not operate machine unless all shields and
safety devices are in place. If a shield, safety device or
decal is illegible or damaged, repair or replace it before
operation is commenced. Also tighten any loose nuts,
bolts and screws to assure machine is in safe operating
condition.

3
SAFETY INSTRUCTIONS
7. Do not operate machine while wearing sandals,
tennis shoes, sneakers or shorts. Also, do not wear
loose fitting clothing which could get caught in moving
parts. Always wear long pants and substantial shoes.
Wearing safety glasses, safety shoes and a helmet is
advisable and required by some local ordinances and
insurance regulations.
8. Fill fuel tank with gasoline before starting the en
gine. Avoid spilling gasoline. Since gasoline is flam
mable, handle it carefully.
A. Use an approved gasoline container.
B. Do not fill tank while engine is hot or running.
C. Do not smoke while handling gasoline.
D. Fill fuel tank outdoors and up to about one inch
(25 mm) from top of the tank, not the filler neck.
E. Wipe up any spilled gasoline.
WHILE OPERATING
9. Start engine when parking brake is set, blade is
disengaged, and transmission is in neutral.
10. Do not run the engine in a confined area without
adequate ventilation. Exhaust fumes are hazardous
and could possibly be deadly.
11. Using the machine demands attention, and to pre
vent loss of control:
A. Mow only in daylight or when there is good artifi
cial light.
B. Watch for holes or other hidden hazards.
C. Do not drive close to a sand trap, ditch, creek or
other hazard.
D. Reduce speed when making sharp turns and
when turning on hillsides.
12. Do not operate unless grass deflector, Recycler
cover or entire grass collector is installed. The grass
deflector must always be installed and in lowest posi
tion on the side discharge cutting unit. This product is
designed to drive objects into the ground where they
lose energy quickly in grassy areas. However, don't
take an injury risk!! When a person or pet appears un
expectedly in or near the mowing area, STOP MOW
ING. Careless operation, combined with terrain
angles, ricochets, or improperly positioned guards,
can lead to thrown object injuries. Do not resume mow
ing until area is cleared.
13. Never raise the cutting unit while the blades are ro
tating.
14. If the cutting blades strike a solid object or the ma
chine vibrates abnormally, shut the engine off. Remove
spark plug wire from spark plug to prevent possibility of
accidental starting. Check cutting unit and traction unit
for damage and malfunctioning parts. Repair any dam
age before restarting the engine and operating the cut
ting unit. Be sure blades are in good condition and
blade bolts are tight.
15. Cut grass slopes carefully. Do not start, stop, or
turn suddenly.
16. Do not touch engine or muffler while engine is run
ning or soon after it is stopped. These areas couId be
hot enough to cause a burn.
17. Before leaving the operator's position  behind
handle or leaving mower unattended, shift transmis
sion into NEUTRAL, apply parking brake, release con
trol bail and shut OFF engine.
MAINTENANCE
18. Remove key from switch and disconnect spark
plug wire from spark plug to prevent accidental starting
of the engine when servicing, adjusting or storing the
machine.
19. If traction unit and mower must be tipped to per
form maintenance or an adjustment, drain gasoline
from fuel tank and oil from crankcase.
20. When driving unit forward, always use upper For
ward" traction drive handle. When backing up, always
use lower Reverse" traction drive handle.
21. To reduce potential fire hazard, keep the engine
free of excessive grease, grass, leaves and accumula
tions of dirt.
22. Be sure machine is in safe operating condition by
keeping nuts, bolts and screws tight. Check the blade
mounting bolts and nuts frequently to be sure they are
tightened to specification.
23. If the engine must be running to perform a mainte
nance adjustment, keep hands, feet, clothing and oth
er parts of the body away from the cutting unit blades
and other moving parts.
24. Do not overspeed the engine by changing gover
nor settings. To be sure of safety and accuracy, have an
Authorized TORO Proline Service Dealer check maxi
mum engine speed with a tachometer.
25. Engine must be shut off before checking oil or add
ing oil to the crankcase.
26. Allow engine to cool before storing mower in any
enclosure such as a garage or storage shed. Make
sure the mower fuel tank is empty if machine is to be
stored in excess of 30 days. Do not store mower near
any open flame or where gasoline fumes may be ig
nited by a spark. Always store gasoline in a safety-ap
proved, red metal container.
27. Perform only those maintenance instructions de
scribed in this manual. If major repairs are ever needed
or assistance is desired, contact an Authorized Toro
Proline Service Dealer. To ensure optimum perfor
mance and continued safety conformance of the ma
chine, use genuine TORO replacement parts and ac
cessories. Replacement parts and accessories made
by other manufacturers may result in nonconfor
mance with safety standards and could void the war
ranty.

4
SAFETY AND INSTRUCTION DECALS
The following decals are installed on the machine. If any become damaged or illegible, replace it. The decal part
number is listed below and in your parts catalog. Replacement can be ordered from your Authorized Toro Distribu
tor.
ON UPPER CONTROL BAR
(Part No. 82-2290)
ON CONTROL PANEL
(Part No. 82-7730)
ON CONTROL PANEL
(Part No. 71-1280)
ON LOWER CONTROL BAR
(Part No. 82-2280)
ON CONTROL PANEL
(Part No. 65-3090)
ON CONTROL PLATE
(Part No. 82-7750)
ON REAR FRAME
(Part No. 74-0490)
P
A
R
K
I
N
G
B
R
A
K
E
ON PARKING BRAKE LEVER
(Part No. 52-2010)
SPECIFICATIONS
12.5 hp Kawasaki Engine: four cycle, recoil start with
automatic compression release, vertical shaft engine
has output of 12.5 hp @ 3600 RPM and 20.1 ft-lb
torque @ 2300 RPM. Displacement is 28.1 cubic inch
es. Crankcase oil capacity is 48 ounces and fuel tank
capacity is 5 gallons. Correct spark plug is NGK
BMR-4A, Champion RCJ-8 or equivalent. Spark ar
rester muffler.
Frame: 11 ga. formed steel box with 1 in. dia. axle with
1/4" x 4 U-strap rear frame bolted to frame.
Wheels and Tires: 6.5 x 13 pneumatic tires are
mounted on welded steel wheels which have grease
able ball bearings. Recommended tire pressure is
15 psi.
Transmission: Permanently Iubricated and fully en
closed gear box. In line shift pattern with 4 forward
speeds, neutral and reverse.
Traction Drive Belts: A-section, V-belt with 3 in. dia.
take up idler to gear box from engine. 2 rib A-section
banded belt to each wheel from gear box output shafts.
Gear Drive Reduction:
1st gear - 7.0
2nd gear - 4.5
3rd gear - 3.5
4th gear -3.0
Rev. - 6.0
Ground Speed @ 3200 Engine rpm:
1st gear - 1.9 MPH
2nd gear - 3.0 MPH
3rd gear - 3.9 MPH
4th gear - 4.5 MPH
Rev. - 2.2 MPH
Optional Accessories:
Sulky attachment, Model #30122
Sulky attachment, Model #30123
Lift Kit #84-5010
* Lift kit changes height-of-cut range from 1"- 4" to
2"- 5". The larger tires included in kit will also increase
ground speed. Lift kit cannot be used with a model
30136, 36" Deck.
Specifications and design subject to change without notice.

5
LOOSE PARTS
NOTE: Use this chart as a checklist to assure all parts have been received. Without these parts, total set-up cannot
be completed.
Upper Handle 1
Flange Capscrew 3/8 - 16 X 1" Lg. 4 Install Upper Handle To Frame.
Flangenut 3/8-16 4
Shift Lever 1
Shift Lever Mounting Block 1 Install Shift Lever To Transmission
Plain Washer 1
Capscrew 1/4 - 28 X 2" Lg. 1
Rod Fitting 2
Clevis Pin 2 Install Control Rods
Washer 2
Hairpin Cotter 2
Fuel Tank 1
Control Panel 1
Capscrew 5/16 - 18 X 7/8" Lg. 4 Install Fuel Tank And Control Panel
Lockwasher 5/16 4
Flatwasher 5/16 4
Hose Clamp 2
Cable Ties 1 Connect Wire Harness
Operator's Manual 1 Read Before Operating Machine
Parts Catalog 1
Registration Card 1 Fill Out And Return To Toro
Description UseQty.
SET-UP INSTRUCTIONS
MOUNT FUEL TANK AND CONTROL
PANEL
1. Position fuel tank onto rear frame aligning mount
ing holes as shown in Fig. 1.
Figure 1
1. Fuel tank
2. Rear frame
3. Control panel
2. Loosely mount control panel to bottom of rear
frame and fuel tank with (4) capscrews, lockwashers
and washers (Fig. 1 & 2). Do not tighten capscrews at
this time.
Figure 2
1. Capscrews, lockwashers & washers
2. Fuel line hose clamps
3. Secure fuel line to tank fitting with hose clamp
(Fig. 2).
INSTALL SHIFT LEVER
1. Position shift lever mounting block onto shaft on
top of transmission. DO NOT remove rubber washer on
transmission.

6
SET-UP INSTRUCTIONS
2. Insert shift lever thru slot in control panel and align
mounting hole in lever with mounting block on trans
mission. Secure lever to transmission with 1/4-28 x 2"
lg. capscrew and plain washer. Torque capscrew to
100-125 in - lb (Fig. 3).
Figure 3
1. Shift lever mounting block
2. Shift lever
3. Capscrew & washer
3. Move shift lever to reverse and 4th gear. Control
panel mounting holes are slotted to enable it to be
moved from side to side (Fig. 2). Position control panel
as needed to achieve full shift range. Tighten mounting
screws to a maximum of 90 in - lb. DO NOT OVER
TlGHTEN.
INSTALL UPPER HANDLE
1. Align upper handle mounting holes with desired
mounting holes in frame (upper or lower set of holes)
and secure each side with (2) 3/8 -16 x 1" lg. flange
capscrews and flange nuts (Fig. 4). Torque capscrews
to 23-27 ft.-lbs. Route cables and wire harness inside
of frame (Fig. 4)
Figure 4
1. Upper handle
2. Frame
3. Wire harness
4. Cables
CONNECT THROTTLE CABLE
1. Place throttle control lever in FAST position.
2. Hook wire Z-bend into hole of speed control lever
(Fig. 5).
Figure 5
1. Wire Z-bend
2. Speed control lever
3. Base plate
4. Aligned holes
5. Cable clamp
3. Loosen cable clamp screw allowing cable installa
tion, but do not tighten (Fig. 5).
4. Move control cable casing and wire until hole in
speed control lever is aligned with hole in base plate.
Insert a small dia. pin (1 /4") or bolt into aligned holes to
hold adjustment.
5. Pull throttle cable slightly to remove any slack and
tighten cable clamp screw to lock adjustment in place.
6. Remove alignment pin and check control opera
tion. Refer to Adjusting Throttle - Choke Control,
page 12.
CONNECT WIRE HARNESS
1. Secure clutch and engine in-line wire connectors
(Fig. 6).
Figure 6
1. Clutch wire connectors 2. Engine wire connectors
2. Remove top jam nut from right rear engine mount
ing bolt located behind oil dipstick.

7
SET-UP INSTRUCTIONS
3. Mount remaining wire to engine bolt and secure
with jam nut.
4. Secure wire harness to fuel line (above filter) with a
cable tie.
INSTALL CONTROL RODS
1. Thread a rod fitting onto each control rod approxi
mately 2" (Fig. 7) or until upper control bar (Fig. 8). is
approximately perpendicular to the ground.
2. Mount rod fitting ends to mounting holes in idler
brackets (from outside) with clevis pins, washers and
hairpin cotters (Fig. 7).
Figure 7
1. Control rod fitting
2. Idler brackets
3. Clevis pin, washer
& hairpin cotter
3. Check gap between upper control bar and upper
handle when fully engaging wheel belts. Gap should
be approximately 1 to 1-1/4" (Fig. 8).
Note: The control bar and upper handle must be paral
lel when in relaxed drive and brake positions.
4. Check operation. If adjustment is required, remove
hairpin cotter and washer securing end of control rod
to upper control bar,thread rod into or out of rod fitting
to proper position and reinstall to upper control bar with
washer and hairpin cotter.
5. Brake rods should be adjusted so parking brake le
ver can be swung into a snug position against the up
per handle while pulling back on upper control bar
(Fig. 8).
Figure 8
1. Control rod
2. Upper control bar
3. Parking brake lever
6. If an adjustment to brake rods is required, remove
hairpin cotter and washer securing brake rod fitting to
idler bracket (Fig. 9).
Figure 9
1. Idler bracket
2. Brake rod fitting
3. Hairpin cotter & washer
4. Wing nut
7. Adjust wing nut up or down on brake rod and rese
cure to idler bracket. Check adjustment and readjust if
necessary.
Note: Make sure brake rod is installed in forward (F")
mounting hole in idler bracket.
8. Repeat procedure on opposite side if adjustment is
required.

8
BEFORE OPERATING
FILL CRANKCASE WITH OIL
The engine does not have oil in the crankcase when
it is shipped from the factory. If engine is started be
fore oil is added to the crankcase, engine damage
could result. Therefore, before engine is started for
the first time:
1. Position mower on level surface.
2. Clean area around the oil dipstick to prevent for
eign matter from entering the filler hole when dipstick is
removed.
3. Remove dipstick (Fig. 10).
Figure 10
1. Dipstick
4. Slowly pour approximately 48 ounces of oil into the
filler neck. The engine uses any high quality detergent
oil having the American Petroleum Institute APl 
service classification" SF, SE/CC, CD or SE. The rec
ommended oil to use is: SAE 5W20 or 5W30 (below 32
F) or SAE 30 (above 32F).
5. Wipe end of dipstick with clean rag and insert it into
filler neck. Then remove the dipstick and check level of
oil by reading the dipstick (Fig. 10). If level of oil is low,
add only enough oil to raise level to FULL mark on dip
stick. DO NOT ADD OIL SO LEVEL RISES ABOVE FULL
MARK BECAUSE ENGINE COULD BE DAMAGED
WHEN IT IS STARTED.
6. Insert dipstick into filler neck and tighten.
Note: Check level of oil after every 5 operating hours or
each time the mower is used. Initially, change oil after
the first 5 hours of operation; thereafter, when condi
tions are normal, change oil after every 25 hours of op
eration. However, change oil more frequently when
mower is operated in dusty or dirty conditions.
CHECK TIRE PRESSURE
Tires are over inflated at the factory. Check tires and in
sure they are inflated to 15 psi.
FILL FUEL TANK WITH GASOLINE
THE TORO COMPANY STRONGLY RECOMMENDS
THE USE OF FRESH CLEAN, UNLEADED REGULAR
GRADE GASOLINE IN TORO GASOLINE POWERED
PRODUCTS. UNLEADED GASOLINE BURNS CLEAN
ER, EXTENDS ENGINE LIFE, AND PROMOTES GOOD
STARTING BY REDUCING THE BUILD-UP OF COM
BUSTION CHAMBER DEPOSITS.
NOTE: NEVER USE METHANOL, GASOLINE CON
TAINING METHANOL, GASOHOL CONTAINING
MORE THAN 10% ETHANOL, GASOLINE ADDI
TIVES, PREMIUM GASOLINE, OR WHITE GAS BE
CAUSE ENGINE FUEL SYSTEM DAMAGE COULD
RESULT.
1. Clean area around fuel tank cap and remove cap
from tank.
2. Fill fuel tank to about 1 inch from top of the tank, not
filler neck. Install fuel tank cap securely.
3. Wipe up spilled gasoline.
Because gasoline is flammable, caution
must be used when storing or handling it.
Do not fill fuel tank while engine is
running, hot or when machine is in an
enclosed area. Vapors may build up and
be ignited by a spark or flame source
many feet away. DO NOT SMOKE whiIe
filling the fuel tank to prevent the possi
bility of an explosion. Always fill fuel tank
outside and wipe up any spilled gasoline
before starting engine. Use a funnel or
spout to prevent spilling gasoline before
starting engine and fill tank to about I
inch from top of tank, not filler neck.
Store gasoline in a clean safety- ap
proved container and keep the cap in
place on the container. Keep gasoline in
a cool, well-ventilated place; never in an
enclosed area such as a hot storage
shed. To assure volatility, do not buy
more than a 30 day supply of gasoline.
Gasoline is a fuel for internal combus
tion engines; therefore, do not use it for
any other purpose. Since many children
like the smell of gas, keep it out of their
reach because the fumes are explosive
and dangerous to inhale.
DANGER

9
CONTROLS
Throttle Control (Fig. 11) - The throttle control has
three positions: CHOKE, FAST and SLOW.
Deck Engagement Control Bail (Fig. 11) - Control
bail used in conjunction with deck engagement switch
to release blade brake and engage electromagnetic
clutch to drive deck pulleys. Release bail to disengage
deck pulleys.
Deck Engagement Switch (Fig. 11) - Rocker switch
used in conjunction with control bail to release blade
brake and engage electromagnetic clutch to drive
deck pulleys.
Gear Shift Lever (Fig. 11) - Transmission has four for
ward speeds, neutral and reverse, and has an in- line
shift pattern. Do not shift while unit is moving, as trans
mission damage may occur.
Upper Control Bar (Fig. 11) - Shift to desired gear
and push forward on control bar to engage forward
traction operation and pull back to brake. Pull right side
of control bar to turn right and left side to turn left.
Lower Control Bar (Fig. 11) - Shift transmission to re
verse and pull rearward on lower control bar to engage
rearward traction operation.
Parking Brake Lever (Fig. 11) - Pull back on upper
control bar and swing brake lever up against the upper
handle.
Ignition Switch (Fig. 11) - Key switch is used in con
junction with recoil starter. Switch has two positions:
RUN and OFF.
Recoil Starter - Pull recoil Starter handle to start en
gine.
Fuel Shut-off Valve - (Under fuel tank) Close fuel
shut-off valve when transporting or storing mower.
Figure 11
1. Throttle control
2. Deck engagement control bail
3. Deck engagement switch
4. Gear shift lever
5. Upper control bar
6. Lower control bar
7. Parking brake lever
8. Ignition switch
OPERATING INSTRUCTIONS
STARTING AND STOPPING
1. Make sure spark plug wire is installed on spark
plug and fuel valve is open.
2. Shift into neutral, set parking brake and turn igni
tion key to RUN.
3. Move throttle control to CHOKE position before
starting a cold engine.
Note: A warm or hot engine usually does not require
any choking. To start a warm engine, move throttle con
trol to FAST position.
4. Grasp recoil starter handle firmly and pull out until
positive engagement results; then pull handle vigor
ously to start engine and allow rope to recoil slowly.
IMPORTANT: Do not pull recoil rope to its limit or let
go of the starter handle when rope is pulled out be
cause rope may break or recoil assembly may be
damaged.
5. To engage blade, squeeze deck engagement con
trol bail against upper control bar and press rocker
switch forward. Hold control bail against control bar
while operating. Releasing control bail disengages
deck pulleys. Repeat procedure to engage deck pul
leys if control bail is released.
6. To stop engine, release control bail and control bar,
shift to Neutral, move throttle to SLOW, turn ignition key
to OFF and set parking brake. Wait for all parts to stop
moving before leaving the operating position behind
handle.
7. Pull wire off spark plug to prevent possibility of ac
cidental starting before storing machine.
8. Close fuel shut off valve before storing machine.
IMPORTANT: Make sure fuel shut off valve is closed
before transporting or storing machine, as fuel
leakage may occur.

10
MAINTENANCE
To prevent accidental starting of the en
gine while performing maintenance, shut
engine off. Also, pull wire off spark plug
(Fig. 12). Make sure wire does not contact
plug accidentally.
CAUTION
Figure 12
1. Spark plug wire 2. Spark plug
GREASE WHEELS
Lubricate the wheel bearings every 8 hours with No. 2
general purpose grease. Wipe up any excess grease.
GREASE TRANSMISSION COUPLERS
Lubricate the transmission couplers (Fig. 13) every 250
hours with No. 2 general purpose grease. Pump
grease gun about 4 times. Wipe up any excess grease.
Figure 13
SERVICING AIR CLEANER
The foam air cleaner element must be cleaned after ev
ery 25 hours engine operation if engine is operated in
clean air conditions. The paper element must be
cleaned or replaced after every 50 hours engine opera
tion if engine is operated in clean air conditions. How
ever, elements must be cleaned every few hours if op
erating conditions are extremely dusty or sandy. Re
place paper element yearly.
1. Remove (2) wing bolts and lift off air cleaner cover
(Fig. 14).
Figure 14
1. Wing bolts
2. Cover
2. Remove foam pre-cIeaner by sliding it off the pa
per element (Fig. 15).
Figure 15
1. Foam element
2. Paper element
3. Air cleaner body
3. a. Wash foam pre-cleaner in detergent and warm
water.
b. Wrap foam pre-cleaner in cloth and squeeze
dry. Do not wring precleaner.
c. Saturate foam pre-cleaner in engine oil.
Squeeze to remove excess oil.
4. Remove paper element and clean air cleaner body
carefully to prevent dirt from entering carburetor.
5. Clean paper element by tapping gently on a flat
surface.
a. If very dirty, replace cartridge or wash in a low or
non-sudsing detergent and warm water solution.
b. Rinse thoroughly from OUTSIDE IN until water is
clear.
c. Cartridge must be allowed to stand and air dry
thoroughly before using.
6. Reassemble air cleaner components.

11
MAINTENANCE
CAUTION
Petroleum solvents, such as kerosene, are
not to be used to clean paper element. They
may cause deterioration of the cartridge. DO
NOT OIL PAPER ELEMENT. DO NOT USE
PRESSURIZED AIR TO CLEAN OR DRY PA
PER ELEMENT.
IMPORTANT: Always operate engine with air clean
er elements in place or engine damage will result.
CHANGING CRANKCASE OIL
1. Check level of oil before starting engine and after
every 5 hours of operation. Maintain oil level at FULL
mark on dipstick.
To check level of oil:
a. Position mower on level surface.
b. Clean the area around oil dipstick so foreign
matter cannot enter filler hole when dipstick is re
moved.
c. Remove dipstick and wipe oil off with a clean
rag.
d. Insert dipstick. Let dipstick cap threads rest on
top of tube. Do not screw dipstick in.
e. Remove dipstick and check oil level. If level is
low, add only enough oil to raise level to FULL
mark. Do not overfill or engine damage may result.
f. Insert dipstick back into filler neck.
2. Change oil after first 5 hours of operation; every 25
hours thereafter. Change oil more frequently when op
erating conditions are extremely dusty or dirty.
To change oil:
a. Position mower on level surface. Start and run
engine for a period to warm the oil.
b. Turn engine off and place drain pan under frame,
below drain plug (Fig. 16). Remove drain plug and
allow all oil to flow into drain pan. Install drain plug
after oil stops flowing.
Figure 16
1. Drain plug
c. Remove dipstick and add oil to crankcase. The
engine uses any high quality detergent oil having
the American Petroleum Institute APl  service
classification" SF, SE/CC, CD or SE. The recom
mended oil to use is: SAE 5W20
(below 32F) or SAE 30 (above 32F).Capacity of
crankcase is 48 oz. DO NOT OVERFILL or engine
damage may result.
FUEL FILTER REPLACEMENT
An in-line filter is incorporated into the fuel line be
tween the fuel tank and carburetor (Fig. 17). Use the
following procedures should replacement become
necessary:
Figure 17
1. Fuel filter 2. Hose clamps
1. Close fuel shut off valve, loosen the hose clamp on
the carburetor side of filter and remove the fuel line
from the filter.
2. Place a drain pan under filter, loosen the remaining
hose clamp and remove filter.
CAUTION
Since gasoline is highly flammable, drain it
outdoors and make sure engine is cool to
prevent a potential fire hazard. Wipe up any
gasoline that may have spilled. Do not drain
gasoline near any open flame or where gas
oline fumes may be ignited by a spark. Do
not smoke a cigar, cigarette, or a pipe when
handling gasoline.
3. Install the new filter with arrow on the filter body
pointing towards the carburetor.

12
MAINTENANCE
REPLACING SPARK PLUG
Since air gap between center and side electrodes of
the spark plug increases gradually during normal op
eration of the engine, check condition of electrodes af
ter every 25 operating hours. Recommended air gap is
0.024-0.027 of an inch (0.6-0.7 mm). Correct spark
plug to use is:
NCK BMR-4A or Champion RCJ-8.
Note: The spark plug usually lasts a long time; howev
er, the plug should be removed and checked whenever
the engine malfunctions.
1. Clean area around spark plug so foreign matter
cannot fall into cylinder when spark plug is removed.
2. Pull spark plug wire off spark plug and remove plug
from cylinder head.
3. Check condition of side electrode, center elec
trode, and center electrode insulator to assure there is
no damage.
IMPORTANT: A cracked, fouled, dirty or otherwise
malfunctioning spark plug must be replaced. Do
not sand blast, scrape, or clean electrodes by using
a wire brush because grit may eventually release
from the plug and fall into the cylinder. The result is
usually a damaged engine.
4. Set air gap between center and side of electrodes
at 0.024-0.027 of an inch (0.6-0.7 mm (Fig. 18).
Install correctly gapped spark plug w/gasket seal, and
tighten plug to 18 ft-lb (24.4 Nm). If torque wrench is
not used, tighten plug firmly.
Figure 18
ADJUSTING THROTTLE-CHOKE CON
TROL
Proper choke operation is dependent upon proper ad
justment of the throttle control. Before adjusting the
carburetor, assure the throttle control is operating
properly.
1. Remove the wing bolts holding air cleaner in place
and lift air cleaner assembly off carburetor.
2. Move throttle control to CHOKE position and check
the position of the choke butterfly; it should be closed
fully.
3. Move throttle control to FAST position. The butter
fly should be in the fully open position.
Figure 19
1. Clamp screw
2. Aligned holes
3. Control plate
4. Mounting screws (2)
4. If the choke butterfly is positioned as described in
steps 2 and 3, replace the air cleaner assembly and
continue operation.
If either the choke butterfly does not close or is not fully
open in the FAST position, adjust the throttle control as
follows:
1. Place throttle control in FAST position.
2. Loosen the throttle cable clamp screw (Fig. 19) and
move the control cable casing and wire until the hole in
speed control is aligned with hole in control plate.
Tighten cable clamp.
3. Turn in choke adjusting screw (located behind
control plate) until light contact is made with flange on
control lever.
4. Reassemble air cleaner to carburetor.
DANGER
Engine must be running so final adjustment
of the throttle can be performed. To guard
against possible personal injury, shift into
neutral, and engage parking brake. Keep
hands, feet, face, and other parts of the body
away from the cutter blades, underside of
mower housing, discharge area, and any ro
tating engine parts.

13
MAINTENANCE
5. Start engine and let it warm up for approximately
two minutes. Next, make sure throttle control is in FAST
position.
6. Loosen (2) control panel mounting screws
(Fig. 19).
7. Slide control panel up or down to obtain
3200 +100 RPM. Check with tachometer.
8. Tighten control plate mounting screws making
sure adjustment is not disturbed.
9. Recheck choke adjusting screw adjustment per in
structions in step #3.
10. After throttle is adjusted, stop engine.
ADJUSTING CARBURETOR
The carburetor has been set at the factory, but an occa
sional adjustment may be required. An adjustment
may be required to compensate for differences in fuel
or temperature.
IMPORTANT: Before the carburetor is adjusted,
throttle control must be checked for proper opera
tion: refer to Adjusting Throttle-Choke Control,
page 12.
1. Idle Mixture Screw (Fig. 20)  Close screw by
gently rotating it clockwise.
Figure 20
1. Idle mixture screw 2. Throttle stop screw
IMPORTANT: Do not close the screw too tight be
cause the valve and seat in carburetor will likely be
damaged.
2. Rotate  open  the screw 1-1/8 turns counter
clockwise (Fig. 20).
Note: The idle mixture screw setting is an approximate;
however, the setting will allow engine to be started so
carburetor can be fine tuned.
3. Start engine and let it warm up at half throttle for
approximately five to ten minutes. Next, move throttle
control into SLOW detent.
DANGER
Engine must be running so final adjustment
of the throttle can be performed. To guard
against possible personal injury, shift into
neutral, and engage parking brake. Keep
hands, feet, face, and other parts of the body
away from the cutter blades, underside of
mower housing, discharge area, and any ro
tating engine parts.
IMPORTANT: Air cleaner must be installed on the
engine whenever it is being adjusted. The air clean
er mounting bolts must also be installed when en
gine is running.
4. Adjust the throttle stop screw to obtain1400 +100
RPM.
5. Adjust the idle mixture screw by turning it clock
wise (lean) or counterclockwise (rich) until it idles
smoothly.
6. Next, rotate idle mixture screw 1/4 turn counter
clockwise.
7. Check and adjust the throttle stop screw to obtain
1400 +100 RPM when idling.
8. After carburetor is adjusted, shut engine off.
Carburetor  High Altitude Correction:
Carburetor jetting should be changed for high altitude
operation.
Standard Main Jet Size is #112.5
Above 3000 feet, use main jet size #110.
Above 6000 feet, use main jet size #107.5.
ADJUSTING AND REPLACING TRACTION
BELT
1. Loosen capscrew and flange locknut securing
idler pulley to frame (Fig. 21). Slide pulley outward re
lieving belt tension.
2. Disconnect in-line wire connectors.
3. Remove left front engine mounting bolt securing
clutch retainer to frame (Fig. 21). Unhook retainer from
clutch and remove retainer.
4. Remove belt from drive pulley and clutch (Fig. 21).
5. Install new belt around clutch and drive pulley.
6. Reinstall clutch retainer to clutch and frame with
engine mounting bolt. Torque engine mounting bolt to
170-220 in-lb.
7. Secure in-line wire connectors.

14
MAINTENANCE
Figure 21
1. Idler pulley
2. Clutch retainer
3. Locknut on flange stud
8. Position and secure idler pulley to frame so belt
deflection is no more than 11/64" when 5-1/2 lb of
force is applied to mid span of long leg of belt
(Fig. 21).
ADJUSTING CLUTCH
The clutch is adjustable to ensure proper engagement
and proper braking.
1. To adjust clutch, tighten or loosen locknuts on
flange studs (Fig. 21).
2. Check adjustment by inserting feeler gauge thru
slots next to flange studs.
3. The proper disengaged clearance between the
clutch plates is .012 - .018 inches. It will be necessary
to check this clearance at each of the three slots to en
sure the plates are parallel to each other.
BRAKE ADJUSTMENT
An adjustment to the brake may be required to com
pensate for belt stretching or brake seating.
1. To adjust brakes, refer to Install Control Rod,
page 7.
DRIVE BELT REPLACEMENT
1. Remove top capscrew securing idler support and
idler bracket to rear frame (Fig. 22).
Figure 22
1. Idler bracket
2. Hairpin cotter, washer
& brake rod fitting
3. Idler support
4. Top capscrew
5. Bottom capscrews
2. Loosen bottom two mounting screws enough to al
low belt to pass between drive pulley and idler support
(Fig. 22).
3. Raise wheel off ground enough to allow belt remov
al.
CLEANING COOLING SYSTEM
Clean engine cooling system frequently, by removing
any build-up of grass, dirt or other debris from the cyl
inder and cylinder head cooling fins, air intake screen
on flywheel end, and carburetor-governor levers and
linkage. This will help insure adequate cooling and cor
rect engine speed and will reduce the possibility of
overheating and mechanical damage to the engine.

15
WIRING SCHEMATIC
85 87
86 30
Blue / White
Brown
Clutch
Switch
Relay
Bail Switch
Blade Clutch Coil
3 ohms
Minimum
Engagement
Requirements
11.6 vdc
2.9 amps
Module
Alternator
Magneto
Engine
-
+
Red
Red
Red
Red
Blue
Orange
Black
White / Black
White / Black
Black
Green
Rectifier
AC
AC
Key Switch Black
IDENTIFICATION AND ORDERING
The mower has two identification numbers: a model
number and a serial number. The two numbers are
stamped into a plate that is riveted to the frame on right
front corner of mower. In any correspondence con
cerning the mower, supply the model and serial num
bers to assure that correct information and replace
ment parts are obtained.
To order repIacement parts from an authorized TORO
Distributor, supply the foIlowing information:
1. Model and serial numbers of the machine.
2. Part number, description and quantity of parts de
sired.
Note: Do not order by reference number if a parts ca
taIog is being used; use the part number.