THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF TECUMSEH OR IT’S SUCCESSORS. TECUMSEH AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Service Manual

Serv

ice

Man

ual

8 Horse Power and Larger Engines

(1975)

TE-S-8HP+

MECHANICS HANDBOOK

8 H.P. and LARGER

• • C? U)

~ ~ % LAUSON· POWER PRODUCTS ¥ ~~ «)

... '</' POWER \'f>..c,,*,~

LAUSON-POWER PRODUCTS PARTS DEPOT DIY TECUMSEH PRODUCTS CO.

GRAFTON, WISCONSIN

WHERE IMAGINATION AND INNOVATION HELP SHAPE AN INDUSTRY

LITHO IN U.S.A. ,FORM' NO".~691462

GENERAL INFORMATION

GOVERNOR CARBURETION

·AIR CLEANERS

STARTERS, STARTER MOTOR GENERATOR

CYLINDER BREATHER

PISTON, RINGS CONNECTING ROD CRANKSHAFT

VALVES CAMSHAFT

BEARINGS SEALS GASKETS

IGNITION, BATTERY SERVICE, & CHARGING SYSTEMS

TROUBLE SHOOTING AND ANALYSIS

SPECI FICATIONS .

TABLE OF CONTENTS

Chapter Page 1. GENERAL INFORMATION

Engine Identification ............ 1-A-1 Engine Care (Consumer) ......... 1-A-1 Lubrication ................... 1-A-2 Gasoline Requirements .......... 1-A-2 Engine Preparation for the

Consurfler . . . . . . . . . . . . . . . . . 1-B-1 Engine Break-in Procedure ....... 1-B-2

2. AIR CLEANERS-CARBURETION­GOVERNOR Air Cleaners ................... 2-A-1 Walbro Carburetors ............. 2-B-1 Tecumseh Float Feed Carburetors .. 2-B-5 Throttle ...................... 2-B-5 Choke ....................... 2-B-5 Idle Adjustment Screw .......... 2-B-5 High Speed Adjustment Screw .... 2-B-6 Fuel Bowl Retaining Nut ......... 2-B-6 Fuel Bowl .................... 2-B-6 Float ........................ 2-B-6 Inlet Needle ................... 2-B-6 Servicing the Viton Seat ......... 2-B-6 Setting the Float . . . . . . . . . . . . . . . 2-B-7 High Speed Nozzle ............. 2-B-7 W~lch Plug Service .............. 2-B-9 Fixed Main Jet Type Carburetor ... 2-B-9 Fuel Pump Service Procedure ..... 2-B-9 Mechanical Governor Gear

Service ............... . . . . 2-C-1 Governor Rod Service ........... 2-C-2 Horizontal Crankshaft Engine

Governor Adjustment ........ 2-C-2 Vertical Crankshaft Engine

Governor Adjustment ........ 2-C-3 Setting Variable Speed Adjustment

Screw to Maximum R.P.M ..... 2-C-3 Adjusting Fixed Speed .......... 2-C-4 Crankcase Impulse Fuel Pump

No. 32959 General .......... 2-D-1 Operation .................... 2-D-1 Service . . . . . . . . . . . . . . . . . . . . . . . 2-D-1 Testing ...................... 2-D-2

3. STARTERS/GENERATORS Rope Replacement ............. 3-A-1 Disassembly ................... 3-A-1 Spring Replacement ............ 3-A-1 Reassembly ................... 3-A-2 Rewinding Spring and Reassembly . 3-A-2 Motor Generator Wiring Diagram .. 3-B-1 Wiring Diagram for Key

Switch and Solenoid ......... 3-B-1 Manual Starter Switch ........... 3-B-2 Solenoid and Key Switch

Diagram-The Solenoid ...... 3-B-2 Service Starter Kit with

Solenoid Diagram . . . . . . . . . . . 3-B-3

Chapter Page Starter 32510 (Stamped on Starter)

Service, Disassem bly and Inspection ................ 3-B-4

Starter 32817 (Stamped on Starter) Service, Disassembly and Inspection ................ 3-B-5

Performance Test ............... 3-B-6 Starter Installation ............. 3-B-6 Starter 33835 Service, Disassem-

bly and Inspection .......... 3-B-7 12 Volt Starter Trouble Shooting

Chart ................... 3-B-10 Starter Motor Tests ............ 3-B-12 Motor Generator Voltage

Regulator ................. 3-C-1

4. CYLINDER AND BREATHER Cylinder Service ............... 4-A-1 Valve Seat and Guide Service ..... 4-A-1 Head Bolt Installation ........... 4-A-1 Fuel Pump Mounting ......... ' ... 4-A-2 Breather Service ............... 4-A-2

5. PISTON RINGS - CONNECTING ROD AND CRANKSHAFT Rings and Wrist Pin Service ....... 5-A-1 Piston Wear Checks ............. 5-A-1 Ring and Cylinder Wear

Checks ..... . . . . . . . . . . . . . . 5-B-1 Ring Installation ............... 5-B-1 Connecting Rod Service ......... 5-C-1 Crankshaft Bearing Service ....... 5-D-1 Connecting Rod Journal Wear

Checks ..... . . . . . . . . . . . . . . 5-D-1 Oil Slinger .................... 5-E-1 Dyna-Static ................... 5-F-1 Installation of Counterweight

Bearing ................... 5-F-2 Aligning the Counterweights ...... 5-F-2 Crankshaft Positioning .......... 5-F-2

6. VALVES AND CAMSHAFT Valve Guide Service ............. 6-A-1 Valve Gap Adjustment .......... 6-A-1 Valve Spring Checks ............ 6-A-1 Valve Grinding Procedures ....... 6-A-1 Camshaft Service ............... 6-B-1 Insta-Matic Ezee-Start

Compression Release ........ 6-B-1 Valve Timing .................. 6-B-1

7. BEARINGS, SEALS, GASKETS Roller Bearing Removal .......... 7-A-1 Roller Bearing Installation. ; ...... 7-A-2 Bearing Cup Service ............. 7-A-3 Crankshaft End Play Adjust-

ment ..................... 7-A-3 "O"Ring Placement ............. 7-A-4

TABLE OF CONTENTS (Cont'd.)

Chapter Page

End Play Adjustment ........... 7-A-4 Oil Seal in Cover ............... 7-A-4 Engine Knocking ............... 7-A-4 Oil Seal Service ................ 7 -B-1

8. IGNITION

ii

Ignition Service Checks .......... 8-A-1 Point Installation and Adjust-

ments .................... 8-A-1 Flywheel Removal .............. 8-A-2 Magneto Coil Service ............ 8-B-1 Magneto Tests ................. 8-B-1 Coil Tests .................... 8-B-2 Magneto Ignition Wiring Diagram .. 8-C-1 Battery Ignition Wiring

Diagram .................. 8-C-1 Solid State Ignition System

Service ................... 8-D-1 Solid State Ignition System

(Non Alternator Type) ....... 8~D-3 Electrical Control Panel Service

Part No. 730155 ............ 8-E-1 On-Off Switch - Ignition

Ground Circuit ............. 8-E-1 On-Off Switch - DC Relay

Circuit ................... 8-E-1 Starter Switch ................. 8-E-2 Ammeter ..................... 8-E-2 Electric Control Panel Trouble

Shooting .................. 8-E-3 Battery Check ................. 8-F-1 Battery Size Ratio: Amperage

to Temperature ............ 8-F-1 Battery Condition .............. 8-F-1 Battery Precautions ........... " 8-F-1 Battery Maintenance ............ 8-F-2 Testing the Battery ............. 8-F-2 Specific Gravity Check .......... 8-F-3 Trouble Shooting the 10 AMP

or 20 AMP Alternator System . . . . . . . . . . . . . . . . . . . 8-G-1

Testing the Regulator-Rectifier .... 8-G-1 Maintenance .................. 8-G-1 Wire Size Requirements .......... 8-G-1 Precautions ................... 8-G-1 Pre-Service Checks .............. 8-G-2

10 AMP ALTERNATOR TESTS Test No.1 (No Charge

to Battery) ................ 8-G-2 Test No.2 (No Charge

to Battery) . . . . . . . . . . . . . . . . 8-G-3 Test No.3 (No Charge

to Battery) .. . . . . . . . . . . . . . . 8-G-3 Test No.4 (Battery Always

Charging At High Rate ....... 8-G-3 Test No.5 (Battery Boiling

or Fuming) ................ 8-G-4

Chapter

20 AMP ALTERNATOR TESTS Test No.1 (No Charge

Page

to Battery) ................ 8-G-4 Test No.2 (No Charge

to Battery) ................ 8-G-5 Test No.3 (Low Charge

to Battery) ................ 8-G-5 Test No.4 (Battery Always

Charging At High Rate), ...... 8-G-5 Test No.5 (Battery Boiling

or Fuming) ................ 8-G-5 10 Amp. Systems and 20 Amp.

Systems with Solenoids ...... 8-G-6 Electrically Regulated 20 Amp.

Circuit with a Solenoid. . . . . . . 8-G-6 Electrically Regulated 5.75 Amp.

A.C. Alternator Circuit ...... 8-G-6 Electrical Circuitry Troubleshooting; 8-G-6

9. TROUBLE SHOOTING AND ANALYSIS Upon Receiving an Engine

for Repair ................. 9-A-1 Trouble Shooting .............. 9-B-1 A. Engine Fails to Start ......... 9-B-1 B. Engine Knocks ............. 9-B-1 C. Engine Misses Under Load .... 9-B-2 D. Engine Lacks Power ......... 9-B-2 E. Engine Overheats ........... 9-B-2 F. Engine Surges or Runs Unevenly 9-B-3 G. Engine Vibrates Excessively ... 9-B-3 H. Engine Uses Excessive

Amount of Oil ............. 9-B-3 1. Oil Seal Leaks . . . . . . . . . . . . . . 9-B-4 J. Breather Passes Oil ., ........ 9-B-5 K. Trouble Shooting Carburetion . 9-B-6 Engine Tune-Up Procedure ....... 9-C-1

10. SPECIFICATIONS Cross Reference List

for Table of Specifications for Craftsman ............. 10-A-1

Table of Specifications ......... 10-B-1 Torque Specifications .......... 10-B-5

COVER ELEMENT

SEALING EDGES

Figure 2-A-l

ELEMENT

GASKET

ADAPTER ~/ "" ~y;,

I I I I I I I I I I

j

COVER

(A

BODY~

~::::=I=:::::~ : I I I

//////' /~ I /// OIL LEVEL. \ v USE CLEAN LOCKING

CRANKCASE WING NUT OIL

GASKET

Figure 2-A-2

2-A-l Dry type air cleaners are treated paper elements with rubbe~like sealing edges. It is. im­portant that the edges of these elements seat properly to prevent dirt leakage. Compressed air may be used to clean the element. Com­pressed air should be directed from the inside of the element blowing toward the outside to f) dislodge the accumulated dirt. Tap.ping the ele-ment on a block of wood will also dislodge accumulated dirt. Wash element in soap and water solution and thoroughly flush or rinse element from inside until water is free of soap.

Allow element to completely dry, use LOW pres­sure compressed air to aid in quick drying element. Blow air through element from inside.

Inspect the element for cracks and holes. If there is any doubt concerning filter's condition, replace.

Clean frequently to assure full engine power and performance. Never operate the engine without the air cleaner properly assembled. Do not puncture element. Carefully inspect element for cracks and holes.

NOTE: It is mandatory to use only factory parts in a Tecumseh engine. This is especially important with an air filter since the use of any other than the specified part number may result in serious damage to the engine.

2-A-2 Frequent service of the oil bath air cleaner will assure adequate engine protection. Clean all parts in solvent and dry thoroughly. Fill with oil and assemble in the sequence shown, Figure 2-A-2, or as instructed in the owners manual. Gaskets must be used at the pOints in­dicated in Figure 2-A-2. Replace the gaskets if damaged.

2-A-3 Maintain the oil level at the pointindicat­ed on the air cleaner body, Use the same grade of oil for the air cleaner as used in the engine crankcase.

2-A-l

FLOAT FEED CARBURETORS - SPECIFIC MODELS

IDLE ADJUSTMENT \ NEEDLE \1

FUEL BOWL----

FUEL BOWL RET AINING NUT

\ ~ HIGH SPEED ADJUSTMENT NEEDLE

FUEL BOWL DRAIN

Figure 2-B-1

CHOKE STOP SPRING THROTTLE LEVER

/ THROTTLE RETURN ~SPRING

~ SECONDARY ~LE DISCHARGE

OO~) ~PRfM.ARY IDLE (1 DISCHARGE

THROTTLE SHUTTER

BOWL fzT---U-:;;"';:::::"---FUEL BOWL NUT

FUEL BOWL DRAIN

THROTTLE

---- HIGH SPEED ADJUSTMENT NEEDLE

Figure 2-B-2

/THROTTLE LEVER

~~~m THROTTLE STOP SCREW

~~ / INSTALL WITH '\...::::iV7..JIiJ..J.---OIJI' LETTERING OUT

Figure 2-B-3

2-8-1 WALBRO CARBURETORS. Following are initial carburetor adjustments to be used to start the engine. After the engine has reached operating temperature make final adjustments.

Idle Adjustment: 1-1/4 turn off seat High Speed Adjustment: 1-1/2 turn off seat Throttle Stop Screw: 1 turn after con

throttle lever Recommended Speeds: For HH80, HH100 and HH120 engines

Idle: 1700 to 2000 rpm High Speed: 3400 to 3600 rpm

For VH80 and VH100 engines Idle Speed: 1650 to 1950 rpm High Speed: 3450 to 3750 rpm

For proper carburetion the atmospheric vent MUST be open. Examine and clean ifnecessary.

Sluggish engine speed control may at times be caused by dirt or paint on the throttle return spring. Clean if required.

The fuel bowl drain is a convenient way of clearing the carburetor of foreign matter and gasoline for storage.

2- 8 - 2 Choke lever positioning is maintained by the stop spring, replace if damaged.

The fuel inlet fitting should be checked if leak­age is detected in the carburetor area. Do not screw in too tight, this may crack the carbur­etor body. The fuel bowl drain should also be examined in event fuel leakage is detected. It may be necessary at times to replace the in­ternal rubber seat. Examine the throttle return spring if slow engine response is noted during operation. Correct by cleaning the throttle re­turn spring or realigning the throttle plate.

2-8-3 Install the throttle plate with the letter­ing (if present) facing out when closed. Move the throttle shaft to the closed position, place the throttle plate on the shaft and secure with the retaining screws. The throttle should move free­ly. If binding is present, correct by loosening screws and repositioning throttle plate.

2-B-l

EARLY NEW

Figure 2-B-10. Valve and Seat Arrangements

2-B-4

GASKET GOES OVER SPRING

CHOKE END OF CARBURETOR

ENDS OF SPRING POINT TOWARD CHOKE END OF CARBURETOR

Figure 2-B-ll

HOLD SLIGHT SPRING TENSI01'l WITH THUMB

•

Figure 2-B-12

2-8-13 Figure 2-B-10 shows early and new valve, seat, gasket and spring assembly arrange­ments for large horsepower engine carburetors.

Early carburetors have a metal-to-metal needle and seat contact. The float setting for this model will be .110"-.130".

New carburetors contain a viton seal in the seat and a spring on the needle. For engines with the new carburetor, and having a fuel pump, the float setting is .140 (9/64").

For engines with the new carburetor, without a fuel pump, the float setting is .075 (5/64").

2 - 8 -14 The float setting on carburetors used on vertical 8 and 10 H.P. engines is .070" to .110" (5/64" to 7/64"). No variance for carbu­retor having a fuel pump.

The gasket must fit over the float spring as shown in Figure 2 - B-11 to a void cutting by the spring when assembled.

When assembling the float to the carburetor body, position the needle spring on the adjusting tang so that it hangs down. Hold the float spring under tension until the carburetor body will support the slight spring tension.

NOTE: THE SPRING ENDS MUST POINT TO­WARD THE CARBURETOR CHOKE END.