John Deere 200 / 208 / 210 / 212 / 214 / 216 Lawn Garden Tractor OEM Service & Repair Manual

SERVICE MANUAL 200, 208, 210, 212, 214 and 216 Lawn and Garden Tractors 200, 208, 210, 212, 214 and 216 Lawn and Garden Tractors SM2105 (01OCT81) English ico Lawn & Grounds Care Division SM2105 (01OCT81) John Deere ÿHo LITHO IN U.S.A. ENGLISH = LO |o E C\| Ico

JOHN DEERE 200, 208, 210, 212, 214 AND 216 LAWN AND GARDEN TRACTORS Service Manual SM-2105 (June-81) TABLE OF CONTENTS SECTION 10 Group 5 - Group 10 - Group 15 - Group 20 - - GENERAL Tractor Identification Specifications Fuet and Lubricants Tune-Up and Adjustments SECTION 20 - ENGINE Group 5 - General Information Group 10 * Cylinder Head, Valves and Breather Group 15 - Minor Engine Recondition Group 20 - Major Engine Recondition Group 25 - Specifications SECTION 30 - FUEL SYSTEM Group 5 Group 10 Group 15 Group 20 Group 25 Group 30 SECTION Group Group Group Group Group Group Group 40 5 - 10 - 15 - 20 - 25 - 30 - 35 - General Information Carburetor Air Cleaner Fuel Strainer and Fuel Tank Fuel Pump Specifications - ELECTRICAL SYSTEM General Information Cranking System Ignition System Charging System Lights Electric Lift Electric PTO Clutch SECTION 50 - POWER TRAIN Group 5 - Genera] Information Group 10 - Clutch and Variable Speed Drive Group 15 - Brakes Group 20 - 4-Speed Transaxle Group 25 - PTO Clutch SECTION 60 - HYDRAULIC LIFT SYSTEM Group 5 - General Information Group 10 - Control Valve Group 15 - Pump Group 20 - Cylinder SECTION 70 - MISCELLANEOUS Group 5 - Steering Linkage Group 10 - Front Wheels and Axles Group 15 - Lift Linkage SECTION 80 - SPECIAL SERVICE TOOLS Group 5 - Engine Convenience Service Tools Group 10 - Tractor Essential Service Tools Group 15 - Tractor Convenience Service Tool; SECTION 90 - TRACTOR ATTACHMENTS Group 5 - 37A Snow Thrower Group 10 - 39 and 47 Rotary Mowers Group 15 - 541A PTO Group 20 - 31 Rotary Tiller OOA- (AH information, illustrations, and specifications contained in this service manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.) Copyright ÿ£) 1980 DEERE & COMPANY Moline, Illinois All rights reserved Litho in U.S.A

2 Tractors, 200 Series SM-2105 (Jun-81) INTRODUCTION This service manual contains service and mainte¬ nance information for the John Deere 200, 208, 210, 212, 214 and 216 Lawn and Garden Tractors and attachments through 1982 model (SN 195,001- )- The manual is divided into sections. Each section pertains to a certain component or operational system of the tractor or attachment. The information is divided into groups within each section. Emphasis is placed on diagnosing malfunctions, analysis and testing. Diagnosing malfunctions includes possible troubles, their causes and how to correct them. Under specific components these troubfes are analyzed to help you understand what is causing the problem, In this way, you can eliminate the cause rather than just replace the part. Metric equivalents have been included,, where ap¬ plicable, throughout this service manual, Specifications and special tools are found in the last group of each section. Whenever new or revised pages are provided, insert them into your manual as soon as you receive them. Your service manual will always be up-to-date and be a valuable asset in your service department. A This safety alert symbol identifies impor¬ tant safety messages in this manual. When you see this symbol, be alert to the possibility of personal injury and carefully read the message that follows. FOR YOUR CONVENIENCE Vertical lines appear in the margins of many of the pages. These lines identify new material and revised information that affects specifications, procedures, and other important instructions, Litho in U.S.A.

Section 10 GENERAL Group 5 TRACTOR IDENTIFICATION CONTENTS Page GROUP 5 - TRACTOR IDENTIFICATION Serial Numbers 5-2 Tractor 5-2 Engine 5-2 Transaxle 5-2 Identification Codes 5-2 Tire Codes 5-2 GROUP 10 - SPECIFICATIONS Engine Specifications 10-1 Battery Specifications 10-2 Tractor Specifications 10-2 Tire Specifications 10-3 Rear Wheel Weight Bolt Size Chart 10-3 BoEt Torque Chart 10-4 Set Screw Seating Torque Chart 10-4 GROUP 15 - FUEL AND LUBRICANTS Fuel 15-1 Lubricants 15-1 Engine Crankcase 15-1 Transaxle 15-1 Tractor Grease Fittings 15-1 Hydraulic System (Optional Equip.) ...... 15-1 Capacities 15-1 Service Intervals 15-2 Lubricating Grease Fittings 15-2 Changing Engine Crankcase Oil 15-3 Changing Transaxle Lubricant 15-3 Repacking PTO Clutch Bearing 15-4 Lubricating Integral Hitch Grease Fitting 15-4 Checking Hydraulic Lift System Fluid Level 15-4 Page GROUP 20 - TUNE-UP AND ADJUSTMENTS Purpose of Tune-Up and Adjustments ..... 20-1 Visual Inspection 20-1 Engine Tune-Up 20-1 Tractor Adjustments 20-1 Tune-Up Guide 20-1 Tune-Up and Adjustments 20-2 Clean Engine Shrouds and Cooling Fins 20-2 Clean or Replace Air Filter Element 20-2 Clean Fuel Strainer 20-2 Check and Clean Engine Crankcase Breather 20-2 Check Spark Plug Gap 20-3 Check Ignition Breaker Points and Engine Timing 20-3 Adjust Carburetor 20-5 Check Engine Speed 20-5 Change Engine Crankcase Oil 20-6 Check or Change Transaxle Lubricant .. . 20-6 Lubricate Grease Fittings 20-6 Repack PTO Clutch Bearing 20-6 Service Battery 20-6 Check Tire Pressure 20-6 Check Operation and Condition of: Lights 20-6 Lift System 20-6 Steering 20-6 Brakes 20-6 Belts and Equipment 20-6 Litho in U.S.A.

1 0 General 5-2 Tractor Identification Tractors, 200 Series SM-2105 (Sep-78) SERIAL NUMBERS Tractor Fig. 1 -Tractor Serial Number The tractor serial number, Fig. 1, is located on the pedestal below the steering wheel. The first letter indicates the "family of machine"; the next three numbers or letters, the "model or ma¬ chine designation"; the letter in the fifth position indi¬ cates the "model year". This is followed by a space (for computer purposes), and a six-digit serial num¬ ber and the letter "M" denoting Horicon as the facto¬ ry of manufacture. Machine Designation J 200 One Space Family (Tractor) D + Model Year D=f975 E=-1976 etc. 030001 Serial Number Factory Designation (Horicon) iJl When ordering parts, use only the six-digit serial number. When writing about or filling out warranty claims, use all thirteen numbers, letters and spaces shown on the machine serial number plate. Engine Hj $3 ? The engine serial number, Fig. 2, is located on the engine shroud. Transaxie f &26973K \ . " ite!? iff' Fig. 3-Transaxle Serial Number The transaxie serial number, Fig. 3, is located on the transaxie case next to the L.H: axle housing. IDENTIFICATION CODES Tire Codes John Deere 200, 210, 212, 214 and 216 Tractors can be equipped with four different combinations of tires as follows: Tire Code Size Front Size Rear Tread GT-3 16x6.50-8 23x8.50-12 High- Flotation GT-4 4.80/4.00-8 23x8.50-12 Studded Traction GT-5 16x6.50-8 23x10.50-12 High- Flotation GT-8 Bar Tread 16x6.50-8 or 4.80/4.00-8 23x10.50-12 High- Flotation Traction NOTE: The 200 Tractor is equipped with GT-3 tires as standard equipment. The 208 Tractor is equipped with 4.80 x 4.00-8 (2-ply) front tires and 23 x 8.50-12 rear tires as standard equipment. The 208 Tractor can be equipped with GT-3, GT-4, GT-5, or GT-8 tires fisted above if desired. The 210, 212, 214 and 216 Tractors are equipped with GT-5 tires as standard equipment. Fig. 2-Engtne Serial Number Litho in U.S.A.

Tractors, 200 Series SM-2105 (Jun-81) General 10 Specifications 10-1 Group 10 SPECIFICATIONS ENGINE SPECIFICATIONS ftem 200 2oe 210 Engine Model No K181GS K181S K241AQS Manufacturer Kohler Kohler Kohler Cylinders One One One Stroke/Cycle Four Four Four Bore 2.94 in, (74.6 mm) 2.94 in. (74.6 mm) 3.25 in. (82.5 mm) Stroke 2.75 in. (69-8 mm) 2.75 in, (69.8 mm) 2.88 in, (73,1 mm) Displacement 18.6 cu. in. 18.6 cu. in. 23.9 cu. in. Speeds (Fast) No Load . 3400 to 3500 rpm 3400 to 3500 rpm 3400 to 3500 rpm Speeds (Idle) 1700 to 1900 rpm 1700 to 1900 rpm 1700 to 1900 rpm Horsepower*" 8 a 10 Normal Compression 110 to 120 psi 110 to 120 psi 110 to 120 psi Valve Clearance Intake (Cold) 0.007 in. (0.178 mm) 0.007 in. (0.178 mm) 0.010 in. (0.254 mm) Exhaust (Cold) 0.016 in. (0.408 mm) 0.016 in. (0.406 mm) 0.020 in, (0.508 mm) Ignition Battery Battery Battery Spark Plug** Champion-J-8 or XJ8 Champion- RJ8 Champion-H-10 AC-45-M or R-46 AC-45L Prestolite-14-7 Prestolite-14-L7B or 14-R8 Spark Plug Gap 0.025 in. (0.635 mm) 0 025 in. (0.635 mm) 0.035 in. (0.889 mm) Breaker Point Gap 0.020 in. (0.508 mm) 0.020 in. (0,508 mm) 0.020 in. (0.508 mm) Charging System Alternator Alternator Alternator Starter 12- Volt 12-Volt 12-Volt Air Filter Dry-type Dry-type Dry-type Item 212 214 216 Engine Modet No K301AQS K321AQS K341AQS Manufacturer Kohler Kohler Kohler Cylinders One One One Stroke/Cycle Four Four Four Bore 3.38 in. (85.8 mm) 3.50 in. (88.9 mm) 3.75 in. (95.2 mm) Stroke 3.25 in. (82.5 mm) 3.25 in. (82.5 mm) 3.25 in. (82.5 mm) Displacement 29.1 cu. in. 31 .3 cu. in. 35.9 cu. in, Speeds (Fast) No Load . 3400 to 3500 rpm 3400 to 3500 rpm 3400 to 3500 rpm Speeds (Idle) 1700 to 1900 rpm 1700 to 1900 rpm 1700 to 1900 rpm Horsepower* 12 14 16 Normal Compression 110 to 120 psi 110 to 120 psi 110 to 120 psi Valve Clearance Intake (Cold) 0.010 in. (0.254 mm) 0.010 in. (0.254 mm) 0.010 in. (0,254 mm) Exhaust (Cold) 0.020 in. (0.508 mm) 0.020 in. (0.508 mm) 0.020 in. (0.508 mm) Ignition Battery Battery Battery Spark Plug** Champion- H-10 Champion-H-10 Champion-H-10 AC-45L AC-45L AC-45L Prestoiile-14-L7B Prestolite-l4-L7B Prestolite- 14-L7 B Spark Plug Gap 0.035 in. (0.889 mm) 0.035 in, (0.889 mm) 0.035 in. (0.889 mm) Breaker Point Gap 0.020 in. (0.508 mm) 0.020 in. (0.508 mm) 0.020 in. (0.508 mm) Charging System Alternator Alternator Alternator Starter 12-Volt 12-Volt 12-Volt Air Filter Dry-type Dry-type Dry-type *The horsepower rating shown is established by the engine manufacturer in accordance with Standard Internal Combustion Engine Institute procedure, tt is corrected at 60°F. and 29.22 in. Hg. Barometer and is developed from laboratory test engines equipped with standard air cleaner and muffler. **in Canada, compliance with radio interference regulations certified. Replace spark plug with resistor-type spark plug only. Use Champion RJ8 for 200 and 208 Tractors. Use Champion RH10 for 210, 212, 214 and 216 Tractors. Litho in U.S.A.

10 General 1 0-2 Specifications Tractors, 200 Series SM-2105 (Jun-81) BATTERY SPECIFICATIONS Tractor Battery 200, 208 John Deere, 12 Volt, (AM30094), BCl Group U1, 135 cold cranking amps at 0°F (-17°C), 30-minute reserve capacity. 210, 212, 214, 216 John Deere, 12 Volt, (AM31186), BCl Group 22F, 255 cold cranking amps at 0°F (-17°C), 55-minute reserve capcaity. TRACTOR SPECIFICATIONS Item 200, 208 210, 212, 214, 216 CAPACITIES Fuel Tank 3-1/2 U.S. Gallons (13.25 L) 3-1/2 U.S. Gallons (13.25 L) Crankcase 2-1/2 U.S. Pints {1.18 L) **(S.N, 30001-95261) 3 U.S. Pts. (1.42 L) ***(S,N. 95262 and up) 4 U.S. Pints (1.89 L) Transaxle 3-1/2 U.S. Pints (1.65 L) 3-1/2 U.S. Pints (1.65 L) Hydraulic System (optional) 2 U.S. Pints (0.94 L) TRANSMISSION Type Transaxle Transaxle Gear Selections 4 forward - 1 reverse 4 torward - 1 reverse TRAVEL SPEEDS - C« 3400 rpm 1st Gear (Variable) 0.3 to 0.9 mph (.6 to 1.6 kms/hr) 0.3 to 0.9 mph (.6 to 1.6 kms/hr) 2nd Gear (Variable) 1.0 to 2.7 mph (2.1 to 4.6 kms/hr) 1.0 to 2.7 mph (2.1 to 4.6 kms/hr) 3rd Gear (Variable) 1.8 to 4.7 mph (3,8 to 8.0 kms/hr) 1.8 to 4.7 mph (3.8 to 8.0 kms/hr) 4th Gear {Variable) 2.6 to 7,0 rnph (5.5 to 11,9 kms/hr) 2.6 to 7.0 mph (5.5 to 11,9 kms/hr) Reverse (Variable) 1.4 to 3.7 mph (2,4 to 5.3 kms/hr) 1.4 to 3.7 mph (2.4 to 5.3 kms/hr) DIMENSIONS Wheelbase 46 in. (1.168 m) 46 in. (1.168 m) Overall Length 67-1/2 in. (1.715 m) 67-1/2 in. (1.715 m) Overall Height 42 in. (1,067 m) 42 in. (1.067 m) Overall Width (maximum) 41-1/2 in. (10.54 m) 41-1/2 in. (1.054 m) WHEEL TREAD Front 31 in. (78.74 cm) 31 in. (78.74 cm) Rear (GT-3 Tires) ... 27 in, or 33 in. (68.58 cm or 83.82 cm) 27 in. or 33 in. (68.58 cm or 83.82 cm) (GT-5 Tires) 28-1/2 in. or 31 in. (72.39 cm or 78.74 cm) 28-1/2 in. or 31 in. (72.39 cm or 78 74 cm) BRAKES Type Band, pedal-operated Band, pedal-operated Parking Hand-lock foot brake Hand-lock foot brake CLUTCH V-belt system V-be!t system PTO CLUTCH Manual Manual STEERING Enclosed gear Enclosed gear LIFT' Manual, Electric Manual, Electric, Hydraulic SHIPPING WEIGHT 200 Tractor - 691 lbs. (313 kg) 759 fbs. (344 kg) 208 Tractor - 673 lbs. (305 kg) 'Electric end Hydraulic Lifts are dealer installed options, "Aluminum Pan "'Steel Pan Litho in U.S.A.

Tractors, 200 Series SM-2105 (Sep-78) General 10 Specifications 10-3 TIRE SPECIFICATIONS Tire Code Location Size Tubeiess Ply-Rating Tread Tire Inflation Pressure * * Front Rear 4.80x4.00-8 23x8.50-12 Yes 2 Yes 2 Studded High- Flotation 10 to 12 psi (69 to 82 kPa) 5 to 10 psi (34 to 69 kPa) GT-3 Front Rear 16x6.50-8 23x8.50-12 Yes* 2 Yes* 2 High- Flotation 6 to 16 psi (41 to 110 kPa) 5 to 10 psi (34 to 69 kPa) GT-4 Front Rear 4.80/4.00-8 23x8.50-12 No 4 Yes* 2 Studded Traction 12 to 40 psi (82 to 276 kPa) 5 to 10 psi (34 to 69 kPa) GT-5**** Front Rear 16x6,50-8 23x10.50-12 Yes* 2 Yes* 2 High- Flotation 6 to 16 psi (41 to 110 kPa) 5 to 10 psi (34 to 69 kPa) GT-8 Bar Tread Front** Rear 16x6.50-8 23x10.5-12 Yes* 2 Yes* 2 High- Flotation Traction 6 to 16 psi (41 to 110 kPa) 5 to 10 psi (34 to 69 kPa) *Tubes Available for service. See your parts catalog. **Use 4.80/4.00-8 (4-ply) front tires with front-end loaders. ***Regu!ar equipment tires on 208 Tractor. ****Reguiar equipment tires on 210, 212, 214 and 216 Tractors. REAR WHEEL WEIGHT BOLT SIZE CHART Tire/Wheel Option Wheel Position No. of Weights Bolt Size GT-3 or GT-4 Narrow 1 1/2 x 5-1/2 GT-3 or GT-4 Narrow 2 1/2x7-1/2 GT-3 or GT-4 Wide 1 1/2x5-1/2 GT-3 or GT-4 Wide 2 1/2x7-1/2 GT-5 Narrow 1 1/2x5-1/2 GT-5 Narrow 2 1/2x8 GT-5 Wide 1 1/2x5-1/2 GT-5 or GT-8 Wide 2 1/2x7-1/2 Litho in U.S.A.

10 General 10-4 Specifications Tractors, 200 Series SM-2105 (Sep-78) BOLT TORQUE CHART AVERAGE TIGHTENING TORQUE FOR BOLTS (BASED ON 85% OF YIELD) Bolt Size A17B A17D A17F in-lb ft-lb Nm in-lb ft-lb Nm in-lb ft-lb Nm 1/4 72 6 8 120 10 13.5 168 14 19 5/16 156 13 17.6 240 20 27 360 30 40.7 3/8 276 23 31.2 420 35 47.5 600 50 67.8 7/16 420 35 47.5 660 55 74.6 960 80 108.5 1/2 660 55 74.6 1020 85 115.2 1440 120 162.7 9/16 900 75 101.7 1560 130 176.3 2100 175 237.3 5/8 1260 105 142.4 2040 170 230.5 2880 240 325.4 3/4 2220 185 250.8 3600 300 406.7 5100 425 576.2 7/8 1920 160 216.9 5340 445 603.3 8220 685 928.7 1 3000 250 339 8040 670 908.4 12360 1030 1396.5 1-1/8 3960 330 447.4 10920 910 1233.8 17520 1460 1979.5 1-1/4 5760 480 650.8 15000 1250 1694.8 24720 2060 2793 B-grade bolts larger than 3/4-inch are sometimes formed hot rather than cold , which accounts for the lower mean tightening torque. SET SCREW SEATING TORQUE CHART Screw Size Seating Torque in-lb Nm #5 9 1.0 #6 9 1.0 #8 20 2.3 #10 33 3.7 1/4 87 9.8 5/16 165 18.6 3/8 290 32.8 7/16 430 48.6 1/2 620 70.1 9/16 620 70.1 5/8 1225 138.4 3/4 2125 240.1 Litho in U.S.A.

John Deere 200 / 208 / 210 / 212 / 214 / 216 Lawn Garden Tractor OEM Service & Repair Manual

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