MTD vertical shaft P90 engine service manual lawn mower

Professional Shop Manual P90 Series Vertical Shaft Engines NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals. These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperienced individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all instructions and use common sense when working on power equipment. This includes the contents of the product’s Oper- ators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication, although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a product. The company reserves the right to make changes at any time to this publication without prior notice and without incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations used in this publication are for reference use only and may not depict actual model and component parts. © Copyright 2011 MTD Products Inc. All Rights Reserved www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

I Chapter 1: Introduction Professional Service Manual Intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Model and serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Oil type and capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Oil pre-screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Servicing the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Valve lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cleaning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 General torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Chapter 2: Basic Troubleshooting Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Steps to troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Define the problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Identify factors that could cause the problem . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Repairing the problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Prime test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 PCV testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Chapter 3: Air Intake System Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Blower/air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Carburetor and Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Table of Contents www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

II Chapter 4: The Fuel System and Governor Inspecting the fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Test fuel for alcohol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Choke/throttle cable adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Carburetors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Inspecting the carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Disassembly and rebuilding the carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Engine speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Afterfire solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Testing the afterfire solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Governor arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Governor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Governor cup and the governor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Chapter 5: Lubrication Oil type and quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Dip stick tube removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Testing the oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Positive crankcase ventilation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Chapter 6: Starter and Charging Systems Starter removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Bench testing the electric starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Rebuilding the starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Charging system testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Chapter 7: Ignition System Troubleshooting the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 The module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Installing the module and setting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Cleaning the spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Inspection of the spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Spark plug removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

III Chapter 8: Exhaust Spark arrestor (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Muffler removal/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Chapter 9: Cylinder Head Cylinder head removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Cylinder head installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Push rod guide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Chapter 10: Crankshaft, piston and Connecting Rod Crankshaft inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Connecting rod inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Cylinder inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Engine specifications chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Engine torque values chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Chapter 11: Failure Analysis Abrasive Ingestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Insufficient lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Mechanical Breakage/ Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Detonation/preignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

IV www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

Introduction 1 Professional Service Manual Intent This manual is intended to provide service dealers with an introduction to proven diagnostic and repair procedures for MTD P90 series vertical shaft engines. Disclaimer: The information contained in this manual is correct at the time of writing. Both the product and the information about the product are subject to change without notice. About the text format: NOTE: Is used to point out information that is relevant to the procedure, but does not fit as a step in the procedure. • Bullet points: indicate sub-steps or points. 1. Numbered steps indicate specific things that should be done, and the order in which they should be done. 1a. Substeps will be lettered and nested within steps. Two or more substeps may be combined to describe the actions required to complete a step. Disclaimer: This manual is intended for use by trained, professional technicians. • Common sense in operation and safety is assumed. • In no event shall MTD be liable for poor text interpretation or poor execution of the procedures described in the text. • If the person using this manual is uncomfortable with any procedures they encounter, they should seek the help of a qualified technician or MTD Technical Support. Safety This Service Manual is meant to be used along with the Operator’s Manual. Read the Operator’s Manual and familiarize yourself with the safety and operational instructions for the equipment being worked on. Keep a copy of the Operator’s Manual for quick reference. Operator’s manuals may be viewed for free at the brand support website. It will be necessary to have the complete model and serial number for the equipment. Caution is used to point out potential danger to the technician, operator, bystanders, or sur- rounding property. ! CAUTION Warning indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. ! WARNING ! DANGER Danger indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations CHAPTER 1: INTRODUCTION www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

P90 Series Vertical Shaft Engines 2 • Be prepared in case of emergency: Keep a fire extinguisher nearby Keep a first aid kit nearby Keep emergency contact numbers handy • Replace any missing or damaged safety labels on shop equipment. • Replace any missing or damaged safety labels on equipment being serviced. ! CAUTION • Grooming and attire: Do not wear loose fitting clothing that may become entangled in equipment. Long hair should be secured to prevent entanglement in equipment. Jewelry is best removed. • Protective gear: includes, but is not limited to Clear eye protection ................................ while working around any machinery Protective gloves ..................................... where necessary Armored footwear .................................... when working around any machinery Hearing protection ................................... in noisy environments Chemically resistant gloves ..................... when working with chemicals or solvents Respirator ................................................ when working with chemical or solvents Appropriate tinted eye protection............. when cutting or welding Flame resistant headgear, jacket, chaps . when cutting or welding ! WARNING ! CAUTION • Remember that some hazards have a cumulative effect. A single exposure may cause little or no harm, but continual or repeated exposure may cause very serious harm. • Clean spills and fix obviously dangerous conditions as soon as they are noticed. • Lift and support heavy objects safely and securely. • Be aware of your surroundings and potential hazards that are inherent to all power equipment. All the labels in the world cannot protect a technician from an instant of carelessness. • Exhaust fumes from running engines contain carbon monoxide (CO). Carbon monoxide is a colorless odorless gas that is fatal if inhaled in sufficient quantity. Only run engines in well ventilated areas. If running engines indoors, use an exhaust evacuation system with adequate make-up air ventilated into the shop. ! DANGER www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

Introduction 3 Fasteners • Most of the fasteners used on the MTD engine are metric. Some are fractional inches. For this reason, wrench sizes are frequently identified in the text, and measurements are given in U.S. and metric scales. • If a fastener has a locking feature that has worn, replace the fastener or apply a small amount of releas- able thread locking compound such as Loctite® 242 (blue). • Some fasteners, like cotter pins, are single-use items that are not to be reused. Other fasteners such as lock washers, retaining rings, and internal cotter pins (hairpin clips) may be reused if they do not show signs of wear or damage. This manual leaves that decision to the judgement of the technician. Assembly instructions • Torque specifications may be noted in the part of the text that covers assembly. They may be summarized in tables along with special instructions regarding locking or lubrication. Whichever method is more appropriate will be used. In many cases, both will be used so that the manual is handy as a quick-reference guide as well as a step-by-step procedure guide that does not require the user to hunt for information. • Lubricant quantity and specification may be noted in the part of the text that covers maintenance, and again in the section that covers assembly. They may also be summarized in tables along with special instructions. Whichever method is more appropriate will be used. In many cases, the information will be found in several places in the manual so that the manual is handy as a quick-reference guide as well as a step-by-step procedure guide that does not require the user to hunt for information. • The level of assembly instructions provided will be determined by the complexity of reassembly, and by the potential for damage or unsafe conditions to arise from mistakes made in assembly. • Some instructions may refer to other parts of the manual for subsidiary procedures. This avoids repeating the same procedure two or three times in the manual. www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

P90 Series Vertical Shaft Engines 4 MTD Vertical Engine Model Designators • Starter/Alternator s 1=Recoil start • 2=Electric start (12V) • 3=E. start/alt. 18W • 4=E. start/alt. 3A/5A • 5= AutoChoke/ Recoil • 6= AutoChoke/Electric Start • 7= AutoChoke/Electric Start/Alt 1 P 6 1 M U A P= Vertical (1 cyl.) Q= Vertical (2 cyl.) Bore Dia. (mm) End Product B Mower (long shaft M0) C Chipper/Shredder M Mower (long shaft/no shroud) D Mower (long shaft M1) N Mower (short shaft M0) E Mower (short shaft M1) P Mower (long shaft M0) F Mower (short shaft/no shroud) Q Mower (short shaft M0) R Mower (long shaft/no shroud) T Tiller L Log splitter W World Tiller Compliance U United States (50 State) H Europe C California 0 (Zero) 49 State G U.S.(49) and Europe W U.S.(50) and Europe Major Revision Change MTD Engine Serial Numbers Model number 1P65FH/0510271A0023 Month Year Producing Line# and Shift#: 1A=Line 1, 1 st Shift 1B=Line 1, 2 nd Shift 2A=Line 2, 1 st Shift 2B=Line 2, 2 nd Shift 3A=Line 3, 1 st Shift 3B=Line 3, 2 nd Shift 4A=Line 4, 1 st Shift 4B=Line 4, 2nd Shift Date Engine number www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com For Discount Cub Cadet Parts Call 606-678-9623 or 606-561-4983

MTD vertical shaft P90 engine service manual lawn mower

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