TECUMSEH VLV VECTOR 4 CYCLE EngineS Full Service & Repair Manual

This handbook covers VLV40 - 675. Other illustrated Tecumseh 2 and 4-Cycle Engine and Transmission handbooks, booklets and wall charts are available from Tecumseh. For complete listing write, call or check our website at www.TecumsehPower.com T E C H N I C I A N ' S H A N D B O O K TECUMSEH Form No. 695578 Rev. 6/02 Litho in U.S.A. ENGINES & TRANSMISSIONS Tecumseh Products Company Engine & Transmission Group 900 North Street Grafton, WI 53024 Phone: 262-377-2700 FAX: 262-377-4485 Tecumseh Europa S.p.A. Strada delle Cacce, 99 10135 Torino, Italy Tel. 011 39 11 391-8411 Telefax 011 39 11 3910031 ENGINES & TRANSMISSIONS www.TecumsehPower.com VLV (Vector) 4-CYCLE ENGINES www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

IMPORTANT NOTICE! SAFETY DEFINITIONS Statements in this manual preceded by the following words are of special significance: WARNING or WARNING indicates a potentially hazardous situation which if not avoided, could result in death or serious injury. NOTE Refers to important information and is placed in italic type. It is recommended that you take special notice of all items discussed on the next page and wear the appropriate safety equipment. Before operating this engine it is your responsibility to read this Operator’s Manual. Follow these basic rules for your personal safety: • Keep this manual handy at all times for future reference. • Read it carefully and familiarize yourself with operating, maintenance, components and safety instructions Notice Regarding Emissions NOTE Engines which are certified to comply with California and U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certified to operate on regular unleaded gasoline, and include the following emission control systems: (EM) Engine Modification and (TWC) Three- way Catalyst (if so equipped). Tecumseh Website Visit the Tecumseh website at: www.TecumsehPower.com www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

Table Of Contents Chapter 1 General Information .......................................................................................... 1-1 Engine Identification ....................................................................................................... 1-1 Prior to 1999 ................................................................................................................... 1-1 Short Blocks ................................................................................................................... 1-1 Parts Identification .......................................................................................................... 1-2 Parts List ......................................................................................................................... 1-3 Oil and Fuel Specifications ............................................................................................. 1-4 Oil ............................................................................................................................... 1-4 Fuel ............................................................................................................................. 1-4 Filling Fuel Tank ......................................................................................................... 1-4 Stopping the Engine and Short Term Storage ................................................................ 1-4 Maintenance and Adjustments ....................................................................................... 1-5 Checking and Changing Oil ........................................................................................ 1-5 Removing Debris from Engine .................................................................................... 1-5 Spark Plug .................................................................................................................. 1-6 Cleaning/replacing Air Cleaner ................................................................................... 1-6 Servicing Paper Filters ............................................................................................... 1-6 Carburetor .................................................................................................................. 1-6 Engine Speed ............................................................................................................. 1-6 Engine Stopping Mechanism ...................................................................................... 1-6 Seasonal Storage ........................................................................................................... 1-7 Fuel System ................................................................................................................ 1-7 Method 1 ..................................................................................................................... 1-7 Method 2 ..................................................................................................................... 1-7 Oil ............................................................................................................................... 1-7 Lubricating Cylinder Bore ........................................................................................... 1-7 Quick Maintenance Chart ........................................................................................... 1-7 4-Cycle Engine Theory ................................................................................................... 1-8 Intake .......................................................................................................................... 1-8 Compression ............................................................................................................... 1-8 Power .......................................................................................................................... 1-8 Exhaust ....................................................................................................................... 1-8 Chapter 2 Air Cleaners ....................................................................................................... 2-1 General Information ........................................................................................................ 2-1 Air Cleaner Service ......................................................................................................... 2-1 Polyurethane Pre-Filters ............................................................................................. 2-1 To Service Air Cleaner ............................................................................................... 2-2 Carburetion ..................................................................................................................... 2-3 General ....................................................................................................................... 2-3 Identification ............................................................................................................... 2-3 Float Bowl Service .......................................................................................................... 2-3 Rebuilding Carburetor Body ....................................................................................... 2-3 Removing Welch Plug ................................................................................................ 2-3 Chapter 3 Governors and Linkage .................................................................................... 3-1 General Information ........................................................................................................ 3-1 Linkage Assembly/Disassembly ..................................................................................... 3-2 Governor Adjustment ...................................................................................................... 3-2 Speed Controls ............................................................................................................... 3-2 Page Page i www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

Chapter 4 Starters .............................................................................................................. 4-1 Disassembly and Inspection ........................................................................................... 4-1 Assembly and Inspection ................................................................................................ 4-1 Stylized Rewind Starter with Plastic Retainer ................................................................. 4-2 Disassembly and Inspection ....................................................................................... 4-2 Assembly and Inspection ............................................................................................ 4-2 12 Volt Electric Starters .................................................................................................. 4-3 Removal ..................................................................................................................... 4-3 Parts List ..................................................................................................................... 4-3 Drive Assembly Service .............................................................................................. 4-3 Check Brushes ........................................................................................................... 4-4 Armature Check .......................................................................................................... 4-4 Assembly .................................................................................................................... 4-5 Chapter 5 Flywheels ........................................................................................................... 5-1 General Information ........................................................................................................ 5-1 High Inertia Flywheel ...................................................................................................... 5-1 Diecast Aluminum Flywheel ........................................................................................... 5-1 Removal ......................................................................................................................... 5-1 Cored Holes .................................................................................................................... 5-2 Installation ...................................................................................................................... 5-2 Brake System ................................................................................................................. 5-3 Method 1 ..................................................................................................................... 5-3 Method 2 ..................................................................................................................... 5-3 Stopping the Engine ...................................................................................................... 5-3 To Start Engine ............................................................................................................. 5-3 Wiring Diagrams ............................................................................................................. 5-4 Battery ............................................................................................................................ 5-4 Brake Pad Replacement ................................................................................................. 5-4 Brake Control Lever Replacement ................................................................................. 5-5 Control Switch ................................................................................................................ 5-5 Checking Control Switch ................................................................................................ 5-5 Chapter 6 Alternator ........................................................................................................... 6-1 Alternator ........................................................................................................................ 6-1 Troubleshooting Electric Start Engines .......................................................................... 6-1 Troubleshooting for Both Mechanical and Electric Start Systems .................................. 6-1 Chapter 7 Ignition ............................................................................................................... 7-1 Solid State Ignition .......................................................................................................... 7-1 Solid State Ignition Operation ......................................................................................... 7-1 Spark Plug Service ......................................................................................................... 7-1 Ignition Timing ................................................................................................................ 7-1 Chapter 8 Piston, Rings and Connecting Rod ................................................................. 8-1 Piston and Rings ............................................................................................................ 8-1 Connecting Rods ............................................................................................................ 8-2 Chapter 9 Cylinders and Cylinder Heads ......................................................................... 9-1 Cylinder Service ............................................................................................................. 9-1 Reboring ..................................................................................................................... 9-1 Cylinder Heads ............................................................................................................... 9-1 Table Of Contents (Continued) Page www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

Chapter 10 Crankshafts, Camshafts and Lubrication ................................................... 10-1 Crankshafts .................................................................................................................. 10-1 Crankshaft Timing Mark ........................................................................................... 10-1 Camshaft Removal ....................................................................................................... 10-1 Lubrication System ....................................................................................................... 10-2 Oil Pump ....................................................................................................................... 10-2 Chapter 11 Valves, Lifters, Spring and Valve Seats ...................................................... 11-1 General Information ...................................................................................................... 11-1 Valve Removal ............................................................................................................. 11-1 Valve Seats .................................................................................................................. 11-1 Valve Adjustments ........................................................................................................ 11-2 Valve Installation .......................................................................................................... 11-2 Valve Lifters .................................................................................................................. 11-2 Oversize Valve Guides ................................................................................................. 11-2 Chapter 12 Oil Seal Service and Mounting Flange ........................................................ 12-1 Oil Seal Service ............................................................................................................ 12-1 Seal Replacement ........................................................................................................ 12-1 Chapter 13 Troubleshooting ........................................................................................... 13-1 Table 1. 4-Cycle Engine Troubleshooting Chart ........................................................... 13-2 Table 2. Carburetor Malfunction Check Points ............................................................. 13-5 Table 3. Troubleshooting 12 Volt Starters .................................................................... 13-6 Chapter 14 Engine Specifications .................................................................................. 14-1 Torque Specifications .................................................................................................. 14-2 Chapter 15 Education Materials and Tools .................................................................... 15-1 Tool Kit ......................................................................................................................... 15-2 Chapter 16 Sears Craftsman Reference Chart .............................................................. 16-1 Decimal/Fraction Conversions ...................................................................................... 16-2 Table Of Contents (Continued) Page Page iii © Tecumseh Products Company 2002 www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

I. General Safety Precautions A. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause head- aches, dizziness, drowsiness, nausea, confusion and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly-ventilated areas. If you experience any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. To prevent serious injury or death from carbon monoxide: • NEVER run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels. • NEVER run engine in poorly-ventilated or partially enclosed areas such as barns, garages, basements, carports, under dwellings, or in pits. • NEVER run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. B. Avoid Gasoline Fires Gasoline (fuel) vapors are highly flammable and can explode. Fuel vapors can spread and be ignited by a spark or flame many feet away from engine. To prevent injury or death from fuel fires, follow these instructions: WARNING Read equipment manufacturer’s manual and this material thoroughly before using this engine. Failure to do so can result in serious injury or death. Call Tecumseh Products Company at 1-800-558-5402 if you have any questions. • NEVER store engine with fuel in fuel tank inside a building with potential sources of ignition such as hot water and space heaters, clothes dryers, electric motors, etc. • NEVER remove fuel cap or add fuel when engine is running. • Allow engine to cool before refueling. • NEVER fill fuel tank indoors. Fill fuel tank outdoors in a well-ventilated area. • DO NOT smoke while refueling tank. • Use only an approved red GASOLINE container to store and dispense fuel. • DO NOT attempt to pour fuel from engine. Empty fuel tank by running engine. C. Transporting Engine DO NOT transport engine with fuel in tank. Fuel vapor or spilled fuel may ignite. D. Avoid Other Fires To reduce the risk of fire, keep all materials that can burn, including grass and leaves, away from muffler and the rest of the engine. E. Stay Away from Hot Surfaces The muffler and other engine parts become extremely hot during operation and remain hot after the engine has stopped. To avoid severe burns on contact, stay away from these areas. F. Do Not Modify Engine To avoid serious injury or death, DO NOT modify engine in any way. NEVER tamper with the factory setting of engine governor. Running the engine faster than the speed set at the factory can be dangerous and will VOID THE ENGINE WARRANTY. G. Avoid Accidental Starts To prevent accidental starting when working on equipment, always disconnect spark plug wire and keep it away from spark plug. H. Stay Away from Rotating Parts Never operate engine with covers or guards removed. Rotating parts can cause severe injury. Keep hands, feet, hair, jewelry and clothing away from all moving parts. Page iv www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

I. General Safety Precautions A. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause head- aches, dizziness, drowsiness, nausea, confusion and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly-ventilated areas. If you experience any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. To prevent serious injury or death from carbon monoxide: • NEVER run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels. • NEVER run engine in poorly-ventilated or partially enclosed areas such as barns, garages, basements, carports, under dwellings, or in pits. • NEVER run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. B. Avoid Gasoline Fires Gasoline (fuel) vapors are highly flammable and can explode. Fuel vapors can spread and be ignited by a spark or flame many feet away from engine. To prevent injury or death from fuel fires, follow these instructions: WARNING Read equipment manufacturer’s manual and this material thoroughly before using this engine. Failure to do so can result in serious injury or death. Call Tecumseh Products Company at 1-800-558-5402 if you have any questions. • NEVER store engine with fuel in fuel tank inside a building with potential sources of ignition such as hot water and space heaters, clothes dryers, electric motors, etc. • NEVER remove fuel cap or add fuel when engine is running. • Allow engine to cool before refueling. • NEVER fill fuel tank indoors. Fill fuel tank outdoors in a well-ventilated area. • DO NOT smoke while refueling tank. • Use only an approved red GASOLINE container to store and dispense fuel. • DO NOT attempt to pour fuel from engine. Empty fuel tank by running engine. C. Transporting Engine DO NOT transport engine with fuel in tank. Fuel vapor or spilled fuel may ignite. D. Avoid Other Fires To reduce the risk of fire, keep all materials that can burn, including grass and leaves, away from muffler and the rest of the engine. E. Stay Away from Hot Surfaces The muffler and other engine parts become extremely hot during operation and remain hot after the engine has stopped. To avoid severe burns on contact, stay away from these areas. F. Do Not Modify Engine To avoid serious injury or death, DO NOT modify engine in any way. NEVER tamper with the factory setting of engine governor. Running the engine faster than the speed set at the factory can be dangerous and will VOID THE ENGINE WARRANTY. G. Avoid Accidental Starts To prevent accidental starting when working on equipment, always disconnect spark plug wire and keep it away from spark plug. H. Stay Away from Rotating Parts Never operate engine with covers or guards removed. Rotating parts can cause severe injury. Keep hands, feet, hair, jewelry and clothing away from all moving parts. Page iv www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

1-1 695578 Tecumseh engine model, specification and serial numbers are stamped or on a decal on the blower housing. The decal also contains any emission compli- ance information. The letters which precede the model numbers indicate the basic type of engine: VLV - Vector Lightweight Vertical Prior to 1999 The numbers which followed the engine type letters indicated the basic engine horsepower: 40 - 4.0 Horsepower 50 - 5.0 Horsepower The current designation indicates cubic inch displace- ment 126 - 12.6 cubic inches Following the engine model numbers are the engine specifications numbers. The specification number is used when identifying engine parts. Example 502012A. The serial or D.O.M. Number is the production date code. 2039 - serial number (example) 2 - Year in decade of manufacture (2002) 39 - The last 3 digits of date code represent the calendar (the 39th day of 2002) D - represents the shift and line on which the engine was built at the factory. Emitted engines that meet the California Air Resource Board (C.A.R.B.) or the Environmental Protection Agency (E.P.A.) Standards will include additional required engine information on the engine decal. NOTE To maintain best possible emission performance, use only Genuine Tecumseh Parts. Short Blocks New short blocks are identified by a tag marked SBH (Short Block Horizontal) or SBV (Short Block Vertical). These tags are used to properly identify the correct parts if service is required. They are attached to either the sump bolts or valve box cover. Chapter 1 General Information Engine Identification 6215C 207cc THIS ENGINE MEETS 1995-1998 CALIF. EMISSION REGULATIONS FOR ULGE ENGINES AS APPLICABLE FUEL: REGULAR UNLEADED OIL: USE SAE 30 VLV60-502012A VLV60-502012A (D) VLV60-502012A (D) RTP358UIG2RA 6215C www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

1-2 695578 Parts Identification This is a parts breakdown of a typical VLV engine. Use this parts breakdown to identify parts. When ordering parts always refer to the engine model and specification number stamped on the engine blower housing. Carburetor and starter breakdowns are found in the chapters referring to their repair. NOTE If the short block has been replaced, an identification tag for service parts is located on the valve box cover. SBV-XXX SER-XXX Optional Pre-Filter NOTE On newer VLV models the breather tube will be a straight hose. Model and Serial Numbers Located Here 106 www.mymowerparts.com For Discount Tecumseh Engine Parts Call 606-678-9623 or 606-561-4983

TECUMSEH VLV VECTOR 4 CYCLE EngineS Full Service & Repair Manual

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