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Tecumseh 2-Cycle Engines AH/AV520-600 Technician Handbook
Manuals Includes info on:
GENERAL INFORMATION ...................................... 1
ENGINE IDENTIFICATION................................... 1
INTERPRETATION OF MODEL NUMBER .......... 1
ENGINE CARE ......................................................... 2
SHORT BLOCKS .................................................. 2
STORAGE: ............................................................ 2
TUNE-UP PROCEDURE ...................................... 3
EXHAUST PORT CLEANING .............................. 3
2-CYCLE THEORY OF OPERATION ...................... 4
OPERATION OF PISTON PORT STYLE ............ 4
OPERATION OF REED PORTED STYLE
WITH LOOP SCAVENGING.............................. 4
TERMS .................................................................. 4
EXHAUST OR SCAVENGE PHASE .................... 4
PORTS .................................................................. 4
EXHAUST PORTS ................................................ 4
THIRD PORT ........................................................ 4
REED VALVE ........................................................ 4
LUBRICATION ...................................................... 4
AIR CLEANERS, CARBURETORS, GOVERNORS
AND LINKAGE ......................................................... 5
AIR CLEANERS .................................................... 5
POLYURETHANE-TYPE AIR CLEANER ............ 5
KLEEN-AIRE® SYSTEM ...................................... 5
PAPER-TYPE AIR CLEANER SERVICE............. 5
GENERAL CARBURETOR INFORMATION ........... 6
CARBURETOR IDENTIFICATION ....................... 6
FLOAT-TYPE CARBURETORS ........................... 6
DIAPHRAGM (PRESSURE DIFFERENTIAL)
CARBURETORS ................................................... 6
OPERATION.......................................................... 7
CARBURETOR SERVICE .................................... 7
THROTTLE............................................................ 7
CHOKE .................................................................. 8
ADJUSTING SCREWS......................................... 8
FUEL BOWL RETAINING NUT ............................ 8
CARBURETOR VENTING .................................... 8
HIGH TILT FLOAT STYLE .................................... 8
FUEL BOWL .......................................................... 8
FLOAT ................................................................... 8
INLET NEEDLE AND SEAT (FLOAT
CARBURETORS) .............................................. 9
NEEDLE AND SEAT OPO-OFF TEST ................ 9
FLOAT HEIGHT SETTINGS ................................. 9
PRIMER BULB .................................................... 10
CLEANING CARBURETOR BODY.................... 10
DIAPHRAGMS .................................................... 10
INLET NEEDLE AND SEAT ............................... 11
FUEL INLET FITTING......................................... 11
PRIMER BULB (DIAPHRAGM
CARBURETOR) ................................................ 11
CARBURETOR CHECK VALVE......................... 11
CARBURETOR SERVICE PROCEDURE ......... 12
EMISSIONIZED DIAPHRAGM CARBURETION13
OUTBOARD CARBURETORS .............................. 13
OUTBOARD CONTROL PANEL ........................ 14
CARBURETOR ADJUSTMENTS .......................... 15
IDLE SPEED ADJUSTMENT ............................. 15
FLOAT TYPE-FIXED MAIN, IDLE ADJUST ...... 15
DIAPHRAGM - SINGLE AND DUAL
ADJUSTMENT .................................................. 15
TROUBLESHOOTING CARBURETION ............... 16
FLOAT CARBURETOR CHECKS ...................... 16
CHECKS FOR DIAPHRAGM ............................. 16
STANDARD SERVICE CARBURETORS.............. 17
FUEL FITTING .................................................... 17
INLET FUEL FITTING......................................... 17
CHOKE SHAFT ................................................... 17
THROTTLE LEVER ................................................ 17
IDLE SPEED ADJUSTMENT SCREW .................. 17
GOVERNORS AND LINKAGE .............................. 18
AIR VANE GOVERNORS ................................... 18
OPERATION........................................................ 18
LINKAGE INSTALLATION ..................................... 18
REWIND STARTERS, ELECTRIC STARTERS
AND ALTERNATORS ............................................. 20
REWIND STARTERS.......................................... 20
COMPONENTS................................................... 20
ROPE SERVICE ................................................. 20
STYLIZED REWIND STARTER ......................... 21
VERTICAL PULL STARTER HORIZONTAL
ENGAGEMENT TYPE ........................................ 22
STYLIZED REWIND STARTER WITH PLASTIC
RETAINER ........................................................ 23
VERTICAL PULL STARTER, VERTICAL
ENGAGEMENT TYPE ...................................... 24
REWIND STARTER MOUNTED IN HOUSING . 25
ELECTRIC STARTERS .......................................... 26
DRIVE ASSEMBLY SERVICE ............................ 26
STARTER CHECKING AND SERVICE ............. 27
CHECK FIELD..................................................... 27
ARMATURE CHECK........................................... 27
TROUBLESHOOTING STARTERS ....................... 27
ALTERNATORS ...................................................... 28
CHECKING THE SYSTEM ................................. 28
FLYWHEEL (INSIDE-EDGE) BRAKE SYSTEM ... 29
INSIDE EDGE SYSTEM ..................................... 29
COMPONENTS................................................... 29
SERVICE ............................................................. 29
CONTROL CABLE .............................................. 30
IGNITION ................................................................. 31
IGNITION OPERATION (Pre- 1985
Production)........................................................ 31
MAGNETO IGNITION ......................................... 31
CONTACT POINTS............................................. 31
CONDENSER ..................................................... 31
OPERATION OF THE TECUMSEH
MAGNETO IGNITION ....................................... 31
SOLID STATE IGNITION (1985 to Present)...... 32
SOLID STATE IGNITION OPERATION ............. 32
IGNITION SERVICE ............................................... 33
SPARK PLUG SERVICE .................................... 33
FLYWHEEL REMOVAL AND SERVICE............. 33
FLYWHEEL MAGNETS ...................................... 33
FLYWHEEL KEYS............................................... 34
ADAPTER KEY TO FLYWHEEL ASSEMBLY.... 34
FLYWHEEL SLEEVE .......................................... 34
FLYWHEEL TORQUE......................................... 34
REPLACING MAGNETO BREAKER POINTS .. 34
CONDENSER CHECK ....................................... 34
IGNITION COIL ................................................... 34
IGNITION TIMING .............................................. 34
FIXED TIME SPEED (EXTERNAL COIL) .......... 36
SOLID STATE (CDI) ........................................... 36
OTHER IGNITION SYSTEMS ............................ 36
OUTBOARD TIMING .............................................. 38
OUTBOARD TIMING (STANDARD IGNITION) . 38
OUTBOARD TIMING (SOLID STATE) ............... 39
CYLINDERS & INTERNAL COMPONENTS......... 41
PISTON & RING SERVICE ................................ 41
CONNECTING ROD SERVICE .............................. 42
NEEDLE BEARINGS .......................................... 42
CRANKSHAFT, BEARING AND OIL SEAL
SERVICE ................................................................. 43
NEEDLE BEARINGS .......................................... 43
OIL SEALS .......................................................... 43
ONE PIECE SEALS ............................................ 43
THREE PIECE SEALS ....................................... 44
OUTBOARD SEAL SERVICE ............................ 44
CYLINDERS, REEDS & COMPRESSION
RELEASE................................................................ 45
CYLINDER & HEAD SERVICE .......................... 45
GASKETS............................................................ 45
REED VALVES .................................................... 45
AUTOMATIC COMPRESSION RELEASE
(DOUBLE REED TYPE) ................................. 45
AUTOMATIC COMPRESSION RELEASE
(SINGLE REED TYPE)................................... 45
CYLINDER EXHAUST PORTS .......................... 46
TROUBLESHOOTING............................................ 47
ENGINE FAILS TO START OR STARTS
WITH DIFFICULTY ............................................. 47
ENGINE KNOCKS .............................................. 47
ENGINE MISSES UNDER LOAD ...................... 48
ENGINE LACKS POWER................................... 48
ENGINE OVERHEATS ....................................... 48
ENGINE SURGES OR RUNS UNEVENLY ....... 49
ENGINE VIBRATES EXCESSIVELY ................. 49
SPECIFICATIONS .................................................. 50
ENGINE TYPE NUMBER AND LETTER
REFERENCE ................................................... 50
SEARS CRAFTSMAN CROSS REFERENCE ...... 51
TABLE OF SPECIFICATIONS ....................... 52 - 61
TABLE OF TORQUE LIMITS ................................. 62
EDUCATIONAL MATERIALS AND TOOLS ......... 63
AVAILABLE TECHNICIAN'S HANDBOOKS ...... 63
AVAILABLE FOREIGN TECHNICIAN'S
HANDBOOKS .................................................. 63
TOOL KIT 670195D ................................................ 64
TOOLS..................................................................... 65
Index
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