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MTD 90 Series User Manual

MTD 90 Series
136 pages
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Professional Shop Manual
78/83/90 Series Horizontal Shaft Engines
(277/357/420 cc 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 inexperi-
enced 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 2010 MTD Products Inc. All Rights Reserved

Table of Contents

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MTD 90 Series Specifications

General IconGeneral
BrandMTD
Model90 Series
CategoryEngine
LanguageEnglish

Summary

Chapter 1: Introduction

Professional Service Manual Intent

Explains the purpose of the manual for service dealers.

Safety

Covers essential safety instructions for working with the equipment.

Fasteners

Details metric and fractional inch fasteners used on MTD engines.

Assembly instructions

Provides guidance on torque specs, lubricants, and assembly procedures.

Model and serial number

Explains how to locate and interpret engine model and serial numbers.

Maintenance

Discusses basic maintenance practices for engine longevity.

Air filter (summer engines)

Explains the function, types, and maintenance of air filters.

Oil type and capacity

Specifies recommended oil types, capacities, and checking procedures.

Changing the oil

Details the procedure for draining and refilling engine oil.

Fuel

Discusses fuel types, alcohol content, and storage best practices.

Fuel filters

Explains the function and location of fuel filters.

Valve lash

Describes how to check and adjust valve lash for optimal engine performance.

Cleaning the engine

Provides instructions for cleaning the engine to maintain operating temperature.

General torque specifications

Lists torque specifications for various fasteners.

Maintenance Chart

Outlines a schedule for routine engine maintenance tasks.

Frequently used specifications

Summarizes key engine specifications for quick reference.

CHAPTER 2: BASIC TROUBLESHOOTING

Definitions

Defines key terms like Troubleshooting and Diagnosis.

Introduction

Introduces the principles of engine diagnosis.

Steps to troubleshooting

Outlines a systematic approach to diagnosing engine problems.

Define the problem

Explains the first step in troubleshooting: clearly identifying the issue.

Identify factors that could cause the problem

Guides on identifying potential causes for engine malfunctions.

Prime test

Describes a test to isolate fuel system issues.

Leak-down test

Explains how to perform a leak-down test for compression issues.

Compression test

Details how to conduct a compression test for engine health.

PCV testing

Covers testing the Positive Crankcase Ventilation system.

CHAPTER 3: AIR INTAKE SYSTEMS

Heat box (snow engines)

Explains the function and removal/installation of the heat box.

Air filter (summer engines)

Details the types, maintenance, and replacement of air filters.

Air filter base and control panel (summer engines)

Covers the removal and installation of the air filter base and control panel.

Carburetor and Insulator

Describes the carburetor and insulator assembly, and their removal.

CHAPTER 4: THE FUEL SYSTEM AND GOVERNOR

Inspecting the fuel

Provides guidance on inspecting fuel quality for issues.

Test fuel for alcohol

Explains how to test fuel for alcohol content.

Fuel tank vent

Discusses the function and testing of the fuel tank vent.

The fuel filter

Details the location, cleaning, and replacement of the fuel filter.

Inspect the fuel lines

Guides on inspecting fuel lines for cracks, clogs, or brittleness.

The fuel tank

Covers the removal and installation of the fuel tank.

Evaporative (EVAP) emissions system

Explains the EVAP system and its components.

Troubleshooting the EVAP System

Provides steps for testing and troubleshooting the EVAP system.

Testing the roll over valve

Details how to test the function of the roll over valve.

Charcoal canister

Covers the removal and installation of the charcoal canister.

Roll over valve

Describes the removal and installation of the roll over valve.

Choke

Explains choke operation and adjustment.

Primers (snow engines)

Details how to test and replace the primer for snow engines.

Carburetors

Covers inspection, disassembly, and rebuilding of carburetors.

Fuel shut-off valve

Describes servicing the fuel shut-off valve on the carburetor.

Governor

Explains the function of the governor in controlling engine speed.

Governor arm

Details the removal and installation of the governor arm.

Governor shaft

Covers the removal and replacement of the governor shaft.

Governor cup and the governor gear

Explains servicing the governor cup and gear assembly.

Governor adjustment

Details the procedure for adjusting the governor.

CHAPTER 5: LUBRICATION

Oil type and quantity

Specifies recommended oil types, grades, and capacities.

Oil dip stick

Explains how to check the oil level using different dipstick types.

Dip stick tube removal

Details the procedure for removing and replacing the dipstick tube.

Lubrication system

Describes the engine's splash lubrication system.

Positive crankcase ventilation valve

Covers the removal, inspection, and reassembly of the PCV valve.

CHAPTER 6: STARTER AND CHARGING SYSTEMS

Recoil Starter Removal

Explains how to remove the recoil starter assembly.

Starter Cup

Details inspection, removal, and installation of the starter cup.

Starter Rope

Covers common failure modes and replacement of the starter rope.

Starter pulley and recoil spring

Describes disassembly and inspection of the starter pulley and recoil spring.

Electric starter

Explains the operation and replacement of the electric starter.

Charging system

Describes the components of the engine's charging system.

Charging system testing

Guides on testing the charging system's voltage output.

Stator

Covers the removal, installation, and testing of the stator.

Rotor

Explains how to check the rotor for damage.

CHAPTER 7: IGNITION SYSTEM

Troubleshooting the ignition system

Provides steps for diagnosing ignition system problems.

Stop switch

Details how to test the throttle-mounted stop switch.

Remote (ignition) stop switch (snow engines)

Explains how to test the remote stop switch found on snow engines.

Test for ignition that won’t turn off

Guides on diagnosing issues where the engine fails to shut off.

The module

Discusses the ignition module, its function, and performance expectations.

Module removal

Covers the steps for removing the ignition module.

Installing the module and setting the air gap

Details the process of installing the module and setting the spark gap.

Flywheel

Covers flywheel removal, inspection, and installation, including the keyway.

About the spark plug

Provides information on the recommended spark plug and its specifications.

Cleaning the spark plug

Discourages spark plug cleaning and recommends replacement.

Inspection of the spark plug

Explains how spark plug inspection indicates engine condition.

Spark plug removal

Details the procedure for removing and installing spark plugs.

CHAPTER 8: EXHAUST

Summer engines

Notes differences in exhaust systems between summer and snow engines.

Spark arrestor (if equipped)

Covers the inspection, cleaning, and replacement of the spark arrestor.

Muffler removal/replacement

Details the removal and installation of the muffler and manifold pipe.

Muffler removal/replacement (snow engines)

Covers the removal and replacement of the muffler on snow engines.

CHAPTER 9: CYLINDER HEAD

Cylinder head removal

Provides steps for removing the cylinder head.

Cylinder head installation

Details the procedure for installing the cylinder head.

Valves

Explains how to service valves, including removal and inspection.

CHAPTER 10: CRANKSHAFT, PISTON AND CONNECTING ROD

Crankshaft inspection

Covers inspection of crankshaft journals, crank pin, and run out.

Piston Inspection

Details piston cleaning, ring gap measurement, and piston pin bore checks.

Connecting rod inspection

Guides on inspecting the connecting rod for damage and measuring clearances.

Cylinder inspection

Covers cleaning, inspection, and measurement of the cylinder bore and cross hatch.

Balance Shaft (483 & 490)

Explains the function of the balance shaft in reducing engine vibrations.

Reassembly

Provides detailed steps for engine reassembly.

Engine specifications chart

Lists various engine specifications and service limits.

Engine torque values chart

Provides a chart of torque values for engine fasteners.

CHAPTER 11: FAILURE ANALYSIS

Abrasive ingestion

Explains how abrasive particles enter the engine and cause wear.

Insufficient lubrication

Discusses failures related to lack of proper lubrication.

Engine Overspeed

Covers issues arising from the engine exceeding its maximum speed.

Overheated

Explains how overheating affects engine parts and performance.

Mechanical Breakage/ Wear

Discusses failures due to part breakage, wear, abuse, or defects.

Detonation/preignition

Explains conditions causing premature fuel combustion in the cylinder.

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