!! Toro Lawn Boy Walk Behind Power Mower Drive Systems Manual

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WALK BEHIND POWER

MOWER DRIVE SYSTEMS

SERVICE MANUAL

This service manual was written expressly for Toro servicing dealers. The Toro Company has

made every effort to make the information in this manual complete and correct.

This manual was written with the assumption that the reader has basic mechanical knowledge

and skills. This book contains material covering the Toro and Lawn-Boy Walk Behind Mower Drive

Systems models from 1990 through 2006, and may be specifi ed for use on products built after

2006 that are similar in design.

We are hopeful that you will fi nd this manual a valuable addition to your service shop. If you have

any questions or comments regarding this manual, please contact us at the following address:

The Toro Company

LCE Service Training Department

8111 Lyndale Avenue South

Bloomington, MN 55420

The Toro Company reserves the right to change product specifi cations or this manual without

notice.

ABOUT THIS MANUAL

Copyright© All Rights Reserved

©2006 The Toro Company

THIS PAGE INTENTIONALLY LEFT BLANK.

iWPM Drive Systems Manual

TABLE OF CONTENTS

QUICK REFERENCE

Transmission Remove and Replace

3 speed transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21” steel & cast deck Personal Pace, Easy Stride transmission . . . . . . . . . . . . . . . .

22” steel deck transmission, Toro and Lawn-Boy . . . . . . . . . . . . . . . . . . . . . .

21” Lawn-Boy Insight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Internal Repair

3 speed transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spur/Bevel gear transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bevel gear transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Clutch Troubleshooting & Repair

Rocking Key style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spring Ratchet style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Clutch System Troubleshooting & Repair

Blade Brake Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Override System (Toro - BOS) Blade Clutch System (Lawn-Boy - BCS) . . . . . . . . . . .

Handle Disassembly

Toro 2 Bail handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Pace Easy Stride (Generation 1) . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Pace Easy Stride (Generation 2) . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy Sens-a-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt Replacement

Mowers with Toro Blade Brake Clutch . . . . . . . . . . . . . . . . . . . . . . . . . .

Mowers with Toro Blade Override System . . . . . . . . . . . . . . . . . . . . . . . . .

Zone start 21” Rear Wheel Drive Toro & Lawn-Boy (except Insight) . . . . . . . . . . . . . . .

Zone start 22” Toro Rear Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . .

Zone start 22” Toro Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy Insight Zone Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy Insight with Blade Clutch System . . . . . . . . . . . . . . . . . . . . . . . .

4-5

2-3

3-10

3-20

4-6

2-4

3-16

5-2

5-9

6-2

6-28

7-2

7-3

7-6

7-9

8-3

8-3

8-2

3-10

3-5

3-19

8-3

ii WPM Drive Systems Manual

TABLE OF CONTENTS

WORM DRIVE TRANSMISSION

GENERAL

INTERNALLY CLUTCHED

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Shifting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal & Installation (front wheel drive applications) . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONSTANT MESH

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHEEL CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION

GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Remove & Replace . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SINGLE SPEED BEVEL GEAR TRANSMISSION

EXPLODED VIEW - SINGLE SPEED BEVEL GEAR TRANSMISSION . . . . . . . . . . . . . .

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT AXLE & TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .

22” FRONT WHEEL DRIVE MODELS

Remove Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt Service - Front Wheel Drive Models . . . . . . . . . . . . . . . . . . . . . . . .

22” TORO & LAWN-BOY REAR WHEEL DRIVE MODELS

Transmission Removal & Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

Rear Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LAWN-BOY INSIGHT TRANSMISSION REMOVE & REPLACE . . . . . . . . . . . . . . . .

Tranmission Removal & Belt Replacement . . . . . . . . . . . . . . . . . . . . . . .

Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THREE SPEED TRANSMISSION

GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION

Input System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

1-3

1-3

1-4

1-5

1-7

1-9

1-10

1-11

1-12

1-13

1-14

2-2

2-3

2-3

2-3

2-4

2-5

3-2

3-3

3-4

3-5

3-7

3-7

3-8

3-9

3-10

3-15

3-16

3-16

3-17

3-19

3-20

3-24

3-24

3-24

3-25

4-2

4-3

iiiWPM Drive Systems Manual

TABLE OF CONTENTS

Speed Reduction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Selection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal - Toro Vacu Power/Lawn-Boy Medallion Models . . . . . . . . . . . . . . . . .

Removal - Recycler/Rear Bagger Chassis . . . . . . . . . . . . . . . . . . . . . . .

Alternate Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intermediate Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Assembly Notes for Toro Vacu Power/Lawn-Boy Medallion . . . . . . . . . . . . .

TROUBLESHOOTING TIPS - 3 SPEED TRANSMISSION

Hard Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slipping Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHEEL PINION CLUTCH

GEAR CASE & WHEEL ASSEMBLY, ROCKING KEY STYLE . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Defi nitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test for Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Height-of-Cut & Wheel Pinion Clutch - Disassembly . . . . . . . . . . . . . . . . .

Rear Height-of-Cut & Wheel Pinion Clutch - Assembly . . . . . . . . . . . . . . . . . .

GEAR CASE & WHEEL ASSEMBLY SPRING RATCHET STYLE . . . . . . . . . . . . . . . .

Spring Ratchet Key Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHEEL PINION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLADE BRAKE CLUTCH SYSTEMS (BBC), BLADE OVERRIDE SYSTEM (BOS),

BLADE CLUTCH SYSTEM (BCS)

BLADE BRAKE CLUTCH SYSTEM

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BBC Clutch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Box Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Box Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORO BBC SERVICE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLADE BRAKE CLUTCH ASSEMBLY (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . .

TORO VACU POWER/LAWN-BOY MEDALLION BBC . . . . . . . . . . . . . . . . . . . .

Bellcrank System Disassembly (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . .

Bellcrank System Assembly (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . .

BBC Cover and Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Under Deck Components Disassembly (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . .

Under Deck Components Assembly (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . .

BBC Cable Removal (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . . . .

BBC Cable Installation (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . . . .

ENGINE & BLADE ASSEMBLY (Toro Recycler/Rear Bagger) . . . . . . . . . . . . . . . . .

TORO RECYCLER/REAR BAGGER BBC . . . . . . . . . . . . . . . . . . . . . . . . .

Idler Arm System Disassembly (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . .

Idler Arm System Assembly (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . .

4-3

4-4

4-5

4-6

4-6

4-6

4-7

4-8

4-9

4-10

4-10

4-11

4-12

4-12

5-2

5-3

5-3

5-4

5-4

5-4

5-5

5-8

5-9

5-9

5-9

6-2

6-2

6-2

6-3

6-6

6-7

6-10

6-11

6-12

6-12

6-13

6-14

6-15

6-17

6-19

6-20

6-21

6-22

6-22

6-25

iv WPM Drive Systems Manual

TABLE OF CONTENTS

BBC Cable Removal (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . . . . .

BBC Cable Installation (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . . . .

BLADE OVERRIDE SYSTEM (BOS), BLADE CLUTCH SYSTEM (BCS) . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOS/BCS System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HANDLES AND CONTROL CABLES

Toro 2 Bail Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Pace Generation 1/Easy Stride Generation 1 . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Personal Pace Cable . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Pace Generation 2/Easy Stride Generation 2 . . . . . . . . . . . . . . . . . .

Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Personal Pace/Easy Stride Cable . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy 2 Bail Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy Sens-a-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Disassembly, Zone Start Models . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle Disassembly, Lawn-Boy Blade Clutch System (BCS) Models . . . . . . . . . . . . .

3 Speed Transmission Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Speed Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BBC Cable Adjustment (Toro Vacu Power/Lawn-Boy Medallion) . . . . . . . . . . . . . . .

Toro BBC Cable Adjustment (Recycler/Rear Bagger) . . . . . . . . . . . . . . . . . . .

Toro BOS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Toro BOS Control Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy BCS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lawn-Boy BCS Control Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . .

SELF-PROPEL BELT REPLACEMENT

Toro 21” Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22” Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22” Rear Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21” Steel & Cast Deck Toro & Lawn-Boy Mowers Belt Replacement . . . . . . . . . . . . .

21” Cast Deck Mowers with 3 Speed Transmission . . . . . . . . . . . . . . . . . . . .

21” Toro & Lawn-Boy Mowers with Blade Brake Clutch . . . . . . . . . . . . . . . . . .

21” Toro Mowers with Blade Override System & Lawn-Boy Mower

with Blade Brake Clutch System . . . . . . . . . . . . . . . . . . . . . . . . .

21” Lawn-Boy Insight Mowers . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-27

6-28

6-28

6-28

6-32

6-33

7-2

7-3

7-3

7-3

7-5

7-6

7-6

7-6

7-8

7-8

7-9

7-9

7-9

7-10

7-11

7-11

7-11

7-13

7-13

7-15

7-16

7-17

7-18

7-18

7-18

8-2

8-2

8-2

8-2

8-2

8-3

8-3

8-3

vWPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

10301 CD SB RK 2B None

10302 CD SB RK 2B None

10304 CD SB RK 2B None

10305 CD SB RK 2B None

10307 CD SB RK 2B None

10309 CD SB RK 2B None

10310 CD SB RK 2B None

10311 CD SB RK 2B None

10312 CD SB RK 2B None

10313 CD SB RK 2B None

10314 CD SB RK 2B None

10316 CD SB RK 2B None

10317 CD SB RK 2B None

10318 CD SB RK 2B None

10319 CD SB RK 2B None

10320 CD SB RK 2B None

10321 CD SB RK 2B None

10323 CD SB RK 2B None

10324 CD SB RK 2B None

10324C CD SB RK 2B None

10327 CD SB RK 2B None

10328 CD SB RK 2B None

10329 CD SB RK 2B None

10330 CD SB RK 2B None

Using this manual

Following each model number in the list below are codes identifying the type of

deck material, transmission, wheel pinion clutch, hand controls, and if it has a

blade clutch system. Use this information to select the correct sections of the

service manual for the mower being serviced.

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

vi WPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

10331 CD SB RK 2B None

10332 CD SB RK 2B None

10334 CD SB RK 2B None

10335 CD SB RK 2B None

10342 CD SB RK 2B None

10343 CD SB RK 2B None

10344 CD SB RK 2B None

10345 CD SB RK 2B None

10356 CD SB RK 2B None

10357 CD SB RK 2B None

10358 CD SB RK 2B None

10359C CD SB RK 2B None

10360 CD SB RK 2B None

10360C CD SB RK 2B None

10361 CD SB RK 2B None

10362 CD SB RK 2B None

10363 CD SB RK 2B None

10515 CD 3S RK 2B None

10516 CD 3S RK 2B None

10517 CD 3S RK 2B None

10518 CD 3S RK 2B None

10519 CD 3S RK 2B None

10520 CD 3S RK 2B None

10521 CD 3S RK 2B None

10522 CD 3S RK 2B None

10523 CD 3S RK 2B None

10524 CD 3S RK 2B None

10525 CD 3S RK 2B None

10527 CD 3S RK 2B None

10528 CD 3S RK 2B None

10533 CD 3S RK BBC BBC VP

10545 CD 3S RK 2B None

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

viiWPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

10546 CD 3S RK 2B None

10547 CD 3S RK 2B None

10548 CD 3S RK 2B None

10550 CD SB RK ES1 None

10551 CD SB RK ES1 None

10552 CD SB RK ES1 None

10655 22stl B SR ES2 None

10656 22stl B SR ES2 None

10672 Ins B SR SS None

10673 Ins B SR SS None

10682 Ins B SR 2B None

10684 Ins B SR 2B None

10684C Ins B SR 2B None

10685 Ins B SR SS None

10686 Ins B SR SS None

10686C Ins B SR SS None

10687 Ins B SR SS BCS

10695 Ins B SR SS None

10696 Ins B SR SS None

10696C Ins B SR SS None

10697 Ins B SR SS BCS

10910 CD SB RK 2B None

10910B CD SB RK 2B None

10926 CD SB RK 2B None

10927 CD SB RK 2B None

10928 CD 3S RK ? None

10929 CD SB RK 2B None

10995 Ins B SR SS None

10997 CD B SR SS BCS

11001 CD 3S RK 2B None

11001B CD 3S RK 2B None

11003 CD 3S RK 2B None

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

viii WPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

16212 W Worm None None None

16212B W Wom None None None

16212W W Worm None None None

16212WG W Worm None None None

16401 W Worm None None None

16402 W Worm None None None

16404 W Worm None None None

16411 W Worm None None None

16775 W Worm None None None

16776 W Worm None None None

16785 W Worm None None None

16793 W Worm None None None

20001 22stl B SR 2B None

20003 22stl B SR 2B None

20005 22stl B SR 2B None

20007 22stl B SR 2B None

20011 22stl SB RK 2B None

20012 22stl B SR 2B None

20013 22stl B SR PP2 None

20014 22stl B SR PP2 None

20016 22stl B SR 2B None

20017 22stl B SR PP2 None

20018 22stl B SR PP2 None

20019 22stl B SR 2B None

20020 CD SB RK 2B None

20021 CD SB RK 2B None

20028 CD SB RK 2B None

20031 22stl B SR PP2 None

20036 CD SB RK PP2 None

20037 CD SB RK PP2 None

20038 CD SB RK PP2 None

20039 CD SB RK PP2 None

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

ixWPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

20041 22stl B SR PP2 None

20044 CD 3SP RK 1B None

20047 22stl B RK PP2 None

20049 22stl B SR PP2 None

20051 22stl B SR PP2 None

20054 CD SB RK PP2 None

20055 CD SB RK PP2 None

20056 CD SB RK PP2 BOS

20057 CD SB RK PP2 None

20058 CD SB RK PP2 BOS

20070 22stl B SR PP2 None

20079 22stl B SR PP2 None

20106 CD 3SP RK 1B BBC

20107 CD 3SP RK 1B BBC

20210 CD 3SP RK 1B BBC

20211 CD 3SP RK 1B BBC

20214 CD 3SP RK 1B None

20216 CD 3SP RK 1B None

20218 CD 3SP RK 1B None

20219 CD 3SP RK 1B BBC

20320 CD 3SP RK 1B None

20321 CD 3SP RK 1B None

20322 CD 3SP RK 1B None

20324 CD 3SP RK 1BBC BBC

20325 CD 3SP RK BBC BBC

20327B CD 3SP RK 1B None

20328B CD 3SP RK 1B None

20436 CD 3SP RK 1B None

20436WF CD 3SP RK 1B None

20437 CD 3SP RK 1B None

20438 CD 3SP RK BBC BBC

20438WF CD 3SP RK BBC BBC

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

x WPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

20439 CD 3SP RK BBC BBC

20439WF CD 3SP RK BBC BBC

20462 CD 3SP RK 1B None

20463 CD 3SP RK 1B None

20464 CD 3SP RK 1B None

20465 CD 3SP RK BBC BBC

20466 CD 3SP RK BBC BBC

20470 CD 3SP RK 1B None

20472 CD 3SP RK 1B None

20473 CD 3SP RK 1B None

20474 CD 3SP RK 1B None

20475 CD 3SP RK BBC BBC

20476 CD 3SP RK BBC BBC

20478 CD 3SP RK 1B None

20479 CD 3SP RK 1B None

20480 CD 3SP RK 1B None

20481 CD 3SP RK 1B None

20482 CD 3SP RK BBC BBC

20483 CD 3SP RK BBC BBC

20486 CD 3SP RK 1B None

20487 CD 3SP RK BBC BBC

20488 CD 3SP RK 1B None

20489 CD 3SP RK 1B None

20490 CD 3SP RK BBC BBC

20494 CD 3SP RK 1B None

20495 CD 3SP RK 1B None

20622 CD 3SP RK BBC BBC

20632 CD 3SP RK BBC BBC

20652 21” stl SB RK PP1 None

20654 21” stl SB RK PP2 None

20655 22” stl B SR PP2 None

20656 22” stl B SR PP2 None

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

xiWPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

20666 CD 3SP RK 1B None

20667 CD 3SP RK BBC BBC

20668 CD 3SP RK 1B None

20677 CD 3SP RK 1B None

20680 CD 3SP RK 1B None

20692 CD 3SP RK 1B None

20695 CD 3SP RK BBC BBC

20761B CD 3SP RK 1B None

20763B CD 3SP RK 1B None

20764B CD 3SP RK 1B None

20764BC CD 3SP RK 1B None

20766B CD 3SP RK 1B None

20766BC CD 3SP RK 1B None

20767B CD 3SP RK 1B None

20768B CD 3SP RK 1B None

20776 CD 3SP RK 1B None

20777 CD 3SP RK 1B None

20778 CD 3SP RK 1B None

20781 CD SB RK PP2 None

20783 CD SB RK PP2 None

20784 CD SB RK PP2 None

20786 CD 3SP RK 1B None

20787 CD 3SP RK 1B None

20792 CD SB RK PP2 None

20793 CD SB RK PP2 None

20795 CD SB RK PP2 None

20796 CD SB RK PP2 None

20817 CD SB RK PP2 None

20819 CD SB RK PP2 None

20828 CD SB RK PP2 None

20831 CD SB RK PP2 None

20832 CD SB RK PP2 None

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

xii WPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

20833 CD SB RK PP2 None

20905 CD Worm RK 1B None

20905B CD Worm RK 1B None

20906B CD Worm RK 1B None

20911B CD Worm RK 1B None

20915 CD Worm RK 1B None

20916B CD Worm RK 1B None

20920 CD Worm RK 1B None

20920B CD Worm RK 1B None

20921B CD Worm RK 1B None

20925 CD Worm RK 1B None

20925B CD Worm RK 1B None

20926B CD Worm RK 1B None

20927B CD Worm RK 1B None

26620B CD VP 3 SP RK 1B None

26620BF CD VP 3 SP RK 1B None

26620BG CD VP 3 SP RK 1B None

26621 CD VP 3 SP RK BBC BBC VP

26621B CD VP 3 SP RK BBC BBC VP

26622 CD VP 3 SP RK BBC BBC VP

26623 CD VP 3 SP RK BBC BBC VP

26624 CD VP 3 SP RK BBC BBC VP

26625B CD VP 3 SP RK 1B None

26625BG CD VP 3 SP RK 1B None

26626 CD VP 3 SP RK BBC BBC VP

26630B CD VP 3 SP RK 1B None

26630BC CD VP 3 SP RK 1B None

26630BG CD VP 3 SP RK 1B None

26631B CD VP 3 SP RK BBC BBC VP

26631BC CD VP 3 SP RK BBC BBC VP

26632 CD VP 3 SP RK 1B None

26632B CD VP 3 SP RK 1B None

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

xiiiWPM Drive Systems Manual

TABLE OF CONTENTS

Model Trans Trans Wheel Handle Blade

R&R Internal Pinion Repair Clutch

Repair

26633 CD VP 3 SP RK BBC BBC VP

26633B CD VP 3 SP RK BBC BBC VP

26635B CD VP 3 SP RK 1B None

26635BC CD VP 3 SP RK 1B None

26635BG CD VP 3 SP RK 1B None

26636 CD VP 3 SP RK 1B None

26636B CD VP 3 SP RK 1B None

26637 CD VP 3 SP RK 1B None

26638 CD VP 3 SP RK BBC BBC VP

26639 CD VP 3 SP RK 1B None

26640B CD VP 3 SP RK 1B None

26640BC CD VP 3 SP RK 1B None

26643 CD VP 3 SP RK 1B None

26643B CD VP 3 SP RK 1B None

26680 CD VP 3 SP RK 1B None

26680WG CD VP 3 SP RK 1B None

26682 CD VP 3 SP RK BBC BBC VP

26683 CD VP 3 SP RK BBC BBC VP

27500 CD VP 3 SP RK BBC BBC VP

27501 CD VP 3 SP RK BBC BBC VP

27502 CD VP 3 SP RK BBC BBC VP

20442 CD SB RK 1B None

20444 CD SB RK 1B None

20711 CD SB RK 1B None

Code List

1B - one bail CDVP - cast deck Vacu Power

2B - two bail ES1 - Easy Stride 1st generation

3S- 3 speed ES2 - Easy Stride 2nd generation

21” stl - 21” steel deck Ins - Insight

22” stl - 22” steel deck PP1 - Personal Pace 1st generation

B- bevel gear PP2 - Personal Pace 2nd generation

BBC - blade brake clutch RK - rocking key

BBC VP - blade brake clutch SB - spur bevel

for Vacu Power SR - spring ratchet

BOS - blade override system SS - Sens-a-Speed

CD - cast deck W - worm

xiv WPM Drive Systems Manual

TABLE OF CONTENTS

THIS PAGE INTENTIONALLY LEFT BLANK.

1-1WPM Drive Systems Manual

Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .

Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .

Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Brake Clutch Systems (BBC), Blade Override

System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .

Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

2

3

4

5

6

7

8

1

WORM DRIVE TRANSMISSION

1-2 WPM Drive Systems Manual

WORM DRIVE TRANSMISSION

GENERAL

There are two versions of the worm drive transmission.

The fi rst is a clutch type and is used on 21” front wheel

drive mowers. The second version is constant mesh and

is used on International 48cm rear wheel drive mowers.

This is a worm and helical gear transmission. The worm

shaft (input shaft) is driven by a belt from the engine

crankshaft. A spring which hooks into the tab on the

front of the transmission (where the roll pin is) and to

Fig 001 fi g 1

INTERNALLY CLUTCHED

Description

the mower housing, pivots the transmission forward to

maintain tension on the belt.

The worm is in constant mesh with the helical gear. The

clutching action is provided by a sliding clutch jaw. A shift

fork moves the clutch jaw to engage and disengage the

transmission. When the clutch jaw engages the helical

gear, power is transferred from the clutch jaw to the

sleeve inside the clutch jaw. The sleeve is pinned to the

axle. The axle then begins to rotate (Fig. 001).

A. Belt E. Shift Fork

B. Spring F. Sleeve

C. Helical Gear G. Input Shaft

D. Clutch Jaw (worm shaft)

A

B

E

G

CDF

1-3WPM Drive Systems Manual

This transmission requires 90 wt. gear oil. A variable

weight such as 85w90 is acceptable as long as the

range includes 90 weight. The second part of the

requirement is an EP rating of GL 5 or higher.

The transmission has a fi ll/check plug in the front. With

the transmission level, fi ll until level with the hole. NOTE:

This is equal to about the center of the axle.

Unless the case is cracked, oil can not leak out. Even if

a seal fails, oil will leak out only to the bottom of the seal

on the axle.

If gear failure occurs, the resulting friction can cook the

oil down to a smear in the bottom of the case. This does

not indicate a lack of lubrication.

This type of transmission will last less than 30 minutes

with no lubrication. If a transmission lasts even a few

weeks in consumer use, it had lubrication to start.

The shift rod has a roll pin protruding through the top

of the transmission. This pin goes through a latch plate

with an L shaped slot in it. The slot guides the pin in its

travel from engagement to disengagement. Above the

latch plate is a dust fi lter and a dust cover. The shift arm

on top of the transmission holds all these parts in place

(Fig. 003).

Fig 003 3428-0165

When the shift arm is pulled to the rear by the shift

cable, the pin moves to the left side of the mower, then

to the rear. This moves the shift pin, the shift fork, and

the clutch jaw to the disengage position.

NOTE: Dirt packed in the latch plate can prevent

disengagement. The dust fi lter and dust

cover help prevent this failure.

When the shift cable is engaged, tension on the shift

arm is released. The spring on the shift rod applies

pressure to the rod, fork, and clutch jaw to engage the

transmission.

WORM DRIVE TRANSMISSION

Lubrication

The Shifting Process

The upper end of the clutch fork slides over a groove in

a spring loaded rod. This spring pushes the shift fork and

clutch jaw towards the engaged position (Fig. 002).

Fig 002 3428-0150

A. Shift Rod B. Shift Fork

A. Roll Pin E. Shift Arm

B. Latch Plate F. Screw

C. Dust Filter G. Shift Rod

D. Dust Cover

A

B

G

B

C

D

E

F

A

1-4 WPM Drive Systems Manual

WORM DRIVE TRANSMISSION

4. Remove both front wheels and wheel covers (Fig.

005).

Fig 005 3428-0129

5. Pivot (both) front spring arms forward until they

point straight down. (This removes the tension from

the pivot arms so the roll pin can be removed) (Fig.

006).

Fig 006 3428-0131

2. Raise the front of the mower off the bench and

support it with blocks.

3. Disconnect the shift cable.

Fig 004 3428-0127

1. Remove the belt cover and unhook the spring on

the front of the transmission. Slip the belt off the

transmission pulley (Fig. 004).

A. Cable Clamp C. Spring

B. Shift Cable

A

B

C

C

Removal & Installation (front wheel drive

applications)

1-5WPM Drive Systems Manual

Fig 008 3428-0137

7. The wheel pinion, thrust washer, pivot, and spring

arm will now slide off the end of the axle (Fig. 008).

Repeat the process on the other side.

Fig 007 3428-0135

6. Place a block of wood under the wheel pinion for

support and drive the roll pin out of the axle (Fig.

007). Repeat the process on the other side.

8. Remove the transmission from the chassis.

9. Reverse the procedure to install.

NOTE: Support the wheel pinions with the wood

block while driving the roll pins in. This will

prevent the axle from being bent. Fill the

transmission with oil after it is installed in

the mower (Fig. 009).

Note the front of the transmission is identifi ed by the oil

fi ll/check screw and the fl at tab which is part of the lower

case.

Fig 009 3428-0166

WORM DRIVE TRANSMISSION

Disassembly

1. Cut and discard the push-on retainer on top of the

transmission pulley. Remove the belt and pulley.

A. Wood Block

A. Fill/Check C. Tab

B. Plug

A

A

B

AC

1-6 WPM Drive Systems Manual

WORM DRIVE TRANSMISSION

5. Push the worm shaft out of the cover. This may

require a little pressure.

6. To remove the axle, slide the clutch jaw to the side

and drive the roll pin out of the sleeve and axle (Fig.

012).

Fig 012 3428-0151

7. If the axle bearings are to be re-used, clean the end

of the axle before drawing it out of the case.

8. Remove the sleeve, clutch jaw, helical gear, and

thrust washer (Fig. 013)

Fig 013 3428-0153

Fig 010 3428-0146

2. Drive the roll pins out of the fl anges in the front

and rear of the case. (These pins align the top and

bottom parts of the case) (Fig. 010).

Fig 011 3428-0148

3. Remove the 4 self-tapping screw that connect the

top and bottom cases.

Note: If you turn this transmission on its side or

upside down, oil may leak out of the top. This

is not a sealed case.

4. Remove the transmission cover. The shift fork may

come with the cover or may fall into the bottom of

the case (Fig. 011).

A. Helical Gear C. Sleeve

B. Thrust Washer D. Clutch Jaw

ABCD

1-7WPM Drive Systems Manual

Assembly

Fig 014 3428-0157

9. Clean the old gasket material from the mating

surfaces of the case and cover.

10. A hook or small screwdriver can be used to pry the

seals out of the case.

11. An arbor press or large vise will be needed when

removing and replacing the bushings.

12. Clean the oil residue and any metal shavings from

the case.

13. Worm and helical gears are sold as a set. Even after

a short run time, they will develop a wear pattern.

Replacing only one gear will result in rapid failure

(Fig. 014).

14. Remove the screw from the shift arm and remove

the shift arm, dust cover, and wear plate (Fig. 015). If

the ball bearing is to be replaced, press it out at this

time.

Fig 015 3428-0165

15. Remove the roll pin and pull shifter rod out of the

cover. Clean the cover.

WORM DRIVE TRANSMISSION

1. Use bushing installation tool P/N 27-0460, to press

in new axle bushings. This tool helps keep the

bushing straight and keeps the inner diameter of the

bushing correctly sized.

A. Worm Shaft B. Helical Gear

A. Roll Pin E. Shift Arm

B. Latch Plate F. Screw

C. Dust Filter G. Shift Rod

D. Dust Cover

A

B

G

B

C

D

E

F

A

1-8 WPM Drive Systems Manual

WORM DRIVE TRANSMISSION

3. Note: Some replacement axles have more than one

hole that can be used to pin the sleeve to the axle.

Refer to the original axle to identify the correct hole

to use. Then drive a roll pin through the sleeve and

axle (Fig. 017).

Fig 017 3428-0151

2. Clean the rust and dirt from the both ends of the

axle. Wipe the inner diameter of the bushings with

a clean cloth. Lightly oil the axle and insert it into

the gearcase. When facing the front of the gearbox,

insert the short end of the axle from left to right.

Install the thrust washer, helical gear, and the sleeve

and clutch jaw. Then push the axle through the other

side of the case.

Fig 016 3428-0158

Note: The bushings are two different lengths. The

side of the case with the thicker boss uses

a longer busing to support the axle. The

bushings should be fl ush with the inside of

the case (Fig. 016).

A. Tool P/N 27-0460

A

4. Using a seal protector, slide new seals down each

side of the axle, Install the seal with the lip facing the

transmission. The outer edge of the seal should be

fl ush with the outside of the case. If a seal protector

is not available, wrap a piece of cellophane around

the axle (Fig. 018).

Fig 018 3428-0170

A. Seal protector or B. Seal

Cellophane

AB

1-9WPM Drive Systems Manual

Controls

6. Install worm shaft in bearing.

7. Use a new gasket. Install the cover on the bottom

case and start the 4 self-tapping screws. Do not fully

tighten them.

8. Install the front and rear roll pins to align the cover

and case. Then secure the 4 self-tapping screws.

Fig 019 3428-0159

5. If the bearing in the cover is being replaced, use tool

P/N 27-0490 to press it in place. This bearing only

has one seal. Install the bearing such that the seal

is visible from the top of the cover and the open side

faces the gears. Press the bearing in until it is fully

seated in the case (Fig. 019).

WORM DRIVE TRANSMISSION

9. Fill the transmission with gear oil AFTER it is

installed in the mower. The top of this transmission is

not sealed. It will leak if tipped on its side (Fig. 020).

Fig 020 3428-0166

There are two control cables used with this system. One

cable operates the engine kill switch and fl ywheel brake;

the other controls the transmission.

A. Tool P/N 27-0490

A. Fill/Check B. Plug

A

B

A

1-10 WPM Drive Systems Manual

WORM DRIVE TRANSMISSION

Fig 021 3428-0127

The transmission cable is a standard lever type. Since

the spring and pin on top of the transmission pushes the

shift fork towards the engaged position, the cable pulls

the shift arm to the rear to disengage the transmission.

The adjustment point is on the mower housing just to

the rear of the transmission. To adjust, pull the control to

the rear (disengage). Go to the cable clamp/adjustment.

Loosen the clamp, pull the cable to the rear until the shift

lever is as far back as it will go. Hold it there and tighten

the clamp (Fig. 021).

Adjustment

A

A. Cable Clamp

1-11WPM Drive Systems Manual

CONSTANT MESH

Description

This transmission is very similar to the “INTERNALLY

CLUTCHED” on page 1 – 1. However, the helical gear

is different as there is no internal clutching (Fig. 022).

Engagement and disengagement is accomplished by

pivoting the transmission to tighten or loosen the belt.

Internal repair procedures are the same, as is the

lubrication requirement, 90 wt. gear oil rated GL-5 or

higher.

Fig 022 fi g 18-A

WORM DRIVE TRANSMISSION

1. Jam nut 13. Oil Seal

2. Lock washer 14. Output shaft

3. Half pulley 15. Traction bracket

4. V Belt 16. Thread forming screw

5. Pulley spacer 17. Gearbox case

6. Gearbox cover 18. Thrust washer

7. Shaft & worm 19. Roll pin

8. Ball bearing 20. Helical gear

9. Gearbox gasket 21. Thrust washer

10. Check plug 22. Bushing

11. Gasket check plug 23. Roll pin

12. Bushing

The constant mesh type transmission is used in a 48cm

rear wheel drive application.

1-12 WPM Drive Systems Manual

WORM DRIVE TRANSMISSION

Fig 023 20911B sprearaxleassy

Removal and Installation

Ref. No. Qty Description

1

2

3

4

5

6

7

9

10

11

12

13

14

15

1

2

2

2

2

1

2

1

2

1

2

1

2

2

Rear Pivot Assembly RH

(incl. Ref. #2, 4, 5 & 14)

Grease Fitting

Washer

Sleeve Bushing

Grease Seal

Rear Pivot Assembly LH

(incl. Ref. #3, 4, 5 & 14)

Locknut

Thread Forming Screw

Trigger Return Spring

H.O.C. Saddle

Thread Forming Screw

Push Nut

Needle Bearing

Friction Washer

Ref. No. Qty Description

16

17

18

19

20

21

22

23

24

25

26

27

28

34

35

4

4

1

2

2

2

2

2

4

2

2

2

4

2

1

Keyed Thrust Washer

Retaining Ring

LH Rocking Key

Pinion Gear

Compression Spring

Wheel Cover

Tire & Gear Assy Wheel

(incl. Ref. #24)

Wheel Bolt

Wheel Bushing

Wheel Spacer

Clutch Washer

Rear Suspension Plate

Thread Forming Screw

Roll Pin

Gearbox Assembly

1-13WPM Drive Systems Manual

WORM DRIVE TRANSMISSION

To remove the transmission from the mower proceed as

follows:

1. Remove both rear wheels.

2. Remove the retaining rings, springs, gears, keys,

clutches, and pivot arms on both sides (“Wheel

Pinion Clutch” on page 5-2).

3. Remove the belt.

4. There is a suspension bracket on each side that

secures the transmission and pivot arms to the

chassis. Each bracket has 2 screws. Once they are

removed, the transmission will drop out.

To install, reverse the above process.

Fill the transmission level with the fi ll plug opening after it

is installed in the chassis. The top of the transmission is

not sealed, so it may leak if fi lled and tipped.

Fig 025 fi g 20

3. To check the adjustment, slowly squeeze the control

bar towards the handle. The cable is adjusted

correctly when resistance is felt when the control bar

is approximately 1” (25mm) from the upper handle

(Fig. 025).

Fig 024 fi g 19

2. Rotate the adjustment knob under the lower left-

hand side of the control panel ½ turn clockwise to

tighten the belt, or ½ turn counterclockwise to loosen

the belt. Hold the control cable while rotating the

knob to prevent the cable from turning (Fig. 024).

Controls

Adjusting Wheel Traction Drive

1. Stop the engine.

1. Knob 2. Cable

1-14 WPM Drive Systems Manual

WORM DRIVE TRANSMISSION

WHEEL CLUTCH

4. If loss of traction or improper engagement still

occurs after adjustment, repeat steps 2 – 3 until

properly adjusted.

See Rocking Key Wheel Clutch, page 5-3.

2-1WPM Drive Systems Manual

3

4

5

6

7

8

SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION

Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .

Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .

Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Brake Clutch Systems (BBC), Blade Override

System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .

Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

1

2

2-2 WPM Drive Systems Manual

SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION

GEAR CASE ASSEMBLY

Fig 026 snglspspurbvlgearbox

Ref. No. Qty Description

1

2

3

4

5

6

7

8

9

10

1

1

1

1

2

2

2

2

1

1

Gear Case Casting

Gear Case Cover

HWH Screw

Retaining Ring

Flat Washer

Groove Pin

Lock Nut NI

Washer

Thrust Washer

Bushing

Ref. No. Qty Description

11

12

13

14

15

16

17

18

19

2

1

1

2

2

2

2

2

2

Output Bushing

Intermediate Shaft

Pulley Half

Ball Bearing

Pulley Spacer

Bevel Gear 15t Spur, 37t

Pinion Gear Bevel

Gear

Output Shaft

2-3WPM Drive Systems Manual

This basic transmission has been in use for several

years. There are minor variations, such as different

shafts on the bevel pinion gear to accommodate belt

alignment on different chassies. All use a bevel pinion

input gear which mates with a combination bevel/spur

gear, which drives a fi nal spur gear.

SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION

1. Raise the rear of the mower and support with a block

(Fig. 027).

Fig 027 PICT-1870

2. Remove transmission belt cover.

3. Remove both rear wheels.

4. Remove retaining ring, spring, thrust washer, and

pinion from both axles (Fig. 028). Refer to “Wheel

Pinion Clutch” on page 5-3 for additional information

about the clutch mechanism.

Fig 028 PICT-1873a

Description

Lubrication

Proper lubrication for this transmission is 2.5 – 3 fl uid

ounces (7.1cc – 9.0cc) of lithium based No. 2 grease.

Transmission Removal and Replacement

5. Continue disassembly, remove rocking key, clutch

washer, klip ring, keyed thrust washer, pivot arm

thrust washer, and friction ring. The pivot arm and

spring arm will then slide off the axle (Fig. 029).

Fig 029 PICT-1874a

A

A. Wood block

2-4 WPM Drive Systems Manual

On some models, removing these 2 screws makes

transmission removal easier (Fig. 032).

SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION

Transmission Internal Repair

Fig 032 3428-0121

The nut on the pulley can be removed now. The spacer

under the pulley varies with the chassis and the length

of the shaft on the pinion (Fig. 033). Remove the self-

tapping screws holding the cover on the transmission.

Fig 033 3428-0008

A. End cap

A

A

6. Remove the belt guide. Note the location of the

spacer under the front mounting screw (Fig. 030).

Do not try to force the belt off the pulley without

removing the belt guide. This often results in

damage to the belt or slightly bending the belt guide,

causing an increased tendency for belt jumping.

Fig 030 PICT-1880a

7. The transmission can be moved to the right until

the short end of the axle clears the housing and

the transmission can be removed (Fig. 031). Some

models have the axle shaft retained by an end cap.

Fig 031 3128-0074

2-5WPM Drive Systems Manual

Fig 035 3428-0018

Remove the axle and intermediate shaft with the gears.

The bearing in the cover should be sealed on both sides.

Inspect the bearing and its seals for damage (Fig. 035).

Replace as necessary. The bearing is pressed into the

cover. Make sure bearing is fully seated.

Fig 034 108-8140-1b

Before removing the parts from the case, note the

quantity and location of the thrust washers (Fig. 034).

Clean the gears in solvent and inspect carefully. Any

damaged gear must be replaced. Also replace the mate

for the damaged gear. When gears run together, they

develop a wear pattern that will result in premature

failure if only one gear is replaced. The exception for this

is if the transmission has VERY little running time before

failure.

The axle has two roll pins through it. One connects the

single spur gear to the axle (Fig. 036). The other pin

aligns the axle and transmission case.

Fig 036 3428-0016

SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION

Assemble with the correct number of thrust washers.

Refer to the parts manual if there is any doubt at all. It

is not possible to locate the shafts and bearings in the

wrong location, due to differences in sizes.

Assembly

2-6 WPM Drive Systems Manual

SINGLE SPEED SPUR/BEVEL GEAR TRANSMISSION

Prior to installation of oil impregnated bushings, it is

wise to apply a light coating of engine oil to the running

surface (Fig. 037). Add grease and install the cover.

Fig 037 3428-0019

Finally, install the spacer and pulley on the input shaft.

The internal gears will help hold the pinion while the nut

is tightened (Fig. 038).

Fig 038 3428-0022

Insert the transmission back into the chassis. Refer

to the section on the wheel pinion clutch for assembly

instructions.

Install self propel cable. Adjust as needed; see “Handles

and Control Cables” Section 7.

3-1WPM Drive Systems Manual

2

4

5

6

7

8

SINGLE SPEED BEVEL GEAR TRANSMISSION

Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .

Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .

Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Brake Clutch Systems (BBC), Blade Override

System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .

Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

1

3

3-2 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

EXPLODED VIEW - SINGLE SPEED BEVEL GEAR TRANSMISSION

A. Nut H. Bushing

B. Washer I. Thrust washer

C. Pulley J. Bevel Gear

D. Spacer K. Bushing

E. Housing L. Roll pin

F. Bearing M. Axle

G. Pinion

Fig 039 single speedtrans a

A

B

C

D

E

F

G

H

IJ

K

LM

3-3WPM Drive Systems Manual

GENERAL INFORMATION

This transmission was fi rst used on 22” steel deck

models for 2002. It is used in both front wheel and rear

wheel drive confi gurations. The bevel gear is reversed

when used in the front drive versus the rear drive to

change axle shaft direction of rotation.

In both cases, the gears are in constant mesh. Clutching

is done by rocking the transmission to tighten or loosen

the drive belt (Fig. 040). The control cable will move

the transmission to tighten the belt. When released, the

weight of the transmission causes it to rock towards the

engine to disengage.

Fig 040 MVC-485

SINGLE SPEED BEVEL GEAR TRANSMISSION

3-4 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

FRONT AXLE AND TRANSMISSION ASSEMBLY

3354-613 Rev A

Fig 041 3354-613(5)

Ref. No. Qty Description

1

2

2:1

3

4

5

7

7:1

7:2

8

9

10

11

12

13

2

2

2

4

2

6

2

1

1

2

2

2

2

2

2

Bolt-Shoulder

Wheel Gear ASM

Bushing

Klipring-Locking

Gear-Pinion, 13T

Washer-Thrust

Cover-Wheel

Cover

Washer-Stepped

Arm-Pivot, Front

Arm-Spring

Knob-Lever, HOC

Ring-Retaining

Retainer-Bearing, HOC

Bearing-Ball

Ref. No. Qty Description

14

15

16

17

18

19

20

21

22

23

24

25

26

27

2

2

1

1

2

1

2

1

1

2

1

1

1

1

Spring-Compression

Key

Transmission ASM

Gasket-Gearbox

Screw-HWH

Bracket-Pivot, Fwd

Screw-HWH

Spacer

V-Belt

Pulley-Half, Front

Washer-Flat

Nut-Lock

Cover-Belt, Front

Washer

3-5WPM Drive Systems Manual

22” FRONT WHEEL DRIVE MODELS

1. Block the front of the mower up. There are two

screws that secure the belt cover to the housing.

They are accessed from the bottom (Fig. 042).

Fig 042 MVC-482

2. Slip the belt out between the transmission pulley and

belt guide.

3. Grip the axle with locking pliers and remove the

locknut on the transmission pulley (Fig. 043)

Fig 043 MVC-486

Fig 044 MVC-472

4. Remove the nut, washer, transmission pulley halves,

and spacer.

5. Remove the belt guide.

6. Remove both front wheels; note there is a washer

between the wheel and wheel cover.

7. To remove the wheel pinions, remove the klip ring

and thrust washer. The pinion will now slide off the

axle (Fig. 044).

Note: The spring-loaded drive key is under the

pinion.

SINGLE SPEED BEVEL GEAR TRANSMISSION

Remove Transmission

A

A

A. Key B. Wheel cover

B

8. Remove the wheel cover.

3-6 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

9. Remove the two bolts and nuts securing each pivot

arm to the housing. There is a notch in the pivot arm

for clearance of a socket (Fig. 045).

Fig 045 MVC-475

The axle assembly will now drop out of the chassis

(Fig. 046).

Fig 046 PICT-1857a

Fig 048 MVC-478

11. To disassemble the pivot arm assembly, compress

the components with two clamps or locking pliers

(Fig. 048).

10. Remove the klip ring and thrust washer from each

end of the axle (the left side has 2 thrust washers,

the right side, one). The bearing, bearing retainer,

HOC plate, spring arm and pivot arm all come off as

one unit (Fig. 047).

Fig 047 PICT-1858a

3-7WPM Drive Systems Manual

Transmission Disassembly

The snap ring can now be removed. Loosen the

clamps with care due to the spring arm tension.

Separate the spring arm components (Fig. 049).

1. Remove the 4 screws holding the cover onto the

transmission. The axle, bearings, and bevel gear

can be lifted out (Fig. 050).

Fig 050 MVC-462

Assemble in reverse order.

See Assembly Tips next page.

Fig 051 MVC-468

2. Since the pulley was previously removed, the input

shaft will now slip out of the transmission case.

3. If the input bearing is to be removed, press it out of

the case now.

4. Slide the bearings and thrust washer off the axle.

Drive the roll pin out and the bevel gear can be

removed (Fig. 051).

SINGLE SPEED BEVEL GEAR TRANSMISSION

Transmission Assembly

Fig 049 PICT-1869a

3-8 WPM Drive Systems Manual

1. The same axle is used for both front and rear drive

versions. There are two holes in the axle about one

inch apart. Front wheel drive transmissions use the

hole in the axle that is about 5 ¾” (14.6cm) from the

end or closest to the center of the axle (Fig. 052).

Slip the gear on such that the teeth and longest hub

face the longer end of the axle. Drive the pin into

place. A double check is that neither of the pin holes

should be visible when the gear is installed.

SINGLE SPEED BEVEL GEAR TRANSMISSION

Assembly Tips

Fig 052 MVC-466

2. Install the trust washer on the side of the gear with

the shorter hub, away from the gear teeth (Fig. 053).

Fig 053 MVC-468

4. If the input bearing was removed, press the new one

in until it bottoms in the case.

5. Fill the transmission case approximately 2/3 full with

#2 lithium base grease.

6. Assemble the bearing, bearing retainer, height of

cut plate, spring arm and pivot arm. Use two clamps

or vise grips to compress the assembly so the snap

ring can be installed.

Note: Install the snap ring with the sharp edge

facing away from the spring arm.

Fig 054 MVC-470

3. Install the transmission bearings with the fl ange

facing the gear (Fig. 054).

3-9WPM Drive Systems Manual

7. Coat the axle, key, and spring with #2 molybendum

disulfi de base grease or anti-seize compound before

installing the pinion (Fig. 055).

Fig 055 MVC-472

Fig 058 MVC-487

3. Slip the belt off the transmission pulley and push it

towards the engine (Fig. 058).

Fig 057 MVC-482

To replace the self-propelled drive belt, proceed as

follows:

1. Drain the fuel and oil and tip the mower on its right

side.

2. Remove the two screws securing the belt cover from

under the housing (Fig. 057).

SINGLE SPEED BEVEL GEAR TRANSMISSION

Belt Service - Front Wheel Drive Models

Fig 056 MVC-474

8. The wheel pinion is marked with an R and L for right

and left. Identify right and left from the operator’s

position (Fig. 056). On the right side, the letter R

should face out. The letter L should face out on

the left side. If the wheel pinions are reversed, the

wheels will not drive.

R

Note: For more information on the wheel clutch see

Section 5, Wheel Pinion Clutch.

3-10 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

22” TORO & LAWN-BOY REAR

WHEEL DRIVE MODELS

Transmission Removal and Belt

Replacement

4. Remove one of the mounting screws for the belt

guide and loosen the other. DO NOT bend the belt

guide (Fig. 059).

Fig 059 MVC-490

5. Slip the belt out of the crankshaft pulley and over the

blade (Fig. 060).

Fig 060 MVC-491

Fig 061 MVC-733

On rear wheel drive models, it is necessary to separate

the rear drive assembly from the mower housing in order

to change the drive belt.

1. Drain fuel and oil from the engine.

2. Remove the single retaining screw from the center of

the bag door spring. Slide the door to one side and

remove it from the rear HOC side plates (Fig. 061).

Note: Blade removed for clarity. The blade can

be removed, but it is not required for belt

replacement.

3-11WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

3. Remove the plug from the hole next to where the

self propel cable goes through the chassis (Fig.

062).

Fig 062 MVC-735

4. Tip the mower on its side. The cable snaps in from

the top and connects to an arm on the transmission

belt guide (Fig. 063).

Fig 063 PICT-1884a

Fig 064 PICT-1895a

5. The cable tool (P/N 105-6819) will compress the

locking tabs on the cable so it can be removed from

the housing.

6. Slide the cable tool over the end of the cable and

push (Fig. 064). At the same time, reach around the

mower and pull the cable out of the housing.

Fig 065 PICT-1904

7. With the plug removed from the larger hole next to

the cable, move the cable through the slot (Fig. 065).

A. Cable B. Belt guide

A

A

B

B

A

A

A. Cable tool

3-12 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

12. Tip the mower onto its right side (carburetor up) and

remove the blade.

13. Remove one of the belt guide screws and loosen

the other enough to pivot the guide away (Fig. 069).

Do not bend the belt guide. Slide the pulley/blade

adapter and belt off the crankshaft.

Fig 069 MVC-738

Fig 066 PICT-1897

8. Push it into the larger hole (Fig. 066).

9. Remove both rear wheels and both wheel covers.

10. Remove the stop cable from the engine (Fig. 067)

and disconnect the self propel cable spring from the

transmission.

Fig 067 DSC-017

Fig 068 MVC-737

11. Pinch the ends of the lower handle together to

disengage them from the pins on the HOC plates

(Fig. 068).

A. Stop cable

A

3-13WPM Drive Systems Manual

14. Place the mower right side up and remove the three

hex head and one Allen head cap screws on each

side that hold the height of cut plates to the chassis

(Fig. 070). The transmission assembly will now drop

down.

Fig 070 MVC-848

Fig 072 MVC-743

16. The belt cover must be removed in order to remove

the belt (Fig. 072).

Fig 071 MVC-852

15. There is a cross brace underneath the mower that is

held in place by two of the cap screws shown above

(Fig. 071).

SINGLE SPEED BEVEL GEAR TRANSMISSION

17. Remove 3 screws that secure the belt cover to the

housing (Fig. 073).

Fig 073 MVC-744

A

A. Belt cover

3-14 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

21. Pull the belt towards the crankshaft and remove.

If only the belt is to be replaced, install a new one

now. Reverse the process to assemble.

If transmission service is necessary proceed as

follows.

19. Clamp the axle with locking pliers and remove the

pulley nut and transmission pulley (Fig. 075).

Do not bend the belt guide. The pulley must be lifted

up slightly to slip the belt off.

18. Pull the belt cover out from under the rear wall and

the belt is exposed (Fig. 074).

Fig 074 MVC-745

Fig 076 MVC-741

20. The cable may be unhooked from the arm on the

transmission to help prevent cable damage (Fig.

076).

Note: It is not necessary to remove the transmission

to replace the control cable.

Fig 075 MVC-740

3-15WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

Rear Axle Disassembly

1. Remove the klip rings and thrust washers that

secure the pinions to the axle (Fig. 077).

Fig 077 MVC-746

Fig 079 MVC-747

4. The pivot assembly will slide off the axle. This

includes the bearing, bearing retainer, HOC plate,

spring arm, and pivot arm (Fig. 079).

Fig 078 MVC-850

2. When removing the pinions, note that there is a

spring-loaded key under them.

3. Remove the other thrust washer and retaining ring

holding the pivot assembly to the axle (Fig. 078).

5. Clamp the pivot assembly with 2 pairs of locking

pliers or other clamps and remove the snap ring

(Fig. 080).

Fig 080 MVC-748

3-16 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

2. Since the pulley was previously removed, the input

shaft will now slip out of the transmission case.

3. If the input bearing is to be removed, press it out

now.

4. Slide the bearings and thrust washer off the axle.

Drive the roll pin out and the bevel gear can be

removed (Fig. 083).

Fig 083 MVC-470

Assemble in reverse order.

Transmission Assembly

Transmission Disassembly

6. You can now release the clamps and separate the

HOC plate, spring arm, and pivot arm (Fig. 081).

Fig 081 MVC-750

Fig 082 MVC-462

1. Remove the 4 screws holding the cover on the

transmission. The axle, bearings, and bevel gear

can be lifted out (Fig. 082).

3-17WPM Drive Systems Manual

Fig 084 MVC-469

1. The same axle is used for both front and rear wheel

drive models. There are two holes in the axle about

one inch apart.

Rear wheel drive models use the hole about 4-3/4”

(12cm) from the end. Slip the gear on such that the

teeth and the longest hub face the short end of the

axle. Drive the pin into place. A double check is that

neither of the pin holes should be visible when the

gear is installed (Fig. 084).

3. Install the transmission bearings with the fl ange

facing the gear (Fig. 085).

Fig 085 MVC-470

SINGLE SPEED BEVEL GEAR TRANSMISSION

Axle Assembly Tips

2. Install the thrust washer on the side of the gear with

the shortest hub, away from the gear teeth (Fig.

084).

4. Fill the transmission approximately 2/3 full with #2

Lithium base grease (1.5 oz or 43gm).

5. Assemble the bearing, bearing retainer, HOC plate,

spring arm, and pivot arm. Use two vise grips or

clamps to compress the assembly so the snap ring

can be installed (Fig. 086).

Note: Install the snap ring with the sharp edge

facing away from the spring arm.

Fig 086 MVC-748

A. Gear B. Thrust washer

3-18 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

Fig 087 MVC-472

6. Coat the axle, key, and spring with #2 molybendum

disulfi de grease or anti-seize compound before

installing the pinion (Fig. 087).

7. The wheel pinion is marked with an R and L for right

and left. Identify right and left from the operator’s

position (Fig. 088). On the right side, the R should

face outward. The letter L should face outward on

the left side. If the wheel pinions are reversed, the

wheels will not drive.

Fig 088 MVC-474

R

Note: See Chapter 5 for more information on Wheel

Clutches.

3-19WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

LAWN-BOY INSIGHT TRANSMISSION REMOVE AND REPLACE

3352-960 Rev B

Rear Axle and Transmission Assembly

4

Fig 089 3352-960(6)

Ref. No. Qty Description

1

2

3

4

6

7

7:1

7:2

8

9

10

11

12

13

2

2

4

2

6

2

1

1

2

1

2

2

2

2

Bolt-Shoulder

Rear Wheel ASM

Klipring-Locking

Gear-Pinion, 15T

Washer-Thrust

Wheel Cover ASM

Cover-Wheel

Washer-Stepped

Ring-Retaining

Arm-Rear, Pivot, LH

Arm-Spring, Rear

Knob-Lever, HOC

Retainer-Bearing, HOC

Bearing-Ball

Ref. No. Qty Description

14

15

16

17

18

19

20

21

22

23

24

25

27

28

2

2

1

1

1

2

1

2

1

1

1

1

1

1

Spring-Compression

Key

Transmission ASM

Washer-Shield

Bracket-Transmission

Screw-HWH

Spacer

Pulley-Half

V-Belt

Washer-Flat

Nut-Lock

Shield-Trailing

Washer

Arm-Rear Pivot, RH

3-20 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

Transmission Removal & Belt Replacement

The following steps will show one method of replacing

the belt or removing the transmission on the Lawn-Boy

Insight mowers.

1. Prepare the mower. Drain the gas and oil and

disconnect the spark plug wire.

2. Remove two screws that secure the rear cover (Fig.

090).

Fig 090 MVC-285

Fig 092 MVC-288

4. The belt cover will drop off the bottom (Fig. 092).

Fig 091 MVC-286

3. Remove the 3 belt cover screws (Fig. 091).

A. Belt cover

5. If you have an electric start model, remove the

battery and battery box.

6. Clamp the axle with a locking pliers and remove the

nut from the transmission pulley. If you are using an

air wrench, you may not need to hold the axle (Fig.

093).

Fig 093 MVC-291

A

A

3-21WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

7. Lift the top half of the transmission pulley off. If just

replacing the belt, push the belt into the cutting

chamber and slip the belt over the blade. Reverse

the process to install the new belt (Fig. 094).

Note: Do not get anti-seize on the belt or the drive

will slip.

Fig 094 MVC-292

Fig 096 MVC-295

9. Bend the trailing shield slightly in the middle and

remove it from the mower. Rotate both rear spring

arms down to disengage them from the mower

housing (Fig. 096).

Fig 095 MVC-294

If the transmission is to be removed, continue:

8. Support the back of the mower on a wood block and

remove the rear wheels (Fig. 095).

10. Remove klip ring, thrust washer, pinion, key spring

and thrust washer (Fig. 097).

Fig 097 PICT-1914a

3-22 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

13. Push the bearings and bearing retainers inward,

towards the transmission (Fig. 100).

Fig 100 MVC-297

Fig 101 PICT-1923

14. Unhook the traction cable from the transmission belt

guide (Fig. 101 and Fig 102).

11. Remove klip ring, keyed thrust washer, and standard

thrust washer (left side of mower has the standard

thrust washer, right side does not) (Fig. 098).

Fig 098 PICT-1915a

12. Remove the snap ring, pivot arm and spring arm

(Fig. 099).

Fig 099 PICT-1921a

3-23WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

Fig 103 PICT-1926

15. Remove the nut, washer, 2 pulley halves, and

spacer from the transmission input shaft. Remove 2

screws securing the belt guide to the transmission

(Fig. 103).

Fig 102 MVC-211x1

A. 2 screws on top D. Pulley half

of transmission E. Washer

B. Spacer F. Nut

C. Pulley half

A

A

B

B

C

C

D

D

E

E

F

F

16. Push the transmission to the left, as shown, and

rotate to clear the tunnel. Drop the left side down,

then pull the assembly out to the left side (Fig. 104).

Fig 104 MVC-300

17. The last step is to slide the bearings and bearing

retainers off the axle (Fig. 105).

Fig 105 MVC-301

3-24 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

Transmission Disassembly

Fig 106 MVC-462

1. Remove the 4 screws holding the cover on the

transmission. The axle, bearings, and bevel gear

can be lifted out (Fig. 106).

2. Since the pulley was previously removed, the input

shaft will now slip out of the transmission case.

3. If the input bearing is to be removed, press it out

now.

4. Slide the bearings and thrust washer off the axle.

Drive the roll pin out and the bevel gear can then be

removed (Fig. 107).

Fig 107 MVC-470

Assemble in reverse order. See Axle Assembly and

Installation Tips following.

Fig 108 MVC-469

1. The same axle is used for both front and rear wheel

drive models. There are two holes in the axle about

one inch apart.

Rear wheel drive models use the hole about 4-3/4”

(12cm) from the end. Slip the gear on such that the

teeth and the longest hub face the short end of the

axle. Drive the pin into place. A double check is that

neither of the pin holes should be visible when the

gear is installed (Fig. 108).

Transmission Assembly & Installation

Axle Assembly Tips

3-25WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

Fig 111 MVC-472

1. Reconnect the cable to the belt guide and install the

washer and spacer before installing the guide on the

transmission.

2. Install the snap rings and klip rings with the sharp

side out (in the direction of the force). The left end

of the axle uses the extra thrust washer, the one

without the tab. Install the snap ring, the regular

thrust washer then the thrust washer with the tab.

3. Coat the axle, key, and spring with #2 molybendum

disulfi de grease or anti-seize compound before

installing the pinion (Fig. 111).

Fig 109 MVC-470

2. Install the thrust washer on the side of the gear with

the shortest hub, away from the gear teeth (Fig.

108).

3. Install the transmission bearings with the fl ange

facing the gear (Fig. 109).

4. Fill the transmission approximately 2/3 full with #2

Lithium base grease (1.5 oz or 43gm).

5. Assemble the bearings and bearing retainers; install

the transmission in the housing (Fig. 110).

Fig 110 MVC-301a

Transmission Installation Tips

3-26 WPM Drive Systems Manual

SINGLE SPEED BEVEL GEAR TRANSMISSION

7. When installing the rear cover, note the bosses on

the back side of the cover. They must go behind the

notch in the chassis to secure the cover. The top of

the cover is retained with screws (Fig. 113).

Fig 113 MVC-303

A. Boss B. Notch

Note: Wheel Clutch Service - see Spring Ratchet

Key Style Clutch, page 5-8. Control Cable

Adjustment - see Handles & Control Cables.

A

B

5. Make sure the stepped washer is properly seated

in the wheel cover. The best way is to assemble the

wheel, wheel cover, and wheel bolt, then put them all

on the mower together.

6. Do not use an impact wrench on the crankshaft belt

guide screws. Over-tightening can cause the belt

guide to deform and cause the belt not to declutch

properly. Tighten fi rmly with a ratchet.

4. The wheel pinion is marked with an R and L for right

and left. Identify right and left from the operator’s

position (Fig. 112). On the right side, the R should

face outward. The letter L should face outward on

the left side. If the wheel pinions are reversed, the

wheels will not drive.

Fig 112 MVC-474

R

4-1WPM Drive Systems Manual

2

3

5

6

7

8

THREE SPEED TRANSMISSION

Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .

Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .

Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Brake Clutch Systems (BBC), Blade Override

System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .

Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

1

4

4-2 WPM Drive Systems Manual

THREE SPEED TRANSMISSION

GEARCASE ASSEMBLY

Fig 114 gearcaseassy

Ref. No. Qty Description

1

2

3

4

5

8

9

11

12

13

14

15

17

18

19

20

1

1

1

2

2

1

1

1

1

1

1

1

1

1

1

6

Pinion-25T

Pinion-20T

Gear-15t Spur, 37t Bevel

Washer - Thrust

Bushing

Bushing - Output

Washer

Gear-49 T

Gear-44 T

Gear-39 T

Sleeve - Gear

Pin - Spring

Shaft - Intermediate

Case - Gear, Upper

Cover - Case, Gear

Screw - Tapping

Ref. No. Qty Description

21

22

23

24

26

27

28

29

30

31

32

34

36

37

38

1

1

1

1

1

2

1

1

1

1

1

1

1

1

2

Bushing - Yoke

Retainer - Fork, Shift

Shaft - Output

Yoke - Shift

Spacer

Pulley - Half

Gear - Pinion, Bevel

Nut - Lock NI

Washer - Flat

Bearing - Ball

Bushing - Output

Collar - Shift

Clip - Spring

Sleeve - Key, Shift

Key - Shift

4-3WPM Drive Systems Manual

THREE SPEED TRANSMISSION

OPERATION

Input System:

Power is transferred from the engine to the transmission

by a belt. The self-propel pulley at the engine is keyed

to the crankshaft. The pulley on top of the transmission

is supported by a ball bearing and drives a pinion

gear inside the transmission. Tensioning of the belt is

accomplished by pivoting the transmission. When the

operator squeezes the control bar toward the handle,

a control cable tilts the transmission backward and

tensions the belt. When the control bar is released,

gravity pivots the transmission forward to loosen the belt.

Belt guides at the engine pulley and atop the

transmission ensure disengagement by forcing the belt

to loop around the engine pulley (Fig. 115).

Fig 115 3428-0196

A. Intermediate shaft C. Shift key

& gears D. Gear sleeve

B. Bevel gear E. Output shaft & gears

Fig 116 3428-0058

Speed Reduction System:

Speed reduction is accomplished by two sets of gears

– one set on the intermediate shaft and the other set on

the output shaft. The gears on the intermediate shaft

are powdered metal and ride on a hexagonal shaft

supported on each end by oil impregnated bushings.

These gears are driven by the pinion at the bottom of the

input shaft. The driven bevel gear turns the shaft so that

all three gears on the intermediate shaft have the same

rotational velocity (Fig. 116).

A

A

B

B

C

C

D

D

E

E

4-4 WPM Drive Systems Manual

THREE SPEED TRANSMISSION

There are also three gears on the output shaft. These

three gears rotate freely on the gear sleeve. The gear

sleeve is coupled to the output shaft with a roll pin so

the gear sleeve always rotates with the output shaft. The

gear selection system determines which one of these

three gears will be coupled with the gear sleeve and the

output shaft. This determines the fi nal drive ratio.

Gear Selection System:

Gear selection is determined by moving sliding shift

keys in a sleeve that is fi xed to the output shaft. These

keys engage one of the three gears that rotate on the

gear sleeve. Once the key engages one of the gears,

that gear will rotate the output shaft. Table 1 shows

approximate speeds in gears for two different engine

speeds.

Table 1

Gear Ground Speed @

3000 RPM

Ground Speed @

2000 RPM

1 1.8 mph (2.9km/h) 1.2 mph (1.9km/h)

2 2.7 mph (4.4km/h) 1.8 mph (2.9km/h)

3 3.8 mph (6.1km/h) 2.5 mph (4.3km/h)

The operator controls movement of the shift fork by

means of the gear selection control and cable.

Note: There are no shift detents in or on the

transmission on 1988 and newer mowers.

Fig 117 3428-0065

The shift keys are retained on one end by the shift

collar. Movement of the shift fork positions the shift collar

and shift key. The shift fork is supported, both top and

bottom, by nylon bushings for smooth operation and long

wear (Fig. 117).

A. Gear Sleeve C. Keys

B. Shift Collar

AB

C

4-5WPM Drive Systems Manual

THREE SPEED TRANSMISSION

Removal - Toro Vacu Power/Lawn-Boy

Medallion Models

Complete transmission removal on the Toro Vacu

Power/Lawn-Boy Medallion mower is quite easy and is

recommended for most self-propel system repairs.

1. Remove the spark plug lead from the engine to

prevent accidental starting. Drain the fuel and oil.

2. Place the ground speed selector in neutral. This will

make it easier to remove the speed selection cable

later.

3. Remove the two fl anged head self-tapping screws

securing the screen panel to the housing and

remove the panel (Fig. 118).

Fig 118 fi g 94

A. End cap

Fig 119 3428-0121

4. Remove the black plastic transmission cover from

the top rear of the housing.

5. Remove the two fl anged head self-tapping

screws securing the belt cover to the top of the

transmission. Pull the cable from belt guide and

remove the belt guide.

6. Remove the transmission access cover from the rear

of the housing by pressing from underneath.

7. Loosen the gear selection control cable clamp screw

until the cable comes free. Do not attempt to remove

the gear selection cable from the control arm at this

time.

8. Turn the mower onto its right side and remove the

four fl anged head self-tapping screws securing the

end caps to the housing (Fig. 119).

A. Screen panel C. Transmission access

B. Screws cover

9. Slowly pull the transmission from the housing being

very careful not to damage the gear selection cable.

Once clear of the housing, rotate the assembly until

the cable can be safely removed.

C

A

A

4-6 WPM Drive Systems Manual

THREE SPEED TRANSMISSION

Removal - Recycler/Rear Bagger Chassis

To remove the transmission from the chassis, raise the

rear and support it with blocks.

1. Remove both rear wheels and wheel covers.

2. Remove the rocking key clutches (see “Wheel Pinion

Clutch” on page 5-3).

3. Slide the pivot arm and spring arm off the axles.

4. Remove the belt cover. Loosen the belt guide and

slip the belt off the pulley. Disconnect shift and clutch

cables.

5. Slide the transmission to the right to slip the short

end of the axle out of the chassis.

1. Pivot both spring arms until they point straight.

2. Remove belt cover and belt.

3. Disconnect shift and clutch cables.

4. Remove 4 self-tapping screws securing end caps to

housing (Fig. 120).

Fig 120 3428-0121

2. Before disassembling further, check for proper

operation of the input system, the gear reduction

system and gear selection system. For more

information on this, refer to “OPERATION” on page

4-3.

Fig 121 3428-0120

Inspection of this transmission can be accomplished

without removing the pivot arm assembly from the output

shaft. Only if components on the output shaft require

replacement will pivot arm removal be necessary.

1. Remove the six fl anged head self-tapping screws

securing the transmission cover to the transmission

case. Remove the cover (Fig. 121).

Alternate Method

Disassembly

4-7WPM Drive Systems Manual

THREE SPEED TRANSMISSION

3. Removal of the input shaft and pulley assembly can

be diffi cult because the input pinion has a tendency

to turn as the pulley nut is loosened. This situation

can be addressed by using an impact wrench or by

removing the 20 (B) and 25 (A) tooth gears (Fig.

122) from the intermediate shaft and then putting

the intermediate shaft assembly back onto the

transmission. The hexagonal intermediate shaft

can then be held with a 7/16” end wrench while the

pulley nut is loosened.

Note: A cut-away transmission cover can be

fabricated to hold the intermediate shaft in

place to facilitate pulley nut removal.

Fig 122 3428-0058

The transmission uses 6 oz. (177cc) No. 2 lithium-based

grease as a lubricant. When assembling, be sure to coat

all moving components with grease to ensure proper

lubrication.

5. Remove the cotter pin from the top of the shift fork

and remove the shift lever.

6. Carefully pull the output shaft from the transmission

case, clean, and inspect all components for wear

or damage. Check the input shaft ball bearing for

roughness or excessive drag and replace any parts

necessary. If ball bearing replacement is required,

press the ball bearing out using an arbor press.

7. If service of any of the output shaft gears, or the

gear selection system, is required, remove the left

pivot arm as described under “Rear Height-of-Cut

and Wheel Pinion Clutch – Disassembly” on page

5-4 and 5-5.

Note: It is possible to replace the shift keys and

spring clip without removing the pivot arm

if the roll pin securing the gear sleeve to the

output shaft is fi rst driven out. However, it

is not recommended since inspection of the

inside of the output gears is not possible.

8. Pull the output shaft bushing, the spacer, the shift

collar, the shift keys and spring clip, and the shift key

sleeve from the output shaft.

9. Remove the three output shaft gears form the output

shaft.

10. Drive out the roll pin securing the gear sleeve to the

output shaft. Remove the gear sleeve and remaining

output shaft bushing. Inspect all parts for wear and

damage and replace if necessary.A. 25-tooth gear B. 20-tooth gear

4. Remove the intermediate shaft from the transmission

and clean. Inspect all gears for wear, cracks, and/or

broken teeth. Inspect the bushings for excessive

wear. Replace any parts necessary. Be careful not to

lose the two spacers that fi t between the bevel gear

and the bushing.

Transmission - Assembly

A

B

B

4-8 WPM Drive Systems Manual

THREE SPEED TRANSMISSION

Output Shaft Assembly

1. Slide the output bushing onto the output shaft,

fl anged side last. Assemble from the end of the shaft

closest to the hole for the roll pin.

2. Slide the gear sleeve onto the output shaft, tabs last

and secure with a new roll pin.

3. Apply a light coat of lithium-based grease on the

output shaft under the output busing, on the gear

sleeve, and on the three output shaft gears. Slide

the three output shaft gears onto the gear sleeve,

notched sides last.

4. Slide the nylon shift key sleeve onto the output shaft,

large end fi rst. Make sure that it engages the tabs on

the gear sleeve (Fig. 123).

Fig 123 492-4733 fi g. 4-1

A. Shift key sleeve

Fig 125 3428-0066

6. Slide the shift key assembly into the shift key sleeve

until the shift collar bottoms out.

7. Complete the output shaft assembly by sliding a

spacer washer and the other output bushing, fl anged

side fi rst, onto the output shaft. Don’t forget to coat

these components with a light coat of grease (Fig.

125).

Fig 124 3428-0065

5. Coat the shift key sleeve with grease and prepare

the shift keys, shift collar, and spring clip for

assembly as shown in Figure 124.

A

4-9WPM Drive Systems Manual

THREE SPEED TRANSMISSION

Input Shaft Assembly

8. If the left pivot arm was removed for servicing,

reassemble now as described under “Rear Height-

of-Cut and Wheel Pinion Clutch – Assembly” on

page 5-5.

1. If the input bearing was removed, press a new one

into the gearcase using an arbor press. Press only

on the outer race or bearing damage may result.

2. Slide the input shaft and pinion through the ball

bearing and assemble the spacer and two pulley

halves as shown in Figure 126. Install a fl at washer

and a nylon locknut fi nger tight.

Fig 126 Fig. 100

A. Intermediate shaft C. Shift fork retainer

B. Flange

Fig 127 3428-0059

3. The input pulley nut can be tightened after complete

transmission assembly, or at this point using the

process in step 3, under Disassembly, page 4-7.

4. Slip the shift fork into the slot on the shift collar and

place the shift fork and output shaft assembly into

the transmission.

Note: The long end of the shift fork shaft should go

through the hole in the gearcase. Make sure

that the output bushings are trapped in the

proper locations. Note that the larger output

bushing holes on the longer end of the shaft

and the shorter output bushing goes on the

shorter end of the shaft.

5. Slide the yoke bushing onto the lower end of the

shift fork, then secure the shift fork with the white

nylon shift fork retainer (Fig. 127).

A. Pulley C. Ball bearing

B. Spacer D. Pinion

4-10 WPM Drive Systems Manual

THREE SPEED TRANSMISSION

Intermediate Shaft Assembly

Note: Before assembling, coat the intermediate

shaft with No. 2 lithium-based grease. Apply a

light bead of lithium-based grease to fl ange.

1. Slip an intermediate shaft bushing onto the left end

of the intermediate shaft, fl anged end fi rst (Fig. 128).

Fig 128 MVC-000

Fig 129 3428-0196

For assembly, reverse the removal process.

Torque the belt guide fasteners to 130 in-lbs. (15 Nm)

(Fig. 129).

2. Slide the intermediate shaft gears onto the

intermediate shaft in this order:

a. 25 tooth gear

b. 20 tooth gear

c. 15 tooth gear/bevel gear

3. Slide 2 spacer washers onto the intermediate

shaft next to the bevel gear and follow with an

intermediate shaft bushing, fl anged side fi rst.

4. Drop the intermediate shaft into the gearcase,

making sure that all gears engage properly.

5. Fill the gear case with 6 oz. (177cc) of No. 2 lithium-

based grease, then install the cover with the six

fl anged head self-tapping capscrews.

6. Secure the input pulley nut.

A. Bushings C. Spacers

B. Gears

Installation

4-11WPM Drive Systems Manual

THREE SPEED TRANSMISSION

Special Assembly Notes for Toro Vacu

Power/Lawn-Boy Medallion

1. Slip the gear selection cable into the shift fork lever

through the bottom as shown in Figure 130.

Fig 130 3428-0123

2. Bring the transmission assembly into position

underneath the deck, making sure that the end

caps are on the outside of the housing. Before

securing, install the shift fork control arm onto the

shift fork and secure with the cotter pin. Place the

transmission and pivot arm assembly into the deck.

3. Loosely install the two front end cap fasteners.

5. Slip the traction belt into position on the transmission

pulley. Make sure that it does not bind on any of the

bosses.

6. Slip the end of the traction cable into the belt guide

bracket from the outside. Install the belt guide

bracket onto the top of the transmission, making

sure that the traction belt is inside the guide.

Note: Belt guide fastener torque: 130 in-lbs. (15 Nm)

7. Slip the black plastic transmission cover into place

making sure that the belt falls in the appropriate

grooves. Install the upper BBC cover with the two

fl anged head self-tapping capscrews. Make sure

that the top edge is trapped underneath the lip of the

housing.

Fig 131 3428-0122

4. Slip the two rear end cap fasteners through the

safety shield guide wires then install. Tighten all four

end cap fasteners (Fig. 131).

Note: End cap fastener torque: 225 in-lbs. (26 Nm)

A. End cap

A

A

4-12 WPM Drive Systems Manual

THREE SPEED TRANSMISSION

TROUBLESHOOTING TIPS - 3 SPEED

TRANSMISSION

Hard Shifting

A raised boss molded into each gear causes the leading

edge of the key to depress before it can enter the next

gear (Fig. 132).

Fig 132 3428-0067

The ring on the shift collar end of the key holds the drive

end of the key up. If dried grease or dirt keeps the keys

from rocking up and down, the force required to shift

gears will increase. Check the cable for free movement

where it enters the transmission. These are quick checks

and should be made before opening the transmission.

Fig 133 3428-0065

Look at the key and the notch in the gear that it engages.

Excessive wear to the tip of the key or the notch in the

gear may be the problem (Fig. 133).

If the forces push straight on the key, it will drive the

axle. However, if due to wear the force tries to depress

the key, it can lower enough to disengage from the notch

in the gear (Fig. 134).

A

A

B

B

C

D

Fig 134 gear and key

A. Shift collar B. Shift keys

A. Gear C. Good gear and key

B. Key D. Worn gear and key

A

B

The actual gears are in constant mesh. Unless gear

teeth are broken off, they cannot slip. If the wheels lurch

forward, then pause and lurch again, along with a loud

bang each time, the keys might be slipping.

Slipping Gears

5-1WPM Drive Systems Manual

2

3

4

6

7

8

WHEEL PINION CLUTCH

Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .

Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .

Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Brake Clutch Systems (BBC), Blade Override

System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .

Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

1

5

5-2 WPM Drive Systems Manual

WHEEL PINION CLUTCH

GEARCASE AND WHEEL ASSEMBLY, ROCKING KEY STYLE

Fig 135 gearcase wheel assy

Ref. No. Qty Description

1

2

3

4

5

6

7

8

8:2

8:3

8:4

9

10

11

12

1

1

1

1

2

2

2

2

1

1

1

2

4

4

2

V-Belt

Lever-Shift

Pin-Cotter

Clamp-Cable

Cap-End

O-Ring

Spring Arm ASM

Pivot Arm ASM

Bushing

Bushing

Fitting-Zerk

Washer-Arm, Pivot

Washer-Thrust, Keyed

Ring-Klip

Ring-Friction

*Not illustrated

Ref. No. Qty Description

13

14

*15

16

17

18

19

20

20:1

22

23

24

25

26

27

2

1

1

2

2

2

2

2

2

1

2

2

2

2

1

Washer-Clutch

Key-Rocking, LH

Key-Rocking, RH

Gear-Pinion

Spring-Compression

Cover-Wheel

Spacer-Cover, Wheel

Wheel ASM

Bushing

Screw-HH

Knob-Arm

Screw-HH

Nut

Bolt-Shoulder

Output Shaft

10

11

27

5-3WPM Drive Systems Manual

The wheel pinion clutch has a three-fold purpose. One,

when the transmission is engaged, it causes the pinions

to move with the output shaft and drives the wheels.

Two, it provides differential action to allow easy turning

and excellent maneuverability. Three it disengages the

wheel pinions from the output shaft when the operator

is not squeezing the handle. This allows the wheels

to turn backwards without turning the gears inside the

transmission and provides low pull back forces similar to

those on a hand-push version (Fig. 136).

WHEEL PINION CLUTCH

Fig 136 3428-0028

27. Output Shaft – turns when the operator squeezes

the handle to provide power to the wheels.

8. Pivot Arm Assembly – provides support for the

output shaft with a bushing and a needle bearing. It

can be rotated in the end cap to change height-of-

cut.

9. Washer Pivot Arm – fi ts in corresponding recesses

on the pivot arm to protect pivot arm from premature

wear.

Wheel Pinion Clutch

Component Defi nitions

10. Keyed Thrust Washer – internal tab fi ts in the

keyway on the output shaft. This washer rotates

with the output shaft and protects outboard clutch

components from wear.

11. Clip Ring – fi ts in a groove on the output shaft to

retain the pivot arm and spring arm. The tab at the

center of the clip is extended and fi ts in the keyway

of the output shaft to prevent rotation. If an E-clip

is substituted, premature failure of the wheel pinion

clutch system will result.

12. Friction Ring – fi ts in a circular groove in the pivot

arm and works with the clutch washer to actuate the

key. It does not rotate.

13. Clutch Washer – is affi xed to the output shaft by

means of the key so it turns with the output shaft.

It is also allowed to rotate slightly with respect to

the output shaft. This slight back and forth rotation

actuates the wheel pinion key. Friction between the

clutch washer and friction ring causes the clutch

washer to lag the output shaft slightly once it is

engaged. That slight rotation is all that is necessary

to raise the wheel pinion key and engage the pinion.

14. LH Rocking Key – causes the wheel pinion to turn

with the output shaft when up. Allows the wheel

pinion to “free-wheel” when down. Clutch washer

brings key up. Wheel pinion turning forward “wipes”

key down. There is a left-hand and right-hand key.

15. RH Rocking Key – causes the wheel pinion to turn

with the output shaft when up. Allows the wheel

pinion to “free-wheel” when down. Clutch washer

brings key up. Wheel pinion turning forward “wipes”

key down. There is a left-hand and right-hand key.

16. Pinion Gear – positively engages the wheel gear

at all times. Engagement with the output shaft is

controlled by the wheel pinion key. The wheel pinion

is a powdered metal part and is symmetrical so that

it can be put on either way and still function properly.

5-4 WPM Drive Systems Manual

WHEEL PINION CLUTCH

Test for Function

17. Compression Spring – provides the light, constant,

inward force necessary for proper clutch washer and

friction ring engagement.

It is extremely important that the wheel pinion clutch be

maintained according to the instructions in the operator’s

manual, which is greasing every 25 hours with one or

two pumps of grease. Greasing regularly will prevent

contaminants from damaging or wearing the system.

Note: Over-greasing will also cause the system to

malfunction.

Function

The rocking keys provide a differential action by

engaging and disengaging each drive wheel individually.

When the drive is engaged and the axle begins to turn,

friction between the friction ring and clutch washer cause

them to rotate the tail on the key. This results in the main

part of the key engaging the teeth on the inside of the

pinion gear.

Should one or both wheels turn faster than the axle,

the pinion rotates and pushes the key back down into

the groove. The pinion can now roll freely over the key.

When turning the inside wheel will drive the mower. The

outside wheel must turn faster and overrides the key.

When the mower is straightened out the pinion is no

longer turning faster than the axle so the key re-engages

the pinion.

If you are unsure that the keys are disengaging properly,

stop the mower, shut the engine off and push the mower

forward a few inches. If the keys disengage the system

is working correctly. Start the engine and engage the

drive, if both engage they are ok. If one or the other

do not engage or disengage properly try greasing the

pivot arm. Use #2 lithium grease and only one or two

pumps from a hand grease gun. If grease does not help

disassembly is necessary.

To operate this system, practice the following. Walk

along at a normal pace. When you stop walking, keep

your elbows at your sides. The mower will continue

forward for a few inches due to its momentum. As

the mower rolls away, the drive will disengage as

the personal pace/ easy stride handle extends and

disengages the transmission. From the point where the

transmission is no longer turning the axle, the mower

must roll about 1-1/2” forward. This causes the pinions to

rock the drive keys to the disengage position. At this time

the mower can be pulled backward with minimal effort.

When the drive is engaged and the axle begins to turn

the keys should re-engage.

Quick Test

The rear height-of-cut system and the wheel pinion

clutch can be serviced with the transmission in or out of

the unit. For information on removing the transmission

from the unit, see Transmission – Removal, page 2-3,

4-5 or 4-6 depending on mower type.

1. Remove the shoulder bolt securing the wheel and

tire assembly to the pivot arm and remove the wheel

and tire assembly complete with shoulder bolt,

spacers, wheel cover, and nylon locknut.

Rear Height-of-Cut and Wheel Pinion Clutch

- Disassembly

5-5WPM Drive Systems Manual

WHEEL PINION CLUTCH

2. Remove the special retaining clip at the end of the

output shaft and pull off the following six wheel

pinion clutch components:

• Spring

• Internally tabbed thrust washer

• Wheel pinion

• Wheel pinion key

• Clutch washer

• Friction ring

3. Remove the inner special retaining clip from the

output shaft and remove the following components:

• Internally tabbed thrust washer

• Externally tabbed thrust washer

• Pivot arm and spring arm assembly

• End cap (if desired)

4. Check all components at this time for damage and

wear. Pay particular attention to the grooves at

the end of the output shaft, the bearing surfaces

on the output shaft, and the wheel pinion clutch

components. Replace parts as necessary.

5. Check the innermost groove on the output shaft

which is located 2-1/4” (5.7cm) in from the end of the

shaft; make sure that the O-ring seal is present and

intact. This seal is important to keep grease in and

contaminants out. Replace it (Item 6) if necessary

(Fig. 137). Some models do not have this O-ring.

Fig 137 gearcase wheel assy 2

1. Pack the caged needle bearing with grease, then

press into the outside of the pivot arm until it is fl ush

with the groove that houses the externally tabbed

thrust washer.

2. Press the oil impregnated bushing into the boss on

the pivot arm until it is fl ush with the face of the boss.

3. If spring arm disassembly was required, install the

knob making sure that the detent is pressed out

about .060” (1.5mm). Install the spring arm knob so

that the concave side of the knob and the convex

side of the rivet align.

6. Press the needle bearing and the oil impregnated

bushing from the pivot arm using an arbor press.

7. Removal of the grease fi tting is not recommended

because it is pressed in. However, if damaged or

lost, we suggest tapping and installing a threaded

grease fi tting.

8. If the spring arm knob requires replacement, push in

on the detent tab, then pull the knob straight off.

Note: The detent rivet is not replaceable.

Rear Height-of-Cut and Wheel Pinion Clutch

- Assembly

5-6 WPM Drive Systems Manual

WHEEL PINION CLUTCH

4. Assemble the spring arm and pivot arm as shown in

Figure 138.

Fig 138 3428-0028

5. To increase service life, make sure all parts are

clean prior to assembly and coated with new grease.

6. If removed, install a new O-ring in the innermost

groove 2-1/4” (5.7cm) in from the end on each

output shaft, making sure that it is fully seated in the

groove. Refer to Figure 000 (3428-0028) above. Not

all models use an O-ring.

7. Slip the end cap onto the output shaft, but do not

fasten at this time.

8. Slide the pivot arm and spring arm assembly onto

the output shaft, boss fi rst.

Note: The convex side of the spring arm rivet and

the concave side of the knob on the spring

arm should both be facing the housing. Fig 139 3428-0028

9. Slide the externally tabbed thrust washer and the

internally tabbed thrust washer onto the output shaft.

Make sure that the tab on the internally tabbed thrust

washer enters the keyway. Secure with the special

retaining clip. Make sure that the center tab fi ts

properly into the keyway. This will prevent rotation of

the clip on the output shaft.

10. Place the friction ring into the groove on the pivot

arm, fl at side out.

11. Slide the clutch washer onto the shaft so that the

recesses for the key are facing out.

12. Place the wheel pinion key in the groove on the

output shaft with the leg toward the clutch washer.

Note: There is a left and a right wheel pinion key.

You are using the correct key if, when placed

in the groove, the top of the key is fl at and the

straight portion of the leg is perpendicular to

the shaft.

Before assembling further, rotate the clutch washer

back and forth slightly, making sure that the key

actuates properly (Fig. 139).

A. Pivot arm C. Key

B. Friction washer D. Spring arm

B

B

D

D

C

C

A

A

5-7WPM Drive Systems Manual

WHEEL PINION CLUTCH

13. Place the wheel pinion onto the output shaft. It is

symmetrical and can be put on either way.

14. Install the internally tabbed thrust washer onto the

output shaft making sure that the tab enters the

keyway.

15. Slip the spring onto the end of the output shaft and

secure with the special retaining clip. Again, make

sure that the center tab fi ts properly into the keyway

to prevent rotation of the clip (Fig. 140).

Fig 140 3428-0040

16. Slip the wheel, the original number of spacers, and

the wheel cover onto the shoulder bolt and secure to

the pivot arm using the nylon locknut.

17. Grease with No. 2 lithium-based grease. Use a

hand grease gun to avoid excess pressure that may

prevent the friction parts from working. As a rule, use

two pumps to ensure that you do not over-grease.

Be sure to grease after every 25 hours of use for

maximum service life.

5-8 WPM Drive Systems Manual

WHEEL PINION CLUTCH

GEARCASE AND WHEEL ASSEMBLY, SPRING RATCHET STYLE

3354-613 Rev A

Fig 141 3354-613(5)

Ref. No. Qty Description

1

2

2:1

3

4

5

7

7:1

7:2

8

9

10

11

12

13

2

2

2

4

2

6

2

1

1

2

2

2

2

2

2

Bolt-Shoulder

Wheel Gear ASM

Bushing

Klipring-Locking

Gear-Pinion, 13T

Washer-Thrust

Cover-Wheel

Cover

Washer-Stepped

Arm-Pivot, Front

Arm-Spring

Knob-Lever, HOC

Ring-Retaining

Retainer-Bearing, HOC

Bearing-Ball

Ref. No. Qty Description

14

15

16

17

18

19

20

21

22

23

24

25

26

27

2

2

1

1

2

1

2

1

1

2

1

1

1

1

Spring-Compression

Key

Transmission ASM

Gasket-Gearbox

Screw-HWH

Bracket-Pivot, Fwd

Screw-HWH

Spacer

V-Belt

Pulley-Half, Front

Washer-Flat

Nut-Lock

Cover-Belt, Front

Washer

5-9WPM Drive Systems Manual

WHEEL PINION CLUTCH

The Spring Ratchet type wheel clutch system has been

used on a wide variety of models. It consists of a spring

supporting a drive key which engages the pinion. When

the mower drive is engaged the axle turns the key which

is engaged with an internal tooth on the pinion. The

pinion turns the wheel gear. When the mower is pushed

or turned, the pinion must rotate faster than the axle.

As the pinion rotates it depresses the key, allowing the

differential action.

The axle drives both keys and pinions equally but they

will ratchet individually. When the mower is pulled

backwards, this type of clutch does not disengage. It will

require the axle and transmission to turn backwards. It is

critical to easy backing to make sure the self propel belt

properly disengages.

Spring Ratchet Style

The things that can impede the function are dirt, rust or

wear. The owner’s manual requires that ordinary engine

oil be added to each side of the pinion periodically.

This is to keep the anti seize from drying up. If that is

not done, it will be necessary to remove the pinion,

key and spring to clean and re-lubricate with anti-seize

compound.

On the left side there will be two keyed thrust washers

and one regular thrust washer. Clean the end of the axle,

keyway, and the parts removed. Inspect the key; if worn,

replace. Make sure the thrust washers have the key tab

on them. If the tab is broken, the pinion will tend to push

the retaining rings out of their grooves.

Lubricate the key, spring, and axle with anti-seize

compound and reassemble. Note the pinion has the

letter “R” stamped on one side and “L” on the other. If

you are on the right side of the mower, the letter “R”

should face you when you install the pinion. The letter

“L” should be visible on the left side of the mower.

Servicing the System

WHEEL PINION SERVICE

The steps to service the wheel pinions are the same for

both front and rear wheel drive models.

1. Raise the mower until the wheel is off the ground.

Support with a block.

2. Remove the wheel bolt, wheel and wheel cover (Fig.

142).

Fig 142 MVC-739

3. Remove the retaining ring and thrust washer (Fig.

143).

Fig 143 MVC-746

5-10 WPM Drive Systems Manual

WHEEL PINION CLUTCH

Fig 144 MVC-850

4. Slide the wheel pinion off the axle.

Note: There is a spring-loaded key under the pinion

(Fig. 144).

5. Behind the pinion should be another thrust washer

and retaining ring (Fig. 000). (MVC-850)

A. Retaining ring and B. Key

thrust washer

A

B

2. Lubricate with anti-seize and assemble in the

original order.

Reassemble in reverse order:

1. Install one thrust washer, then the fi rst retaining ring

with the sharp edge facing the chassis (Fig. 145).

Fig 145 MVC-472

6-1WPM Drive Systems Manual

2

3

4

5

7

8

BBC / BOS / BCS

Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .

Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .

Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Brake Clutch Systems (BBC), Blade Override

System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .

Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

1

6

6-2 WPM Drive Systems Manual

BBC / BOS / BCS

Description

There are two basic blade clutching system designs.

The fi rst is commonly referred to as the BBC or Blade

Brake Clutch. It has two versions which have been used

on many Toro models as well as Lawn-Boy Medallion

mowers. The second design was introduced in 2005 and

is used on Toro (Blade Override System) and Lawn-Boy

(Blade Clutch System) (Fig. 146 and Fig. 147).

Fig 146 3428-0001

Fig 147 3428-0004

The clutch operates by using a fl ywheel which turns with

the engine crankshaft and a brake drum and blade that

are free to turn separately from the fl ywheel. The two

are connected by tensioning a drive belt between the

fl ywheel and brake drum. The combination idler arm and

brake controls the belt. When the control is engaged,

the idler with the brake pad backs away from the brake

drum and tightens the belt. When the control is released,

a spring causes the idler to pivot towards the brake drum

releasing the belt and engaging the brake. This stops the

blade but allows the fl ywheel and crankshaft to continue

to turn.

The blade clutch system offers the customer

convenience to stop the blade while allowing the engine

to continue to run.

Before troubleshooting the BBC deck mechanism, be

sure that it is adjusted properly. Refer to the BBC cable

adjustment section for proper adjustments.

BBC Clutch Operation

BBC Control Box Operation

The BBC control mechanism’s purpose is to actuate

the deck mechanism. It does this by tensioning and

loosening the BBC cable. The control mechanism meets

the federal government’s “2-step” blade engagement

procedure. The traction drive can also be integrated with

this control system.

BLADE BRAKE CLUTCH SYSTEM

(BBC)

6-3WPM Drive Systems Manual

BBC / BOS / BCS

The normal or “at rest” position of the control bar is

indicated by the number 1 in the Figure 148. In order

to engage the blade, the operator must fi rst “cock” the

control bar down to position 2, then raise the control bar

to position 3.

Fig 148 fi g 27

Notice that position 3 is approximately 5” (12cm) below

the handle. This distance between position 3 and the

handle is reserved for engagement of the transmission

on those models equipped with self-propel. On units

without self-propel, the control bar can be lifted to the

handle without affecting operation of the BBC system.

After engagement of the blade, release of the control bar

disengages the blade and, on self-propel models, the

transmission. By gradually releasing the control bar, the

operator can regulate the ground speed of self-propel

models without disengaging the blade.

a. Left Control Housing: serves as the cover for the

BBC control mechanism. It also houses the end of

traction and BBC cables.

b. Control Bar: pivots on upper shoulder bolt. Transfers

operator inputs to control box components.

c. Traction Cable: engages the transmission by trans-

ferring inputs from the control box. The transmission

is engaged when the cable is tightened; disengaged

when the cable is loosened.

d. BBC Cable: transfers inputs from the control box to

the BBC deck mechanism.

Fig 149 fi g. 28

The control box components and their functions (Fig.

149) are described below.

Handle Controls

6-4 WPM Drive Systems Manual

BBC / BOS / BCS

e. Traction Lever: provides input to the traction cable

since the end of the traction cable is retained in it.

It also pivots on the upper shoulder bolt when the

control bar is moved.

f. Rocker Arm: pivots on the upper carriage bolt. It is

affi xed solidly to the control arm by means of the roll

pin. It houses both the control hook and cable lever.

It also provides slot and stop for the buckling spring.

g. BBC Cable Lever: controls tensioning and loosening

of the BBC cable since the end of the BBC cable

is retained by it. Pivots freely on the upper carriage

bolt. Movement is controlled by the control hook.

h. Control Hook and Spring: pivots on the roll pin and

is spring-loaded in the counterclockwise direction by

the torsion spring. The control hook “grabs” the cable

lever when the control bar is cocked and releases

the cable lever when the control bar is dropped.

i. Buckling Spring: sole purpose is to hold the control

bar in the middle position when at rest. The spring is

fl exed or “buckled” when the control bar is operated.

It rides in a slot on the rocker arm to prevent it from

applying force to the control bar when the control bar

is at its lowest or uppermost positions.

j. Right Control Housing: serves as the other half of

the control box cover. Houses the leaf spring.

k. Leaf Spring: releases the control hook as the

control bar drops to “at rest” position. Because of its

orientation, it allows the control hook to slip by as the

control bar is raised.

Fig 150 3428-0278

These components interact to provide control to the BBC

deck mechanism. Notice in Figure 150 the position of

the traction cable lever and the BBC cable lever. This is

the “at rest” position; both the BBC and the transmission

are disengaged. When the control bar is in this position,

it is the buckling spring that supports it. Notice that the

buckling spring is not fl exed and is at the left end of the

slot in the rocker arm.

A. Control hook C. Traction cable lever

B. BBC cable lever D. Buckling spring

A

A

B

B

C

C

D

D

6-5WPM Drive Systems Manual

BBC / BOS / BCS

When the control bar is cocked to its lowest position as

in Figure 151. The buckling spring is fl exed and moved

to the right end of the rocker arm slot. Another event

takes place inside the rocker arm: The spring-loaded

control hook slides over the cable lever and grasps it so

that when the lever is raised, the BBC cable will come

with it.

Fig 151 3428-0286

Raising the control bar straightens the buckling spring.

Also important is the function of the leaf spring. As the

control bar is raised, the left tip of the control hook slips

by the leaf spring without causing release of the cable

lever.

Continuing to raise the control bar causes the traction

lever to move and the traction cable engages the

transmission.

Fig 152 3428-0289

When the control bar is raised to a point 5” (12.7cm)

below the handle, the BBC cable has been tightened

enough to engage the blade (Fig. 152).

A. Rocker arm C. Control hook

B. BBC cable lever

A. Leaf spring B. Control hook

A

A

B

B

C

C

A

A

B

B

6-6 WPM Drive Systems Manual

BBC / BOS / BCS

Control Box Disassembly

When the control bar is released, the tip of the control

hook catches on the leaf spring causing it to rotate. This

releases the BBC cable lever, thereby causing the BBC

to declutch and apply the blade brake (Fig. 153).

Fig 153 3428-0290

NOTE: When servicing the BBC control box, be careful

not to disassemble the unit any further than necessary

as it will then become diffi cult to trouble shoot. Instead,

remove the right housing half, then operate the control

box while watching for proper function of internal

components. See Step 5 below for more information.

1. Place a piece of duct tape over the heads of the

carriage bolts passing through the handle and the

BBC control box. This will prevent them from falling

out later during troubleshooting.

2. Bend the locking tab securing the throttle control to

the control panel, then tap the throttle control out

using a rubber mallet.

3. Remove the 3 fl anged head screws retaining the 2

control box halves.

4. Carefully remove the 2 fl ange nuts retaining the

control box to the handle and remove the right

control box half. Be careful not to dislodge any

internal components.

5. Reinstall the fl ange nuts to help hold things together.

Determine if any of the components inside the

control box are malfunctioning.

CAUTION! Wear gloves and eye protection when

operating an open control box as the buckling

spring could fl y out.

Note: The cable ends and end of the spring are not

retained once the right cover is removed. Be

sure to use one of the two methods below to

retain them.

The fi rst and quickest method is to manually hold the

ends of the cable and the end of the buckling spring

while operating the control bar. However, with the

right case half removed, the leaf spring is no longer

in place and you will not be able to observe release

of the BBC cable lever.

A. Contact point C. Flange nut

B. Leaf spring

A

A

B

B

C

C

6-7WPM Drive Systems Manual

A better method is to make a special cut-away

version of the right control box housing half as

shown in Figure 154. When this cut-away version

is installed, all components will function normally.

Notice the cut-away cover and how it houses the leaf

spring. This will aid in diagnosis.

BBC / BOS / BCS

Fig 154 3428-0289b

6. If further disassembly is required, remove the

buckling spring and washer from the rocker arm

assembly.

7. Remove the BBC cable from the BBC cable lever

and the left-hand control box half.

8. Remove the rocker arm as an assembly, complete

with cable lever and control hook.

9. Remove the cable lever from the rocker arm

assembly.

10. Press the roll pin from the rocker arm and remove

the control hook and torsion spring.

11. Remove the traction cable from the traction lever

and the left-hand control housing.

Fig 155 fi g 34

1. Slip the lower carriage bolt through the handle, then

slide the left control housing onto it.

2. Slip the end of the traction cable into the traction

lever. Place the control housing, traction lever, and

the control bar into position as shown in Figure 155.

Once in position, slide the carriage bolt through all

three components.

12. Pull the tape from the outside of the handle. Remove

the upper carriage bolt along with the cable lever

and spacer.

13. Remove the lower carriage bolt and remove the left

control housing.

14. Inspect all parts for wear and/or damage and replace

as required.

A. Leaf spring

Control Box Assembly

A. Leaf spring C. Traction cable

B. Traction lever

A

A

6-8 WPM Drive Systems Manual

BBC / BOS / BCS

3. Place a piece of duct tape over the heads of the

carriage bolts that slide through the handle and the

left control box housing. This will aid in assembly.

4. Slide the sleeve onto the upper carriage bolt making

sure that it passes through the control bar, traction

lever, and left control housing.

5. Position the control hook and torsion spring in the

rocker arm as shown in Figure 156. Secure with the

roll pin making sure that the roll pin is fl ush with the

side indicated in the fi gure. Loosely install the BBC

cable lever as indicated. When correctly installed,

the control hook and the cable lever will be engaged.

Fig 156 fi g 35

Fig 157 fi g 3 6

6. Slide the rocker arm assembly over the upper

carriage bolt and sleeve making sure that the sleeve

passes through the cable lever. Also make sure that

the roll pin passes through the hole in the control

bar.

7. Release the BBC cable lever from the control hood

and install the BBC cable into the cable lever (Fig.

157).

Note: The BBC cable lever is behind the spring.

A. Control hook C. Cable lever

B. Roll pin fl ush with

this side

A. BBC cable lever B. BBC cable

6-9WPM Drive Systems Manual

8. Slip the white nylon washer onto the J end of the

buckling spring. The slotted side of the washer

should face away from the end of the spring. Slip

the spring into position in the rocker arm and the left

control housing as shown in Figure 158.

Fig 158 3428-0281

9. Assemble the right control housing by installing the

leaf spring and pin to retain the leaf spring (Fig.

159).

Fig 159 MVC-488

10. Before installing the right control housing, check

to make sure that both cable sheath ends are fully

seated in their slots in the left housing. Also make

sure that the sleeve passes through all components

including the left control housing. Finally, make sure

that the roll pin passes through the rocker arm and

control bar.

Install the right control housing and secure with the 2

nylon locknuts or 1 locknut and 1 fl ange nut.

11. Install the 3 fl anged head screws that retain the two

control box halves.

12. Check for proper operation of the entire BBC

system. Correct as required.

13. Bend the throttle control locking tab forward to

provide positive lock with the throttle control and

install the throttle control.

14. Adjust the BBC cable and traction cables as needed.

See page 7-16.

BBC / BOS / BCS

A. Nylon washer B. Buckling spring

A. Leaf spring

A

A

B

B

A

6-10 WPM Drive Systems Manual

BBC / BOS / BCS

TORO BBC SERVICE GUIDE

Fig 160 bbc scan

Disassembly Sequence

6-11WPM Drive Systems Manual

BBC / BOS / BCS

BLADE BRAKE CLUTCH ASSEMBLY (Toro Vacu Power/Lawn-Boy Medallion BBC)

Fig 161 bladebrakeclutchassy

Ref. No. Qty Description

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

1

1

1

2

2

1

1

1

1

1

1

1

1

5

1

1

2

1

1

1

1

Brake Shoe

Plate Hub

V Belt

Pulley Hub

Lock Nut

Spring Rod

Shoulder Bolt

Compression Spring

Flange Bushing

Lever Wa

Bushing

Ring Seal

HWH Screw

TAP Screw

Flange Nut

Cable Bracket Support

Flat Washer

Bellcrank Bushing

Crank

Spring Pin

Control Link

Ref. No. Qty Description

22

23

24

25

26

27

28

31

32

33

34

35

36

37

38

39

42

43

44

45

46

1

1

1

1

1

1

2

1

1

1

1

1

1

2

1

1

2

1

2

1

1

HH Screw

Compression Spring

Spring Retainer

Woodruff Key

Driver Pulley

BBC Flywheel

Blade Bolt

Brake Drum

Hub ASM

BBC Shield

Blade Spacer

21” Blade

Anti Scalp Cup

Lock Nut

Lock Nut

BBC Screen

Vibration Damper

Idler Pulley

HH Screw

Thd Forming Screw

Flat Washer

6-12 WPM Drive Systems Manual

1. Remove the fl anged head self-tapping capscrews

securing the upper BBC cover to the housing and

remove the upper BBC cover (Fig. 163).

TORO VACU POWER/LAWN-BOY

MEDALLION BBC

Bellcrank System Disassembly (Toro Vacu

Power/Lawn-Boy Medallion)

Fig 162 DSC-068a Fig 164 3428-0082

2. Pull the black plastic transmission cover up to

remove it from the housing (Fig. 164).

Fig 163 3428-0079

Fig 165 3428-0090

3. Remove the shoulder bolt and fl anged nut securing

the bellcrank to the control cable bracket. Once

loose, remove the bellcrank assembly complete with

control link from the unit (Fig. 165).

BBC / BOS / BCS

A. Control link C. Bellcrank

B. Shoulder bolt

A

A

B

B

C

C

6-13WPM Drive Systems Manual

4. Remove the bushing from inside the bellcrank.

5. Using the control link to hold the control pin, remove

the fl anged head screw from the control pin (Fig.

166).

CAUTION! Always wear safety goggles and

gloves when disassembling items under spring

tension or compression.

6. Remove the control link from the control pin.

7. Inspect all parts for wear and damage and replace

as necessary.

BBC / BOS / BCS

Bellcrank System Assembly (Toro Vacu

Power/Lawn-Boy Medallion)

Fig 166 3428-0093

1. Insert the control pin into the recessed area on the

bellcrank.

Fig 167 3428-0088

2. Place the spring onto the control pin. Place the

spring retainer onto the spring and insert the screw

into the control pin. Using the control link to prevent

rotation of the control pin, tighten the fl anged head

screw until the retainer bottoms out on the control

pin (Fig. 166).

3. Note the orientation of the control link in Figure

167. Make sure that it is installed correctly into the

bellcrank.

A. Brake plate lever D. Bellcrank

B. Control link E. Cable bracket support

C. Shoulder bolt

4. Slide a fl at washer and a bushing onto the shoulder

bolt and slide into the front side of the bellcrank

as shown in Figure 000. (3428-0088) Complete

reassembly of the bell crank system by sliding

another fl at washer onto the carriage bolt.

Note: Lubrication of the bushing is not

recommended.

A

A

B

B

C

C

D

D

E

E

6-14 WPM Drive Systems Manual

BBC / BOS / BCS

5. Hook the end of the control link into the brake plate

lever, then slip the BBC control cable onto the

bellcrank. Finally, slip the shoulder bolt through the

hole in the cable bracket support and secure with the

fl anged nut.

Note: The serrations in the fl anged nut must fully

seat on the control cable bracket.

6. Check the adjustment of the BBC cable as described

under “BBC Cable Removal (Recycler/Rear

Bagger)” on page 6-19.

7. Slide the black plastic transmission cover into place

making sure that the belt slides into the grooves

provided. Some contact between the belt and the

cover may be evident.

Note: It may be necessary to push the transmission

back slightly to get the transmission cover to

slide in completely.

8. Place the upper BBC cover into position on the

housing and secure with the two self-tapping fl anged

head capscrews.

9. Check for proper operation of all controls, especially

the BBC, and adjust as necessary.

Note: The spring length on the bellcrank assembly

is the primary indicator of proper BBC

adjustment. It should measure 1” (25mm) with

the blade engaged when properly adjusted.

If spring measures more than 1-1/4” (32mm),

correct by adjusting the BBC control cable.

Fig 168 MVC-000

BBC Cover and Screen:

The BBC cover and screen are two important com-

ponents that keep dirt and debris out of the BBC

mechanism. The screen (Fig. 168) is installed, sharp

edge down, to allow air to be drawn in through the

screen panel on top of the deck and down underneath

the deck. This venting improves the airfl ow underneath

the deck thereby improving quality of cut and bagging

performance. Be sure to clean the screen on occasion,

especially if quality of cut or bagging performance has

degraded.

A. BBC fl ywheel C. Bearing block

B. Brake drum D. Screen

6-15WPM Drive Systems Manual

BBC / BOS / BCS

Under Deck Components Disassembly

(Toro Vacu Power/Lawn-Boy Medallion)

1. Stop the engine and disconnect the spark plug lead

to prevent accidental starting. Drain fuel.

2. Remove the 2 fl anged nylon locknuts securing the

blade to the bearing block and remove the anti-scalp

cup, the blade, the blade spacer, and the lower BBC

screen (Fig. 169).

Fig 169 3428-0099

3. Remove the 4 fl anged head self-tapping screws

securing the lower BBC cover to the housing, and

remove the lower BBC cover.

4. Before disassembling further, check to make sure

that the BBC components are functioning normally.

Make sure that the brake and brake drum fully

disengage when the control bar is cocked, then

raised. Make sure that the BBC fl ywheel and the

brake drum rotate together when the control bar

is raised. Make sure that the belt loosens properly

when the control bar is lowered. Repair or replace

parts as required.

Fig 171 MVC-726

6. Pivot the brake plate counterclockwise slightly and

remove the bearing block and brake drum from the

crankshaft (Fig. 171).

Fig 170 MVC-724

5. If further disassembly is required, begin by removing

the crankshaft nut. An impact wrench works best.

However, if you must remove it manually, use a large

screwdriver or bar to wedge the BBC fl ywheel while

removing the nut (Fig. 170).

Note: Be careful not to damage the bearing seal

when removing this nut, or premature bearing

failure could result.

6-16 WPM Drive Systems Manual

BBC / BOS / BCS

7. Again, pivot the brake plate counterclockwise and

remove the BBC fl ywheel.

8. BBC Belt or Idler Pulley Replacement: If the BBC

belt or idler pulley requires replacement, it can be

done without removal of the brake plate. Remove

the idler pulley capscrew and nylon locknut then

pull the belt and pulley from the brake plate as an

assembly.

Note: The hubs of the pulley are replaceable,

however, the bearing inside the idler pulley is

not replaceable separately.

9. If the brake pad has reached its service life or if the

brake plate has been damaged, remove the other

capscrew securing the brake plate to the brake plate

hub and lever and remove the brake plate assembly.

The brake pad is not replaceable separately.

10. If necessary, remove the fl anged head capscrew

securing the brake lever and hub to the housing.

CAUTION! The brake plate lever is under

moderate spring-loading. Heavy gloves and eye

protection are recommended when removing the

brake plate lever.

Note: Do not use an air wrench on the brake lever

self-tapping screw as thread damage to the

housing may result.

12. Complete disassembly of the brake plate by

removing the brake plate screws and the bearing

block.

13. Remove the two bearings from the bearing block by

pressing the bearings out on an arbor press. Press

only on the outer race to prevent bearing damage

(use an appropriately sized arbor or a 1-1/8” (28mm)

socket.

14. Inspect all parts for damage and/or wear and replace

as necessary.

Fig 172 3428-0106

11. Remove the brake plate and hub assembly from the

housing and disassemble the seal/oil impregnated

bushing, the hub, self-tapping capscrew, and washer

from the brake lever. Be careful not to lose the

plastic bushing which fi ts on the end of the brake

spring rod (Fig. 172).

A. Plastic bushing B. Brake rod

AB

6-17WPM Drive Systems Manual

BBC / BOS / BCS

Under Deck Components Assembly (Toro

Vacu Power/Lawn-Boy Medallion)

1. Check to make sure that the brake plate seal is in

good condition, then stretch onto the brake plate

bushing (Fig. 173).

Fig 173 3428-0108

2. Hook the control link into the slot on the brake lever.

Place the spring and bushing onto the brake rod,

then slip the bushing and brake rod through the

hole provided in the brake lever. Finally, install the

bushing hub and fl anged head self-tapping screw

with the washer through the brake lever.

Note: Brake plate capscrew torque: 225 in-lbs.

(25.5 Nm)

Note: If the self-tapping screw strips the threads in

the housing, do not helicoil; rather, place a

hex nut in the recess provided in the top side

of the deck.

4. Install an idler hub into each side of the idler pulley

bearing, then slip the belt onto the idler pulley. Slip

the entire assembly between the brake plate and

brake lever. Secure the carriage bolt and nylon

locknut as shown in Figure 174.

5. Tighten the idler pulley bolt. Make sure that the idler

pulley spins freely.

Note: Idler pulley bolt torque: 100 in-lbs. (11.33 Nm)

Fig 174 3428-0101

3. Loosely secure the brake plate, complete with brake

pad, to the brake lever and brake hub as shown in

Figure 174. Note that the bolt should go through

the brake plate fi rst. Secure with a nylon locknut

but do not tighten at this time. This will allow proper

alignment of the idler pulley later.

A. Seal B. Brake plate bushing A. Brake plate B. Bolt

B

A

A

AB

6-18 WPM Drive Systems Manual

BBC / BOS / BCS

6. Install the BBC fl ywheel onto the crankshaft, making

certain that the slots in the BBC fl ywheel align with

the bumps on the bottom of the self-propel pulley

(Fig. 175).

Fig 175 3428-0117

Note: If the crankshaft nut is tightened with these

bumps misaligned, the boss at the bottom of

the keyway on the self-propel pulley will break

and the self-propel pulley will be free to slide

up and down on the crankshaft (Fig. 176).

This can result in noisy operation, premature

belt wear, and belt jumping.

Fig 176 3428-0116

Fig 177 MVC-726

7. Press the bearings into the bearing block, using an

arbor press. Press only on the outer race, otherwise

bearing damage will result (use an appropriately

sized arbor or a 1-1/8” (28mm) socket to press the

bearing into the block).

8. Make sure that the foam rubber anti-vibration pads

are in place on the brake drum and assemble the

brake drum bearing block and BBC screws onto the

crankshaft as shown in Figure 177. Secure with the

crankshaft nut.

Note: Crankshaft nut torque: 45 – 70 ft-lbs. (61 –

95 Nm)

A. Bumps B. Slots

A. Boss

CAUTION! As with disassembly, the fl ywheel can

be wedged to tighten the nut. Make sure the bumps

in the self-propel pulley stay engaged with the

fl ywheel or the pulley will be damaged.

Note: Make sure that the blade bolts are properly

aligned before tightening the crankshaft nut.

9. Install the BBC cover with the four fl anged head self-

tapping screws.

10. Install the BBC screen, the blade spacer, the blade,

and the anti-scalp cup onto the BBC screw and

secure with the two fl anged nylon locknuts. Torque

to 300 in-lbs. (37 Nm).

Note: Blade locknut torque: 300 in-lbs. (37 Nm)

A

A

B

B

A

A

6-19WPM Drive Systems Manual

BBC Cable Removal (Toro Vacu Power/

Lawn-Boy Medallion)

BBC / BOS / BCS

11. Complete BBC service by checking BBC and self-

propel controls, making sure that all are functioning

normally. Adjust as necessary.

1. Remove the two fl anged head self-tapping screws

securing the screen panel to the housing and

remove the screen panel as shown in Figure 178.

Fig 178 3428-0079

Fig 179 fi g 3 6

3. Bend the throttle control locking tab back slightly and

tap the throttle control from the control panel with a

rubber mallet. Place a piece of duct tape over the

heads of the handle and the BBC control box. This

will prevent the control box components from falling

out of the handle during disassembly.

4. Remove the three fl anged head screws securing the

control box halves.

5. Remove the two nylon locknuts securing the control

box to the handle and carefully remove the right

control housing half.

6. Slip the end of the BBC cable from the cable lever

and remove the cable (Fig. 179).

A. Screws B. Screen Panel

2. On early models, the end of the BBC cable sheath

has two protruding ears that catch the underside of

the cable bracket. Remove the cable by squeezing

the ears together, then pulling the cable out

vertically. Later models use a clip that must be

pushed to the side to remove.

A. BBC cable lever B. BBC cable

A

A

B

B

6-20 WPM Drive Systems Manual

BBC / BOS / BCS

BBC Cable Installation (Toro Vacu Power/

Lawn-Boy Medallion)

1. Slide a new BBC cable into the BBC cable lever.

Then install the end of the cable sheath in the recess

provided in the left control housing half (Fig. 180).

Fig 180 fi g 3 6

2. Before installing the right control housing half, make

sure that the traction and BBC ends are completely

seated in their recesses. Also make sure that the

sleeve on the upper carriage bolt passes completely

through the BBC control box components to the

handle. Finally, make sure that the roll pin in the

rocker arm passes through the hole in the control

bar. Install the right control housing half. Secure with

two nylon locknuts.

Note: The fl anged locknut fi ts on the upper carriage

bolt.

6. Before installing the screen panel, adjust the BBC

cable as described under “BBC Cable Adjustment

(Toro Vacu Power/Lawn-Boy Medallion Models)”,

which follows. See page 7-15.

Fig 181 fi g 68

3. Install the three fl anged head screws securing the

control box halves.

4. Bend the throttle control locking tab forward so that

it will provide positive engagement with the throttle

control. Install the throttle control.

5. Hook the lower end of the BBC cable onto the bell-

crank. Slip the cable through the slot in the cable

bracket. Push the end of the cable sheath into the

cable support bracket as shown in Figure 181.

A. Plastic fi tting C. Spring

B. Cable fi tting

6-21WPM Drive Systems Manual

BBC / BOS / BCS

ENGINE AND BLADE ASSEMBLY (Toro Recycler / Rear Bagger)

Fig 182 engineandbladeassy

Ref. No. Qty Description

1

2

3

4

5

6

7

8

9

10

11

12

13

13:1

14

16

17

18

19

20

21

1

1

1

1

1

1

3

1

1

1

1

2

1

2

1

1

1

1

1

1

1

Gts Ohv 200 Engine

Gas Cap ASM

Toro Nameplate

Recoil Decal

Clamp Screw

Casing Clamp

HWH Screw

Belt Guide Bracket

Woodruff Key

Pulley

Flywheel

Blade Bolt

Brake Drum ASM

Vibration Dampener

Hub ASM

Shield

Blade Spacer

Blade Nut

Recycler Blade

Blade Stiffener

Anti-Scalp Cup

Ref. No. Qty Description

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

2

1

2

1

1

1

1

1

1

1

2

1

1

1

1

1

1

2

3

2

1

Lock Nut

HH Screw

Flat Washer

Control Link

Bellcrank

Bellcrank Sleeve

Lever

HH Screw

Torsion Spring

Washer

Bearing

Torsion Spring

Brake ASM

Idler Pulley

V Belt

Idler Hub Pulley

HH Screw

NI Lock Nut

HWH Screw

HH Screw

Rope Stop

6-22 WPM Drive Systems Manual

BBC / BOS / BCS

TORO RECYCLER/REAR BAGGER

BBC

Idler Arm System Disassembly (Recycler/

Rear Bagger)

Fig 183 1350-001 a

1. Drain the fuel and oil. Remove the spark plug wire.

Disassembly for the idler arm begins on top of the

mower housing.

Fig 185 3428-0177-2

3. Take a loop of wire or rope and unhook the spring

under the lever (Fig. 185). With the tension removed

you can now remove the long screw through the

lever. We would suggest loosening this screw, but

leave it engaged at this time (Fig. 187).

Fig 184 3428-0174

2. On the left side of the mower next to the rear wheel,

loosen the clamp that secures the BBC cable to the

mower housing. Near the left front wheel, unhook

the spring end of the cable from the bellcrank.

Remove the screw, bellcrank, sleeve, and unhook

the control link from the lever (Fig. 184).

A. Spring C. Wire loop

B. Screwdriver

A

A

B

B

C

C

6-23WPM Drive Systems Manual

BBC / BOS / BCS

4. Turn the mower on its side. Remove the blade and

the BBC cover. Brush any grass clippings out of the

area. Locate the idler arm. Remove the bolt and

locknut that retains the idler pulley. Note the pulley

is on the deck side and there is a spacer between

the pulley and idler arm (Fig. 186). With the pulley

removed, the idler arm can pivot away from the

brake drum and the belt can be removed.

Fig 186 3428-0182

5. Now reach around to the top of the housing and pull

the screw out of the lever (Fig. 187).

Fig 187 3428-0179

Fig 189 3428-0185

There are two bearings pressed into the housing that

the idler shaft rides on. If they are to be replaced,

press them out at this time (Fig. 189).

Fig 188 3428-0192

Slide the lever off the shaft and the idler/brake shaft

can be pulled down and out of the housing (Fig.

188).

A. Bearings

A

6-24 WPM Drive Systems Manual

BBC / BOS / BCS

6. Now, disassemble the components on the

crankshaft. If you have an impact wrench, the large

nut on the crankshaft can be spun off. If you must

remove it manually, wedge a bar or large screwdriver

into the BBC fl ywheel (Fig. 190). This will hold the

crankshaft so the nut can be removed.

Fig 190 3428-0187

7. Remove the hub assembly and brake drum. The

fl ywheel is pressed onto a taper on the crankshaft.

It might require a tap with a hammer to loosen (Fig.

191).

Fig 191 3428-0103

Fig 192 3428-0116

8. Roll the self-propel belt off the pulley and remove the

pulley and the key in the crankshaft.

9. Inspect the pulley. One end of the keyway is

blocked off. If that is broken, the pulley will bounce

up and down during use and make a rattling noise

(Fig. 192). There are two bumps on the outside

of the pulley that are intended to engage two

holes in the fl ywheel. If this wall is broken out or

the bumps on the pulley are damaged, the pulley

must be replaced. Usually this is caused by an

error in assembly. Refer to “Idler Arm System

Assembly (Recycler/Rear Bagger)” on page 6-25 for

instructions to avoid this.

B

A

A. Wall B. Bumps

6-25WPM Drive Systems Manual

BBC / BOS / BCS

Idler Arm System Assembly (Recycler/Rear

Bagger)

1. Start by installing the key and self-propel pulley. The

two bumps on the pulley should face you (Fig. 193).

Slip the belt over the pulley.

Fig 193 3428-0117

2. Install the fl ywheel. The two bumps on the pulley

MUST engage the holes in the fl ywheel. If not, when

the nut on the crankshaft is tightened, the fl ywheel

will push the pulley upwards, either breaking the wall

out of the key groove or crushing the two bumps or

both.

Fig 195 3428-0188

3. Note the two small foam pads inside the brake drum

(Fig. 195).

Fig 194 MVC-727

The fl ywheel must be installed with the side that

looks like 1/2 of a pulley facing the brake drum

(Fig. 194). Push the fl ywheel fi rmly on the taper of

the crankshaft. If you can’t push the fl ywheel on far

enough to hold, do not be concerned. DO NOT drive

it on with a hammer.

A. Bumps B. Holes in fl ywheel

A. Foam pad

A

A

B

B

A

A

6-26 WPM Drive Systems Manual

They are noise dampeners. Without them, when the

brake pad hits the drum, the drum will ring like a bell.

Also look at the two blade mounting bolts. Each has

a fl at side on the head to prevent them from rotating

when the nut is tightened (Fig. 196). Make sure the

bolts are fully seated. Install the brake drum.

BBC / BOS / BCS

Fig 196 3428-0189

4. Inspect the hub assembly if the old one is to be

reused. Rust on the outside is harmless. But the

seals in the bearing need to be intact. If the seals

are damaged or the bearing feels rough when it is

turned, replace the hub assembly.

5. Start the nut on the crankshaft. As during

disassembly, an impact wrench works best.

Fig 197 3428-0187

CAUTION! The two bumps on the pulley MUST

engage the fl ywheel. If you do not have an

impact wrench, this is where the two bumps

become important. If you engage the bumps on

the pulley into the fl ywheel, you can now wedge

the fl ywheel and through the pulley and key, it

will hold the crankshaft from rotating while you

tighten the nut (Fig. 197).

6. Slip the BBC belt over the parts on the crankshaft.

7. Check the shaft of the idler/brake arm. Clean as

necessary and apply a light coat of grease.

6-27WPM Drive Systems Manual

BBC Cable Removal (Recycler/Rear Bagger)

Fig 199 3428-0192

9. Start the shaft into the hole in the housing. Rotate

the idler/brake arm clockwise so the upper tab on

the spring can engage the boss in the housing.

Rotate the idler/spring arm counterclockwise (Fig.

199) and push the rest of the way into the housing.

The brake pad should now ride on the brake drum.

Fig 198 3428-0190

8. Slip the spring over the shaft. One tang of the spring

must engage the tab as shown (Fig. 198).

BBC / BOS / BCS

10. Hold the idler/brake arm in place. Slip the spring

over the end on top of the deck as shown. Install

the lever and install the screw through the lever and

idler/brake arm shaft (Fig. 200). Once the screw is

secured take a loop of wire or rope and hook the end

of the spring. Pull it towards you and hook the end

as shown.

Fig 200 3428-0177-3

1. Loosen the cable clamp and pull cable out from

under the screw (Fig. 201).

Fig 201 3428-0172

A. Idler/brake arm

A. Spring C. Wire loop

B. Screwdriver

A

A

B

B

C

C

6-28 WPM Drive Systems Manual

BBC / BOS / BCS

BBC Cable Installation (Recycler/Rear

Bagger)

6. Slip the end of the BBC cable from the cable lever

and remove the cable (Fig. 203).

Fig 203 fi g 3 6

1. Slide a new BBC cable into the BBC cable lever.

Install the end of the cable sheath in recess provided

in the left control housing half.

2. Before installing the right control housing half, make

sure that the traction and BBC ends are completely

seated in their recesses. Also make sure that the

sleeve on the upper carriage bolt passes completely

through the BBC control box components to the

handle. Finally, make sure that the roll pin in the

rocker arm passes through the hole in the control

bar. Install the right control housing half. Secure with

two nylon locknuts.

Note: The fl anged locknut fi ts on the upper carriage

bolt.

3. Install the three fl anged head screws securing the

control box halves.

A. BBC cable lever B. BBC cable

3. Bend the throttle control locking tab back slightly

and tap the throttle control from the control panel

with a rubber mallet. Place a piece of duct tape

over the heads of the handle and the BBC control

box mounting bolts. This will prevent control box

components from falling out of the handle during

disassembly.

4. Remove the three fl anged head screws securing the

control box halves.

5. Remove the two nylon locknuts securing the control

box to the handle and carefully remove the right

control housing half.

Fig 202 3428-0173

2. Unhook the spring and cable from the bellcrank (Fig.

202).

6-29WPM Drive Systems Manual

6. Slip end of cable under screw. See page 7-16.

BBC / BOS / BCS

Fig 206 MVC-197

3. Remove the blade and blade stiffener (Fig. 206).

Fig 205 MVC-195

The following steps are disassembly of the system,

including the steps necessary to replace the blade drive

and self-propel belts.

1. Drain the fuel and oil and tip the mower on its side.

We recommend carburetor side up to prevent any

oil or gasoline from draining into the air fi lter and

causing hard starting.

2. Remove the two locknuts securing the blade (Fig.

205).

BLADE OVERRIDE SYSTEM (BOS)

BLADE CLUTCH SYSTEM (BCS)

Both Toro and Lawn-Boy use the same blade clutching

system on some models. On Toro it is named the Blade

Override System. On Lawn-Boy it is named the Blade

Clutch System.

It is designed to allow the blade to stop while the engine

keeps running. This is especially helpful when bagging,

as the engine will not need to be restarted each time you

stop to empty the bag.

Disassembly

Fig 204 3428-0173

4. Bend the throttle control locking tab forward so that

it will provide positive engagement with the throttle

control. Install the throttle control.

5. Hook the spring on the end of cable and into the

bellcrank arm (Fig. 204).

6-30 WPM Drive Systems Manual

BBC / BOS / BCS

Fig 210 MVC-203

7. Unhook both springs from the slot in the brake arm

(Fig. 210).

Fig 209 MVC-200

6. Remove the brake pivot bolt. You will need a second

wrench to hold the bolt head (Fig. 209).

4. Remove the blade support and disc (Fig. 207).

Fig 207 MVC-198

5. Remove the 3 capscrews and lift off the belt cover

(Fig. 208).

Fig 208 MVC-199

6-31WPM Drive Systems Manual

8. Lift the brake assembly and blade drive belt from the

mower (Fig. 211).

9. To replace the blade drive belt, remove the idler

pulley bolt (Fig. 212).

BBC / BOS / BCS

Fig 211 MVC-205

Fig 212 MVC-207

Fig 214 MVC-218

11. Continuing with the disassembly, remove the bolt

securing the pulley to the crankshaft.

Note: Use a large screwdriver or pry bar to keep the

pulley from turning while you unscrew the

bolt (Fig. 214).

Fig 213 MVC-209

10. The components of the idler assembly are shown

here (Fig. 213).

A. Belt E. Washer

B. Nut F. Bearing with fl ange

C. Brake arm G. Spacer

D. Belt guard H. Bolt

A

E

FG

BCD

H

6-32 WPM Drive Systems Manual

BBC / BOS / BCS

Fig 218 MVC-224

15. The anchor plate contains a pivot screw with a

bushing. Remove the locknut (Fig. 218).

Fig 217 MVC-223

14. Remove the two bolts holding the anchor plate to the

chassis (Fig. 217).

12. Rock the pulley half slightly and lift it off. The blade

bolts will now drop out of their pockets (Fig. 215).

Fig 215 MVC-220

13. Lift the crankshaft pulley half off of the crankshaft.

Note this pulley half is keyed to the crankshaft

and this pulley half is also the drive pulley for the

self-propel belt. Go to the transmission to continue

replacing the self-propel belt (Fig. 216).

Fig 216 MVC-222

6-33WPM Drive Systems Manual

Brake Arm Assembly

BBC / BOS / BCS

A. Tab B. Notch

16. The bushing has a notch removed from the fl ange

end. Align that notch in the bushing with the tab in

the anchor plate (Fig. 219).

Fig 219 MVC-257

1. Place the spacer with the large diameter down on

the brake arm (Fig. 220).

Fig 220 MVC-211

Fig 222 MVC-216

3. Install the belt, belt guide, and carriage bolt on the

brake arm and secure with the carriage bolt (Fig.

222).

Fig 221 MVC-213

2. Place the bearing with the fl ange side down on the

spacer and place the washer on top of the bearing

(Fig. 221).

A

A

B

B

6-34 WPM Drive Systems Manual

BBC / BOS / BCS

BOS/BCS System Assembly

Assemble all other parts in reverse order.

Bolt torque as follows:

Blade nuts: 350 - 400 in-lbs. (39.5 – 45.2 Nm)

Crankshaft Bolt: 45 - 55 ft-lbs. (60.9 – 74.5 Nm)

7-1WPM Drive Systems Manual

2

3

4

5

6

8

HANDLES AND CONTROL CABLES

Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .

Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .

Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Brake Clutch Systems (BBC), Blade Override

System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .

Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

1

7

7-2 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

Toro 2 Bail Handle

There are four types of handle and control assemblies

on mowers not covered in other parts of this manual.

This section will cover disassembly and repair of those

types.

Fig 223 3428-0049

The 2 bail style is shown here. The top bail is the engine

kill. Release it and the ignition is grounded and a brake

comes on to help stop the fl ywheel. The lower bail is the

self propel bail. Squeeze it to tension the belt and drive

the transmission. It should be adjusted so that lowering

the bail about 1” (25mm) disengages the self propel.

Handle disassembly is self explanatory so we will not

discuss that.

Turning the knob tightens or loosens the cable. When

the bail is lowered about 1” (25mm) the drive should

disengage.

Fig 224 fi g 19

The engine stop cable is not adjustable. If it fails to

function, it must be replaced.

The self propel cable is adjustable through a clamp

which is typically located a few inches down the handle.

Loosen this clamp and push the cable jacket up or down

to adjust. When the bail is lowered about 1” (25mm) the

drive should disengage. This is a gap that is comfortable

for most operators.

Some models used a knob to adjust the self propel cable

(Fig. 224).

1. Knob 2. Cable

A. Self-propel cable adjuster

A

7-3WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

This is the original Toro Personal Pace/ Lawn Boy Easy

Stride system. The handle is telescoping and as it slides,

it tensions the transmission drive belt.

The best way to use this system is as follows: Hold your

elbows at your sides and your hands straight out in front

of you and just walk. If you want to go faster, walk faster.

The key is keeping your elbows at your sides. This

applies the right amount of pressure to the handle to

engage the drive. If you just push the handle down it will

engage too rapidly and the mower will jump forward.

Fig 227 DSC-4808

2. Turn the handle over and remove the cable clamp,

screw and the cable from the pocket (Fig. 227).

Fig 226 DSC-4804

1. Squeeze the ends of the control bail to disengage it

from the handle. Disconnect the cable from the bail

and set aside (Fig. 226).

Personal Pace Generation 1/Easy Stride

Generation 1

Operation

Fig 225 DSC-4801

Disassembly

7-4 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

3. Remove 6 screws from the traction rod retainer (Fig.

228).

Fig 228 DSC-4810

4. Remove the traction rod retainer. Note the location

of the traction control rod (Fig. 229).

Fig 229 DSC-4811 Fig 231 DSC-4814

6. Unhook the springs from each side of the handle

(Fig. 231).

Fig 230 DSC-4815

5. Disconnect the cable from the traction lever (Fig.

230).

7-5WPM Drive Systems Manual

Reassembly

HANDLES AND CONTROL CABLES

7. Slide the handle up and off (Fig. 232).

Fig 232 DSC-4819a

8. If you need to replace the traction control rod or

either of the springs, one of the handle guides will

need to be removed. The guides are held on by 2

screws (Fig. 233).

Fig 233 DSC-4821a

2. One end of the springs goes into a hole in the

handle, the other around the traction control rod. The

springs apply pressure to the handle to hold it in the

retracted, upper position (Fig. 235).

Fig 234 DSC-4828a

Reassemble in reverse order.

1. There are 3 bosses on the inside of the guide. The

top and bottom ones receive the mounting screws.

The boss in the photo must line up with the end of

the control rod. This boss keeps the rod from moving

sideways and falling out of the handle (Fig. 234).

Fig 235 DSC-4814

7-6 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

Adjusting the Personal Pace Cable

Ensure the transmission belt is disengaged, transmission

tilted forward. Loosen the cable clamp on the handle.

When you pull the cable down the personal place handle

should raise to the stop. Hold the cable and secure the

clamp (Fig. 236).

Fig 236 DSC-4829a

Fig 237 20018_handle

Fig 238 MVC-712

To ease removal of the Personal Pace handle from a 22”

Recycler, make a tool from a piece of metal strapping

or banding material. You will need two pieces about 5”

(12.7cm) long each. Bend them as shown in the photo

and round the ends to remove burrs. This tool permits

the handle to slide up and over the internal handle stops

(Fig. 238).

This is the second generation of the personal pace/

easy stride handle assembly. It works the same as the

original in the sense that the handle is telescoping. As

the handle is depressed it tightens the self propelled belt

and drives the transmission.

Personal Pace Generation 2/Easy Stride

Generation 2

Handle Removal

1. Disconnect the control cables and the key switch

(electric start models) from the upper handle and

Personal Pace handle. Separate the upper and

lower handle. Remove the brake bail by pressing the

two ends together until they come out of the holes in

the handle.

7-7WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

2. Install the tool over the stop in the handle guides as

shown, one on each side. Push the handle down.

The tool will allow the handle to slide over the stop

built into the handle guide (Fig. 239).

Fig 239 MVC-005a

Fig 241 MVC-709a

4. Continue pushing the handle down until it slides off

the end of the upper handle (Fig. 241).

Fig 240 MVC-707a

3. As the handle begins to slide downward, pull the

traction control bar farther out of the handle (Fig.

240).

5. When reinstalling the handle, reconnect the spring

as shown. The spring should push the handle

upwards toward the disengage position (Fig. 242).

Fig 242 MVC-710

A

A. Traction Control Bar

7-8 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

Adjusting the Personal Pace/Easy Stride

Cable

Ensure the transmission belt is disengaged, transmission

tilted forward. Loosen the cable clamp on the handle.

When you pull the cable down the Personal Pace/Easy

Stride handle should raise to the stop. Hold the cable

and secure the clamp (Fig. 243).

Fig 243 DSC-4829

The engine stop cable is not adjustable. If it does not

function, it must be replaced.

The self propel cable is adjustable through a clamp. It

should be adjusted so that lowering the bail about 1”

(25mm) disengages the self propel. This is a gap that is

comfortable for most operators.

Fig 244 3428-0049

The 2 bail style is shown here (Fig. 244). The top bail is

the engine stop. Release it and the ignition is grounded

and a brake comes on to help stop the fl ywheel. The

lower bail is the self propel bail. Squeeze it to tension the

belt and drive the transmission.

Lawn-Boy 2 Bail Handle

7-9WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

Fig 245 DSC-4864a

The Lawn-Boy Sens-a-Speed handle is made in two

forms, zone start and blade clutch. The basic function is

the same but the addition of the blade clutch mechanism

makes the handle for those models a little more

complex.

Fig 246 DSC-4869a

1. Loosen the cable clamp and disconnect the Sens-a-

Speed cable (Fig. 246).

On blade clutch models, the engine on and off is

controlled by a switch on the left hand handle. The bail

engages and disengages the blade. The Sens-a-Speed

handle controls the self propel the same way as on a

zone start model.

Lawn-Boy Sens-a-Speed

Operation

The top mounted bail is the engine stop control on

zone start models and the blade control on blade clutch

models.

On a zone start model, pull the top bail down and

hold to keep the engine running. The Sens-a-Speed

handle telescopes and as it is depressed tensions the

transmission drive belt. To operate this keep your elbows

at your sides, hold your hands straight out in front of you

and walk. If you want to go faster, walk faster. Do not

push the Sens-a-Speed handle down. That will activate

the drive too aggressively and the mower will jump

forward.

Handle Disassembly, Zone Start Models

A

A. Top bail

7-10 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

2. Squeeze the ends of the upper bail to disengage

them from the handle. On some models the right

side of the bail may be connected to the pin by a

push nut. The push nut can be removed or the bail

removed with the pin attached (Fig. 247).

Fig 247 DSC-4871a

3. Remove the shoulder bolt and the traction lever (Fig.

248).

Fig 248 DSC-4880a

4. Slide the pin out of the left hand handle and pull the

upper handle up and out.

5. The plastic sleeves will slide off the upper handle.

6. The springs can be removed from the top slides if

necessary.

If the handle has been binding, clean the top slides and

the sleeves before assembling. Dirt and grit in the sliding

part of the handle can cause a bind.

Assemble in reverse order. When you install the upper

handle, line up the holes and install the pivot pins (Fig.

249).

Fig 249 DSC-4885a

Assembly

7-11WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

The engine brake cable is not adjustable. If it fails to

function it will need to be replaced.

Fig 251 G002634

Fig 250 G002635

To properly adjust the self propel cable, loosen the cable

clamp, pull the cable downward to remove all the slack

(Fig. 250) then push the cable jacket up 1/8” (3.17cm)

(Fig. 251) and secure with the cable clamp.

Cable Adjustment

Self-Propel Cable

Handle Disassembly, Lawn-Boy Blade

Clutch System (BCS) Models

1. Remove the upper wire bail. On the right hand side

it slides over a pin. On some models this pin has a

push nut on it (Fig. 252). It can be compressed so

that either the bail slides off the pin or it draws the

pin out of the handle. Either is acceptable.

Fig 252 DSC-4871a

1. Cable

1. Cable clamp 2. Cable

7-12 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

Fig 254 DSC-4899a

3. Slide the pivot assembly, bail and the brake cable to

the right until the bail slides off the pin (Fig. 254).

4. Continue sliding the pivot assembly and brake cable

off the pin.

5. Remove the shoulder bolt that the traction lever

pivots on and remove the traction lever.

6. Pull the pin out of the left hand handle. Note it

is snapped in and will require a locking pliers or

something similar to remove. When removed, the

springs will push the handle upwards (Fig. 255).

Fig 255 DSC-4907a

A

B

A. Traction lever C. Top slide

B. Pivot assembly

2. Remove the e-clip on the left side pivot pin (Fig.

253).

Fig 253 DSC-4896a

C

A

A

A. E-clip

7-13WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

The shift cables are not adjustable. To install the shift

cable, insert the end of the cable in the shift arm and slip

the end of the cable jacket into the bracket (Fig. 257).

Fig 257 3428-0196

Fig 258 3428-0195

The traction control cable tilts the transmission backward

to tighten the belt and engage the transmission (Fig.

258). It must tighten suffi ciently to fully drive the

transmission, yet allow the transmission to rock forward

and loosen the belt to disengage.

3 Speed Control Cables

Fig 256 DSC-4908a

7. Slide the upper handle out of the top slide.

Reverse the process to assemble.

Note how the switch assembly, bail and control cable

are assembled before they are installed on the pin (Fig.

256).

3 Speed Transmission Models

Handles on 3 speed models are basic and easily

disassembled.

7-14 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

The objective is to have the wheels begin to drive when

the bail is about 1” (25mm) below the upper handle,

yet be able to lower the bail enough to stop the wheels

without releasing the bail (Fig. 261).

Fig 261 fi g 20

To adjust, turn the knob or loosen the cable clamp and

slide the cable jacket up or down. Secure with the clamp.

Fig 259 3428-0043-2

The adjustment point for this cable is a knob, jam nuts,

or a clamp to the handle (Fig. 259 and Fig. 260).

A. Clamp

A

A. Blade brake cable B. Jam nuts

Fig 260 fi g 69

1” (25mm)

7-15WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

1. Remove the two fl anged head self-tapping screws

securing the screen panel to the housing and

remove the screen panel (Fig. 262).

BBC Cable Adjustment (Toro Vacu Power/

Lawn-Boy Medallion)

2. With the engine off and the spark plug wire discon-

nected, cock and lift the control bar to engage the

blade. Tape the control bar to the handle with the

blade engaged, then measure the length of the over-

travel spring (Fig. 263). When adjusted properly, it

should measure 1” (25mm). If it does, skip ahead

to step 5. Otherwise proceed with adjustment in the

following step.

Fig 263 fi g. 68

A. Plastic fi tting C. Spring

B. Cable fi tting

Fig 262 3428-0079

3. There is a turnbuckle in the cable about halfway

between the control panel and the chassis. Adjust

the turnbuckle until the over-travel spring measures

1” (25mm).

4. Remove the tape from the handle and disengage the

blade.

1”

7-16 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

The cable adjustment is the clamp on top of the housing

on the left side of the mower. Loosen the screw holding

the cable clamp. Pull the cable to the rear just enough to

remove the slack (Fig. 265). Hold and tighten the clamp.

The spring on the forward end of the cable should be

suspended just off the housing.

Note: An overly tight cable will cause the BBC to

disengage before the bail can be raised to

the normal operating position. Cock the bail

downward and raise to the handle. If the BBC

disengages and you hear the brake engage

with a snap, the cable is likely too tight.

Excessive cable tension causes the control

hook in the control box to release. It doesn’t

do any permanent damage to any parts.

Loosen the cable slightly and repeat the test.

Toro BBC Cable Adjustment (Recycler/Rear

Bagger)

Fig 265 348-0172

5. Install the screen panel with the two fl anged head

self-tapping screws. Make sure that the top edge

of the screen panel is under the lip at the top of

the housing. The screen is installed, sharp edge

down, to allow air to be drawn in through the screen

panel on top of the deck and down underneath the

deck. This venting improves the airfl ow underneath

the deck thereby improving quality of cut and

bagging performance. Be sure to clean the screen

on occasion, especially if quality of cut or bagging

performance has degraded.

Note: An overly tight cable will cause the BBC to

disengage before the bail can be raised to

the normal operating position. Cock the bail

downward and raise to the handle. If the BBC

disengages and you hear the brake engage

with a snap, the cable is likely too tight.

Excessive cable tension causes the control

hook in the control box to release. It doesn’t

do any permanent damage to any parts.

Loosen the cable slightly and repeat the test.

On BBC models, the control bail also controls the

transmission belt engagement. The adjustment point

is a knob about halfway between the control panel and

transmission. Ideally, the cable should be set so that

the transmission drive will disengage when the bail is

lowered about 1” (25mm). This allows the bail to be

lowered so that the wheels stop driving and the BBC

remains engaged, but the gap isn’t so large that the

handle is hard to hold (Fig. 264). This measurement

is not an exact requirement. It can be varied to

accommodate a customer with small hands, etc.

Fig 264 fi g 20

1” (25mm)

7-17WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

On BBC models, the control bail also controls the

transmission belt engagement. The adjustment point

is a knob about halfway between the control panel and

transmission. Ideally, the cable should be set so that

the transmission drive will disengage when the bail is

lowered about 1” (25mm). This allows the bail to be

lowered so that the wheels stop driving and the BBC

remains engaged, but the gap isn’t so large that the

handle is hard to hold (Fig. 266). This measurement

is not an exact requirement. It can be varied to

accommodate a customer with small hands, etc.

Fig 266 fi g 20

The BOS control is the upper bail on the handle. For the

required 2 step engagement, there is a pivoting stop on

the right hand handle. Rotate it out of the way and then

pull the bail down for blade engagement (Fig. 267).

Toro BOS Control

Fig 267 MVC-102

1” (25mm)

A

A. Pivoting stop

7-18 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

The blade clutch control is adjusted by removing the

cover between the engine and bag door. Loosen the

cable clamp and draw the cable to the rear to remove

the slack. Now push the cable outer jacket forward 5/8”

(1.5cm) and secure. This will create 5/8” (1.5cm) slack in

the cable (Fig. 268).

Toro BOS Control Cable Adjustment

Fig 268 MVC-BOS457x

To engage the blade clutch, press the control button.

Then pull the control bar to the handle. To disengage the

blade, release the control bar. (Fig. 269).

Lawn-Boy BCS Control

Fig 269 lwpm_10797a

Lawn-Boy Insight and Insight Gold:

1. Remove the grass bag and tunnel (Fig. 270).

Lawn-Boy BCS Control Cable Adjustment

Fig 270 DSC-5360a

2. Loosen cable clamp. Draw cable to rear to remove

slack. Now push outer jacket of cable forward 5/8”

(1.5cm) and secure. This will create 5/8” (1.5cm)

slack in the cable (Fig. 271).

Fig 271 DSC-5357a

7-19WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

Lawn-Boy Insight Platimun:

1. Remove the gas and oil and tip the mower on its

side with the air fi lter up.

2. Remove the BCS cover and belt cover.

3. Loosen the 2 cap-screws securing the bracket to

the housing. Pull the cable to the rear to remove

the slack. Push the cable forward 5/8” (1.5cm) and

secure. This will create 5/8” (1.5cm) of slack (Fig.

272).

Fig 272 DSC-5352a

4. Install the BCS cover, belt cover and tunnel.

7-20 WPM Drive Systems Manual

HANDLES AND CONTROL CABLES

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8-1WPM Drive Systems Manual

2

3

4

5

6

7

SELF-PROPEL BELT REPLACEMENT

Worm Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Single Speed Spur/Bevel Gear Transmission . . . . . . . . . . . . .

Single Speed Bevel Gear Transmission . . . . . . . . . . . . . . . .

Three Speed Transmission . . . . . . . . . . . . . . . . . . . . . . .

Wheel Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blade Brake Clutch Systems (BBC), Blade Override

System (BOS), Blade Clutch Systems (BCS) . . . . . . . . . . . . .

Handles and Control Cables . . . . . . . . . . . . . . . . . . . . . .

Self-Propel Belt Replacement . . . . . . . . . . . . . . . . . . . . . .

1

8

8-2 WPM Drive Systems Manual

SELF-PROPEL BELT REPLACEMENT

There are several different procedures for replacing

the self propelled belt. Mowers with a blade clutch

mechanism are the most complex as parts of that will

need to be removed to access the self propel belt.

See Single Speed Bevel Gear Transmission page 2-1.

These mowers usually have a model number that starts

with 200XX.

Drain the fuel and oil before you tip the mower on its

side. To remove the belt cover, tip the mower to access

the two mounting screws from the bottom. There are

belt guides on both the transmission and around the

crankshaft. DO NOT bend them or force the belt out

from under the guides. Loosen or remove the mounting

screws to pivot the belt guides out of the way. If the belt

guides are bent or out of place the belt will have a larger

tendency to jump and may not disengage properly. It

may be necessary to remove the blade to replace the

belt. Do not force the new belt between the blade and

mower housing. A nick or cut in the new belt can cause

premature failure.

See Worm Drive Transmission page 1-1.

These mowers usually have a model number that starts

with 16xxx.

Remove the belt cover, push the top of the transmission

to the rear to create slack in the belt and remove the

belt. Push the belt towards the engine. Drain fuel and oil

to prevent spillage and tip the mower on its side, air fi lter

side up. Slip the belt off the crankshaft pulley. In some

cases there might not be enough clearance between

the blade and mower housing. It might be necessary to

remove the blade to slip the belt off.

Reverse the process to assemble.

Toro 21” Front Wheel Drive

22” Front Wheel Drive

These are steel deck mowers, made in both Toro and

Lawn-Boy brands.

In order to replace the self propel drive belt the

transmission must be removed from the chassis. This

is necessary to access the pulley and belt guide on

top of the transmission. See Single Speed Bevel Gear

Transmission, Rear Wheel Drive Models, Transmission

Removal and Belt Replacement, see page 3-10.

Do not bend the belt guides or force the belt between

the pulley and belt guide. Drain the gas and oil before

tipping the mower to avoid fuel spillage. Remove or

loosen the belt guide mounting screws and move the

belt guide out of the way. A bent belt guide will cause an

increased tendency for belt jumping and damage.

22” Rear Wheel Drive

Drain the gasoline and oil before tipping the mower

to avoid fuel spillage. Remove the belt cover. Loosen

or remove the belt guides so the belt can be replaced

without forcing. See the Single Speed Spur/Bevel Gear

Transmission section for a typical transmission and drive

layout, see page 2-2.

21” Steel and Cast Deck Toro and Lawn-Boy

Mowers Belt Replacement

Made in both Toro and Lawn-Boy brands.

To replace the belt, drain both the gasoline and oil from

the engine. Remove the belt cover, just behind the

engine on top of the mower, to access the transmission.

Loosen or remove the belt guides so the belt can be

replaced without forcing. See the section on the three

speed transmission starting on page 4-1.

21” Cast Deck Mowers with 3 Speed

Transmission

8-3WPM Drive Systems Manual

SELF-PROPEL BELT REPLACEMENT

The Zone Start models use a basic self propel system.

See Transmission Remove and Replace, page 3-19,

which also explains the belt replacement process.

Part of the blade clutch must be disassembled to access

the self propel belt. See the BBC section starting on

page 6-1 for more information.

21” Toro and Lawn-Boy Mowers with Blade

Brake Clutch

Part of the BOS or BCS must be removed to replace the

self propel belt. (See page 6-18 for more information.)

The Lawn-Boy Insight has a black access cover just to

the rear of the engine on top of the chassis. Remove it

for easy access to the top of the transmission.

21” Toro Mowers with Blade Override

System and Lawn-Boy Mower with Blade

Clutch System

21” Lawn-Boy Insight Mowers

8-4 WPM Drive Systems Manual

SELF-PROPEL BELT REPLACEMENT

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