John deere trs21 e walk behind snowthrowers & snowblowers service repair manual (tm1466)

TECHNICAL
MANUAL
Litho in U.S.A
John Deere
Lawn & Grounds Care Division
TRS21/21E/22/24/26/27/32 and
TRX24/26 Walk-Behind
Snowthrowers/Snowblowers
TM1466 (20Jan95)
Replaces TM1466 (25Aug92)

FOREWORD
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions
presented throughout the text of the manual.
N This is the safety-alert symbol. When you see
this symbol on the machine or in this manual,
be alert to the potential for personal injury.
Technical manuals are divided in two parts: repair
and diagnostics. Repair sections tell how to repair the
components. Diagnostic sections help you identify the
majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, other materials needed to
do the job and service parts kits.
Section 10, Group 15—Repair Specifications, consist
of all applicable specifications, near tolerances and
specific torque values for various components on
each individual machine.
Binders, binder labels, and tab sets can be ordered
by John Deere dealers direct from the John Deere
Distribution Service Center.
This manual is part of a total product support
program.
FOS MANUALS—REFERENCE
TECHNICAL MANUALS—MACHINE SERVICE
COMPONENT MANUALS—COMPONENT SERVICE
Fundamentals of Service (FOS) Manuals cover basic
theory of operation, fundamentals of troubleshooting,
general maintenance, and basic type of failures and
their causes. FOS Manuals are for training new
personnel and for reference by experienced
technicians.
Technical Manuals are concise guides for specific
machines. Technical manuals are on-the-job guides
containing only the vital information needed for
diagnosis, analysis, testing, and repair.
Component Technical Manuals are concise service
guides for specific components. Component technical
manuals are written as stand-alone manuals covering
multiple machine applications.
MX,TMIFC,A -19-18OCT91
Introduction
TM1466 (25AUG92) TRS/TRX Series Snowblowers
270995

Contents
SECTION 10—GENERAL INFORMATION
Group 05—Safety
Group 10—General Specifications
Group 15—Repair Specifications
Group 20—Fuels and Lubricants
Group 25—Serial Number Locations
SECTION 20—4 AND 5-HP ENGINE
REPAIR—TRS22 AND TRS/TRX24
Group 05—Carburetor, Fuel Tank, and Muffler
Group 10—Remove and Install Engine
Group 15—Blower Housing, Cylinder Head, and
Breather
Group 20—Governor, Camshaft, and Tappets
Group 25—Flywheel, Crankshaft and Piston
Assembly
Group 30—Cylinder Block
Group 35—Recoil Starter
SECTION 21—8 AND 10-HP ENGINE
REPAIR—TRS/TRX26, TRS27,
TRS32
Group 05—Carburetor, Fuel Tank, and Muffler
Group 10—Remove and Install Engine
Group 15—Blower Housing, Cylinder Head, and
Breather
Group 20—Governor, Camshaft, and Tappets
Group 25—Flywheel, Crankshaft and Piston
Assembly
Group 30—Cylinder Block
SECTION 25—4 AND 5-HP ENGINE REPAIR—TRS21
Group 05—Fuel System and Muffler
Group 10—Engine
SECTION 40—ELECTRICAL
Group 05—Electric Starter—4-Cycle Engines
Group 06—Electric Starter
Group 10—4 and 5-HP Ignition and Charging
System
Group 15—8 and 10-HP Ignition and Charging
System
Group 20—4 HP (2-Cycle) Ignition System
SECTION 50—POWER TRAIN—TRS22,
TRS/TRX24 & 26
Group 05—Drive Belt Care and Maintenance
Group 10—Power Train Repair
Group 15—Blower and Auger Drive Repair
SECTION 55—POWER TRAIN—TRS27 AND 32
Group 10—Power Train Repair—TRS27 and 32
(S.N. —140000)
Group 15—Blower and Auger Drive Repair
Group 20—Power Train Repair—TRS27 and 32
(S.N. 140001— )
SECTION 85—AUGER DRIVE SYSTEM—TRS21
Group 10—Auger Drive Repair
SECTION 210—TEST AND ADJUSTMENT
SPECIFICATIONS/OPERATIONAL
CHECKOUT PROCEDURES
Group 05—Test and Adjustment Specifications
Group 10—Operational Checkout Procedures
SECTION 220—ENGINE—4-CYCLE ENGINES
Group 05—Component Location
Group 10—Theory of Operation
Group 15—Diagnosis, Tests and Adjustments
SECTION 225—ENGINE—2-CYCLE ENGINES
Group 05—Component Location
Group 15—Diagnosis, Tests and Adjustments
Continued on next page
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
TM1466-20Jan95
COPYRIGHT© 1995
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION™ Manual
Previous Editions
Copyright© 1989 Deere & Company
i
10
20
21
25
40
50
55
85
210
220

SECTION 230—FUEL SYSTEM—4-CYCLE ENGINES
Group 05—Component Location—4-Cycle Engine
Group 15—Diagnosis and Adjustments—4-Cycle
Engine
SECTION 235—FUEL SYSTEM—2-CYCLE ENGINE
Group 15—Diagnosis and Tests—2-Cycle Engine
SECTION 240—ELECTRICAL SYSTEM—4-CYCLE
ENGINES
Group 15—Diagnosis, Tests and Adjustments—
4-Cycle Engine
SECTION 245—ELECTRICAL SYSTEM—2-CYCLE
ENGINES
Group 15—Diagnosis and Adjustments—2-Cycle
Engine
SECTION 250—POWER TRAIN—TRS22,
TRS/TRX24 AND 26
Group 05—Component Location—TRS22,
TRS/TRX24 and 26
Group 15—Diagnosis and Adjustments—TRS22,
TRS/TRX24 and 26
SECTION 255—POWER TRAIN—TRS27, AND 32
Group 05—Component Location—TRS27 and 32
Group 15—Diagnosis and Adjustments—TRS27 and
32
SECTION 280—AUGER DRIVE SYSTEM—2 STAGE
Group 05—Component Location—2 Stage
Group 15—Diagnosis and Adjustments—2 Stage
SECTION 285—AUGER DRIVE SYSTEM—TRS21
Group 05—Component Location—Single Stage
Group 15—Diagnosis and Adjustments—Single
Stage
Contents
ii
10
20
21
25
40
50
55
85
210
220

Section 10
GENERAL INFORMATION
Contents
Page
Group 05—Safety . . . . . . . . . . . . . . . . 10-05-1
Group 10—General Specifications
Machine Specifications
TRS21 and 22 . . . . . . . . . . . . . . . . . 10-10-1
TRS/TRX24 and 26 . . . . . . . . . . . . . . 10-10-3
TRS27 and 32 . . . . . . . . . . . . . . . . . 10-10-6
Group 15—Repair Specifications
Repair Specifications
TRS21/21ES . . . . . . . . . . . . . . . . . . 10-15-1
TRS22 and TRS/TRX24 . . . . . . . . . . . 10-15-2
TRS/TRX26 . . . . . . . . . . . . . . . . . . . 10-15-5
TRS27 and 32 . . . . . . . . . . . . . . . . . 10-15-7
Inch Cap Screw Torque Values . . . . . . . 10-15-10
Set Screw Seating Torque Chart . . . . . . 10-15-11
Group 20—Fuels and Lubricants
Two-Cycle Gasoline Engine Oil . . . . . . . 10-20-1
Two-Cycle Engine Fuel . . . . . . . . . . . . . 10-20-1
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Engine Oil . . . . . . . . . . . . . . . . . . . . . 10-20-2
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
Grease . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
Group 25—Serial Number Locations
Serial Number Information . . . . . . . . . . . 10-25-1
Product Identification Number Location . . 10-25-1
Engine Serial Number Location . . . . . . . 10-25-2
Group 30—Features and Accessories . . 10-30-1
TM1466 (25AUG92) 10-1 TRS/TRX Series Snowblowers
270995
10

RECOGNIZE SAFETY INFORMATION
This is the safety-alert symbol. When you see this
symbol on your machine or in this manual, be alert to
the potential for personal injury.
Follow recommended precautions and safe operating
practices.
T81389-UN-07DEC88
UNDERSTAND SIGNAL WORDS
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187-19-30SEP88
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair
the function and/or safety and affect machine life.
If you do not understand any part of this manual and
need assistance, contact your John Deere dealer.
TS201-UN-23AUG88
DX,ALERT -19-04JUN90
DX,SIGNAL -19-09JAN92
DX,READ -19-04JUN90
Group 05
Safety
TM1466 (25AUG92) 10-05-1 TRS/TRX Series Snowblowers
270995
10
05
1

HANDLE FLUIDS SAFELY—AVOID FIRES
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.
TS227-UN-23AUG88
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
TS291-UN-23AUG88
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
TS206-UN-23AUG88
DX,FLAME -19-04JUN90
DX,FIRE2 -19-04JUN90
DX,WEAR -19-10SEP90
Safety
270995
10
05
2

OTHER MATERIAL
Number Name Use
SCOTCH-BRITE abrasive pads Remove carbon deposits from
combustion chamber
REMOVE AND INSTALL BLOWER HOUSING
IMPORTANT: Remove blower housing when engine is
cold to prevent cylinder head warpage.
1. Loosen cap screws (A).
2. Remove cap screws (B) and (C).
3. Remove plate (D).
4. Remove blower housing.
5. Disconnect hose (E) from primer bulb.
6. Inspect blower housing.
7. Connect hose (E) to primer bulb.
8. Install blower housing.
9. Install plate (D).
10. Tighten cap screws (A) and (B) to 200 lb-in. (20.3
N·m).
A—Cylinder Head Cap Screw
B—Cylinder Head Cap Screw
C—Blower Housing Cap Screw
D—Inspection Plate
E—Primer Hose
M53691-UN-25OCT89M53692-UN-25OCT89
MX,2515FA,A1A -19-16OCT89
MX,2515FA,A1 -19-15SEP89
Group 15
Blower Housing, Cylinder Head, and Breather
270995
20
15
1

REMOVE AND INSTALL CYLINDER HEAD
1. Remove blower housing. (See this group.)
2. Remove fuel tank. (See Group 05 in this section.)
3. Remove muffler. (See Group 05 in this section.)
4. Remove spark plug.
IMPORTANT: Remove cylinder head when engine is
cold to prevent cylinder head warpage.
5. Remove cylinder head, gasket and fuel tank bracket.
6. Inspect cylinder head. (See this group.)
7. Install new cylinder head gasket.
8. Install cylinder head and fuel tank bracket.
NOTE: Install special cap screw (A) and short cap
screws (B) in locations shown.
9. Tighten cylinder head cap screws in sequence shown
to 180 lb-in. (20.3 N·m) in 50 lb-in. (5.5 N·m) increments.
10. Install muffler and fuel tank. (See Group 05 in this
section.)
11. Install spark plug. Tighten to 21 lb-ft. (28 N·m).
M53693-UN-25OCT89M53694-UN-25OCT89
MX,2515FA,A2 -19-15SEP89
Blower Housing, Cylinder Head, and Breather/Cylinder Head
270995
20
15
2

INSPECT CYLINDER HEAD
1. Remove carbon deposits from combustion chamber
and gasket surface using SCOTCH-BRITE abrasive pads
or equivalent.
2. Clean head with solvent.
3. Inspect for cracks or broken cooling fins.
4. Inspect gasket surface for burrs and nicks.
5. Check cylinder head for distortion on a surface plate.
Check at several points around the head. Replace head
if distortion is more than 0.002 in. (0.05 mm).
M53695-UN-25OCT89
REMOVE AND INSTALL BREATHER
NOTE: Intake manifold removed for clarity.
1. Remove carburetor cover. (See Group 05 in this
section.)
2. Remove cover (A) and gasket.
3. Remove element (B), bowl (C), and gasket.
4. Clean and inspect breather. (See this group.)
NOTE: Install bowl with drain hole on bottom.
5. Install gasket, bowl, and element.
6. Install gasket and cover.
7. Install carburetor cover.
M53696-UN-25OCT89M53697-UN-25OCT89
MX,2515FA,A3 -19-15SEP89
MX,2515FA,A4 -19-15SEP89
Blower Housing, Cylinder Head, and Breather/Breather
270995
20
15
3

INSPECT BREATHER
1. Clean element (A) and bowl with solvent. Blow dry.
2. Check that drain hole (B) is open.
3. Check that reed valve (C) moves freely and closes
when released.
M53698-UN-25OCT89
REMOVE AND INSTALL VALVE ASSEMBLY
1. Remove cylinder head. (See this group.)
2. Remove intake manifold. (See this group.)
3. Remove breather assembly. (See this group.)
4. Compress valve spring and remove retainer (A).
5. Remove and inspect valve and spring. (See this
group.)
6. Install spring and retainer (A).
7. Install valves.
8. Compress valve spring. Seat retainer in groove in
valve stem.
M53699-UN-25OCT89
MX,2515FA,A5 -19-15SEP89
MX,2515FA,A6 -19-15SEP89
Blower Housing, Cylinder Head, and Breather/Valve Assembly
270995
20
15
4

INSPECT VALVE SPRINGS
1. Clean and inspect valve springs. Replace if cracked or
broken.
2. Inspect valve spring (A) for squareness on a surface
plate (C). Turn spring and measure space between top
spring coil and square (B).
3. Measure free length of valve spring.
4. Compress valve spring. Measure compressed tension
and length.
Replace valve spring if not within specifications.
VALVE SPRING SPECIFICATIONS
Squareness Tolerance . . . . . . . . . . . . . . . . . . . 0.09 in. (2.387 mm)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . 1.56 in. (36.690 mm)
Compressed Length . . . . . . . . . . . . . . . . . . . 0.70 in. (17.856 mm)
Compressed Tension . . . . . . . . . . . . . . . . . . . . . . 48 lbs (21.77 kg)
M53828-UN-06NOV89M25949-UN-06NOV89
INSPECT VALVES
1. Remove carbon from valve head, face and stem with
a power-operated wire brush. Be sure carbon is
removed, not merely burnished.
2. Check valve for damage. Replace warped valves (A)
or valves with less than 0.0312 in. (0.792 mm) margin
(B).
3. Grind valve stem ends (C) square before
valve-to-tappet clearance is checked.
M38087-UN-29AUG88
MX,2515FA,A7 -19-18SEP89
MX,2515FA,A8 -19-18SEP89
270995
20
15
5

4. Inspect valve stem for bend using V-blocks and dial
indicator. Turn valve slowly and read variation on
indicator. Replace valve if variation is greater than 0.001
in. (0.03 mm).
M51753-UN-07SEP88
ANALYZE VALVES
Lead deposits on the intake valve are caused by exhaust
gas leakage past the valve, when using leaded gasoline.
Grind intake valve and reface seat to correct this
condition.
Use unleaded fuel to prevent lead deposits.
M29934-UN-06SEP88
Valve stem corrosion is caused by moisture in the
engine which occurs during hot engine cool-down periods
or during storage.
Fogging combustion chamber with oil before storage
helps prevent corrosion.
Replace badly corroded valves.
M5563-UN-31AUG88
MX,2515FA,A9 -19-18SEP89
MX,2515A,A9A -19-11OCT89
MX,2515A,A9B -19-11OCT89
270995
20
15
6

Operating at high temperatures for long periods of time
can cause exhaust valve burning. Burned valve will show
dark discoloration into the area protected by the valve
guide. Another indication is distortion of the margin (A)
and face (B). The valve seat may also show erosion.
An overheated engine can cause valve burning. Check
for clogged engine cooling fins. Do not run engine with
blower housing removed. Also check for worn valve
guides, springs or tappets, lean fuel-air mixture or
incorrect spark plug.
M30024-UN-06SEP88
Use of old or stale gasoline can cause valves to stick.
Gummy deposits (A) build up on valve and can also gum
carburetor, requiring cleaning.
Always use fresh gasoline and drain fuel tank, lines and
carburetor before storage.
M29936-UN-06SEP88
MX,2515A,A9C -19-11OCT89
MX,2515A,A9D -19-11OCT89
270995
20
15
7

MEASURE VALVES AND VALVE GUIDES
1. Clean inside of valve guide (A).
2. Measure inside diameter of guide with telescoping
gauge. Ream guide if not within specifications.
3. Measure outside diameter of valve stem (B). Replace
valve if not within specifications.
IMPORTANT: If guide is reamed oversize, an oversize
valve must be installed.
4. Replace cylinder head if guide cannot be reamed to
specifications.
SPECIFICATIONS
Valve Guide (STD) . . . . . . . . . . 0.312—0.313 in. (7.924—7.950 mm)
Valve Guide
(Oversize) . . . . . . . . . . . . . . . . 0.343—0.344 in. (8.712—8.737 mm)
Valve Guide Wear
Tolerance . . . . . . . . . . . . . . 0.0015—0.0020 in. (0.038—0.050 mm)
Intake Valve Stem
Diameter (STD) . . . . . . . . . . . . 0.309—0.310 in. (7.848—7.874 mm)
Intake Valve Stem Diameter
(Oversize) . . . . . . . . . . . . . . . . 0.340—0.341 in. (8.636—8.661 mm)
Exhaust Valve Stem
Diameter (STD) . . . . . . . . . . . . 0.308—0.309 in. (7.823—7.848 mm)
Exhaust Valve Stem Diameter
(Oversize) . . . . . . . . . . . . . . . . 0.339—0.340 in. (8.610—8.636 mm)
M53700-UN-25OCT89M52082-UN-16DEC89
RECONDITION VALVE SEATS
1. Hold the valve seating surface (A) as close to 0.0469
in. (1.191 mm) as possible.
A—Valve Seating D—Valve Margin
Surface 0.0469 in. 0.0313 in. (1.587
(1.91 mm) mm)
B—Valve Seat E—Valve Narrowing
Angle (45˚) Angle (30˚)
C—Valve Face
Angle (45˚)
M9552-UN-01SEP88
MX,2515FA,A10 -19-18SEP89
MX,2515FA,A9E -19-11OCT89
270995
20
15
8

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2. On seats with more than 0.0313 in. (0.795 mm)
seating surface, cut back seating surface with a 31˚
cutter (A).
3. The valve seat angle (B) depends on valve face angle
(C). New valves have a 45˚ face. Recondition valve
seats with 56˚ cutter (A), to 0.0469 in. (1.19 mm).
4. Lap valves to seats after refacing.
M25952-UN-26APR89
5. Match valve to seat. Be sure valve seat is centered
on valve face. The position of valve in seat is evident
after lapping valve.
A—Right
B—Wrong
C—Wrong
M25953-UN-25APR89
LAP VALVES
Lap valve and seat if they do not make good contact.
1. Apply a small amount of lapping compound to valve
face.
2. Turn valve in seat using vacuum cup tool.
3. Check valve every eight strokes until a uniform ring
appears around surface of valve face.
4. Wash parts in solvent to remove lapping compound.
5. Check position of lap mark on face. Lap mark must
be on or near center of valve face.
6. Check valve-to-tappet clearance. (See Section 220,
Group 15.)
M53701-UN-25OCT89
MX,2515FA,A9F -19-11OCT89
MX,2515FA,A9G -19-11OCT89
MX,2515FA,A11 -19-05AUG92
270995
20
15
9

OTHER MATERIAL
Number Name Use
T43512 Thread Lock and Sealer (Medium Apply to governor shaft.
Strength)
PT569 John Deere NEVER-SEEZ® Apply to crankshaft end.
Lubricant
NEVER-SEEZ is a trademark of the Emhart Chemical Group. MX,2620FA,A1A -19-05AUG92
Group 20
Governor, Camshaft, and Tappets
270995
20
20
1

REMOVE CRANKCASE COVER—TRS/TRX24
(S.N. —120000)
1. Drain oil.
IMPORTANT: Camshaft is a tight fit in crankcase
cover and can come out of crankcase
with cover removal. To prevent damage
to camshaft lobes or tappets, rotate
camshaft so sheave key (E) is at 12
o’clock position (facing cylinder head
end of engine).
2. Remove cap screw (A), lock washer, and washer.
3. Remove crankshaft sheave, spacer (B), and washers.
4. Loosen set screw (C). Remove camshaft sheave and
key.
5. Remove cap screw (D). Dipstick tube can be removed
from crankcase, if necessary, by turning tube
counterclockwise.
IMPORTANT: Camshaft sheave set screw can cause
burrs on camshaft surface. Remove
burrs before removing crankcase cover,
to prevent damage to seal or camshaft
bearing surface.
A—Crankshaft Sheave Cap Screw
B—Sheave Spacer
6. Remove crankcase cover. C—Camshaft Sheave Set Screw
D—Cap Screw
E—Camshaft Sheave Key
M53702-UN-25OCT89
MX,2520FA,A1 -19-05AUG92
Governor, Camshaft, and Tappets/Crankcase Cover—TRS/TRX24 (S.N. 120000)
270995
20
20
2

John deere trs21 e walk behind snowthrowers & snowblowers service repair manual (tm1466)

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