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Shop Manual for John Deere

Shop Manual for John Deere

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JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION

1756 March 2005

Garden Tractors GT225, GT235, GT235E and GT245
TM1756 MARCH 2005

TECHNICAL MANUAL

North American Version Litho in U.S.A.

INTRODUCTION
Manual Description
Introduction

This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: • • • • • • • • • • • • Table of Contents Specifications and Information Identification Numbers Tools and Materials Component Location Schematics and Harnesses Theory of Operation Operation and Diagnostics Diagnostics Tests and Adjustments Repair Other

Safety Specifications and Information Engine - Kohler Engine - Briggs & Stratton Engine - Kawasaki (FH580V) Engine - Kawasaki (FH601V) Electrical Power Train - Hydrostatic Steering Attachments Miscellaneous

NOTE: Depending on the particular section or system being covered, not all of the above groups may be used. The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section through the last section. We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us.

All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT© 2005 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© 2002, 2003

Introduction

SAFETY
Safety

Handle Fluids Safely - Avoid Fires
Be Prepared For Emergencies

Recognize Safety Information

MIF

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 servicing practices.

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.

MIF

• 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. • • Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy.

Replace Safety Signs

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Use Care In Handling and Servicing Batteries

MIF

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

MIF

Safety

-1

SAFETY
Prevent Battery Explosions
• Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. • Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. • Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). 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.

Use Care Around High-Pressure Fluid Lines
Avoid High-Pressure Fluids

Prevent Acid Burns
• Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10 - 15 minutes. 4. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately.
MIF

Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid injury from escaping fluid under pressure by stopping the engine and relieving pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Avoid Heating Near Pressurized Fluid Lines

Wear Protective Clothing

MIF MIF

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

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. -2

Safety

SAFETY
Service Machines Safely Using 120 Volt Electric Outlet System Safely
• 120 Volt electric outlet system is an on-board highvoltage generator. Failure to observe all safety messages may result in property damage, injury or death. • Do not use 120 Volt electric outlet system as a backup for a main power source, such as in a house that is powered by a utility company. Doing so may cause a power backfeed that could electrocute utility workers or others who contact power lines.
MIF

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

• Do not use 120 Volt electric outlet system in an enclosed area. Engine gives off carbon monoxide. Breathing carbon monoxide can cause illness, unconsciousness or death. • Do not use 120 Volt electric outlet system in wet conditions. • Do not use 120 Volt electric outlet system if it does not pass all safety system tests. • A ground fault occurs when, instead of following its normal safe path, electricity passes through a person’s body to the ground. Ground fault circuit interrupter (GFCI) shuts off power to receptacle if it detects a ground fault. • GFCI receptacle protects against ground faults. It does not protect against current overloads, short circuits or shocks. • Do not use 120 Volt electric outlet system if electric power is lost and cannot be restored by resetting GFCI or 120 Volt electric outlet system. • Do not use 120 Volt electric outlet system with hood open. • Do not modify 120 Volt electric outlet system in any way. • Perform only service functions described in this manual. For all other service, see a John Deere dealer. • Use only John Deere approved replacement parts. • Do not connect a battery charger to 120 Volt electric outlet system. Connecting this way may damage certain types of battery chargers.

Use Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.

Park Machine Safely

MIF

Before working on the machine: 1. Lower all equipment to the ground. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a “DO NOT OPERATE” tag in operator station.

Safety

-3

SAFETY
Support Machine Properly and Use Proper Lifting Equipment Work In Ventilated Area

MIF MIF

If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Warning: California Proposition 65 Warning
Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Work In Clean Area
Before starting a job: 1. Clean work area and machine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts.

Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Using High Pressure Washers
Directing pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle.

Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Safety

-4

SAFETY
Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area.

Avoid Injury From Rotating Blades, Augers and PTO Shafts

MIF

Keep hands and feet away while machine is running. Shut off power to service, lubricate or remove mower blades, augers or PTO shafts.

Service Tires Safely

Service Cooling System Safely

MIF

Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

MIF

Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off machine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Safety

-5

SAFETY
Handle Chemical Products Safely Live With Safety

MIF

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

MIF

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

Dispose of Waste Properly
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Safety

-6

SPECIFICATIONS & INFORMATION TABLE OF CONTENTS
Specifications & Information

Table of Contents Fastener Torques..............................................9 Metric Fastener Torque Values ......................9 Inch Fastener Torque Values .......................10 General Information........................................11 Gasoline .......................................................11 Gasoline Storage..........................................11 Engine Oil - North America...........................12 Engine Oil - Europe ......................................12 Engine Break - In Oil ....................................12 Hydrostatic Transmission Oil........................13 Anti-Corrosion Grease .................................13 Alternative Lubricants...................................13 Synthetic Lubricants .....................................13 Lubricant Storage .........................................14 Mixing Of Lubricants.....................................14 Chassis Grease............................................14 Oil Filters ......................................................14 Serial Number Locations ...............................15 Product Identification Number (PIN).............15 Engine Identification Number - Kohler..........15 Engine Identification Number - Kawasaki.....15 Engine Identification Number Briggs & Stratton ..........................................15 Hydrostatic Transaxle Identification Number ..................................15

Specifications & Information Table of Contents - 7

8 .SPECIFICATIONS & INFORMATION TABLE OF CONTENTS Specifications & Information Table of Contents .

This will prevent them from failing when tightening.9 12.9 Property Class and Nut Markings 10 10 10 5 10 MIF Class 4. Check tightness of fasteners periodically.5 11 21 37 60 92 125 180 250 310 450 625 Class 8. Shear bolts are designed to fail under predetermined loads.9 Lubricated a Dry a N•m 13 32 63 110 175 275 375 530 725 925 1350 lb-ft 9.8 Lubricated a Dry a SIZE N•m M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 4.8 Property Class and Head Markings 8.9 Lubricated a Dry a N•m 15 37 75 130 205 320 440 625 850 1075 lb-ft 11.8 Lubricated a Dry a N•m 9 22 43 75 120 190 260 375 510 650 950 lb-ft 6.SPECIFICATIONS & INFORMATION FASTENER TORQUES Fastener Torques Metric Fastener Torque Values 4. a “Lubricated” means coated with a lubricant such as engine oil.5 24 47 80 130 200 275 400 540 675 N•m 17 40 80 140 225 350 475 675 925 lb-ft 12 30 60 105 165 225 350 500 675 Class 12.8 10 10 9. Reference: JDS . torque values should be applied to the NUT instead of the bolt head.5 35 70 120 109 300 410 580 1075 800 1350 1000 1150 850 1200 875 1000 1700 1250 1600 1350 2300 1700 2150 1850 3150 2350 2900 2350 4050 3000 3750 1150 2000 1500 1600 2700 2000 2150 3700 2750 2750 4750 3500 1300 950 1650 1200 1850 1150 850 1750 1300 2200 1650 2500 1450 1075 2250 1650 2850 2100 3200 DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application.9 10.5 20 40 70 110 175 250 350 475 600 Class 10.9 12 12 12 12.5 28 55 95 150 240 325 460 625 800 N•m 19 47 95 165 260 400 560 800 lb-ft 14.8 12 23 40 63 100 135 190 260 330 490 675 900 1150 lb-ft 3.8 9.8 9.8 8.8 or 9. Always replace shear bolts with identical grade.8 10. Tighten toothed or serrated-type locknuts to the full torque value.G200. Fasteners should be replaced with the same grade.9 4.9 12.9 .5 8. “Dry” means plain or zinc plated (yellow dichromate Specification JDS117) without any lubrication.8 10. or fasteners with phosphate and oil coatings. DO NOT use air powered wrenches.9 12. Specifications & Information Fastener Torques . When bolt and nut combination fasteners are used.5 16 32 55 88 140 195 275 375 475 700 N•m 11 28 55 95 150 240 330 475 650 825 lb-ft 8. Torque values listed are for general use only and include a ±10% variance factor.8 4.8 5 5 8.5 17 29 47 73 100 140 190 250 360 490 675 850 N•m 6 15 29 50 80 125 175 240 330 425 625 850 lb-ft 4. Make sure fastener threads are clean and that you properly start thread engagement.

Shear bolts are designed to fail under predetermined loads.2 Lubricated a Dry a N•m 9.5 20 35 55 85 125 170 300 490 725 900 lb-ft 7 15 26 41 63 90 125 225 360 540 675 N•m 12 25 44 70 110 155 215 375 625 925 lb-ft 9 18 33 52 80 115 160 280 450 675 Grade 8 or 8. b “Grade 2” applies for hex cap screws (Not Hex Bolts) up to 152 mm (6 in.7 7.5 10 16 25 36 50 87 140 210 300 425 550 Grade 2b Lubricated a Dry a lb-ft 4. “Grade 1” applies for hex cap screws over 152 mm (6 in.5 9 16 26 39 56 78 140 140 210 300 425 550 725 N•m lb-ft 7. and for all other types of bolts and screws of any length. “Dry” means plain or zinc plated (yellow dichromate Specification JDS117) without any lubrication.2 8 8.2 Lubricated a Dry a N•m 13.SPECIFICATIONS & INFORMATION FASTENER TORQUES Inch Fastener Torque Values SAE Grade and Head Markings 1 or 2b No Marks 5 5.) long. Torque values listed are for general use only and include a ±10% variance factor. or fasteners with phosphate and oil coatings.5 11 20 32 50 70 100 175 175 270 375 530 700 Grade 5. Check tightness of fasteners periodically.1 or 5.5 28 50 80 120 175 215 425 700 lb-ft 10 21 36 58 90 130 160 310 500 N•m 17 35 63 100 150 225 300 550 875 lb-ft 12. Reference: JDS .8 5.) long.7 10 17 28 42 60 85 150 240 360 510 725 950 3.5 7 13 20 31 45 62 6 12 22 35 53 75 105 110 190 175 190 270 290 375 470 530 570 700 750 1050 750 1300 975 1150 850 1450 1075 1850 1350 1300 950 1650 1200 2050 1500 2600 1950 1700 1250 2150 1550 2700 2000 3400 2550 2250 1650 2850 2100 3600 2650 4550 3350 head. 5.G200 1000 725 1250 925 990 1250 930 DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. When bolt and nut combination fasteners are used.2 2 SAE Grade and Nut Markings No Marks 5 8 MIF Grade 1 Lubricated a Dry a SIZE 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 N•m 3.5 26 46 75 115 160 225 400 650 N•m lb-ft N•m 4. Tighten toothed or serrated-type locknuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil. DO NOT use air powered wrenches. Make sure fastener threads are clean and that you properly start thread engagement. Fasteners should be replaced with the same grade.7 14 22 33 48 67 120 190 290 470 570 750 lb-ft 2.5 15 27 44 67 95 135 240 240 360 510 725 950 5. This will prevent them from failing when tightening. torque values should be applied to the NUT instead of the bolt Specifications & Information Fastener Torques . Always replace shear bolts with identical grade.10 .1 5.

allow it to cool sufficiently first. keep machine clean and in good repair . handle it with care. engine is hot. fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher. and faulty or damaged parts. it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling:•ONLY use a clean. oil. always fill gas tank outdoors. smoking. BE SURE to follow directions on container and to properly discard empty container.11 . BE SURE to properly discard unstable or contaminated gasoline. Keep gasoline stored in a safe. machine is near an open flame or sparks. debris. To avoid engine damage: • DO NOT mix oil with gasoline. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter. be sure fill cap is tight after fueling. unleaded gasoline is acceptable as long as: • The ethyl or grain alcohol blends DO NOT exceed 10% by volume or • Methyl tertiary butyl ether (MTBE) blends DO NOT exceed 15% by volume RFG (reformulated) gasoline is acceptable for all machines designed for use of regular unleaded fuel.SPECIFICATIONS & INFORMATION GENERAL INFORMATION General Information Gasoline 4 . engine is running. water or other foreign material out of gasoline. When storing the machine or gasoline. STOP engine. is HIGHLY CAUTION: Avoid Injury! Gasoline DO NOT refuel machine while: indoors. scale. Older machines (that were designed for leaded fuel) may see some accelerated valve and seat wear.free of excess grease. Use a water separator installed in the storage tank outlet. any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark. clean up any gas spills IMMEDIATELY. • Keep up with specified service intervals.Cycle Engines c FLAMMABLE. birth defects. MIF c 65 Warning:Avoid Injury! California Proposition CAUTION: Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer. gasohol blended. Use of alternative oxygenated. • Fill gas tank at the end of each day's operation to help prevent condensation from forming inside a partially filled tank. properly marked (“UNLEADED GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. Help prevent fires: fill gas tank to bottom of filler neck only. protected area. Specifications & Information General Information . Storage of gasoline in a clean. this includes any appliance with a pilot light. or other reproductive harm. • ONLY use clean. Gasoline Storage IMPORTANT: Avoid damage! Keep all dirt.

rings. provided they meet one of the following specifications: • CCMC Specification G4 or higher. SAE 30 . The following John Deere oil is PREFERRED: • TORQ-GARD SUPREME® . UNI-GARD™ .In Oil IMPORTANT: Avoid damage! ONLY use a quality break-in oil in rebuilt or remanufactured engines for the first 5 hours (maximum) of operation. from abnormal wear. John Deere BREAK-IN ENGINE OIL is formulated with special additives for aluminum and cast iron type engines to allow the power cylinder components (pistons. Engine rebuild instructions should be followed closely to determine if special requirements are necessary.API Service Classification SE or higher.SAE 30.SAE 30 UNI-GARD™ . John Deere BREAK-IN ENGINE OIL is also recommended for non-John Deere engines.SAE 10W-30. UNI-GARD™ . provided they meet one of the following specifications: • • • SAE 5W-30 . these oils will not allow rebuilt or remanufactured engines to break-in properly. The following John Deere oil is PREFERRED: • John Deere BREAK-IN ENGINE OIL. and liners as well) to “wear-in” while protecting other engine components.SAE 10W-30. based on their specified temperature range: • • • TURF-GARD® . use a break-in engine oil meeting the following specification during the first 5 hours (maximum) of operation: • SAE 5W-30 .SAE 30.SAE 10W-30. The following John Deere oils are PREFERRED: • • TORQ-GARD SUPREME® . Operating outside of these recommended oil air temperature ranges may cause premature engine failure.North America Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes.SAE 5W-30.SAE 10W-30. Other oils may be used if above John Deere oils are not available. TORQ-GARD SUPREME® . valve train and gears.SAE 5W-30. The following John Deere oils are also recommended.SAE 5W-30. Specifications & Information General Information . based on their specified temperature range: • • TORQ-GARD SUPREME® . If the above recommended John Deere oils are not available. PLUS-4® . DO NOT use oils with heavier viscosity weights than SAE 5W30 or oils meeting specifications API SG or SH.API Service Classification SG or higher.SPECIFICATIONS & INFORMATION GENERAL INFORMATION Engine Oil . The following John Deere oil is also recommended as a break-in engine oil: • TORQ-GARD SUPREME® . The following John Deere oils are also recommended. SAE 10W-30 .API Service Classification SC or higher.Europe Use the appropriate oil viscosity based on their expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. both aluminum and cast iron types. -10 SAE 10W-30 SAE 30 Other oils may be used if above John Deere oils are not available.API Service Classification SG or higher.SAE 5W-30. SAE 10W-40 SAE 5W-30 -40 -40 -22 -30 -4 -20 14 32 F 0 C 50 10 68 20 86 30 104 40 122 50 Engine Break . -10 SAE 10W-30 SAE 30 Engine Oil .12 . SAE 10W-40 SAE 5W-30 -40 -40 -22 -30 -4 -20 14 32 F 0 C 50 10 68 20 86 30 104 40 122 50 • • TORQ-GARD SUPREME® .

SAE 5W-30 J13A2 NLGI Grade 1 Hydrostatic Transmission Oil Use the appropriate oil viscosity based on these air temperature ranges. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. use the John Deere oil that is recommended for this engine. Other oils may be used if above recommended John Deere oils are not available. -10 5W30 or 10W30 Specifications & Information General Information . or types of oil. Synthetic Lubricants JDM J20C -40 -40 -22 -30 -4 -20 14 32 F 0 C 50 10 68 20 86 30 104 40 122 50 Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry classification and/or military specification) as shown in this manual.JDM J20C.JDM J20C can be mixed with 5W30 or 10W30 in this application.SPECIFICATIONS & INFORMATION GENERAL INFORMATION • SAE 5W-30 . NLGI Grade 1. Consult with your John Deere Dealer. Use LOW VISCOSITY HY .GARD® oil. to obtain the alternative lubricant recommendations.CCMC Specification G4 or higher.13 . grades. it is recommended that the factory fill be thoroughly removed before switching to any alternative lubricant. IMPORTANT: Avoid damage! After the break-in period. This grease is also superior in its resistance to separation and migration. or Sales Branch. The following John Deere oil is PREFERRED: • HY-GARD® . Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission or hydraulic system failures. IMPORTANT: Avoid damage! Use of alternative lubricants could cause reduced life of the component. provided they meet one of the following specifications: • John Deere Standard JDM J20C. The following anti-corrosion grease is PREFERRED: • DuBois MPG-2® Multi-Purpose Polymer Grease M79292. Avoid mixing different brands. IMPORTANT: Avoid damage! Use only the oils recommended. The recommended air temperature limits and service or lubricant change intervals should be maintained as shown in the operator’s manual. The following John Deere transmission oil is also recommended if above preferred oil is not available: • 5W30 or 10W30. HY-GARD® . BREAK-IN OIL -40 -40 -22 -30 -4 -20 14 32 F 0 C 50 10 68 20 86 30 104 40 122 50 -10 Other greases may be used if they meet or exceed the following specifications: • John Deere Standard JDM J13A2. -40 -40 -22 -30 -4 -20 14 -10 32 F 0C 50 10 68 20 86 30 104 40 122 50 Alternative Lubricants Conditions in certain geographical areas outside the United States and Canada may require different lubricant recommendations than the ones printed in this technical manual or the operator's manual. which is one of the major causes of corrosion. If alternative lubricants are to be used. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Anti-Corrosion Grease This anti-corrosion grease is formulated to provide the best protection against absorbing moisture.

The following John Deere oil filters are PREFERRED: • Automotive And Light Truck Engine Oil Filters. Most John Deere filters contain pressure relief and antidrainback valves for better engine protection. Mixing different lubricants can interfere with the proper functioning of these additives and lubricant properties which will downgrade their intended specified performance. Other oil filters may be used if above recommended John Deere oil filters are not available. Make sure all containers are properly marked as to their contents. provided they meet the following specification: • ASTB Tested In Accordance With SAE J806. J13E4 NLGI Grade 2 -40 -40 -22 -30 -4 -20 14 -10 50 10 68 20 86 30 104 40 122 50 32 F 0C Specifications & Information General Information . Store drums on their sides. Oil Filters IMPORTANT: Avoid damage! Filtration of oils is critical to proper lubrication performance. DO NOT use any BIOGREASE in this application. Mixing Of Lubricants In general. DO NOT mix any other greases in this application. Other greases may be used if above preferred John Deere grease is not available. Always change filters regularly. Use clean storage containers to handle all lubricants. • GREASE-GARD™ . provided they meet the following specification: • John Deere Standard JDM J13E4. The following John Deere grease is PREFERRED: • HIGH-TEMPERATURE EP GREASE® .14 . NLGI Grade 2. and other contamination. Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements. moisture.SPECIFICATIONS & INFORMATION GENERAL INFORMATION Lubricant Storage All machines operate at top efficiency only when clean lubricants are used.JDM J13E4. Store them in an area protected from dust. Operating outside of the recommended grease air temperature range may cause premature failures. avoid mixing different brands or types of lubricants. IMPORTANT: Avoid damage! ONLY use a quality grease in this application. Dispose of all old. Chassis Grease Use the following grease based on the air temperature range.JDM J13E4. NLGI Grade 2. NLGI Grade 2. used containers and their contents properly.

Engine Identification Number .Kohler M99656 Hydrostatic Transaxle Identification Number M99653 M99749 Specifications & Information Serial Number Locations .Briggs & Stratton M99748 Engine Identification Number .SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS Serial Number Locations Product Identification Number (PIN) When ordering parts or submitting a warranty claim.15 . it is IMPORTANT that you include the product identification number and the component product identification numbers.Kawasaki MX16331 Engine Identification Number . The location of identification numbers and component product identification numbers are shown.

16 .SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS Specifications & Information Serial Number Locations .

................19 Repair Specifications.. 54 Piston Ring End Gap Measurement ...............30 Crankcase Vacuum Test ........................................ 49 Camshaft Inspection ............. 59 Cylinder Block Removal and Installation ......35 Air Intake System Components.20 Torque Specifications (Alphabetical).................. 52 Governor Inspection ................................ 59 Cylinder Block Inspection ............................42 Valves and Springs Removal and Installation ...................................................... 55 Piston Assembly Measurement ...... 51 Balancer Shaft Removal and Installation........................45 Valve Seats Recondition ..........46 Breather Inspection .............................................. 52 Governor Removal and Installation .................43 Valves Inspection .................................................42 Cylinder Head Removal and Installation ..............................................................33 Fuel and Air Repair..................................26 Governor Adjustment ..................40 Stator Removal and Installation ....................Kohler Table of Contents Specifications ...............ENGINE .............................. 54 Piston Inspection ..... 53 Piston Assembly Disassemble .............. 54 Piston Ring Side Clearance Measurement.26 Throttle Cable Adjustment................25 Engine Will Start........................... 63 Engine . 48 Oil Pump Relief Valve Inspection ...................... 48 Camshaft Removal and Installation .......................... 57 Crankshaft Removal and Installation ........................................................................................... 60 Starting Motor ............ 53 Piston Assembly Removal ..17 .........................23 Special or Required Tools ................... 55 Piston Assembly .....................................Kohler Table of Contents ........................................41 Rocker Arms Removal and Installation .............................................................................. 56 Piston Installation............. 59 Cylinder Bore Deglazing ................47 Crankcase Oil Seal Removal and Installation ...35 Carburetor Removal and Installation.........................................KOHLER TABLE OF CONTENTS Engine ..........27 Slow Idle Screw Adjustment.27 Fast Idle Speed Adjustment .........................25 Tests and Adjustments ....... 51 Balancer Shaft Inspection......................................26 Choke Cable Adjustment.......................................................................................................24 Other Materials. 58 Crankshaft Alignment ........................... 48 Oil Pump Installation.....................47 Oil Pickup Inspection ...............................19 General Specifications ...... 58 Crankshaft and Main Bearing Inspection.....................................45 Lap Valves ...........................................................28 Automatic Compression Release (ACR) Check ......36 Fuel Pump Removal and Installation.................19 Tests and Adjustments Specifications.........................38 Engine Removal and Installation....... 49 Camshaft End Play Measurement .....................................37 Engine Repair............................................ 60 Voltage Regulator/Rectifier.35 Carburetor Inspection...........................................46 Oil Pan Seal Removal and Installation .........24 Diagnostics ....46 Oil Pan Removal and Installation .......43 Cylinder Head Inspection ...........31 Fuel Flow Tests ..............................27 Cylinder Leak Test ............................................................................ 50 Hydraulic Valve Lifters Inspection ...................42 Inspect Push Rod ......................38 Flywheel Removal and Installation............................................................32 Oil Pressure Test.................... 50 Hydraulic Valve Lifters Removal and Installation ......................................................

18 .ENGINE .KOHLER TABLE OF CONTENTS Engine .Kohler Table of Contents .

. . . . .) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 mm (3. . . . . . . . . . . 69 . . . . . . . . . . . . . 4 Valves . . . . . .0 mm (0. . . . .Vertical (Counterbalanced) Lubrication . . . . . . . . . . . . . . . . . . . .60 psi) Oil Filter . . . . . . . . . . . . . . . Overhead Valves Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 in. . . . . . . . . . . . Single Element. . . . . . . . . . . . . . . . . . . . . . . . .040 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 psi) Fuel Flow (Minimum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ml (1. . . . . . . . . .Automatic/Centrifugal Crankshaft Type . . . . . . . . . . . 67 mm (2. . . . . . . . . . . .8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 ± 100 rpm Fast Idle Speed . . . . . . . . . . . . . . . . . . .) Ignition Module Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 kPa (0. . . . . . . . . . . . . . . . 2:1 Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 kPa (4 psi) Crankcase Vacuum (Minimum At Operating Temp. . . . . . . . . . . . . .02 mm (0. . . . . . . . . . . 1. . . . . . . . . . . . . 1. . . . . . . . . . . . . . .76 . . . . . . . . . . 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Seconds) . . . . . . . . . . . . . . .1. . . None (Hydraulic Lifters) Oil Pressure (at 3350 rpm) . . . . . . .KOHLER SPECIFICATIONS Specifications General Specifications Engine Use . . . . . . . . . . . . . . . . . . . . . . . . . .0 hp) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5:1 Running Compression Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replaceable (Below Carburetor Float Bowl) Weight . . . . . . . . . . . . . . . . . . . . . . . . .) Fuel/Air System: Carburetor Slow Idle Mixture Screw Initial Setting . . . . . . . . . . . . . . . . . . . . . Kohler Model Number. . . . . . . . . . . . . . . . . . . Command 15 QT / CV15S-41571 Power . . . . . . . . . . . . . . . . . . . . . . Horizontal Discharge Below Frame Maximum Angle of Operation (With Full Crankcase) Continuous (All Directions) . . . . . . . . . . . . . . . . . . . . . .Kohler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Then 1 Turn Out Fuel Pressure (Minimum). . . . . . . . . . . . . . . . . . .9 qt) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 . . . . . . . . . . . . . . . . . Full Flow. . . . . . . . . . . 426 cm3 (26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm (4. . . . . . . . . . . . . . . . . .25 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .517 kPa (10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lightly Seat. . . . . . . . . . . . . . 40 N•m (30 lb-ft) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper w/ Outer Foam Element Muffler . . . . . . . . . . . .030 . . . .0. . 0. . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . .) . . . . . .) Automatic Compression Release Minimum Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 L (1. . . . . GT225 Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010 in. . . . . . . .4 qt) Crankcase Oil Capacity w/ Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Cylinders . . . . . . . . . . . .) Stroke . . . . 1. . . . . . . . . . . . . . . . . . .54 kg (87 lbs) Tests and Adjustments Specifications Valve Adjustment . . . . . . . . . Champion RC12YC Spark Plug Gap.19 kW (15. . . . . . . . . . . . . . . . . . . . . . . . .75 psi) (Minimum at 1250 rpm) . . . . . . . . . . . . . .ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Gerotor Pump 0 . . . . . . . . . . . . .040 in. . . . . . . . . . . . . . . . . . .0 US oz) Slow Idle Speed . . .413 kPa (0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type) Fuel Shut-Off Solenoid. . . . . . . . . . . . . .20° Maximum Angle of Operation (With Full Crankcase) Intermittent (All Directions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 cu in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 in. . . . . . . . . . . . . . . . . . . . . . . . . Spin-On Filter Crankcase Oil Capacity w/o Oil Filter) . . . . . . . . . . . . . . . . . . . . . . . 3350 ± 50 rpm Spark Plug Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 in. . . . . . .35° Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. . . . . . . . . . . . . . .3 L (1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . .127 mm (0. . . . .) Push Rod Maximum Bend . . . . . . . . . . .) Valves and Valve Lifters Hydraulic Lifter Clearance . . . . . . . . . . . . . .038 . . . . . . . . . 8. . 15. . .) Intake Valve Lift (Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .038 . . . . . . . .2873 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .970 . . . . . . .0575 . . . . . . . . . . . . . . . . . . . . . . . . . . .288 in. .7. . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . .) Maximum . . . . . . . . . . . . . . . . . . .278 in. . . 9. . . .0. . . . . . . . . . . . . . . . . .050 . . .) Intake Valve Guide ID: New . . . . . . . . . . .Engine Cold) . . . 0. . . . . . . . . . . . . .0015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENGINE . . . . . . . . .288 in. . .64 in. . . . . . . . . . 0. 7.) Valve Guide Reamer: Standard . . .030 in. . . . . . . . . . . . . . . . . . . .0023 . .) Intake Valve Stem OD. . . . . . . .288 . . . . . . .0. .000 mm (0. . . . . . . . . . . . .) Rocker Shaft Rocker Shaft OD: New . . . . . . . . . . . . . . . . . . . .) Exhaust Valve-to-Guide Clearance . . . . 1. . . . . . . 0. . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . .16. . . .7. . . . . . . . . . . . . . . . .002 . . . . . . .Engine Cold) . . . . . . . . . .7. . . . . . . . .298 mm (0. . . . . . . . . . . . . . . 15. . . . . . . . . . . .) Exhaust Valve Lift (Minimum . . .0005 . . . . . . . . . . . . . . . . . . . . . . . . . . .250 mm (0. . . . .) Wear Limit . . .) Oversize. . . . . . . . . . .25 mm). . . .0.238 mm (0. . . . . . . .4925 mm (0. . . . .134 mm (0. . . . .) Oversize. . . . . .284 . . . . . . . . . . . . . . . . . . . . . . . . . .16. . .20 . . . . . . .) Exhaust Valve Guide ID: New . .727 mm (0. . . . . . . . . . . .) Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275 in. . . . . .281 in. . . . . . . . .) Wear Limit . .7. . . . . . . . . . . . . . 15. . . . . . . . . . . . .) Exhaust Valve Stem OD . . . . .0.0124 .) Oversize. . . 0. .159 mm (0. . . . . . . . . . . . . . . . . . . . . .282 in. .Kohler Specifications . . . . . . . . . . . . .) Oversize. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0194 in. . . . . . . . . . .0. . . . . . . . .0035 in. . . .) Engine . . . . . . 0. . . . . . . .277 .274 . . . . . . . . . . . .0030 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2775 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . . . 7. . . . . . . . . . . . . . . . . . 0. . . . . . . .0501 mm (0. . . .5 mm (0.275 . . . . . . . . . . . . .285 . . . . .0. . . . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . . . . . . . .64 in. . . .) Valve Face Angle . . . . . . . . . . . . .0.058 mm (0. .619 in. .14 mm (0. . . . . . . . . . . . . . .0. . . . . .0. . . . . .) Crankshaft End Play . . .285 in.220 . . . . . . . . . . . .232 .988 mm (0. . . . . . . .76 mm (0. . . . . . . .0. . . . . . . . . .837 . . . . . .284 . . .0. 7. . .7. . . . . . . . . . . . . . . 7. . . . . .003 in. . . . . . .038 . . . . . . . . . . . . . . . .285 in. . . . . . . . . . .619 in. . .63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .837 . . . . . . . . .308 mm (0. . .727 mm (0. . . . . . . . . . . . . . . . . . . .076 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277 . . . . . . 7. . . . . . . . .076 mm (0.088 mm (0. . . . . . . .6. . . . . . . . . .127 mm (0. . . . . . . . . . . 44. .238 . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . .059 in. . . 7. . . . . . . . . . . . . . .45° Valve Seat Angle. . .) Intake Valve-to-Guide Clearance. . . . . . . . . . . . . .076 mm (0. . . . .058 mm (0. . . . . . . . . . . . . . . .) Valve Stem Bend (Maximum). . . 15. . . . . . . .) Rocker Arms Rocker Arm Bearing ID: New . . . . . . . . . . . . . 7.353 in. . . .308 mm (0. . . .0. . . .96 mm (0. . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . .0020 in. . . .5° Valve Margin (Minimum). . . . .) Oversize (0. . . . . .0. . . . . . . . . . . . . . . .278 in. . . . . 6. . .003 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276 in. . .287 . . . . . .KOHLER SPECIFICATIONS Repair Specifications Cylinder Head Cylinder Head Flatness (Maximum Warp) . . . . . . . . . . . . . . . . . .0. . . . .63 . . . . . . 7.048 mm (0. . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .360 in. . . . . . . . .982 . . . . .

20. . . 20. . . . . . . . . . . .0008 in. . . . . . . . . . . . . .5328 in. . . . . . . . . . . . . . . . . . 44. . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . .962 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7889 in. . .7884 in. . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . .7874 . . . . . .44. . . . . . . . . . . . . . . . . . . . .0. . .0. . . . . . . . . . . . . . . . . . . . . . . . .025 mm (0. . . . . . . . . . . . . . . . . . .0. . . . . 0. . . .6510 in. . . . . . . . . . . . . . . . . . . . .5433 . . .10 mm (0. .86 mm (1. . . . . . . . . . 19. .003 mm (1. . . . .) Maximum Taper. . . .025 mm (0.) Bore ID: New .0. . . . . . . . . . 0. . . . . . . . . . . . . . . . 38. . . . . . . . 0.) Maximum . .) Maximum Out-of-Round. . . . . . . .025 . . . . . . . .935 mm (1. . . . . . . . .0. . . . . . . . . . . . . .) Entire Crankshaft (In Bench V-Blocks) .0. . . . .765 in. . . 41. . . . . . . . . .000 . . . .0025 in. . . . . . Piston and Rings Cylinder Bore ID: New . . . . . . . . . . 44. . . . . . . .000 . . . . . . . . .) Maximum . . . . . . . . . . . . . .6502 . . . . . . . .45. . .959 mm (0. . . .965 . . . . 20. . . . . .7884 in. . . .) Bearing Journal OD: New . . . .5343 in. . .7874 . . . . . . . . . . . . . . .0. . . . . . . . . . .) (Clearance (New) . . . . . . . . .) Minimum . . . . . . . . . .84 mm (1. . . . . . . . . . . . . . . . .90. . .5443 in. . . . . . . . . . . . . .022 mm (0. .025 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19. . . . . . 20. . . . . .935 mm (1. . . . . . . . . .15 mm (0. . . . . . . . . . . . . 44. . .94 mm (1. . . . . . . . . . .0143 in. . . 20. . . . . .7718 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Minimum . . . . . . . . .0. . . . . . . . . .) Main Bearing Journal OD (Oil Pan End): New . . . . . . . . . . . . . . . . . . . . . . . . . .0. .21 . . . . . .0010 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .915 . . . . . .025 . . . . . . . . . .016 mm (1. . . . . .) Cylinder Bore. . . . . . . . . . . . . . . . . . . .063 mm (0. . . . .09 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . .45.958 . . . . . . . . .0. . . .025 mm (0. . 90. . . . . . . . .648 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7858 in. . . . . . . .) Minimum . . . . . . . . . . . . . . . . . . . . .38. . . .) Balance Shaft End Play . . . .KOHLER SPECIFICATIONS Crankshaft Bore ID (Crankcase Half): New . . . . . . . . . . . . . . . . . . . . . . .0. . . . .962 . . . . . . . . . . . . . . . . . . . . . . .975 mm (0. . . . . . . . . . . . . .0009 in. . . .127 mm (0. . . . . . . . . . . .0010 in. . . . . . . . . . . . . . .0035 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45. . . . . .005 in. . 0. .0010 in. . . . . . . . . . . . . . . . . . . . . . . 41. . . . . . . . . . . . . . . . . . . . . . . . . . . .7864 in. .038 mm (0. . . . . . . . . . . . . . . . . .7703 . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Clearance . . . . . . . . . . . .959 mm (0. .3625 mm (0. . .965 . . . . . . . 0. . . . . . . . . . . . . . . .) Balance Shaft Bearing Surface (Journal) OD: New . . . . . . . . .913 . . . . . . .7691 in. . . . . . 19. . .) Maximum Out-of-Round. . . . . . . . . . . . . . . . . . . . . . . . . . .025 mm (0. . . . . . . . . . . . . . . . . . . . .ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . .5338 . . . . . . . . . . . . . .1.7858 in. . . . . . . . . . . . . . . . . . . . . . . . . .0575 .1. . .) Minimum . . .19. .1. . . . . . 0. . . . . . . . . . . . . . . . . . 0. . .0005 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Crankshaft Bore (Oil Pan Half): New . . . . . . . . . . . . . . . . . . . .7703 . . . . . . . . . . . . . . . . . . . . . . . .012 mm (0. . . . . . . . . .0059 in. . . . . . .0023 . . . . . . . . . . . . . . . . . . . . . . . 45. .003 . . . .41. . . . . . . . . . . . . . .) Crankshaft Total Indicated Runout (TIR): PTO End (In Engine) . . . . . . . . . . . . . . . . . . . .970 mm (1. . . . . . . . . . .7864 in.20.) Main Bearing Journal OD (Flywheel End): New . . .7682 . . . . . . . . . . . . . . .) Maximum . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . 19.) Maximum Taper. . . . . . . . . . . . 38. . . .) Connecting Rod Journal OD: New . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . .) Bore ID: New . . . .19. . . . . . . . . . .0. . . 44. . . . . . .0039 in. . . . .025 mm (3. . . . . . . .0012 . . . . . . . . . . . . . . . . . . .0010 . . . .0012 . . . . . . . . . . . . . . .7889 in. . . . . . . . .038 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .7859 .) Maximum Out-of-Round. . . . . . . . . . . . . . . . . . . . . .7859 . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .003 mm (1. .076 . . . 0. . . . . . . . .975 mm (0.03 . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Maximum . . . . . . .) Clearance (New) . . . .Kohler Specifications . . . . . . . . . .7718 in. . . . . . . . . . . . . . . . .0035 in. . . . . . . . .000 . . . . . . . . . . .063 mm (0. . .03 . . . . . . . . . .0009 . . . . . .020 mm (0. . . . . . . . . . . . . . . .09 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1. . . . .7723 in. . . . . . . . . . . . . . . . . . . . . .016 mm (1. . . . . . . . .) Minimum . . . . . . . . . . .) Engine . . . . . . . . . . . . . . 0.) Camshaft End Play (with shims) . . . .0. . . . .) Maximum Taper. . . . . .7723 in. . . .) Clearance . . . .0025 in. .

. . .0. . . . . . . . . . . . . . . . . . . . . . . . . .951 . . . . . . . . .) Top and Center Compression Ring End Gap: New Bore . . . . . . . . . . . . . . . . . . . . . . . . . . .030 . . . . . . . . . . . . . . . .0. . . . . . . . . . . . .7490 in. .0. . . . . . . . . . . . . . . . . . . . . . . .2362 in. . . . . . . . . . .0. . . . . . . . . . . . .) Piston Pin OD: New . . . . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . . . .) Minimum . . . . . . . . . . . . . . . . . . . . . .060 . . . .41 mm (0. . .2382 in. . . . .) Gear Shaft-To. 89. . . . .) Top Compression Ring-To-Groove Side Clearance. . . . . . 0. . . . . . .0. . . . . . . . . .025 . . .2353 in. . . . . .22 . . . . . . . . . . . . . . .) Minimum . . . . . . . . .) Side .0. . . . .0012 .7483 . . . . . . 0.076 mm (0. 18. . . . . . . . . . .007 . . . . . . 0.89. . .0069 . . . .) Maximum . . . . . . . . . . . .012 mm (0. . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . .7478 in. 0. . . . . . . . . . . . .7485 in. . . . . . . .0015 . . . . . . . . . . . . . . . . . . . .0. . . . . . .7489 in. . . . . . . .) Oil Pump Cover-to-Rotor Clearance . . . . . . . .) Maximum . .025 mm (0. . .0006 . . . . . . . . . . . . . . . . .025 . . . . . . .) Maximum Out-of-Round. . . . . . . . . .Gear Bore Clearance . . . .7480 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19. . . . . . .) Gear Shaft OD: New . . . . .0. . . . . . . . . . . . . . . . . . . . . . .07 mm (0. . . . . . . . . .140 mm (0. . . . . . . . . . . . . . . . . .969 mm (3. . . . . . . . . . .12 mm (0.27 . . . . . . . . . . . . . . . . 19. 0. . . . . . . . . . . . .6. 0. .) Piston Thrust Face OD: New . .0. .) Piston Pin Bore ID: New . . . . . . .) Minimum . . . . . . . . . . 0. . .006 . . . .5413 . . . . . . . . . . . . . . . . . .19. . . . . . . . . . . . . . . . . . . . . . .) Maximum . 19. . . . . 0. . . . . . . . . . . .2352 . . . . . . 5.0025 in. . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000 mm (0. . . . . . . . . . . . .0007 in. . . .023 mm (0. .016 in.015 .028 mm (0.0041 in.0. . . . . . . 19. . . . . . . . . . . . . . . .) Crankcase Bore-To-Control Arm Clearance. . . . . . . . . . . . . . . . . 0. . .) Minimum . . . . . . . . . . . . . . . . .0012 . . . . . . . . . . . . . . .6. 6. . . . . . . . . . . . . . . . . . . . 0. . .0047 in. . . . . . . . . . . . . . . . . . . . . . . . .7495 in. . . .) Maximum Taper.977 mm (0. . . . . . . . . . . . . . . . . . . . . . .77 mm (0. . . . . . . . . . . . .000 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . .990 . . . . . . 0. . . . . . . . . . . . . . . . .015 . . . . . . . . . . . .0002 in. . . . . . . . . . . . . . .050 mm (0. . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . .030 in. . . . . . . . . . . . . . . . . . . .Kohler Specifications . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . .99 in. . . . . . . . . . .0. . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . .036 mm (0. . . . . .0016 in. . . . .7486 . . . . . .2347 in. . . . . . . .) Piston Pin Clearance . . . . .) Governor Crankcase Control Arm Bore ID: New . . . . .994 mm (0. .0010 in. . . . . . . . .020 in.003 in. 89.0. . . .) Maximum . . . . . . . . . . . . . . . . . . . . . 19. . . . . . . . . . . . . . .043 mm (0.0. . . . . . . . . . . . . . . . . . . . . .105 mm (0. . .0.0020 in. . . . . .0012 .0. . .063 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . .176 . .0. . .18 . . . . . .) Middle Compression Ring-To-Groove Side Clearance . . . . . . . . . . . .0023 . . . . . . . . . . . . . . .0055 in. . . . . . .) Oil Control Ring-To-Groove Side Clearance . . . . . 0. . . . . . . . .0. . . . . . .) Engine . . . . . .085 mm (0. . 0.19 mm (0. . . . . . 0. . .0. . . . . . . . . . . . . . . . . . . . . . . . . . .0022 in. . . . . . 25. . . . . . . . . .824 mm (3. . . . . . . . . . . . . . . .5420 in. . .51 mm (0. . . . . . . 0. . . . . . . .031 . . . . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . .0. . . . . . . . . . . .017 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .962 mm (0. . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Control Arm OD: New . . . . . . .0006 . . . . . . . . . . . . . . . . . . . .031 . . . . . . . . . . .0010 . . . . . . . . 90. . . . . . . . . .000 mm (0. .0030 in. . . . . . . .5681 in. . . . . . . . .19. . . . . . . .2372 .055 mm (0. . . .) Piston Thrust Face-To-Cylinder Bore Clearance: New . . . . . . . . .0. . . . . . . .63 mm (3. . .010 . .006 .ENGINE . . . . . . . . . . . . . . . .3. . . . . . . . . .) Oil Pump Relief Valve Spring Free Length . . . . . . . . . . .0016 in. . . . . . . . . . . . .043 mm (0.2387 in. . . . . . .) Connecting Rod Crankshaft (Big End) Clearance: New . . . . . . . . .6. . . . . .) Piston-To-Pin Clearance . . . . . . . . . . .995 .7478 . . . . . . 0.2358 . . . . . . . . . . . . . . . .) Used Bore (Maximum) . 18. . .075 mm (0. . . . . . . . . . . . . . .5363 in.040 . . . . . . . .0. . . . . . . . . . .015 . . . .05 mm (0. . . . . . . . .026 mm (0. . . . . . .0. . . . . .975 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Piston-to-Cylinder Clearance . . . . . . .KOHLER SPECIFICATIONS Maximum . . . . . . .0. . . .0011 in. . .2362 in. . . .0002 . . . . . . . . . . . 0. . . .) Piston Pin End ID: New . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) 6 mm Straight Shank Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Governor Arm Clamp Nut . . . . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. . . . . . . . . . . . . . . . . . . . . . .) Throttle Plate Cap Screw . . . . . 9. . . . . . . . . . . . .Kohler Specifications . . . . 32 N•m (24 lb-ft) Fan Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 N•m (55 lb-in. . . . . . . .) Oil Filter Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 N•m (65 lb-in. . . . . . . . . . . . . . . . . . . . . . . .) Muffler Nut. . . 4. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .3 N•m (65 lb-in. . . . .) Oil Pan Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 N•m (124 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. . . . .4 N•m (216 lb-in. . . . . . . . . . . . . . . .9 N•m (88 lb-in. . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . .) Engine . . . . . . . . . . . . . . . . . .5 lb-in. . . . . . . . . . . . . .0 N•m (35 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 N•m (30 lb-ft) Connecting Rod Cap Screws: 8 mm Straight Shank Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 N•m (65 lb-in. . . . . . . . . . . . . . . . . . . . 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 N•m (130 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . .) Final . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . . . . . . . .3 N•m (100 lb-in. . . . .0 N•m (35 lb-in. . . . . . . .7 N•m (200 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. .) Spark Plug. . . . . . . . . . . . . . . . . . . . . .) Step Down Shank Bolt . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . . 8. . . . . . . . . .3 N•m (65 lb-in. . . . . . . . . . . . . .) Oil Pressure Switch . . . . . . . . . . . . . . . . . . .) Voltage Regulator/Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Ignition Module Screw: New Installation (Thread Forming) . . . . . . .) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 14. . . . . . . . . . . . . . . . . . . . .) Governor Control Panel Screw . . . . . . . . . . . . . . . . 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Flywheel Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . .ENGINE . . . . . . . . . . . . . . . . . . . . . . . . .) Cylinder Head Cap Screw: Initial . . . . . . . 24. . . . . . . . . . . . . . . . 24 N•m (216 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 N•m (70 lb-in. . . . . . . . . . . . . . . . . . .) Replacement . . . . . .) Engine Mounting Cap Screws . . . .) Replacement . . . . . 40 N•m (30 lb-ft) Starting Motor Mounting Cap Screws . . . . .0 N•m (35 lb-in. . . . . . . .) Oil Filter . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Rocker Arm Pivot Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Fuel Bowl Nut . . . . . . . . . . . . . . . . . . . . . . . 7. . . . . . . . . . . .15 N•m (72. . . . . . . 24. . . . . . .2 N•m (55 lb-in. . . . . . . . . . . .) Oil Pump Cover Screw: New Installation (Thread Forming) . . . . . . . . . . . . . . . . . .9 N•m (88 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .KOHLER SPECIFICATIONS Torque Specifications (Alphabetical) NOTE: Use appropriate torque wrench which will read within the inch pound range given. . . . 9. . . . . . . . . 4. . . . . . . . . . . . . . . . . . . .) Stator Cap Screw . . . . . . . . . . . . . . . . . .) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 N•m (80 lb-in. . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 N•m (95 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (89 lb-in. . . . . . . . .) PTO Clutch to Engine Mounting Cap Screw . . .9 N•m (88 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . .4 N•m (216 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. . . . . . . . . . . . . . . . . . . . . . . . .0 N•m (35 lb-in. . . 68 N•m (50 lb-ft) Fuel Pump/Cover Screw: New Installation (Thread Forming) . . . . . . . . . . . . . . . . . . . . . . .) Valve Cover Cap Screw: New Installation (Thread Forming) . . . . . 20 N•m (177 lb-in. . . . . . . . . . . . . . . .23 . . . . . or convert inch pounds to foot pounds as follows: Inch-pounds ³ 12 = Foot-pounds Air Cleaner Base Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. . . . .7 N•m (95 lb-in.

) Tool No. 0 .24 .25 in.700 kPa (0 . M79292 Part Name MPG-2® Multipurpose Grease SCOTCH-BRITE® Abrasive Sheets/Pads Valve Guide Cleaner Lithium Base Grease Mineral Spirits Valve Lap Compound TY15130 / 595 LOCTITE® Form-in-Place Gasket Part Use Apply to engine crankshaft Clean cylinder head Clean valve guides Pack oil seals Clean armature Lap valves Rocker arm cover mating surfaces MPG-2® is a registered trademark of DuBois USA SCOTCH-BRITE® is a registered trademark of the 3M Co. LOCTITE® is a registered trademark of the Loctite Corp. Crankcase Vacuum Test Kit Oil Pressure Test Adapter w/ O-ring (required only on engines without test ports) Connector Hose Assembly Coupler Gauge.KOHLER SPECIFICATIONS Special or Required Tools Special or Required Tools Tool Name Reaming Tool (7. Tool Use Used to clean or size valve guides Used to bore oversize valve guide Used to remove and install valve springs Throttle and choke adjustment Automatic compression relief test.05 mm) Reaming Tool (7.100 psi) Lapping Tool JT07270 JT05719 JDM74A5 JT035029 JT05697 JT03503 JT07262 D20020WI JDG705 JDM70 6. crankshaft end play Slow and/or fast idle adjustment Slow and/or fast idle adjustment Used to prevent accidental engine starting during tests Cylinder leak test Crankcase vacuum check Oil pressure test JT05487 JT03017 JT03262 JT07034 Valve lapping Other Materials Other Material Part No. Engine .Kohler Specifications .ENGINE . valve inspection.25 mm) Valve Spring Compressor Drill Bit Dial Indicator Digital Pulse Tachometer Photo Tachometer Spark Plug Ground Cylinder Leak Tester U-Tube Manometer Test Kit.4 mm (0. or.

Check electrical system. No .Kohler Diagnostics . No .Go to next step. No . see Electrical section and refer to either Diagnostics or Tests and Adjustments for further guidance.Go to next step. Yes . contaminated fuel. (5) Is the engine hard to turn over by hand? Yes .Go to next step.4 volts or higher? Yes .Go to next step.4 volts or higher? Yes .KOHLER DIAGNOSTICS Diagnostics Engine Will Start Symptom: Engine Cranks But Will Not Start (3) Does fuel shutoff solenoid click when ignition switch is turned to START/RUN? Yes . No . (2) Is battery voltage 12. fuel mixture. See “Cylinder Leak Test” on page 28. No .Go to next step. (6) Is the choke operating properly? Yes .Adjust choke cable.Go to next step.Replace battery. See Electrical section. switch or wiring. Gasoline spray from the open cylinders may be ignited by ignition spark and cause an explosion or fire. Go to next step. Symptom: Engine Cranks But Will Not Start (1) Is battery voltage 12. No .Go to step 6. fuel lines.Check starter motor. or ignition coil air gap not adjusted. See Electrical section. or possible stuck float needle. Go to next step. or “Crankcase Vacuum Test” on page 31. Repair or replace as needed. Engine . (8) Are tappets adjusted properly. No .Replace battery. flywheel magnet weak.Charge battery and perform no-load test. No .Remove spark plugs and turn the engine over by hand.Starter motor defective. (4) Does engine crank slow? Yes .Adjust. and engine vacuum. (3) Does starter solenoid click when ignition switch is turned to START position? Yes . c engine mayAvoid Injury! BEatAWARE! The CAUTION: start to rotate any time.4 volts or higher? Yes . See “Fuel Flow Tests” on page 32. fuel pump. magneto shorted to ground.Defective fuel shutoff solenoid. Keep hands away from all moving parts when testing.Charge battery and perform no-load test.ENGINE . Go to next step. (7) Do spark plugs have strong blue spark? Yes .Go to next step. NOTE: To test specific electrical components. See “Choke Cable Adjustment” on page 26. c with starterAvoid Injury!plugs arerotate engine CAUTION: DO NOT if the spark removed. No .Go to next step. NOTE: Perform a visual inspection first to determine if battery cables are tight and not corroded and if battery is of sufficient size to turn the engine over at minimum cranking speed of 350 rpm. No .4 volts or higher? Yes . (2) Is battery voltage 12.Check fuel shutoff valve. No . Symptom: Engine Will Not Crank (1) Is battery voltage 12. (9) Is engine getting fuel? Yes .Possible defective spark plugs.25 .Pistons or other internal components binding.Check air leaner. No .

6. Pull throttle cable housing rearward to remove any slack in throttle cable. Move choke lever to full CHOKE position. Remove air cleaner assembly from carburetor. Move throttle lever to the slow position. B B A C A M99723 M99724 3. 2. C M99722 6. Adjust slow idle screw (C) to set low idle at 1550 ± 100 rpm. 7. 2. Engine . Start and run engine at MEDIUM idle for 5 minutes. Move throttle lever to full choke position. Correct adjustment also ensures choke is completely open when the choke lever is in the OFF (choke open) position. Loosen cable clamp (A) securing throttle cable. 8. Move throttle lever through full range to be sure linkage is not binding. Place throttle lever in fast idle position. Tighten throttle cable clamp. Carefully bend the choke rod at Vee bend (C) until the choke plate is fully closed. 4. Equipment: • • JT05719 Photo Tachometer. Procedure: 1. 8. Loosen choke cable clamp (A) and pull cable housing rearward to remove any slack in choke cable. Stop engine and set parking brake. Adjust fast idle screw (B) until fast idle is 3350 ± 50 rpm. the choke plate is not fully closed. Tighten choke cable clamp.KOHLER TESTS AND ADJUSTMENTS Tests and Adjustments Throttle Cable Adjustment Reason: To make sure the throttle cable moves the throttle and choke control lever through its full range of movement. 7. 4. Procedure: 1. 3. 5.Kohler Tests and Adjustments . Move choke lever to be sure choke linkage is not binding and choke plate fully opens when choke lever is in the OFF position. or. If the choke rod moves forward.26 .ENGINE . JT07270 Digital Pulse Tachometer Choke Cable Adjustment Reason: To make sure the choke plate is fully closed when the choke lever is in the full choke position. Try to move choke rod (B) forward (choke rod should not move). 5.

Move transaxle to NEUTRAL. . .27 . . repair governor. or. NOTE: Adjust throttle cable before adjusting governor linkage. If governor is not responding properly. . Be careful not to burn skin. Loosen nut (A). Procedure: 1. Put reflective tape on blower housing screen if using a photo tachometer. replace spring and readjust fast idle speed. 5.ENGINE . 2. Lock park brake. c CAUTION: Avoid injury! Engine will be HOT. Move throttle lever through full range to be sure linkage is not binding. Turn governor shaft (C) counter-clockwise until it stops. Equipment: • • JT05719 Photo Tachometer. . Lock park brake. 3350 ± 50 rpm 2. Tighten throttle cable clamp. 3. 6. 5. . 4. Move transaxle shift lever to NEUTRAL position. Pull throttle cable housing rearward to remove any slack in throttle cable. Slow idle is governed. use a digital pulse tachometer to check engine rpm at spark plug wire. JT07270 Digital Pulse Tachometer Procedure: 1. Engine . . B B A M99723 D C A M99723 4. Specifications: Fast Idle Speed Setting . .Kohler Tests and Adjustments . . check that governor spring is in correct hole (D) in governor arm. Use a photo tachometer to check engine rpm at the blower housing screen. . Equipment: • • JT05719 Photo Tachometer. . . or. Adjust fast idle screw (B) until fast idle is 3350 ± 50 rpm. or. Hold governor shaft and tighten nut. Hold top of governor arm (B) toward carburetor. Start and run engine at MEDIUM idle for 5 minutes. JT07270 Digital Pulse Tachometer To set engine slow idle stop screw. Place throttle lever in fast idle position. Move throttle lever to FAST idle position. . 3.KOHLER TESTS AND ADJUSTMENTS Governor Adjustment Reason: To make sure the governor shaft contacts the fly-weight plunger when the engine is stopped. 7. Loosen cable clamp (A) securing throttle cable. IMPORTANT: Avoid damage! DO NOT remove air cleaner for tests 2. If spring did not correct the problem. . Slow Idle Screw Adjustment Reason: Fast Idle Speed Adjustment Reason: To set engine fast idle rpm. Procedure: 1.

It may be necessary to adjust slow idle stop screw again. Move transaxle shift lever to NEUTRAL. .KOHLER TESTS AND ADJUSTMENTS 3. 1550 ± 100 rpm C B M85621 Cylinder Leak Test Reason: To check pressure capacity of piston rings and cylinder bore for efficient engine operation. . 8. Remove hood. . . Warm engine to operating temperature. Check slow idle rpm. Do CAUTION: Avoid Injury! especially the exhaust pipe or muffler while performing test.ENGINE . 2. M99723 7. 4. Equipment: • JT035029 Cylinder Leak Tester 5. . Move throttle between slow idle and fast idle several times. D Procedure: 1.Engine will be HOT. this is pre-set by manufacturer. or. 6. Start and run engine at MEDIUM idle for 5 minutes. Turn slow idle stop screw (A) in either direction until specified slow idle speed is reached. Pry off the flywheel screen. Move throttle lever to SLOW idle position. A A M89073 4. Use flywheel mounting cap screw (D) to turn flywheel and find approximate top dead center (TDC) of the compression stroke. . Disconnect crankcase breather hose (B) from valve cover breather port (C) and remove air cleaner element from engine so you can listen for air leaks. Specification: Slow Idle Stop Screw Setting . use a digital pulse tachometer to check engine rpm at spark plug wire. No preliminary adjustment is required for carburetor limiter slow idle mixture screw. and use a breaker bar (A) on the flywheel nut to hold the flywheel in position when performing the test. 5. Lock park brake. Engine . Use a photo tachometer to check engine rpm at the blower housing screen. 3.28 .Kohler Tests and Adjustments . G E H c not touch with bare skin. F M85624 6. .

11. NOTE: A slight air leak from the breather port (C) is normal as air escapes from the crankcase through the oil drainback hole in the head and breather valve. 10. Pressure should hold steady or reduce only slightly and only a faint air leak should be heard at the breather port.Turn flywheel clockwise until screen TDC mark is between shroud TDC mark and front cap screw. 13.Connect adapter hose (J) to tester.KOHLER TESTS AND ADJUSTMENTS 7. M85626 12. G E M N I J O F M85625 M85622 8. crankcase breather port. and exhaust outlet.Gradually turn regulator knob clockwise until needle aligns with “zero” of the yellow “SET” scale (L). Remove spark plug and put a wooden dowel on top of piston to find actual TDC of the compression stroke.Kohler Tests and Adjustments . IMPORTANT: Avoid damage! Have a helper put a wide blade pry bar (M) between two flywheel teeth (N) and up against engine block post (O) and firmly wedge the pry bar against edge of shroud opening.29 . Engine . Ground ignition high tension lead using JDM-74A-5 Ignition Test Plug (I) to protect ignition system and install test kit adapter hose (J) into spark plug hole.ENGINE . Watch and record gauge reading while listening for excessive air leaks at carburetor intake. Tighten spark plug to 40 N•m (30 lb-ft). K L C M85623 J 9. Then mark flywheel screen rib (E) and shroud (F) as shown between front (G) and left (H) shroud cap screws.Install hood.Remove test equipment and install spark plug. This must be done properly to prevent piston and crankshaft from turning in a clockwise direction when compressed air is applied. First turn regulator knob (K) on tester OFF (fully counterclockwise) then attach appropriate air source to coupler below black regulator valve. 14.

. . . . the automatic compression release tab is faulty and camshaft assembly must be replaced.0. . . . . . 0. . . . .030 . . . Use flywheel mounting cap screw to turn flywheel clockwise until intake valve opens fully. . . . . . exhaust valve bad. . . replace rings and hone cylinder. . . Slowly turn flywheel clockwise further to observe that the automatic compression release mechanism (ACR) on camshaft is functioning: • Exhaust valve (A) must begin to open as the intake valve is nearing its closed position. Specification: Automatic Compression Release (ACR) Check Reason: To determine if the automatic compression release is opening the exhaust valve. • Repeat Steps 2 and 3 to measure exhaust valve ACR minimum movement. . . . fix or replace Gauge Color Codes Green (low) . . . . . . . .02 mm (0. . . . . . . . . . . . . . . . . if so. . . . 2. . . . . . . . . . . . . . . . oil filler (piston rings) or muffler (exhaust valve) for escaping air will provide clues as to where to investigate for problems. . . . • Exhaust valve must return to its fully closed position as the flywheel is turned clockwise further. . . . compression good Yellow (moderate) . . . . . . . . . . intake valve bad. . “low-to-moderate” wear to intake valve excessive. .) Results: • If the exhaust valve does not open or depress properly. “low-to-moderate” wear to intake valve excessive. . . . . .Exhaust Outlet: slight . . Equipment: • • JDM-74A-5 Ignition Test Plug Dial Indicator Exhaust Valve ACR Movement Minimum . • Exhaust valve must continue to open for a distance after the intake valve is fully closed. .or replace short block Air Leaks . Remove valve cover and spark plug and use JDM-74A-5 Ignition Test Plug to ground high tension lead to protect ignition system while turning flywheel. . Air Leaks . . . . . . Procedure: 1. . Engine . . .ENGINE . . . . • Remove test plug and install spark plug. . . . . . . . . . .76 . . . . . . .040 in.1. . . . . . compression borderline Red (high) . . . . .KOHLER TESTS AND ADJUSTMENTS Results: Leakage should not exceed 25%. . . . See “Camshaft Removal and Installation” on page 49. . . . . . . . . . . . . . . rings or cylinder wall bad.30 . . . . . listening at the carburetor (intake valve). . . . 3. . . . . .Kohler Tests and Adjustments . .Carburetor: slight . . . . . . . . . . . • Remove dial indicator and install rocker cover. . fix or replace Air Leaks . . . . . . . . . . . ok excessive. . .compression bad A M55859 • Use a dial indicator on flat of spring washer to measure exhaust valve ACR movement. .Crankcase Breather: slight (normal). . . . . . Tighten spark plug to 40 N•m (30 lb-ft). .

Start engine. Equipment: • • JT05697 U-Tube Manometer Test Kit. if not. Hold finger over rubber plug hole to keep oil from spraying out.2 cm (4. M88761 Engine . Raise engine hood and remove dipstick. or. of vacuum 10.0 in. DO NOT use more than 3 feet of manometer tubing. test will be inaccurate.KOHLER TESTS AND ADJUSTMENTS Crankcase Vacuum Test Reason: To measure the amount of crankcase vacuum to ensure the crankcase is not pressurized. 3. Procedure Using JT05697 U-Tube Manometer: IMPORTANT: Avoid damage! Test must be run with the engine at normal operating temperature. Zero out the manometer by sliding the ruled scale up or down so “0” (C) is located where water level on both sides is even. 4. Open top valves (A) and (B) one turn. 9. 5.31 . B D 7. 8. Quickly attach clear line from manometer to rubber plug in dipstick opening. Gauge should show a minimum vacuum of 10. replace as necessary. DO NOT turn engine OFF until clear line has ben disconnected from U-Tube Manometer. The reading is obtained by adding (D) and (E) water movement from “0” position. 1.Kohler Tests and Adjustments . move the throttle lever to fast idle (3350 rpm) and allow engine to reach operating temperature.Record vacuum reading. IMPORTANT: Avoid damage! DO NOT make connection between U-Tube Manometer clear line and engine crankcase BEFORE engine is running or fluid in manometer could be drawn into crankcase.) of water movement. Install appropriate size rubber plug in dipstick tube. 2. Check dipstick/ oil fill cap and O-ring for cracks or damage. A E M88764 Picture Note: Example: 3 + 3 = 6 in.ENGINE . Insert barbed fitting in rubber plug so that clear line to fitting (A) can be connected at a later step. Attach manometer magnets to a solid metal surface. A pressurized crankcase will force oil to leak past the seals and through the breather into the carburetor. JT03503 Crankcase Vacuum Test Kit M88762 C 6. Park machine on level surface. If a longer hose is used the readings will be inaccurate.

IMPORTANT: Avoid damage! DO NOT make connection between test gauge (H) and rubber plug BEFORE engine is running at FAST idle or gauge damage may result. .Remove line from manometer before stopping engine. To repeat test. Continue with step #10. Move throttle to SLOW idle and turn engine OFF. 10. Gauge should show a minimum vacuum of 10.0 in. 2. DO disconnect test gauge WHILE engine is running at FAST idle to prevent damage to gauge. . Rings. Head warp. STOP engine and allow to cool. move the throttle lever to fast idle and allow engine to reach operating temperature.32 . . 10. . Valves and valve seats for wear or damage. 11. Fuel Flow Tests Reason: To determine fuel pump pressure and flow to the carburetor. . .2 cm (4. Rocker arm cover O-ring for leakage. water) NOTE: A new engine may have low vacuum readings due to the fact that the rings are not seated. Perform step #7 then reattach manometer tube to side “D”. Check for sufficient volume of fuel in tank to perform test. . 12. Hold finger over rubber plug hole to keep oil from spraying out. Check dipstick/ oil fill cap and O-ring for cracks or damage. F M85637 3. .0 in. Seals and gaskets for leakage. Specification: Minimum Crankcase Vacuum at 3350 rpm . 5. After test reading is made. . 8. Alwaysextremelya injury! Gasoline is flammable. Connect gauge. Disconnect spark plug wire and ground it with a JDM74A-5 Ignition Test Plug. 2.Remove rubber plug and install dipstick. 9. Start engine. Disconnect barbed fitting. Results: If crankcase vacuum does not meet specification. . Record crankcase vacuum reading. . . Install appropriate size rubber plug (F) in dipstick tube. clear line. c CAUTION: AvoidNOT SMOKE. This prevents damage to ignition system while cranking engine during test. . 6. Park machine on level surface. 3.ENGINE . and gauge from rubber plug while engine is running at FAST idle. Procedure Using JT03503 Crankcase Vacuum Kit: 1.2 cm (4. . Test Equipment: • JDG356 Pressure Gauge JDM-74A-5 Ignition Test Plug Graduated Container • • H G Procedure: 1. .Kohler Tests and Adjustments . 4. including equipment that utilizes pilot lights.). clear line. remove the manometer tube from top of manometer at “D”.KOHLER TESTS AND ADJUSTMENTS IMPORTANT: Avoid damage! Repeat test at least three times for accuracy. Park machine on level surface. replace as necessary. Engine . check the following: • • • • • • Breather reed valve clearance and condition. Hold finger over rubber plug hole to keep oil from spraying out. 7. 4.Stop engine then remove dipstick hose connection and install dipstick. . piston. and barbed fitting to rubber plug. Insert barbed fitting (G) in rubber plug so that clear line to fitting (A) can be connected at a later step. DO NOT remove manometer tube from engine. and cylinder bore for wear or damage. DO work in well ventilated area away from open flame or spark producing equipment. Raise engine hood and remove dipstick. .

• If after retest. Engine . minimum flow should be 30 ml (1. Record flow. oz). check carburetor inlet tube. Equipment: • JT07262 Oil Pressure Test Adapter w/ O-ring (required ONLY on engines without test ports) • M85605 E JT05487 Connector JT03017 Hose Assembly JT03262 Coupler JT07034 Gauge. or other problems. Disconnect hose (B) from carburetor inlet tube (C) and metal fuel line (D). replace fuel pump. • If fuel pump pressure or flow DO NOT meet specifications. D A B M85604 5. Oil Pressure Test Reason: D To verify that the engine has enough oil pressure to lubricate the internal engine components.5 seconds only. starter may be damaged. and float for proper function. reconnect hose to metal fuel line then carburetor inlet tube.Crank engine for 15 seconds only.33 . fuel pump pressure or flow DO NOT meet specifications.700 kPa (0 .Kohler Tests and Adjustments . The connector pipe thread (NPT) also matches the oil pressure switch port on early Kohler engines. minimum pressure should be 6. otherwise. Record pressure. Slide fuel line clamps (A) to right off the hose. put a shop cloth below carburetor inlet to soak up any escaping fuel. Connect JDG356 Pressure Gauge (E) hose to metal fuel line. and “Carburetor Inspection” on page 36.12 kPa (0. 0 . Turn key switch OFF. Results: • If fuel pump pressure and flow DO meet specifications. Crank engine for 3 . coupler. F D G M85606 10. fuel tank. NOTE: The connector.Remove test equipment.Remove pressure test equipment and install a long piece fuel hose (F) onto metal fuel line (D) and a large graduated beaker (G). 7. 12. 6.100 psi) • • • 8. varnish/sticking conditions. pickup tube. fasten with fuel line clamps. See “Air Intake System Components” on page 35.S. and gauge are found in other SERVICEGARD™ test kits. inlet needle. Wipe up any spilled fuel immediately.90 psi).KOHLER TESTS AND ADJUSTMENTS C 11. and fill cap vent for restrictions and retest.0 U. 9. hose assembly.ENGINE . obstructions. check fuel lines. and reconnect spark plug lead. respectively. On left side of engine. in-line filter.

Run engine for 30 seconds and stop engine. Check crankcase oil level and adjust to full mark. coupler.JT03262 Coupler . 6.JT07262 Oil Pressure Adapter w/ O-Ring Engine . 14. 11. coupler. Results: • If oil pressure readings are not within 69 . 4. -Oil suction screen -Oil passages A -Bearing wear -Oil Seals B E C D M91215 A B C D E .Check crankcase oil level and adjust to full mark. Remove oil filter and wipe filter base clean.0 .Install new oil filter. Connect spark plug wire. 13.KOHLER TESTS AND ADJUSTMENTS Procedure: 8. 16. connector.ENGINE . DO protective eye glasses and clothing.JT05487 Connector .0 psi) at FAST idle. 5. Disconnect spark plug wire and allow engine to cool. and gauge (B) on to oil filter base.JT03017 Hose Assembly . 2.Kohler Tests and Adjustments . hose assembly.Warm-up engine by running at MEDIUM idle for five minutes. A B c CAUTION:NOT touch with bare skin. inspect and/or replace the following: -Oil pump assembly. and gauge.STOP engine immediately and correct cause before continuing. M89105 1. 10.JT07034 Gauge . if oil pressure is below 28 kPa (4 psi) .Record oil pressure readings at SLOW and FAST idle. Stop engine.75.34 . See “Oil Pump Relief Valve Inspection” on page 48. 12. 3.Remove adapter. 9. hose assembly.517 kPa (10. ONLY hand-tighten adapter to oil filter base. 7. connector.Stop engine and allow to cool. Install pre-assembled adapter (A). Drain engine oil from oil filter. Monitor oil pressure during cranking. Perform test procedure with engine level. Wear are Avoid injury! Engine components HOT. 15.

Avoid Injury! Gasoline is extremelya CAUTION: DO NOT SMOKE.Cover .ENGINE .Knob .Gasket . Always work in well ventilated area away from open flame or spark producing equipment. including equipment that utilizes pilot lights.KOHLER FUEL AND AIR REPAIR Fuel and Air Repair Air Intake System Components F G A B E C D H I J Q P O N L M55326 M K Carburetor Removal and Installation C A B C D E F G H I J K L M N O P Q .9 N•m (88 lb-in. Turn ignition switch OFF and disconnect battery negative (-) ground cable.Stud A D B M89099 c flammable.)) .Wing Nut .Shield .Rubber Seal . Engine .Paper Element . Disconnect fuel shut-off solenoid wire.Air Cleaner Housing .Stud (Remove studs to remove carburetor) .Washer (Used on stud w/o electrical eyelet of grounding lead) .Foam Element .Kohler Fuel and Air Repair .35 .Sleeve .Gasket .Gasket . 2. Procedure: 1.Stud Retaining Screw (Use Thread-Lock & Sealer) .Nut (Tighten to 9.

Main Jet . See “Tests and Adjustments” on page 26.Choke Shaft .KOHLER FUEL AND AIR REPAIR 3.36 . and air filter assembly. . . 5.) J K F M E L N Carburetor Inspection A B O C D G I H M52127 A B C D E F G H I J K L M N O .Float Bowl . Tighten nuts.ENGINE .Choke Plate .Fuel Shut-Off Solenoid (Optional) .Throttle Plate .Needle . Always work in well ventilated area away from open flame or spark producing equipment.Avoid Injury! Gasoline is extremelya CAUTION: DO NOT SMOKE. securing carburetor and air cleaner assembly. 4. Adjust carburetor. 9. 9. 8. Remove and discard gaskets (D). Connect linkage rods and install carburetor.Choke Spring . .Seal c flammable. install new ones.Float .Inlet Seal .Kohler Fuel and Air Repair . Torque Specification: Air Cleaner Assembly Nuts .Fuel Screw . Disconnect linkage rods (C) from carburetor levers. 6.Body . . . Pinch fuel line (A) to block fuel flow then disconnect fuel line.Throttle Shaft . including equipment that utilizes pilot lights. to specification.9 N•m (88 lb-in. Engine . 7. .Idle Screw . Connect fuel line and remove clamp from line. Remove air filter assembly (see above) and carburetor. studs. . DO NOT damage threads of studs (B).

. Further disassembly will require replacing parts with new parts. Apply pressure on shafts to center plates in bore. . If throttle and choke plates were removed. 8. . this may indicate seat damage and carburetor may need to be replaced.3 N•m (65 lb-in.only turn screw (limited to maximum 1/4 turn in either direction) until specified slow idle speed is obtained. Clean chamber. . . no preliminary adjustment is required for idle mixture screw (A).) A 9. 7. 9.turn clockwise until LIGHTLY seated and back-out (counterclockwise) one full turn. .) Replacement. DO NOT remove idle port welch plug unless absolutely necessary. float. On standard carburetors.Perform slow idle adjustment. 4. Press new jet in until flush with surface.0 N•m (80 lb-in. To remove. then tighten screws. 7. 10. . . Clean out all passages. 6. . Clamp fuel line shut. pierce with sharp tool. . bent or broken. . NOTE: High altitude jet is available.37 . . 4. On new emissions carburetors. Install components in reverse order of removal. If screw is grooved. Cleaner may damage these components. . .KOHLER FUEL AND AIR REPAIR Procedure: 1. B M89103 A M58370 Picture Note: New Emissions Carburetor Engine . Install screws slightly loose. . Clean carburetor using pressurized carburetor cleaner and compressed air. Install new plug using a flat tool about the same size as plug. . . use a high strength thread lock and sealer on the small retaining screws. . . If inlet seat was leaking or damaged it can be replaced by pulling it out with a drill bit or screw. Low idle mixture screw has a precision taper. 2. . DO NOT soak carburetor in carburetor cleaner when fiber. . .ENGINE . 3. . . . 2. . . Replace with new jet. rubber or foam gaskets are still installed. inlet needle. this is preset by manufacturer . Torque Specifications: New installation (Thread forming) . 5. .Kohler Fuel and Air Repair . Press in new seat until it bottoms in bore. . IMPORTANT: Avoid damage! Further disassembly of carburetor is not required for general cleaning. . . Flatten plug but do not force below the surface of the cavity. See “Slow Idle Screw Adjustment” on page 27. Disconnect fuel lines (A). . Remove bolts (B) from fuel pump. low idle mixture screw and spring. Main jet can be pressed out. to set preliminary adjustment for idle mixture screw . . Fuel Pump Removal and Installation Procedure: 1. Disassemble bowl. . 3. Always replace with new parts.

Lock parking brake. c MOVING PARTS. Engine . F H G E M99571 A 7. Have a suitable container ready to catch draining fuel and prevent spillage. 6. Wait for all moving parts to STOP. 2. NOTE: Fuel may come out of fuel line when it is disconnected from the engine fuel pump. M M95517 J 5. Always work in well ventilated area away from open flame or spark producing equipment. Remove two lock washers and nuts (C) securing the muffler exhaust tube (D) to the cylinder head. 11. Remove nut and lock washer (I) from bottom of start motor solenoid (J). 3. B 8. level surface. Disconnect fuel hose from fuel pump elbow (G) by removing clamp (H).38 . Remove CAUTION: Avoid Injury! ROTATING BLADES/ ignition key. Remove four cap screws (A) and upper muffler heat shield (B).Kohler Engine Repair . including equipment that utilizes pilot lights.Avoid Injury! Gasoline is extremelya CAUTION: DO NOT SMOKE. 1. 4. Disconnect battery negative (-) cable from the battery. K C I L M99571 D M95525 9.KOHLER ENGINE REPAIR Engine Repair Engine Removal and Installation Removal: c flammable. Park machine on a hard. Plug end of fuel hose or raise end of hose above level of fuel tank to prevent fuel drainage.Disconnect positive (+) battery cable (K) and charging wire (L) from solenoid.ENGINE . Disconnect fuel hose (E) from J-clamp (F). Remove hood. See “Hood Removal And Installation” in Miscellaneous Section.Disconnect key switch connector (M) from solenoid. STOP engine. Open the hood. 10.

R NOTE: PTO clutch and traction drive sheave will fall off when cap screw and washer (Y) are removed.4 N•m (216 lb-in. Install engine to machine frame. 13. T S U V M99573 14. turn belt tensioner to relieve tension on belt.ENGINE . Install a new muffler gasket. 19. 12. 21. 17. Installation: Installation is the reverse of removal. c approximately 36Injury! Engine weighs CAUTION: Avoid kg (80 lbs). Engine .Remove PTO clutch. 3. and disconnect ground wires (O) and battery negative (-) cable (P) from engine ground bracket (Q). See “Electric Clutch Removal and Installation” in Electrical section. break-in oil should be used for the first five hours (maximum) of operation. Use a suitable hoist or obtain assistance when removing engine. locate the traction drive belt tensioner. Clean muffler flange and engine mating surfaces of any old gasket material. Using a pry bar.On underside of machine. 1.Remove cap screw and washer attaching PTO clutch and traction drive sheave to engine crankshaft. 18. If necessary. 20. and disconnect throttle (U) and choke cables (V) from engine.Remove engine from machine frame. Tighten muffler mounting nuts to 24.KOHLER ENGINE REPAIR P 15.Kohler Engine Repair . Tighten engine mounting cap screws to 32 N•m (24 lbft). Z Q W N Y O X M95555 16. and slip belt off of flat idler. 2.). hold flats (Z) on PTO clutch with a wrench to prevent engine crankshaft from turning. etc. 4.).Disconnect PTO clutch (W) electrical connector (X).39 .Remove four cap screws securing engine.Remove cap screw and nut (N). M99572 NOTE: Left closeout panel removed for clarity.Remove drive sheave.Loosen screws (S) on two clamps (T).Disconnect wiring harness electrical connector (R) from engine. NOTE: If the engine has been rebuilt (cylinder rebored or deglazed.

Install muffler heat shield. Slip traction drive belt into groove of traction drive sheave. 6. 22. Retain with four cap screws. Remove cap screw (C). M52084 A B Flywheel Removal and Installation Procedure: 1. 19. 15.Install PTO clutch to engine crankshaft. Be sure washer is installed with cup side toward PTO clutch. Rotate traction drive sheave to align keyways on engine crankshaft and drive sheave.Rotate tensioner assembly with a suitable pry bar to extend spring. 21.40 . Be sure clutch properly engages welded anti-rotation pin on machine frame. C 3. chips. 17. 7. NOTE: Flywheel and magnets are not serviceable. Replace as necessary.ENGINE . 24.Install hood. 14. M52085 Engine . 10.KOHLER ENGINE REPAIR 5. 13.Attach battery negative (-) cable and ground wires to engine ground bracket.Attach fuel line to fuel pump fitting.Attach negative (-) cable to battery. 5. 16. 23. Remove four fan cap screws and washers (B) and fan (A). Remove flywheel using a puller. 9. Slip traction drive belt on to flat idler. 8. Hold flywheel with strap wrench. 20. 11.Attach fuel line to engine J-clamp. 6.Install muffler flange lock washers and nuts. See “Engine Oil” in Specifications section. Retain with mounting clamps and screws. M52083 2. Inspect flywheel for cracks. Install square key into slots. 12. Install traction drive sheave to engine crankshaft with thicker hub side toward engine. Tighten cap screw to 75 N•m (55 lb-ft).Attach battery positive (+) cable and charging wires to engine start motor solenoid terminal. Retain with cap screw and washer.Attach choke and throttle cables to engine controls. Remove blower housing sheet metal.Attach key switch wire to engine start motor solenoid. Fill engine to proper level with oil of correct specifications. Inspect for sheared or partially sheared key. Apply DuBois MPG-2‚ Multi-Purpose Grease . Retain with hose clamp. 4. See “Throttle Cable Adjustment” on page 26.Connect engine wiring harness connector.Adjust throttle cable.Kohler Engine Repair . and broken teeth.Connect PTO clutch wiring harness connector.M79292 to engine crankshaft before installing engine drive sheave and PTO clutch. replace as necessary. 18.

. . . . .010 in.ENGINE . 2. . . Turn flywheel magnet (A) away from ignition module (B). . . . 68 N•m (50 lb-ft) Fan Cap Screws . . Remove clamp (B). • Install armature-with coil loosely.0 N•m (35 lb-in. .0 N•m (35 lb-in. .0 N•m (35 lb-in.25 mm (0. . B C A Stator Removal and Installation Procedure: 1. . . . Installation is done in the reverse order of removal. . . D C • M58360 Tighten four cap screws to 4. Hold flywheel with strap wrench. 8. . .) Flywheel Cap Screw . 4. . . . . . . . Tighten cap screws to specification. Tighten cap screw (C) to specification.) Stator Cap Screws . . Remove feeler gauge and connect wire (D) to terminal. 5. . . 4. . Specifications: Ignition Module Air Gap . 7.9 N•m (88 lb-in. Inspect for damage. See “Ignition Module Air Gap:” on page 41. . 7. . . and flywheel key is installed properly in keyway. 6.) Engine . Place 0. 9.) feeler gauge blade (E) or shim stock across magnet face. 9. .Kohler Engine Repair . . 5. . 6.KOHLER ENGINE REPAIR IMPORTANT: Avoid damage! Check that crankshaft end and flywheel hub are clean and free of lubricant. . . . 0. . Improperly installed flywheel can cause machine damage and serious personal injury. . . . Ignition Module Air Gap: 1.010 in. Remove two white stator wires (A) from connector. Remove flywheel.41 . • Adjust armature air gap. . . DO NOT tighten cap screws. 2. 4. . A B E 4. Check ignition module air gap.). . M58361A 3. Align flywheel magnet (A) with mounting posts for ignition module. .) Module Cap Screws . . . . . . . . Install flywheel and key on crankshaft. 3. Remove four cap screws (C) and stator. . IMPORTANT: Avoid damage! Ensure flywheel magnet is centered on ignition module so all three poles of the ignition module are properly gapped from the flywheel magnet. Disconnect ignition wire (D) from ignition module. . Loosen module cap screws (C). . . . . . . Remove ignition module. .25 mm (0.

1. Remove splash plate (E). 6. NOTE: Cylinder head can be serviced without removing engine from machine. . Remove rocker arms (C). Remove push rods (D).ENGINE . Engine . Remove valve cover. Installation is in reverse order of removal. Turn rod slowly and read variation on indicator. .KOHLER ENGINE REPAIR Rocker Arms Removal and Installation Procedure: 1. See “Rocker Arms Removal and Installation” on page 42. 0. 14 N•m (124 lb-in. Specifications: Rocker Arm Pivot Cap Screws .) Push Rod Bend (maximum) .42 M55861 . Cylinder Head Removal and Installation Procedure: B M55859 IMPORTANT: Avoid damage! Engine must be cold before removing cap screws to avoid warping aluminum cylinder head.030 in.Kohler Engine Repair . . 3.). IMPORTANT: Avoid damage! Loosen cylinder head cap screws (A) 1/4 turn at a time to avoid warping the head. . Remove spark plug. Clean mating surfaces of any sealant residue. 4. Inspect and replace components as necessary. IMPORTANT: Avoid damage! Mark push rods for assembly in original locations. • Apply TY15130 John Deere Form-In-Place Gasket to mating surfaces. .76 mm (0. to specifications.030 in. . 7.) Inspect Push Rod M50044 E B D C A • Inspect push rod for bend using V-blocks and a dial indicator. 2. Remove cap screws (A) and pivot ball spacers (B). 3. . Remove blower housing. Replace if variation is greater than 0. Remove rocker arms. in sequence illustrated. 2. .76 mm (0. . 4 2 1 A B 5 3 M83660 • Tighten rocker arm cap screws. 5.

Remove keepers (C). . . Clean valve cover and install using RTV silicone sealant between mating surfaces. 41 N•m (30 lb-ft) Rocker Arm Pivot Cap Screws .KOHLER ENGINE REPAIR 4. . . Install rocker arm assembly and cylinder head in reverse order. 5 3 M52075 Cylinder Head Inspection Procedure: 1.ENGINE . 1. . 7. 9. 5. 1 4. in sequence illustrated. 7. Tighten valve cover cap screws. Valves and Springs Removal and Installation Procedure: 4 2 A B 1 E 3 5 C M52074 D M55867 6. to 41 N•m (30 lb-ft). . 2. . 5. . 2. .) increments in sequence illustrated.43 . cap screws and spacer. . Install push rods and rocker arms. Tighten spark plug to 40 N•m (30 lbft). Compress spring (A) and install keepers (C) in grooves (D). .3 N•m (65 lb-in. spacer (B) and cylinder head. apply an approved room temperature vulcanizing (RTV) silicone sealant to bottom surface of bolt heads. Inspect head for cracks or damage. . . . Tighten cylinder head cap screws in 7 N•m (62 lb-in. Remove cap screws (A). Install valve components. . Install spark plug. . 14 N•m (124 lb-in. . . Remove carbon deposits and clean gasket surface with SCOTCH-BRITE® abrasive or equivalent. Make sure oil drain port is open. Clean head and block. Torque Specifications: Cylinder Head Cap Screws . spring caps (B). 4 2 3. 10. Discard gasket. . springs (A). . Install new gasket with cylinder head. Following tube instructions.) Valve Cover Cap Screws .) Engine . 8. IMPORTANT: Avoid damage! Make sure keepers (C) are seated in valve stem groove (D). Compress intake and exhaust springs using an appropriate size spring compressor. and valves (E).Install blower housing.Kohler Engine Repair .

988 mm (0.282 in.284 .) Standard (Wear Limit) . .) Oversize .) Exhaust Valve: Standard .275 in. 0. .) Oversize . . . 7.238 . .003 in.25 mm (0. .0015 . . . .238 mm (0. . .134 mm (0. replace cylinder head. . 7. . . 0.288 in.220 . .038 . Subtract valve stem OD (use largest OD) from valve guide ID to find valve stem-to-guide clearance.6. .276 in. . A Valve Stem OD Specifications: Intake Valve: Standard . .058 mm (0.284 . . . oversized valves must be installed. .288 . .) Valve Guides: NOTE: Valve guides cannot be replaced.281 in. .0. . . 1. .7.Kohler Engine Repair . . 7.) oversize.7.) Oversize (Wear Limit) . . . face. . . . IMPORTANT: Avoid damage! If guide is reamed oversized. . .) M52080 Oversize (Wear Limit) .0.0.0. . . .0. .291 in. . . . .010 in. . Replace cylinder head if guides are worn beyond oversize wear limit. . .0. . .25 mm (0. . . 7. .038 .076 mm (0. .0035 in.) 6. .0. . .7.384 mm (0. If guides have been reamed.7. M52082 5.285 in.0020 .982 . 7.277 . and stem with a power-operated wire brush. . . . . Measure outside diameter of valve stem at several points wear stem moves in guide. .277 . . .285 in. . If guide is worn beyond oversize wear limit. .7. 6.) Exhaust Guide: Standard . . Put head on a flat surface plate.0. . .301 in.0. an oversize valve must be installed.159 mm (0.003 in. 3. Replace head if distorted beyond specification. . Measure inside diameter of guide with gauge (A). . Replace valve if stem-to-guide clearance is too great.308 mm (0.088 mm (0.970 . .0. 7.278 in. . . . . . .) Oversize . . .) Exhaust . Standard valve guide reamer (D20020WI) can be used. . .0.) 2. 7. . Engine . .076 mm (0.050 . .287 . Clean inside of valve guide. . . . . . 7. .058 mm (0. . . . . . Check for distortion at several points with a feeler gauge. . but if worn can be reamed to 0.409 mm (0. . . .) 4. . .7.285 .000 mm (0. . .ENGINE .288 in. . . . .308 mm (0.0. If valve guide is worn beyond standard wear limit. .) M52081 Oversize . . . . 7. Be sure carbon is removed. Specification: Cylinder Head Warp (maximum) . . .7.) Standard (Wear Limit) .275 .278 in.038 . .44 . not merely burnished.274 . .) oversize is available. .KOHLER ENGINE REPAIR Valve Guide ID Specifications: Intake Guide: Standard . .232 . Valve Stem-to-Guide Clearance: Intake. 6.250 mm (0. 0. Remove carbon from valve head.010 in. 7. . ream guide using JDG705 Oversize Reaming Tool. . . NOTE: An 0. 3.

. . 45° Engine . .003 in. .5° Valve Face Angle . . . . .013/ 33.982/7. . .5 44.000 M55939 M51753 4. . Check seat for good contact using Prussian Blue Compound.ENGINE . .970/6. .5° 37. . . . Specification: Valve Stem Bend (maximum) . .37 1. .Kohler Engine Repair . . .KOHLER ENGINE REPAIR Valves Inspection Special or Required Tools: • Dial Indicator 1.37 Procedure: 1.988 6.033/ 7. . . 2.) Valve Margin (minimum) . Valve stem ends (C) should be square. . . face. . Replace if needed. Specification: Valve Seat Angle .5 Valve Seats Recondition Procedure: 31.987 6. Replace cylinder head if seats are warped or distorted beyond reconditioning.63/ 35.5° 34. . . .5 B A 7.058 C 3. Replace if variation is greater than specification.5 mm (0. Replace warped valves (A) or valves with less than serviceable margin (B). Inspect valve stems for bends using V-blocks and dial indicator. and stem with a power-operated wire brush.63/ 45° 31. . . . .033/ 7. . . . . .Exhaust Insert . . . . B A 44. . 4.013 D 6. . .) A B C D .058 C M38087 7. . Be sure carbon is removed. . Check valve for cracks or damage. not worn uneven as shown. . 1. . 44. . Inspect valve seats. .076 mm (0.987/ 38. . Turn valve slowly and read variation. 0. . . . . . .059 in.Intake Valve 1. 45° 35. . . . . Lap valves after refacing. . . Remove carbon from valve head. . Cut valve seating to specification.45 .Exhaust Valve . 2. not merely burnished. Reface pitted or worn seats as shown in drawing. . . . 3.Intake Insert . 5.

Replace crankshaft seals. Apply just enough to seal both sides of oil passage when case halves are fastened together. IMPORTANT: Avoid damage! DO NOT get sealant in oil passage (C). 2. M52134 1. Breather Inspection Procedure: A B C C D M55868 1. and reed (C). 2. 4. Lap mark must be on or near center of valve face. 2.ENGINE . Check position of lap mark on face. Clean mating surface of any sealant residue (D). plate (B). 4. M55901 Engine . Oil Pan Removal and Installation Procedure: Procedure: IMPORTANT: Avoid damage! Valves and seats should be lapped if they do not make good contact. Clean mating surfaces of crankcase and oil pan. and “Crankcase Oil Seal Removal and Installation” on page 47. Check valve every 8 strokes until a uniform ring appears around surface of valve face. 5.46 . then turn valve in seat using vacuum cup tool.Kohler Engine Repair . 1. Check that breather opening is clear. Apply light coat of lapping compound to valve face.KOHLER ENGINE REPAIR Lap Valves Special or Required Tools: • Lapping Tool 3. Apply a light coat of clean engine oil to seat and valve to prevent rusting. 3. 4. A B M55945 NOTE: Do not pry on gasket surface when removing oil pan from crankcase. 3. See “Oil Pan Seal Removal and Installation” on page 47. Wash parts in solvent to remove lapping compound. Remove cap screw (A). Remove cap screws (A). Replace reed if it does not lie flat on casting. Pry oil pan from crankcase using flat blade screwdriver on splitting tabs (B).

Remove and discard crankcase oil seal (A). When replacing crankshaft seals. IMPORTANT: Avoid damage! Be sure to align flats of balancer shaft and oil pump inner rotor when installing oil pan.49 .) or until its top surface is flush with machined bore opening. 6. apply a thin film of LOCTITE® 598 or equivalent to the OD of seal. Install oil pan onto crankcase. Using a suitable driver and disc (B). 4. Remove and discard seal (A). apply a thin film of LOCTITE® 598 or equivalent to the OD of seal. 8. 9. B 2.). 1.Kohler Engine Repair . Specification: 9 8 4 6 M52076 2 11 Oil Pan Seal Depth 2. Install oil pan over crankshaft carefully to avoid damaging main bearing seal. When replacing crankshaft seals. tighten oil pan cap screws to 24 N•m (216 lb-in. 1. IMPORTANT: Avoid damage! Be sure to align flats of balancer shaft and oil pump inner rotor when installing oil pan. Apply 1.47 . Engine . install new oil seal to specification. 12 10 1 3 5 7 M94785 3. Apply grease to inside lip of seal to aid installation. Oil Pan Seal Removal and Installation Procedure: Crankcase Oil Seal Removal and Installation Procedure: A A M55902 M55903 IMPORTANT: Avoid damage! DO NOT damage crankcase bore when removing seal. In sequence shown. Apply grease to inside lip of crankshaft main bearing seal.2. DO NOT block oil passage (C). IMPORTANT: Avoid damage! DO NOT damage pan bore when removing seal. Prepare and install oil pan.98 mm (0.KOHLER ENGINE REPAIR 5.ENGINE .6 mm (1/16 in.117 in.) bead of TY1530 John Deere Form-in-Place Gasket to oil pan flange.0. 7.098 . 2.

. 2.157 in. . . 4. . M52123 E D C Oil Pump Relief Valve Inspection A B Oil Pickup Inspection Procedure: 1.) 3. . . . . IMPORTANT: Avoid damage! Coat inside seal lip with grease to aid installation. . .19 mm (0. Replace parts that are damaged or worn.48 . . . and cap screw. Oil Pump Installation M55872 1. Clean screen with approved solvent. . Install oil pan. pump outer rotor (C). . and pump inner rotor (B). . pump. . . Remove and measure spring (A). Remove cap screw (A) and plate (B) to remove pickup screen (C). Inspect rotor. replace if not to specification. and wear. 25. Install components with retainer and cap screw. . . C 4. Replace if damaged. Loosen cap screw (C) and retainer (B) to gain access to individual components. .0 mm (0. Using a suitable driver and disc. . . . and body (D).KOHLER ENGINE REPAIR 3. 4. Inspect spring. and inside surface of cavity (A) for scoring. . . Install screen.ENGINE . . Remove cover (E).99 in. . 2. piston (E). .Kohler Engine Repair . 4. Carefully install crankshaft seal. 5. Install oil pan. discoloration. See “Oil Pan Removal and Installation” on page 46. Install crankshaft carefully to avoid damaging seal. plate. Specification: Crankcase Seal Depth . . . A B Specifications: Relief Valve Spring Free Length . install new oil seal to specification.) or until its top surface is flush with machined bore opening. 2. . Engine . . Procedure: A B C E D M94786 1. O-ring (D). 3.

.7858 in. .0. .975 mm (0.) Camshaft Inspection Procedure: A B Camshaft Removal and Installation Procedure: 1.127 mm (0. See “Oil Pan Removal and Installation” on page 46. .) 3. . Replace spring if necessary and check that weight moves freely.076 .Kohler Engine Repair . . . Inspect camshaft closely. Replace camshaft if measurements do not meet specifications. Coat entire camshaft with engine oil. . . . Install in cavity. . Lubricate parts (A. Oil Pump Cover Cap Screw Torque Specifications: New Oil Pan (Thread Forming) . . 5. A M55873 3. . Measure camshaft journals (A) at both ends. Engine . . .0. . If not within specification.) Oil Pump Cover-to-Rotor Clearance . M52091 D 5. . . . . Measure camshaft bore (D) in oil pan. .959 mm (0. 4. . . Remove oil pan. . Check camshaft end play. . 0.7864 in. replace as necessary. Tighten cap screws to specification.Align flat surface of balancer shaft with bore flat of oil pump inner rotor gear as you install oil pan. 2.KOHLER ENGINE REPAIR 3. 11. 5. . and valve cover. 6. Replace camshaft if lobes show excessive wear. . . B. 6. Replace parts as necessary. 10. .ENGINE . . . Install O-ring and cover. Rotate crankshaft to align two sets of marks (A). . . .) Used Oil Pan (Threads Cut) . . 7. . use appropriate shims from Camshaft Shim Kit. . . . . 19.) Maximum Wear Limit . . . A 2. .49 . . See “Cylinder Head Removal and Installation” on page 42. . .003 in.) Specification: Camshaft End Play . . . 4. . 6. . . . . .076 mm (0.962 . . Install camshaft with four timing marks (A) aligned. . . Inspect camshaft for worn or broken teeth. Inspect lobes (B). 0. . 9.2 N•m (55 lb-in.005 in. . . . . Remove camshaft (B). Inspect ACR mechanism (C). . . 4. 19. . . rocker arm assembly. . . 8. .Install push rods. . . .19. .003 .0. . . Subtract camshaft journal OD from bore ID to determine clearance with camshaft journal. See “Camshaft Inspection” on page 49.0 N•m (35 lb-in. and C) with engine oil. B Camshaft Journal OD New . Remove cylinder head. . M58327 C A Plastic Gear Camshaft Shims 1. Replace if not within specifications. . . . . 4.7859 .

.0. . . . .KOHLER ENGINE REPAIR Specifications: Oil Pan Camshaft Bore New .7844 in. . 0. . Yellow . .063 mm (0.0352 . . Coat lifters with engine oil and install in correct bore. . . M52092 0.) Maximum Wear Limit . . . . . . Blue . . Measure camshaft bore (E) in crankcase.) 0.0333 .50 .127 mm (0. .Kohler Engine Repair . . . .0. .0373 .0288 in. Camshaft End Play Measurement Procedure: 1. . . . 3.20.0. . . .7874 .063 mm (0. .) 0.0010 .0. Black .0.1.895 .883 mm (0.0293 . . . Gray . . . . .0. .0368 in. .0010 . .0. . Remove lifters (A).) Camshaft to Bore Clearance .0273 . . .) 7. . . Inspect lifters for wear. . . 20. Install camshaft. .005 in.) 2.025 .743 . Measure play (A) between camshaft and straight edge (spanning crankcase) using flat feeler gauge. 20.794 . .ENGINE .0. . .692 .) 0. .7889 in.781 mm (0. Red . . . Green. .0388 in. A M52093 Engine .0313 .0.0408 in. replace as necessary. . . . . IMPORTANT: Avoid damage! Used lifters are mated to their camshaft lobes.025 mm (0. . . .0. .0. A M85611 2. . Specifications: Crankcase Camshaft Bore (New) .0. .0. 20.0025 in. . Remove camshaft. . . Check that camshaft is seated in crankcase bore. . . . 5.) 0. . .025 mm (0.0393 .) Hydraulic Valve Lifters Removal and Installation Procedure: 1. .0. . . 3.035 mm (0. .025 .003 . . .000 . . . . .832 mm (0.946 .0308 in. .038 mm (0.0328 in. .994 mm (0.038 mm (0. .7889 in. . .845 .) Shim Thickness Range: E White . . .0.) (Maximum Wear Limit) . 8. . . .) 0. Replace if not within specification.0025 in. . .7874 . . Subtract journal OD from bore ID to determine clearance with camshaft journal. . . . .0. .0.730 mm (0. 0.000 . Mark them for installation in the correct bore. .984 mm (0. 4. 20. .076 . . 0. .0.0. . . .) 0. .20.0348 in. . .) Camshaft to Bore Clearance . . . . . .7884 in. Specifications: Camshaft End Play Specification: Maximum (with shims) . Use shims from Shim Kit as necessary until end play is within specification.997 . . . . .0. . . .0.

Remove balancer shaft (B). 0. Reassemble engine and allow 10 minutes for lifters to bleed down. When installing oil pan. Crank engine over by hand and check for compression. or force oil into lifter with oil can (shown above). Measure outside diameter of lifter. lifters have not bled down. 5. 2. Use push rod to depress plunger (B). Check camshaft before replacing lifters. Subtract lifter OD from bore ID to determine if clearance is not within specification. Replace components as necessary.0005 .) Balancer Shaft Removal and Installation Procedure: D C B A M55899 M85612 NOTE: When installing new lifters.ENGINE . 5. 2. replace as necessary.0. Check that oil hole (C) is clear to inner piston. . Replace lifters that are worn or damaged. Face should be flat and smooth. Align marks (A) on balancer shaft and crankshaft.0020 in. Wait 10 minutes more to allow lifters to bleed down. Measure inside diameter of crankcase lifter bore (D). make sure lifters are full of oil. Plunger should offer resistance but move smoothly.Kohler Engine Repair . 4. 4. If no compression exists or engine cannot be turned. . 7. until lifter feels solid. and may have trapped air inside.0124 . Engine . Inspect lifter face (A) for wear. be sure to align flat (D) of balancer shaft with bore flat of oil pump inner rotor gear.KOHLER ENGINE REPAIR Hydraulic Valve Lifters Inspection Procedure: IMPORTANT: Avoid damage! Damaged or worn lifters usually indicate a damaged camshaft. Specification: M52095 C 1. Align marks (A) and install balancer shaft (B) so it also aligns with governor gear (C). A D B M52097 6.0. Inspect balancer shaft. 3.0501 mm (0.51 . 3. 1. Submerge lifters in oil and use old push rod to pump lifter several times to purge air and fill with oil. Valve Lifter To Bore Clearance (maximum) .

) Maximum.0. Install control arm. . Inspect governor shaft/gear assembly (B).7874 . . 6. . . . . 0. 2. replace as necessary. .) Balancer Shaft to Crankcase Bore Clearance . Engine . Remove governor lever (not shown) from end of control arm (E).7884 in.063 mm (0. . . 0. if plastic gear.) Balancer Shaft to Crankcase Bore Clearance . washers (C).0009 . . .000 . Measure journals (A). Replace shaft if cracked or damaged.038 mm (0. . . . . . . .063 mm (0. 4. . .7889 in. . . . . . Install lever (not shown).19. . 2.0025 in. . C NOTE: Check governor shaft/gear assembly.959 mm (0. 3.025 mm (0. . . . Install governor shaft/gear assembly. .0. Install new seal (D) using suitable driver. . and governor control arm (A) from inside of crankcase. . .0025 in.0009 . .025 . . the complete assembly must be replaced. .0. . . .962 . . . . .7864 in. .000 . . . Replace if not within specification. . . Remove and discard seal (D). 5. . 5. . Subtract journal OD from bore ID to determine clearance with balancer shaft journal. . Measure balancer shaft bore (B) in crankcase.20. 19. . . .025 . .7889 in. and clip. .0.0.0. .7858 in. 20.7859 .ENGINE . . Replace oil pan if measurements not within specifications. 6.) Minimum . . 20. . 4. . Inspect shaft for cracks and broken teeth. . 19. .975 mm (0.0. Replace crankcase if measurements are not within specifications. . . . Determine clearance with balancer shaft journal.20. . . Remove spring clip (F). Governor Removal and Installation Procedure: B A C B D F E M52101 C 3. M52104 1. . washers. . . .038 mm (0. .025 mm (0. flyweight cap. flyweight assembly. . 20. 20. .KOHLER ENGINE REPAIR Balancer Shaft Inspection Procedure: Specifications: Balancer Shaft Journal OD: New .52 .) Balancer Shaft Oil Pan Bore ID: New . .) M52100 A 1.) Balancer Shaft Crankcase Bore ID: New . . 8.7874 . Measure balancer shaft bore (C) in oil pan. . M52102 7. . . . .Kohler Engine Repair . . . and/or shaft are damaged. .) Maximum. . .7884 in.

if present.2358 .2362 in.Kohler Engine Repair . Remove carbon ridge. Governor Control Arm Specifications: OD (New) .6.) B Piston Assembly Removal Procedure: M52106 1. . 2.53 .990 .KOHLER ENGINE REPAIR Governor Inspection Procedure: IMPORTANT: Avoid damage! DO NOT remove governor shaft with vise-grips or pliers.025 . Determine governor control arm shaft-to-bore clearance. . C M52105 1. install new governor shaft/ gear assembly by pressing or lightly tapping shaft into crankcase bore to specified height (C).140 mm (0.977 mm (0.0. .0055 in. . . .962 mm (0.639 . 6. . Replace block if inside diameter exceeds wear limit. . . . . 5. .063 mm (0. Replace governor shaft/gear assembly as necessary. .) 4. .) Wear Limit (Minimum) . 0. Replace if not within specification.) Diameter . B A C M55875 Engine . . Governor Control Arm-to-Crankcase Bore: Clearance . . 6.2372 . . damage to case may result. .) Diameter (Minimum).0. .975 . . Remove balance shaft.0. .6. . . .0. .842 mm (1.0010 . Replace governor shaft/gear assembly as necessary. Inspect flyweights (B) for proper operation and free movement. .2352 . if present at top of cylinder. . .050 mm (0. 6. . . .32. . . and camshaft.0.015 .285 . . Governor Gear Shaft Specifications: A Height (C) . . from cylinder before removing piston.) Gear Shaft-to-Gear Bore Clearance . . From inside of crankcase.) Maximum . 5. 32. . .0. . . using a ridge reamer. .) M42195 5. . Measure outside diameter of control arm shaft. . . .2347 in.0. 5. . . . 0. . .2353 in. . . Governor Control Arm Crankcase Bore: ID (New) . . .293 in.000 mm (0.000 mm (0.2382 in.0006 . .1.) 3. .025 . . With a small punch. . .0030 in. 2. . . CAREFULLY drive governor shaft toward inside of crankcase to remove it.075 mm (0. . . Measure inside diameter of crankcase bore (A). . . . . .2387 in. . .ENGINE . IMPORTANT: Avoid damage! Remove carbon ridge.2362 in. 5.6. .

Piston damage can result Piston Assembly Disassemble Procedure: B A A C M29946 2. Engine . . Remove piston assembly through top of cylinder.) Piston Ring End Gap (Used Bore) Maximum . . 0. Inspect parts. 6. Remove ring and file ends squarely until gap meets specification. . see following two topics.54 . 5. 4.) Piston Inspection Procedure: 1. Clean carbon from grooves using ring groove tool (A). Remove cap screws (A) to remove cap (B) from connecting rod (C).KOHLER ENGINE REPAIR 3. Piston Ring End Gap Measurement D M55894 Procedure: IMPORTANT: Avoid damage! If new rings are to be installed. Remove rails (A). Rings with too large a gap must be replaced.ENGINE .0. 1. See “Cylinder Bore Deglazing. . . . .” later in this section. 5. Clean piston. . all must be replaced as a set. . Inspect for scoring or fractures. If one piston ring needs replaced. to a point where it normally runs. .020 in. 1. . . 3. 3. Measure end gap (A). F E A H G M55878 4. Inspect piston assembly. . . IMPORTANT: Avoid damage! Do not use caustic cleaners or wire brush to clean aluminum piston. Specifications: Piston Ring End Gap (New Bore) .77 mm (0. 0. deglaze cylinder so rings will seat properly.0. Use a clean or new piston to push piston compression ring squarely into bore. 2. Remove spacer (D). Remove compression rings (C) from piston (B) using ring expander. M52110 2. .51 mm (0. Carefully remove piston rings. Use wooden dowel to remove pin (F) from piston and connecting rod (G).030 in. Remove retaining rings (E) by prying at indent (H). 3.Kohler Engine Repair . .27 . . .010 .

.085 mm (0. . . 2. . . Engine . . .) undersize.0069 .0. . . Measure inside diameter of connecting rod (B). D D M52148 5. . 4. Measure cylinder bore. 0.105 mm (0.060 .0010 in.ENGINE . Replace parts that are not within specifications.0. Measure piston ring side clearance (A) as shown at several points around piston. 0.0033 in. .25 in. Determine connecting rod-to-crankshaft clearance.0. .KOHLER ENGINE REPAIR Piston Ring Side Clearance Measurement Procedure: Piston Assembly Measurement Procedure: NOTE: Connecting rod is available 0. . 0.026 mm (0.0023 .0041 in. Tighten cap screws (A) to specification.25 mm (0. M52112 2. 6 mm (0. 3.0. .55 .) from skirt bottom and perpendicular to piston pin. Measure outside diameter of crankshaft journal (C). .) Oil Control Ring .0. .040 . . .) 1.Kohler Engine Repair .0. . .176 . .010 in.) Middle Compression Ring . M52125 6.0015 . A B A M52111 C 1. Specifications: Piston Ring-To-Groove Side Clearance Top Compression Ring . . Replace piston if measurements exceed clearance specifications. Measure diameter of piston at a point (D). .

.) M55898 F D C E G H Thrust Face to Cylinder Bore Clearance .0. .5363 in.) Crankshaft-to-Connecting Rod Clearance: New . . .56 . .“Pip” Mark . . .19.19. . Top compression ring has a blue Dykem stripe.7478 . . .043 mm (0.0.) Minimum . . .07 mm (0. . . . . . . . Install rings as shown on piston using ring expander. . . . .030 . . . .) Maximum . . . 19. . . . . 0. . . . . . .025 mm (0. . .) Cap Screw Torque: 8 mm Straight Shank .031 . . . . .5328 in. . . .7480 in. . .3. .994 mm (0. . . 14. 89. .055 mm (0.7478 in.89.38. . . 19. . . . . . .824 mm (3.015 .0. 89.036 mm (0. . . 11. .958 . . . . 19. .Piston .970 mm (1. .0010 in. . .) Wear Limit . . . . .Ring Gap . . . .012 mm (0.ENGINE . .Kohler Engine Repair . .5343 in. . .) Taper (maximum) . .7486 . Bottom compression ring has a pink Dykem stripe.5413 .Center Compression Ring .7495 in.Oil Rails . . . . . .0.006 . . Replace piston and/or rebore cylinder block if not within specifications. . . . . . . . .7489 in. 0. .) Connecting Rod Specifications: B A Piston Assembly Procedure: IMPORTANT: Avoid damage! Side of ring marked TOP faces top of piston with Dykem stripe to left of end gap. .) A B C D E F G H • . . . . .0. . . . .) Piston Pin Bore ID: New . . . . . . .Dykem Stripe . 0.) Piston Specifications: Piston Thrust Face OD: New . . . . . . . 22. . . .0016 in.Top Compression Ring . . .7485 in. . . . . . .7 N•m (200 lb-in. . 19. . . . . . .3 N•m (100 lb-in. . .) 6 mm Straight Shank . . . . .5338 . . . 18. .) Maximum . 0. .0012 . .7483 . . . .0. .025 mm (0. . . . . Piston Pin End ID: New .012 mm (0. . . . . . .) Minimum . . . 18. . .) Piston Pin OD: New .995 . .000 mm (0. . .5420 in.023 mm (0. . .94 mm (1. . . Crankshaft Specifications: Connecting Rod Journal OD: New . .1. .0022 in. . . 38. • Note shape of compression rings and install as shown • Compression rings should be installed with “Pip” mark up and Dykem strip to left of ring gap Engine . . . .951 . . .0025 in.0012 .KOHLER ENGINE REPAIR 7. . . 38. . . . .7 N•m (130 lb-in. . .) Maximum . . . . .) Step Down Shank . . . . . .0005 in.7490 in.0. .19. . . . . . .Oil Spacer Compression ring gaps should be staggered 120° 1. .) Out-Of-Round (maximum) . . . 0.969 mm (3. . .

Install piston with FLY mark (A) toward flywheel side of crankcase. . Compress rings with ring compressor tool.) Piston Installation Special or Required Tools: • Piston Ring Compressing Tool Procedure: 1. . 2. . and cap bearing surfaces with oil. Install pin (C) through piston bore (E) and connecting rod (D). . 4. . rod. . Use wooden dowel to push piston into bore. . 11.) 6 mm Straight Shank . . NOTE: Install piston pin before retaining ring to prevent possible scoring of bore. . . . . . . . camshaft.) Step Down Shank.0. . Install piston rings so piston ring end gaps are staggered 120° apart. . oil pan. M55871 A B C 4.3 N•m (100 lb-in.7 N•m (130 lb-in.ENGINE .57 .41 mm (0.0. and cylinder head. See appropriate procedures in this section. . . . . . Coat cylinder. 8. Install remaining retaining ring (B) in opposite side.7 N•m (200 lb-in. . . Fasten connecting rod (D) and cap (C) to crankshaft. 22. Connecting Rod Specifications: Cap Screw Torque: 8 mm Straight Shank . piston skirt. Check connecting rod to crankshaft side clearance. 6. .) Side Clearance . . Pin should install easily with thumb pressure. . 0. . 3. Replace if not within specification. . .KOHLER ENGINE REPAIR • Install oil ring spacer first. Install one piston pin retaining ring (B) in groove of piston bore (E). 3.18 . . . .007 . M55875 5. E D C M55879 B D 2. . .Kohler Engine Repair . 14.016 in. Install balance shaft. Engine . . . . 7. Tighten cap screws (B) to specification. Make sure that its ends do not overlap • • Stagger end gaps of oil rails 180° apart Rings should turn freely in grooves A IMPORTANT: Avoid damage! Retaining rings (B) should be installed with end gap (A) pointing up.

41.7682 . .) Out-of-Round (maximum) .913 . 5. 4. .84 mm (1. .765 in. . .) Out-of-Round (maximum) . Measure inside diameter of crankshaft main bearing bore (D) in oil pan. (B). . . 6. . . . . A M52115 4. or not within specifications. . . Remove and inspect crankshaft (A). Inspect for cracks or chipped teeth. . . Replace crankshaft if bent.) Taper (maximum) . .58 . damaged. .) Minimum . .) 2.KOHLER ENGINE REPAIR Crankshaft Removal and Installation Procedure: 1. . . . . . . .44. . .) A B C M52114 Flywheel End Main Journal OD: New . . . 41. . Replace parts if not within specifications. Check crankshaft alignment. . 0.022 mm (0. . Measure journals (A). . .935 mm (1.0008 in.935 mm (1. . 0. . . .ENGINE . . . .1. 44. .86 mm (1. . M52116 Crankshaft and Main Bearing Inspection Procedure: 1. . . Install crankshaft carefully. . . . 44. .020 mm (0. . . . . . Engine . . 0. .41. . .6502 .) Minimum . see next heading. .0010 in. .1. . . . . . . . DO NOT damage seals.025 mm (0.6510 in.025 mm (0. E B M58334 2. . and (C). . . Remove camshaft and balancer assemblies. . . Install new seals (B) in crankcase and oil pan.0009 in. . . 3. 0.0010 in. . .648 in. Subtract journal OD from bore ID to determine if clearance is within specifications. . . D 3.7691 in. Crankshaft Journal Specifications: Oil Pan End Main Journal OD: New . Measure inside diameter of crankshaft main bearing bore (E) in crankcase. .915 .) Taper (maximum) . . . . .Kohler Engine Repair . . . . . . . .

0010 in. . 0. . .09 mm (0.1. .) Taper (maximum) .0039 in. . . . two measurements 90° apart at top. . Replace block if any cracks are found.94 mm (1. .5343 in. . . . . Specifications: Crankshaft Maximum TIR: In Alignment Jig . . . coating becomes discolored at the defective area. . 4.) In Engine . Measure piston outside diameter perpendicular to piston pin bore.38. 44. . 3. .45. . . . Measure cylinder bore inside diameter at six places. In engine: • Rotate crankshaft slowly. . . . . . . .0059 in. . If crack is present. . . Clean and check block for cracks. . M80432 • Rotate crankshaft slowly.0. .012 mm (0.Kohler Engine Repair .ENGINE .) oversize. 0. . . . . 38. . . .5338 . Engine . .03 . . .50 mm (0.0012 . . . .958 .965 . . .5328 in. .0. . .020 in.970 mm (1. .1. . . . and bottom of ring travel. . .003 mm (1.7718 in.010 and 0. .) Cylinder Block Removal and Installation Procedure: Crankshaft Alignment Procedure: In alignment jig: M52133 All components must be removed from block before inspection or machine work can be performed. . .7703 .15 mm (0.0035 in. . .) Minimum . .10 mm (0.25 and 0. . . . Replace crankshaft if not within specification. . . 6. . Cylinder Block Inspection Procedure: 1.KOHLER ENGINE REPAIR Connecting Rod Journal OD: New .) M52125 5. 0. Replace block or bore cylinder to accept larger piston if clearance exceeds specification. 38. Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 percent kerosene and 75 percent light engine oil. Measure TIR at oil pan end of crankshaft using dial indicator. . .) Crankshaft Sleeve Bearing Bore Specifications: Oil Pan and Crankcase Main Bearing Bore ID. . 0. . 0. NOTE: Pistons and rings are available 0.) Out-of-Round (maximum) . . . . . 2.0005 in. middle. . . . . . Dial indicators (A) measure maximum Total Indicated Runout (TIR). Wipe area dry and immediately apply coating of zinc oxide dissolved in wood alcohol. . .59 . . . . . . .025 mm (0. .) Main Bearing Bore-to-Crankshaft Clearance .

.025 mm (3.063 mm (3. level surface. . 3. 6. . F E B C G A D M99571 5. . Clean abrasive residue from cylinder using warm soapy water until clean white rags show no discoloration. . Dry cylinder and apply engine oil.). . . . .0020 in. 4.000 . . . . .) Maximum . Deglaze cylinder bore using flex-hone to obtain 23 . . Remove nut and lock washer (A) from bottom of start motor solenoid (B).90. STOP engine. . .5443 in. Use the appropriate size flex-hone to deglaze cylinder bore.3. Specification: Deglaze Crosshatch Pattern .12 mm (0. . . . . . Analyze Condition: The starter overheats because of: • • Long cranking.Kohler Engine Repair . . . Open the hood. . Cylinder Bore Deglazing IMPORTANT: Avoid damage! Remove crankshaft and internal engine components when deglazing cylinder. Remove CAUTION: Avoid Injury! ROTATING BLADES/ ignition key. . . M58336 8. 23 .0012 . Disconnect positive (+) battery cable (C) and charging wire (D) from solenoid. .33° • Clean all battery cable connections before installing cable.043 mm (0. 90. . 0. . . Park machine on a hard. . . 90. . Installation is done in the reverse order of removal.0047 in. .) Taper (maximum) .05 mm (0. . . . Engage parking brake. . .KOHLER ENGINE REPAIR Specifications: Cylinder Bore: New . 0. 2. . NOTE: Connect negative (-) battery cable last. . .60 . . .) Piston-to-Cylinder Clearance .) Out-of-Round (maximum) . 1. . Remove two cap screws (F) and starter (G).5681 in. . 7. • Tighten cap screws to 24 N•m (216 lb-in. . . . .ENGINE . .0.0. .33° crosshatch pattern. . . Disconnect negative (-) battery cable at the battery.031 . . .5433 .0016 in.) Starting Motor Removal and Installation: c MOVING PARTS. . . Disconnect key switch connector (E) from solenoid. NOTE: Disconnect negative (-) battery cable first. . . Abrasives can cause engine damage. 4. Wait for all moving parts to STOP. 3. . . . . 0. 2. Engine . Armature binding. . 1. Disconnect positive (+) cable from starting motor.

Inspect parts for wear or damage.Armature .5 mm (0.ENGINE .KOHLER ENGINE REPAIR The starter operates poorly because of: • • • • • • Armature binding. 4.61 . Push pinion stopper (E) toward pinion (F) to remove retaining clip (D). Measure field coil brush lengths.Brush Springs .Front Cover . Mark body and covers for correct alignment during reassembly. (See “Inspection/Test” procedures below. Armature shaft spline. There should be no continuity.Kohler Engine Repair . 2. MX9622 Engine . end caps.Insulator . 4. A B C D E F G H I J K L .).413 in. J G I A B D M51705 C H 3. 2.Pinion Stopper . Test solenoid terminals (A and B) for continuity. If housing or armature is damaged.Solenoid . There should be continuity. starter armature (G) and brushes (O). Dirty or damaged starter drive. Test solenoid (C). Depress switch arm (C). Fields in starter are permanent magnets and are not serviceable. opens. Inspect brush springs for wear or damage. Points where shaft contacts cover. 3. Test for open circuits between terminal (B) and tang (D). A Inspection and Test: E D E F B L K C E L 1.Shift Lever .End Cover . Replace if necessary. If any one brush length is less than 10.) Assembly is done in the reverse order of disassembly. 5. or grounds in armature. and starter drive. Battery or wiring defective. Disassembly and Assembly: 1.Brush NOTE: Starter repair is limited to brushes. Apply a thin coat of multipurpose grease to: • • • Sliding surfaces of armature and solenoid shift lever. Excessive voltage drop in cranking system.Retaining Clip . replace starter.Brush Holder . Shorts. Badly worn brushes or weak brush springs. replace all four brushes.Pinion . There should be continuity when arm is fully depressed.

8. the coil is grounded and the field coil housing must be replaced. Touch one probe of tester to field coil brush and the other probe to the field coil housing. If there is continuity. it is defective and must be replaced. M50115 9. M50112 12. If there is no continuity. replace armature.If test indicates short circuited windings. Use only mineral spirits and a brush. Check armature again. If test shows no continuity. the field coil is open and the field coil housing assembly (G) must be replaced. Test for open field coil. Inspect for this condition.ENGINE . If test still indicates short circuit. Touch one probe of tester to each field coil brush (F). Engine . a winding is grounded and the armature must be replaced.Test for open circuited windings using an ohmmeter.KOHLER ENGINE REPAIR 6.Locate short circuits by rotating armature on a growler while holding a hacksaw blade or steel strip on armature. The hacksaw blade will vibrate in area of short circuit. Armature windings are connected in parallel. G 11. Be sure the brush lead is not touching the frame. Test for grounded field winding.Kohler Engine Repair . If solenoid fails any test. Test for open circuits between tang (D) and body (E). Touch probes on each commutator bar. so each commutator bar needs to be checked. NOTE: Shorts between bars are sometimes caused by dirt or copper between bars. If test shows continuity. There should be continuity.62 . M50116 M50113 13. Solvent can damage insulation on windings. clean the commutator of dust and fillings. Touch probes on each commutator bar.Test for grounded windings using an ohmmeter. 7. there is an open circuit and armature must be replaced. IMPORTANT: Avoid damage! Do not clean armature with solvent. F MIF 10.

3. 4.Kohler Engine Repair . 1.KOHLER ENGINE REPAIR Voltage Regulator/Rectifier Removal and Installation: IMPORTANT: Avoid damage! Disconnect battery negative (-) cable (if engine is still in machine) to prevent damage to voltage regulator/rectifier.3 N•m (65 lb-in. Disconnect battery negative (-) cable. B A C M83666 2.). Installation is done in the reverse order of removal. Disconnect wiring harness connector (A).63 .ENGINE . Remove voltage regulator/rectifier. Engine . Remove cap screws (B) and ground wire (C). • Tighten cap screws to 7.

ENGINE .KOHLER ENGINE REPAIR Engine .64 .Kohler Engine Repair .

........................76 Choke Cable Adjustment.....................................................85 Carburetor Inspection................................67 Torque Specifications.............................77 Without Cylinder Leak Tester .....................96 Valve Installation ..................................................82 Repair.....65 .............95 Valve Removal ..........................................70 Tests and Adjustments ...87 Carburetor Assembly..............82 Air Cleaner Removal and Installation .......................................................................82 Upper Blower Housing Removal and Installation .......96 Piston......................................77 With Cylinder Leak Tester ......70 Engine Diagnostics.......................97 Piston Inspection ..................... Rings and Rod Removal and Installation .......................83 Carburetor Disassembly..............................................76 Throttle Cable Adjustment.....98 Cylinder Bore Inspection ...........................92 Cylinder Head Inspection and Repair..........................................................80 Valve Clearance Adjustment ......................Briggs and Stratton Table of Contents ...........69 Diagnostics .67 Repair Specifications..76 Fuel Shutoff Solenoid Test .. 102 Flywheel Removal and Installation ................ 111 Starting Motor Disassembly and Inspection .........................67 Tests and Adjustments Specifications......77 Compression Test ..................... 101 Resizing Cylinder Bore . 110 Starting Motor Removal and Installation............................................. 105 Magneto Bearing Inspection ..............................................................101 Cylinder Bore Cleaning.95 Valve Inspection and Repair ......79 Governor Adjustment .............................................81 Ignition Armature Air Gap Adjustment......... 109 Oil Pump Removal...................................................83 Carburetor Removal and Installation..88 Engine Removal and Installation.............69 Special or Essential Tools ....................................BRIGGS AND STRATTON TABLE OF CONTENTS Engine ................................101 Cylinder Bore Honing ..98 Connecting Rod Inspection ........................................................................Briggs and Stratton Table of Contents Specifications ................... 112 Starting Motor Assembly....................90 Cylinder Air Guides Removal and Installation .. 109 Lubrication ...........................81 Engine Oil Pressure Test ............... 108 PTO and Cam Bearing Inspection ................................................. 113 Engine ........... 103 Crankshaft Removal and Installation ...................95 Valve Guide Ream ......78 Carburetor Adjustment ...........................................67 General Specifications ...ENGINE ...........92 Cylinder Head Removal and Installation ..............................................................................................................................................92 Intake Manifold Removal and Installation................

66 .Briggs and Stratton Table of Contents .BRIGGS AND STRATTON TABLE OF CONTENTS Engine .ENGINE .

. . . . . . . .234 . . . . . . . . . . . . . . . . . . GT235 and GT235E Make . . . . . . . . . .0. . . . . . . . . . . . . 5. . . . . . 1. . . . . . . . . . . . . . . . . . . .) Valve Seat Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Element with Foam Pre-cleaner Muffler . . . . . . . . . . . . . . . . .006 in. . . . . . . . . . . . . . . . . . . . .) Repair Specifications Valves: Valve Guide Standard Dimension . . . . . . . . . . .234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281 in. . . . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .062 in. . . . . . . . . . Replaceable Full Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E35777A-0113 Horsepower. . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 in. . . .) Valve Stem Wear Limit Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Valve Margin (Minimum). . . . . . . . . . . . .91 mm (0. . . . . . . . . . . . Air Cooled with Oil Cooler Air Cleaner . . 13. .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . . . . . . . . . 5. . . . . . . . . . . Overhead Valves Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233 in. . . . . . . . . . . . . . . . . . .) Exhaust . . . . . . . . . . . .16 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 . . . . . . . . . . . . . . . .91 mm (0. . . . 3350 ± 50 rpm Oil Pump Operating Pressure . 5. . . . . . . . . . . . . . . . . Spin-On Filter Cooling System . . . . . . . . . . . Horizontal Discharge Below Frame Tests and Adjustments Specifications Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 L (1. . . . . .7 cu in. . . . . . . . . . . . . . . . . . .7 mm (0. . . . . . . . . . . . . . . . . . . . .030 in. . . . . . . . . . . . . .45° Valve Seat Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Valve Guide Depth . . . . . . 1. .233 in. . . . . . . . . . . . . . . . . . . . . . . Fully Pressurized Crankcase Oil Capacity w/o Oil Filter . . . . 72 mm (2. . . . . . . . . . . . . . . . . . .) Slow Idle . . . . . . . . . . .65 L (1. . . . . . . . . . . 2 (V-twin) Stroke/Cycle . . . . . . RC12YC Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350777-1137 Model Number GT235E . . . . . . . . . . . .008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 qt) w/ Oil Filter . . 0. . . . .0. . . . . . . . . . . . .02 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Ignition Coil Air Gap. . . . . . . . . . . .1. . . . . . . . . . .004 . . . . . . . 30° Engine . . . . . . .0. . . . . . . . . . . Briggs & Stratton Vanguard V-Twin Model Number GT235. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 . . . .BRIGGS AND STRATTON SPECIFICATIONS Specifications General Specifications Engine Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . .4 mm (0. . . . . . . . . . . . . . .6. . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 ± 100 rpm Fast Idle . . . . . . . . . . . . . .237 in. . . . . . . .96 mm (0. . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (0. . . . . . . .) Valve Stem Standard Dimension Intake . . . . . . . . . . 0. . .047 . . . . . . . . . . . . . . . . . . . . . . . .) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344 kPa (10 . . . . . . . . . . . . . . . . . . . . . . . . .6 mm (0. . . . . . .2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 in. . . . . . . . . . . .236 . . . .50 psi Spark Plug Type . . . . . . . . . . . . .) Displacement . .76 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Briggs and Stratton Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 570 cm3 (34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .016 in. . 0. . . . . . . . . . . . . . . . . . . . . . . .235 in. . . . . . . . . . . . . . . . . . . . . . . . . . .83 in. . . .4 kW (18 hp) Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 qt) Oil Filter . . . . . 70 mm (2. . . . . . . . . . . . . . . . . . . . . .) Cylinders . . . . . . . . . .92 mm (0. . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01 . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . .94 . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . .

. . . .) Wear Limit . . . . . . . . . . .377 . . . . .008 in. . . . . . . . . . . . . . . . . .) Cam Gear PTO Journal Standard Dimension . . . . . . . . . . . . . . . .92 mm (1. . . . . . . . . 17. . . .789 in. . . . . . . . . . .35. . . .92 mm (0. . . . . . . . . . . . . . . . .3805 in. . . . . 34. . . . . . . .) Wear Limit . . 0. . . . . . .) Wear Limit . . . .0. . . .) Magneto Bearing Standard Dimension . . . . . . . . . . . . .629 in. . . . . . . . . . . . . 17. . . . . . . . . . . . . . . . . . . . . . . . .788 in. . . . . . . .97 mm (1. . . . . . . . . . . . . . . . . . 34.191 in. . . . .376 in. . . . . . . . . . . . . . . . .04 mm (0. . . . . . . . . .) Wear Limit . . . . . . .35.377 in. . . . . . .672 in. . . . . . . .) Wear Limit . . . . . . . .95 mm (1.460 in. . . . . . . . . . . . . . . . . . 35. .68 . . . . . . . . . . .787 . . . . . .07 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375 in. . . . . .674 in. . . .379 . . . . . . . . . . . . .95 . . . . . . .628 . . . . . . .20 mm (0. . . . . . . . . . . . . . .673 in. 37. .) Wear Limit . . . 30. . . . . . . . . . .0. . . . . . . . . . . . . . . . .72. . . . . . . . . . . . . . . . . . . . .20 . . . . Dimension . . . . . . . . . . . .1. . . . . . . . .37. . . 19. . . . . . . . . . . . . . . .673 in. .784 in. . . . . . .0.94 . . . .) Compression Ring Groove Wear Limit (New Ring Installed) . . . . . . .02 mm (2. . . 0.194 . . . .0. . . . . . . .96 . . .383 in. . . .10 mm (0. . . .030 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . 15. . . .457 in. . . . . . . . . . . . . . . . . . 34. . . . . . . .58 mm (0. . . . .023 in.) Wear Limit . . .33 . . .1. . . . . . 17. .34. .12 mm (1. . . . . . . . . . . . 72 . . . . . .0. . . . . . . . . . . . . . . .10 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 . . . . . . . . . . . . . .97 mm (0. . . . . . .674 in. . . . . . .95 mm (1. . . . . . . . . . . . . . . . . .05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Ring End Gap Standard Dimension .37. . .836 in. . . . . .1. .025 mm (0. . . . . . .2. . . . . . .) Cam Gear Magneto Journal Standard Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .835 . . . . . . .02 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . 30. . .202 in. .008 . . . .96 mm (0. . . . . . . . . . . . . . . . . . . . .) Piston Pin Bore Standard Dimension . .Briggs and Stratton Specifications . . 37. . . . . . . . . . . . . . . . .) Crankshaft End Play. . . . . . . . . . .016 in. .) Connecting Rod Piston Pin Bearing Std. . . . . . . .1. . . . . . . . . .) Oil Ring Groove Clearance Wear Limit (New Ring Installed) . . . . . . . . .04 . . . . . . . . . . . . . . . . . . . . .40 mm (0.08 mm (1. . . . . . . . . . . . . . . . . . .631 in. . . . . . .10 mm (0. . . . .30. . . . . . . . . . . . . . . . .76 mm (0. . . . . . . . . . . .19. . . . . . . .06 mm (1. . .627 in. .20. . . . 20 . . . . . .) Piston Pin Standard Dimension . .) Wear Limit . . . 35. . . . . . . . .002 . . . . . . . .455 in.) Wear Limit . . . .08 mm (0. . .15. . 35. . . .380 in. . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . 20. . . . . . . . . . . Pistons and Rings: Cylinder Bore Standard Dimension . . . . . . . 19. . . . . . .02 mm (1. . . . . .461 in. .0. . . . . 16. . . . . .004 in. . . . . . . . . . . . . . . . . . . . . . . . . . .) Cam Lobe Standard Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Crankshaft Magneto Journal Standard Dimension . . . . . . . . . . . .12 mm (1. . . .456 . . . . . . . . .12 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37. . . . . . . . . . . . . .93 mm (0. . . . . . . . . . . . . 17. . . . . . .785 . . . .0 . . . . . .378 in. . .25 mm (1. . . . . .) Engine . . . . .BRIGGS AND STRATTON SPECIFICATIONS Cylinder Bore. . . . . . . . . . .05 mm (1.) Crankshaft PTO Journal Standard Dimension. . . . . . . . . . . . . . 0. . . . . .379 . . . .630 . . 0. . . 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . 36. . . . . . . . . . . . . 15. . . . . . .16. . . . . .459 . . . .) Cam Bearing (PTO Side) Standard Dimension . . . . . . . . . 34. . . . . . . . . . . . . . . .35. . . . . . . . . . . . . . . .12 mm (0. . . .633 in. . . . . . . . . . . .376 . . . . . . . . . . . .) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Wear Limit . . . . . . . . . . . . . . . . .786 in. . . . . . . .) Connecting Rod and Crankshaft: Connecting Rod Crankpin Standard Dimension . . . . .01 mm (1. . . .0. . . 0. . . . . . .53 mm (1. . . . . . . . . . . . . . . . . . . . . . . . .ENGINE . .) Wear Limit . . . . . . . . . . . . .1. . . . . . . . .) Crankpin Standard Dimension .1. . . . . .06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Cam Bearing (Magneto Side) Standard Dimension. . .99 . . . . .) PTO Bearing Standard Dimension . . . . . . .) Wear Limit . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in. . . . . . . . . . . . .8 N•m (25 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) PTO Clutch to Engine Mounting Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Ignition Armature Mounting Screws . . . . . . . . . . . . . . . . . . . .2 N•m (20 lb-in. . . . . . . . . . . . . . . . . . . . . 11 N•m (100 lb-in. . .) Special or Essential Tools Order tools according to information given in the U. . . . . . . . . . . 3 N•m (30 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . .) Oil Breather Mounting Bolt . . . . . . . . . . . . . .S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in. . . . . . . . . . . . . . . . . . . 16 N•m (140 lb-in. . . . . . 3 N•m (25 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Cylinder Shield . . . . . . . . . . . . . . . . .) Cylinder Head Cap Screws . . . . . . . . . 7 N•m (65 lb-in. . . . . . . . . . . . .) Rocker Arm Studs . . . . .) Flywheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 N•m (125 lb-ft) Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special or Required Tools Tool Name Flywheel Puller JDG640 Tool No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICEGARD™ Catalog or in the European Microfiche Tool Catalog (MTC). . . . . . . . . . . . . . . . . . . 7 N•m (65 lb-in. . . . . . . . . . . . . . . . . . .BRIGGS AND STRATTON SPECIFICATIONS Torque Specifications Alternator to Cylinder Block . . . . . . . . . .69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Connecting Rod Cap Screws . . . . . . .) Spark Plug. . . . . . . . . . . . . . . . . . .) Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Briggs and Stratton Specifications . .ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Oil Pump Mounting Screws . . . . . . . . 11 N•m (100 lb-in. . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (45 lb-in. . . . . . . . . . . . . . .) Governor Lever Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Valve Cover Nuts . . . . . . 17 N•m (150 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (165 lb-in. . . . . . . . . . . . . . . . . .) Oil Filter Adaptor Mounting Bolts . . . . . . . . . . . . 17 N•m (150 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 75 N•m (55 lb-ft) Rocker Arm Adjustment Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Use Use to remove and install the flywheel on models with electrical outlet. . . . . . 8 N•m (70 lb-in. . . . . . . . . . . . . . . . . . . . . . . .

(4) Has engine seized? Yes . (11) Is carburetor adjusted properly.Replace. No . Symptom: Engine Doesn’t Crank (1) Are battery cables loose or dirty? Yes . (10) Is ignition coil air gap adjusted properly? See “Ignition Armature Air Gap Adjustment” on page 82. See “Charge Battery” on page 331 in the Electrical section. No . See “Cranking Circuit Operation” on page 269.Briggs and Stratton Diagnostics .Go to next step. No .Replace. See “Starting Motor No-load Amperage and RPM Tests” on page 336 or See “Starting Motor Solenoid Test” on page 335. No .Reset switch.Clean or replace.Go to next step.Go to next step.Tighten or clean. (6) Is fuel old or contaminated? Yes . (8) Is fuel shutoff solenoid defective? See “Fuel Shutoff Solenoid Test” on page 77.Go to next step. See “Air Cleaner Removal and Installation” on page 83.Clean or replace and tighten to specifications. See “Carburetor Adjustment” on page 79. Yes .Go to next step.Go to next step.Go to next step.ENGINE . Yes .Test switch.70 . (4) Is air cleaner dirty? Yes . No . No .Charge battery. Test Conditions: • • • Operator On Seat PTO Switch In Off Position Brake On (3) Is switch position improper? See “Cranking Circuit Operation” on page 269.Go to next step. No .Repair or replace. See “Cranking Circuit Operation” on page 269 in the Electrical section.Go to next step.Charge battery.Go to next step.Go to next step.Adjust or clean. Yes .Tighten or clean. Replace as needed. No . (9) Is fuel pump defective? Yes . No .Replace or clean. see Electrical Section and refer to either Diagnostics or Tests & Adjustments for further guidance.BRIGGS AND STRATTON DIAGNOSTICS Diagnostics Engine Diagnostics Symptom: Engine Cranks But Does Not Start No . Yes .Adjust. Yes . Keep hands away moving parts when testing.See Engine Repair Section. Symptom: Engine Cranks But Does Not Start (1) Are battery cables loose or dirty? Yes . (3) Is key switch working correctly? Yes .Replace. (2) Is battery fully charged? Engine . (2) Is battery fully charged? No .Go to next step. Yes . No . No . c to rotate atAvoid Injury! The engine mayfrom CAUTION: start any time. clean? See “Carburetor Adjustment” on page 79. (5) Is starting motor or solenoid defective? Yes .Go to next step. No . NOTE: To test specific electrical components. (5) Are spark plugs loose/dirty? Yes . See “Ignition Armature Air Gap Adjustment” on page 82. No . (7) Are fuel filter/lines clogged? Yes .Go to next step.Go to next step.

Go to next step. (6) Is carburetor adjusted properly. (2) Is battery fully charged? See “Battery Test” on page 330.Go to next step. (3) Is air cleaner dirty? Yes . No . (17) Is camshaft worn? Yes .Adjust or clean.Go to next step.Briggs and Stratton Diagnostics .Go to next step. IMPORTANT: Avoid damage! Perform a visual inspection first to determine if battery cables are tight and not corroded and if the battery is of sufficient size to turn the engine over at minimum cranking speed of 350 rpm. (15) Are valves and/or valve seats burned or are valve seats loose? See “Valve Inspection and Repair” on page 95.See “Valve Inspection and Repair” on page 95. NOTE: To test specific electrical components.Charge battery. Yes . Gasoline spray from the open cylinders may be ignited by ignition spark and cause an explosion or fire. (1) Are battery cables loose or dirty? Yes . (13) Does engine lack compression? See “Compression Test” on page 77. c with starting motor if theDo not plugs are CAUTION: Avoid Injury! rotate engine spark removed.71 .Go to next step. No . (4) Is fuel pump defective? Yes . See “Air Cleaner Removal and Installation” on page 83.Go to next step.ENGINE . No . (16) Has engine seized? Yes . clean? See “Carburetor Adjustment” on page 79.Clean or replace.Go to next step.BRIGGS AND STRATTON DIAGNOSTICS Symptom: Engine Cranks But Does Not Start (12) Is magneto kill circuit grounded . No .Go to next step. Yes . (5) Is ignition coil air gap adjusted properly? See “Ignition Armature Air Gap Adjustment” on page 82. No . Yes .See “Engine Removal and Installation” on page 90.Go to next step. Yes . No .Go to next step.Go to next step. No .Tighten or clean.Go to next step. (14) Do valve tappets need adjustment? See “Valve Inspection and Repair” on page 95. Yes .Clean or replace and tighten to specifications. Engine .Repair as needed.Replace. No . No . Symptom: Engine Starts Hard. see Electrical Section and refer to either Diagnostics or Tests & Adjustments for further guidance.Check valves. pistons and rings.See “Valve Inspection and Repair” on page 95. See “Charge Battery” on page 331. Yes .shorted? See “Ignition Circuit Diagnosis” on page 276 in the Electrical section. No . (7) Are spark plugs loose/dirty? Yes .Adjust as needed. No . Yes .See repair section. No .

(2) Are fuel filter/lines clogged? Yes . Yes . Yes . Symptom: Engine won’t shut off (1) Is magneto kill circuit grounded .Adjust as needed. No . No .Adjust or clean carburetor. Rings and Rod Removal and Installation” on page 97.Go to next step. (16) Are cylinder bore or rings worn? See “Cylinder Bore. No .Go to next step.Replace. (7) Is fuel shutoff solenoid defective? See “Fuel Shutoff Solenoid Test” on page 77. Yes .Repair as needed. (13) Is exhaust system restricted? Yes . clean? See “Carburetor Adjustment” on page 79.Go to next step. (4) Is ignition coil air gap adjusted properly? See “Ignition Armature Air Gap Adjustment” on page 82. Yes . No .Replace.72 .Go to next step. See “Air Cleaner Removal and Installation” on page 83.Go to next step. Symptom: Loss of power (1) Is air cleaner dirty? Yes .Go to next step.Go to next step. Yes . No .Replace No .Briggs and Stratton Diagnostics .Go to next step.Check valves.ENGINE . (14) Is camshaft worn? Yes .Clear exhaust system. No .Go to next step. pistons and rings.Go to next step. (3) Is fuel shutoff solenoid defective? See “Fuel Shutoff Solenoid Test” on page 77.Repair or replace valves and/or seats as needed.See “Cylinder Bore.Go to next step. Pistons and Rings:” on page 68. Yes . See “Cylinder Head Removal and Installation” on page 92 and “Cylinder Head Inspection and Repair” on page 95. No .Replace. No .Replace.Go to next step. No . Pistons and Rings:” on page 68. Engine . Yes . (12) Is cylinder head warped? See “Cylinder Head Inspection and Repair” on page 95. Yes . No . No . Yes .Adjust as needed. (2) Is carburetor adjusted properly. No . (3) Is fuel pump defective? Yes .BRIGGS AND STRATTON DIAGNOSTICS Symptom: Engine Starts Hard. (15) Is connecting rod broken? See “Connecting Rod Inspection” on page 98. No .Go to next step.Clean or replace.Clean or replace and tighten to specifications. (10) Do valve tappets need adjustment? See “Valve Inspection and Repair” on page 95. (5) Are spark plugs loose/dirty? Yes .Replace. (8) Is fuel old or contaminated? Yes .shorted? See “Ignition Circuit Diagnosis” on page 276 in the Electrical section.Go to next step. (9) Does engine lack compression? See “Compression Test” on page 77.Replace or clean No .Go to next step.Go to next step. (6) Is fuel old or contaminated? Yes . No .See “Piston.Replace fuel. Yes . No . Yes . (11) Are valves and/or valve seats burned or are valve seats loose? See “Valve Inspection and Repair” on page 95.Go to next step.

No . Excessive drive belt tension may cause premature bearing wear or result in bearing seizure. Yes . No .Adjust as needed. Yes . see Electrical Section and refer to either Diagnostics or Tests & Adjustments for further guidance. (13) Is exhaust system restricted? Yes . (16) Are cylinder bore or rings worn? See “Cylinder Bore Inspection” on page 101 and “Piston Inspection” on page 98. Yes .See repair section.Clear exhaust system. (11) Are valves and/or valve seats burned or are valve seats loose? See “Valve Inspection and Repair” on page 95. Yes .Go to next step. Pistons and Rings:” on page 68. clean? See “Carburetor Adjustment” on page 79.Clean or replace and tighten to specifications.Check valves.Replace. See “Cylinder Head Removal and Installation” on page 92. that coil could be fired by the other module.Go to next step. Low lubricant levels in the spindles will buildup heat causing excessive resistance for the engine to deal with.Adjust or clean as needed. (14) Is camshaft worn? Yes . This diode prevents feedback from one module to the other. pistons and rings. No . (3) Are cylinder head bolts loose? See “Cylinder Head Removal and Installation” on page 92. Grass clippings that build up near the cutting blades can cause excessive resistance and heat buildup that causes problems with the engine’s ability to turn the blades at a constant speed. No . (15) Is connecting rod broken? See “Connecting Rod Inspection” on page 98. No .Go to next step.Repair or replace valves and seats as needed. Yes .Go to next step. No . (5) Are valves and/or valve seats burned or are valve seats loose? See “Valve Inspection and Repair” on page 95. (4) Is head gasket defective? Yes . A loose belt like a loose blade can cause a backlash effect that will counteract engine cranking effort.See “Cylinder Bore. Without these diodes. If a diode fails in one of the magneto kill wires.BRIGGS AND STRATTON DIAGNOSTICS Symptom: Loss of power (8) Is carburetor adjusted properly. (10) Does engine lack compression? See “Compression Test” on page 77.Adjust as needed. Yes . No .Go to next step. Yes .Briggs and Stratton Diagnostics . No . There is a diode in-line in the magneto kill wire coming from each ignition module.Go to next step.Go to next step. A two cylinder engine may run adequately on one cylinder as long as the power required for the application does not exceed the power produced by the one cylinder. Symptom: Low compression (1) Are spark plugs loose/dirty? Yes .73 . No .See “Piston.Go to next step. See “Cylinder Head Removal and Installation” on page 92.Replace. Engine .Tighten to specification. one magneto could fire the coil for the other magneto. Engine Runs Erratically/Loss Of Power IMPORTANT: Avoid damage! Before proceeding. Yes . Yes . (9) Do valve tappets need adjustment? See “Valve Inspection and Repair” on page 95. No .Go to next step.ENGINE .Go to next step. NOTE: To test specific electrical components. the result may be similar to that of an erratic running engine. Rings and Rod Removal and Installation” on page 97. No .Go to next step. (12) Is cylinder head warped? See “Cylinder Head Inspection and Repair” on page 95.Go to next step. No . inspect the mower deck and belts for binding in the spindle assemblies or belts that are too tight/loose. (2) Do valve tappets need adjustment? See “Valve Inspection and Repair” on page 95.

Rings and Rod Removal and Installation” on page 97. See “Cylinder Head Removal and Installation” on page 92 and “Cylinder Head Inspection and Repair” on page 95. or “54-Inch Convertible Deck Spindles” on page 546. No .See repair section. (8) Is connecting rod broken? See “Connecting Rod Inspection” on page 98.BRIGGS AND STRATTON DIAGNOSTICS Symptom: Low compression Yes .Fill to specification. No . (4) Are the mounting bolts loose? Yes . “48-Inch Deck Spindles” on page 540. Symptom: Excessive engine noise/vibration (1) Is there grass buildup under deck? Yes . (4) Are the internal bearings worn or is there excessive tolerance? Yes .Clean deck. “42Inch Deck Spindles” on page 534. Yes .Go to next step. Rings and Rod Removal and Installation” on page 97. No .74 .See “Piston. Symptom: Excessive engine noise/vibration No .Repair or replace as needed.Go to next step. Engine . (3) Is there sufficient lubrication in gear box or hydro/transaxle? No . Pistons and Rings:” on page 68. No .Go to next step. Pistons and Rings:” on page 68. Yes .Go to next step.Go to next step. (3) Is the oil pump defective? See “Engine Oil Pressure Test” on page 81. No .North America” on page 12 or “Engine Oil . “44-Inch Deck Spindles” on page 537. No .See “Cylinder Bore.Replace.Go to next step. Yes .Go to next step. Yes . Yes .Go to next step.Clean or replace filter. No .See “Balance Blades:” on page 527 in the Attachments section. Symptom: Low oil pressure (1) Is the oil level low or is the oil the wrong viscosity? Yes . (5) Is cutter blade or other rotating part bent or out of balance? Yes .See “PTO and Cam Bearing Inspection” on page 109.Go to next step.Repair or replace as needed. (6) Have the deck spindles seized? Yes .Briggs and Stratton Diagnostics .Go to next step.ENGINE . No .See “Piston. No . (2) Are the oil galleries or filter clogged? Yes .Go to next step.Tighten bolts.See “Mower Decks Troubleshooting Chart” on page 511 in the Attachments section.See “38-Inch Deck Spindles” on page 533. See “Oil Pump Removal” on page 110.See “Engine Oil . No . (2) Is mower deck binding or dragging? Yes . (8) Are cylinder bore or rings worn? See “Cylinder Bore Inspection” on page 101. Symptom: Engine is running on one cylinder (1) Is ignition coil air gap adjusted properly? See “Ignition Armature Air Gap Adjustment” on page 82. No . (7) Is camshaft worn? Yes .Go to next step.Go to next step.Go to next step. (6) Is cylinder head warped? See “Cylinder Head Inspection and Repair” on page 95. Yes .Go to next step. Yes .Europe” on page 12 in the Specifications section. No . (7) Is connecting rod broken? See “Connecting Rod Inspection” on page 98. No . (9) Are cylinder bore or rings worn? See “Cylinder Bore.See “Cylinder Head Inspection and Repair” on page 95.

pistons and rings.Clean. No .Go to next step. No . No . (7) Is head gasket defective? Yes . No . No .Go to next step.Go to next step. Yes . (4) Is there sufficient lubrication in gear box or hydro/transaxle? No . (9) Is cylinder head warped? See “Cylinder Head Inspection and Repair” on page 95.ENGINE .Go to next step.Europe” on page 12. No .Go to next step.Go to next step.Clean deck. (3) Is mower deck binding or dragging? Yes . Yes .Tighten to specification.75 .Go to next step. No . Yes .Repair or replace as needed. See “Cylinder Head Removal and Installation” on page 92. Yes .Go to next step.Adjust air gap to specification. No . Yes . No .Replace. (4) Do valve tappets need adjustment? See “Valve Inspection and Repair” on page 95.shorted? See “Ignition Circuit Diagnosis” on page 276. “48-Inch Deck Spindles” on page 540. or “Engine Oil . (3) Is magneto kill circuit grounded .BRIGGS AND STRATTON DIAGNOSTICS Symptom: Engine is running on one cylinder No .Clean or replace and tighten to specifications. (8) Are valves and/or valve seats burned or are valve seats loose? See “Valve Inspection and Repair” on page 95. Yes . No .Go to next step. (10) Is camshaft worn? Yes .Go to next step. or “54-Inch Convertible Deck Spindles” on page 546. (6) Have the deck spindles seized? Yes .See “Engine Oil . “44-Inch Deck Spindles” on page 537.See “Valve Inspection and Repair” on page 95. Yes . Yes .See “Traction Drive Belt Removal and Installation” on page 442 and “Traction Drive Belt Tensioner Assembly” on page 444. No . Yes . Engine .Fill to specification.See repair section.Repair as needed.Go to next step.Go to next step.North America” on page 12. Rings and Rod Removal and Installation” on page 97. Symptom: Engine is running on one cylinder (11) Is connecting rod broken? See “Connecting Rod Inspection” on page 98.Go to next step. (6) Are cylinder head bolts loose? See “Cylinder Head Removal and Installation” on page 92. Yes . No .Go to next step.See “Mower Decks Troubleshooting Chart” on page 511.Check valves. “42Inch Deck Spindles” on page 534.See “Piston. (5) Is there excessive drive belt tension? Yes .Briggs and Stratton Diagnostics . Symptom: Engine overheats (1) Is there grass buildup under deck? Yes .Go to next step. No . (5) Does engine lack compression? See “Compression Test” on page 77.Go to next step. See “Cylinder Head Removal and Installation” on page 92.Replace.Repair or replace as needed. (12) Are cylinder bore or rings worn? See “Piston Inspection” on page 98 and “Cylinder Bore Inspection” on page 101. (2) Are spark plugs loose/dirty? Yes .See “38-Inch Deck Spindles” on page 533. (2) Are cylinder cooling fins or blower housing filled with grass clippings? Yes . No . No . (7) Is the oil level low or is the oil the wrong viscosity? Yes .Go to next step.

See “Carburetor Adjustment” on page 79. Reason: To make sure the throttle cable moves the throttle through its full range of movement.BRIGGS AND STRATTON TESTS AND ADJUSTMENTS Symptom: Engine overheats No . 5. B A M92400 4. Tests and Adjustments Throttle Cable Adjustment Symptom: Fuel mixture too rich (1) Is air cleaner dirty? Yes . No . Remove air cleaner assembly from carburetor. Yes . Engine . (8) Is the exhaust system restricted? Yes . (2) Are cylinder bore or rings worn? See “Piston Inspection” on page 98 and “Cylinder Bore Inspection” on page 101. Move throttle cable until governor control swivel (B) is at end of travel. NOTE: Nuts securing air cleaner base to carburetor also secure carburetor to intake manifold.Go to next step.76 . and base. See “Air Cleaner Removal and Installation” on page 83. See “Air Cleaner Removal and Installation”. No .Go to next step. Remove air cleaner assembly.Clear exhaust system.Go to next step (9) Is air/fuel mixture excessively lean? Yes .See repair section. Procedure: 1. No . 2.Replace as needed. Procedure: 1. Loosen throttle cable clamp (A).Go to next step. Choke Cable Adjustment Reason: To make sure the choke cable moves the choke through its full range of movement. Yes . Remove key. Install nuts on carburetor studs. Park machine on a level surface. (4) Is camshaft worn? Yes . Tighten throttle cable clamp. STOP engine. DO NOT run engine with nuts removed. 6. (3) Is connecting rod broken? See “Connecting Rod Inspection” on page 98.Repair or replace as needed.Clean or replace.ENGINE . Check choke lever to make sure it is completely OFF (rear most position).Briggs and Stratton Tests and Adjustments . No .Go to next step. 3. Move throttle lever to FAST idle position. Set parking brake. 3. 2.

Remove spark plugs. Readjust if necessary. Disconnect wire from solenoid. the solenoid is working properly. Repeat steps 2 and 3 with the next cylinder and record reading. 5. If either valve is off its seat the leak test will be invalid. If choke butterfly is not completely open: • Loosen choke cable clamp (B). with or without a cylinder leak tester. Momentarily place a jumper wire from solenoid wire to battery positive terminal. Listen for an audible click when ignition switch is turned from OFF to ON. Without Cylinder Leak Tester IMPORTANT: Avoid damage! The battery must be fully charged for this test. 5. 4. 6. 2. problem could be in equipment wiring. 3. If solenoid does not click. M95087 1. Check choke butterfly (A) to make sure it is completely open.Briggs and Stratton Tests and Adjustments . Engine . 2. Required Tools: • Jumper wire Procedure: 1. Two methods follow. as it is difficult to obtain an accurate reading without special equipment. B A Fuel Shutoff Solenoid Test Reason: To test proper operation of fuel shutoff solenoid. Briggs & Stratton recommends calculating the difference in compression readings between the two cylinders. 4. Ground the magnetos by attaching a jumper wire (A) from the magneto kill circuit connector to the engine to prevent a spark that could ignite anything combustible. • Tighten choke cable clamp. 3. Turn engine over with the starting motor until the highest pressure reading is obtained and record reading. Use the following example and insert the recorded readings to determine the percent of leakage between cylinders. Results: • Solenoid is operating properly if a click is heard when ignition switched from OFF to ON. Push choke lever forward and make sure choke is completely closed at full choke. • Move choke cable (C) until butterfly is completely open.ENGINE . If solenoid now clicks. Check and adjust the valves to ensure the valves have not been adjusted too tight.BRIGGS AND STRATTON TESTS AND ADJUSTMENTS Compression Test Reason: A C To determine the performance difference between cylinders. B Required Tools: NOTE: Briggs & Stratton does not publish compression pressures. Insert a compression gauge (B) into either cylinder. • JDM59 Compression Gauge M92400 4. 5.77 .

With Cylinder Leak Tester Required Tools: • • JTO3502 Cylinder Leak Tester Breaker Bar & 30 mm Socket B NOTE: If the directions that come with the tester being used are different than the following. Engine . Remove valve covers. IMPORTANT: Avoid damage! The piston must be positioned at Top Dead Center (TDC) to ensure that the intake valves are away from the compression relief balls.333 = 26.Briggs and Stratton Tests and Adjustments . 4.7% Cyl #2 55 psi 5. the intake valve will be open and the leak test will be invalid. If either valve is off its seat the leak test will be invalid. Ground the magnetos by attaching a jumper wire from the magneto kill circuit connector to the engine to prevent a spark that could ignite anything combustible. The engine is still usable but an overhaul or replacement should be considered • Gauge reading in the RED (high) area indicates excessive compression loss and engine reconditioning or replacement is necessary c CAUTION: the magnetosWith spark plugs to Avoid injury! removed.ENGINE . Connect the adaptor hose (A) to the tester (B) and record the needle position while holding the flywheel in position with a socket and long drive handle (C). 2. 100 .95 psi) to calibrate the tester.655 kPa (85 . Push the locking ring toward the tester to lock it. Remove the rotating screen. 7. Turn crankshaft until piston is at TDC. IMPORTANT: Avoid damage! The air supply must have supply pressure of 586 . 3. Pull back the locking ring and rotate the regulator knob clockwise until the gauge needle rests in the SET range of the gauge. Remove spark plugs.73.7333 x 100 = 73. NOTE: A small amount of air escaping from the crankcase breather is normal. use the directions that came with the tester.333. Screw the adaptor into the spark plug hole but do not attach it to the tester at this time. Pull back the locking ring and rotate the regulator knob fully counterclockwise. C Highest Reading Lowest Reading Results: • A difference of more than 25% indicates a loss of compression in the cylinder with the lowest reading. must be grounded the engine to prevent a spark that could ignite anything combustible.BRIGGS AND STRATTON TESTS AND ADJUSTMENTS Example: Cyl #1 75 psi Formula: 55 ÷ 75 = 0. The engine should be run for at least five minutes to bring the engine to operating temperature A M88957 9. on the compression stroke (both valves closed) 6. If not. 8. IMPORTANT: Avoid damage! Check and adjust the valves to ensure the valves have not been adjusted too tight.78 . 1. Results: • Excessive air escaping from the crankcase breather indicates worn piston rings or cylinder wall • Air escaping from the carburetor indicates a worn intake valve or seat • Air escaping from the exhaust pipe indicates a worn exhaust valve or seat • Gauge reading in the GREEN (low) area indicates good compression (less than 25% is considered normal) • Gauge reading in the YELLOW (moderate) area indicates borderline compression. Connect an air line to the tester.

NOTE: Nuts securing air cleaner base to carburetor also secure carburetor to intake manifold. Turn screw to the midpoint between rich and lean mixture settings. Install air cleaner base and air cleaner. Turn idle mixture screw clockwise until it just seats. readjust idle mixture screw 1/8 turn counter-clockwise (richer mixture). DO NOT FORCE. 4. DO NOT run engine with nuts removed. 3.Briggs and Stratton Tests and Adjustments . 12. Move throttle lever to SLOW position. IMPORTANT: Avoid damage! DO NOT attempt to disassemble or adjust the carburetor unless you are a factory trained technician with authorization to service CARB/EPA Certified Emissions Carburetors. Remove limiter cap. Equipment: • JT07270 Pulse Tachometer IMPORTANT: Avoid damage! To obtain correct operation of the carburetor. Initial Adjustment Procedure: 1. Turn idle mixture screw (B) slowly clockwise until engine speed just starts to slow (lean mixture).ENGINE . If necessary. M92398 A M92399 5. Install pulse tachometer. Hold throttle lever against idle speed screw (A) and temporarily adjust idle speed to 1400 rpm. Install nuts on carburetor studs. air cleaner assembly. Start and run engine for five minutes to allow engine to reach operating temperature. 14. Final Adjustment NOTE: All carburetor adjustments with engine running must be made with the air cleaner installed.Engine should accelerate smoothly. Engine .BRIGGS AND STRATTON TESTS AND ADJUSTMENTS Carburetor Adjustment Reason: To set the carburetor screw for proper operation of the carburetor. 9. 8. Hold throttle lever against idle speed adjustment screw and readjust idle speed to 1200 rpm. B 6. 7. 5. 11.If necessary bend idle tang (C) to obtain 1750 rpm. See “Air Cleaner Removal and Installation” on page 83.With throttle lever in the SLOW position and engine running at governed idle rpm.Move throttle lever to FAST position. This setting will allow the engine to start. 3. 2. Turn screw 1¼ turns counter-clockwise. and base. the adjustment procedure MUST be performed in the sequence shown.Position limiter cap so that stops on limiter cap are at midpoint between stops on carburetor. 1. 10. Release throttle lever and note rpm. bend throttle restrictor tang (D) so that it just contacts governor lever (E). 4. 2.79 . 13. Remove hood.

Loosen governor lever bolt (A) and nut.80 . Bend governor idle tang (A) to obtain specified slow idle of 1750 ± 100 rpm. . . 4. . . . . . . Hold lever in this position and rotate governor shaft (C) counterclockwise as far as it will go. . . 3. could result in engine overspeeding. . . . . . . .Briggs and Stratton Tests and Adjustments . IMPORTANT: Avoid damage! Do not bend governor link or distort governor lever. . . . Push on governor lever (B) until throttle is wide open. . Procedure: B A C M92396 C 2. . . Move throttle lever to FAST idle position and bend fast idle tang (D) to obtain specified top no load engine speed. . . Failure to make static adjustments first. . . . 1550 ± 100 rpm Fast Idle. . . . . . governor must be made. . . B D A M89124 1. . c CAUTION: Avoid static adjustment of theor injury! Before starting running engine. Move throttle lever to SLOW idle position. Specifications: Slow Idle . bend throttle restrictor tang (B) so that it just contacts the governor lever (C). 3350 ± 50 rpm Engine . . 4. . throttle restrictor and top no load rpm adjustments.ENGINE . Remove: • • • Hood Top muffler shield Air cleaner assembly M92397 2. . . . . .BRIGGS AND STRATTON TESTS AND ADJUSTMENTS Governor Adjustment Special or Required Tools: Pulse Tachometer JT07270 Procedure: 1.). With throttle lever in SLOW position and engine running at governed idle. . and may result in engine or equipment damage causing personal injury and/or property damage. . . Dynamic Adjustment (Engine Running) NOTE: Carburetor mixture adjustments must be made before adjusting governed idle. . . . Hold lever and shaft in position and tighten governor lever bolt and nut to 8 N•m (70 lb-in. Static Adjustment (Engine OFF) NOTE: All linkage must be installed to make adjustment. 3. .

. Test Procedure: 1. . .). Install valve cover. Tighten locknut to 7 N•m (60 lb-in. Make adjustments as required.004 . Monitor the oil pressure during cranking.JTO3262 Coupler . . 7. Perform test procedure with engine level. Check crankcase oil level and adjust to full mark. Disconnect spark plug wires. . . Remove oil pressure switch from the oil filter adapter.) E C D M91215a A B C D E . Insert a screwdriver through the spark plug opening until it touches the top of the piston. coupler. and gauge are found in other SERVICEGARD™ test kits. Recheck valve clearance. 7 N•m (65 lb-in. Valve clearance should be 0. w/ O-Ring 7. Stop engine.10 . 3. 4. Check valve clearance with a feeler gauge (A) between valve stem and rocker arm.TO3017 Hose Assembly .006 in. If not. Screw connector end (4) of gauge assembly into oil pressure switch opening. .0.25 in. hose assembly. A B A B M87841 5. .ENGINE .81 .004 . Specifications: Locknut .JTO7034 Gauge . Equipment: • • • • JT05487 Connector JT03017 Hose Assembly JT03262 Coupler JT07034 Gauge.4 mm (0. adjust as necessary using a 13 mm open end wrench (B) and a 5 mm hex wrench (C). 4. . . 0. .16 mm (0. .006 in.10 . Allow engine to cool. If the pressure is below 28 kPa (4 psi) . .16 mm (0. .) Valve Clearance . . .STOP cranking the engine immediately and correct the cause before continuing. . . . Remove valve cover.0.0.100 psi) NOTE: The connector.700 kPa (0 . 8. 0 . .). . . . 2. . 6. Turn crankshaft until piston is at TDC of the compression stroke (both valves closed).JT07262 Oil Pressure Adapter. Engine . 1.).JTO5487 Connector .0. 3. 2. . Connect spark plug wires. C Engine Oil Pressure Test Reason: To verify that the engine has sufficient oil pressure to lubricate internal engine components. 6. .BRIGGS AND STRATTON TESTS AND ADJUSTMENTS Valve Clearance Adjustment NOTE: Correct position of crankshaft is necessary to eliminate interference by the compression release mechanism on the cam gear when adjusting valve clearance. 5. Continue to turn the crankshaft clockwise until the piston has moved down 6. .Briggs and Stratton Tests and Adjustments . 8. .

and loosen the top two cap screws (D). inspect and/or replace the following: • Oil pump assembly.ENGINE .008 . • • • • Oil suction screen Oil passages Bearing wear Oil Seals B A M95088 12. 1. Remove upper blower housing.Reinstall oil pressure switch. Remove fuel pump (B) and bracket. See “Oil Pump Removal” on page 110.345 kPa (15 .30 mm (0.50 psi) at FAST idle.). 5. 2.20 . Repair Upper Blower Housing Removal and Installation Procedure: C c CAUTION:NOT touch with bare skin. Ignition Armature Air Gap Adjustment Reason: To set proper ignition coil air gap.) thickness gauge (A) between the flywheel magnet and the armature. Remove bottom cap screw securing oil cooler cover. Repeat for remaining cylinder.Record oil pressure reading at FAST idle. and gauge. 2. Rotate the flywheel until the flywheel magnet is underneath the armature. 14. 15. 3. 6. connector. Place a 0. Warm-up engine by running for five minutes. DO protective eye glasses and clothing. Install in reverse order of removal.Stop engine and allow to cool. Remove rotating screen. 7. D M95089 NOTE: Steps 5 and 6 are only required on engines with oil coolers. Remove top carburetor access plate (C). coupler. Move cover out of the way.BRIGGS AND STRATTON REPAIR 9. 6. 4.82 .012 in. allowing the magnet to pull the armature against the thickness gauge. Disconnect upper bolt (A) on dipstick tube. Rotate the flywheel to remove the thickness gauge. 8. Loosen the mounting screws. 4. Procedure: 1.Briggs and Stratton Repair . Engine . 10.Check crankcase oil level and adjust to FULL mark. Tighten the mounting screws to 2. Results: If oil pressure reading is not within 103 . hose assembly. 11.8 N•m (25 lb-in.Remove adapter. Wear are Avoid injury! Engine components HOT.Run engine for 30 seconds and stop engine.0. 5. 13. 3. Remove two cap screws securing oil cooler to the blower housing.0.

air cleaner housing (H). If paper cartridge is dirty replace with new cartridge. Remove upper blower housing. Replace cartridge if dirty. Remove cover (A). NOTE: Nuts (K) securing air cleaner base to carburetor also secure carburetor to intake manifold. Squeeze dry in a clean cloth. DO NOT run engine with nuts removed. 2. M87006 Installation: IMPORTANT: Avoid damage! Be sure breather tube is not kinked and that it is installed onto nipple as far as possible. See “Air Cleaner Removal and Installation” on page 83. to clean foam precleaner. Remove air cleaner base and breather tube. Installation is the reverse of removal. Wrap in a clean absorbent cloth and squeeze to remove excess oil.BRIGGS AND STRATTON REPAIR Air Cleaner Removal and Installation I K E D G J F B C H M88900a A 5. Carburetor Removal and Installation Removal: 1. 3. DO NOT oil paper cartridge. 3. 4. Remove the hood. NOTE: The engine is equipped with fuel shutoff solenoid. DO NOT use pressurized air to clean or dry paper cartridge. Disconnect fuel shutoff solenoid wire from equipment switch wire. They may cause foam to deteriorate. gasket (G). • • Wash pre-cleaner in liquid detergent and water.83 . Remove air cleaner. Remove cartridge and clean by tapping gently on a flat surface.ENGINE . • Saturate in clean engine oil. such as kerosene. Remove screws (F). air inlet tube (I) and breather tube (J). Engine . The blower housing should be removed so that the solenoid wire can be properly routed during reassembly. Slide foam pre-cleaner (D) off cartridge (E). IMPORTANT: Avoid damage! DO NOT use petroleum solvents. 2. 1. knob (B) and plate (C).Briggs and Stratton Repair .

Tighten to 7 N•m (65 lb-in. gaskets and spacer. 6. gaskets and carburetor. Install spacer. 8. breather tube (E). 2. nuts (H). Install gasket (D). 5. Failure to make static adjustments first could result in engine over-speeding and may result in engine or equipment damage causing personal injury or property damage IMPORTANT: Avoid damage! Be sure breather tube is not kinked and that it is installed onto nipple as far as possible. 9.Briggs and Stratton Repair . air cleaner base (F). 6. Then install governor link spring in loop on retainer. 7. Installation: 1. Install blower housing. Connect governor link to throttle lever and snap retainer over link.84 . M88870 4. Disconnect governor link (D). G H D D E F I E M88900a M88901 7. Engine . Remove carburetor. Install air cleaner bracket (A) and tighten two screws to 7 N•m (65 lb-in.ENGINE . Remove two screws (B) and choke control bracket. Remove air cleaner bracket (A). and screws (I). Install fuel line and fuel line clamp.BRIGGS AND STRATTON REPAIR C B A B A C M88899 3. c CAUTION: Avoid injury! Static governor adjustment must be made whenever carburetor or manifold has been removed from engine.). Disconnect choke link (C) from carburetor. air inlet tube (G). 5. retainer (E) and spring. Connect link to choke control lever and install choke control bracket (C). Remove fuel line clamp and fuel line from carburetor. 4. Install choke link (B) on choke lever on carburetor.).

ENGINE - BRIGGS AND STRATTON REPAIR
8. Install air cleaner cartridge, pre-cleaner and cover.
C

B C

M88873 J

3. With a small punch, drive the float hinge pin (C) out of float hinge. Remove float and fuel inlet valve assembly.
M88902

9. Connect choke link (B) to choke lever. Install choke control bracket (C). Tighten screws (J) to 7 N•m (65 lb-in.). 10.Install blower housing and rotating screen. Install fuel pump and bracket and connect fuel line to carburetor. NOTE: Make sure air inlet tube is installed correctly in air cleaner base. 11.Rotate fuel line clamp so that it will not interfere with carburetor cover. DO NOT install carburetor cover at this time.

D

M88874

Carburetor Disassembly
Procedure: 1. Observe position of bowl drain screw to aid in reassembly.

4. Remove carburetor bowl gasket (D).

E

A

M88875

B M94887

5. Remove fixed main jet (E) using a small blade screwdriver.

2. Remove fuel shutoff solenoid (A) and washer (B) and bowl.

Engine - Briggs and Stratton Repair - 85

ENGINE - BRIGGS AND STRATTON REPAIR

H L

E

F

G

M88876

M88879

6. With the fixed main jet removed, the high speed nozzle (F) can be removed. Reach into carburetor throat (G) with a flat blade screw driver and push the high speed nozzle up through fixed main jet tube (H).

10.Remove two screws (L) holding throttle valve to throttle shaft and remove throttle valve

M

I J

M88880

M88877

11.To remove throttle shaft it is necessary to first remove welch plug (M) from side of carburetor. Use a punch to pry plug out.

7. Remove idle jet plug (I) and idle jet (J).
K O N P Q

M88881 M88878

8. The idle mixture valve (K) is equipped with a adjustment limiter cap. Use pliers to remove the cap. 9. Remove the idle mixture valve.

12.Remove external snap ring (N) and throttle shaft washer (O). 13.Remove throttle shaft, throttle shaft collar (P) and throttle shaft seal (Q) (lip out).

Engine - Briggs and Stratton Repair - 86

ENGINE - BRIGGS AND STRATTON REPAIR
U

S R V U V T A

M88882

B M88884

NOTE: The choke shaft has a ball (R) and spring (S) that keeps tension on the choke shaft. Use care when removing choke shaft. 14.Remove choke valve screw and choke valve. Remove E- ring (T), then remove choke shaft, washer (U) and felt seal (V).
W

4. Inspect throttle and choke shaft and bushings for wear. Wear between throttle shaft and bushing should not exceed 0.25 mm (0.010 in.). 5. Check wear by placing carburetor on a flat surface 3 mm (1/8 in.) thick (A). Measure the distance between the throttle lever and flat surface with a feeler gauge (B) while moving shaft up and down. A difference greater than 0.25 mm (0.010 in.) indicates the throttle shaft and/or bushings are worn.

X

C

M88883

15.Using a punch (W), remove small welch plug (X) from top of carburetor body.

Carburetor Inspection
M88885

IMPORTANT: Avoid damage! A clean fuel system is necessary in order to maintain proper operation of the engine. Gummy or dirty fuel tanks and carburetors should be cleaned with a commercial carburetor cleaner. DO NOT soak rubber, neoprene or plastic parts in cleaner. 1. Check all moving parts for wear, nicks and burrs. Replace, if worn or damaged. 2. Check float for leaks or damage. Replace, if damaged or leaking. 3. Check all mating surfaces for nicks, burrs, foreign material, or cracks. Replace all damaged parts.

6. Wear on the throttle shaft (C) can be checked by comparing the worn and unworn portions of the shaft. 7. Choke shaft and bushings are checked in the same manner. 8. Throttle and choke shaft are replaceable. If throttle or choke shaft bushings are worn, replace carburetor.

Engine - Briggs and Stratton Repair - 87

ENGINE - BRIGGS AND STRATTON REPAIR
Carburetor Assembly
IMPORTANT: Avoid damage! When assembling the carburetor, use new seals and gaskets. With throttle valve in closed position, tighten screws securely. Then, install new welch plug in side of carburetor body. Use a round punch to tap in plug until it is flat. Use sealant on outside diameter of plug to prevent air leaks.
J A B H

J L K J I H

M88886

1. Install new secondary idle port welch plug (A). Use a round punch (B) and tap in plug until it is flat. Use a sealant such as Permatex® #2 or nail polish on outside diameter of plug to prevent air leaks.

M88889

4. Install new E-ring (H), washer (I) and felt seal (J) onto choke shaft. 5. Insert spring (K) and check ball (L) in to spring pocket. Push choke shaft into hole until ball engages groove in choke shaft.

D C E F

6. Place choke valve onto flat on choke shaft with flat edge of choke valve up and dimples down. 7. With choke valve in closed position, install and tighten screw securely.

M88887

M

2. Install throttle shaft seal (C) with sealing lip out. Slide collar (D) over throttle shaft and insert throttle shaft through carburetor body. Place washer (E) over end of throttle shaft and install new snap ring (F).

M88890

8. Install carburetor bowl gasket (M) in carburetor body groove. Make sure gasket does not twist or kink.
G

M88888

3. Install throttle valve on shaft with numbers down (G).

Engine - Briggs and Stratton Repair - 88

ENGINE - BRIGGS AND STRATTON REPAIR

O N T

M88891

S M88894

9. Install fuel inlet valve retainer (N) in fuel inlet valve groove (O).

12.Hold carburetor in vertical position, with float hinge up. The float should be parallel (S) to the carburetor bowl mounting surface.

P Q U V

M88892

10.Slide fuel inlet valve assembly (Q) onto float tang (P). Place assembly in carburetor.
M88895

13.Install idle jet (U), plug and gasket (V). Tighten plug securely
W

R

M88893

11.Install float hinge pin (R) into place.
M88896

14.Install idle mixture valve with spring (W), and adjustment limiter cap. NOTE: Special high altitude jets may be required in certain areas. Engine - Briggs and Stratton Repair - 89

ENGINE - BRIGGS AND STRATTON REPAIR
A B X

C

M88875

M99588

15.Install high speed nozzle and fixed main jet (X).

6. Remove wiring harness tie down clip (A) from left hood bracket. 7. Remove four cap screws (B) securing heat shield. 8. Remove left and right side flange nuts (C) securing hood brackets to frame. Remove hood brackets 9. Remove top heat shield.

D Z

E

Y M94887

16.Install bowl, washer (Y) and screw or fuel shutoff solenoid (Z) and washer. Tighten to 5 N•m (45 lb-in.). Position bowl drain.

M99592

Engine Removal and Installation
Removal: 1. Allow engine to cool before removing the engine. 2. Drain engine oil. Oil Capacity w/o Oil Filter . . . . . . . . . . . . 1.42 L (1.5 qt) Oil Capacity w/ Oil Filter . . . . . . . . . . . . . 1.61 L (1.7 qt) 3. Disconnect battery negative (-) terminal ground cable. Disconnect positive (+) battery cable. Remove battery. 4. Disconnect headlight connector and remove hood. See “Hood Removal and Installation - Models GT225, GT235” on page 558 or “Hood Removal and Installation - Models GT235E, GT245” on page 558. 5. Remove four screws securing front bumper and remove bumper.

10.Remove four cap screws (D) securing lower heat shield, and remove heat shield. Remove two cap screws (E) securing muffler to frame.

F M99593

11.Remove four allen head bolts (F) and lock washers securing muffler to engine. Remove muffler. 12.Clean muffler and engine of all old gasket material.

Engine - Briggs and Stratton Repair - 90

ENGINE - BRIGGS AND STRATTON REPAIR
J M

H G

N

I M99594 M92382

13.Disconnect engine electrical connectors (G) and white ground wire (H). Remove starting motor cable (I) and wires from starting motor.

17.Disconnect choke cable (M) and throttle cable (N). NOTE: It is not necessary to completely remove drive belt to remove engine.

c CAUTION: Avoidainjury! DO NOTarea away from SMOKE. Always work in well ventilated
open flame or spark producing equipment; this includes equipment that utilizes pilot lights. 14.Disconnect fuel line (J) from fuel pump. Plug line.

P

O K M95314

18.On underside of machine, locate the traction drive belt tensioner. Using a pry bar (O), turn belt tensioner to relieve tension on belt, and slip belt off of flat idler (P).
L M99595 T Q

15.Disconnect wiring harness connector (K) on left hand rear side of engine. Remove cap screw and ground wire (L) from engine and frame. 16.Remove air cleaner. See “Air Cleaner Removal and Installation”.

S R M99596

19.Disconnect electric clutch connector (Q). 20.Remove cap screw (R), washer (S) and electric clutch (T) from engine shaft. Engine - Briggs and Stratton Repair - 91

ENGINE - BRIGGS AND STRATTON REPAIR
21.Remove electric PTO clutch. See “Electric Clutch Removal and Installation” on page 348 in the Electrical section. 22.Remove traction drive belt and sheave from engine shaft. NOTE: Drive key is a part of the sheave. DO NOT attempt to remove key from sheave bore. 23.Remove four engine mounting bolts and engine. Installation: Installation is the reverse of removal: • Tighten four engine mounting bolts and flange nuts to 32 N•m (24 lb-ft). • Install electric clutch. Tighten clutch bolt to 75 N•m (55 lb-ft). • Install traction drive belt. See “Traction Drive Belt Removal and Installation” on page 442. • Inspect muffler flanges for flatness. Install muffler with new gaskets. Tighten exhaust manifold bolts to 17 N•m (150 lb-in.). 8. Install air filter assembly. 9. Install upper blower housing.

Intake Manifold Removal and Installation
1. Remove upper blower housing. See “Upper Blower Housing Removal and Installation” on page 82. 2. Remove air filter assembly. See “Air Cleaner Removal and Installation” on page 83. 3. Remove carburetor. See “Carburetor Removal and Installation” on page 83. NOTE: Replace intake manifold and carburetor gaskets.

A A

Cylinder Air Guides Removal and Installation
B

Removal: 1. Remove upper blower housing. See “Upper Blower Housing Removal and Installation” on page 82. 2. Remove air filter assembly. See “Air Cleaner Removal and Installation” on page 83. 3. Remove carburetor. See “Carburetor Removal and Installation” on page 83.
A M88979

4. Remove intake manifold bolts (A) and intake manifold (B). Installation: Installation is the reverse of removal.

Cylinder Head Removal and Installation
IMPORTANT: Avoid damage! Mark all parts when disassembling cylinder heads to prevent interchanging. 1. Disconnect spark plug leads and remove spark plugs. 2. Remove intake manifold. See “Intake Manifold Removal and Installation” on page 92. 3. Remove cylinder air guides. See “Cylinder Air Guides Removal and Installation” on page 92.
A M88980

4. Remove front and side cylinder air guides (A). 5. Install right, front and side cylinder air guides. 6. Install carburetor. 7. Install carburetor linkage.

Engine - Briggs and Stratton Repair - 92

ENGINE - BRIGGS AND STRATTON REPAIR
B A C

M87033

4. Remove seals and nuts (A), and valve cover (B). 7. Remove rocker arms (C).
D

M87022

8. Lift out push rods.

C

E M89840 H

NOTE: To release spring pressure from rocker arms (C), rock the arm against spring pressure and allow push rod (D) to drop out of the rocker arm socket. Push rod will move out of position, releasing valve spring (E) pressure.
M87023

5. Release valve spring pressure IMPORTANT: Avoid damage! Exhaust valve push rods are aluminum. Intake valve push rods are steel. Mark push rods for correct reinstallation.
F

9. Remove cylinder head bolts (H)

I J

G

K

M87021

M87024

6. Using a 10 mm wrench (F), remove rocker studs (G).

10.Remove cylinder head (I) and gasket (J).

Engine - Briggs and Stratton Repair - 93

ENGINE - BRIGGS AND STRATTON REPAIR
Installation: 1. Clean gasket surfaces. 2. Place new gasket and cylinder head on cylinder. Align head with cylinder head alignment sleeves (K) located in the cylinder. 3. Apply approved lubricant to threads and install four cylinder head bolts. IMPORTANT: Avoid damage! Do not use sealer of any kind on gaskets.
A B

1 3 M87022

6. Assemble rocker arms (B) with rocker studs (A), to the cylinder head.

A 4 2

C

M87023

4. Tighten four head bolts down evenly by hand. Use a torque wrench to tighten cylinder head bolts in 6 N•m (55 lb-in.) increments in the sequence shown to 19 N•m (165 lb-in.). IMPORTANT: Avoid damage! Do not tighten one head bolt to the final torque before all of the other head bolts have been tightened to the second torque. Uneven tightening may cause a warped cylinder head. 5. Insert push rods into recess in tappets. IMPORTANT: Avoid damage! Exhaust valve push rods are aluminum. Intake valve push rods are steel. Return the push rods to their original location.

B D M89840

7. Compress valve spring (D) with rocker arm (B). Insert push rod (C) into rocker arm socket. Be sure push rods remain seated in recess in tappets. 8. Tighten rocker studs (A) to 16 N•m (140 lb-in.). 9. Adjust valves. See “Valve Clearance Adjustment” on page 81.

E

M87033

10.Install gasket and valve cover. Place seal washers and nuts (E) on studs.

Engine - Briggs and Stratton Repair - 94

ENGINE - BRIGGS AND STRATTON REPAIR
11.Install intake and exhaust manifold, governor control bracket, cylinder air guides, valley cover, blower housing and air cleaner assembly. 12.Install spark plugs. Tighten to 20 N•m (180 lb-in.). 13.Install spark plug leads. Procedure: 4. Remove rocker studs. 5. Repeat procedure on other cylinder head.

Valve Inspection and Repair

Cylinder Head Inspection and Repair
Procedure: 1. Remove combustion chamber deposits from combustion chamber and around valves using a soft, hand wire brush or scraper. With piston at TDC, remove combustion chamber deposits from top of piston. IMPORTANT: Avoid damage! Use care to prevent combustion chamber deposits from entering push rod or oil return cavity in cylinder. Take care not to damage cylinder, top of piston, cylinder head and cylinder head gasket surfaces. Remove only the combustion chamber deposits. It is not necessary to remove the discoloration marks on the piston, valves and cylinder head. These marks are normal and will not affect engine operation. 2. Inspect cylinder head for broken fins or cracks. Repeat procedure for other cylinder head and cylinder.
A

M87026

1. To remove valve stem seals (A), grasp seal with pliers and pull up on seal while turning. IMPORTANT: Avoid damage! Always replace valve stem seals whenever valves are removed for servicing.

Valve Removal
Procedure: 1. Remove the valves, place cylinder on workbench with support to hold valves in place.
A B

C

D

E

B

M87027

2. Faces on valves may be resurfaced with a valve grinder to 45° (E). Valve seats can be reconditioned using valve seat cutter. Valves and seats should then be lapped with valve lapping tool and valve lapping compound. Remove grinding marks and assure a good seal between valve and seat. Thoroughly clean lapping compound from valve seat and valve face.
C

3. Valve margin (B) should be 0.8 mm (0.031 in.) (C). If 0.4 mm (0.016 in.) or less, resurface or replace valve.
M87025

2. Reinstall rocker studs (A) into cylinder head. Do not tighten. Slip end of valve spring compressor (B) under stud of valve spring. Press down on tool handle to compress valve spring and remove split retainers (C). 3. Release pressure and remove retaining washer and spring.

4. Valve seat width (D) should be 1.2 - 1.6 mm (0.047 - 0.063 in.). 5. If seat is wider, it may be narrowed using valve seat cutter. Use 30° side of cutter to narrow the seats. If the valve is badly burned, it should be replaced. Replace valve if margin is badly burned; if damaged, replace cylinder head. Valve seats are not replaceable.

Engine - Briggs and Stratton Repair - 95

the reject dimension for both valve guides is 6. Ream through entire guide.238 in. Flush out all chips. Engine . Lightly coat valve stems with valve guide lubricant and insert valves into valve guides. compress spring and install split retainers (C). Remove rocker studs. Valve stems must be free of foreign material and burrs or sticking will occur and valve stem seals will be damaged. use finish reamer (A) and reamer pilot guide (B) to finish ream valve guide.05 mm (0. Inspect valve springs and replace if broken or worn.). Install springs and valve spring retainers over valve stems. Support cylinder head and press out valve guide. use bushing driver (F).Briggs and Stratton Repair .BRIGGS AND STRATTON REPAIR 6. To install new valve guides (G).). M87028 8. 2. 3. To ream valve guides.) or more. Repeat procedure for other valves. To remove valve guides (G). 7. C B M87025 1. With valve spring compressor (B). Press in valve guide to dimension (H) 7.ENGINE . seat or end of valve stem. Install new seals over valve guides. Press down on seal until it bottoms.96 . Be sure valve guides are free of foreign materials and burrs. If plug gauge is not available. IMPORTANT: Avoid damage! Insure valve guide lubricant is not on valve face. F H Valve Installation Procedure: A G M87029 9.276 in.0 mm (0. Use oil.25 in.4 mm (0. Stanisol or kerosene to lubricate reamer. Inspect valve guides by inserting plug gauge into valve guide. the guide must be replaced. place new valve guide on bushing driver (F). Valve guide can be installed either way. 2. Keep turning reamer clockwise when removing reamer. Valve Guide Ream Procedure: B A F G M87030 1. Temporarily install rocker studs (A) in cylinder head. If plug gauge inserts 6.

each rod. Remove air filter and bracket. Rings and Rod Removal and Installation Procedure: 1. since a new oversized piston assembly must be used.) out of round. IMPORTANT: Avoid damage! When servicing pistons.04 mm (0. Piston pin is a push fit in piston and rod. 2. remove piston pin locks with screwdriver. NOTE: Oil control ring (B) is shown being spiraled into compression ring groove. 3. piston pins or rods. alternator. Deposits may build up on piston pin and require the piston pin to be pressed out. To remove connecting rod from piston. there is no reason to check the piston.0016 in. This will prevent breaking the rings when removing the piston and connecting rod from the engine. B M87036 4. it must be resized. piston pin and ring set must be kept as a set for the cylinder that it was removed from. 5. Remove starting motor. flywheel. Repeat for bottom oil control ring. or 0. the cylinder is not to be resized and the piston shows no signs of wear or scoring.08 mm (0. piston. If cylinder bores require re-sizing it will not be necessary to check pistons and rings since a new oversized piston assembly must be used. Repeat into top compression ring groove.003 in. A M87038 6. upper blower housing.) oversize. NOTE: Remove any carbon or ridge at the top of the cylinder bore. carburetor. cylinder heads and crankcase cover. rings. only the piston rings must be replaced. Spiral top oil control ring from oil ring groove into center compression ring groove.97 . intake manifold and governor linkage. M86904 IMPORTANT: Avoid damage! Remove top and center compression rings using ring expander (A). Mark each set before removing from the engine.ENGINE . providing that cylinder bores are within specifications. Engine . Remove the connecting rod cap. If cylinder bore is more than 0. New piston rings must be installed whenever the engine is disassembled for major servicing or overhaul. NOTE: If the cylinder is to be resized.Briggs and Stratton Repair . NOTE: Measure cylinder bores before checking pistons and rings. and then off piston. Then push the piston and connecting rod out through the top of the cylinder.BRIGGS AND STRATTON REPAIR Piston. If however.

Connecting Rod Inspection Procedure: A B M88925 1. . . .0 in.98 .12 mm (1.674 in. If a 0.Briggs and Stratton Repair . .) for compression and oil ring (B). Reject size of crankpin bearing and piston pin bearing (B) is: Wear Limit Crankpin Bearing .461 in.12 mm (0.BRIGGS AND STRATTON REPAIR Checking End Gap 1.) Engine . . or a 0. 17. . . Never reuse worn piston rings. A worn ring will usually show scratches caused by abrasives and/or have a shiny appearance. . . Never reuse worn piston rings. The correct cylinder cross hatch ensures proper lubrication and piston ring rotation. . Place a new ring in each piston groove. .) Piston Pin Bearing . If the crankpin bearing (A) in the connecting rod is scored. .ENGINE . . the rod must be replaced.20 mm (. .004 in. . . 37. . . 2. . If ring gap is greater than 0. This will restore the proper cross hatch angle in the cylinder bores. Clean carbon from top two ring grooves.) down into a cylinder bore. . Insert old rings one at a time approximately 25. .) or larger feeler gauge (A) can be inserted in the compression ring grooves. . .030 in. the ring is worn and should be replaced. . NOTE: Before installing new piston rings. the cylinder bore should be reconditioned using a rigid hone with finishing stones. B C A M86906 2.) or larger feeler gauge can be inserted in the oil ring grooves.10 mm (. the compression and ring grooves are worn and the piston should be replaced. 3. 3. Piston Inspection Procedure: 1. M86905 c CAUTION: Avoid injury! Note that extremely the top and bottom edges of the ring may be sharp.80 mm (0.4 mm (1.008 in. . Check end gap with feeler gauge (C).

6. The oil ring is installed with the expander (F) between the two oil control rings. 8. . . . . 7. . Then install other piston pin lock. . . . J D E M88927 5. Install expander first. M88929 K M88930 Engine .672 in. . Using ring expander.674 in. .ENGINE .99 . . 17. Spiral bottom oil control ring into top ring groove. .) out of round or below reject size. . it must be replaced. 17. . The top and second compression rings are installed with “ID” mark (G) toward top of piston. . . .12 mm (0. . . Be sure both locks are seated in grooves. Repeat procedure for top oil control ring. . top compression ring (barrel face) (I) as shown above. The piston pin is a slip fit in both piston and connecting rod.0004 in.BRIGGS AND STRATTON REPAIR C G M88926 M88928 2. or “Out 2” cylinder number two) (D) in relation to notch or circle (E) on piston.Briggs and Stratton Repair . . . install center compression ring (taper face) (H) then.) Piston Pin Bore. Insert piston pin from opposite side of piston until pin stops against piston pin lock. If piston pin is worn 0. The correct piston ring positions are shown above.) 4. . Replace connecting rod if either bore is worn. . Reject sizes for piston pin and piston pin bore (C) are as follows: Specifications Piston Pin .01 mm (0. then into second ring groove and into position below expander. . Use a thin nose pliers or screwdriver and install a piston pin lock in groove on one side of piston. .06 mm (0. . . . Refer to above drawing to determine correct location of rod (“Out 1” cylinder number one. . . . 3. .

1 and “OUT-2” on the side of the connecting rod for cylinder No.Rotate crankshaft two revolutions to check for binding. NOTE: Failure to use a torque wrench can result in loose connecting rods causing breakage. Tighten ring compressor until rings are fully compressed. Rod should also be free to slide sideways on crankpin. Rotate crankshaft until crankpin journal is at bottom of stroke.BRIGGS AND STRATTON REPAIR 9. 15. when pushed into cylinder. piston and rod assembly. N E L M O M88933 13. Compress rings with ring compressor tool (K).Thoroughly clean and oil cylinder bore. 2 (D) should face toward the PTO side (M) of the crankcase. Push down until head of piston and edge of ring compressor are even.100 . If other piston and rod assembly was removed. When the circle on piston (E) is facing toward the flywheel side (L) of engine.Install connecting rod bolts (O) and tighten to 11 N•m (100 lb-in. NOTE: The pistons have offset piston pin bores. This permits complete entry of compressed rings. Apply oil to piston rings and piston skirt. Then loosen ring compressor very slightly so that compressor can be rotated on piston skirt while holding connecting rod. 14. or tight connecting rods causing scoring. 11. NOTE: Approximate location of projections (J) on ring compressor shown above. 12.Install rod cap with match marks (N) aligned. M88932 Engine .ENGINE . These will be inserted to the cylinder bore when assembling piston to cylinder. Place piston and ring compressor upside down on bench.Briggs and Stratton Repair . the words “OUT-1” on the side of the connecting rod for cylinder No.Clean and oil crankshaft crankpin. repeat procedure for that cylinder.). M88931 D 10.Pull connecting rod against crankpin.

. Specifications Standard Bore Size Minimum . stripped bolt holes. .003 in. Use a telescoping gauge (A) and a dial caliper. . . . . . Then thoroughly wash cylinder and crankcase using a stiff brush with soap and hot water. or replaced. . .101 . . 2. or 0.) of the desired size or when reconditioning a cylinder bore.038 mm (0. Rinse thoroughly with hot running water. Be careful not to hone oversize or it will be necessary to resize the cylinder. . The cross hatch cylinder finish should be applied after cylinder bore has been resized to within 0. and ensure proper lubrication and piston ring rotation. new piston rings may be installed providing the cylinder bores are reconditioned using a rigid hone with finishing stones.0016 in. .) oversize. . . . middle (C) and bottom (D). The correct hatch angle is approximately 45° (A).Briggs and Stratton Repair . 72. or use an inside micrometer to determine the size of the cylinder bore.ENGINE . NOTE: To produce the proper cross hatch finish use a drill speed of approximately 200 rpm and 40 . . . .) out of round. This is necessary to restore the cross hatch angle in the cylinder bores. 3.) Maximum . Honing grit is highly abrasive and will cause rapid wear to all of the internal components of the engine unless it is completely removed. If cylinder bores are within specification and show no signs of scoring or other damage. Cylinder Bore Cleaning IMPORTANT: Avoid damage! Ensure that the entire cylinder and crankcase are thoroughly cleaned after honing. .) 1. .025 mm (2. .60 strokes per minute. . . Measure at right angles at six locations from the top (B). Lubricate hone liberally to prevent build up on finishing stones. If the cylinder bore is more than 0. . . . See “Resizing Cylinder Bore” on page 102.BRIGGS AND STRATTON REPAIR Cylinder Bore Inspection Procedure: C A C D Cylinder Bore Honing Procedure: A M86883 M86885 1. . it must be resized. . . Always inspect cylinder after engine has been disassembled. . 72.836 in.835 in. . . . Visual inspection will show if there are any cracks. . First wash the cylinder and crankcase carefully in a solvent such as kerosene or commercial solvent. broken fins or if the cylinder walls are damaged. . It is recommended that the cylinder bores be reconditioned to restore the cross hatch when new piston rings are to be installed in a cylinder that is within specification.0 mm (2.0015 in.04 mm (0.08 mm (0. . . 2. The finishing stones will produce the correct cross hatch necessary for proper lubrication and piston ring rotation. Repeat washing and rinsing until all traces of honing grit are gone. . Engine . .

10. with a starting point below the wearing of ring travel (F). If a hone is used to resize the cylinder bore.102 . . Do not travel more than 19. 4.835 in. use a clean white rag or napkin to wipe the cylinder bore.836 in. Lubricate hone frequently to prevent build up on stones. 72.51 mm (0. Start drill and. . . 11. Tighten adjusting knob with finger until stones fit snugly against cylinder wall. . . See “Cylinder Bore Honing” on page 101. . Oil the cylinder bore to prevent rusting.) (G) above cylinder bore.After cylinder bore has been brought to proper resizing dimension.) Maximum . . 72. . Connect driveshaft to hone. When there is no trace of honing grit on the rag.025 mm (2. . .) over standard size. When the cylinder and crankcase have been thoroughly cleaned. the cylinder bore will be round above and below ring travel (D). .60 strokes per minute. 9. 5. maintaining proper clearances. Always resize to exactly 0. rewash and rinse entire cylinder and crankcase and check again. it will have to be resized using a boring bar or hone. the service oversize rings and pistons will fit correctly. . . move it up and down at the bottom of the cylinder bore. . .BRIGGS AND STRATTON REPAIR Procedure: 1. . Gradually increase the length of the strokes until hone travels full length of cylinder bore (E). If this is done accurately. . place hone in middle of cylinder bore (A). If any honing grit is evident. 12. . . a cross hatch must be applied to bore. . 7. a hone must be used after the boring operation to produce the proper cylinder cross hatch. 2.As cutting tension decreases. . If honing grit is present it will appear as a gray residue on the rag.Briggs and Stratton Repair . as hone spins. . .ENGINE . Specifications: Standard Bore Size Minimum . . . If the cylinder bore is not within specifications.Check cylinder bores at top and bottom for burrs. . .Check cylinder bore size frequently. Because cylinder bores normally wear (B) only in the area of ring travel (C). . 6.5 mm (0. 3.020 in. . the cylinder is properly cleaned. .) to 25. IMPORTANT: Avoid damage! If a boring bar is used. stop hone and tighten adjusting knob following hone manufacturer’s recommendations. DO NOT FORCE.) Engine . . . . .0 in. . . . Remove burrs. . The recommended drill speed is 300 to 700 rpm maximum and 40 . D A G E F 13.750 in. B C Resizing Cylinder Bore Procedure: 8. Be sure that cylinder and hone are centered and aligned with driveshaft and drill spindle.4 mm (1. G M88942 1.0 mm (2. Lubricate hone as recommended by hone manufacturer. Cylinder head and crankcase cover surfaces must be free of burrs and gasket material.

using 30 mm (B) socket and wrench. Install flywheel.ENGINE . Place flywheel holder (A) on fan retainer with lugs of flywheel holder engaging slots on fan retainer. broken flywheel fins.BRIGGS AND STRATTON REPAIR Flywheel Removal and Installation Models Without Electrical Outlet: 1. While flywheel holder. M89926 3.103 . 8. B M89927 12. Engine . C D E G H A MX9624 4. 9. 2. Before installing flywheel. 7. While holding flywheel holder. Flywheel should be inspected for cracks. clean taper and crankshaft taper removing all oil. Install flywheel puller (F) turning puller screws into flywheel puller holes evenly. to 175 N•m (125 lb-ft). Remove blower housing. 6.Place flywheel holder (A) on fan retainer with lugs of flywheel holder engaging the slots of the fan retainer. loosen flywheel nut using 30 mm (B) socket and wrench. F MX9625 A B 5.Align boss (G) on back of fan (E) with notch (H) in flywheel. Remove rotating screen. rust or other damage. Remove two screws (C). burrs on taper or keyway and distortion of keyway. 11. Replace crankshaft.Briggs and Stratton Repair . IMPORTANT: Avoid damage! Protect crankcase threads during flywheel removal. if damaged. Remove flywheel. dirt or grease. Also check taper of crankshaft for burrs. 10. tighten flywheel nut. Tighten puller screws equally until flywheel loosens.Install flywheel nut. fan retainer (D) and fan (E).

fan retainer and fan. 9. Back out the puller screw (D) until the until the puller flange rests on the flywheel as shown. Tighten the screws securely. 3.BRIGGS AND STRATTON REPAIR Models With Electrical Outlet . Remove the flywheel nut. Mark the flywheel (B) as shown to locate the flywheel keyway (C) when reinstalling.Removal: c CAUTION: Avoid injury!will rapidly draw the The flywheel magnets are very powerful and flywheel to the engine or to any metal surface. Remove ignition stators. Align the holes in the puller flange with the holes in the flywheel. 6. Install the puller screws (F) to the flywheel. Use only correct tools and procedures. F MX14268 A B 7. Disconnect negative (-) battery cable. G MX14267 Engine . Special or Required Tools: • JDG640 Flywheel Removal Tool F D E Procedure: 1. 2. C D MX14266 5. Install the correct flywheel pilot (A) to the crankshaft. 4.Briggs and Stratton Repair . through the puller flange holes. Place the flywheel removal tool (E) over the flywheel pilot. Serious hand and/or finger injury can result. 8.ENGINE .104 . Access the flywheel.

Continue tightening the puller screw until the flywheel is clear of the stator and can be lifted from the crankshaft.Leave the flywheel puller attached to the flywheel. tap lightly with soft hammer on alternate sides near dowel pins (B). Models With Electrical Outlet . NOTE: Leave the flywheel puller screw (D) in this position.012 in. Install the flywheel nut. Remove crankcase cover. Remove governor control bracket.0. 1. Place the flywheel and puller on a clean work surface with the ring gear side down. This will eliminate or reduce chances of damaging the crankcase cover bearing. Reassemble the fan and fan retainer to the flywheel. Align the flywheel keyway mark with the crankshaft key (D). remove the flywheel puller tool and pilot from the flywheel. 2. 4. Make certain the pilot is correctly inserted to the crankshaft. With the flywheel puller removal tool (B) installed to the crankshaft (C).Installation: 3. Remove oil fill tube and dipstick assembly. If crankcase cover sticks.Briggs and Stratton Repair . 1.ENGINE .105 . NOTE: Be sure the flywheel magnets are free of debris before installation. Engine . With the flywheel in place on the crankshaft and with the keyway engaged to the key. place flywheel (E) with the puller attached.Hold the hex on the flywheel puller (G). Slowly loosen the flywheel puller screw (A) to lower the flywheel into position over the stator as shown. A M87035 A NOTE: Before crankcase cover (A) is removed. Adjust ignition coil air gap to 0. Be certain the correct flywheel puller is properly installed to the flywheel and that the puller is extended to the position it was in when the flywheel was removed. Crankshaft Removal and Installation Procedure: c CAUTION: Avoid injury!will rapidly draw the The flywheel magnets are very powerful and flywheel to the engine. Use care when handling the flywheel.30 mm (0. Serious hand and/or finger injury may result! IMPORTANT: Avoid damage! The flywheel magnets are fragile. 5. Tighten the puller screw (D) until the flywheel loosens. MX14270 E B C D IMPORTANT: Avoid damage! DO NOT remove dowel pins. 6. Do not drop or handle the flywheel roughly. onto the pilot. it is recommended that any rust. Tighten to 175 N•m (125 lb-ft). intake manifold and cylinder heads. Remove governor lever and disconnect governor link and springs. Install ignition coils. 3. paint or burrs be removed from power take off end of crankshaft. 2.).BRIGGS AND STRATTON REPAIR 10. 11. Remove exhaust manifold.008 . Make sure the flywheel keyway engages the crankshaft key.20 0.

92 mm (1. . . . . 5.) IMPORTANT: Avoid damage! All wear points on the crankshaft must be measured. 7.Check timing gear for chipped or cracked teeth. Journal .Remove crankshaft from crankcase. . With cam gear in this position the valve tappets will remain clear of cam lobes. .Mag.Gear Teeth . Keyways should be checked to be sure they are not worn or spread. .Timing Gear Teeth .Oil Galleries . .106 .95 mm (1. 34. . . 34. Check oil galleries for blockage or obstructions. . .PTO Journal . Mark the connecting rods and caps to prevent interchanging when reassembling.12 mm (1. . .Mag.Exhaust Lobe . C Specifications Wear Limit Sizes PTO Journal . . . . . . . 11.Flywheel Pivot . the balls should move up into the locked position. Tappets must not be mixed. lobes and journals for wear and nicks.Intake Lobe 12.Crankpin .276 in.) Crankshaft Crank Pin.Briggs and Stratton Repair . .Spring . . . .Inspect cam gear teeth. . . Engine . When the centrifugal weight is released. . .461 in. M88934 4.Oil Galleries .PTO Journal . Journal . Remove piston and connecting rod assemblies. 13. Replace if needed. .Keyway .375 in. Support engine to prevent end of crankshaft from resting on workbench. Rotate crankshaft until timing marks (C) are aligned.Threads and Keyway A B C D E F G H I .BRIGGS AND STRATTON REPAIR 10.Compression Release Balls . .Cam Lobes .ENGINE . .Replace crankshaft if worn or if journals are scored. 6. . Cam gear journal and lobe reject sizes are as follows: 8. . Journal . Tip engine onto flywheel side of crankcase. . 9. . . Remove burrs from keyway edges to prevent damaging the bearing or oil seal. IMPORTANT: Avoid damage! If engine is rotated from this position. tappets will fall out.) Mag. 14. . . . . . . B C D C D E B A A I H G F M88937 E H G F M88935 A B C D E F G H . . Lift out cam gear and governor assembly. 37. .The compression release balls must be clean and free to move when the centrifugal weight is rotated counterclockwise.

Install governor lever and governor springs.Install engine shrouding. . 8 6 5 7 2 9 4 M88941 21. . 16. . .Install air filter assembly. 22.BRIGGS AND STRATTON REPAIR Specifications PTO Journal . .Tighten cover bolts to 17 N•m (150 lb-in.) Cam Lobe . NOTE: Be sure O-ring (H) is installed in crankcase.Install intake manifold and carburetor assembly. . . 19. Engine .107 . 30. . . 24. . . Flywheel must pivot freely.) in the sequence shown above. M88938 3 1 15. . . .) J I D E M88940 F G 19.) Mag Journal . .Install flywheel. 25. . . . . . . . .Install crankshaft and camshaft. . . .25 mm (1. Make sure hinge pins are not loose.Rotate governor shaft (I) against boss (J).ENGINE . .92 mm (0. . . . . . . .93 mm (0.Assemble governor slider onto PTO journal on cam gear making sure that slot on slider fits over locating pin (E) on cam gear. Tip engine to position crankshaft horizontally. . Governor weights must move freely on hinge pins.Take care to protect the oil seal while assembling crankcase cover. . . if required. 17. . No force should be used. . 15. . .Briggs and Stratton Repair .191 in.Governor slider (D) must move freely on PTO journal of cam gear. 26. Be sure the weights are in the proper location so that they will be able to move freely without binding.Install cylinder heads.627 in. .Place new crankcase cover gasket on crankcase. .Install oil fill tube and dipstick assembly. aligning timing marks (F) accordingly. . Perform static governor adjustment. . . .784 in. . H M88939 28. 20. Install thrust washer (G). . 23. 18. . 27. . . Make sure flyweight spring is not stretched. .

8 mm (3/16 in. The magneto bearing has a roll pin (A) installed in the oil gallery to prevent the bearing from turning. grind off the taper (E). Use a 4. M88947 5. C M88945 Engine .Briggs and Stratton Repair . Check the main magneto bearing as shown. Replace if scored or if not within tolerance. . To install magneto bearing. . . .383 in. Specifications Mag Bearing Reject Size (ID) .108 .BRIGGS AND STRATTON REPAIR Magneto Bearing Inspection Procedure: 3. first remove oil seal. To remove magneto bearing. Position new bushing against counterbore bearing in crankcase and carefully align oil holes in bushing with oil gallery holes in bearing.12mm (1. Press in new bushing with a suitable bushing driver tool. . .) D M88946 NOTE: Be sure oil holes in bushing are aligned (D) with oil gallery holes in bearing. Remove all burrs and clean thoroughly. .) (F) from one end of new roll pin. Press out old bushing with a suitable bushing driver tool (C). . . Before installing the new roll pin. Place the new roll pin into a second oil gallery hole.) punch (B) to drive roll pin into oil gallery. . approximately 3 mm (1/8 in. place cylinder on a suitable cylinder support. E F B A M88944 2. To remove the magneto bearing. 35. Quench pin in water periodically to prevent loss of temper. 4. M88943 1. .ENGINE . . . . place cylinder on a suitable cylinder support. NOTE: The old roll pin was driven into an oil gallery hole. . Do not use same gallery as the original pin.

. . M88912 PTO and Cam Bearing Inspection Procedure: NOTE: A leak at the seal between the tube and crankcase cover. This vacuum prevents oil leakage past piston rings. Place tapered end of new roll pin in oil hole in bearing. Install new oil seal using a suitable cylinder support. Remove oil pump. 35. Always use the correct seal protector to prevent damaging oil seal.109 .07mm (1. . Press in seal until it is flush with mounting surface. Install new PTO oil seal using a cylinder support. .Briggs and Stratton Repair . M88950 1. can result in a loss of crankcase vacuum and a discharge of oil or smoke through the muffler. 4. . oil seals. . Before breather valve assembly (A) can be removed for inspection. Specifications: PTO End Bearing Reject Size . 20. Remove oil seal. valve guides.ENGINE .04mm (0. to install new roll pin. The crankcase cover must be replaced if PTO bearing or cam bearing is scored or if dimensions exceed reject size. 1. . governor shaft and gaskets. 3. Drive in new roll pin until tool bottoms. Engine . . . .789 in.) Cam Bearing Reject Size . Use roll pin driver. or at the seal at the upper end of the dipstick.381 in. The engine utilizes a breather valve to control and maintain a vacuum in the crankcase.) NOTE: Always install new oil seal whenever engine is disassembled for major servicing or when repairing bearings. The breather valve closes on the up stroke of the piston and opens on the down stroke of the piston to maintain a vacuum in the crankcase. the air cleaner assembly and support bracket must be removed. Inspect PTO bearing and cam bearing. Press in new oil seal until it is flush with cylinder.BRIGGS AND STRATTON REPAIR Lubrication Breather Valve Service M88948 6. 7. A M88913 2. 2.

A .ENGINE . Slip large O-ring (D) onto mounting screw and install screw and tighten to 3 N•m (30 lb-in. Check to see that reed valve is not deformed. IMPORTANT: Avoid damage! Do not use force on reed valve (B).Outer Rotor M88918 Engine .).110 . Replace if damaged. Place breather on gasket (C). C A M88915 4. M88919 B A C M88916 C E D D 5. The reed valve (B) is spring loaded and must make a complete seal around the vent hole in breather body.Briggs and Stratton Repair .BRIGGS AND STRATTON REPAIR E B M88914 3. M88917 6. holes or hardening. The breather is vented through the air cleaner to prevent dirt from entering the crankcase. When installing breather valve assembly (A). Oil Pump Removal This engine is equipped with a full pressure lubrication system with an oil filter. Check breather tube (E) for cracks. make sure breather gasket (C) is located properly.

. ambient air temperature differences. Remove crankcase cover. lubricating the connecting rods. Disconnect the negative (-) battery cable from the battery.). Tighten screws (F) to 7 N•m (65 lb-in. Starting Motor Removal and Installation Removal: 1. . operating temperatures and engine load. . 6. Disconnect battery positive (+) cable (A) from starting motor. The filtered oil flows through oil galleries (passages) in the crankcase cover and cylinder where it is distributed to the main bearings and cam gear bearings. G F M88920 3. . Slip oil intake screen (H) into slots in crankcase cover. . . .Pressure Relief Valve . . . 4. . Specifications: Oil Pressure . . Engine . . Disconnect wires (B) from the starting motor. The oil pump is attached to the inside of the crankcase cover. 4. 5. . Install oil pump. .BRIGGS AND STRATTON REPAIR B C D E . . 2. Remove two screws (F) and O-Rings (G) attaching oil pump assembly to crankcase cover. An oil gallery in the crankshaft supplies oil from the magneto bearing to the crankpin. . . . .Inner Rotor . Remove oil fill dipstick assembly.Pump Housing The gear driven oil pump supplies lubrication to all bearing journals. oil intake screen may be removed for cleaning. The oil pump draws oil through a screened pick up in the engine base and pumps the oil through the oil filter.ENGINE . Remove starting motor bolts (C) and starting motor. . . Procedure: 1.50 psi NOTE: Engine oil pressure will vary with oil viscosity. . . G C I H F M88921 B M95074 A 2. With pump removed. Be sure to install new “O” rings (G) on pump mounting screws (F). The outer rotor of pump can be removed for inspection and cleaning. A pressure relief valve located in the oil pump housing limits the maximum oil pressure in the system. 3. .Briggs and Stratton Repair .111 . . .Drive Gear . NOTE: Boss (I) on oil pump body holds intake screen in proper position. 10 .

. M95076 3. NOTE: Solenoid plunger is hooked over solenoid shift lever in starting motor housing. . . . . . . . . . E F M95077 7. .Briggs and Stratton Repair . . . If the solenoid plunger is broken. . Using a multimeter or ohm meter. . replace the solenoid. . . . . D A M95075 1.BRIGGS AND STRATTON REPAIR Installation: 1. . . . . . check the following for correct resistance: B D to E.ENGINE . . . . . . G 4. . . No Continuity E to F . . . . . . Install starting motor bolts and tighten to 15. does not move freely. . . . . . 3. Slide wire off of solenoid lug. . . 6. . . .). . . Connect electrical wires and battery cable. Engine . . . . . . . . Remove nuts (B) from solenoid mounting bolts. . . 2. . . . .112 M95083 . . . Slide solenoid out of staring motor housing and lift away from starting motor housing to remove plunger (C) from shift lever. . No Continuity D to F . . replace the solenoid. 2. . . . Remove nut (A) securing braided copper wire to solenoid. Less than 1 ohm D and F to solenoid housing. Starting Motor Disassembly and Inspection Special or Essential Tools: • Multimeter or ohm meter C M95078 Procedure: 5. . . . . . . . . . . If the resistance measured is not correct. . Connect the negative (-) battery cable to the battery. . . .8 N•m (140 lb-in. . . Inspect plunger (C) for wear or damage. . . . Press plunger into solenoid to check spring compression and freedom of movement. . or there is little or no spring tension. .1 to 2 ohms 8. . . . . . . .

113 . replace the lever. dirt. IMPORTANT: Avoid damage! DO NOT use emery cloth to clean the commutator (J). The pinion gear should rotate and slide on the armature shaft smoothly. Inspect starting motor pinion gear (G).Briggs and Stratton Repair .Inspect the shift lever (H) for damage. 14.Shift Lever Engine . Starting Motor Assembly M95084 10. Ensure that shift lever operates pinion gear. H NOTE: The armature should not be soaked in a cleaning solution.Check the brushes should for proper seating.When all parts have been thoroughly cleaned.BRIGGS AND STRATTON REPAIR 9. 12. If the shift lever is damaged or does not move the pinion gear in and out of starting motor. oil or corrosion. 15. A E D H E L M95079 F B 11.Remove the shift lever and pivot.Remove the two bolts securing the starting motor housing halves together. Slide the armature housing off of the starting motor.ENGINE . can be used to clean the armature. lightly lubricate the bearings with #20 oil.Front Cover B .Remove the armature assembly (I) from starting motor housing. The particles from the cloth will become embedded in the commutator and cause rapid brush wear. weak brush springs. M94902 A . K C J I H I G M95080 G J 13. Fine sandpaper. such as crocus cloth.

ENGINE . 11. Tighten bolts to 15.Solenoid . Carefully slide braided copper wire over solenoid lug. 9.Briggs and Stratton Repair . Install starting motor.Connect wires (F) to starting motor. C F G M95074 8.BRIGGS AND STRATTON REPAIR C D E F G H I J K L .Insulator . Secure wire to lug with flange nut (D). Install starting motor drive. 10. A E M95079 1. Ensure shift lever fork is seated in pinion gear shift collar (B).Pinion Stopper . M95076 6. 3.). brush housing and end cap over armature. Engine .114 . Secure solenoid with two nuts (C). Liberally lubricate shift lever with grease. Install armature housing. 2.Pinion .8 N•m (140 lbin.Connect negative (-) battery cable to battery. Install solenoid to starting motor. 4. Ensure solenoid plunger seats over shift lever fork.Brush Holder .Brush D M95075 B 7.Armature .Brush Springs . Place armature in housing end.Retaining Clip . Install through bolts (E) in starting motor. 5. Install shift lever (A). Secure with two long cap screws.End Cover . Connect battery cable (G) to starting motor.

........................141 Blower Housing Removal and Installation .......................................................................... 149 Lap Valves ....................124 Theory of Operation .....130 Fast Idle Speed Adjustment .........120 Tools........................................138 Air Cleaner Assembly Removal.... 163 Starting Motor Disassembly and Assembly.................. 162 Armature Removal and Installation.......................... 166 Engine ...................118 Torque Specifications........140 Fuel Pump Replacement........................120 Other Materials.........................132 Cylinder Compression Pressure Test........................................ 148 Recondition Valve Seats........125 Lubrication System Operation ................................................ 146 Cylinder Head Removal and Installation..... 161 Stator Removal and Installation............................. 161 Governor Inspection and Replacement .............127 Tests and Adjustments .........123 Engine Oil Flow Chart ......................................115 ................................................................................................. 150 Piston and Connecting Rod .. 151 Analyze Crankshaft and Connecting Rod Wear .. 162 Starting Motor Removal and Installation........... 161 Governor Shaft Inspection and Replacement .............................ENGINE ...................................126 Starting Motor Troubleshooting Guide ............... 155 Camshaft and Tappets ............117 General Specifications .................................................................................................139 Carburetor Removal and Installation..............138 Throttle Control Lever and Cable ..............................................KAWASAKI (FH580V) TABLE OF CONTENTS Engine .....117 Repair Specifications............Kawasaki (FH580V) Table of Contents .......................125 Diagnostics ...............................................137 Repair...................................121 Service Parts Kits .................122 Engine Components....135 Fuel Pump Test ..128 Throttle Cable Adjustment.................143 Engine Removal and Installation ........................................................................................117 Test and Adjustment Specifications .................122 Carburetor Component Location ... 158 Resize Cylinder Bore ...................... 143 Rocker Arm Removal and Installation ......................... 163 No-Load Amperage Draw and RPM Test ...........128 Choke Cable Adjustment....139 Carburetor Disassembly and Assembly .......142 Breather Removal and Installation .........130 Slow Idle Speed Adjustment ...... 159 Oil Pump Disassembly and Assembly ...........................120 Tools and Materials ...................... 158 Deglaze Cylinder Bore....................129 Governor Adjustment ...... 150 Crankcase Cover Removal and Installation . 159 Oil Filter Manifold..................128 Choke Plate Check and Adjustment .................................138 Muffler Removal and Installation ........135 Spark Test .........................133 Engine Oil Pressure Test .................................... 155 Crankshaft and Main Bearings .....................................126 Engine Troubleshooting Guide...133 Crankcase Vacuum Test ........................................... 157 Crankshaft Oil Seals ..........................................121 Component Location..............................142 Flywheel Removal and Installation....136 Spark Plug Gap Adjustment ...................................................131 Valve Clearance Check and Adjustment.........................Kawasaki (FH580V) Table of Contents Specifications ............... 147 Cylinder Head Inspection...........137 Ignition Coil Air Gap Adjustment ...

116 .KAWASAKI (FH580V) TABLE OF CONTENTS Engine .ENGINE .Kawasaki (FH580V) Table of Contents .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . .4 cm (0. . . . . . . . . . .) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 N•m (61 lb-in. . . . . . . . . . . . . . . . . . . . . . . . .006 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Rocker Arm Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENGINE . . . . . . . . . . . . 241 . .002 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spin-On Filter Engine Oil Capacity With Filter . . . . . . .6 US qt Cooling System . . . . . . . . . . . . . Gasoline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. . . . . . . . . . . . . . . .27 . . . . . . . . . . . . . . . . . . . . 4 Cycle Bore . . . . . Champion RCJ8Y Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . Single Element. . . . . . . . . . 74 mm (2. . . . . . . . . . .9 N•m (61 lb-in. . . . . . . . . . . . . . . . . . . . . . . .) Engine . . . . . . . . . . . . GT235 Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki V-Twin Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25. . . . 13. . . . . . . .Horizontal discharge below frame Test and Adjustment Specifications Slow Idle (Governed) . . . . . . . . . . . . . . . . . . . . . . . . . . .004 . . . . . . . . . .8 qt/60 seconds) Fuel Pump Push Rod Bend (Maximum) . . . . . . . . . . . . . 390 kPa (57 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . .) Valve Adjustment Screw Jam Nut Torque . . .15 mm (0. . . . . . . . . . .117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . .Kawasaki (FH580V) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . .10 . . . . . . . . . 1700 rpm Fast Idle . . . . . . . . . . .0. . . . . . . . 22 N•m (195 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Lubrication . . . . . . . . . . . .7 cu in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Replaceable with Foam Pre-cleaner Muffler . . . . . . . . 2 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 US qt) Without Filter . . . . . . . . . . . . . . . . . .91 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Spark Plug Type . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 psi) Fuel Pump Minimum Flow (at slow idle). . . . Pressurized Oil Filter . . . . . . . . . . . . . . . . . . . .68 in. . . . . . . . . . . . . . . . . . . . . . .) water Oil Pressure at Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 kPa (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Stroke/cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5:1 Valves . . . . . . . 0. . . . . . . . . . . . . . . . . . . . .) Minimum Crankcase Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Stroke . . . .05 mm (0. . . . 585 cm3 (35. . . . . . . . . . . . . . . . . . . .030 in.0 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 L 1. . . . . . . . . . . . . . . . .45 psi) Oil Pressure Switch (open to close) . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . .7 L (1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow.10. . . . . . . . . . . . . 3400 rpm Minimum Cylinder Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . .5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . .310 kPa (35 . . . . . . . . . . . . . . . . . .2 psi) Fuel Pump Minimum Pressure (at slow idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 kPa (14. . . . . . . . . . . . . . . 41 kPa (6 psi) Valve Clearance (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .KAWASAKI (FH580V) SPECIFICATIONS Specifications General Specifications Engine Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH580V-AS04 Horsepower. . . . . . . 800 mL/60 seconds (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 kW (18 hp) Cylinders . . . . . . . . . . .75 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2. . . . . . . .

. .) Repair Specifications Cylinder Head: Cylinder Head Flatness (Maximum Warp) .) Piston Pin Bore OD (Maximum) . . . . . . . . . . . . . . . . . . . . .Kawasaki (FH580V) Specifications . . . . .) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 mm (0. . . . .) Valve Seating Surface Width Intake . . . . . . . .08 mm (0. . . . . .0004 in. . . . . . . . . . . . . 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . .) Cylinder Bore Out of Round: Standard . . . . . . . . . . . . . . . .628 in. . . . . . . . . . . . . . . . . . . . .6 . . . . . . 0. . . . . .) Valve Stem OD . . . . . 0. . . . . . . .79 mm (2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 mm (0. . . 5. 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 in. . . . . . . . 5. .633 in. . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . .118 . . . . . .) Piston OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 mm (0. . . . 6. . .8 N•m (69 lb-in. . . . . . 50 amps at 5000 rpm Brush Length (Minimum) . .01 mm (0. . . . . . . . . . . . . . . . . 15 N•m (132 lb-in. . . . . . . . . . . . . . . . . .006 in.024 . . . . . . . . . . . . . . . . . . . 20° BTDC Resistance between primary lead and core. . . . . . . . . .KAWASAKI (FH580V) SPECIFICATIONS Ignition Coil: Ignition Coil Air Gap.234 in. . . . . . . . . . . . . . . . . . . . . . . . . . 75. . .0. . . . . . . . . . . . . . . . . . . . .) Wire Connection to Solenoid Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . .15 mm (0. . . . . . . . . . . . 73. . . . . . . . . . . . . . . . . . . . . . . . . . . .06 in. . . . .) Wear Limit .04 . . . . . . . . . . . . . . . . . .) Piston Pin Bearing ID (Maximum) .49 mm (2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002 in.) Engine . .) Valve Seating Surface Width Exhaust . . . . . . . . . . . . . . . . . . . . . . . . .633 in. . . . . . . . . .008 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 k Cap Screw Torque . . . . . . . . . . . . .) Mounting Bolts . . . . . .ENGINE . . . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . .) Starting Motor: Amperage (No Load) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 mm (0. . . . . . . .30° Cylinder Bore. . . . . . . . . . . . . . . . . . .05 mm (0. . . . . . . . . . . . . . . .1. . . . . . . . . . . . .20 mm (0. . .) Valve Stem Bend (Maximum). . . . . . . . . . . . . . . . 6. . . .014 in. . . . . . 16. . . . . . . . . . . . . . . . . . . . . . .05 mm (0. . . . . . . . .020 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 mm (0. . . . .30 mm (0. . . . . . . . . . . . . . . . . . . . . .) Valve Guide ID (Maximum). . . . . . .239 in. . .0 mm (1. . . . . . . .220 in. . . . . . . . . . . . . . . . . .006 in. . . . . . . . . . . . .08 mm (0. . . . . . . . . . . . . . . . . . . . . . 0. . . . . . .233 in. 1. . . .) 0. . . . .Intake (Minimum) . . . . . . . . . .) Valves and Valve Lifters: Push Rod Bend (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . .93 mm (0. . . . . . .002 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . . . . . . . . . . . .8 N•m (84 lb-in. . . . . 0. . . . . . . . . . . . . . . . . . . . . . .905 in. . 9. . . . . . . . . . . . . . . . . . . . . 31. . . . . . . . . . . . . .056 mm (0.4 mm (0. . . . . Pistons and Rings Ring Groove Side Clearance (Maximum): Top Ring . . . .) Ignition Timing (@3000 rpm) . . . . . . 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0022 in. . . . . . . . . . . . . . . .9 mm (0. . . . . . . .45° Valve Narrowing Angle. . . . . . .) Second Ring . . . . . . . . . . . . . . . . . .012 in. . . . . . . .) Oversize Piston . . . . . . . . . . . . . . . . . . . . . .970 in. . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . 0. . . . . . .) Valve Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . .020 in. . . .) Valve Seat and Face Angle .) Valve Stem OD . . . . . . . . . . . . . . . . . . . . . . . . .5 mm (0. . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Piston Pin OD (Minimum) . . . . . . . . . . .) Valve Margin (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . .Exhaust (Minimum) . . . . . . . .035 in. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .374 in.) Wear Limit (Maximum) . . . . . . . . . . . . . . . . . . . . . 0.4747 . . . 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4752 in. . . . . . . . . . . .50 mm (0. . . . . . . . . . . . . . . . . . .912 . . . . . . . . . . . . . . . . . .93 mm (1. . . . . . . . . . . . .80 mm (0. . . . . . . . . . . . . 9. . . . . . .) Lobe Height (Minimum) . . . . . . . . . . . . . . . . . .) Engine . .2. . 73. . . . . . . .50 mm (1. . . . . . . . . . . . . . . .) Crankcase Cover Plain Bearing ID (Maximum) . . . . . . . . . . .) Oil Ring End Gap (Minimum) . . . . . . . .) Wear Limit (Maximum) .430 in. . . . . . . . . .1. . .90 mm (1. . . . . . . . . . . . . . . . . . . .) Compression Ring (Second) . . .50 mm (2. . . . . 39. . . . . . . . . . . . . . . . . .131 mm (1. . . .74. . . . . . .932 . . . . . . . . .) Crankshaft Crankpin Width (Maximum) .37. . . . . . . . . . . . .Kawasaki (FH580V) Specifications . . . . . . . . . . . . . . . .ENGINE . . .2 mm (0. . . 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .933 in. . . . . . . . . . . . . . . . . 16. . . . . . . . . . . . . . . . .94 mm (1. .498 in.) Crankshaft Main Bearing Flywheel Journal OD (Minimum) . . . 40. . . . . . . . . . . . . . . . . . . . . . . . . . . .913 in. . . . . .05 mm (0. . . . . . . . . . . . . . . . . . . . . . . .136 mm (0. . . . .) 0. . . . . . . . . . . . . . . . . . 15. . . . . . . . . . . . . . . . .) Bearing ID (Minimum) . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . .15 mm (1. . . . . . . . . . . . . . . 40.78 mm (0. . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . .632 in. . .) Connecting Rod Big End Width (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .923 mm (0. . .387 in. . . . . . . . . .) Connecting Rod: Connecting Rod Small End ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . .18 mm (0. . . . . . . . . . . . . . . . . . . .23 mm (0. . . . . . . . . .375 in. . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . 34. . . .384 in. . . . . . . 10. . . .74.) Piston Rings: Ring Thickness (Top and Second Ring) (Minimum) . . . . . . . .) Rotor Bearing ID (Maximum) .) Oil Pump: Rotor Shaft OD (Minimum) . .) Crankshaft Crankpin OD (Minimum). . . . . . .) Connecting Rod Big End ID (Maximum).635 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1469 in. . . . . . . . . . .74 in. . . . . . . . . . . . . . 16. . . . . . . . 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .775 in. . . . . . . . . . . . . .937 in. . . . . . 19. . . . 74. . . . . .48 . . . . . . . . 35. . . . . . . . .) Oversize Cylinder Bore: Standard . . . . . . . . . . . . . .606 in.436 in. . . . . . . . .40 mm (0. . .985 mm (0. . . . . . . . . . . . . . . . . . .028 in. . . . . . . . . . .) Rotor Bearing Depth (Maximum) . .007 in. . .) Outer Rotor Thickness (Minimum) . . . . . .) Rotor Shaft Bearing ID (Maximum) . . 18. . .05 mm (0. . . . . . . . .) Crankshaft: Crankshaft Runout (TIR) (Maximum) .457 . . . . . . . .) Inner and Outer Rotor Clearance (Maximum) . . . . . . . 0. . .430 in. . . . . . . . . . . . . . . . . . .629 in.002 in. . . . . . . .10 mm (2. . . . . . . . . . . .031 in. .830 mm (0. . . . . . . . . . . . 0. . . . . . . .70 mm (0. . . . . . . . . . . . . . . . . . . . . . . . .008 in.) Relief Valve Spring Free Length (Minimum) . . . . . .05 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . .47 mm (1. . . . . . . . . . . .041 in. . . . 29.) Outer Rotor OD (Minimum) . . . . . .055 in.50 mm (0. . . . . . . . .470 mm (1. . . . .) Camshaft: End Journal OD (Minimum) . . . . . . . . . . . . . . . . . . .98 . . . .) Crankshaft Crankpin OD (Resized). . . . . 10. . . . . . .) Crankshaft Main Bearing PTO Journal OD (Minimum) .) Oil Ring End Gap (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00 mm (2. . . . . . . . . . . . . . . . . . . . . . . . .60 mm (2. . .055 mm (1. . . . . . . . . . . 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74. . . . . 0. 0. . . . . . . . . . . . . . . . . .072 mm (0. . . . . . . . . .593 in. . . . . . . . . . . . . . . . . . . .119 . . . . . 37. . . .494 in. . . . . . . . . . . . . . . . . . .020 in. . . . . . . . . . . .80 mm (1. . . . . . .KAWASAKI (FH580V) SPECIFICATIONS Cylinder Bore ID: (Standard) . . . . . . . . . . .) Ring End Gap (Maximum): Compression Rings (Top) . . 37. . . . . . . .56 in. . . . . . . . . . . . . . . .917 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . Used to check engine crankcase vacuum. . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle and choke adjustment. . . . . . . Used to check engine compression. . . . . . . . . . . . . .25 in. . . . 56 N•m (41 lb-ft) Cylinder Head and Valves Cap Screw Torque in Sequence (Lubricated) Final Torque . . . . . Used to check idle speed and starter performance. . . . . . .KAWASAKI (FH580V) TOOLS AND MATERIALS Torque Specifications NOTE: Use appropriate torque wrench which will read within the inch pound range given. .8 N•m (69 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . Used to connect pressure gauge to engine when performing Engine Oil Pressure Test. . . . . . . . . . . . . . . . 25 N•m (221 lb-in. . . . . . . .) Governor Lever Nut Torque . . Used to check fuel pump performance. . . . . Used to bore oversize valve guide. . . . . . . . . Used to connect pressure gauge to engine when performing Engine Oil Pressure Test. . . . . . . Valve lapping Automatic compression relief test. . . . . . . . . . . . . . . . . . . . . . . . . . .8 N•m (87 lb-in. . . . . . . . . . . . . . . . . . . . . . 9. Used to connect pressure gauge to engine when performing Engine Oil Pressure Test. . . . . . . . . . . . . . . . . . . 6.05 m) Reaming Tool (7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Used to prevent accidental engine starting during tests. . . . . . . . . . . . . . . . . . . . . . . .Kawasaki (FH580V) Tools and Materials . . . Engine . . . . . . . . . . . .) Flywheel Bolt Torque . . . . . . . . . . . . crankshaft end play. . . . . . . . . . . . . . . . . . . . Used to check engine crankcase vacuum. . . . . . . . . . . . . . SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). . . . . Used to clean or size valve guides. . . . . . . . .) Oil Drain Plug Torque . . . . . . . .) Crankcase Cover Cap Screw Torque . . . or convert inch pounds to foot pounds as follows: Inch-pounds/12 = Foot-pounds Engine Mounting Cap Screw Torque . . . . . .) Intake Manifold Mounting Cap Screws . Special or Required Tools Tool Name Hand-Held Digital Tachometer Digital Pulse Tachometer Compression Gauge U-Tube Manometer Test Kit Vacuum Gauge Drill Bit Reaming Tool (7. . . . . . . . . . . . . . . . . . valve inspection. . . . . 25 N•m (221 lb-in.) Connecting Rod End Cap Screw Torque . . .120 . . . . . .S.) Tools and Materials Tools NOTE: Order tools according to information given in the U. . . . . . . . . . . . . . . . . . . . . . . . . . .25 mm) Lapping Tool Dial Indicator Spark Plug Ground 90° Elbow Fitting Connector Hose Assembly Pressure Gauge Assembly Pressure Gauge Tool No. . . . . . . . . . . . . . . .9 N•m (61 lb-in. . . 26 N•m (230 lb-in. .) D20020WI JDG705 ----JDM74A5 JT03338 JT03349 JT03017 JT03344 JDG356 Tool Use Used to check idle speed and starter performance. . 7. . . . . . . JT05719 JT07270 JDM59 JT05698 JT03503 6. . . . . . . Used to read engine oil pressure when performing Engine Oil Pressure Test.4 mm (0. . . . . . 20 N•m (171 lb-in. . . . . .ENGINE . . . . . . . . .

Used to check starter performance.KAWASAKI (FH580V) TOOLS AND MATERIALS Special or Required Tools Tool Name Spark Tester Valve Spring Compressor Current Gun Tool No. Other Materials Other Material Part No. D-05351ST JDM70 JT05712 Tool Use Used to check overall condition of ignition system. M79292 Part Name MPG-2® Multipurpose Grease SCOTCH-BRITE® Abrasive Sheets/Pads Valve Guide Cleaner Prussian Blue Compound Lithium Base Grease Zinc Oxide/Wood Alcohol Mineral Spirits Valve Lap Compound T43512 / TY9473 / LOCTITE‚242 TY15130 / LOCTITE‚595 TY9375/TY9480/ LOCTITE‚592 Thread Lock and Sealer (Medium Strength) Form-in-Place Gasket Thread Sealant (General Purpose) with TEFLON‚ Part Use Apply to engine crankshaft Clean cylinder head Clean valve guides Check valve seat contact Pack oil seals Check block for cracks Clean armature Lap valves Apply to threads of throttle and choke plate screws Rocker arm cover mating surfaces Apply to threads of oil pressure switch MPG-2‚ is a registered trademark of DuBois USA.ENGINE . LOCTITE‚ is a registered trademark of the Loctite Corp.Kawasaki (FH580V) Tools and Materials .121 . TEFLON® is a registered trademark of DuPont Service Parts Kits The following kits are available through your parts catalog: • • • Carburetor Gasket Kit High Altitude Carburetor Kit Engine . Used to remove and install valve springs. SCOTCH-BRITE‚ is a registered trademark of the 3M Co.

KAWASAKI (FH580V) COMPONENT LOCATION Component Location Engine Components C B A D E Q R S T F G H P O J N M L K Y X I U V Crankcase O P W M95399/M95400 A .Dipstick H .Spark Plug P .Air Cleaner Cover U .Drain Plug L .Throttle and Choke Linkage N .Blower Fan E .Oil Pressure Switch I .Throttle Control Panel O .Air Cleaner Housing T .Stator G .Fuel Shutoff X .ENGINE .Fuel Pump S .Crankcase K .Carburetor W .Vacuum Hose R .Starting Motor Engine .122 .Flywheel F .Voltage Regulator/Rectifier Y .OIl Filter J .Rocker Arm Cover Q .Screen D .Kawasaki (FH580V) Component Location .Blower Housing B .Governor Linkage M .Carburetor Inlet Hose V .Ignition Module C .

3 N•m (20 lb-in.ENGINE .Stud V .Gasket T .) N .123 .Choke Shaft J .Gasket W .Float Valve X .Kawasaki (FH580V) Component Location .5 N•m (40 lb-in.Spring F .Choke Valve K .Pin U .Carburetor Body D A B C E F G H X L W V U M J N T O I K P S R Q MX19760 Engine .Solenoid Wiring Harness R .Main Nozzle M .) S .KAWASAKI (FH580V) COMPONENT LOCATION Carburetor Component Location A .Float Bowl Q .Seal G .4.Throttle Valve H .Limiter B .Spring D .2.Gasket P .Float O .Seal L .Fuel Shutoff Solenoid .Low Idle Screw E .Valve Seat .Pilot Air Screw C .Throttle Shaft I .

Camshaft .Oil Pressure Sensor .Crankshaft Main Bearings .Rocker Arms and Valves .Crankshaft .Oil Pump .Oil Pressure Relief Valve .ENGINE .Oil Filter .Pick-up Screen .Kawasaki (FH580V) Component Location .Oil Pump Gear .Tappets .Connecting Rods .124 .Push Rods Engine .KAWASAKI (FH580V) COMPONENT LOCATION Engine Oil Flow Chart B A C E D F G N M I H L K J M99565 A B C D E F G H I J K L M N .Pistons .

Pressure oil flows past the relief valve to the oil filter. An oil pressure switch mounted above the oil filter turns on a warning light if oil pressure is below 98 kPa (14. and crankshaft gear are lubricated by oil splash generated by the internal moving parts during operation.117. Theory of Operation: A positive displacement gerotor pump is used to pressurize the lubrication system. As this oil/ air mixture is swirled around the rocker arm chamber. The relief valve is not adjustable.Kawasaki (FH580V) Theory of Operation . A small return passage is provided to return this liquid state oil back into the crankcase. the rocker arms. The oil pressure relief valve limits the oil pressure to approximately 296 kPa (43 psi) and protects the oil pump from damage if an oil passage becomes blocked. lubricating them.5 kPa (11. Eventually these oil particles collect into a liquid state again in the lower portion of the rocker arm chamber.125 .2 psi). Pressure oil from the pump flows through the pump outlet passage past the oil pressure relief valve. coolant pump gear.1 psi) if the element becomes plugged to ensure engine lubrication. and pushrods are lubricated by an oil/air mixture carried through an upper lubrication passage from the breather chamber.5 . the relief valve opens allowing oil to return to the sump. Drilled passages in the crankshaft distribute oil from the main bearings to the connecting rod journals and crankshaft main bearings (flywheel side). The camshaft gear. The filter contains a bypass valve which opens at 78. governor gear. the oil particles cling to the moving parts. and an oil filter with bypass valve. The oil pump draws oil from the sump through the pick-up screen. If the oil pressure exceeds 296 kPa (43 psi). valves. Filtered pressure oil flows through a passage in the oil sump to the crankshaft main bearing (PTO side). In the cylinder head. camshaft. The lubrication system is protected by an oil pressure relief valve. Engine .KAWASAKI (FH580V) THEORY OF OPERATION Theory of Operation Lubrication System Operation Function: To provide pressurized oil to lubricate internal engine components. oil pump gear. tappets. low oil pressure switch.ENGINE .4 . A drilled passage in the connecting rods allows oil from the connecting rod journal to lubricate the piston and cylinder walls.17.

KAWASAKI (FH580V) DIAGNOSTICS Diagnostics Engine Troubleshooting Guide c CAUTION: Avoid injury! Keep spark plug as far away from the plug hole as possible. Gasoline spray from the open cylinders may be ignited by ignition spark and cause an explosion or fire. No . Is compression sufficient? Yes . See “Cylinder Compression Pressure Test” on page 133. NOTE: To test specific electrical components.Go to next step. See “Starting Motor Solenoid Test” on page 335. (3) Check compression. No . or See “Starting Motor No-load Amperage and RPM Tests” on page 336 in the Electrical section.Check for plugged air/fuel passages in carburetor. No .Check if sparks are produced between high tension lead and ignition block.Check for excessive use of choke.Make starting attempts a number of times. Keep hands away moving parts when testing. Yes .126 . No . No .Charge battery. (5) Compression is low? Yes . Inspect cylinder head. float bowl level too high. c to rotate atAvoid Injury! The engine mayfrom CAUTION: start any time. are spark plug electrodes wet? Yes . ignition coil air gap. Recheck for spark and go to next step. Test Conditions: • • • Operator On Seat PTO Switch In Off Position Brake On Symptom: Engine Hard To Start (1) Is there a strong blue spark? See “Spark Test” on page 136. (4) After starting attempts. See “Fuel Pump Test” on page 135.Go to next step. Symptom: Engine Malfunctions At Low Speed (1) Is unusual smoke emitted out of muffler? Engine .Kawasaki (FH580V) Diagnostics . Check high tension lead.Go to next step.Go to step 3. (3) Is key switch working correctly? Yes . See “Cylinder Head Inspection” on page 148. Yes . No .Repair or replace.Replace spark plug. pulser coil. remove spark plug and observe electrodes. See “Piston Inspection:” on page 153. (2) Is battery fully charged? See “Battery Test” on page 330 in the Electrical section.Check for contamination.Check engine starting. Replace as needed. Go to next step.ENGINE . See “Carburetor Disassembly and Assembly” on page 140. No . See “Cranking Circuit Operation” on page 269 in the Electrical section.Test switch. or an air or vapor lock in the fuel tank and lines.Go to next step. Symptom: Engine Doesn’t Crank (1) Are battery cables loose or dirty? Yes .Go to step 5.See Engine Repair Section. No . plugged air cleaner. see Electrical Section and refer to either Diagnostics or Tests & Adjustments for further guidance. See “Charge Battery” on page 331 in the Electrical section. Yes .Check piston rings and cylinder for wear. (2) Is there a strong blue spark? Yes .Tighten or clean. (5) Is starting motor or solenoid defective? Yes . No . Symptom: Engine Runs Erratically (1) Is fuel delivery correct. (4) Has engine seized? Yes .Check fuel tank and lines.

No .Plug in carburetor interior.127 .Go to next step.Go to next step.Charge battery. No . Starting Motor Troubleshooting Guide c to rotate atAvoid Injury! The engine mayfrom CAUTION: start any time.Go to next step. No . IMPORTANT: Avoid damage! If starting motor does not by turning ignition switch to Off position. See “Charge Battery” on page 331 in the Electrical section. No . incorrect oil viscosity. clean carburetor. (4) Is starting motor or solenoid defective? Yes .Check for oil leaks. Go to next step. See “Choke Plate Check and Adjustment” on page 129. See “Carburetor Disassembly and Assembly” on page 140. (2) Is battery fully charged? See “Battery Test” on page 330.Repair or replace. (2) Does engine rpm drop or engine stall at a certain point when throttle is gradually opened by hand? Yes . plugged drain back hole in breather. (3) Is air sucked through carburetor or intake manifold flanges? Yes . No .Go to next step. No .Repair starting motor. No . See “Cranking Circuit Operation” on page 269 in the Electrical section. clogged breather valve.KAWASAKI (FH580V) DIAGNOSTICS Symptom: Engine Malfunctions At Low Speed Yes .Go to next step. disconnect negative (-) lead from battery as soon as possible. NOTE: To test specific electrical components.Charge battery.ENGINE . (3) Is battery fully charged? See “Battery Test” on page 330 in the Electrical section.See Engine Repair Section. No .Check that all starting conditions are met.Go to next step. Replace as needed.Test switch. Is compression sufficient? Yes . Symptom: Starter Rotates Slowly (1) Are battery cables loose or dirty? Yes . Yes . Symptom: Starter Does Not Rotate (1) Is there a click sound from starter solenoid? Yes . Tests & Adjustments for further guidance. No .Kawasaki (FH580V) Diagnostics . or worn cylinder bore.Tighten manifold flange nuts or replace damaged gasket.Go to next step. plugged oil ring groove.Go to next step.Adjust valves. stuck or broken piston rings. See “Starting Motor Removal and Installation” on page 163. (5) Has engine seized? Yes .Check choke. (2) Are battery cables loose or dirty? Yes .Check for worn. No . high oil level. oil seals. No . (4) Is key switch working correctly? Yes . see Electrical Section and refer to either Diagnostics or Engine . and “Starting Motor Disassembly and Assembly” on page 163. No . (4) Are valve clearances set correctly? See “Valve Clearance Check and Adjustment” on page 132. Yes .See Engine Repair Section. See “Starting Motor Solenoid Test” on page 335. Symptom: Oil Consumption Is Excessive (1) Check compression. See “Charge Battery” on page 331 in the Electrical section.Go to next step.Tighten or clean. or See “Starting Motor No-load Amperage and RPM Tests” on page 336 in the Electrical section. Keep hands away moving parts when testing. See “Cylinder Compression Pressure Test” on page 133. (3) Has engine seized? Yes .Tighten or clean.

12. See “Hood Removal and Installation Models GT235E. Remove two flange nuts (B) securing hood support brackets. and tighten throttle cable clamp. 2. and lock parking brake. Loosen throttle cable clamp (D).) Drill Bit M99558 C E Procedure: 1. Align the hole (C) in the speed control lever (E) with the hole in the base plate by moving the speed control lever. 1.) pin or bolt through the base plate and speed control lever holes. Remove four cap screws and upper heat shield. 2. Choke Cable Adjustment Reason: B To make sure the choke is fully closed when the choke control lever is in the full choke position.ENGINE . Remove hood.Install upper heat shield and hood brackets.Install hood. Remove hood.Kawasaki (FH580V) Tests and Adjustments . A 11.24 in.KAWASAKI (FH580V) TESTS AND ADJUSTMENTS Tests and Adjustments Throttle Cable Adjustment Reason: To make sure the throttle control arm contacts the slow idle stop at slow idle.128 . 4. C A D B M99555 6. Procedure: M99525 3. Remove brackets. GT245” on page 558. GT245” on page 558. Remove headlight wiring harness clip (A) from frame. and lock parking brake. 7. Pull up the cable housing until there is almost no slack in the throttle cable. Insert a 6 mm (0. 10. Turn engine OFF. Turn engine OFF. 9. M99525 Engine . 8.Remove pin or bolt. Equipment: • 6 mm (15/64-in. 5. Park machine on a flat surface. See “Hood Removal and Installation Models GT235E. Park machine on a flat surface.

Move the choke control lever between the choke fully open and fully closed position several times. NOTE: If the choke will not fully close when the engine choke lever is fully rotated clockwise. to ensure accurate adjustment. Engine . Remove four cap screws and upper heat shield. 8. 4. Remove two flange nuts (B) securing hood support brackets. Loosen choke cable clamp (D). Try to move choke rod (C) down (arrow).Install the hood. 10. perform “CHOKE PLATE CHECK AND ADJUSTMENT”. Choke rod should NOT move.Kawasaki (FH580V) Tests and Adjustments . M99557 4. Move choke control lever to fully open position.129 . 3. 6. Move throttle control lever to full CHOKE position. 7. 13. Choke Plate Check and Adjustment Reason: To make sure the choke plate is fully closed when the choke control lever is in the full choke position. 12. C M95376 6. Readjust cable as needed. Remove headlight wiring harness clip (A) from frame. Ensure the choke plate fully opens and closes. the choke plate is not fully open. M95376 C 8. Carefully pull air cleaner base away from carburetor and remove crankcase vent tube from back of air cleaner base.KAWASAKI (FH580V) TESTS AND ADJUSTMENTS 3. Check and adjust choke cable.Install the upper heat shield and hood brackets. 9. Tighten choke cable clamp. Remove brackets. 5. Remove air cleaner cover and filter. 7. 5. If choke rod moves down. Choke rod should NOT move. Place both nuts back on carburetor studs and secure finger tight only. Remove the two screws (B) and two nuts (A) that hold the air cleaner base to the carburetor. 11. A C B E D M95366 2. CHECK Procedure: IMPORTANT: Avoid damage! Check and adjust choke cable before adjusting choke. If choke rod moves up. Move the engine choke lever until the carburetor choke plate (C) is fully closed.Install the air filter and air cleaner cover. Place and hold the choke control lever (E) in the full choke position.ENGINE . Try to move choke rod (C) toward carburetor (arrow). 1. the choke plate is not fully closed.

Slow idle is governed at 1550 ± 75 rpm. 2. 3. 5.). Adjust throttle cable and choke plate. Tighten nuts securing housing and carburetor to 6. 3. 7. 4.Kawasaki (FH580V) Tests and Adjustments . perform ADJUSTMENT procedure. Move forward/reverse pedals to NEUTRAL position. Engine . The idle mixture screw can be adjusted within limiter range. 2.). Equipment: • JT07270 Digital Pulse Tachometer.KAWASAKI (FH580V) TESTS AND ADJUSTMENTS Results: • If choke rod DOES NOT move in either direction with choke control lever in the specific positions. 2.). 6.9 N•m (61 lb-in. Lock parking brake. Access idle mixture screw and slow idle stop screw through holes in front shroud. Slow Idle Speed Adjustment Reason: The slow idle speed is not adjustable. 4. Repeat CHECK Procedure. 5.130 . Using a small pin (C). • If choke rod MOVES in either direction with throttle control lever in the specific positions. Move throttle control lever to FAST idle position. Install hood. Bending the rod more will open the choke. Procedure: NOTE: Adjust throttle cable and choke plate before adjusting governor linkage. choke operation is OK. Loosen nut (A).8 N•m (69 lb-in. 1. rotate shaft (D) counterclockwise as far as it will go. Hold governor arm (B) in the fully clockwise. Carefully bend the choke rod (C) at the corner (arrow) to balance the open and closed position of the choke valve plate. while bending the rod straighter will close the choke valve. and screws securing housing to 3. or. 4. Hold governor shaft and governor arm in place and tighten nut to 7. Raise hood. Put reflective tape (for photo tachometer) on blower housing screen. Turn key switch OFF. Adjustment Procedure: D B A C C M95384 3. 5. Move throttle control lever through full range to be sure linkage is not binding. Procedure: 1.ENGINE . JT05719 Photo Tachometer • Governor Adjustment Reason: To ensure the governor shaft contacts the fly-weight plunger when the engine is stopped.9 N•m (35 lb-in. Park machine on level surface. DO NOT force the idle mixture screw. NOTE: Idle mixture is factory set. and the slow idle stop can be set. Install air cleaner housing. M95379 1.

JT05719 Photo Tachometer C Procedure: M99560 Air Filter and Housing Removed for Clarity. Then turn idle mixture screw counterclockwise (approximately 1/2 turn) until it contacts the limiter stop. Remove hood.Kawasaki (FH580V) Tests and Adjustments . NOTE: Idle speed is governed at 1550 ± 75 rpm.) Drill Bit.Release the throttle and adjust the low idle speed screw on the control plate (D) until the engine idles at 1550 ± 75 rpm. 6. the idle stop screw should not be in contact with throttle rod. Before performing this procedure. 5.131 . 6. Initial Adjustment: Turn idle mixture screw (A) clockwise until it contacts the limiter stop. Be careful not to burn hands 7. 3. Engine . Park machine on level surface. 9.) drill bit or 6 mm pin (C) through holes to keep the throttle control arm from moving. Move throttle control lever to SLOW idle position. 8.ENGINE . Turn idle mixture screw clockwise to midpoint. 2. Put a 6 mm (15/64-in. When throttle lever rod is released. B Equipment: • • • • 6 mm (15/64 in. B D M99560 A C M99561 12. turn SLOW idle stop screw (B) counterclockwise until slow idle speed is 1450 rpm. 8. Use Photo Tachometer to check engine rpm. 6 x 30 mm Flat Head Pin (45M7036) JT07270 Digital Pulse Tachometer. Start and run engine at MEDIUM idle for five minutes. Start and run engine at MEDIUM idle for five minutes to warm engine. c CAUTION: Avoid injury! Engine will be HOT. Put reflective tape (for photo tachometer) on blower housing screen. See “Slow Idle Speed Adjustment” on page 130. Turn idle mixture screw until best idle is obtained.KAWASAKI (FH580V) TESTS AND ADJUSTMENTS Fast Idle Speed Adjustment A Reason: To set engine fast idle speed setting. Move forward/reverse pedals to NEUTRAL position. 10. Lock parking brake. or. Turn key switch OFF. Be sure drill bit is perpendicular to the throttle control panel. 9. Fast idle speed setting should be 3350 ± 50 rpm. 4. or. 7.Pull throttle lever rod (C) down until movement stops (holds the throttle lever on the carburetor in the closed position and turns the governor arm clockwise all the way) when the idle stop screw (B) is contacted.While maintaining contact (downward pressure). 11. 1. Align hole in throttle arm (A) with hole in throttle control panel (B). Move throttle control lever to FAST idle position. adjust slow idle speed.

KAWASAKI (FH580V) TESTS AND ADJUSTMENTS Results: If fast idle speed does not meet the specifications: • Adjust throttle control panel 5. Turn key switch OFF. 1.Kawasaki (FH580V) Tests and Adjustments . . . and readjust the idle speed as necessary. 4. . Install hood. . Loosen cap screws (A). 2. . . Equipment: • Feeler Gauge (blade type) M95401 C Procedure: IMPORTANT: Avoid damage! Perform valve clearance check or adjustment when engine is cold. Hold adjusting nut and tighten lock screw to 6. . . Park machine on level surface. .9 N•m (61 lb-in. If valve clearance does not meet the specifications.) drill bit or pin. . .). Valve clearance should be to specification. . .9 N•m (61 lb-in. 3. . 4. Use a feeler gauge (B) to measure valve clearance.132 . . 7. 6. . . . Turn crankshaft until piston. . . . 8. . Move forward/reverse pedals to NEUTRAL position. Turn adjusting nut (D) to adjust valve clearance to specifications.). 6. 6. loosen lock screws (C). 2. Check fast idle speed. 0. NOTE: Moving the control panel changes the governor spring tension to adjust fast idle. 22 N•m (195 lb-in. . . Remove spark plug.0. . 1. . Remove valve cover.ENGINE . .9 N•m (61 lb-in. .) Jam Nut (C) Torque . Move left side of throttle control panel (B) up to increase rpm or down to decrease rpm. 6. Hold the throttle control panel and tighten cap screws to 6.0. . IMPORTANT: Avoid damage! DO NOT adjust high idle speed with the air cleaner removed. . 2. Allow engine to cool. 5. B A A B A M99561 M95401 1. . . Specifications: Intake and Exhaust Valve Clearance (cold) .) Spark Plug Torque . .006 in. . is at TDC (top dead center) of the compression stroke (both intake and exhaust valves will be closed). .) Valve Cover Cap Screw Torque. . . 3. Remove and ground spark plug lead. . Check clearance again.15 mm (0. . .9 N•m (61 lb-in. .004 . Stop engine. Remove the 6 mm (15/64-in. Lock parking brake.) Engine . . visible in spark plug hole (A). Results: D Valve Clearance Check and Adjustment Reason: To obtain the proper valve clearance that is critical for the valves to seat properly. Raise hood. .10 . .

A Test Equipment: • • M99562 8741-F66 Plug JT05703 Barb Fitting JT05699 Line JT05698 U-Tube Manometer JT03503 Crankcase Vacuum Test Kit • • or. . IMPORTANT: Avoid damage! DO NOT overheat starting motor during test. . • If compression pressure does not increase after retest: check for leaking valves. 7. . Lock parking brake. Park machine on level surface and turn key switch OFF. . 4. 3. Starter duty cycle is 5 seconds ON. valve seats. .Crank engine for three to five compression strokes. . 7. Replace as necessary. .Kawasaki (FH580V) Tests and Adjustments . Move throttle control lever to FAST idle position.ENGINE . 390 kPa (57 psi) Maximum difference between cylinders . . Check that choke is fully open and that air filter is clean. 41 kPa (6 psi) Procedure Using JT05698 U-Tube Manometer: 1. Raise hood. Remove dipstick. Valve clearance must be adjusted properly before doing a compression test. A pressurized crankcase will force oil leakage past the seals and gaskets and affect fuel pump operation. Check exhaust for restriction. 6. Move forward/reverse pedals to NEUTRAL position. . . 8. Lock parking brake. pistons. Test Equipment: • JDM59 Compression Gauge Results: NOTE: Above specification is for an engine that has sufficient time to allow rings to fully seat. . . . . which ensures the crankcase is not pressurized. . Engine . Run engine for five minutes to bring engine to operating temperature. . and cylinder bores for broken rings. • If below specification. scoring. Specifications: Minimum Compression . Install 8741-F66 Plug (A) in dipstick hole. 11. 12. Install JT05703 Barbed Fitting (B) in Plug and connect JT05699 Line (C).133 . 9. . Crankcase Vacuum Test B Reason: To measure the amount of crankcase vacuum. rings. adjust valves and check fuel and air intake systems. wear or damage. . 5. . Ground high tension leads (B) or disconnect positive lead from ignition coil. Move forward/reverse pedals to NEUTRAL position. . 5.Record pressure reading. . cylinder walls. 10. . and valves. 2. 4. . or cylinder head gaskets. .KAWASAKI (FH580V) TESTS AND ADJUSTMENTS Cylinder Compression Pressure Test Reason: To determine the condition of the pistons. Install JDM59 Compression Gauge (A) in one spark plug hole. • 6. 2. . . squirt clean engine oil into cylinder and repeat test. . Park machine on level surface.Repeat test with other cylinder. . . raise hood and remove spark plugs. • If compression pressure increases after retest: check rings. 3. • If above specification. . 10 seconds OFF. Compression that is lower than specifications on low hour machines (but relatively equal on both cylinders) probably does not indicate a problem. Turn key switch OFF. Procedure: 1.

Connect JT05698 Manometer (D) to Line (C). Seals and gaskets for leakage.134 . Park machine on level surface. and barbed fitting (E) to rubber plug (F). DO disconnect test gauge WHILE engine is running at FAST idle to prevent damage to gauge.) of water at fast idle.27 . 8.Plug . Insert barbed fitting (E) in rubber plug (F) so that clear line (G) to fitting can be connected at a later step. Hold finger over rubber plug hole to keep oil from spraying out.Turn engine OFF.10 in. Move throttle to SLOW idle and turn engine OFF. 7.Line .25.25. DO NOT turn engine OFF until Line (C) has been disconnected from Manometer. Record crankcase vacuum reading.Barb Fitting .27 . clear line (G).10 in. 2. 8. Specification: Crankcase Vacuum at 3350 ± 50 rpm . 4. Install appropriate size rubber plug in dipstick tube. Start and run engine at slow idle.Open Manometer vent and record crankcase vacuum reading.4 cm (0. Engine .Remove Barbed Fitting and Plug from dipstick tube and install dipstick. D C B A F E G M45642 A B C D . 6.5 .Run engine at slow idle. Rings. Procedure Using JT03503 Crankcase Vacuum Kit: 1. 9. 9. replace as necessary.25 cm (0.5 . and gauge from rubber plug while engine is running at FAST idle. clear line. .U-Tube Manometer M99563 5. .Kawasaki (FH580V) Tests and Adjustments . Rocker arm cover O-ring for leakage. IMPORTANT: Avoid damage! DO NOT make connection between test gauge and rubber plug BEFORE engine is running at FAST idle or gauge damage may result. . Connect gauge. move the throttle lever to fast idle and allow engine to reach operating temperature.Run engine at fast idle. check the following: • • • • • Breather reed valve clearance and condition. 14.KAWASAKI (FH580V) TESTS AND ADJUSTMENTS IMPORTANT: Avoid damage! DO NOT make connection between U-Tube Manometer (D) and Line (C) BEFORE engine is running or fluid in Manometer could be sucked into crankcase. Hold finger over rubber plug hole to keep oil from spraying out. 1.) of water NOTE: A new engine may have low vacuum readings due to the fact that the rings are not seated. and cylinder bore for wear or damage.) of water at fast idle. 15. 12. Gauge should show a vacuum of 1.ENGINE . 10. Manometer should show a vacuum of 1. After test reading is made. Disconnect barbed fitting. 10. . DO NOT TURN ENGINE OFF! 13.10 in. 11. Fuel pump vacuum hose leakage. Check dipstick/ oil fill cap and o-ring for cracks or damage.25 . 3. Results: • If crankcase vacuum is BELOW specifications. Raise engine hood and remove dipstick.4 cm (0.5 . Start engine.Disconnect Line (C) from Manometer (D).Remove rubber plug and install dipstick. piston.

. Wear protective eye glasses and clothing. . 8. Specifications: Oil Pressure Minimum . 7. Install JT03349 Connector (A). Allow engine to cool. Always work in well ventilated area away from open flame or spark producing equipment. Connect JT03017 Hose Assembly (C) and JT03344 Pressure Gauge Assembly (B).310 kPa (35 . . Procedure: 1. 9.Run engine at fast idle and check oil pressure. c flammable. Park machine on level surface. . BeAvoid Injury!to touch.Monitor oil pressure while cranking engine. this includes equipment that utilizes pilot lights. . . . 2. Raise hood. Determine and correct cause before running engine. Start and run engine at slow idle for one minute to fill carburetor with fuel. . .Start and run engine at MEDIUM idle for five minutes to heat engine oil to normal operating temperature. 5.310 kPa (35 . Move forward/reverse pedals to NEUTRAL position. Oil pump suction screen or oil passages plugged. Results: If oil pressure is BELOW specifications. . 6. 10. .Kawasaki (FH580V) Tests and Adjustments . IMPORTANT: Avoid damage! If pressure reading is below 69 kPa (10 psi). Lock parking brake. Lock parking brake. Turn key switch OFF. . . . . . . Test Equipment: • JDG356 Pressure Gauge Graduated Container A • B Procedure: 1. . Stop the engine. 5. . Test Equipment: • • • JT03344 Pressure Gauge Assembly JT03017 Hose Assembly JT03349 Connector 11. . . Engine . . Fuel Pump Test Reason: To check condition of fuel pump and determine fuel pressure. . C M49880 4. .Avoid Injury! Gasoline is extremelya CAUTION: DO NOT SMOKE. Worn or damaged oil pump. 3. If no oil pressure is present. . Check engine oil level. . .KAWASAKI (FH580V) TESTS AND ADJUSTMENTS Engine Oil Pressure Test Reason: To verify if the engine has enough oil pressure to lubricate internal components. . . inspect or replace the following: • • • • Oil pressure relief valve for broken or worn spring. 2. . Move forward/reverse pedals to NEUTRAL position. 69 kPa (10 psi) Fast Idle. . Oil pressure relief valve for stuck or damaged valve. . . Park machine on level surface. STOP ENGINE IMMEDIATELY and determine cause.ENGINE . Raise hood.135 . . . Turn key switch OFF. discontinue cranking engine. .componentsthe CAUTION: Engine careful not especially exhaust pipe or muffler while making adjustments. Remove oil pressure switch. Gauge should read an oil pressure of 241 . . 12. . . 6. . • Excessive wear of connecting rod and main bearing journals. • Oil filter plugged.45 psi).45 psi) c are HOT. . 4. 3. 241 . bring level to full mark. .

Gauge should read a minimum pressure of 6. Turn key switch OFF.2 mL/15 seconds .12 kPa (0. A steady. Start and run engine at fast idle for 15 seconds.2 ml/15 seconds (1. Check vent holes (B) for plugging or clogging. . Connect high tension lead to Spark Tester. Park machine on level surface. blue spark should be observed. .ENGINE .) (5 turns). Results: • If spark is weak. . 11. . .KAWASAKI (FH580V) TESTS AND ADJUSTMENTS Spark Test A B Reason: Check overall condition of ignition system. .200 in. . A B D C M49887 5.2 mm (0. Disconnect and plug fuel pump outlet hose (A).136 . . watch spark with engine running.Stop engine. install a new spark plug and repeat test. filter and fuel tank cap for restrictions.) (4 turns) with screw (C). 7. . . check the following: • • • • Fuel lines. then stop the engine and record container measurement. . . . Adjust spark tester gap to 4. . Specifications: Minimum Fuel Pressure . . 10. Minimum flow is 54. . 54. . then record pressure reading. Test Equipment: • D-05351ST Spark Tester Procedure: 1.Spin engine with starter and watch spark (D) at spark tester. Connect D-05351ST Spark Tester (B) to spark plug. .12 kPa (0. 6. . 7. . . . . (1.0 mm (0. . . . 4. . .9 psi). • If spark is still weak. Connect JDG356 Pressure Gauge to fuel pump outlet (B). . 12. 9. Lock parking brake. Replace fuel pump. . . M99564 3. 2. . . Remove high tension lead (A) from spark plug. 9. . run tests on individual components to find the cause of the malfunction. as damage to ignition components could occur. . Move forward/reverse pedals to NEUTRAL position. . or no spark is present. . .166 in. . .Remove pressure gauge from fuel pump outlet and connect a length of hose long enough to reach into a graduated container.Kawasaki (FH580V) Tests and Adjustments . . 6. strong. 8. Move key switch to RUN position. If engine will start.8 oz/15 seconds) Engine . Results: If fuel pump pressure or flow does not meet the specifications.Start and run engine at fast idle for 15 seconds. . . IMPORTANT: Avoid damage! Do not adjust spark tester gap beyond 5. .8 oz/15 seconds).90 psi) Minimum Fuel Flow . . . or no spark is present. Check crankcase vacuum. . Raise hood. . . 10. 8.

6. 0. .) feeler gauge between flywheel and armature. . Specifications: Air Gap .137 .) Ignition Coil Cap Screws . . Turn key switch OFF.Kawasaki (FH580V) Tests and Adjustments . 2.ENGINE . 9. Insert a 0. . Scrape or wire brush deposits from spark plug.012 in. . .) M48365 8. . . .). . . Engine scoring can result. .KAWASAKI (FH580V) TESTS AND ADJUSTMENTS Spark Plug Gap Adjustment Equipment: • • Feeler Gauge. . 3. 4. Inspect spark plug for: • • Cracked porcelain Pitted or damaged electrodes 1. . . . . . or Wire Gauge Ignition Coil Air Gap Adjustment Procedure: 1. . A M458969 c are HOT. 5. .012 in.componentsthe CAUTION: Engine careful not especially exhaust pipe or muffler while making adjustments. 3. Park machine on level surface. 7. . Move forward/reverse pedals to NEUTRAL position.030 in. .75 mm (0. Check spark plug gap using a feeler or wire gauge. Remove spark plug. 7. Center flywheel magnet under armature. . Lock parking brake. Turn flywheel to remove feeler gauge. . .). .30 mm (0.8 N•m (69 lb-in. Set gap to 0.30 mm (0. Wear protective eye glasses and clothing. . . BeAvoid Injury!to touch. Push armature against flywheel and tighten cap screws (A) to specification. Engine . Raise hood. . Install and tighten spark plug to 22 N•m (195 lb-in. . . IMPORTANT: Avoid damage! Do not clean spark plug with sand paper or abrasives. 2. 4.

Remove four cap screws (B) from top heat shield. allow engine to cool preventremoving CAUTION: Avoid Injury! To possible before muffler. 3. Engine . Remove dash panel. 3. B MX16323 Muffler Removal and Installation Removal: 1. Remove two retaining screws (A) on each side of bumper and remove bumper. Replace throttle control lever or cable as required.Models GT225. See “Hood Removal and Installation . Remove nut (C) on each hood support bracket (D) and remove hood brackets. Installation is done in the reverse order of removal.ENGINE . G MX16329 6. 5.Models GT235E. See “Throttle Cable Adjustment” on page 128 and “Choke Plate Check and Adjustment” on page 129.138 . • Adjust throttle control cable and choke plate. GT245” on page 558 in the “Miscellaneous” section. Disconnect throttle control cable at engine. 2. Remove throttle control cable assembly. GT235” on page 558 or “Hood Removal and Installation . F H E MX16320 2. Remove top heat shield.KAWASAKI (FH580V) REPAIR Repair Throttle Control Lever and Cable Removal and Installation: 1.Kawasaki (FH580V) Repair . D C c burns. Remove engine hood. A MX16321 4. Remove lower heat shield cap screws (E) and remove lower heat shield (G).

Always ventilated area away from open flame or spark producing equipment. Air Cleaner Assembly Removal IMPORTANT: Avoid damage! Any time the air cleaner is removed.9 N•m (61 lb-in. Remove muffler. gasket (D). Remove the two screws and two nuts (A) that hold the air cleaner base to the carburetor. • Use new gaskets for installation. Unsnap and remove air cleaner cover and air filter. including equipment that utilizes pilot lights 1.139 . 6. 7. check for free choke operation during reassembly. Inspect element. 3. Replace parts as necessary. Wrap element with a clean rag and squeeze out excess oil. Remove the cable ends from the engine. dirty. Dry element. or damaged in any way. and base (E) for damage.15 drops of clean engine oil to foam element (A). • Element is still usable if you can see light through it and element appears clean. Carburetor Removal and Installation Removal: c CAUTION: Avoid injury! Gasoline iswork in a extremely flammable. IMPORTANT: Avoid damage! Do not clean paper element with solvent or compressed air. Carefully pull air cleaner base away from carburetor and remove crankcase vent tube from back of air cleaner base. 4. Remove and disassemble air cleaner. • Replace if oily.Kawasaki (FH580V) Repair . F E D A B B M99557 C A 2. M95376 Engine . 5. 2. Drain fuel from carburetor. Remove and plug the fuel inlet hose (C).KAWASAKI (FH580V) REPAIR 7. M95367 3. Do not smoke. Loosen the clamps (B) securing the throttle and choke cables. Installation is done in the reverse order of removal. 8.) 5. Wash foam element (A) in detergent and water. Gently tap paper element (B) to remove dust. 8. Apply 12 . 1.ENGINE . 4. Tighten locknuts (F) to 6. C D E 6. Remove two muffler mounting bolts (F) and nuts and washers (H) from each side of engine. Assemble and install air cleaner. Inspect cover (C).

ENGINE . . . . .) 6. Disconnect wire connector (D) to the fuel shutoff solenoid and wire connector (E) grounding the fuel shutoff solenoid. M95379 10. Specifications: Ground Screw . 1. . 3. .Avoid Injury! Gasoline iswork in a CAUTION: extremely Do not smoke. Clean/Inspect/Rebuild: IMPORTANT: Avoid damage! Do not clean holes or passages with small drill bits or wire. . Spray all passages with a carburetor cleaning spray to verify that all internal passages are open. . Be careful not to turn pilot air screw at this point. . . DO NOT remove these plugs. . Remove two capscrews (G) holding the air cleaner mounting bracket (F) in place.Kawasaki (FH580V) Repair . 1. IMPORTANT: Avoid damage! To remove float. and the two capscrews (H) holding the control panel (I) in place. . . . . . use a long nosed pliers on end of pin. Always F G H I ventilated area away from open flame or spark producing equipment. Remove limiter. .While pulling the carburetor forward disconnect the choke rod (J) and then the throttle link and throttle spring (K) from the carburetor. . Soak all carburetor metal parts in carburetor cleaning solvent for 1/2 hour maximum. this includes equipment that utilizes pilot lights. IMPORTANT: Avoid damage! Rinse carburetor body in warm water to neutralize corrosive action of cleaner on aluminum. Do not strike opposite end of pin. use a cleaning solvent with a high flash point that will not damage these parts when cleaning. . 2. . 3. Carburetor Disassembly and Assembly Disassembly: c flammable. . • Tighten fasteners to specification. Control Panel Mounting Screws .4 N•m (30 lb-in. . . . assembly and component location. carefully mark the position of the air screw limiter on the carburetor body so that it can be installed and set to its original position later. . Turn out the pilot air screw and replace with a new one.140 . .) 6.9 N•m (61 lb-in. . Record the number of turns needed to close the pilot air screw. . . .) 3. When removing the pilot air screw (#2). Air Cleaner Base Screws . Remove rubber and plastic parts from carburetor. Air Cleaner Base Nuts .9 N•m (61 lb-in. Refer to illustration shown for disassembly. . . NOTE: If all rubber and plastic parts cannot be removed for cleaning. There are several passage plug balls in carburetor body. 5. . . . 6. . . 4.9 N•m (61 lb-in. Installation is done in the reverse order of removal. K J M95379 8. . 2. . 9.KAWASAKI (FH580V) REPAIR 7. . .) 6. 7. Damage to pin holder may result.) Engine . Carefully pull the control panel away from engine and disconnect the governor spring and choke rod from the control panel. Turn the pilot air screw clockwise and count the number of turns until screw is gently seated in the pilot passage.9 N•m (35 lb-in. . . Air Cleaner Mounting Plate .

3. . this includes equipment that utilizes pilot lights.KAWASAKI (FH580V) REPAIR c CAUTION: Avoid injury! Reduce compressed air to less than 210 kPa (30 psi) when using for cleaning purposes. Inspect all parts for wear or damage. . Install new pilot air screw until screw is gently seated. Clear area of bystanders. lint may plug holes or passages. . 6. . . 5. .9 N•m (52 lb-in.Avoid Injury! Gasoline iswork in a CAUTION: extremely Do not smoke. . . Install the choke valve on the shaft so that the metering hole is towards outside of the carburetor. . Park machine on level surface. . Install the float pin so that it’s big diameter side faces the engine flange side. 7. . Install the throttle valve on the shaft with numerical mark on the valve facing to the outside.) Fuel Shutoff Solenoid . . Raise hood. . Open the screw the same number of turns as recorded prior to removal. Float is plastic. • • Replace fuel pump. 6. 2. 4. Assembly: 1. Do not use rags or paper to dry parts. and wear personal protection equipment including eye protection. Note the metering hole in the choke valve. . 1. Move forward/reverse pedals to NEUTRAL position. . Engine . 4. . Installation: Installation is done in the reverse order of removal. . .) Valve Seat . . taking care not to turn the pilot air screw.141 . . .ENGINE . The float cannot be adjusted. Lock parking brake. . 2. . 3. . . . . Disconnect vacuum line (A) (hidden from view) and fuel lines (B). . replace as necessary. A C B B C M99564 5. . . .3 N•m (20 lb-in. Tighten mounting screws to 5. Remove two mounting screws (C). Specifications: Throttle Valve Screws. . . . Tighten all fasteners to specification listed. . .5 N•m (40 lb-in.) Fuel Pump Replacement Removal: 1. .). . 4. c flammable. . 2.0 N•m (9 lb-in. Replace if necessary. Rinse carburetor with warm water and dry with compressed air. 4. Align the limiter with the mark on the carburetor body to install. Always ventilated area away from open flame or spark producing equipment. . . . .Kawasaki (FH580V) Repair . 3. Turn key switch OFF. guard against flying chips. . . NOTE: Main jet high altitude kits are available.

Disconnect spark plug caps (A). Remove flywheel screen. See “Blower Housing Removal and Installation” on page 142. . Remove two screws (F) (upper photo) and remove left side lower blower housing (G).ENGINE .Kawasaki (FH580V) Repair . Remove both armature coils (A). Hold flywheel (B) and remove cap screw (C). . Flywheel Removal and Installation Removal: 1. . . . Remove two screws (H) (lower photo) and remove left side lower blower housing (I). . . Remove upper blower housing. See “Ignition Coil Air Gap Adjustment” on page 137. 6. A C A A J G F M95399 B B C E M95382 2. D H 3. . 3. Engine . 56 N•m (41 lb-ft) H I M95400 1.KAWASAKI (FH580V) REPAIR Blower Housing Removal and Installation Removal: B C 4. 5. . 4. Specification: Flywheel Nut Torque . 2. Installation: • A Tighten nut to specification. Installation: E D D F Installation is done in the reverse order of removal. Remove three screws (B) securing the flywheel screen (C) to the flywheel. Remove flywheel using a flywheel puller. .142 . . . . Remove blower housing. • Adjust armature air gap. Remove four screws (D) (two on each side) securing the upper blower housing (E) to the block and lower housings. . Remove dipstick tube (J).

A M95368 4. . 56 N•m (41 lb-ft) 9. Raise and remove hood.143 . Remove four cap screws (B) from heat shield. 5. 8.ENGINE . . . . Remove mower deck. Engine Removal and Installation Removal: 1. . . or clean with solvent and allow to dry. Remove fan and flywheel. 3. Remove carburetor and intake manifold. . . C MX16320 M95369 4. Apply sealant to the mating surface of the crankcase and install a new gasket (D). 5.9 N•m (52 lb-in. Remove two retaining screws (A) on each side of bumper and remove bumper. Engine . D B M95370 MX16323 7.) Flywheel Nut Torque . Remove four screws (A) securing the breather chamber cover (B) to the crankcase. Install flywheel. Remove and replace breather element (C). Specifications: Breather Cover Cap Screws . . . . . . Remove screen and blower housing. A B 2. Check drain hole on breather chamber make sure no foreign material has accumulated. . 5. . Disconnect negative cable from battery. .KAWASAKI (FH580V) REPAIR Breather Removal and Installation Procedure: 1. 2. See “Flywheel Removal and Installation” on page 142. . . 3. Install the breather chamber cover and tighten four capscrews to specification. .Kawasaki (FH580V) Repair . 6. .

Kawasaki (FH580V) Repair . 10.Remove throttle and choke cable clamps (M) and disconnect cables from lever ends (N).ENGINE . and oil pressure switch wire (F). c flammable. this includes equipment that utilizes pilot lights. Engine . 9. Remove heat shield. G F N E M MX16322 12.Avoid Injury! Gasoline is extremelya CAUTION: DO NOT SMOKE. Always work in well ventilated area away from open flame or spark producing equipment. Remove cap screw from cable clamp (G).KAWASAKI (FH580V) REPAIR K D J C L H I L MX16318 MX16321 6. MX16319 8. NOTE: Be sure to remove fuel hose and wiring from any clips or tie wraps securing them to engine prior to removing engine. Remove nut (C) on each hood support bracket (D) and remove hood brackets. Disconnect the engine wire harness (E). Remove cap screw from clamp (K). 11. 7.Disconnect fuel line at fuel pump (J).144 .Remove four nuts (L) securing exhaust pipe flanges to cylinder heads. Disconnect purple wire (I) from solenoid. Disconnect positive (+) battery cable and orange wire from large terminal of starter solenoid (H).

orange wire.KAWASAKI (FH580V) REPAIR 4. 5. Install four engine mounting cap screws (U).ENGINE . and purple wire to the starting motor. 2. Install new gaskets between cylinder head and exhaust pipe flanges. 13. 8. Tighten cap screws and locknuts to 26 N•m (230 lbin. Reconnect the fuel line to the fuel pump. Install traction belt tension spring (S).).Install washer (Q) with concave side toward PTO clutch. Connect the engine wire harness to main wiring harness. 18. MX16326 12. Installation: Installation is done in the reverse order of removal. 16. 15. 1.Remove cap screw (P).Tighten cap screw (P) to 61 N•m (45 lb-ft).Disconnect traction belt tension spring (S). Q P R 6. O 9. Install traction drive sheave (T) and place belt on sheave. Connect the throttle cable and choke cable and adjust cables. P Q R U S O V T MX16325 11.Slide belt off of sheave (T) and remove sheave. Engine .Disconnect wiring connector (O). 3. Be sure to connect the ground wire to the left rear mounting cap screw.Kawasaki (FH580V) Repair . 10. 14. See “Throttle Cable Adjustment” on page 128. washer (Q) and PTO clutch (R). 7. MX16325 13. and “Choke Cable Adjustment” on page 128. 17. Fill engine to proper level with oil of correct specifications. Connect the battery cable.Remove four engine mounting cap screws and nuts (U).Apply MPG-2‚ Multipurpose Polymer Grease to engine crankshaft. make sure slot in clutch is positioned around pin (V).Connect wiring connector (O) and install PTO clutch (R) on crankshaft.145 .Remove engine.

Kawasaki (FH580V) Repair . 2.146 . IMPORTANT: Avoid damage! Mark push rods for reassembly in original locations 4.5 mm (0. replace the rocker arm.9 N•m (52 lb-in.) Inspection: G M95402 1. IMPORTANT: Avoid damage! Align rocker arms over push rods during assembly C • Check and adjust valve clearance. Installation: Installation is done in the reverse order of removal. See “Valve Clearance Check and Adjustment” on page 132. Compress valve spring and remove collet halves (E). Turn rod slowly and read variation on indicator. Replace if variation is greater than 0. • Install rocker covers. Remove valve clearance adjustment nut (A) and rocker arms (B). Engine .). D M95394 • Clean and inspect the rocker arm where it contacts the push rod and valve stem (D).020 in.KAWASAKI (FH580V) REPAIR Rocker Arm Removal and Installation Removal: 1. 2. Check the inside of the rocker arm where it pivots on the special nut (C). Turn crankshaft until piston is at TDC of compression stroke for the cylinder being worked on. M50044 A • Inspect push rod for bend using V-blocks and a dial indicator. Remove spring retainer (F) and spring (G). (See Inspection procedure below. If the contact points are worn or damaged.). Tighten rocker cover cap screws to 5.ENGINE . Remove rocker arm cover. Disassembly and Assembly: B E F M95401 3. Inspect all parts for wear or damage.

. Do not damage surfaces or gasket during installation. . .) Final torque. Disassemble. Assembly is done in the reverse order of disassembly. guides. . . 8. Slide the push rods into the crankcase by sliding the end of the rods down along the inside wall of the crankcase. . valves. . See “Cylinder Head Inspection” on page 148. . .) increments for the number one (A) and number two (B) cylinders. and seals. . . Mark push rods for installation in their original position during assembly. . . Set the cylinder head with gasket onto crankcase. 10. .) Engine .ENGINE . Align the upper push rod end under the rocker arms. . 4 2 M95385 4. 7. . . . 3. . . B M95386 6.147 . . . . Remove cylinder head assembly. . . . . . . A 2. . .) Second torque . Turn crankshaft until piston is at TDC of compression stroke for the cylinder being worked on. 4. . Torque Specifications: First torque . Remove the following using procedures in this section: • • • • • Upper blower housing Air cleaner and carburetor assemblies. . Torque should be applied in the sequence shown.Kawasaki (FH580V) Repair . . . . . . . 14 N•m (124 lb-in. .) Third torque . . 1. . . . . . . . 21 N•m (186 lb-in. . . in 7 N•m (62 lb-in. . carefully pry up from bottom (C) with a screwdriver. . . Remove rocker arms. . Muffler Intake manifold Spark plug 3 1 M95403 C 9. See “Rocker Arm Removal and Installation” on page 146. 7 N•m (62 lb-in. . . . Set cylinder to TDC of compression stroke for the cylinder being worked on. clean and inspect cylinder head and valves. 3. 6. Loosen the cylinder head bolts 1/4 turn at a time. 2. .KAWASAKI (FH580V) REPAIR Cylinder Head Removal and Installation Removal: 1. . 5 Installation: IMPORTANT: Avoid damage! Gasket surfaces are coated with sealant. . . . . 25 N•m (221 lb-in. . Position the push rod end on the tappet. 5. Remove rocker cover and gasket. . in sequence (above) to prevent warping the cylinder head during removal. .Inspect springs. . . . . . 5. . . . . . . If necessary to replace stem seal. .

002 in. guard against flying chips. and wear personal protection equipment including eye protection. Replace head if distortion is more than 0. 5. Inspect gasket surface for burrs and nicks. warped or distorted beyond reconditioning. M95403 1.KAWASAKI (FH580V) REPAIR 7.9 N•m (52 lb-in.08 mm (0.).05 mm (0. seat too deep (B) and seat too high (C)). Check that oil drainback passages are not plugged. 2. Install rocker covers. 4.9 mm (0. Remove cylinder heads. A c air to less than 210 kPa (30 psi) when using for CAUTION: Avoid Injury! Reduce compressed cleaning purposes. Remove carbon deposits from combustion chamber and gasket surface using SCOTCH-BRITE® abrasive pads or an equivalent. Replace cylinder head if inside diameter is greater than 6.). Check for distortion at several points around the head using a feeler gauge. Check and adjust valve clearance. See “Valve Clearance Check and Adjustment” on page 132. Engine . Inspect for cracks or broken cooling fins.1 1.) exhaust. If valve seats are loose. Clean inside of valve guides (A) with valve guide cleaner. Inspect head gasket for burns and traces of gas leakage.Kawasaki (FH580V) Repair . Replace if necessary. Pitted or worn seats can be re-faced using a seat cutter. If valve seat width is not within 0. Clear area of bystanders. recondition valve seat.).0. 8. 9. Tighten rocker cover cap screws to 5. Measure inside diameter of valve guides in several places down the length of the guide. Clean head with a suitable solvent and dry with compressed air.6 mm (0. See “Lap Valves” on page 150. replace cylinder head.024 . 8. Check valve seating pattern for correct width and evenness all around (Note: correct seat position (A).06 in. Valve Seats: 1.0. Lap valve after reconditioning with lapping compound and recheck valve seating surface for proper width and evenness of seating pattern.148 . replace head if worn. 3.6 . 6. 7.239 in.0. 3. Put cylinder head on a surface plate. See “Rocker Arm Removal and Installation” on page 146. Install the rocker arms.ENGINE . Cylinder Head Inspection Procedure: 1.) intake or 1.04 . 2.035 in. Valve Guides: NOTE: Intake and exhaust valve guides cannot be replaced. See “Cylinder Head Removal and Installation” on page 147. A C B M18615 M95403 2.

. .6 .KAWASAKI (FH580V) REPAIR Valve Springs: 1. . . . Minimum Valve Stem OD Specifications: Intake . . . . . and burrs. not merely burnished. . . M51753 5. 4. 5.Valve Narrowing Angle. Replace valve if variation is greater than 0.) 2. . . .22 in.035 in. . M50036 2. . Replace spring if measurement is less than 31. 45° C .014 in.) Exhaust .234 in.1 . . . . . . . . . face.0. . 1.063 in. .Valve Margin (Minimum) . . . . . . Grind the intake valve to 45°. .233 in. . . . 6. .6 mm (0. . Replace valve if diameter is less than specification. . 2. . Intake and Exhaust Valves: 1.0 mm (1. .35 mm (0. . Finish cut at 45° (B) to establish seating surface width (A).35 mm (0. Cut narrowing angle (E) at 30°. Recondition Valve Seats Procedure: 1. Measure outside diameter of valve stem. .Valve Seating Surface (Standard) Intake . cut at 45° angle (B) to clean up seat. . Replace warped valves (A) or valves with less than 0. . . Pitted or worn seats can be refaced using a seat cutter. . . . .05 mm (0. .Valve Face Angle . .93 mm (0. .) margin (B).) (Standard) Exhaust . Inspect valve head. . Cut valve seating surface (A) as close as possible to specifications. . . 45° D . .9 mm (0. . Check valve stem for bend using V-blocks and a dial indicator. . .014 in. . IMPORTANT: Avoid damage! Do not grind the exhaust valve or life will be shortened. .Valve Seat Angle.35 mm (0.). . . . . . 0. . .0. Turn valve slowly and read variation on indicator. . and stems for defects. Replace if necessary.) B . . .) E . . Inspect valve seats for damage. . . Be sure carbon is removed. and stem with a power-operated wire brush. . Remove carbon from valve head.014 in. .1. 30° Engine . . .) after grinding. . .Kawasaki (FH580V) Repair . . . . . Inspect spring for pitting. . . .002 in. . . A A B B D C E C M38087 M9552 3. Replace if necessary. .95 mm (0.024 . If seats are warped or distorted beyond reconditioning. . Specifications: A . rust. . . . .ENGINE . .). face. . . . . . . .04 . Replace valve if margin is less than 0. . . . . . . . . 0. To recondition seat. . . . . . . . . Measure spring free length. . . . . . 3.149 . . . 5. . replace cylinder head. . . . .0. .

3. 10 N•m (88 lb-in. .ENGINE . Drain crankcase.Kawasaki (FH580V) Repair . Gears must mesh for proper positioning. . . . . 6. . . Clean crankcase and crankcase cover gasket surfaces. . Capacity (with filter) is approximately 1. . See “Lap Valves” on page 150. Center valve seat on the valve face.8 US qt). . . . 2. . Lap valves to seats after re-facing. Lap until a uniform ring appears around the surface of the valve face. 3 M95380 6 2 5 4 4. Apply a small amount of fine lapping compound to face of valve. Lap mark must be on or near center of valve face. lap the valve into the seat.7 L (1. . Wash all parts in solvent to remove lapping compound. . . Tighten cap screws in a two step process to specification. . 3.) Engine . Torque Specifications: Initial torque . Dry all parts. . Install gasket and cover. . Check position of lap mark on valve face. Grip top of valve with a vacuum cup tool and rotate valve to lap valve to seat. Check seat for good contact using Prussian Blue Compound. Remove crankcase cover and gasket. Lap Valves Procedure: NOTE: If valve seat does not make proper contact. . Crankcase Cover Removal and Installation Removal and Installation: 1. . . . Use the sequence shown above. . NOTE: Do not force cover. . . 5. .150 . Lift valve from seat every 8 to 10 strokes. . 25 N•m (221 lb-in. . . .KAWASAKI (FH580V) REPAIR 4. . 8 7 9 1 M50041 10 1. . 2. . . 5. .) Final torque. . . . . 4.

Install the upper and lower steel oil rails.Plated Compression Ring G . Push piston and connecting rod into the cylinder and pull out of the cylinder bore. Remove the three piece oil ring. A M51726 F 5. remove ridges from top of cylinder bore with a ridge reamer. 3. Keep parts together as a set. 2.Steel Oil Rails G E C M38074c F . Remove the cap screws (A) and take off the connecting rod caps (B). remove the top and second rings. Remove the camshaft. C . They can be installed either way. 4. Using a piston ring pliers. 2. Split the crankcase. 6.Kawasaki (FH580V) Repair . 7. Install the chrome-plated top ring and second ring with “N” mark facing up. 1. 4. Note the position of the connecting rod caps for reinstalling the caps. Remove one of the piston pin snap rings with a needle nose pliers.KAWASAKI (FH580V) REPAIR Piston and Connecting Rod Removal: 1. C Assembly: D M95389 B 1. Disassembly: • Remove piston rings with a piston ring expander.ENGINE . The rings should turn freely in the grooves. NOTE: Location of the arrow match mark on the piston head in relation to “K” mark on the connecting rod. Remove the piston pin by pushing it out of the side of the piston that has the ring removed. 8. There is no up or down to the rails. Replace as necessary. Install the expander (C) in the piston oil ring groove so that the expander ends (D) touch together. Remove cylinder head. Check cylinder bore for carbon and varnish ridges. If necessary. Be sure that they do not overlap. 2. Turn the crankshaft to expose the connecting rod cap screws. Engine .First Chrome . 3. • Inspect all parts for wear or damage.Expander E .Second Compression Ring 3. These ridges can cause piston damage if not removed.151 .

152 .45° K . Install piston pin and snap ring. 1 Cylinder Piston M95391 M . Compress rings with a ring compressor. lower steel rail end gap 4.30° .“K” Mark O . 2 cylinder piston: Align the arrow match mark on the piston head with the raised letter “K” mark on the connecting rod. Deglaze cylinder bore. Align the piston and rings with the piston ring end gap as shown above. 9. No.Kawasaki (FH580V) Repair .KAWASAKI (FH580V) REPAIR H I K J 7.No.Top ring end gap.No.Arrow match mark I . No. M50074 H 3. Engine . 5. Fit a new piston pin snap ring into the side of the piston so that the ring opening of the snap ring does not coincide with the notch in the edge of the piston pin hole. Apply a light film of oil to piston and rings. Apply a light film of clean engine oil to piston pin and connecting rod bearing during assembly. 2. 2 Cylinder Piston N .Second ring end gap.Arrow match mark L . Compress snap ring only enough to install the snap ring.“K” Mark on Opposite Side 6. 8. Install piston assembly in cylinder bore with engraved match mark/arrow (H) on piston head facing flywheel side (P) of engine. K H I J Installation: 1. 1 cylinder piston: Align the arrow match mark on the piston head with opposite the raised letter “K” mark on the connecting rod. upper steel rail end gap J . 4. Apply a light film of oil to piston skirt. cylinder bore. M95393 H . P N O A L M M95392 H . connecting rod bearing surface and cap screws.ENGINE .

).) 2nd Compression Ring (Middle) . . . A M29946 2. It is difficult to measure the ring groove clearance and thickness. .KAWASAKI (FH580V) REPAIR B A M51726 M38102 5. NOTE: Inspect ring groove clearance visually.).16 mm (0. break an old ring and use it to carefully clean groove. . Install connecting rod cap (B) and cap screws (A). 5.18 mm (0. 3. B M82050A 7. .8 N•m (87 lb-in. Replace pin if measurement is less than 15. Clean carbon from piston ring grooves with a ring groove cleaner (A).628 in. 6. Tighten cap screws to 9. Install crankcase cover and cylinder head. 4. Replace piston if clearance is greater than specifications.153 .007 in. If cleaning tool is not available. Measure piston pin diameter at six places (B).) 6. Piston Inspection: IMPORTANT: Avoid damage! Do not use a caustic cleaning solution or a wire brush to clean piston.96 mm (0. visually inspect only. 0. Replace piston if clearance appears excessive.Kawasaki (FH580V) Repair . 1. . Check that oil return passages in grooves are open. The oil ring is a three piece assembled ring. Inspect piston for scoring or fractures. Remove all deposits from the piston. Engine .ENGINE . 0.006 in. . Replace piston if damaged. Check ring grooves for wear at several points around piston. Ring Groove Side Clearance Specifications: 1st Compression Ring (Top) .

.74. . . .632 in. . Replace piston if measurement is greater than 16. . . 73. .2. Pistons and rings are available in 0. . . . . . . .98 . . . . oversize piston and rings must be installed. . . . . . . (See Resize Cylinder Bore procedure. .Measure cylinder bore diameter at three positions. 73.Kawasaki (FH580V) Repair . . . . . . . 0. . .917 in. .68 .10 mm (2. top (D). .78 mm (2. Piston and rings are available in 0. .70 mm (2. oversize piston and rings may have been installed. . . . 75. . .00 mm (2. .50 mm (0.154 . . . . .05 mm (0.ENGINE .). .2. in both directions.) Wear Limit .) Oversize Bore: Standard .) Oversized Piston . Measure piston OD (C) perpendicular to piston pin bore. Cylinder Bore ID: Standard Size Bore: Standard . . . . . Measure piston pin bore.) Wear Limit . .020 in. . NOTE: If the engine has had a previous major overhaul. .0004 in. . . . . . . 75.979 .50 mm (0. . . . . . . 0. . . . . . .912 . .50 mm (0. . . . . . . .) If cylinder bore exceeds wear limit. . .01 mm (0. . . . NOTE: If the engine has had a previous major overhaul.) Engine . . . .020 in. . . middle (E) and bottom (F).) oversize. . oversize piston and rings may have been installed.020 in. . 74.) 0. . along crankshaft centerline (G) and direction of crankshaft rotation (H).980 in.) Cylinder Bore Out of Round: Standard . . .75. . .KAWASAKI (FH580V) REPAIR D E F M80427 8. . . . . . . . 75. . At these three positions. . . . . .) NOTE: If cylinder is rebored.970 in. . rebore cylinder or replace cylinder block. Piston OD Specifications: Standard Piston .056 mm (0. If piston diameter is less than specifications.983 in. measure. install a new piston. M80398 9.79 mm (2. H G M82411A C 10. . . . .905 in. .49 mm (2.) Wear Limit .0022 in.913 in. . .) oversize. .

. . . 3.) Piston Pin Bearing . . Replace if end gap is greater than specifications.). . Measure connecting rod crankshaft bearing diameter (A) and piston pin diameter (B). 0. .632 in. .155 . Crankshaft and connecting rod damage can result from: • M50066 Engine run low on oil or without oil. Tighten to 9. . .0 in. . Inspect block carefully before rebuilding engine. .05 mm (0. . . .78 mm (0. . . . . Replace connecting rod if either measurement is greater than specifications.) Second Ring .KAWASAKI (FH580V) REPAIR Connecting Rod: 1.031 in. .05 mm (0.055 mm (1. 1. . . . . IMPORTANT: Avoid damage! Align timing marks to prevent damage to tappets when removing camshaft. . . 2. . Check piston ring end gap. . . Rotate crankshaft until timing marks (A) align. . . When the rod and cap seize to the crankshaft. Remove crankcase cover. Install each ring squarely in bore approximately 25.). Lack of lubrication or improper lubrication can cause the connecting rod and cap to seize the crankshaft. If thickness is less than 1. 38. . B A Analyze Crankshaft and Connecting Rod Wear Procedure: Check connecting rod and cap for damage or unusual wear patterns. . . Connecting Rod Bearing ID. Remove and inspect camshaft (B). 16. . . . . replace piston ring. 2. NOTE: Mark tappets so they can be installed in their original guides during assembly. .Kawasaki (FH580V) Repair . Engine . . 5. A M50073 B 2. . End Gap Specifications: Maximum End Gap Top Ring . . . • • 3.8 N•m (87 lb-in. Remove rocker arm assemblies. . . Install connecting rod cap. (Wear Limit): Crankshaft Bearing . .ENGINE . . Bearing cap installed incorrectly. Oil not changed regularly.041 in. . .055 in.) M95374 4. . Check end gap. . . . . . 0. .70 mm (0.) Oil Control Ring (Side Rails) . .498 in. . .) Piston Rings: 1. .) down from top of cylinder. Camshaft and Tappets Removal: 1. .4 mm (1. Replace if scored. .028 in. 3. the connecting rod and piston may both break causing other internal damage. . . . . Measure thickness of top and second piston rings at several places.40 mm (0. . Clean and inspect rod. Remove fuel pump.

131 mm (1. Replace block or cover if either diameter is greater than 16. .635 in. 4. Shake the camshaft assembly and check that the ACR weight (H) swings smoothly. . flywheel side journal (D) and lobes (E). Replace camshaft and tappets if any measurement is less than specifications. . • Align timing marks when installing camshaft. Inspect camshaft for worn or broken teeth. . Camshaft Specifications (Minimum): Side Journals . . . Engine . Replace if necessary.13 mm (0. .629 in. . . . Replace if worn or damaged.). . .) Cam Lobe Height . . . .ENGINE . . . . 29.147 in. . Inspect spring (G).98 mm (0. . .156 . Inspect Automatic Compression Release weight (H) for damage. M95371 3.Kawasaki (FH580V) Repair .) M51723 Picture Note: Cylinder Block Bearing M51724 Picture Note: Crankcase Cover Bearing 6. Measure camshaft bearings in cylinder block and crankcase cover. Inspection: 1. . . E F D M95373 2. . Installation is done in the reverse order of removal. . Measure PTO side journal (F). Remove and inspect tappets (C) for wear or damage. .KAWASAKI (FH580V) REPAIR H C G M53975 6. . 15. 5. .

) replace crankshaft. Place crankshaft into an alignment jig and slowly rotate crankshaft. . Apply a light film of clean engine oil on crankshaft bearing surfaces before installation. . . . Inspection: IMPORTANT: Avoid damage! A bent crankshaft must be replaced. . . . replace crankshaft. . . . 2.002 in. . . . . . .374 in. Connecting Rod Journal OD (Wear Limit): Standard . Remove flywheel and split crankcase. .8 N•m (87 lb-in. 6.475 in. . . . Mark connecting rod caps to aid in installation. Use dial indicators (B) to measure maximum Total Indicated Runout (TIR). . Pack oil seals with lithium base grease. . . . . .05 mm (0.157 .95 . . Inspect crankshaft for wear or damage. . Have grinding done by a reliable repair shop. .0945 in. it cannot be straightened. If undersized journal diameter is less than specifications.020 in. .) F .470 mm (1.) Resizing Specifications: E. IMPORTANT: Avoid damage! Connecting rod caps must be installed on the same connecting rods they were removed from.1. 3. Cover keyway on flywheel end of crankshaft with tape to prevent seal damage when installing crankshaft. . Remove camshaft.0 .90 mm (1. .494 in. E Installation is done in the reverse order of removal. . B H F G M57348 4. . . 4. .2.555 in.50 mm (1. 37. . . . . Measure main bearing journal diameters.) H.) replace crankshaft.0787 . . 1. C D 2.93 mm (1.50 mm (0. 39. 1. .) G (Maximum) . A 0.4 mm (0.37. . If runout exceeds 0. If flywheel side journal (C) OD is less than 34. Connecting rod journal can be resized to accept undersized rod. . . 33. replace crankshaft. .337 .05 mm (1.457 . Install connecting rod caps and tighten to 9. . 3.474 .34. . . . connecting rod journal may have been resized for undersized rod. . Remove crankshaft. . 2.1. . . Remove connecting rod caps (A) and push pistons to top of cylinder. 5. 37. . . . Clean and inspect crankshaft. .Kawasaki (FH580V) Repair . . . If PTO side journal (D) OD is less than 34. 2.).375 in. . . .ENGINE . . M51729 A 3. . . .340 in. . Measure connecting rod journal diameter (E) and inspect journal radii (F) for cracks.) M80432 Engine . . .94 mm (1. . Replace if scratched or damaged. .) undersized rod is available. M51726 4. . . . . . .0. NOTE: If the engine has had a previous overhaul. .KAWASAKI (FH580V) REPAIR Crankshaft and Main Bearings Removal: 1.). . .

Crankshaft Oil Seals NOTE: Oil seals can be replaced with crankshaft installed. Clean cylinder walls using clean white rags and warm soapy water. MX9596 2. install seal flush with top of bore.KAWASAKI (FH580V) REPAIR Replacement (PTO End): 1. M50072 5. simply pry out seals with a large screwdriver and install new ones with a seal driver. Engine . 3. Install seal with lip toward inside of engine using a seal driver. Press in seals until flush with flange surface. Deglaze cylinder bore using a rigid hone with a 220 to 300 grit stone. Continue to clean cylinder until white rags show no discoloration. Remove blower housing.15 mm (1. or commercial solvent to clean cylinder bores. MX9582 2. Using a seal driver. IMPORTANT: Avoid damage! Do not use gasoline. Remove engine from machine. 2. If engine is disassembled. kerosene. pry seal out of crankcase cover 3. Apply lithium based grease inside lips of new seal. PTO End: Remove clutch and sheave assemblies.ENGINE . Use hone as instructed by manufacturer to obtain 45° crosshatch pattern. Using care not to contact crankshaft. Install seal with lip toward inside of engine.158 . Deglaze Cylinder Bore Procedure: 1. 4. Measure crankshaft main bearing diameter in crankcase and crankcase cover. pry seal out of bore. and flywheel. Replace crankcase cover or crankcase if diameter is greater than 35. Make sure oil seal removal tool does not contact crankshaft. Solvents will not remove all abrasives from cylinder walls.384 in. fan. Replacement (Flywheel End): 1. Apply lithium based grease inside lips of new seal.).Kawasaki (FH580V) Repair . Using care not to contact crankshaft or coils on stator. 3.

Fill rotor housing with engine oil for initial lubrication.25 mm (0. Move hone up and down in cylinder approximately 20 times per minute.0003 in.006 . Adjust rigid hone stones until they contact narrowest point of cylinder.250 rpm. Use correct stone for the job. Inspect all parts for wear or damage.Hone the cylinder an additional 0. warm water and clean rags. taper. Engine .Dry the cylinder. Remove crankcase cover. NOTE: Measure bore when cylinder is cool. NOTE: Finish should not be smooth.159 . Adjust if too tight. Lower and raise hone until ends extend 20 . Have a reliable repair shop resize the block. Turn hone by hand. but have a 40 -60° cross-hatch pattern. 3. A IMPORTANT: Avoid damage! DO NOT use gasoline or commercial solvents to clean cylinder bores. Stop press and check cylinder diameter. Oil Pump Disassembly and Assembly Disassembly: 1.0002 . Assembly is done in the reverse order of disassembly. 4. Align center of bore to drill press center. Remove the inner (E) and outer (F) rotors.50 mm (0.) for final bore specifications. Continue to clean cylinder until white rags show no discoloration. Run drill press between 200 . Remove the three mounting cap screws (A) and lift the oil pump gear and shaft assembly (B) and cover plate (C) out of the crankcase. 12. 5. Remove relief valve spring and ball (D). 6. 7. Coat inside of cylinder with honing oil. 2.Kawasaki (FH580V) Repair . 1. Install the outer (F) and inner (E) rotors.) past ends of cylinder. 8.0. Adjust hone so lower end is even with end of cylinder bore. 4. 5.1.ENGINE . The cylinder block can be resized to use 0. 3.KAWASAKI (FH580V) REPAIR Resize Cylinder Bore Procedure: IMPORTANT: Avoid damage! Check stone for wear or damage.75 . 1. See “Crankcase Cover Removal and Installation” on page 150. Resize cylinder with a honing tool to initial and final bore specifications. 9.020 in.0. Apply engine oil to cylinder wall.) oversize pistons and rings. 2. Check bore for size. and out-of-round. Solvents will not remove metal particles produced during honing 11.Clean the cylinder thoroughly using soap. or use the drill press and honing tool. B A A C 40-60° E D F M95415 M82412A 2. 10.008 mm (0. This allows for shrinkage when cylinder cools.0 in.

).593 in.92 mm (0.80 mm (1. replace crankcase cover. If shaft OD is less than 10.9 N•m (52 lb-in. Measure outer rotor housing depth.). Engine . Measure rotor shaft diameter. Measure thickness of outer rotor. 5. Install oil pump gear and shaft assembly (B).). If free length is less than 19.).).).403 in. Measure rotor shaft bearing.47 mm (1.387 in. Replace as necessary.).23 mm (0. If thickness is less than 9. If ID is greater than 40.436 in. Measure relief valve spring. replace shaft. replace both rotors. replace crankcase cover.83 mm (0. Measure inside diameter of rotor housing. If OD is less than 40.160 .Kawasaki (FH580V) Repair . M80015/M82908 5.07 mm (0. replace crankcase cover. G MX9543 7.770 in. If depth is greater than 10. cover plate (C).430 in. Measure inner to outer rotor clearance (G) with a feeler gauge.50 mm (0. If bearing ID is greater than 11.606 in.ENGINE . 6.KAWASAKI (FH580V) REPAIR 3. M80083 8. Install relief valve ball and spring (D). Measure outside diameter of outer rotor. and secure with three cap screws (A).).008 in. 4. 4. M53970/M53971 3. M53968/M53969 1. Inspection: Inspect all parts for wear or damage.). 2. replace spring. Tighten the three cap screws (A) to 5.2 mm (0. If clearance is greater than 0. replace outer rotor. replace rotor.

1. Remove crankcase cover. 3. Unscrew the governor shaft plate screws and pull the governor shaft out of the crankcase cover. 6.Snap Ring . Turn engine upside down and remove camshaft (G). Engine .0 N•m (17 lb-in.Automatic Compression Release Spring . Replace the oil seal if the lip shows signs of leakage or it has been damaged.Camshaft . 3. See “Crankcase Cover Removal and Installation” on page 150.). 5.Kawasaki (FH580V) Repair .Ball Plate . M95372 G 4. be sure the steel balls are seated in slots on the ball guide and that the snap rings are fully seated in there grooves.Governor Plate .Plug . Replace if necessary. 2. 2. Apply clean engine oil to the governor shaft.Oil Filter . Installation is done in the reverse order of removal. When assembling. 2.Seals .Oil Pressure Sender Switch .161 .Steel Balls (6) • Apply Pipe Sealant with TEFLON‚ to threads of oil pressure switch (C).ENGINE . Install the governor shaft plate to the shaft and tighten the screws to 2. Disassemble the governor assembly from the camshaft. Replace if necessary. Governor Inspection and Replacement Procedure: 1.Sleeve . Remove crankcase cover. 4.KAWASAKI (FH580V) REPAIR Oil Filter Manifold Removal and Installation: C D D A B C B E F G H B E A I F M95423 M82801A A B C D E F . 1.Mounting Cap Screw (3 used) A B C D E F G H I . 3. See “Crankcase Cover Removal and Installation” on page 150.Washer . Remove rocker covers and push rods. Insert the governor shaft into the crankcase. Inspect governor shaft for wear or damage. Inspect governor for wear or damage. Governor Shaft Inspection and Replacement Removal: NOTE: It is not necessary to remove governor shaft unless damaged.Manifold .Ball Guide .

press a new seal into crankcase with the seal lip to the inside. Remove blower housing and flywheel. Disconnect stator lead (A). Remove blower housing.) Test: 1. . 5. . . . .). If oil seal has been removed. Disconnect wiring lead (A). C M50146 Air Gap Specifications: Air Gap . Turn flywheel to remove feeler gauge.30 mm (0.18 k C 2 . 2. 6. See “Ignition Coil Air Gap Adjustment” on page 137. Remove cap screws (B) and armature with coil (C).012 in.18 k 2 .18 k Engine . Center flywheel magnet under armature. A B C A B 2 .ENGINE .) feeler gauge between flywheel and armature. (See Test procedure.4 mm (0. Test armature with coil. . Push armature against flywheel and tighten screws (B) to 7. Press the seal in to flush to 1.162 .8 N•m (69 lb-in. 3. . B Armature Removal and Installation Removal: A B C C A M82802 1. Installation is done in the reverse order of removal. 4. .Kawasaki (FH580V) Repair .2 . Check that governor shaft turns freely within its operating range.18 k 2 . Adjust armature air gap. Insert a 0. . .008 . replace armature with coil. If resistance is not within specification. 2. Stator Removal and Installation Removal: B B M45869 2. Measure resistance between each point as shown in the chart below.) below crankcase surface.0.) Installation is done in the reverse order of removal. 1. 5. .0. A 3. 0. Remove screws (B) and stator (C).KAWASAKI (FH580V) REPAIR 4. 3.016 in. M50147 1.0 mm (0. . 4. .04 in.

and starting motor drive.8 N•m (84 lb-in. Armature binding.Kawasaki (FH580V) Repair . Remove two cap screws (A) and starter assembly (B). Connect purple wire (C) to solenoid. Dirty or damaged starting motor drive. Battery or wiring defective. Tighten nut securing wires to 9. Armature binding. Fields in starting motor are permanent magnets and are not serviceable. Disconnect positive (+) battery cable and orange wire from large terminal (D) of starter solenoid. Installation: A NOTE: Starting motor repair is limited to brushes. Connect positive (+) battery cable and orange wire to large terminal (D) of starter solenoid. A Starting Motor Disassembly and Assembly Analyze Condition: The starting motor overheats because of: • • • • • Long cranking. replace starting motor. or grounds in armature. Disconnect negative (-) battery terminal. Badly worn brushes or weak brush springs. opens. Connect negative (-) battery terminal.). 3. Disconnect purple wire (C) from solenoid. 2. Engine .). end caps.ENGINE . If housing or armature is damaged.KAWASAKI (FH580V) REPAIR Starting Motor Removal and Installation Removal: 1. Shorts. B C D MX16330 1.163 . The starting motor operates poorly because of: B C D MX16330 • • • 2. 3. Tighten two cap screws (A) to 15 N•m (132 lbin. Excessive voltage drop in cranking system. Install starter assembly (B) and secure with two cap screws (A).

Depress switch arm (C).Solenoid .Front Cover .ENGINE . Push pinion stopper (E) toward pinion (F) to remove retaining clip (D). Measure field coil brush lengths. 4. There should be continuity. M94902 A B C D E F G H I J K L . Engine . Test solenoid (C). L F K C E J I C A H G D B M51705 3.End Cover .Insulator . If solenoid fails any test.) Assembly is done in the reverse order of disassembly. replace all four brushes. Test for open circuits between terminal (B) and tang (D).Kawasaki (FH580V) Repair .Brush 5. starting motor armature (G) and brushes (O).Brush Holder . Apply a thin coat of multipurpose grease to: • E D L E B A Sliding surfaces of armature and solenoid shift lever.164 .Armature . 7. Points where shaft contacts cover.250 in. it is defective and must be replaced.Pinion . If any one brush length is less than 6. 3.Shift Lever . Inspect brush springs for wear or damage. Test solenoid terminals (A and B) for continuity.Retaining Clip .KAWASAKI (FH580V) REPAIR Disassembly and Assembly: 1. Replace if necessary. Test for open circuits between tang (D) and body (E). 6. There should be no continuity.Brush Springs . 2. • • Inspection/Test: 1. Inspect parts for wear or damage. 2. 4. (See Inspection/Test procedures. Mark body and covers for correct alignment during reassembly. There should be continuity. Armature shaft spline.4 mm (0.Pinion Stopper .). There should be continuity when arm is fully depressed.

ENGINE . Solvent can damage insulation on windings. F M50112 12. Be sure the brush lead is not touching the frame. Touch probes on each commutator bar. Test for grounded field winding. the field coil is open and the field coil housing assembly (G) must be replaced. so each commutator bar needs to be checked.Test for open circuited windings using an ohmmeter. F G 11.KAWASAKI (FH580V) REPAIR The hacksaw blade will vibrate in area of short circuit. If test shows continuity. Armature windings are connected in parallel. Test for open field coil.Test for grounded windings using an ohmmeter.If test indicates short circuited windings. Touch probes on each commutator bar. Touch one probe of tester to each field coil brush (F). Use only mineral spirits and a brush. Inspect for this condition.Kawasaki (FH580V) Repair . Touch one probe of tester to field coil brush (F) and the other probe to the field coil housing (G). Check armature again. MIF 10. a winding is grounded and the armature must be replaced. M50113 13. If test shows no continuity. IMPORTANT: Avoid damage! Do not clean armature with solvent. If test still indicates short circuit. G M50116 9. replace armature. If there is continuity.165 . If there is no continuity. clean the commutator of dust and fillings. there is an open circuit and armature must be replaced.Locate short circuits by rotating armature on a growler while holding a hacksaw blade or steel strip on armature. NOTE: Shorts between bars are sometimes caused by dirt or copper between bars. Engine . M50115 8. the coil is grounded and the field coil housing must be replaced.

Kawasaki (FH580V) Repair . Repair or replace starting motor.ENGINE . check for binding or seizing bearings. 3. A B M45867 1.166 . NOTE: Check that battery is fully charged and of proper size to ensure accuracy of test. dirty or worn commutator. Connect positive cable to terminal (A). Measure starting motor amperage and rpm. Connect jumper cables to battery. Maximum starting motor amperage is 50 amps at 5000 rpm. 2. Use jumper wire to briefly connect terminals (A and B).KAWASAKI (FH580V) REPAIR No-Load Amperage Draw and RPM Test Reason: To determine if starting motor is binding or has excessive amperage draw under no-load. Results: • If amperage is out of specification. Test Equipment: • • JT05712 Current Gun JT03719 Photo Tachometer Procedure: IMPORTANT: Avoid damage! Complete this test in 20 seconds or less to prevent starting motor damage. Connect negative cable to starting motor body. Engine . sticking brushes.

.... 221 Oil Filter Manifold...........................173 Service Parts Kits ............................................................. 221 Oil Pump Disassembly and Assembly ......................................169 General Specifications ......... 205 Rocker Arm Removal and Installation .... 220 Deglaze Cylinder Bore.........................................................179 Throttle Cable Check and Adjustment...............184 Fuel Pump Test .....................................................184 Engine Oil Pressure Test ..............................170 Torque Specifications..181 Valve Clearance Check and Adjustment.................175 Carburetor (Internally Vented)...176 Diagnostics ..............186 Spark Plug Gap Adjustment .....................169 Test and Adjustment Specifications ...................................................................177 Engine Troubleshooting Guide.....177 Starting Motor Troubleshooting Guide ........................... 224 Starting Motor Removal and Installation..180 Governor Adjustment .........202 Blower Housing Removal and Installation ...................167 ....KAWASAKI (FH601V) TABLE OF CONTENTS Engine ...........................................172 Tools and Materials ...........................Kawasaki (FH601V) Table of Contents ................ 220 Resize Cylinder Bore ......187 Repair.......... 217 Crankshaft and Main Bearings ................. 219 Crankshaft Oil Seals .... 211 Lap Valves ................................. 223 Stator Removal and Installation........187 Air Cleaner Removal and Installation ...... 208 Cylinder Head Removal and Installation.. 213 Analyze Crankshaft and Connecting Rod Wear ..............204 Breather Removal and Installation.................................................. 204 Engine Removal and Installation .... 228 Engine ........203 Intake Manifold Removal and Installation ......................182 Cylinder Compression Pressure Test..................................ENGINE ...................188 Carburetor (Externally Vented) Removal ..191 Carburetor (Internally Vented) Removal......................180 Slow Idle Speed Adjustment .......174 Engine Components............................ 217 Camshaft and Tappets ............172 Tools.......... 212 Piston and Connecting Rod ............................................................179 Choke Plate Check and Adjustment ......169 Repair Specifications.....189 Carburetor (Externally Vented) Repair ...............................................................................181 Fast Idle Speed Adjustment ...............172 Other Materials..............................................................183 Crankcase Vacuum Test ............. 223 Governor Shaft Inspection and Replacement ............196 Carburetor (Internally Vented) Repair ........ 223 Governor Inspection and Replacement ......... 225 Starting Motor Disassembly and Assembly...........202 Flywheel Removal and Installation.................. 210 Recondition Valve Seats.174 Carburetor (Externally Vented).... 209 Cylinder Head Inspection.........................197 Fuel Pump Replacement.........................Kawasaki (FH601V) Table of Contents Specifications .................................................................................................186 Ignition Coil Air Gap Adjustment ............................ 225 No-Load Amperage Draw and RPM Test ......................187 Throttle Control Lever and Cable ............................................ 212 Crankcase Cover Removal and Installation ......................173 Component Location.......................................187 Muffler Removal and Installation .............. 224 Armature Removal and Installation............................................178 Tests and Adjustments ...................185 Spark Test .

KAWASAKI (FH601V) TABLE OF CONTENTS Engine .Kawasaki (FH601V) Table of Contents .168 .ENGINE .

. . . 1700 ± 75 rpm Throttle stop screw setting . . . . . . . . . . . . . . . .) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .KAWASAKI (FH601V) SPECIFICATIONS Specifications General Specifications Engine Use . . . . . . .) Stroke . . . . . . . 2 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 mm (0. . . . . . . . .Horizontal discharge below frame Test and Adjustment Specifications Slow Idle (Governed) . . . . . . . . . . . . . . . 100 rpm lower than governed idle setting Fast Idle . . .9 N•m (61 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Type . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675 cm3 (41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 75. . . . . . . . . . . . . 6. . . . . . . . .25 mm (0. . . . . . . . . . . . .7 L (1. . . . . . . . . . . . . . . . . . . . .75 mm (0. . . . . . John Deere “K” Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 US qt) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 psi) Fuel Pump Minimum Flow .) Minimum Crankcase Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH601V-BS15 Horsepower (SAEJ1940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 ± 50 rpm Minimum Cylinder Compression Pressure . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310 kPa (35 . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 cm (10 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169 . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm (2. . . . . . . . . . . . . . . . . . . . 8. . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . .) Stroke/cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1:1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Valve Adjustment Screw Jam Nut Torque . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kawasaki (FH601V) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005 in. . .) Minimum Exhaust Valve ACR Movement . . . Full Flow Filter Engine Oil Capacity With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . Gasoline Model . . . . . . . . . . . . . . .99 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Engine . . . . . . . . . . . . . . . . . . . . . .01 in. . . . . . . . . . . . . . . . . . . .) Rocker Arm Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . .2 cu in. . . . 65 ml/15 seconds (2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage Paper Air Filter and Foam Precleaner Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .075 . . . . . . . . . . .) water Oil Pressure at Fast Idle. . . .45 psi) Fuel Pump Minimum Pressure . . . . . . . . . . . . . . . . . . . .8 US qt) Without Filter . . . . . . . . . .9 N•m (52 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 mm (2. . . . . . . . . . . . . . . 41 kPa (6 psi) Valve Clearance (cold) . . . . . . . . . . . . . . . . . . . . . . 4 Cycle Bore . . . . . . . .003 . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . 15 N•m (132 lb-in. . . . . . .2 oz/15 seconds) Spark Plug Type . . . . . . . . . . 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .030 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 kW (20 HP) Cylinders . . . . . NGK BPR4ES Spark Plug Gap. . . . . . . . . . . . . . . 390 kPa (57 psi) Maximum Difference Between Cylinders . . . . . .6 L (1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GT245 Make.0. . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 kPa (0. . . . . . .

KAWASAKI (FH601V) SPECIFICATIONS Ignition Coil: Ignition Coil Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . .) Piston Pin Bearing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . .4 mm (0. . . . . . . . . . . . . .950 in. . . .50 mm (0. . . . . . . . . . . . . . 7. . . . . . . . . . . . . . . . . . . . . . . . . .99 mm (2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 mm (0. . . . . . . . . . . . . . . . . . . . . . . .0022 in. . . . . . . . . . 75. . .49 mm (2. . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31. . . . . . . . . . . . . . . . . . . . . . .633 in. . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Cylinder Bore Out of Round: Standard . . . . . .0. . .8 N•m (69 lb-in. . . . . . . . . . . . . .ENGINE . . . . . . . . . . . . . . . . . . . . . .45° Valve Narrowing Angle. . . .18 mm (0. . . . . . . . . . . . . . . . . . . . . . . .) Cap Screw Torque . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . .35 mm (0. .628 in. . . . . . . . . . . .08 mm (0. . . . . . . . .2 . . . . . . . .) Valves and Valve Lifters: Push Rod Bend (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . .96 mm (0. . . . . . . . . .4 mm (0. . . . . .0 mm (1. . . . . . . . . . .) Piston Pin OD (Minimum) . . . . . . . . . .8 . .031 . . . . . . . . . . . . . . . . . . . . . . . . . . .05 mm (0. . . . . . . . . . . . .632 in. . .) Mounting Bolts . . . . . . . . . 8 . . . . . . . . . . . . . .016 in. . . . . . . Pistons and Rings Ring Groove Side Clearance (Maximum): Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 N•m (52 lb in. . . . . . .) Repair Specifications Cylinder Head: Cylinder Head Flatness (Maximum Warp) . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 in. 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .014 in. . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . .4 mm (0. . . 50 amps at 5000 rpm Brush Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. . . . . . . . . . . .) Piston Pin Bore OD (Maximum) . . . . . . . . . .08 mm (0. . . . .01 mm (0. . . . . . .) Wire Connection to Solenoid Nut Torque. . . . . . .) Valve Seating Surface Width Exhaust . . . . . . . . . . . .) Starting Motor: Amperage (No Load) (Maximum) . .8 N•m (84 lb-in. . . . .056 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 in. . . . .Kawasaki (FH601V) Specifications . . .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16. . . . . . . . . . . . . . . . . . . . . . .) Wear Limit . . . . . . . . .) Piston OD (Standard Piston) . . . . . . . . . . . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . .) 0. . . . .1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .055 in. . . . . . . .) Valve Stem Bend (Maximum). . . . . . . . . . . 0. . . .05 mm (0. . . . . . . . .16 mm (0. . . . . . . . . . . . . . . . . . . . 0. . . . . . .220 in. . .006 in. . . . . . . . . . . . . . . . . . . . . .008 in. . . . . . . . . . . . .020 in. . . . . . . . . . . . . . . . .239 in. . . . . . . . . . . . . 15 N•m (132 lb-in. . 74. . . . . . . . . . . . . . . . . . . . . .) Second Ring . . . . . . . . . . . . .970 in. . . . . . . . .002 in. . . . . . . . . . . . . . . . . . . . . . . . . . .11 k Stud torque (If Equipped) . . .) Oversize Piston . . . . . . . .04 . . . . . .05 mm (0. . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . .) Valve Guide ID (Maximum).) Valve Spring Free Length (Minimum) . 0. . . . . . . . . . . . . .0004 in. . . .) Valve Seating Surface Width Intake . . . . . . . . . . . . . . .) Engine . . . . . . 6. . . . . . . . .007 in. . . . . . . . . . .008 . . . . . . . . . . . . . . . . . . . . .) Oil Ring . . . . . . . . . . 0. .1.) Resistance between primary lead and core. . . . . . . . . . . . . . . .) Valve Margin (Minimum). . . . . . . . . 9 k Resistance between plug cap and core . . . . . . 16. . .6 mm (0. . . . . .170 . . . . .020 in. . . . . . .30° Cylinder Bore. . . . . . . . . . . . . . . .5 mm (0.002 in. . . . . 0. . . . . . . . .

. . . . .) Connecting Rod Journal OD (Minimum): Standard .65 mm (0. . . . . . .026 in. . . . .50 mm (0. . . . . .) Oversize Cylinder Bore: Standard . . . . . . . . . . . . . . . . . . .387 in. .KAWASAKI (FH601V) SPECIFICATIONS Cylinder Bore ID: (Standard) . . . . .) Crankshaft Main Bearing Journal OD (Minimum) . . . . . . 11. . . . . . . . . . . . . . . . . . . . . . . . . . 75. . . . . . . . . . . .020 in. . . . . . .) Outer Rotor Bearing Depth (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . .494 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 mm (0. . . . . . . .) Connecting Rod Maximum Crankshaft Bearing ID: Standard . . . . . . . . . . . .) Compression Ring (Second) . . . . . . . . 10. . . . . . . . . . . . . . . . . . . . 15. . . . . . . . .171 . . . .) Oil Pump: Rotor Shaft OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 mm (0.964 in. . . . . . . . .68 mm (2. . . . . . . . . . . . . . . . . . . .) Relief Valve Spring Free Length (Minimum) . . . . . . . . 19. . .) Outer Rotor OD (Minimum) . . . . . . . . . .923 mm (0. . . . . . . . . . . . . . . . . . .403 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 mm (1. . . . . . . . .593 in. .) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .007 in. . . . . . . . . . . . . . . .072 mm (0. . . . . . . . . . . . . . . . . .041 in. . . . . . . . . . . . . . . . . . . . . . . . . . .ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .985 mm (0. . . . . . . . . . . . . . . . . . . . 0. . . . . . . .477 in.) Oil Ring Side Rails . . . . . . . . . . 39. . . . . . . . . . . . . . . . . . . . . . . . . .) Undersized . .983 in. . . . . . . . . . . . . . . .15 mm (1. . . . . . . . . . . . . . . . . . .775 in. . . . . . . . . . . . . . . . . . . .581 in. . . . . . . . . . . . . . . . .002 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 mm (1. .) Piston Rings: Ring Thickness (Top and Second Ring) (Minimum) . . . . . . . . . . . . . . . . . . . .436 in. . . . . . . 75. . . . . . . .50 mm (0. . . . . .) Wear Limit (Maximum) . . . . .430 in. . . . . . . . . .) Crankshaft: Crankshaft Runout (TIR) (Maximum) . . . . . . . . . . 9. . . . . . . . . . . . . . . . . . . . 40. . .40 mm (0. . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . 16. . .18 mm (2. . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . 37. . . . . . . . . . . . . . . .) Oil Ring End Gap (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 mm (1.) 0. . . . .635 in. . . . 0.830 mm (0. . . . .136 mm (0. . .05 mm (0. . . . . . .629 in. . . . 10. . . . . . .031 in. . . . . . . . .94 mm (1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 mm (1. . . . . . . . . . . . . .) Ring End Gap (Maximum): Compression Rings (Top) . . . . . . . . . .960 in. . . . . . . . . . . .) Bearing ID (Minimum) . . . . . . . . . . . . . . .) Lobe Height (Minimum) .78 mm (2.28 mm (2. . . .) Undersized . . . . . . . . .Kawasaki (FH601V) Specifications . .571 in. . . . . . .979 in. . . . . . .055 mm (1. . . . . . . . . . . . . . . . . . . . . . 29. . . . . . . . 40. . 37. . . . . . . . . . . . . . . . . . . . . . . . . .) Maximum Crankcase Cover Plain Bearing ID . . . . . . . . . . . . . .166 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 mm (0. 37. . . . . . . . . . . . . . . . .) Rotor Shaft Bearing ID (Maximum) . . . . . . . . .) Outer Rotor Thickness (Minimum) . . . . . . . . . . . . . . . . .) Wear Limit (Maximum) . 75. . . . . . .) Outer Rotor ID (Maximum) . . . . . . . . .606 in.621 mm (1. . . . . . . . . . . . . . . . . . . 40. . .474 in. .18 mm (0. . . . . . . . . . . .498 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Camshaft: End Journal OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .896 mm (1. 1. . . . . .055 in. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . 25 N•m (221 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 . . . . . . . . . . .KAWASAKI (FH601V) TOOLS AND MATERIALS Torque Specifications NOTE: Use appropriate torque wrench which will read within the inch pound range given. . . . . . . . . . . . . . . . . . . . . . . 20 N•m (171 lb-in. . . . . . . . . . . JT05719 JDM59 JT03503 JT03338 JT03017 JT03344 JDG356 D-05351ST JDM70 JT05712 Tool Use Used to check idle speed and starter performance. . . . . .) Flywheel Bolt Torque . . . . . . . . . . . . . . . . . . . . . Used to check fuel pump performance. . . 26 N•m (230 lb-in. . . . . . . . . . . . . . 7. . . . . . . . SERVICE-GARD‰ Catalog or in the European Microfiche Tool Catalog (MTC). . . . . . . . . . . . . . or convert inch pounds to foot pounds as follows: Inch-pounds/12 = Foot-pounds Engine Mounting Cap Screw Torque . . . Used to check overall condition of ignition system. . . . . . . . . . . . . . . . . . . . . . . .) Oil Drain Plug Torque . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 N•m (52 lb-in. . . . . Used to check engine crankcase vacuum. . . .ENGINE . . .Kawasaki (FH601V) Tools and Materials . Engine . . . . .) Governor Lever Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft) Cylinder Head and Valves Cap Screw Torque in Sequence (Lubricated) Final Torque . . . . . . . . .) Intake Manifold Mounting Cap Screws . . . . . . . . . . . . . . . . Special or Required Tools Tool Name Hand-Held Digital Tachometer Compression Gauge Vacuum Gauge 90° Elbow Fitting Hose Assembly Pressure Gauge Assembly Pressure Gauge Spark Tester Valve Spring Compressor Current Gun Tool No. . . . . . . . . . . Used to check engine compression. . . 25 N•m (221 lb-in.8 N•m (69 lb-in. . . . . . . . . . . . . . Used to remove and install valve springs. . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Tools and Materials Tools NOTE: Order tools according to information given in the U. Used to check starter performance. . . . .S. . . Used to read engine oil pressure when performing Engine Oil Pressure Test. . . . . . . . . . . . . . Used to connect pressure gauge to engine when performing Engine Oil Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Crankcase Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Connecting Rod Cap Screw Torque . . . . . . . . . Used to connect pressure gauge to engine when performing Engine Oil Pressure Test.

LOCTITE‚ is a registered trademark of the Loctite Corp.173 .KAWASAKI (FH601V) TOOLS AND MATERIALS Other Materials Other Material Part No. M79292 Part Name MPG-2® Multipurpose Grease SCOTCH-BRITE® Abrasive Sheets/Pads Valve Guide Cleaner Prussian Blue Compound Lithium Base Grease Zinc Oxide/Wood Alcohol Mineral Spirits Valve Lap Compound T43512 / TY9473 / LOCTITE‚242 TY15130 / LOCTITE‚595 TY9375/TY9480/ LOCTITE‚592 Thread Lock and Sealer (Medium Strength) Form-in-Place Gasket Thread Sealant (General Purpose) with TEFLON‚ Part Use Apply to engine crankshaft Clean cylinder head Clean valve guides Check valve seat contact Pack oil seals Check block for cracks Clean armature Lap valves Apply to threads of throttle and choke plate screws Rocker arm cover mating surfaces Apply to threads of oil pressure switch MPG-2‚ is a registered trademark of DuBois USA. SCOTCH-BRITE‚ is a registered trademark of the 3M Co.Kawasaki (FH601V) Tools and Materials .ENGINE . TEFLON® is a registered trademark of DuPont Service Parts Kits The following kits are available through your parts catalog: • • • Carburetor Gasket Kit High Altitude Carburetor Kit Engine .

Throttle and Choke Cables .Voltage Regulator/Rectifier .Fuel Pump .Flywheel .Stator H I J K L M N O .Starting Motor .Spark Plug .174 .KAWASAKI (FH601V) COMPONENT LOCATION Component Location Engine Components E D G F H C I B A J K O N M L MX16330/MX16331 A B C D E F G .Starting Motor Solenoid Engine .Oil Drain Plug .Air Filter Cover .Rocker Arm Cover .Kawasaki (FH601V) Component Location .Carburetor .Ignition Modules .Oil Filter .ENGINE .Oil Pressure Switch .

Fuel Inlet Tube .Screw .Vent Tube .Choke Shaft Seal V .Choke Valve Plate .KAWASAKI (FH601V) COMPONENT LOCATION Carburetor (Externally Vented) A B C D K I H L F E G R M U V W J X Y N O Q F N P M99825 I R S T A B C D E F G H I J K L M N O P Q R S T U .Throttle Shaft Seal Y .Float .ENGINE .Vent Hose .Kawasaki (FH601V) Component Location .Float Chamber .Rubber Gasket .Slow Speed Jet .175 .Right Side Main Jet .Pin . Engine .Screw .Carburetor Body . 2134 m (7000 ft) and up.Collar NOTE: Main jets (7) and (17) change for altitude ranges: 0 to 1067 m (0 to 3500 ft).Throttle Shaft X .Vent Hose Guide .Fuel Shutoff Solenoid .Float Valve .Drain Screw and Spring .Plug .Left Side Main Jet .Throttle Valve Plates W .Choke Shaft . 1067 to 2134 m (3500 to 7000 ft).

Carburetor Body .Spring T .Choke Shaft .Cover .Spacer AA.Float Bowl V .Gasket (2 used) .Throttle Valve (2 used) .Seal .176 .Gasket AD. see Parts Catalog for jet numbers.KAWASAKI (FH601V) COMPONENT LOCATION Carburetor (Internally Vented) I J I B A C D E F G H O AF AF AD AE AD AC AB N M L K P AA Q Z Y X U W V T MX33796 S R A B C D E F G H I J K L M N O P Q .Plug.Float Valve Z .Main Jet. Engine .Pin AB.Needle Jet . Left1 AG.Spring Retainer .O-Ring R .Spring .Throttle Shaft .Gasket 1.Drain Screw S .O-Ring (2 used) AE.Insulator .Seal .Kawasaki (FH601V) Component Location .O-Ring AC.Solenoid . For altitude changes.Screw U .Float Y .Main Jet.ENGINE .Valve Plate .Gasket . Expansion .O-Ring X .Gasket W . Right1 AF.

No .Check for plugged air/fuel passages in carburetor. plugged air cleaner. (5) Is starting motor or solenoid defective? Yes . Recheck for spark and go to next step. Keep hands away moving parts when testing. c to rotate atAvoid Injury! The engine mayfrom CAUTION: start any time. or See “Starting Motor No-load Amperage and RPM Tests” on page 336 in the Electrical section.Make starting attempts a number of times.Go to next step.Check for contamination.Check fuel tank and lines. are spark plug electrodes wet? Yes .Check piston rings and cylinder for wear. (2) Is battery fully charged? See “Battery Test” on page 330 in the Electrical section. ignition coil air gap.Check if sparks are produced between high tension lead and ignition block. (4) After starting attempts.Replace spark plug. No . See “Carburetor (Externally Vented) Repair” on page 191.Repair or replace. Yes .See Engine Repair Section. See “Cylinder Compression Pressure Test” on page 183.177 . Check high tension lead. No . Symptom: Engine Doesn’t Crank (1) Are battery cables loose or dirty? Yes .Go to next step.ENGINE . No . or an air or vapor lock in the fuel tank and lines. (3) Is key switch working correctly? Yes . Symptom: Engine Malfunctions At Low Speed (1) Is unusual smoke emitted out of muffler? Engine . see Electrical Section and refer to either Diagnostics or Tests & Adjustments for further guidance. See “Cranking Circuit Operation” on page 269 in the Electrical section.Test switch. Test Conditions: • • • Operator On Seat PTO Switch In Off Position Brake On Symptom: Engine Hard To Start (1) Is there a strong blue spark? See “Spark Test” on page 186. remove spark plug and observe electrodes. Yes .Check engine starting.Go to step 3. Is compression sufficient? Yes . (2) Is there a strong blue spark? Yes . See “Charge Battery” on page 331 in the Electrical section.Kawasaki (FH601V) Diagnostics . Inspect cylinder head. Replace as needed. (5) Compression is low? Yes . pulser coil. No . No . No . No . See “Cylinder Head Inspection” on page 210.Charge battery. float bowl level too high. See “Piston Inspection:” on page 215.Go to step 5. Gasoline spray from the open cylinders may be ignited by ignition spark and cause an explosion or fire.Tighten or clean. No . Symptom: Engine Runs Erratically (1) Is fuel delivery correct. See “Fuel Pump Test” on page 185.KAWASAKI (FH601V) DIAGNOSTICS Diagnostics Engine Troubleshooting Guide c CAUTION: Avoid injury! Keep spark plug as far away from the plug hole as possible.Go to next step.Go to next step.Check for excessive use of choke. Go to next step. (3) Check compression. (4) Has engine seized? Yes . See “Starting Motor Solenoid Test” on page 335. NOTE: To test specific electrical components. Yes .

clean carburetor. No .Test switch. No . and “Starting Motor Disassembly and Assembly” on page 225. plugged oil ring groove. Go to next step. See “Starting Motor Solenoid Test” on page 335. NOTE: To test specific electrical components. (4) Is starting motor or solenoid defective? Yes . No .Charge battery. (4) Are valve clearances set correctly? See “Valve Clearance Check and Adjustment” on page 182.Repair starting motor. clogged breather valve.178 . See “Charge Battery” on page 331 in the Electrical section. plugged drain back hole in breather. (2) Are battery cables loose or dirty? Yes . No . (2) Does engine rpm drop or engine stall at a certain point when throttle is gradually opened by hand? Yes . disconnect negative (-) lead from battery as soon as possible.See Engine Repair Section.Tighten manifold flange nuts or replace damaged gasket.Go to next step. No . (5) Has engine seized? Yes . (3) Is air sucked through carburetor or intake manifold flanges? Yes . See “Choke Plate Check and Adjustment” on page 180. No . Symptom: Starter Rotates Slowly (1) Are battery cables loose or dirty? Yes . Yes . See “Carburetor (Externally Vented) Repair” on page 191.ENGINE .Check choke. Tests & Adjustments for further guidance.Go to next step. or worn cylinder bore. No .Go to next step.Kawasaki (FH601V) Diagnostics . Keep hands away moving parts when testing. (4) Is key switch working correctly? Yes . or See “Starting Motor No-load Amperage and RPM Tests” on page 336 in the Electrical section.Check for oil leaks.Go to next step. oil seals.Repair or replace. No . Yes . (2) Is battery fully charged? See “Battery Test” on page 330.Adjust valves. see Electrical Section and refer to either Diagnostics or Engine . stuck or broken piston rings.KAWASAKI (FH601V) DIAGNOSTICS Symptom: Engine Malfunctions At Low Speed Yes . (3) Is battery fully charged? See “Battery Test” on page 330 in the Electrical section.Charge battery. IMPORTANT: Avoid damage! If starting motor does not by turning ignition switch to Off position.Check for worn. high oil level.Check that all starting conditions are met. (3) Has engine seized? Yes .Tighten or clean. No . Is compression sufficient? Yes . Symptom: Oil Consumption Is Excessive (1) Check compression. See “Cranking Circuit Operation” on page 269 in the Electrical section. No .Tighten or clean.Go to next step. See “Starting Motor Removal and Installation” on page 225.See Engine Repair Section.Go to next step. incorrect oil viscosity.Go to next step. Starting Motor Troubleshooting Guide c to rotate atAvoid Injury! The engine mayfrom CAUTION: start any time. Replace as needed. See “Charge Battery” on page 331 in the Electrical section. No .Go to next step. No . Symptom: Starter Does Not Rotate (1) Is there a click sound from starter solenoid? Yes .Plug in carburetor interior. See “Cylinder Compression Pressure Test” on page 183.Go to next step.

• If holes DO NOT align in either position. F Check Procedure: 1. 2. 2. Park machine on level surface. Remove hood. Move forward/reverse pedals to NEUTRAL position. Loosen cable retainer screws (H). Move throttle control lever into CHOKE position. 3. Turn key switch OFF.Pull throttle cable (J) back (arrow) and tighten retaining screws (H). GT245” on page 558 or “Hood Removal and Installation . 10.Kawasaki (FH601V) Tests and Adjustments . Remove hood. 6. Check holes (B) in control panel (A) and throttle arm (C).ENGINE . 9. Remove the two capscrews (G) and the hood hinge brackets (F).179 . throttle cable is OK. M99935 C H 6. Align hole in throttle arm (C) with hole in control panel (A). Move throttle control lever to FAST idle position. Results: • If holes align in both positions. Be sure the engine is cool then remove the four capscrews (D) holding the upper muffler shroud (E) to the hood hinge brackets (F) and frame. 7.) drill bit (I) through holes to keep throttle arm from moving. 5. Again. then back into FAST idle position. DoAvoidtouch.KAWASAKI (FH601V) TESTS AND ADJUSTMENTS Tests and Adjustments Throttle Cable Check and Adjustment Reason: To make sure throttle lever and cable are adjusted so the throttle control arm contacts the slow idle stop at slow idle. GT235” on page 558 in the “Miscellaneous” section. A D E D G F M99953 C 5. Lock parking brake. holes in control panel and throttle arm MUST be aligned. perform “Adjustment Procedure”. Check and adjust choke plate. Insert a 6 mm (1/4 in. They MUST be in visual alignment. Be sure drill bit is perpendicular to the control panel. B A I 7. Lock parking brake. 3. Move forward/reverse pedals to NEUTRAL position. Turn key switch OFF. Move throttle control lever from LOW idle to FAST idle position. A J M99937 8. exhaust pipe or muffler CAUTION: Injury! Engine components not while making adjustments. 4. See “Hood Removal and Installation Models GT235E. Park machine on level surface. c are HOT. 4.) Drill Bit Adjustment Procedure: 1. Equipment: • 6 mm (1/4-in.Models GT225. Engine .

KAWASAKI (FH601V) TESTS AND ADJUSTMENTS 11. Move forward/reverse pedals to NEUTRAL position. 10. Move choke control lever to OFF (open) position. Engine . 5. Repeat “Check Procedure”. 4. Check Procedure: 1. Move forward/reverse pedals to NEUTRAL position. Park machine on level surface. 6. 3. Move the choke lever back and forth between the ON and OFF position while looking into the carburetor throat to watch the choke valve plate (A) close and open. Move forward/reverse pedals to NEUTRAL position. Choke Plate Check and Adjustment Reason: To make sure the choke plate is fully open when the choke control lever is in the OFF position. 2. Lock parking brake. Governor Adjustment A Reason: M99815 / M99816 To make sure the governor shaft contacts the fly-weight plunger when the engine is stopped. Results: • If the choke valve plate does not move to either the full open or full closed position. 7. 5. 7.180 . Lock parking brake. Remove hood. B C M99936 6.Reinstall hood. Procedure: NOTE: Adjust throttle cable and choke plate before adjusting governor linkage.Kawasaki (FH601V) Tests and Adjustments . 3. 2. Move throttle control lever to FAST idle position. 4. Park machine on level surface. Watch to see that the choke valve plate (A) contacts the base of the carburetor throat in the closed position (choke ON left side).ENGINE . Move choke lever through full range to be sure linkage is not binding. 4. perform “Adjustment procedure”. 2. Remove hood.Repeat “Check Procedure”. 14. Turn key switch OFF. 9. Remove hood. Park machine on level surface. Lock parking brake.Reinstall muffler shroud. Push choke cable (C) out (arrow) until the choke plate is full open and tighten screw.Remove drill bit. Loosen cable retainer screw (B).Move throttle control lever through full range to be sure linkage is not binding. 13. Adjustment Procedure: 1. Turn key switch OFF. 8. and is in a horizontal position in the open position (choke OFF right side). 5. hood hinge brackets and hood. 12. 3. 1. Turn key switch OFF. Unscrew and remove air cleaner cover and air filter.

13. 8. Fast Idle Speed Adjustment Reason: To set engine fast idle speed setting.Adjust idle stop screw (C) on the control plate to obtain 1700 ± 75 rpm. 8. 9. Using a small pin (C).Release the throttle lever and adjust the governed SLOW idle rpm. or JT05719 Photo Tachometer Engine . Park machine on level surface.Move throttle control lever through full range to be sure linkage is not binding. 12. Loosen nut (A).) Drill Bit JTO7270 Digital Pulse Tachometer.KAWASAKI (FH601V) TESTS AND ADJUSTMENTS A B D B A C M95384A 6.Access SLOW idle stop screw (B) through hole in air cleaner base. Start and run engine at MEDIUM idle for five minutes.ENGINE .). 10. Lock parking brake. or JT05719 Photo Tachometer C M99935a Procedure: 1. NOTE: Be sure idle stop screw on the control panel is in contact with throttle arm when making adjustments. Raise hood. 6. Move forward/reverse pedals to NEUTRAL position. Slow Idle Speed Adjustment Reason: To set engine slow idle rpm. 3. 4. Turn key switch OFF. Hold throttle lever (A) against SLOW idle stop screw (B). 10. 7. Move throttle control lever to SLOW idle position. 5. Equipment: • • JTO7270 Digital Pulse Tachometer. Put reflective tape on blower housing screen.Turn SLOW idle stop screw until engine rpm is set at 1600 rpm. 7.181 . Hold governor shaft and governor arm in place and tighten nut to 7. MX16332 9. rotate shaft (D) counterclockwise as far as it will go.Kawasaki (FH601V) Tests and Adjustments . Equipment: • • • 6 mm (1/4 in. Hold governor arm (B) in the fully counterclockwise position. 11. 2.8 N•m (69 lb-in. Use tachometer to check engine rpm.

Move forward/reverse pedals to NEUTRAL position. Start and run engine at MEDIUM idle for five minutes. Move throttle control panel (C) up to increase rpm or down to decrease rpm. Reason: To obtain the proper valve clearance that is critical for the valves to seat properly. 9. 8.KAWASAKI (FH601V) TESTS AND ADJUSTMENTS Procedure: 1. MX16322 1. is at TDC (top dead center) of the compression stroke (both intake and exhaust valves will be closed). 1. Equipment: • Feeler Gauge (blade type) 2. Lock parking brake. MX16322 6. Hold the throttle control panel and tighten cap screws to 5.). 7. Valve Clearance Check and Adjustment c careful notAvoid Injury! Engine will be HOT. Lock parking brake. A Procedure: IMPORTANT: Avoid damage! Perform valve clearance check or adjustment when engine is cold.075 to 0. Put reflective tape on blower housing screen. Be CAUTION: to burn hands. 4. visible in spark plug hole (A). Valve clearance should be 0. Fast idle speed setting should be 3400 ± 50 rpm. 2.9 N•m (52 lb-in. Loosen cap screws (B). Park machine on level surface. Remove spark plug. Park machine on level surface.005 in. Turn crankshaft until piston. 3. Move throttle control lever to FAST idle position. 3. Raise hood. Align holes in throttle arm and throttle control bracket (A). Raise hood. Turn key switch OFF. Remove valve cover. Results: • If fast idle speed does not meet the specifications: B B A M95401 C 7. Use a feeler gauge (B) to measure valve clearance. 3. 5.125 mm (0.ENGINE . 8. Allow engine to cool. Use tachometer to check engine rpm. Move forward/reverse pedals to NEUTRAL position. Place a 6 mm (1/4-in.182 .003 to 0. Engine . 2.) drill bit through holes to keep the throttle control arm from moving. 4.Kawasaki (FH601V) Tests and Adjustments . 5. Be sure drill bit is perpendicular to the throttle control panel. 6. Turn key switch OFF.). Remove and ground spark plug lead.

.) Spark Plug Torque . . . . and valves. . . . .).003 . 5. adjust valves and check fuel and air intake systems. . . . 12. Compression that is lower than specifications on low hour machines (but relatively equal on both cylinders) probably does not indicate a problem. . . wear or damage. .Crank engine for three to five compression strokes. 10. raise hood and remove spark plugs. . 8. . . • If above specification.Kawasaki (FH601V) Tests and Adjustments . Cylinder Compression Pressure Test Reason: To determine the condition of the pistons. Ground high tension leads (A) or disconnect positive lead from ignition coil. . . . Move forward/reverse pedals to NEUTRAL position. 3. Valve clearance must be adjusted properly before doing a compression test. . . . Engine .ENGINE . 41 kPa (6 psi) Results: NOTE: Above specification is for an engine that has sufficient time to allow rings to fully seat. . • If compression pressure DOES NOT increase after retest. .125 mm (0. . check rings. . . cylinder walls. 5. . . . 9. loosen lock screws (C). 10 seconds OFF. . 4. . and cylinder bores for broken rings. . 2. pistons. . . IMPORTANT: Avoid damage! DO NOT overheat starting motor during test. Turn adjusting nut (D) to adjust valve clearance to specifications. . Starter duty cycle is 5 seconds ON. Test Equipment: • JDM59 Compression Gauge Specifications: Minimum Compression . . or cylinder head gaskets. . . . 2. valve seats. 0. Check clearance again. Run engine for five minutes to bring engine to operating temperature. . . If valve clearance does not meet the specifications.) 6. . Check that choke is fully open and that air filter is clean. .Record pressure reading. . Specifications: Intake and Exhaust Valve Clearance (cold) . .005 in. . . check for leaking valves. . . . . . . 390 kPa (57 psi) Maximum difference between cylinders . . . Replace as necessary. scoring. . squirt clean engine oil into cylinder and repeat test. . . Park machine on level surface and turn key switch OFF.183 . 15 N•m (132 lb-in. rings. Hold adjusting nut and tighten lock screw to 6. 7. Lock parking brake. . .9 N•m (61 lb-in. Move throttle control lever to FAST idle position. . Install JDM59 Compression Gauge (B) in one spark plug hole. . .) Valve Cover Cap Screw Torque .) Jam Nut (C) Torque.075 . . . 6.0. Procedure: 1.9 N•m (52 lb-in. . . . • If compression pressure INCREASES after retest.9 N•m (61 lb-in. Check exhaust for restriction. 11.Repeat test with other cylinder. • If below specification.0. . .KAWASAKI (FH601V) TESTS AND ADJUSTMENTS Results: B D A C M95378 M95401 1.

Connect gauge. BeAvoid Injury!to touch. A B C M49880 8. Record crankcase vacuum reading. 5. c are HOT. 2. and gauge from rubber plug while engine is running at FAST idle.184 . 7.componentsthe CAUTION: Engine careful not especially M99563 4. Insert barbed fitting (B) into clear line (C) and attach to gauge (D). exhaust pipe or muffler while making adjustments. Allow engine to cool. Engine Oil Pressure Test Reason: To verify if the engine has enough oil pressure to lubricate internal components.KAWASAKI (FH601V) TESTS AND ADJUSTMENTS Crankcase Vacuum Test Reason: To measure the amount of crankcase vacuum. 9. Park machine on level surface. Wear protective eye glasses and clothing. 9. Hold finger over rubber plug hole to keep oil from spraying out. Move throttle to SLOW idle and turn engine OFF. IMPORTANT: Avoid damage! After test reading is made.ENGINE . 4. Move forward/reverse pedals to NEUTRAL position. bring level to full mark. Results: If crankcase vacuum is BELOW specification. Test Equipment: • • • JT03344 Pressure Gauge Assembly JT03017 Hose Assembly JT03349 Connector Procedure: 1. 3. which ensures the crankcase is not pressurized. piston.) of water movement. DO disconnect test gauge WHILE engine is running at FAST idle to prevent damage to gauge. check the following: • • • Breather port is obstructed. Turn key switch OFF. Hold finger over rubber plug hole to keep oil from spraying out. Raise hood. Install appropriate size rubber plug (A) in dipstick tube. Engine . Start engine and run at FAST idle. Test equipment: JT03503 Vacuum Gauge Procedure: IMPORTANT: Avoid damage! DO NOT make connection between test gauge and rubber plug BEFORE engine is running at FAST idle or gauge damage may result 1. clear line. Lock parking brake. 6.Kawasaki (FH601V) Tests and Adjustments . and cylinder bore for wear or damage. Condition of breather valve Rings. Park machine on level surface. Raise engine hood and remove dipstick. Check engine oil level. Disconnect barbed fitting. Gauge should show a minimum vacuum of 25 cm (10 in. 10. Connect JT03017 Hose Assembly (C) and JT03344 Pressure Gauge Assembly (B). 2. Install JT03349 Connector (A). 7. A pressurized crankcase will force oil leakage past the seals and gaskets and affect fuel pump operation.Remove rubber plug and install dipstick. Remove oil pressure switch. D C B A 3. 6. 8. 5. clear line and barbed fitting to rubber plug.

Test Equipment: • • JDG356 Pressure Gauge Graduated Container D C Procedure: 1. . . . . Engine . . IMPORTANT: Avoid damage! If pressure reading is below 69 kPa (10 psi).Stop engine. 12. . Gauge should read a minimum pressure of 6.185 . . . . Move forward/reverse pedals to NEUTRAL position. • Oil filter plugged. 6. . . Start and run engine at slow idle for one minute to fill carburetor with fuel. 240 . . Gauge should read an oil pressure of 240 . Stop the engine. .Start and run engine at MEDIUM idle for five minutes to heat engine oil to normal operating temperature.Remove pressure gauge from fuel pump outlet and connect a length of hose (C) long enough to reach into a graduated container (D). .Avoid Injury! Gasoline is extremelya CAUTION: DO NOT SMOKE. Worn or damaged oil pump. 3. M99940 11. . .Run engine at fast idle and check oil pressure. . .Kawasaki (FH601V) Tests and Adjustments . Determine and correct cause before running engine. .90 psi). . inspect or replace the following: • • • • Oil pressure relief valve for broken or worn spring. Results: If oil pressure is BELOW specifications.45 psi) Fuel Pump Test Reason: To check condition of fuel pump and determine fuel pressure. discontinue cranking engine. Oil pump suction screen or oil passages plugged. Park machine on level surface. . . 69 kPa (10 psi) Fast Idle . 2. Turn key switch OFF. . . 5. . .KAWASAKI (FH601V) TESTS AND ADJUSTMENTS 10. M95383 B A c flammable. Connect JDG356 Pressure Gauge to fuel pump outlet (B). 10. 9. this includes equipment that utilizes pilot lights. . .45 psi). then record pressure reading. . . Start and run engine at fast idle for 15 seconds. . . . 8. 11.310 kPa (35 . . . If no oil pressure is present. 7. . . Disconnect and plug fuel pump outlet hose (A). . 4. Oil pressure relief valve for stuck or damaged valve. Lock parking brake.Monitor oil pressure while cranking engine. • Excessive wear of connecting rod and main bearing journals.ENGINE .310 kPa (35 . . Raise hood. Specifications: Oil Pressure Minimum . .12 kPa (0. STOP ENGINE IMMEDIATELY and determine cause. Always work in well ventilated area away from open flame or spark producing equipment. .

7. . or no spark is present.2 oz/15 seconds) Spark Test Reason: Check overall condition of ignition system. . If engine will start. .) (4 turns) with screw (C). Turn key switch OFF. . . . . . 4. M49887 6. . 10. Replace fuel pump. Connect high tension lead to Spark Tester. . BeAvoid Injury!to touch. A steady. Move forward/reverse pedals to NEUTRAL position. Minimum flow is 65 ml/15 seconds (2. . 6.12 kPa (0. . Scrape or wire brush deposits from spark plug. as damage to ignition components could occur.90 psi) Minimum Fuel Flow .componentsthe CAUTION: Engine careful not especially exhaust pipe or muffler while making adjustments.) (5 turns). blue spark should be observed. . 7. IMPORTANT: Avoid damage! Do not adjust spark tester gap beyond 5. 2. Check crankcase vacuum. . A B c are HOT. or Wire Gauge Procedure: Procedure: 1. .ENGINE . .KAWASAKI (FH601V) TESTS AND ADJUSTMENTS 12. . . install a new spark plug and repeat test. . 65 mL/15 seconds . Adjust spark tester gap to 4. . . Move key switch to RUN position. . . Connect D-05351ST Spark Tester (B) to spark plug. 9. . Remove spark plug. Test Equipment: • D-05351ST Spark Tester Spark Plug Gap Adjustment Equipment: • • Feeler Gauge. . filter and fuel tank cap for restrictions. . . Park machine on level surface. Engine . .Kawasaki (FH601V) Tests and Adjustments .2 mm (0. run tests on individual components to find the cause of the malfunction. . then stop the engine and record container measurement. . .186 . Raise hood. Results: • If spark is weak. . strong. 8. . 1. .166 in. • If spark is still weak. . . Turn key switch OFF. Wear protective eye glasses and clothing.2 oz/15 seconds). . . 3. 6. . . D C IMPORTANT: Avoid damage! Do not clean spark plug with sand paper or abrasives. 2.Spin engine with starter and watch spark (D) at spark tester. . 3. 5. Results: If fuel pump pressure or flow does not meet the specifications. . Engine scoring can result. . or no spark is present. . Move forward/reverse pedals to NEUTRAL position. 4. Inspect spark plug for: • • Cracked porcelain Pitted or damaged electrodes 5. Raise hood. (2.200 in. Specifications: Minimum Fuel Pressure . . Lock parking brake. check the following: • • • Fuel lines. .Start and run engine at fast idle for 15 seconds.0 mm (0. watch spark with engine running. Park machine on level surface. . Remove high tension lead (A) from spark plug. Lock parking brake. . . .

). Engine . Check spark plug gap using a feeler or wire gauge. 2. Turn flywheel to remove feeler gauge. .187 .4 mm (0.2 . .). Air Gap Specifications: Air Gap. 3.030 in. .30 mm (0.) MX16320 2. Installation is done in the reverse order of removal.008 . Disconnect throttle control cable at engine.0. 4.75 mm (0. 2. 3.016 in. 0. Remove engine hood.Models GT235E.ENGINE . M48365 8. . . allow engine to cool preventremoving CAUTION: Avoid Injury! To possible before muffler.Kawasaki (FH601V) Repair .KAWASAKI (FH601V) REPAIR Repair Throttle Control Lever and Cable Removal and Installation: 1. Replace throttle control lever or cable as required. .0. Muffler Removal and Installation Ignition Coil Air Gap Adjustment Removal: 1. . See “Hood Removal and Installation . • Adjust throttle control cable and choke plate. . Remove two retaining screws (A) on each side of bumper and remove bumper. GT245” on page 558 in the “Miscellaneous” section.) feeler gauge between flywheel and armature. . . . c burns. Remove throttle control cable assembly.Models GT225. Set gap to 0. Push armature against flywheel and tighten cap screws (A) to 5. . See “Throttle Cable Check and Adjustment” on page 179 and “Choke Plate Check and Adjustment” on page 180. A M458969 A 1. GT235” on page 558 or “Hood Removal and Installation . Install and tighten spark plug to 15 N•m (132 lb-in. Insert a 0. .9 N•m (52 lb-in. Remove dash panel. . 9.).012 in. Center flywheel magnet under armature.

188 . Turn key switch OFF. Remove top heat shield.Kawasaki (FH601V) Repair .KAWASAKI (FH601V) REPAIR 6. F A M99817 H E 5. Remove four cap screws (B) from top heat shield. NOTE: Replace elements annually or every 25 hours. Inspect inside paper element and intake passage for signs of dust. If present. Remove the two retainer nuts (A) and air cleaner cover (B) from the engine. Lock parking brake. B MX16321 4. 7. Move forward/reverse pedals to NEUTRAL position. 4. 3. C MX16323 3. Remove lower heat shield cap screws (E) and remove lower heat shield (G).ENGINE . Remove muffler. Raise hood. replace elements and test engine compression or inspect for damage. • Use new gaskets for installation. Park machine on level surface. Remove two muffler mounting bolts (F) and nuts and washers (H) from each side of engine. Installation is done in the reverse order of removal. Air Cleaner Removal and Installation Removal and Installation: IMPORTANT: Avoid damage! Carefully remove air cleaner cover and elements. B 8. 5. D 2. Remove nut (C) on each hood support bracket (D) and remove hood brackets. G MX16329 Engine . 1.

13. c flammable. IMPORTANT: Avoid damage! Do not clean paper element with solvent or compressed air. See “Air Cleaner Removal and Installation” on page 188. GT235” on page 558 or “Hood Removal and Installation . 8. Remove the foam element (E) from the air cleaner (D).Models GT225. Replace parts as necessary.Kawasaki (FH601V) Repair .ENGINE . foam gasket (G). and air cleaner base (F) for damage. GT245” on page 558 in “Miscellaneous” section. Remove engine hood. Wash foam element (E) in detergent and water. this includes equipment that utilizes pilot lights. 7. Turn key switch OFF.Gently tap paper element (D) to remove dust.189 . Squeeze out excess oil. 7. Lock parking brake.Assemble and install air cleaner. Engine . Remove the two capscrews (D) and two nuts (E) and fuel shutoff solenoid ground wire (F) holding the carburetor (G) and air cleaner base (C) to the intake manifold.15 drops of clean engine oil to foam element (E). Carefully pull air cleaner base (C) away from carburetor (G).Models GT235E. Apply 12 . M99819 12. Loosen the clamp (A) and remove the breather hose (B) from the air cleaner base (C). 4. Move forward/reverse pedals to NEUTRAL position. See “Hood Removal and Installation . • Element is still usable if you can see light through it and element appears clean. Remove air cleaner cover and air filter assembly.KAWASAKI (FH601V) REPAIR Carburetor (Externally Vented) Removal C D Removal: 1.Inspect air cleaner cover.Inspect element. Remove the two wing nuts (C) and lift the air filter (D) and foam element (E) off of the air cleaner base. Always ventilated area away from open flame or spark producing equipment. dirty. E 3. or damaged in any way. 11. 5. A E D F M99820 F G 6. C D E G B • Replace if oily. Dry element.Avoid Injury! Gasoline iswork in a CAUTION: extremely Do not smoke. M99818 6. 2. 8. 9. 10. Park machine on level surface.

11. L C M99822 10.Unsnap the retaining clip (P) from around the choke rod (Q) and pull the choke rod out of the carburetor. Unsnap the retaining clip (N) from around the throttle rod (O) and pull the throttle rod (O) out of the carburetor.Kawasaki (FH601V) Repair .Disconnect the fuel shutoff solenoid red wire (I) from the engine wiring harness green wire (J).190 . R M99823 14.KAWASAKI (FH601V) REPAIR H O N Q P M M99821 9. I K 13. Loosen the drain screw (L) and allow for all the fuel to drain from the carburetor.Place a suitable container under the carburetor drain port (K hidden from view) to drain the fuel from the float bowl into.ENGINE . J M99824 12.Slide the carburetor (C) forward and off of the intake mounting studs (R). Engine . Installation is done in the reverse order of disassembly.Remove the throttle spring (M) from the retaining clip (N). Remove and plug the fuel inlet hose (H).

Engine . Remove the four screws (D) holding the float chamber (E) to the carburetor body. . Air Cleaner Base Screws . Remove the float chamber drain screw and spring (A). . 3. .9 N•m (61 lb-in. . Carefully pull the float chamber (E) straight away from the carburetor body (F) so as not to damage either the pickup tubes (G) or the float assembly (H). . Disassembly: 1. . NOTE: Float pivot pin end is serrated.9 N•m (61 lb-in. . . Control Panel Mounting Screws . Pin can be removed from one side only without damaging pin and/ or float hinge. . . . .KAWASAKI (FH601V) REPAIR Specifications: Ground Screw . . . . . . Always ventilated area away from open flame or spark producing equipment. . G C H M99829 3. .ENGINE .Kawasaki (FH601V) Repair . . . .) E D Carburetor (Externally Vented) Repair D c flammable.) 6. Remove carburetor from engine. . F E G B M99826 A 4. . fuel shutoff solenoid (B). . . . .) 6.) 6.Avoid Injury! Gasoline iswork in a CAUTION: extremely Do not smoke. . . .) 6.191 . .9 N•m (61 lb-in. this includes equipment that utilizes pilot lights. . See “Carburetor (Externally Vented) Removal” on page 189.9 N•m (35 lb-in. . . . . . Air Cleaner Base Nuts . . . and vent hose (C). . . . Air Cleaner Mounting Plate . . . . M99827 2. .9 N•m (61 lb-in. .

R F M99830 6. Q M99831 10. Mark the choke valve so it can be installed in it’s original position.KAWASAKI (FH601V) REPAIR N I M M99832 8. Lift the float (J) and float valve (K) off of the carburetor body (F). Carefully remove the rubber gasket (L).192 .ENGINE . Using a small pin punch.Mark the throttle valves so they can be installed in their original position. Slide the choke shaft (O) and shaft seal (P) out of the carburetor body (F). 7.Kawasaki (FH601V) Repair . Remove the four screws (Q) securing the two throttle valve plates (R) to the throttle shaft. Remove the two screws (M) securing the choke plate (N) to the choke shaft. carefully drive out the float pivot pin (I) from side opposite throttle lever of the float hinge. P O J K L F M99834 9. Engine . M99828 5.

NOTE: Idle mixture adjustment is factory set.Kawasaki (FH601V) Repair . Inspect all moving parts for wear.Slide the throttle shaft (S). shaft seal (T) and collar (U) out of the carburetor body (F). 15.25 mm 0. M99833 11. The carburetor is marked in two areas. the carburetor is marked “L” for number 1 cylinder and is equipped with a #106 main jet. Clean/Inspect/Rebuild: IMPORTANT: Avoid damage! Do not clean holes or passages with small drill bits or wire. Z 0. Wear between shafts and carburetor bushings should not exceed 0. IMPORTANT: Avoid damage! Carburetor is equipped with a different size fixed main jet for each cylinder. and mixture screws are sealed. 1.Check throttle and choke shafts and bushings for wear. Inspect all mating surfaces for nicks. No adjustment should be performed except by EPA/C. “R” for the number 2 cylinder is equipped with a #116 main jet. foreign material and cracks.193 .KAWASAKI (FH601V) REPAIR E V S U V E T M99835 14. Plate Y W 0.010 in. Engine .Check wear by placing carburetor on 6 mm (1/4 in.010 in.250 in.Remove the left main jet plug (W).25 mm (0. inspect float for leaks or damage. The carburetor upper body near the choke valve and the lower body near the main jet plugs (Z).). burrs.) raised flat surface. certified technicians and repair facilities.R.ENGINE . Repeat the same procedure for the right main jet. nicks and burrs. Measure the up and down movement of the shaft with a feeler gauge or dial indicator while moving the shaft up and down.Remove the two slow speed jets (V) from the float chamber (E). use a cleaning solvent with a high flash point that will not damage these parts when cleaning. NOTE: When cleaning all rubber and plastic parts.A. 13. gasket (X) and main jet (Y) from the float chamber.B. M89909 X M99836 12. Replace all parts that are worn or damaged.

and fuel consumption will increase. Rinse carburetor with warm water and dry with compressed air. c air to less than 210 kPa (30 psi) when using for CAUTION: Avoid Injury! Reduce compressed cleaning purposes. Spray all passages with a carburetor cleaning spray to verify that all internal passages are open. 1. IMPORTANT: Avoid damage! Rinse carburetor body in warm water to neutralize corrosive action of cleaner on aluminum. replace as necessary. 2. High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and readjusting idle mixture. 4. Remove any that are found or replace the gasket (X) then install the main jet plug (W) and tighten to 19 N•m (165 lb-in. Soak all carburetor metal parts in carburetor cleaning solvent for 1/2 hour maximum. 2134 m (7000 ft) and up. The main jets are not the same and are specific to the left port and the right port. Then slide the throttle shaft assembly into the carburetor body (F). 3.). X M99836 Engine . Do not use rags or paper to dry parts.7 N•m (6 lb-in. Install the two slow speed jets (V) into the float chamber (E) and tighten to 0. 5. guard against flying chips. Inspect the gasket (X) and gasket seat for any nicks or burrs. NOTE: High altitude operation: The standard carburetor main jets could cause an excessively rich fuel-air mixture at high altitudes. and the #116 jet is installed in the port marked “R” for the number 2 cylinder. Clear area of bystanders. Assembly: IMPORTANT: Avoid damage! Be sure to install main jets in the correct location. Tighten main jets to 0. Z E V V M99835 3. Inspect all parts for wear or damage.7 N•m (6 lb-in. Be sure that the lip of the shaft seal is toward the inside of the carburetor. S U E T M99833 W Y 4.Kawasaki (FH601V) Repair .). Performance will decrease. and wear personal protection equipment including eye protection. 1067 to 2134 m (3500 to 7000 ft).194 . make sure the #106 jet (Y) is installed in the port marked “L” for number 1 cylinder.ENGINE .). NOTE: Main jets change for altitude ranges: 0 to 1067 m (0 to 3500 ft). Slide the collar (U) and the throttle shaft seal (T) onto the throttle shaft (S). lint may plug holes or passages.KAWASAKI (FH601V) REPAIR 2. Install main jets. Remove rubber and plastic parts from carburetor.

Install the two screws (M) and tighten 1 N•m (9 lb-in. Hook the float valve (K) into the float (J) and place the float and float valve onto the carburetor body (F) so that the valve is seated into the inlet jet and the float pin (I) will be aligned. Be sure that the lip of the shaft seal is toward the inside of the carburetor. Insert the throttle valve plates (R) into the carburetor bore over the flats of the throttle shaft. 11. Engine . F M99830 P 8.Carefully set the float chamber (E) straight down onto the carburetor body (F) so as not to damage either the pickup tubes (G) or the float assembly (H). Lightly coat the rubber gasket (L) with grease and carefully place it on the carburetor body (F) in the gasket groove. 10. Install the previously marked throttle valve plates in their original location.Carefully press the float pin (I) into the float and carburetor body until flush. Place the choke plate (N) into the carburetor throat over the flat surface of the choke shaft. Install the previously marked choke plate in it’s original location. F M99834 F G H E 6.). Be sure to insert from the throttle lever side with serrated end toward throttle lever.ENGINE . O 9.Kawasaki (FH601V) Repair .KAWASAKI (FH601V) REPAIR R K J L Q M99831 I 5. Then slide the choke shaft assembly into the carburetor body (F). N G M M99826 M99832 7. Install the four screws (Q) and tighten to 1 N•m (9 lb-in.).195 . Slide the choke shaft seal (P) onto the choke shaft (O).

0.Models GT225. C c flammable. .Install the fuel shutoff solenoid (B) and tighten to 20 N•m (171 lb-in.Remove the carburetor. .Install the four screws (D) holding the float chamber (E) to the carburetor body and tighten to 4 N•m (34 lb-in. . . . . this includes equipment that utilizes pilot lights. 11. . .7 N•m (6 lb-in. . . . 8.) Fuel Shutoff Solenoid . . .) Drain Screw.ENGINE . . . .Pull the carburetor away from the intake manifold and disconnect the wire connector (A) from the fuel shutoff solenoid (B). . Engine . Installation: 1. 13. .Disconnect and plug the fuel inlet line. . Lock parking brake. . . . .) Slow Speed Jet . . . . . . . .Avoid Injury! Gasoline iswork in a CAUTION: extremely Do not smoke. . .) Float Chamber Screws. . . . 1. . . . . . . . . .). Always ventilated area away from open flame or spark producing equipment. . . Park machine on level surface. .) Main Jet .0 N•m (15 lb-in. . . . D 4.Install the vent hose (C) and the float chamber drain screw and spring (A) and tighten to 2. Move forward/reverse pedals to NEUTRAL position. .0 N•m (9 lb-in. Remove the two capscrews and two nuts holding the carburetor and air cleaner base to the intake manifold.Install the carburetor onto the engine.). 6. Remove air cleaner cover and air filter assembly. 5. . . . . . . Remove the crankcase breather line from the intake. . .Remove the four nuts securing the carburetor and choke cable mounting bracket to the intake manifold. .0 N•m (9 lb-in. See “Carburetor (Externally Vented) Removal” on page 189. . . . . . .) B A MX33476 12. . GT245” on page 558 in “Miscellaneous” section. . . .Kawasaki (FH601V) Repair .). 7. . . . .Models GT235E. M99829 12. . 0. . . . .) Main Jet Plugs . . . 15. See “Hood Removal and Installation . . . . . . D 2. . . . 9. Remove engine hood. . . . . See “Air Cleaner Removal and Installation” on page 188. . . 20 N•m (171 lb-in. . 14. .0 N•m (18 lb-in. . . . . . 4. 3. Loosen the clamp and remove the breather hose from the air cleaner base. B 10. Turn key switch OFF. 2. . .KAWASAKI (FH601V) REPAIR Carburetor (Internally Vented) Removal E Removal: 1. .0 N•m (34 lb-in. . . . Specifications: Choke Plate Screws . . 1.) Throttle Valve Plate Screws . . . . . . . 19 N•m (165 lb-in. . . . A M99827 13.7 N•m (6 lb-in. Installation is the reverse of removal.196 . . . . GT235” on page 558 or “Hood Removal and Installation . Carefully pull air cleaner base away from carburetor.

Insulator . A B C D E F G H .Spacer .Carburetor .Gasket . Engine . Tighten nuts to 5.197 . Slide the carburetor into position.ENGINE .Gasket . 4.KAWASAKI (FH601V) REPAIR Carburetor (Internally Vented) Repair Disassembly: A B C D E F E G MX33477A H 1. See “Carburetor (Internally Vented) Removal” on page 196. and two screws (C) holding the float chamber to the carburetor body. 5. Clean the carburetor and intake manifold mating surfaces. MX33479 2. Remove the fuel shutoff solenoid (B). Use new intake manifold gaskets during installation.Thru Bolts .Nuts A 2. 3.9 N•m (52 lb-in). Install the mounting bolts and nuts.Washer . Remove the float chamber drain screw and spring (A). Remove carburetor from engine.Kawasaki (FH601V) Repair . C C B MX33480 3. Replace the insulator between the intake manifold and carburetor if worn or damaged.

Slide the choke shaft (R) and shaft seal (S) out of the carburetor body (E).ENGINE . Inspect the main jets (K) for dirt. Clean the float chamber. Remove two screws (Q) securing the choke plate to the choke shaft. E H J I F 10. Carefully pull the float chamber (D) straight away from the carburetor body (E). Lift the float assembly (G) out of the float chamber (D). M 13. Replace as needed. Inspect the oil ring (L) for damage. or damage.198 .Inspect the float valve seat for wear or damage. Remove the float pivot pin (M) out from the side opposite the throttle lever of the float hinge. Do not damage either the pickup tubes (F) or the float assembly (G). MX33540 7. 8. K R MX33482 S E 6. Carefully remove O-rings (H and I) and the rubber gasket (J) and inspect for damage. Q MX33539 D G L 12. 5. 11.KAWASAKI (FH601V) REPAIR 9.Kawasaki (FH601V) Repair . T N O U MX33537 MX33541 Engine . G P D MX33481 4.Remove the float valve (N) from the float (O).Mark the choke plate (P) so it can be installed in the original position. wear.

Clear area of bystanders. Check throttle and choke shafts and bushings for wear. 0. lint may plug holes or passages. and wear personal protection equipment including eye protection. burrs.ENGINE . nicks and burrs. Y X V W E 1. IMPORTANT: Avoid damage! Rinse carburetor body in warm water to neutralize corrosive action of cleaner on aluminum. Z MX33543 16. shaft seal (W). 15. M89909 6. cover plate (AA) and gasket. NOTE: When cleaning all rubber and plastic parts. inspect float for leaks or damage. Clean/Inspect/Rebuild: IMPORTANT: Avoid damage! Do not clean holes or passages with small drill bits or wire.Mark the throttle valve plates (T) so they can be installed in the original position. Soak all carburetor metal parts in carburetor cleaning solvent for 1/2 hour maximum. 5. and spring collar (Y) out of the carburetor body (E). Inspect all mating surfaces for nicks. Replace all parts that are worn or damaged. replace as necessary.250 in.010 in.Kawasaki (FH601V) Repair . ab 0.25 mm 0. foreign material and cracks. Spray all passages with a carburetor cleaning spray to verify that all internal passages are open. 2. 4. guard against flying chips. Remove four screws (U) securing the plates to the throttle shaft.199 . return spring (X). Engine . Plate ab MX33544 17.Inspect and clean the passages and holes (AB). Remove rubber and plastic parts from carburetor. Do not use rags or paper to dry parts.Remove three screws (Z). Inspect all parts for wear or damage.Slide the throttle shaft (V). use a cleaning solvent with a high flash point that will not damage these parts when cleaning. Inspect all moving parts for wear. Rinse carburetor with warm water and dry with compressed air. aa c air to less than 210 kPa (30 psi) when using for CAUTION: Avoid Injury! Reduce compressed cleaning purposes. MX33542 3.KAWASAKI (FH601V) REPAIR 14.

Assembly: MX33798 A 1. NOTE: When cleaning all rubber and plastic parts. Measure the up and down movement of the shaft with a feeler gauge or dial indicator while moving the shaft up and down.1000m (0 .Kawasaki (FH601V) Repair . O-ring end first (F). Wear between shafts and carburetor bushings should not exceed 0.) raised flat surface.6557 ft) 2000m and higher (6557 ft and higher) Left #102 #99 #96 Right #104 #101 #98 F E MX33800 4. 2.2000m (3279 .ENGINE . into the pickup body.010 in.3279 ft) 1000m . MX33799 3.). Check wear by placing carburetor on 6 mm (1/4 in. use a cleaning solvent with a high flash point that will not damage these parts when cleaning.25 mm (0. Remove and Install Jets: IMPORTANT: Avoid damage! Do not clean holes or passages with small drill bits or wire. Main Jet Use Standard. 0 . Remove the pickup body.200 . Match jet number (E) to the correct side (Left or Right) and install jet. B D C MX33543 1. Carefully press each jet (C and D) into the pickup body to remove. Align the jet to the pickup bore and carefully press the jet into the pickup body until fully seated. A B 5. Position the gasket and cover (A) over the passages and secure with three screws (B).KAWASAKI (FH601V) REPAIR 7. Position the jet body onto the carburetor body and mark the jet body with a “L” (A) and “R” (B) to match the carburetor body. Engine .

N MX33539 7. Install the float pin.Kawasaki (FH601V) Repair . Install the choke plate in its original location. Tighten to 1 N•m (9 lb-in.201 .KAWASAKI (FH601V) REPAIR H The lip of the shaft seal should face the inside of the carburetor. 3. Engine . Install two screws (N).). Place the choke plate (M) into the carburetor throat over the flat surface of the choke shaft.ENGINE . Tighten to 1 N•m (9 lb-in. Slide the choke shaft assembly into the carburetor body (G). D C E F M G MX33542 2. Slide the throttle shaft assembly into the carburetor body (G) and engage the return spring into the retaining hole (H). V U W T L K G X MX33540 MX33482 6. Slide the shaft seal (F) onto the shaft with the lip of the shaft seal facing the inside of the carburetor. Slide the spring collar (C) with the return spring (D) positioned between the halves onto the throttle shaft (E). Place the float and float valve onto the pickup body (Q) so the valve is seated into the inlet jet (R) and the float pin (S) is aligned.). 4. S I R O P J MX33541 MX33537 5. Install the throttle valve plates in their original locations. 8. Slide the choke shaft seal (K) onto the choke shaft (L). Insert the throttle valve plates (I) into the carburetor bore over the flats of the throttle shaft. Hook the float valve (O) into the float (P). Install four screws (J).

Move forward/reverse pedals to NEUTRAL position. Disconnect vacuum line (A) (hidden from view) and fuel lines (B). Raise hood. Installation: X MX33480 Installation is done in the reverse order of removal. Fuel Pump Replacement Removal: 1. Raise hood. Lock parking brake.KAWASAKI (FH601V) REPAIR 9. Install carburetor to engine.Install two screws (AC) holding the float chamber to the carburetor body and tighten to 4 N•m (34 lb-in. Turn key switch OFF. G Y aa Z ab 4. 3. Move forward/reverse pedals to NEUTRAL position. • • Replace fuel pump.202 . Park machine on level surface. 2. See “Carburetor (Internally Vented) Removal” on page 196.Avoid Injury! Gasoline iswork in a CAUTION: extremely Do not smoke. V A MX33481 C B B 10.Apply a light coat of grease to the O-rings (Y and Z) and the rubber gasket (AA) and install in the proper grooves.Install the float chamber drain screw and spring and tighten to 4 N•m (34 lb-in. 2.). this includes equipment that utilizes pilot lights. 13. Remove two mounting screws (C). Blower Housing Removal and Installation Removal: 1. Always ventilated area away from open flame or spark producing equipment.9 N•m (52 lb-in. Turn key switch OFF. Engine .). Park machine on level surface.Install the fuel shutoff solenoid (X). install the float assembly (U) into the float chamber (V) with the float hinge (W) toward the fuel shutoff solenoid port (X). 14.ENGINE .Carefully set the float chamber (V) straight down onto the carburetor body (G) to prevent damage to the pickup tubes (AB) or the float assembly (U).).Kawasaki (FH601V) Repair . 15. C M99564 ac 5. 4. With the O-ring (T) in position. 3. 12. ac 6. U c flammable. Lock parking brake. Tighten mounting screws to 5. 11.

If these capscrews are removed. be careful not to loose the bushings on each capscrew. M99838 Engine . Remove the three screws (C) and blower screen (D). M99837 6. Remove blower housing. Loosen the two capscrews (E) by four to five turns. 3. Loosen the two capscrews (F) by four to five turns.Kawasaki (FH601V) Repair . Remove the two retainer nuts (A) and air cleaner cover (B) from the engine. be careful not to loose the bushings on each capscrew. • F F Tighten nut to 56 N•m (41 lb-ft). See “Ignition Coil Air Gap Adjustment” on page 187. If these capscrews are removed. Lift the upper blower housing off the engine. Remove both armature coils (A). Hold flywheel (B) and remove cap screw (C). Installation is done in the reverse order of removal.203 . These capscrews do not need to be removed. B M95381 4. Installation is done in the reverse order of removal. 7. C D B M95382 E E 2.ENGINE . A 9.KAWASAKI (FH601V) REPAIR B 8. See “Blower Housing Removal and Installation” on page 202. Flywheel Removal and Installation Removal: 1. These capscrews do not need to be removed. M99817 A C A 5. Remove flywheel (B) using a flywheel puller. • Adjust armature air gap.

or clean with solvent and allow to dry. Clean all old gasket residue off the mating surfaces of the intake manifold and the cylinder heads. 3.Kawasaki (FH601V) Repair . Replace the intake manifold if it is cracked. See “Blower Housing Removal and Installation” on page 202. MX16333 A B 3. C 3. 2. Remove two ties (C) holding ignition coil wires in place on intake manifold. Installation: 1. 5. Remove and replace breather element (C). Tighten cap screws to 5. Remove fan and flywheel. Inspect the intake manifold for signs of cracks or porous spots. Remove carburetor. See “Blower Housing Removal and Installation” on page 202. Remove four mounting cap screws (A).ENGINE . Remove four screws (A) securing the breather chamber cover (B) to the crankcase. See “Carburetor (Externally Vented) Removal” on page 189. Install new gaskets. Install blower housing. Remove carburetor and intake manifold. and intake manifold (B) and two gaskets from engine.KAWASAKI (FH601V) REPAIR Intake Manifold Removal and Installation Removal: 1.9 N•m (52 lb-ft). M95368 4. Remove blower housing. C MX16333 Engine . 5. C A B A M95369 5. Install carburetor. 4. 2. 4.204 . or the gasket mounting surfaces are damaged to the point they will not seal properly with new gaskets. 2. Install two ties (C) to hold ignition coil wires in place on intake manifold. Install intake manifold and secure with four (4) mounting cap screws (A). Remove screen and blower housing. See “Carburetor (Externally Vented) Removal” on page 189. A B A Breather Removal and Installation Procedure: 1. Inspect the manifold gasket mounting surfaces for burned areas or nicks and gouges.

Raise and remove hood. 8.Apply sealant to the mating surface of the crankcase and install a new gasket (G).). 11. 9.Install flywheel. Remove mounting screw (D).Install the breather chamber cover and tighten four capscrews to 6. B M95370 10. Remove four cap screws (B) from heat shield. 2. Engine . 7. Replace any parts necessary. Inspect breather valve (F) for breakage. Disconnect negative cable from battery.KAWASAKI (FH601V) REPAIR Engine Removal and Installation F E D Removal: 1. reed plate (E) and breather valve (F). Check drain hole on breather chamber make sure no foreign material has accumulated before installing breather valve. Inspect the valve seating surface it should be free of nicks or burrs. G MX16320 4. A MIF 6. 3. 12.Kawasaki (FH601V) Repair .205 . Remove mower deck.ENGINE . MX16323 5. Inspect the reed plate (E) for damage or rough contact surface. then tighten the mounting screw. See “Flywheel Removal and Installation” on page 203. hair cracks or distortion. Align center of the valve seat with center of the breather valve and the plate.9 N•m (61 lb-in. Remove two retaining screws (A) on each side of bumper and remove bumper.

10. Remove cap screw from cable clamp (G). and oil pressure switch wire (F). this includes equipment that utilizes pilot lights.Disconnect fuel line at fuel pump (J).206 .Remove four nuts (L) securing exhaust pipe flanges to cylinder heads. 7.Remove throttle and choke cable clamps (M) and disconnect cables from lever ends (N).Kawasaki (FH601V) Repair . c flammable. MX16319 8. Disconnect the engine wire harness (E). Disconnect positive (+) battery cable and orange wire from large terminal of starter solenoid (H). NOTE: Be sure to remove fuel hose and wiring from any clips or tie wraps securing them to engine prior to removing engine. Remove heat shield. Remove nut (C) on each hood support bracket (D) and remove hood brackets.ENGINE . Disconnect purple wire (I) from solenoid.Avoid Injury! Gasoline is extremelya CAUTION: DO NOT SMOKE.KAWASAKI (FH601V) REPAIR K D J C L H I L MX16318 MX16321 6. Remove cap screw from clamp (K). 11. G F N E M MX16322 12. 9. Always work in well ventilated area away from open flame or spark producing equipment. Engine .

ENGINE - KAWASAKI (FH601V) REPAIR
4. Install traction belt tension spring (S). 5. Reconnect the fuel line to the fuel pump.
Q P R

6. Connect the battery cable, orange wire, and purple wire to the starting motor. 7. Connect the engine wire harness to main wiring harness. 8. Connect the throttle cable and choke cable and adjust cables. See “Throttle Cable Check and Adjustment” on page 179.

O

9. Fill engine to proper level with oil of correct specifications. 10.Apply MPG-2‚ Multipurpose Polymer Grease to engine crankshaft.
MX16325

13.Disconnect wiring connector (O). 14.Remove cap screw (P), washer (Q) and PTO clutch (R).
P

Q R

U

S O

V T MX16325

11.Connect wiring connector (O) and install PTO clutch (R) on crankshaft. make sure slot in clutch is positioned around pin (V).
MX16326

12.Install washer (Q) with concave side toward PTO clutch. 13.Tighten cap screw (P) to 61 N•m (45 lb-ft).

15.Disconnect traction belt tension spring (S). 16.Slide belt off of sheave (T) and remove sheave. 17.Remove four engine mounting cap screws and nuts (U). 18.Remove engine. Installation: Installation is done in the reverse order of removal. 1. Install new gaskets between cylinder head and exhaust pipe flanges. 2. Install four engine mounting cap screws (U). Be sure to connect the ground wire to the left rear mounting cap screw. Tighten cap screws and locknuts to 26 N•m (230 lbin.). 3. Install traction drive sheave (T) and place belt on sheave.

Engine - Kawasaki (FH601V) Repair - 207

ENGINE - KAWASAKI (FH601V) REPAIR
Rocker Arm Removal and Installation
Removal: 1. Remove rocker arm cover. 2. Turn crankshaft until piston is at TDC of compression stroke for the cylinder being worked on.
M50044

A

• Inspect push rod for bend using V-blocks and a dial indicator. Turn rod slowly and read variation on indicator. Replace if variation is greater than 0.5 mm (0.020 in.). Disassembly and Assembly:

B

E F

M95401

3. Remove valve clearance adjustment nut (A) and rocker arms (B). IMPORTANT: Avoid damage! Mark push rods for reassembly in original locations 4. Inspect all parts for wear or damage. (See Inspection procedure.) Inspection:

G M95402

1. Compress valve spring and remove collet halves (E). 2. Remove spring retainer (F) and spring (G). Installation: Installation is done in the reverse order of removal. IMPORTANT: Avoid damage! Align rocker arms over push rods during assembly

C

• Check and adjust valve clearance. See “Valve Clearance Check and Adjustment” on page 182. • Install rocker covers. Tighten rocker cover cap screws to 6.9 N•m (61 lb-in.).

D M95394

• Clean and inspect the rocker arm where it contacts the push rod and valve stem (D). Check the inside of the rocker arm where it pivots on the special nut (C). If the contact points are worn or damaged, replace the rocker arm.

Engine - Kawasaki (FH601V) Repair - 208

ENGINE - KAWASAKI (FH601V) REPAIR
Cylinder Head Removal and Installation
Removal: 1. Remove the following using procedures in this section: • • • • • Upper blower housing Air cleaner and carburetor assemblies. Muffler Intake manifold Spark plug
3 1 M95403 C

9. If necessary to replace stem seal, carefully pry up from bottom (C) with a screwdriver. 10.Inspect springs, valves, guides, and seals. (See Inspection procedure.) Assembly is done in the reverse order of disassembly.
5

Installation: IMPORTANT: Avoid damage! Gasket surfaces are coated with sealant. Do not damage surfaces or gasket during installation. 1. Set cylinder to TDC of compression stroke for the cylinder being worked on. 2. Set the cylinder head with gasket onto crankcase. 3. Slide the push rods into the crankcase by sliding the end of the rods down along the inside wall of the crankcase.

4 2 M95385

4. Position the push rod end on the tappet. 5. Align the upper push rod end under the rocker arms.
A

2. Remove rocker cover and gasket. 3. Turn crankshaft until piston is at TDC of compression stroke for the cylinder being worked on. 4. Loosen the cylinder head bolts 1/4 turn at a time, in sequence (above) to prevent warping the cylinder head during removal. 5. Remove cylinder head assembly. 6. Mark push rods for installation in their original position during assembly. 7. Remove rocker arms. See “Rocker Arm Removal and Installation” on page 208. 8. Disassemble, clean and inspect cylinder head and valves.

B M95386

6. Torque should be applied in the sequence shown, in 7 N•m (62 lb-in.) increments for the number one (A) and number two (B) cylinders. Torque Specifications: First torque . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (62 lb-in.) Second torque . . . . . . . . . . . . . . . . . . 14 N•m (124 lb-in.) Third torque . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Final torque. . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)

Engine - Kawasaki (FH601V) Repair - 209

ENGINE - KAWASAKI (FH601V) REPAIR
7. Install the rocker arms. See “Rocker Arm Removal and Installation” on page 208. 8. Check and adjust valve clearance. See “Valve Clearance Check and Adjustment” on page 182. 9. Install rocker covers. Tighten rocker cover cap screws to 5.9 N•m (52 lb-in.). Valve Guides: NOTE: Intake and exhaust valve guides cannot be replaced, replace head if worn.

Cylinder Head Inspection
Procedure: 1. Remove cylinder heads. See “Cylinder Head Removal and Installation” on page 209. 2. Remove carbon deposits from combustion chamber and gasket surface using SCOTCH-BRITE® abrasive pads or an equivalent.
A

M95403

c air to less than 210 kPa (30 psi) when using for CAUTION: Avoid Injury! Reduce compressed
cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. 3. Clean head with a suitable solvent and dry with compressed air. 4. Inspect for cracks or broken cooling fins. 5. Inspect gasket surface for burrs and nicks. 6. Inspect head gasket for burns and traces of gas leakage. Replace if necessary. 7. Check that oil drainback passages are not plugged.

1. Clean inside of valve guides (A) with valve guide cleaner. 2. Measure inside diameter of valve guides in several places down the length of the guide. Replace cylinder head if inside diameter is greater than 6.08 mm (0.239 in.). Valve Seats: 1. If valve seats are loose, warped or distorted beyond reconditioning, replace cylinder head. Pitted or worn seats can be re-faced using a seat cutter.

A

C

B

M18615

2. Check valve seating pattern for correct width and evenness all around (Note: correct seat position (A), seat too deep (B) and seat too high (C)). If valve seat width is not within 0.8 - 1.4 mm (0.03 - 0.05 in.) intake or 1.1 - 1.6 mm (0.04 - 0.06 in.) exhaust, recondition valve seat.
M95403

8. Put cylinder head on a surface plate. Check for distortion at several points around the head using a feeler gauge. Replace head if distortion is more than 0.05 mm (0.002 in.).

3. Lap valve after reconditioning with lapping compound and recheck valve seating surface for proper width and evenness of seating pattern. See “Lap Valves” on page 212.

Engine - Kawasaki (FH601V) Repair - 210

ENGINE - KAWASAKI (FH601V) REPAIR
Valve Springs: 1. Inspect spring for pitting, rust, and burrs. Replace if necessary.

M51753

5. Check valve stem for bend using V-blocks and a dial indicator. Turn valve slowly and read variation on indicator. Replace valve if variation is greater than 0.05 mm (0.002 in.). IMPORTANT: Avoid damage! Do not grind the exhaust valve or life will be shortened. 6. Grind the intake valve to 45°. Replace valve if margin is less than 0.35 mm (0.014 in.) after grinding.

M50036

2. Measure spring free length. Replace spring if measurement is less than 31.0 mm (1.22 in.). Intake and Exhaust 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. Inspect valve head, face, and stems for defects. Replace if necessary.

Recondition Valve Seats
Procedure: 1. Inspect valve seats for damage. If seats are warped or distorted beyond reconditioning, replace cylinder head. Pitted or worn seats can be refaced using a seat cutter.

A A B B

D C

E

C M38087

M9552

3. Replace warped valves (A) or valves with less than 0.35 mm (0.014 in.) margin (B). 4. Measure outside diameter of valve stem. Replace valve if diameter is less than specification. Minimum Valve Stem OD Specifications: Intake . . . . . . . . . . . . . . . . . . . . . . . . . 5.95 mm (0.234 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . 5.93 mm (0.233 in.)

2. To recondition seat, cut at 45° angle (B) to clean up seat. Cut narrowing angle (E) at 30°. Finish cut at 45° (B) to establish seating surface width (A). 3. Cut valve seating surface (A) as close as possible to specifications. Specifications: A - Valve Seating Surface (Standard) Intake . . . . . 0.80 - 1.40 mm (0.03 - 0.055 in.) (Standard) Exhaust . . . . . 1.1 - 1.6 mm (0.04 - 0.063 in.) B - Valve Seat Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . 45° C - Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45° D - Valve Margin (Minimum) . . . . . . 0.35 mm (0.014 in.) E - Valve Narrowing Angle. . . . . . . . . . . . . . . . . . . . . . 30°

Engine - Kawasaki (FH601V) Repair - 211

ENGINE - KAWASAKI (FH601V) REPAIR
4. Lap valves to seats after re-facing. See “Lap Valves” on page 212. 5. Center valve seat on the valve face. 6. Check seat for good contact using Prussian Blue Compound.

Crankcase Cover Removal and Installation
Removal and Installation: 1. Drain crankcase. Capacity (with filter) is approximately 1.7 L (1.8 US qt). 2. Remove crankcase cover and gasket. 3. Clean crankcase and crankcase cover gasket surfaces. NOTE: Do not force cover. Gears must mesh for proper positioning.

Lap Valves
Procedure: NOTE: If valve seat does not make proper contact, lap the valve into the seat.

8 7 9

1
M50041

10

1. Apply a small amount of fine lapping compound to face of valve. 2. Grip top of valve with a vacuum cup tool and rotate valve to lap valve to seat. 3. Lift valve from seat every 8 to 10 strokes. Lap until a uniform ring appears around the surface of the valve face. 4. Wash all parts in solvent to remove lapping compound. Dry all parts. 5. Check position of lap mark on valve face. Lap mark must be on or near center of valve face. 3
M95380

6

2

5

4

4. Install gasket and cover. Tighten cap screws in a two step process to specification. Use the sequence shown above. Torque Specifications: Initial torque . . . . . . . . . . . . . . . . . . . . . 10 N•m (88 lb-in.) Final torque. . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)

Engine - Kawasaki (FH601V) Repair - 212

ENGINE - KAWASAKI (FH601V) REPAIR
Piston and Connecting Rod
Removal: 1. Remove cylinder head. 2. Split the crankcase. 3. Remove the camshaft. 4. Turn the crankshaft to expose the connecting rod cap screws.
C

Assembly:
D

M95389

B

1. Install the expander (C) in the piston oil ring groove so that the expander ends (D) touch together. Be sure that they do not overlap. 2. Install the upper and lower steel oil rails. There is no up or down to the rails. They can be installed either way.

A M51726 F

5. Remove the cap screws (A) and take off the connecting rod caps (B). Note the position of the connecting rod caps for reinstalling the caps. 6. Check cylinder bore for carbon and varnish ridges. These ridges can cause piston damage if not removed. 7. If necessary, remove ridges from top of cylinder bore with a ridge reamer. 8. Push piston and connecting rod into the cylinder and pull out of the cylinder bore. Disassembly: • Remove piston rings with a piston ring expander. • Inspect all parts for wear or damage. Replace as necessary. NOTE: Location of the arrow match mark on the piston head in relation to “K” mark on the connecting rod. Keep parts together as a set. 1. Remove one of the piston pin snap rings with a needle nose pliers. 2. Remove the piston pin by pushing it out of the side of the piston that has the ring removed. 3. Using a piston ring pliers, remove the top and second rings. 4. Remove the three piece oil ring. C - Expander E - Steel Oil Rails

G

E

C M38074c

F - First Chrome - Plated Compression Ring G - Second Compression Ring 3. Install the chrome-plated top ring and second ring with “N” mark facing up. The rings should turn freely in the grooves.

Engine - Kawasaki (FH601V) Repair - 213

ENGINE - KAWASAKI (FH601V) REPAIR
H I K J

7. No. 2 cylinder piston: Align the arrow match mark on the piston head with the raised letter “K” mark on the connecting rod. 8. Install piston pin and snap ring. Compress snap ring only enough to install the snap ring. 9. Fit a new piston pin snap ring into the side of the piston so that the ring opening of the snap ring does not coincide with the notch in the edge of the piston pin hole.
K

H

I

J

Installation: 1. Deglaze cylinder bore. 2. Apply a light film of oil to piston and rings. Compress rings with a ring compressor.

M95393

H - Arrow match mark I - Top ring end gap, upper steel rail end gap J - 30° - 45° K - Second ring end gap, lower steel rail end gap 4. Align the piston and rings with the piston ring end gap as shown above. 5. Apply a light film of clean engine oil to piston pin and connecting rod bearing during assembly.
M50074

3. Apply a light film of oil to piston skirt, cylinder bore, connecting rod bearing surface and cap screws.
H P

N

O

A

L

M M95392

H - Arrow match mark L - No. 1 Cylinder Piston M - No. 2 Cylinder Piston N - “K” Mark O - “K” Mark on Opposite Side 6. No. 1 cylinder piston: Align the arrow match mark on the piston head with opposite the raised letter “K” mark on the connecting rod.
M95391

4. Install piston assembly in cylinder bore with engraved match mark/arrow (H) on piston head facing flywheel side (P) of engine.

Engine - Kawasaki (FH601V) Repair - 214

ENGINE - KAWASAKI (FH601V) REPAIR

B

A M51726 M38102

5. Install connecting rod cap (B) and cap screws (A). Tighten cap screws to 21 N•m (185 lb-in.). 6. Install crankcase cover and cylinder head. Piston Inspection: IMPORTANT: Avoid damage! Do not use a caustic cleaning solution or a wire brush to clean piston. 1. Remove all deposits from the piston.

5. Check ring grooves for wear at several points around piston. Replace piston if clearance is greater than specifications. Ring Groove Side Clearance Specifications: 1st Compression Ring (Top) . . . . . . 0.18 mm (0.007 in.) 2nd Compression Ring (Middle) . . . 0.16 mm (0.006 in.) 6. The oil ring is a three piece assembled ring. It is difficult to measure the ring groove clearance and thickness, visually inspect only.

A

M29946

2. Clean carbon from piston ring grooves with a ring groove cleaner (A). If cleaning tool is not available, break an old ring and use it to carefully clean groove. 3. Check that oil return passages in grooves are open. 4. Inspect piston for scoring or fractures. Replace piston if damaged. NOTE: Inspect ring groove clearance visually. Replace piston if clearance appears excessive.
B

M82050A

7. Measure piston pin diameter at six places (B). Replace pin if measurement is less than 15.96 mm (0.628 in.).

Engine - Kawasaki (FH601V) Repair - 215

ENGINE - KAWASAKI (FH601V) REPAIR
D

E

F M80427

8. Measure piston pin bore. Replace piston if measurement is greater than 16.08 mm (0.633 in.). NOTE: If the engine has had a previous major overhaul, oversize piston and rings may have been installed. Piston and rings are available in 0.50 mm (0.020 in.) oversize.

H

G M82411A

C

10.Measure cylinder bore diameter at three positions; top (D), middle (E) and bottom (F). At these three positions, measure, in both directions; along crankshaft centerline (G) and direction of crankshaft rotation (H). NOTE: If the engine has had a previous major overhaul, oversize piston and rings may have been installed. Pistons and rings are available in 0.50 mm (0.020 in.) oversize. Cylinder Bore ID: Standard Size Bore: Standard . . . . . . . . . 75.18 - 75.20 mm (2.960 - 2.961 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . 75.28 mm (2.964 in.) 0.50 mm (0.020 in.) Oversize Bore: Standard . . . . . . . . . 75.68 - 75.70 mm (2.979 - 2.980 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . 75.78 mm (2.983 in.) Cylinder Bore Out of Round: Standard . . . . . . . . . . . . . . . . . . . . 0.056 mm (0.0004 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . 0.01 mm (0.0022 in.) If cylinder bore exceeds wear limit, rebore cylinder or replace cylinder block. (See Resize Cylinder Bore procedure.) NOTE: If cylinder is rebored, oversize piston and rings must be installed.

M80398

9. Measure piston OD (C) perpendicular to piston pin bore. If piston diameter is less than specifications, install a new piston. Piston OD Specifications: Standard Piston . . . . . . . . . . . . . . . 74.99 mm (2.950 in.) Oversized Piston . . . . . . . . . . . . . . 75.49 mm (2.970 in.)

Engine - Kawasaki (FH601V) Repair - 216

ENGINE - KAWASAKI (FH601V) REPAIR
Connecting Rod: 1. Clean and inspect rod. Replace if scored. 2. Install connecting rod cap. Tighten to 21 N•m (185 lb-in.).
B A

Analyze Crankshaft and Connecting Rod Wear
Procedure: Check connecting rod and cap for damage or unusual wear patterns. Lack of lubrication or improper lubrication can cause the connecting rod and cap to seize the crankshaft. When the rod and cap seize to the crankshaft, the connecting rod and piston may both break causing other internal damage. Inspect block carefully before rebuilding engine. Crankshaft and connecting rod damage can result from: •
M50066

Engine run low on oil or without oil. Oil not changed regularly. Bearing cap installed incorrectly.

• •

3. Measure connecting rod crankshaft bearing diameter (A) and piston pin diameter (B). Replace connecting rod if either measurement is greater than specifications. Connecting Rod Bearing ID (Wear Limit): Crankshaft Bearing . . . . . . . . . . . 38.055 mm (1.498 in.) Piston Pin Bearing . . . . . . . . . . . . . 16.05 mm (0.632 in.) Piston Rings: 1. Measure thickness of top and second piston rings at several places. If thickness is less than 1.40 mm (0.055 in.), replace piston ring.

Camshaft and Tappets
Removal: 1. Remove fuel pump. 2. Remove rocker arm assemblies. 3. Remove crankcase cover. IMPORTANT: Avoid damage! Align timing marks to prevent damage to tappets when removing camshaft.

A M50073 B

2. Check piston ring end gap. Install each ring squarely in bore approximately 25.4 mm (1.0 in.) down from top of cylinder. 3. Check end gap. Replace if end gap is greater than specifications. End Gap Specifications: Maximum End Gap Top Ring . . . . . . . . . . . . . . . . . . . . . . 0.65 mm (0.026 in.) Second Ring . . . . . . . . . . . . . . . . . . . 0.78 mm (0.031 in.) Oil Control Ring (Side Rails) . . . . . . 1.05 mm (0.041 in.) Engine - Kawasaki (FH601V) Repair - 217
M95374

4. Rotate crankshaft until timing marks (A) align. 5. Remove and inspect camshaft (B). NOTE: Mark tappets so they can be installed in their original guides during assembly.

) Picture Note: Cylinder Block Bearing M51724 Picture Note: Crankcase Cover Bearing 6. Replace if necessary. . Inspect Automatic Compression Release weight (H) for damage. . Inspect spring (G). . Replace if worn or damaged. .). . Inspection: 1. . flywheel side journal (D) and lobes (E).218 .166 in. Engine . . .Kawasaki (FH601V) Repair . . E F D M95373 M51723 2. . . . Shake the camshaft assembly and check that the ACR weight (H) swings smoothly.635 in. 4. Installation is done in the reverse order of removal. . . 29. .629 in. M95371 3.98 mm (0. . . • Align timing marks when installing camshaft. Camshaft Specifications (Minimum): Side Journals . . 15. Measure PTO side journal (F).) Cam Lobe Height . . .13 mm (0. Replace camshaft and tappets if any measurement is less than specifications. . Replace block or cover if either diameter is greater than 16. . .621 mm (1. . Remove and inspect tappets (C) for wear or damage. . Measure camshaft bearings in cylinder block and crankcase cover.KAWASAKI (FH601V) REPAIR H C G M53975 6. . .ENGINE . . Inspect camshaft for worn or broken teeth. 5.

. . . Install connecting rod caps and tighten to 21 N•m (185 lb-in. replace crankshaft.) replace crankshaft. E Installation is done in the reverse order of removal. .457 . .) G (Maximum) . .). . . Cover keyway on flywheel end of crankshaft with tape to prevent seal damage when installing crankshaft. . 3. . Apply a light film of clean engine oil on crankshaft bearing surfaces before installation. . Clean and inspect crankshaft. .2. . .) undersized rod is available. If flywheel side journal (C) OD is less than 39.) M80432 Engine . . . 1. . .95 .50 mm (0. . .) H. . Remove camshaft. . .) F . .078 .) replace crankshaft.). . .571 in. 1. A 0. . .05 mm (0. . . If PTO side journal (D) OD is less than 39. .896 mm (1. . Measure main bearing journal diameters.470 mm (1. . . Connecting rod journal can be resized to accept undersized rod. . . 37. Place crankshaft into an alignment jig and slowly rotate crankshaft. 6. .094 in. . 5. M51726 4.498 in. . . 2.0. Have grinding done by a reliable repair shop. . . NOTE: If the engine has had a previous overhaul. Pack oil seals with lithium base grease. IMPORTANT: Avoid damage! Connecting rod caps must be installed on the same connecting rods they were removed from.05 mm (1. .ENGINE . Use dial indicators (B) to measure maximum Total Indicated Runout (TIR). Remove crankshaft.1. . .219 . it cannot be straightened. . Connecting Rod Journal OD (Wear Limit): Standard .Kawasaki (FH601V) Repair . . Measure connecting rod journal diameter (E) and inspect journal radii (F) for cracks.475 in. 2. .KAWASAKI (FH601V) REPAIR Crankshaft and Main Bearings Removal: 1. . Replace if scratched or damaged. 2. . . Remove connecting rod caps (A) and push pistons to top of cylinder. .0 . . . . . Inspection: IMPORTANT: Avoid damage! A bent crankshaft must be replaced. . . B H F G M57348 4. 37. 4. . . . 43 mm (1. .896 mm (1.494 in. . .94 mm (1.002 in. .4 mm (0. If runout exceeds 0. Inspect crankshaft for wear or damage. . C D 2. . connecting rod journal may have been resized for undersized rod. .37.494 . 37. . Mark connecting rod caps to aid in installation. . . . .020 in. .571 in. . . .) Resizing Specifications: E.1. M51729 A 3.474 . . . . . If undersized journal diameter is less than specifications. .38. .693 in. . replace crankshaft. . Remove flywheel and split crankcase. 3. .

Apply lithium based grease inside lips of new seal. PTO End: Remove clutch and sheave assemblies. IMPORTANT: Avoid damage! Do not use gasoline. Using care not to contact crankshaft or coils on stator. Crankshaft Oil Seals NOTE: Oil seals can be replaced with crankshaft installed. If engine is disassembled. simply pry out seals with a large screwdriver and install new ones with a seal driver. pry seal out of crankcase cover 3. 3. Press in seals until flush with flange surface. Apply lithium based grease inside lips of new seal. Solvents will not remove all abrasives from cylinder walls. Using a seal driver. Replace crankcase cover or crankcase if diameter is greater than 40. kerosene. Remove engine from machine. Deglaze Cylinder Bore Procedure: 1. or commercial solvent to clean cylinder bores. pry seal out of bore.581 in.ENGINE . Deglaze cylinder bore using a rigid hone with a 220 to 300 grit stone. Clean cylinder walls using clean white rags and warm soapy water.220 . Install seal with lip toward inside of engine using a seal driver. fan.Kawasaki (FH601V) Repair . 2.15 mm (1. Use hone as instructed by manufacturer to obtain 45° crosshatch pattern. Make sure oil seal removal tool does not contact crankshaft. M50072 5. MX9582 2. Remove blower housing. Continue to clean cylinder until white rags show no discoloration. Using care not to contact crankshaft. and flywheel. MX9596 2. Replacement (Flywheel End): 1. Install seal with lip toward inside of engine. install seal flush with top of bore. 3. Measure crankshaft main bearing diameter in crankcase and crankcase cover. Engine .).KAWASAKI (FH601V) REPAIR Replacement (PTO End): 1. 4.

warm water and clean rags. Assembly is done in the reverse order of disassembly. C A IMPORTANT: Avoid damage! DO NOT use gasoline or commercial solvents to clean cylinder bores.Clean the cylinder thoroughly using soap. 4. B A A 40-60° E D F M95415 2. Install relief valve ball and spring (D). 1. Fill rotor housing with engine oil for initial lubrication. Check bore for size. Remove crankcase cover. Have a reliable repair shop resize the block.ENGINE . Move hone up and down in cylinder approximately 20 times per minute. 6. 7. Adjust rigid hone stones until they contact narrowest point of cylinder.) oversize pistons and rings. 12. Solvents will not remove metal particles produced during honing 11.75 . Adjust hone so lower end is even with end of cylinder bore. and out-of-round. 8. Apply engine oil to cylinder wall.250 rpm. 1. 4. 9. Remove the inner (E) and outer (F) rotors 5. 2. Use correct stone for the job. Coat inside of cylinder with honing oil. Resize cylinder with a honing tool to initial and final bore specifications. Lower and raise hone until ends extend 20 .020 in. 2.008 mm (0.0002 . M82412A 3.) for final bore specifications. Continue to clean cylinder until white rags show no discoloration.0.Dry the cylinder.50 mm (0. 3. Inspect all parts for wear or damage. NOTE: Finish should not be smooth. Adjust if too tight. Remove relief valve spring and ball (D). Install the outer (F) and inner (E) rotors 3.) past ends of cylinder. See “Crankcase Cover Removal and Installation” on page 212. 10.Hone the cylinder an additional 0.221 .Kawasaki (FH601V) Repair . Engine .25 mm (0.1. Run drill press between 200 .0 in.006 . This allows for shrinkage when cylinder cools. Oil Pump Disassembly and Assembly Disassembly: 1. Stop press and check cylinder diameter. but have a 40 -60° cross-hatch pattern. The cylinder block can be resized to use 0. Remove the three mounting cap screws (A) and lift the oil pump gear and shaft assembly (B) and cover plate (C) out of the crankcase. 5. taper.0003 in.KAWASAKI (FH601V) REPAIR Resize Cylinder Bore Procedure: IMPORTANT: Avoid damage! Check stone for wear or damage. NOTE: Measure bore when cylinder is cool. Align center of bore to drill press center. or use the drill press and honing tool. Turn hone by hand.0.

770 in.).387 in. replace spring.). Measure inside diameter of rotor housing. If clearance is greater than 0.436 in. replace outer rotor. Measure relief valve spring. Install oil pump gear and shaft assembly (B). 5. M53970/M53971 3. If thickness is less than 9.). and secure with three cap screws (A).07 mm (0. G MX9543 7.). M80083 8. Measure outer rotor housing depth. If depth is greater than 10.50 mm (0.23 mm (0. replace both rotors. Inspection: Inspect all parts for wear or damage.ENGINE . replace crankcase cover. Measure outside diameter of outer rotor. Measure thickness of outer rotor. Measure rotor shaft diameter.). replace rotor.).222 .593 in. M80015/M82908 5.606 in. Replace as necessary. Engine .KAWASAKI (FH601V) REPAIR 4.92 mm (0. If shaft OD is less than 10. Measure rotor shaft bearing. M53968/M53969 1. cover plate (C).). 4. If bearing ID is greater than 11. Tighten the three cap screws (A) to 6.008 in.83 mm (0. If ID is greater than 40.430 in.2 mm (0.). 2.). replace shaft.403 in.47 mm (1. 6.80 mm (1. Measure inner to outer rotor clearance (G) with a feeler gauge. replace crankcase cover.9 N•m (61 lb-in. If OD is less than 40. replace crankcase cover. If free length is less than 19.Kawasaki (FH601V) Repair .

Remove crankcase cover.Automatic Compression Release Spring .Camshaft . be sure the steel balls are seated in slots on the ball guide and that the snap rings are fully seated in there grooves. Replace if necessary. Turn engine upside down and remove camshaft (G).Sleeve . Remove rocker covers and push rods. Disassemble the governor assembly from the camshaft. Inspect governor for wear or damage.223 .Kawasaki (FH601V) Repair .Snap Ring .Seals . 1. 1.).Oil Filter . When assembling. Engine .Washer . Governor Shaft Inspection and Replacement Removal: NOTE: It is not necessary to remove governor shaft unless damaged. 3.Governor Plate .Steel Balls (6 shown) • Apply Pipe Sealant with TEFLON‚ to threads of oil pressure switch (C). 2. 6. 2. Installation is done in the reverse order of removal.Ball Plate .Mounting Cap Screw (3 used) A B C D E F G H I . Apply clean engine oil to the governor shaft. M95372 G 4.KAWASAKI (FH601V) REPAIR Oil Filter Manifold Removal and Installation: C D D A B C B E F G H B E A I F M95423 M82801A A B C D E F . Replace the oil seal if the lip shows signs of leakage or it has been damaged. Inspect governor shaft for wear or damage. Remove crankcase cover. Install the governor shaft plate to the shaft and tighten the screws to 2.0 N•m (17 lb-in. 2.Plug . Insert the governor shaft into the crankcase. See “Crankcase Cover Removal and Installation” on page 212. 3. Replace if necessary. Unscrew the governor shaft plate screws and pull the governor shaft out of the crankcase cover.ENGINE .Manifold . See “Crankcase Cover Removal and Installation” on page 212. 3. 4. 5.Oil Pressure Sender Switch . Governor Inspection and Replacement Procedure: 1.Ball Guide .

A B C A B 9k C 10 k 10 k 20 k Engine . Push armature against flywheel and tighten screws (B) to 5.30 mm (0. . Measure resistance between each point as shown in the chart below. 5.9 N•m (52 lb-in. Stator Removal and Installation Removal: B B M45869 2. . 3. 6. .). Remove blower housing.ENGINE .4 mm (0.224 .008 . press a new seal into crankcase with the seal lip to the inside. 1. Disconnect wiring lead (A).016 in.2 . Insert a 0.KAWASAKI (FH601V) REPAIR 4. C M50146 Air Gap Specifications: Air Gap . Remove cap screws (B) and armature with coil (C).0.04 in. . Installation is done in the reverse order of removal.Kawasaki (FH601V) Repair . Adjust armature air gap. Remove blower housing and flywheel. . 4.0 mm (0.) below crankcase surface. (See Test procedure. .012 in. 0. A 3.) Installation is done in the reverse order of removal. Disconnect stator lead (A). 5. Press the seal in to flush to 1. If resistance is not within specification. Check that governor shaft turns freely within its operating range. .) feeler gauge between flywheel and armature. 2. B Armature Removal and Installation Removal: A B C C A M82802 1. See “Ignition Coil Air Gap Adjustment” on page 187. . . Remove screws (B) and stator (C). . M50147 1. . 3. . . If oil seal has been removed. 4. Center flywheel magnet under armature.0. 2. Test armature with coil.) Test: 1. replace armature with coil. Turn flywheel to remove feeler gauge.

Badly worn brushes or weak brush springs. Armature binding. Tighten two cap screws (A) to 15 N•m (132 lbin. Engine . Remove two cap screws (A) and starter assembly (B). replace starting motor. Connect purple wire (C) to solenoid. Disconnect positive (+) battery cable and orange wire from large terminal (D) of starter solenoid. Starting Motor Disassembly and Assembly Analyze Condition: The starting motor overheats because of: • • Long cranking. Disconnect negative (-) battery terminal.). Battery or wiring defective. Excessive voltage drop in cranking system. 3. Dirty or damaged starting motor drive. Connect negative (-) battery terminal. Armature binding. Installation: NOTE: Starting motor repair is limited to brushes. Disconnect purple wire (C) from solenoid. If housing or armature is damaged. end caps. Fields in starting motor are permanent magnets and are not serviceable. Install starter assembly (B) and secure with two cap screws (A). 2.KAWASAKI (FH601V) REPAIR Starting Motor Removal and Installation Removal: 1.225 .). Connect positive (+) battery cable and orange wire to large terminal (D) of starter solenoid. or grounds in armature. Tighten nut securing wires to 9.Kawasaki (FH601V) Repair .8 N•m (84 lb-in. A B C D MX16330 1. The starting motor operates poorly because of: A • • • • • B C • D MX16330 2. and starting motor drive. opens.ENGINE . Shorts. 3.

226 .Solenoid .) Assembly is done in the reverse order of disassembly. 2. Armature shaft spline. If solenoid fails any test.End Cover . 4. There should be continuity. If any one brush length is less than 6.Shift Lever . Test for open circuits between tang (D) and body (E). There should be continuity when arm is fully depressed.Brush Springs . 6. Test solenoid (C).Kawasaki (FH601V) Repair .Insulator .Front Cover . Inspect brush springs for wear or damage.Brush 5. Mark body and covers for correct alignment during reassembly. Test solenoid terminals (A and B) for continuity. • • Inspection/Test: 1. Engine .Retaining Clip . Replace if necessary. 2. starting motor armature (G) and brushes (O).ENGINE . 7. Apply a thin coat of multipurpose grease to: • E D L E B A Sliding surfaces of armature and solenoid shift lever. M94902 A B C D E F G H I J K L . Test for open circuits between terminal (B) and tang (D).250 in. Push pinion stopper (E) toward pinion (F) to remove retaining clip (D).4 mm (0.KAWASAKI (FH601V) REPAIR Disassembly and Assembly: 1.). replace all four brushes. There should be no continuity.Brush Holder . Measure field coil brush lengths. it is defective and must be replaced. (See Inspection/Test procedures. L F K C E J I C A H G D B M51705 3. 4. Depress switch arm (C). Points where shaft contacts cover.Pinion . Inspect parts for wear or damage. There should be continuity.Armature . 3.Pinion Stopper .

ENGINE - KAWASAKI (FH601V) REPAIR
10.Locate short circuits by rotating armature on a growler while holding a hacksaw blade or steel strip on armature. The hacksaw blade will vibrate in area of short circuit. NOTE: Shorts between bars are sometimes caused by dirt or copper between bars. Inspect for this condition.
F G

11.If test indicates short circuited windings, clean the commutator of dust and fillings. Check armature again. If test still indicates short circuit, replace armature.

M50115

8. Test for grounded field winding. Touch one probe of tester to field coil brush (F) and the other probe to the field coil housing (G). Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing must be replaced.

F M50112

G

12.Test for grounded windings using an ohmmeter. Touch probes on each commutator bar. Armature windings are connected in parallel, so each commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced.

M50116

9. Test for open field coil. Touch one probe of tester to each field coil brush (F). If there is no continuity, the field coil is open and the field coil housing assembly (G) must be replaced. IMPORTANT: Avoid damage! Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush.
M50113

13.Test for open circuited windings using an ohmmeter. Touch probes on each commutator bar. If test shows no continuity, there is an open circuit and armature must be replaced.

MIF

Engine - Kawasaki (FH601V) Repair - 227

ENGINE - KAWASAKI (FH601V) REPAIR
No-Load Amperage Draw and RPM Test
Reason: To determine if starting motor is binding or has excessive amperage draw under no-load. Test Equipment: • • JT05712 Current Gun JT03719 Photo Tachometer

Procedure: IMPORTANT: Avoid damage! Complete this test in 20 seconds or less to prevent starting motor damage. NOTE: Check that battery is fully charged and of proper size to ensure accuracy of test.
A B

M45867

1. Connect jumper cables to battery. 2. Connect negative cable to starting motor body. Connect positive cable to terminal (A). 3. Use jumper wire to briefly connect terminals (A and B). Measure starting motor amperage and rpm. Maximum starting motor amperage is 50 amps at 5000 rpm. Results: • If amperage is out of specification, check for binding or seizing bearings, sticking brushes, dirty or worn commutator. Repair or replace starting motor.

Engine - Kawasaki (FH601V) Repair - 228

ELECTRICAL TABLE OF CONTENTS
Electrical

Table of Contents

General Information......................................231 Reading Electrical Schematics...................231 Theory of Operation Information ................232 Diagnostic Information................................232 Wire Color Abbreviation Chart....................232 Common Circuit Tests................................233 Conductors For 12 Volt Circuit ...................233 Specifications ...............................................234 General Specifications ...............................234 Schematics and Harnesses .........................237 Schematic and Wiring Harness Legend GT225 ........................................................237 Schematic and Wiring Harness Legend GT235 and GT2353E .................................238 Schematic and Wiring Harness Legend GT245 ........................................................239 Electrical Components Location GT225 ........................................................240 Electrical Components Location GT235, GT235E and GT245 ......................241 Main Electrical Schematic - GT225 ............242 Main Wiring Schematic GT235 and GT235E ...................................246 Main Wiring Schematic - GT235 (SN 060001-090000) and GT235E ............250 Main Wiring Schematic - GT235 (SN 090001-) and GT245 (1 of 4) ..............251 W1 Main Wiring Harness (1 of 2) ...............255 W2 Engine Wiring Harness - GT225 ..........257 W3 Engine Wiring Harness - GT225 ..........257 W4 Engine Wiring Harness - GT225 ..........257 W5 Engine Wiring Harness - GT225 ..........257 W6 Headlight Wiring Harness ....................258 W2 Engine Wiring Harness GT235 (SN -060000)..................................258 W2 Engine Wiring Harness - GT235 (SN 060001-090000) and 235E .................258 W3 Engine Wiring Harness - GT235 (SN -090000) and 235E .............................259 W7 Stator Wiring Harness - GT235 (SN -090000)..............................................259 W8 Stator Wiring Harness - GT235E .........259 W9 Inverter Wiring Harness GT235E ......................................................259

W10 Inductor/GFCI Wiring Harness GT235E ..................................................... 259 W2 Engine Wiring Harness - GT235 (SN 090001-) and GT245 .......................... 260 W3 Engine Wiring Harness - GT235 (SN 090001-) and GT245 .......................... 260 W4 Engine Wiring Harness - GT235 (SN 090001-) and GT245 .......................... 260 W5 Engine Wiring Harness - GT245 ......... 260 W11 Stator Wiring Harness - GT235 (SN 090001-) and GT245 .......................... 260 A2 Discharge Module - GT225 .................. 261 Y1 PTO Clutch........................................... 261 Y2 Fuel Shutoff Solenoid - GT225............. 261 Y2 Fuel Shutoff Solenoid - GT235 (SN -090000) and GT235E........................ 261 Y2 Fuel Shutoff Solenoid - GT235 (SN 090001-) and GT245 .......................... 261 N1 Voltage Regulator/Rectifier - GT225 .... 261 N1 Voltage Regulator/Rectifier GT235 (SN -060000) ................................. 261 N1 Voltage Regulator/Rectifier - GT235 (SN 060001-090000) and GT235E............ 261 N1 Voltage Regulator/Rectifier GT245........................................................ 262 W1 Main Wiring Harness Color Code Chart....................................... 262 W2 Engine Wiring Harness Color Code Chart - GT225......................... 262 W3 Engine Wiring Harness Color Code Chart - GT225......................... 263 W2 Engine Wiring Harness Color Code Chart - GT235 (SN -090000) and 235E..... 263 W3 Engine Wiring Harness Color Code Chart - GT235 and 235E ........................... 263 W2 Engine Wiring Harness Color Code Chart GT235 (SN 090001-) and GT245 .............. 263 W3 Engine Wiring Harness Color Code Chart GT235 (SN 090001-) and GT245 .............. 263 W6 Headlight Wiring Harness Color Code Chart....................................... 263 Operation and Diagnostics ......................... 264 Power Circuit Operation............................. 264 Power Circuit Electrical Schematic ............ 265 Power Circuit Diagnosis............................. 266 Cranking Circuit Operation ........................ 269 Cranking Circuit Electrical Schematic........ 270 Cranking Circuit Diagnosis ........................ 271

Electrical Table of Contents - 229

ELECTRICAL TABLE OF CONTENTS
Ignition Circuit Operation............................274 Engine Shutting Off ....................................274 Ignition Circuit Electrical Schematic ...........275 Ignition Circuit Diagnosis............................276 Charging Circuit Operation GT225 and GT235 (SN -060000)...............279 Charging Circuit Electrical Schematic GT225 and GT235 (SN -060000)...............280 Charging Circuit Diagnosis GT225 and GT235 (SN -060000)...............281 Charging Circuit Operation - GT235 (SN 060001-090000) and GT235E ............284 Charging Circuit Electrical Schematic - GT235 (SN 060001- 090000) and GT235E ...........285 Charging Circuit Diagnosis - GT235 (SN 060001- 090000) and GT235E ...........286 Charging Circuit Operation - GT235 (SN 090001-) and GT245...........................289 Charging Circuit Electrical Schematic GT235 (SN 090001-) and GT245...............290 Charging Circuit Diagnosis - GT235 (SN 090001-) and GT245...........................291 120 Volt Circuit Operation - GT235E..........294 120 Volt Circuit Electrical Schematic GT235E ......................................................295 120 Volt Circuit Diagnosis - GT235E..........296 PTO Circuit Operation - PTO Off................298 PTO Circuit Electrical Schematic PTO Off ......................................................299 PTO Circuit Operation - PTO On................300 PTO Circuit Electrical Schematic PTO On ......................................................301 PTO Circuit Diagnosis ................................302 Reverse Implement Option (RIO) Circuit Operation ........................................306 RIO Circuit Electrical Schematic ................307 RIO Circuit Diagnosis .................................308 Low Oil Pressure Light Circuit Operation ........................................312 Low Oil Pressure Light Circuit Electrical Schematic........................313 Low Oil Pressure Circuit Diagnosis ............314 Headlight Circuit Operation ........................316 Headlight Circuit Electrical Schematic........317 Headlight Circuit Diagnosis ........................318 Fuel Shutoff Solenoid Circuit Operation .....320 Fuel Shutoff Solenoid Circuit Electrical Schematic........................321 Fuel Shutoff Solenoid Circuit Diagnosis .... 322 Hourmeter Circuit Operation...................... 325 Hourmeter Circuit Electrical Schematic ..... 326 Hourmeter Circuit Diagnosis...................... 327 Tests and Adjustments ............................... 329 Common Circuit Test ................................. 329 Ground Circuit Test.................................... 329 Battery Test ............................................... 330 Charge Battery........................................... 331 Battery Load Test ...................................... 331 Regulated Amperage Test......................... 332 Regulated Voltage Test ............................. 332 Stator Output Test (B&S Engine)............... 333 Stator Output Test (Kohler Engine) ........... 333 Stator Output Test (Kawasaki Engine) ...... 334 Regulator/Rectifier Test (Kawasaki Engine)..................................... 334 Flywheel Magnet Test................................ 335 Starter Loaded Amperage Draw Test ........ 335 Starting Motor Solenoid Test ..................... 335 Starting Motor No-load Amperage and RPM Tests ........................ 336 Armature Air Gap Adjustment.................... 337 Spark Test ................................................. 338 Light Switch Test ....................................... 338 PTO/RIO Switch Test ................................ 339 Seat Switch Test........................................ 340 Brake/Neutral Start Switch Test................. 340 Oil Pressure Switch Test ........................... 341 Fuel Shutoff Solenoid Test ........................ 341 RIO Switch Test......................................... 342 RIO Switch Adjustment.............................. 342 Electric PTO Clutch Test ........................... 343 Ground Fault Circuit Interrupt (GFCI) Test................................................ 344 Park Brake Interlock Circuit Test ............... 345 Inverter Ground Continuity Test................. 345 Reset (On-Off) Switch Test........................ 345 120 Volt Stator AC Output Test ................. 346 Inductor Test.............................................. 346 Repair............................................................ 348 Electric Clutch Removal and Installation ........................... 348 Connector Body - Blade Terminals............ 348 Metripack® Connector ............................... 349 Starting Motor ............................................ 351

Electrical Table of Contents - 230

ELECTRICAL GENERAL INFORMATION
General Information Reading Electrical Schematics
The schematic is made up of individual circuits laid out in a sequence of related functions. It is formatted with all power wires (A) across the top and all ground wires (B) across the bottom. Current flow is generally from top to bottom through each circuit and component. All components are shown in the off position. The diagram does not list connector (C) information unless needed to avoid confusion. If the connector is shown, the number next to it is the terminal pin location (D) in the connector. Each component is shown by a symbol (E), its name (F), and an identification code (G). The identification code contains a device identifying letter (H) and number (I). The identifying letter is always the same for a specific component, but the identifying numbers are numbered consecutively from upper left to lower right. The terminal designation (J) is placed directly outside the symbol next to the connecting wire path. Switch positions (K) are also placed directly outside the symbol. The solid line (L) shows the position the switch is currently in and dash lines (M) represent other switch positions. Each circuit is identified at the bottom of the drawing by a section number (N) and section name (O). The circuit number (P) and wire color (Q) of the wires are shown directly next to the wire path. The same component name and identification code are used consistently on all diagrams in this section. Components can be easily cross-referenced.

S1 Key Switch B X1
M
Wht Red Wht Red

F2 15 Amp Fuse S1 X3 X2 6

414 Yel/ Blk

On Off Seat Seat S2 A Seat Switch
800 Pink

X3

D

D

Start
210 Red

C

Run Off
L K

30 F3 15 Amp Fuse 86

K2 Ignition Relay 87 85
J

F1 Fusible Link 1
215 Org 721 Pur/ Wht Red

K1 Start Relay X3 H

710 Pur

X2 F 805 Pnk/Blk W2 X3 Engine X4 Wiring Yel/ Harness T2 T1 Wht Ignition Ignition X5 Coil Yel/Wht Yel/Wht Coil
P B

B G1 Battery
Blk

S

G

E X3
I H

M W1 Shielded Ground

M1 Starting Motor

E1 Spark Plug
O C

Yel/ Wht Wht Blk/Yel

E2 Spark Plug
N
105 Blk

Q

F E

SE1-Power and Starting Circuit

SE2-Ignition and Interlock Circuit
MIF

SE3-PTO and Interlock

Electrical General Information - 231

ELECTRICAL GENERAL INFORMATION
Theory of Operation Information
The theory of operation stories divide the electrical system into individual circuits by function. Each circuit is isolated from the main wiring schematic and only shows the components that are used in it. The story contains information on function, operating conditions, and theory of operation. The circuit schematics are drawn with the components in the operating position, with the power, or battery positive, into them across the top and the ground, or battery negative, across the bottom.

Wire Color Abbreviation Chart
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown Grn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray Org. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White Blu/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/White Brn/Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue Dk Brn/Lt Grn . . . . . . . . . . . . . . Dark Brown/Light Green Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . .Dark Brown/Yellow Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/White Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black Red/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black Wht/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White

Diagnostic Information
The diagnostic procedures is used to test the complete circuit regardless of the problem or complaint. Select a symptom or system from the quick check or troubleshooting chart and follow the test procedures under that heading. The diagnostic procedure lists: • • • • • Test conditions Test sequence Test location Normal reading Check or test to perform if reading is not normal

When performing the test or check, be sure to set your machine up to the test conditions listed and follow the sequence carefully. The middle “NORMAL” column gives the reading or condition that should be obtained when performing the test or check. If the results of the test or check are not normal, perform the test, check, or adjustment listed in the third “IF NOT NORMAL” column to repair the malfunction. The detailed tests or adjustments referred to in the “IF NOT NORMAL” column are located at the end of that group. The system diagram that accompanies each test procedure is drawn to resemble machine components. The key number on the art matches the number in the “TEST LOCATION” column and the leader line points to the exact point the test is to be made.

Electrical General Information - 232

ELECTRICAL GENERAL INFORMATION
Common Circuit Tests
Shorted Circuit: A shorted circuit may result in the wrong component operating (i.e. improper wire-to-wire contact). To test for a shorted or improperly wired circuit: 1. Turn component switch on. 2. Start at the controlling switch of the component that should not be operating. 3. Follow the circuit and disconnect wires at connectors until component stops operating.
MIF

High Resistance or Open Circuit: High resistance or open circuits usually result in slow, dim or no component operation (i.e. poor, corroded, or disconnected connections). Voltage at the component will be low when the component is in operation. To test for high resistance and open circuits: 1. Check all terminals and grounds of the circuit for corrosion.

2. If terminals are not corroded or loose, the problem is in the component or wiring. Grounded Circuit:

MIF

4. Shorted or improper connections will be the last two wires disconnected.
MIF

Grounded circuits usually result in no component operation or a blown fuse.

Conductors For 12 Volt Circuit

Stranded Conductors For 12 Volt Circuits SAE Wire Size (Gauge) Metric Wire Size (MM) Typical Stranding Minimum Conductor Area In Circular Mils 20 0.5 7 X 28 1072 18 0.8 16 X 30 1537 16 1.0 19 X 29 2336 14 2.0 19 X 27 3702 12 3.0 19 X 25 5833 10 5.0 19 X 23 9343

Electrical General Information - 233

ELECTRICAL SPECIFICATIONS
Specifications General Specifications
Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC BCI group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Cold Cranking Amps at -17.8°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 amps Reserve Capacity At 26.7°C (80°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 minutes Specific Gravity (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.225 points Electrolyte Quantity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Spark Plug: GT225 (Kohler) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC12YC Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft) GT235 and GT235E (Briggs & Stratton) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC12YC Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) GT235 (Kawasaki) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RCJ8Y Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) GT245 (Kawasaki) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK BPR4ES Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (135 lb-in.) Stator and Regulator: GT225 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amps Regulated Amperage (Minimum) at Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 15 amps Regulated Voltage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 - 14.7 volts DC Unregulated Voltage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 volts AC GT235 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 amps Regulated Amperage (Minimum) at Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 16 amps Regulated Voltage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 - 14.7 volts DC Unregulated Voltage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 volts AC

Electrical Specifications - 234

ELECTRICAL SPECIFICATIONS
GT235E Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 amps Regulated Amperage of 12 Volt System (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 20 amps Regulated Voltage of 12 Volt System (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 - 14.7 volts DC Unregulated Voltage of 12 Volt System (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 volts AC Regulated Amperage of 120 Volt System (Minimum) at Fast Idle (Continuous). . . . . . . . . . . . . . . . . . . . . . . . 8.3 amps Regulated Amperage of 120 Volt System (Minimum) at Fast Idle (Surge). . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 amps Regulated Voltage of 120 Volt System (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 volts AC GT245 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amps Regulated Amperage (Minimum) at Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 13 amps Regulated Voltage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 - 14.7 volts DC Unregulated Voltage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 volts DC Starting Motor: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift Starting motor amp draw (on machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 - 100 amps at 750 rpm Starting motor no-load amp draw (free running). . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 amps (maximum) at 2500 rpm Ignition: GT225 Primary Coil Resistance One Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1000 ohms Other Direction (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 K ohms Secondary Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 - 10.8 K ohms GT235 and GT235E Primary coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.67 - 1.10 ohms Secondary (Plug wire and core) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10 ohms GT245 Primary lead to primary core resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 K ohms Secondary (Plug wire and core) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11 K ohms Ignition Coil Air Gap: GT225 Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.30 mm (0.008 - 0.012 in.) GT235 and GT235E Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.30 mm (0.008 - 0.012 in.) GT245 Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Electric PTO Clutch: Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31 - 0.46 mm (0.012 - 0.018 in.) Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 - 2.7 ohms Current Draw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 amps Lighting: Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GE 1156 or equivalent

Electrical Specifications - 235

ELECTRICAL SPECIFICATIONS
Special or Required Tools Tool Name Weatherpack Extraction Tool Electrical Test Box Electrical Circuit Analyzer Current Clamp-On Probe Analog/Digital Multi-Meter Probe Light Spark Tester JDG364 JDG1639 JT07324A JT02153 JT05791 JDG186 D05351ST Tool No. Tool Use To remove contacts from weatherpack connectors. Used with Digital Multimeter to test 110 V alternator output on models with electrical outlet To diagnose key switch and associated electrical circuits To diagnose current amperage with-in electrical wires To diagnose electrical system circuits and components To test for current continuity and grounds To test condition of spark plug with engine running

Electrical Specifications - 236

ELECTRICAL SCHEMATICS AND HARNESSES
Schematics and Harnesses Schematic and Wiring Harness Legend GT225
Components: A1 - Interlock Module (SE3, W1) A2 - Discharge Module (SE7, W2) B1 - Engine Oil Pressure Switch (SE5, W3) E1 - Spark Plug (SE2, W3) E2 - Right Headlight (SE7, W6) E3 - Left Headlight (SE7, W6) F1 - Fusible Link (SE1, W1) F2 - Fuse 15 amp (SE3, W1) F3 - Fuse 15 amp (SE3, W1) G1 - Battery (SE1, W1) G2 - Stator (SE7, W3) H1 - Engine Oil Pressure Light (SE5, W1) H2 - Discharge Light (SE7, W1) H3 - Not Used (SE4, W1) M1 - Starting Motor (SE1, W1) N1 - Voltage Regulator/Rectifier (SE7, W3) S1 - Key Switch (SE2, W1) S2 - Seat Switch (SE3, W1) S3 - RIO Switch (SE3, W1) S4 - PTO/RIO Switch (SE4, W1) S5 - Brake/Neutral Start Switch (SE5, W1) S6 - Headlight Switch (SE7, W1) T1 - Magneto Ignition (SE2, W3) W1 - Shielded Ground (SE1, W1) Y1 - PTO Clutch (SE4, W4) Y2 - Fuel Shutoff Solenoid (SE6, W3) Wiring Harnesses: W1 - Main Wiring Harness W2 - Engine Wiring Harness W3 - Engine Wiring Harness W4 - Fuel Shutoff Solenoid Ground Wire W5 - Voltage Regulator/Rectifier Ground Wire W6 - Headlight Wiring Harness Connectors: X1 - W1 Main Wiring Harness to S1 Key Switch (SE1, W1) X2 - W1 Main Wiring Harness to A1 Interlock Module (SE2, W1; SE3, W1) X3 - W1 Main Wiring Harness to A1 Interlock Module (SE2, W1; SE3, W1) X4 - W1 Main Wiring Harness to W2 Engine Wiring Harness (SE2, W1; SE5, W1; SE7, W1) X5 - W2 Engine Wiring Harness to W3 Engine Wiring Harness (SE2, W2; SE5, W2; SE6, W2; SE7, W2) X6 - W1 Main Wiring Harness to PTO Clutch (SE4, W1) X7 - W2 Engine Wiring Harness to Y1 Fuel Shutoff Solenoid (SE5, W3) X8 - W2 Engine Wiring Harness to A2 Discharge Module (SE7, W2) X9 - W1 Main Wiring Harness to Headlights (SE7, W1)

Electrical Schematics and Harnesses - 237

W1) X12 . W1) A2 . W8 .Interlock Module (SE3.Inductor (SE8. W7 .Stator Wiring Harness .Spark Plug (SE2. W1) X2 . W2) X9 . W1) X5 .Engine Wiring Harness W6 .Seat Switch (SE3.ELECTRICAL SCHEMATICS AND HARNESSES Schematic and Wiring Harness Legend GT235 and GT2353E Components: A1 .Battery (SE1.GT235 G2 .W1 Main Wiring Harness to A1 Interlock Module (SE2.GT235E X15 .Inverter Module (SE8. W9) .W2 Engine Wiring Harness to N1 Voltage Regulator/ Rectifier (SE7. W1) G2 .GT235E Electrical Schematics and Harnesses .Main Wiring Harness W2 . W2) X8 .W1 Main Wiring Harness to W9 Inverter Wiring Harness (SE6.GT235E W9 . W1) S6 .GT235E B1 . W3) W1 .Fusible Link (SE1. W1) S4 .GT235E) X10 .Left Headlight (SE7. W1) H2 .PTO Clutch (SE4. W3) V1 . W1) S1 .W6 Stator Wiring Harness to N1 Voltage Regulator/ Rectifier (SE7. W10) . W2) P1 . W3) V2 .Headlight Switch (SE7.Magneto Ignition (SE2.Diode (SE2.Fuse 15 amp (SE3. SE3. W1) S5 .Shielded Ground (SE1. W10) M1 . W6) E4 .Spark Plug (SE2.RIO Switch (SE3.GT235E X14 . W3) E2 .Discharge Light (SE7.Engine Wiring Harness W3 . W3) T2 . W7) .Hourmeter (SE4.GT235E Wiring Harnesses: W1 . W1) X3 . W1) T1 . W2) A3 . W1) S3 .Starting Motor (SE1. W9) . W1) Y2 .GT235 W8 .W1 Main Wiring Harness to Headlights (SE7.Headlight Wiring Harness W7 . W1) F2 .Voltage Regulator/Rectifier (SE7.PTO/RIO switch (SE4. W2) X6 .W2 Engine Wiring Harness to W3 Engine Wiring Harness (SE2.GT235E W10 . W1) N1 .GT235E H1 . W1) .Fuse 15 amp (SE3.W1 Main Wiring Harness to PTO Clutch (SE4.Engine Oil Pressure Light (SE5. W1) X7 . (SE7. W1.Inductor/GFCI Wiring Harness .W2 Engine Wiring Harness to Y1 Fuel Shutoff Solenoid (SE5.Diode (SE2.Magneto Ignition (SE2. W9) . W3) E3 .Not Used (SE4.W1 Main Wiring Harness to S1 Key Switch (SE1. W1) F3 .Fuel Shutoff Solenoid (SE6. W2) Connectors: X1 . W1.GT235E X13 . W1) S2 . W1) L1 .W1 Main Wiring Harness to A1 Interlock Module (SE2. SE3.Stator Wiring Harness . W8) . W2) E1 .Right Headlight (SE7.Stator (SE7.GT235).Stator (SE7.W1 Main Wiring Harness to W2 Engine Wiring Harness (SE2. W1. W1) X4 .Inverter Wiring Harness . W1.238 .W9 Inverter Wiring Harness to W10 GFCI Wiring Harness (SE8. SE5.W2 Engine Wiring Harness to A2 Discharge Module (SE7.Key Switch (SE2.Brake/Neutral Start Switch (SE5.GFCI Receptacle (SE8. W6) F1 . W2) X11 . W1) G1 .Discharge Module (SE7. SE7.Engine Oil Pressure Switch (SE5.W9 Inverter Wiring Harness to S8 Reset Switch (SE8. W1) H3 . W1) Y1 .

Stator (SE6.Engine Oil Pressure Light (SE4. W1) H2 .ELECTRICAL SCHEMATICS AND HARNESSES Schematic and Wiring Harness Legend GT245 Components: A1 .Engine Wiring Harness W3 . W2) X6 .Fuse 15 amp (SE3. W1) S2 .Magneto Ignition (SE2.Fuse 15 amp (SE3. W1) F2 . W1.Seat Switch (SE3.Fuel Shutoff Solenoid (SE5. SE5. W3) W1 .Interlock Module (SE3. W1. W1) S1 . W1) X5 .Discharge Light (SE6. W1) N1 . W3) T2 . W6) F1 .W1 Main Wiring Harness to S1 Key Switch (SE1. W1) F3 . W1) M1 . W1) S3 .W1 Main Wiring Harness to A1 Interlock Module (SE2. W1) X4 . W1) S4 .Headlight Wiring Harness W11 . W3) E3 . W1) S5 .Engine Wiring Harness W6 . W1) Y2 .Starting Motor (SE1. W1) T1 . W1) G1 . W6) E4 . W1) Electrical Schematics and Harnesses .Right Headlight (SE7. W1) X3 .Stator Wiring Harness Connectors: X1 . W1) H3 .Main Wiring Harness W2 . W1. W1) S6 . SE3.Brake/Neutral Start Switch (SE4. W1) X7 .239 . SE3.Hourmeter (SE4.Battery (SE1. W2) P1 .Spark Plug (SE2. W2) Wiring Harnesses: W1 .Headlight Switch (SE7.Fusible Link (SE1.W2 Engine Wiring Harness to Y1 Fuel Shutoff Solenoid (SE5.W1 Main Wiring Harness to A1 Interlock Module (SE2. W1. W1) X2 . W2) E1 .Voltage Regulator/Rectifier (SE6.W1 Main Wiring Harness to Headlights (SE7.Engine Oil Pressure Switch (SE4.PTO Clutch (SE4.W1 Main Wiring Harness to W2 Engine Wiring Harness (SE2. SE7. W1) B1 .Magneto Ignition (SE2. W3) E2 .PTO/RIO switch (SE4.W1 Main Wiring Harness to PTO Clutch (SE4.W2 Engine Wiring Harness to W3 Engine Wiring Harness (SE2.Shielded Ground (SE1. W1) Y1 .Key Switch (SE2.RIO Switch (SE4. W1) G2 . W2) X8 .Left Headlight (SE7.Not Used (SE4. W11) H1 .Spark Plug (SE2.

S3 RIO Switch .B1 Engine Oil Pressure Switch Electrical Schematics and Harnesses .S4 PTO/RIO Switch .H1 Engine Oil Pressure Light .ELECTRICAL SCHEMATICS AND HARNESSES Electrical Components Location .E3 Right Headlight .G1 Battery .Y2 Fuel Shutoff Solenoid .F3 15 Amp Fuse .G2 Stator .N1 Voltage Regulator/Rectifier .M1 Starting Motor .240 .T1 Magneto Ignition Coil .S1 Key Switch M N O P Q R S T U V .W1 Shielded Ground .F2 15 Amp Fuse .A1 Interlock Module .S5 Brake/Neutral Start Switch .GT225 N M K J I H L O P Q R S G F T E U D V C B A MIF A B C D E F G H I J K L .H2 Discharge Light .S6 Headlight Switch .S2 Seat Switch .Y1 PTO Clutch .Spark Plug .

S3 RIO Switch .ELECTRICAL SCHEMATICS AND HARNESSES Electrical Components Location .S6 Headlight Switch S .H2 Discharge Light O .S1 Key Switch .Y2 Fuel Shutoff Solenoid .M1 Starting Motor .E3 Right Headlight .A1 Interlock Module .G1 Battery V .GT235E T .G2 Stator .A3 Inverter Module .Spark Plug .241 .H1 Engine Oil Pressure Light P .T1 Magneto Ignition Coil .Y1 PTO Clutch .F3 15 Amp Fuse .GT235E X .GT235E U .B1 Engine Oil Pressure Switch Electrical Schematics and Harnesses .S2 Seat Switch R .F2 15 Amp Fuse .S7 Reset Switch .W1 Shielded Ground Z .X15 GFCI Receptacle .S4 PTO/RIO Switch N . GT235E and GT245 N M O P L K J I H Q R S G T F U E V D X Y W C Z B A MIF A B C D E F G H I J K L M .S5 Brake/Neutral Start Switch W .L1 Inverter Q .N1 Voltage Regulator/Rectifier Y .GT235.

Power & Start Circuits MIF 103 Blk SE2 .GT225 205 Red W Wht Wht Ignition Switch Circuit Logic Pos.242 .Ignition Circuit Electrical Schematics and Harnesses .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic . Connections M&G None Off Run B&A G&S2 Start B&A S1&S2 Note: All Wires Are Soldered To Ignition Switch X1 Red Off Run Wht Start M G B S2 205 Red 210 Red A S1 Key Switch Wht Red S1 Wht 940 Wht F1 Fusible Link 215 B 721 Pur 721 Pur S 940 Wht M M1 Starting Motor W3 Engine Wiring Harness Red X4 Blk W2 Engine Wiring Harness X5 Blk Blk Solid State Ignition Module T1 Magneto Ignition Coil G1 Battery E1 Spark Plug Blk 101 Blk W1 Shielded Ground SE1 .

15A 6 X2 X3 X3 X2 B F3 Fuse .Safety Start & PTO & RIO** Interlock Circuits MIF Electrical Schematics and Harnesses .243 .GT225 (2 of 4) 205 Red Wht 205 Red Wht Wht Red A M S2 2 Wht 940 Wht S1 750 Pur X3 412 Yel 411 Yel 451 Yel 411 Yel 710 Pur F2 Fuse .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .15A X2 H 721 Pur 3 711 Pur 711 Pur X3 F 1 805 Pnk 805 Pnk 5 X3 750 Pur X2 E Start Relay Magneto Relay Ignition Relay PTO Relay S2 Seat Switch (NO) (Off) 105 Blk 106 Blk Seat Switch Delay (On) D X2 X2 800 Pnk 414 Yel A 732 Grn RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay 4 G C Grn 710 Pur X3 X2 X2 730 Org 735 Grn 300 Org 730 Org 725 Grn 300 Org A1 Ignition Interlock Circuit Board 106 Blk 105 Blk 101 Blk 103 Blk 106 Blk 105 Blk 101 Blk 103 Blk SE3 .

244 .GT225 (3 of 4) 205 Red 412 Yel 451 Yel 451 Yel 205 Red 412 Yel S4 PTO/RIO Switch (RIO*) (On) 750 Pur 710 Pur 411 Yel 1 2 6 731 Blu (Off) 3 7 8 4 735 Grn 500 Blu 731 Blu (Off) 810 Pnk 820 Pnk (On) 706 Pur 711 Pur S5 Brake/Neutral Start Switch 711 Pur 805 Pnk 500 Blu 820 Pnk 805 Pnk X4 Grn X6 Blk P1 Hourmeter W3 Engine Wiring Harness Y1 PTO Clutch 414 Yel 452 Yel 451 Yel X5 Grn W2 Engine Wiring Harness 106 Blk X7 Grn 414 Yel (Neutral/ Forward) (Reverse) Org Grn Blk Y2 Fuel Shutoff Solenoid X6 H3 (Not Used) 103 104 Blk Blk 730 Org 725 Grn 300 Org S3 RIO** Switch (NC) 620 Tan H1 Engine Oil Pressure Light X4 W2 Engine Wiring Harness W4 Wiring Harness 300 Org 301 Org X4 Not Used 106 Blk 105 Blk 101 Blk 103 Blk W3 Engine Wiring Harness P X5 Brn B1 Engine Oil Pressure Switch 105 Blk 101 Blk 104 Blk SE4 .PTO Circuit MIF SE5 .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .Fuel Shut-Off Circuit Electrical Schematics and Harnesses .

Charging Circuit MIF SE7 .GT225 (4 of 4) 205 Red 412 Yel 205 Red 412 Yel (On) (Off) S6 Headlight Switch X4 W2 Engine Wiring Harness 450 Yel Red X5 N1 Voltage Regulator/Rectifier W6 Headlight Wire Harness Yel Red Yel X9 W5 Voltage Regulator/Rectifier Ground Wire U Grn W2 Engine Wiring Harness W3 Engine Wiring Harness Wht Wht E2 Left Headlight E3 Right Headlight Blk G Blk X9 G2 Stator X8 A2 Discharge Module 104 Blk X8 W2 Engine Wiring Harness Yel X8 X4 600 Brn + _ 105 Blk 101 Blk 104 Blk H2 Discharge Light 104 Blk SE6 .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .Instrumentation & Headlights Circuits Electrical Schematics and Harnesses .245 .

ELECTRICAL SCHEMATICS AND HARNESSES Main Wiring Schematic . Connections M&G None Off Run B&A G&S2 Start B&A S1&S2 Note: All Wires Are Soldered To Ignition Switch X1 205 Red 210 Red Off Run Wht Start M G Red B S2 A Red Wht Wht S1 Key Switch Wht Red S1 Wht Wht 940 Wht F1 Fusible Link 215 B 721 Pur 940 Wht 721 Pur S X4 Blk M M1 Starting Motor W3 Engine Wiring Harness W2 Engine Wiring Harness X5 Blk Blk V1 Diode Solid State Ignition Module Red Blk T1 Magneto Ignition Coil Blk E1 Spark Plug V2 Diode G1 Battery Blk Solid State Ignition Module T2 Magneto Ignition Coil E2 Spark Plug 101 Blk 103 Blk W1 Shielded Ground SE1 .246 .GT235 and GT235E 205 Red Ignition Switch Circuit Logic Pos.Ignition Circuit Electrical Schematics and Harnesses .Power & Start Circuits MIF SE2 .

15A 6 X2 X3 X3 X2 B F3 Fuse .GT235 and GT235E (2 of 4) 205 Red Wht 412 Yel 451 Yel 205 Red Wht Wht Red A M S2 2 Wht 940 Wht S1 X3 412 Yel 451 Yel 411 Yel F2 Fuse .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .247 .Safety Start & PTO & RIO** Interlock Circuits MIF Electrical Schematics and Harnesses .15A X2 H 721 Pur 3 711 Pur 712 Pur F 1 805 Pnk Go to page 250 X3 5 X3 750 Pur X2 E Start Relay Magneto Relay Ignition Relay PTO Relay S2 Seat Switch (NO) (Off) 105 Blk 106 Blk Seat Switch Delay (On) D X2 X2 800 Pnk 414 Yel A 732 Grn RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay 4 G C 710 Pur X3 730 Org X2 X2 735 Grn 300 Org A1 Ignition Interlock Circuit Board 106 Blk 105 Blk 101 Blk 103 Blk 106 Blk 105 Blk 101 Blk 103 Blk SE3 .

ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .Fuel Shut-Off Circuit Electrical Schematics and Harnesses .PTO Circuit MIF SE5 .GT235 and GT235E (3 of 4) 205 Red 412 Yel 451 Yel 451 Yel 205 Red 412 Yel S4 PTO/RIO Switch (RIO*) (On) 750 Pur 710 Pur 411 Yel 1 2 6 731 Blu (Off) 3 7 8 4 735 Grn 500 Blu 731 Blu 810 Pnk 820 Pnk (Off) (On) 706 Pur 711 Pur S5 Brake/Neutral Start Switch 711 Pur W2 Engine Wiring Harness 800 Pnk 805 Pnk 820 Pnk 805 Pnk 500 Blu X4 810 Pnk X6 X7 Blk P1 Hourmeter 106 Blk 414 Yel (Neutral/ Forward) (Reverse) 732 Grn Org Y1 PTO Clutch 414 Yel 452 Yel 451 Yel Grn Y2 Fuel Shutoff Solenoid Blk X6 H3 (Not Used) 103 104 Blk Blk 730 Org S3 RIO** Switch (NC) 735 Grn H1 Engine Oil Pressure Light 620 Tan 735 Grn 300 Org 300 Org 301 Org X4 Brn X4 Not Used W2 Engine Wiring Harness B1 Engine Oil Pressure Switch 105 Blk 101 Blk 104 Blk P 106 Blk 105 Blk 101 Blk 103 Blk SE4 .248 .

249 .Instrumentation & Headlights Circuits Electrical Schematics and Harnesses .Charging Circuit MIF SE7 .GT235 and GT235E (4 of 4) 205 Red 205 Red (On) (Off) 412 Yel 412 Yel W2 Engine Wiring Harness X4 Red S6 Headlight Switch 450 Yel W6 Headlight Wire Harness N1 Voltage Regulator/Rectifier X10 Yel X11 Yel U Yel 800 Pnk Yel Red E3 Left Headlight Blk E4 Right Headlight Blk W7 Stator Wiring Harness X9 X9 X11 Wht Wht 104 Blk G G2 Stator X8 Red A2 Discharge Module Tan Blk W2 Engine Wiring Harness X8 X8 X4 600 Brn + _ 105 Blk 101 Blk 104 Blk H2 Discharge Light 104 Blk SE6 .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .

120 Volt System Circuit Electrical Schematics and Harnesses .250 .GT235 (SN 060001-090000) and GT235E 205 Red 205 Red (On) (Off) 412 Yel 412 Yel W2 Engine Wiring Harness X4 595 Blu S6 Headlight Switch 450 Yel W6 Headlight Wire Harness Yel X11 N1 Voltage Regulator/Rectifier From page 247 712 Pur X10 Yel X12 Red U X10 Tan Yel Org Yel Red 800 Pnk W2 Engine Wiring Harness X9 X9 W7 or W8 Stator Wiring Harness A3 Inverter Module E3 Left Headlight E4 Right Headlight Blk Blk X11 W9 Inverter Wiring Harness Wht Wht Org Org Grn G 104 Blk G2 Stator Blu Red X10 610 Brn S8 Reset On/Off Switch (Off) (On) X13 W2 Engine Wiring Harness X4 600 Brn X13 Blu + _ H2 Discharge Light L1 Inductor W10 Inductor Wiring Harness Grn Blk Blk Grn Wht X14 Grn Red X14 X14 Grn Blk 105 Blk 101 Blk 104 Blk X15 GFCI Receptacle 120 Volt System .ELECTRICAL SCHEMATICS AND HARNESSES Main Wiring Schematic .GT235E 104 Blk SE7 .Instrumentation & Headlights Circuits MIF SE8 .

ELECTRICAL SCHEMATICS AND HARNESSES Main Wiring Schematic .GT235 (SN 090001-) and GT245 (1 of 4) 205 Red Wht Ignition Switch Circuit Logic Pos.Power & Start Circuits MIF SE2 .Ignition Circuit Electrical Schematics and Harnesses . Connections M&G None Off Run B&A G&S2 Start B&A S1&S2 Note: All Wires Are Soldered To Ignition Switch X1 Red Off Run Wht Start M G B S2 205 Red 210 Red A S1 Key Switch Wht Wht Red Red S1 Wht Wht 940 Wht F1 Fusible Link 215 B 721 Pur 721 Pur S 940 Wht X4 Blk M M1 Starting Motor W3 Engine Wiring Harness W2 Engine Wiring Harness X5 Blk Blk V1 Diode Solid State Ignition Module Red Blk T1 Magneto Ignition Coil Blk E1 Spark Plug V2 Diode G1 Battery Blk Solid State Ignition Module T2 Magneto Ignition Coil E2 Spark Plug 101 Blk 103 Blk 101 Blk 103 Blk W1 Shielded Ground SE1 .251 .

Safety Start & PTO & RIO** Interlock Circuits MIF Electrical Schematics and Harnesses .15A X2 H 721 Pur 3 711 Pur X3 F 1 805 Pnk 5 X3 750 Pur X2 E Start Relay Magneto Relay Ignition Relay PTO Relay S2 Seat Switch (NO) (Off) 105 Blk 106 Blk Seat Switch Delay (On) D X2 X2 800 Pnk 414 Yel A 732 Grn Grn 710 Pur RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay 4 G C X3 X2 X2 730 Org 735 Grn 300 Org A1 Ignition Interlock Circuit Board 106 Blk 105 Blk 101 Blk 103 Blk 106 Blk 105 Blk 101 Blk 103 Blk SE3 .252 .GT235 (SN 090001-) and GT235E (2 of 4) 205 Red Wht 412 Yel 451 Yel 205 Red 205 Red Wht Wht Red A M S2 2 Wht 940 Wht S1 750 Pur X3 412 Yel 451 Yel 411 Yel F2 Fuse .15A 6 X2 X3 X3 X2 B F3 Fuse .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .

GT235 (SN 090001-) and GT235E (3 of 4) 205 Red 205 Red 412 Yel 451 Yel 451 Yel 412 Yel S4 PTO/RIO Switch 750 Pur 710 Pur 411 Yel 1 2 6 731 Blu (RIO*) (On) (Off) 3 7 8 4 735 Grn 500 Blu 731 Blu 810 Pnk 820 Pnk S5 Brake/Neutral Start Switch (Off) (On) 706 Pur 711 Pur 805 Pnk 805 Pnk 500 Blu X4 Grn Grn Grn 820 Pnk X6 P1 Hourmeter 106 Blk Blk Y1 PTO Clutch 414 Yel (Neutral/ Forward) (Reverse) 735 Grn 452 Yel 451 Yel 414 Yel Blk Grn Org X6 H3 (Not Used) 103 104 Blk Blk 730 Org 735 Grn 300 Org S3 RIO** Switch (NC) H1 Engine Oil Pressure Light 620 Tan X4 300 Org 301 Org Brn X4 Not Used 106 Blk 105 Blk 101 Blk 103 Blk W2 Engine Wiring Harness B1 Engine Oil Pressure Switch 105 Blk 101 Blk 104 Blk P SE4 .253 .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .PTO & Instrumentation Circuit MIF Electrical Schematics and Harnesses .

Headlights Circuits Electrical Schematics and Harnesses .ELECTRICAL SCHEMATICS AND HARNESSES Main Electrical Schematic .Charging Circuit MIF SE7 .Fuel Shut-Off Circuit SE6 .254 .GT235 (SN 090001-) and GT235E (4 of 4) 205 Red 205 Red (On) (Off) 412 Yel 412 Yel W2 Engine Wiring Harness X4 Red S6 Headlight Switch 450 Yel W6 Headlight Wire Harness Yel X8 N1 Voltage Regulator/Rectifier Yel U Grn Grn Grn Yel Red E3 Left Headlight W11 Stator Wiring Harness E4 Right Headlight Blk W2 Engine Wiring Harness Grn Wht Wht Blk X8 X7 Grn G 104 Blk Y2 Fuel Shutoff Solenoid G2 Stator W2 Engine Wiring Harness Yel X4 600 Brn + _ 105 Blk 101 Blk 104 Blk 105 Blk 101 Blk H2 Discharge Light 104 Blk SE5 .

300 732 D .750 6 .940 C .255 .411 / 451 730 711 210 X1 to S1 Key Switch Module X3 to A2 Interlock Module 820 106 P1 Hourmeter (GT225 SN 060001-) (GT235 SN 060001-) (GT245 SN 060001-) MIF Electrical Schematics and Harnesses .800 E .710 / 730 5 .732 B .805 G .Not Used 105 106 800 710 940 300 750 721 411 451 1 .711 4 .721 412 2 .412 3 .735 H .ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Harness (1 of 2) S4 PTO/RIO Switch 500 710 750 731 810 820 412 S6 Headlight Switch 450 411 452 706 735 731 H3 (Not Used) 600 414 452 H2 Discharge Light 451 452 301 101 105 620 X2 to A2 Interlock Module 805 735 A .105 F .

ELECTRICAL SCHEMATICS AND HARNESSES W1 Main Wiring Harness (2 of 2) X4 to W2 Engine Wire Harness 805 810 600 205 G1 Battery 300 620 940 301 F1 Fusible Link 215 W1 Ground M1 Starting Motor 101 103 205 210 X9 to W6 .GT225 X11 to W6 .GT245 450 Headlight Wire Harness 104 706 711 S5 Brake/Neutral Start Switch 732 730 500 S3 RIO Switch 103 104 X6 to Y2 PTO Clutch Wire Harness 414 800 S2 Seat Switch MIF Electrical Schematics and Harnesses .GT235 and GT235E X8 to W6 .256 .

GT225 Blk To Carburetor Ground To Engine Ground MIF Blk To N1 Voltage Regulator/Rectifier To Engine Ground MIF Electrical Schematics and Harnesses .GT225 X4 To W1 Main Wiring Harness 620 Tan 940 Wht 940 620 205 600 Brn 805 Pnk 810 Pnk 205 Red 805 X5 To W3 Engine Wiring Harness Ground 100 Blk X8 to A2 Discharge Module 600 Brn 100 Blk 810 Pnk MIF W3 Engine Wiring Harness .GT225 Wht Wht To N1 Voltage Regulator/Rectifier Blk Red 620 940 Grn 805 205 Wht X7 to Y2 Fuel Shutoff Solenoid To B1 Engine Oil Pressure Switch X5 To W2 Adaptor Wiring Harness T1 Magneto Ignition Coil MIF W4 Engine Wiring Harness .ELECTRICAL SCHEMATICS AND HARNESSES W2 Engine Wiring Harness .257 .GT225 W5 Engine Wiring Harness .

GT245 Main Wire Harness 100 Blk 200 Yel/Wht 101 Blk E3 Right Headlight 201 Yel/Wht MIF W2 Engine Wiring Harness .ELECTRICAL SCHEMATICS AND HARNESSES W6 Headlight Wiring Harness E2 Left Headlight X9 to W1 .GT225 X11 to W1 .GT235 and GT235E X8 to W1 .GT235 (SN -060000) X5 To W3 Engine Wiring Harness X4 To W1 Main Wiring Harness 620 Tan 940 Wht 940 Wht X10 to N1 Voltage Regulator/Rectifier 205 Red 600 Brn 805 Pnk 810 Pnk 205 Red X8 to A2 Discharge Module 600 Brn 100 Blk 810 Pnk B1 Engine Oil Pressure Switch 620 Tan 805 Pnk Y2 Fuel Shutoff Solenoid Ground 100 Blk MIF W2 Engine Wiring Harness .258 .GT235 (SN 060001-090000) and 235E X5 To W3 Engine Wiring Harness X4 To W1 Main Wiring Harness 600 Tan 900 Wht 900 Wht X10 to N1 Voltage Regulator/Rectifier 595 Blu 610 Brn 800 Pnk 810 Pnk 610 Brn 800 Pnk 600 Tan 595 Blu B1 Engine Oil Pressure Switch MIF 810 Pnk Y2 Fuel Shutoff Solenoid Electrical Schematics and Harnesses .

GT235E X14 to A3 Inverter Module X9 To N1 Voltage Regulator/Rectifier G2 Stator Wht Wht X15 GFCI Receptacle L1 Inductor W10 Wiring Harness MIF MIF Electrical Schematics and Harnesses .GT235E X9 To N1 Voltage Regulator/Rectifier G2 Stator A3 Inverter Module X14 to X15 GFCI Receptacle X13 to S8 Reset Switch MIF X12 Interlock Module W8 Stator Wiring Harness .GT235 (SN -090000) and 235E X5 To W2 Engine Wiring Harness Blk V1 Diode T1 Magneto Ignition Coil V2 Diode T2 Magneto Ignition Coil MIF W7 Stator Wiring Harness .259 .GT235E To A3 Inverter Module MIF W10 Inductor/GFCI Wiring Harness .ELECTRICAL SCHEMATICS AND HARNESSES W3 Engine Wiring Harness .GT235 (SN -090000) W9 Inverter Wiring Harness .

ELECTRICAL SCHEMATICS AND HARNESSES W2 Engine Wiring Harness .GT245 MIF Blk To Carburetor Ground To Engine Ground MIF Electrical Schematics and Harnesses .260 .GT235 (SN 090001-) and GT245 To N1 Voltage Regulator/Rectifier To Fuel Shutoff Solenoid MIF Wht X7 To W2 Engine Wiring Harness G2 Stator Wht W5 Engine Wiring Harness .GT235 (SN 090001-) and GT245 T1 Magneto Ignition Coil X5 To W2 Engine Wiring Harness Blk Blk Splice Blk T2 Magneto Ignition Coil MIF W4 Engine Wiring Harness .GT235 (SN 090001-) and GT245 B1 Engine Oil Pressure Switch Brn X5 To W3 Engine Wiring Harness Blk X4 To W1 Main Wiring Harness Blk Brn Red Grn X7 To W4 Engine Wiring Harness Yel Grn & Grn Red Grn To N1 Voltage Regulator/Rectifier Yel MIF W3 Engine Wiring Harness .GT235 (SN 090001-) and GT245 Grn W11 Stator Wiring Harness .

GT225 X7 To W3 Kohler Engine Wiring Harness Red X10 To W2 Engine Wiring Harness Y2 Fuel Solenoid MIF N1 Voltage Regulator/Rectifier .ELECTRICAL SCHEMATICS AND HARNESSES A2 Discharge Module .GT235 (SN 060000) X9 To G2 Stator N1 Voltage Regulator/Rectifier Yel Yel Red Y2 Fuel Shutoff Solenoid .GT235 (SN 090001-) and GT245 Grn 600 Brn 100 Blk 810 Pnk X8 to W2 Main Wiring Harness MIF MIF N1 Voltage Regulator/Rectifier .GT235 (SN 090000) and GT235E Yel/Gry Yel/Gry Tan X7 To W2 Engine Wiring Harness Brn Y2 Fuel Solenoid X9 to Engine Stator Org Red MIF X10 to W2 Engine Wiring Harness N1 Voltage Regulator/Rectifier MIF Electrical Schematics and Harnesses .GT225 Y1 PTO Clutch X6 To W1 Main Wiring Harness Wht Blk Blk Blk Wht MIF Y1 PTO Clutch MIF N1 Voltage Regulator/Rectifier .261 .GT225 Y2 Fuel Shutoff Solenoid .GT235 (SN 060001-090000) and GT235E MIF Y2 Fuel Shutoff Solenoid .

X4 X2./Color 0.8 731 Blu 0.0 103 Blk 1. X4 X2. X4 H2.0 100 Blk 1.GT245 Size/No.8 706 Pur 0. X8 X4.8 600 Blu 0.0 600 Brn 1. Headlight Connector H3.8 451 Yel Wire Connection Points W1. M1 X3.8 800 Pnk 0. Splice 205. S5 X3. S5 X3. S4 X2. X5 Electrical Schematics and Harnesses . X4 S4.8 215 Fuse/Link 0. S4 X3.8 620 Tan Yel Grn Wht Wht Red Yel Grn New 0./Color 0.8 411 Yel 1.0 450 Yel 0.8 730 Org Wht Wht Red 0.0 940 Wht Wire Connection Points X8.8 721 Pur 0.8 300 Org 0.ELECTRICAL SCHEMATICS AND HARNESSES N1 Voltage Regulator/Rectifier .8 940 Wht W2 Engine Wiring Harness Color Code Chart GT225 Size/No. S3 X2.8 732 Grn MIF 0. S4 X2.0 205 Red 1. S3 S4. X1 G1.0 805 Pnk 1. The new voltage regulator functions on system voltage.8 810 Pnk The old voltage regulator functioned based on stator output voltage. Headlight Connector X3. S2 X2.8 101 Blk 2.0 412 Yel 0. H1 S4.8 711 Pur 0.8 301 Org 0.0 205 Red 1.8 735 Grn 0. S6 H1.0 810 Pnk 1. X5 X4.0 620 Tan 1.8 105 Blk 3. S2 S6. S4 X3.8 500 Blu 0. X5 X4. X6 X6. X2 F1. X5 X4.8 805 Pnk 0. S4 X6.262 .8 414 Yel 1. X3 X3./Color 1. X8 X4.8 750 Pur 0. Check battery status before checking stator if discharge light comes on during operation. X4 S4. W1 Main Wiring Harness Color Code Chart Size/No. X4 0. H3 W1.8 452 Yel Old Wire Connection Points H2. X4 F1. H2 0. 210 X2.0 104 Blk 0. Frame Ground X4.8 710 Pur 0.0 210 Red 0. S4 H3.

0 205 Blk 1./Color Wire Connection Points X11. Frame Ground X4. T1 and T2 W6 Headlight Wiring Harness Color Code Chart W2 Engine Wiring Harness Color Code Chart GT235 (SN -090000) and 235E Size/No.0 810 Pnk 1. X7 X4.0 205 Red 1.0 Blk Wire Connection Points X5. N1 X5.0 620 Grn 1./Color 1. Y2 X4.0 940 Wht Wire Connection Points X8. Splice. X7 to Y2 X5./Color 1. E4 X11./Color 1.0 100 Blk 1./Color 1.0 600 Brn 1. X8 X4.0 201 Yel/Wht W3 Engine Wiring Harness Color Code Chart GT235 (SN 090001-) and GT245 Size/No.0 805 Red 1. T1 Size/No.0 Brn 1. N1 Electrical Schematics and Harnesses . E3 Splice. X5 W3 Engine Wiring Harness Color Code Chart GT235 and 235E Size/No. B1 X4.0 Blk Wire Connection Points X5.0 Red Wire Connection Points X4./Color 1.0 101 Blk 1.0 Blk 1. B1 X5.0 805 Pnk 1.0 940 Wht Wire Connection Points X5.0 Grn 1.0 Yel 1. X8 X4.263 . E3 Splice.0 620 Tan 1.ELECTRICAL SCHEMATICS AND HARNESSES W3 Engine Wiring Harness Color Code Chart GT225 Size/No. E4 1. N1 X4.0 Grn 1. T1 and T2 W2 Engine Wiring Harness Color Code Chart GT235 (SN 090001-) and GT245 Size/No.0 200 Yel/Wht 1.0 100 Blk 1. N1 X4. X10 X4. Splice. X5 X4. B1 X4.

The ground circuit is equally important as the power circuit connections. Switched Power Circuit: Function: • Provides switched power to the primary machine operating components by means of the key switch. The ground cable connections are equally important as the positive connections.Ignition Relay normally open terminal • • • • • • • A1 Interlock Module . In addition to the fuses. With power now available at various locations on the machine. Proper starter operation depends on good cables and connections in order to carry the high current load. and the operator “off” the seat: • • • • S1 Key Switch . The battery cables and the starter tie point connections must be good working condition in order for the electrical system to function properly.Terminals “A” A1 Interlock Module .ELECTRICAL OPERATION AND DIAGNOSTICS Operation and Diagnostics Power Circuit Operation Unswitched Power Circuit: Function • Provides unswitched power to the primary machine operating components whenever the battery is connected.414 Yel wire The positive battery cable connects the battery to the starter solenoid. 104.Solder joint “A” A1 Interlock Module .Start Relay common terminal A1 Interlock Module . the electrical system is ready to perform the different functions of starting and running the engine. The starter solenoid to starter bolt is used as a tie point for the rest of the electrical system. Grounding for these systems is provided by the 101. Switched Power: In addition to the voltage present for the unswitched circuit. Proper systems operation depends on good wires and connections in order to carry the current needed to operate the various relays and solenoids and lights.Terminals “X3-2” and “X3-6” S6 Headlight Switch . the brake/neutral start switch “off”.411 Yel and 706 Pur wires S5 Brake/Neutral Start Switch . This link is a short length of wire that is designed to protect the main wiring harness and will fail if current load becomes excessive. In addition to the fuses. The circuit between the starter and the key switch is protected by a fusible link.451 Yel wire H3 Light (Not Used) . Electrical Operation and Diagnostics .706 Pur wire H1 Engine Oil Pressure Light . Unswitched Circuits: Voltage should be present at the following locations with the key switch in the “off” position: • • • • Battery positive terminal Battery terminal of starter solenoid bolt “B” Terminal of Key Switch S1 Red wire/terminal of Voltage Regulator/Rectifier N1 Operating Conditions. and the headlights. Operating Conditions. this circuit is also protected by the fusible link. this circuit is also protected by the fusible link. the PTO clutch and the PTO system interlocks.Yel wire/terminal S4 PTO/RIO switch . voltage should be present at the following locations with the key switch in the “run” position. the PTO/RIO switch “off”.452 Yel wire S2 Seat Switch .264 . and 105 Blk wires. 103. engine monitoring lights.F2 and F3 fuse terminals • A1 Interlock Module .

Wht 205 Red S1 Key Off Switch S6 Headlight Switch (On) (Off) 205 Red Wht Wht A 2 S1 8 4 6 6 M S2 Run Start M Wht Wht 412 1 S4 PTO/RIO S5 Brake/Neutral Switch (RIO*) Start Switch (On) (Off) (Off) (On) 706 Pur 3 7 451 Yel X4 Red G Red B A Red X3 Yel 411 Yel 2 S2 S1 Wht F2 Fuse .15A X3 X3 X2 X3 S2 Seat Switch (Off) (On) D Power Circuit Electrical Schematic N1 Voltage Regulator/ Rectifier U Red X1 F3 Fuse .15A 3 H F X2 B 451 Yel 411 Yel X2 210 205 Red Red 5 721 Pur X3 1 MIF Start Relay Magneto Relay Ignition Relay PTO Relay F1 Fusible Link X2 X2 800 Pnk 414 Yel X2 E 215 721 Pur B Seat Switch Delay A S 105 Blk 414 Yel 452 Yel 451 Yel M RIO**Latch RIO** Unlatch Relay Relay 4 G C ELECTRICAL OPERATION AND DIAGNOSTICS Electrical Operation and Diagnostics .265 RIO** Switch Delay Red M1 Starting Motor X3 X2 X2 300 Org 301 Org 300 Org H3 Not Used G1 Battery A1 Ignition Interlock Circuit Board H1 Engine Oil Pressure Light X4 (Not Used) 620 Tan Blk 101 Blk X4 103 Blk W1 Shielded Ground .

X1 connector to key switch and connections.Go to next procedure. Electrical Operation and Diagnostics .Check 205 Red wire and connections.Go to next step. S1 S2 System: Power Circuit A1 M M A A1 S2 S1 MIF (3) Is battery voltage present between S1 Key Switch Connector X1 (C) and ground? Yes .266 . MIF (1) Is voltage measures at battery positive (+) terminal (A) 12. No .Go to next step.Test battery. See “Charge Battery” on page 331. D D GT245 GT245 MIF (4) Is battery voltage present at voltage regulator/ rectifier 205 Red wire (D)? Yes . No .Check F1 fusible link.4 volts or higher? Yes .Check battery cables and connections.Go to next step. 210 Red wire. Charge is necessary.ELECTRICAL OPERATION AND DIAGNOSTICS Power Circuit Diagnosis Procedure A C System: Power Circuit Test Conditions: • Key switch in OFF position. No . No . GT225 GT235 (SN -060000) D D D GT235 (SN 060001-09000) and GT235E Old New B MIF (2) Is battery voltage present between starter solenoid battery terminal (B) and ground? Yes .

Go to next step.Engine NOT running. Seat switch OFF. Headlights OFF. H System: Power Circuit No . pins 2 (F) and 6 (G)? Yes .Check Red wire from key switch.Go to next step. replace key switch. I MIF (4) Is battery voltage present at S5 Brake/Neutral start switch 706 Pur wire (I)? Yes . G S1 S2 A1 J M M F MIF (2) Is battery voltage present at interlock module terminal X3. Electrical Operation and Diagnostics .Red solder connection “A” (E)? Yes . Brake/Neutral start switch OFF. replace interlock module. A1 S2 S1 MIF (1) Is battery voltage present at A1 Interlock Module . If OK.Go to next step.Check 706 Pur wire and connections. (5) Is battery voltage present at H1 Oil Pressure Light 451 Yel wire (J)? Yes . replace PTO/RIP switch. PTO OFF.267 . If OK. System: Power Circuit E MIF S1 S2 (3) Is voltage present at 411 Yel wire (H) at PTO/RIP switch? Yes . A1 M M No . No .Go to next step.Check fuse F2 and F3.Go to next step.ELECTRICAL OPERATION AND DIAGNOSTICS Procedure B Test Conditions: • • • • • Key switch in RUN position . If OK. No .Check 411 Yel wire and connections.

Check 452 Yel wire and connections. L MIF (7) Is battery voltage present at S2 Seat Switch 414 Yel wire (L)? Yes . No .Go to next step. No .Check 412 Yel wire and connections. K MIF (6) Is battery voltage present at H3 Light Socket 452 Yel wire (K)? Yes . M MIF (8) Is battery voltage present at S6 Headlight Switch 412 Yel wire (M)? No .Go to next step.Check 414 Yel wire and connections.268 .ELECTRICAL OPERATION AND DIAGNOSTICS System: Power Circuit No . Electrical Operation and Diagnostics .Check 451 Yel wire and connections.

Electrical Operation and Diagnostics . current flows through the Red wire to the interlock module (A1) and to the start relay common terminal and the 15 amp fuse (F3). Components are solid state and are not serviced separately except for the 15 amp fuses. Park brake locked. 706 Pur wire.ELECTRICAL OPERATION AND DIAGNOSTICS Cranking Circuit Operation Function: The cranking system is used to energize the starting motor which in turn is used to start the engine. With the key switch in the start position. The power circuit provides current to the key switch (S1) and protects the cranking circuit with a fusible link (F1). interlock module (A1) to the ignition relay. The start solenoid is engaged by current flowing through both pull-in and hold-in windings. The start relay is also energized and shifts to the normally open contact allowing current to flow to the 721 Pur wire and the starting motor pull in and hold in coils of the start solenoid. 210 Red wire. brake/neutral start switch (S5). magneto. The plunger closes the solenoid main contacts. high current from the battery flows across the main contacts to the starter motor (M1) causing it to turn. Red wire and key switch. fusible link (F1). The 411 Yel wire provides current flow to the PTO/RIO switch (S4). From the 15 amp fuse (F3) current flows to the ignition relay normally open terminal and the 411 Yel wire. NOTE: The operator does not have to be in the seat (seat switch closed) to crank engine. With the solenoid main contacts closed. The PTO/RIO switch is used in the neutral start circuit to prevent the engine from cranking if the PTO is engaged. With the PTO/RIO switch off (PTO disengaged). System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. When the main contacts are closed. This causes the ignition. PTO/RIO switch in off position. current flows to the brake/neutral start switch (S5). The brake/neutral start switch is located on the top of the transmission and is activated by the brake actuator linkage. The brake/neutral start switch is used in the neutral start circuit to prevent the engine from cranking if the transmission is engaged. The starting motor is a solenoid shift design. At this same time the magneto relay shift away from the normally closed contact and breaks the path to ground allowing the ignition coils to create a spark that will ignite the air fuel mixture. fuel shutoff solenoid and voltage regulator/rectifier. the brake actuator linkage closes the brake/neutral start switch. Current continues through the holdin windings. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. both ends of the pull-in windings have the same voltage so current through the pull-in windings stops. keeping the solenoid engaged. Current flows from the battery (G1) positive (+) terminal to the starter solenoid battery terminal. Operating Conditions: • • • Key switch in start position. and start relays to be energized and shift from the normally closed position to the normally open position. pulling the plunger inward. The ignition relay provides current to the PTO/RIO switch (S4). magneto relay and the start relay coils. When the park brake is locked (transmission is automatically shifted into neutral).269 . X1 connector. 711 Pur wire.

270 . and 245) E2 Spark Plug MIF Electrical Operation and Diagnostics .15A X2 B 6 X3 X3 X2 210 Red F3 Fuse . 235E.15A X2 X3 721 Pur H 3 711 Pur F1 Fusible Link 215 1 F B S 5 X3 X2 M M1 Starting Motor 105 Blk E Start Relay Magneto Relay Ignition Relay PTO Relay D Seat Switch Delay X2 X2 A Red RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay 4 G C X3 X2 X2 A1 Ignition Interlock Circuit Board 940 Wht G1 Battery X4 Blk X5 Blk Blk 105 Blk 101 Blk V1 and V2 diode used on GT235 and GT235E Blk V1 V2 Blk Solid-state Ignition Module W1 Shielded Ground T1 Magneto Ignition Coil E1 Spark Plug Solid-state Ignition Module T2 Magneto Ignition Coil (235.ELECTRICAL OPERATION AND DIAGNOSTICS Cranking Circuit Electrical Schematic S4 PTO/RIO Switch Off Run Wht Start M G Red B S2 A Red 411 Yel Wht (RIO*) (On) (Off) 1 2 6 3 7 8 4 S5 Brake/Neutral Start Switch (Off) (On) 706 Pur S1 Wht Wht M S1 A S2 X1 S1 Key Switch 940 Wht 2 X3 411 Yel F2 Fuse .

D B S1 S2 (4) Is battery voltage present at S4 PTO/RIP switch 411 Yel wire (D)? Yes .Engine NOT running. “A” solder joint (B)? Yes . replace key switch. S1 S2 System: Cranking Circuit No .Go to next step. • Parking brake LOCKED (Brake/Neutral start switch in NEUTRAL position). connector X3. If OK.Check Red wire from key switch. 210 Red wire. No . No . A1 S2 S1 (2) Is battery voltage present at A1 Interlock Module. System: Cranking Circuit M A1 M A1 S2 C S1 S2 S1 A1 M M A (3) Is battery voltage present A1 Interlock Module. pin 6 (C)? Yes .ELECTRICAL OPERATION AND DIAGNOSTICS Cranking Circuit Diagnosis Procedure A Test Conditions: • • Key switch in RUN position . PTO OFF. If OK.Check fuse F3.Check 411 Yel wire and connections. replace A1 Interlock Module. A1 S2 S1 (1) Is battery voltage present at S1 Key Switch X1 connector (A)? Yes .Go to next step. Electrical Operation and Diagnostics . M A1 M No .271 .Check F1 fusible link. X1 connector to key switch an connector.Go to next step.Go to next step.

replace PTO/RIP switch.Go to next step. No . replace interlock module. No . No . S1 S2 S1 S2 A1 A1 M M M M A1 A1 S2 S2 F S1 H S1 (6) Is battery voltage present at A1 Interlock Module connector X3.Go to next step. pin E (G)? Yes . If OK. pin 3 (F)? Yes .ELECTRICAL OPERATION AND DIAGNOSTICS System: Cranking Circuit System: Cranking Circuit S1 S2 A1 M M E S2 A1 (5) Is battery voltage present at S5 Brake/Neutral Start Switch 706 Pur wire (E)? Yes . Electrical Operation and Diagnostics .Check 706 Pur wire and connections. If OK. replace interlock module.Check 711 Pur wire and connections. G S1 (7) Is there continuity to ground at A1 Interlock Module connector X2. Wht wire S2 (H)? Yes .Check 105 and 101 Blk wires and connections.Go to next step. If OK.272 . (8) Is there continuity to ground at S1 Key Switch. No .Go to next step.Check Wht wire and connections to interlock module.

No . pin 1 (J)? Electrical Operation and Diagnostics .If starter motor is not turning. See “Starting Motor Solenoid Test” on page 335.273 . PTO OFF.ELECTRICAL OPERATION AND DIAGNOSTICS Procedure B Test Conditions: • • • • Key switch in START position. If OK.Go to next step. A1 S2 S1 (1) Is there continuity to ground at A1 Interlock Module S1 solder joint (I)? Yes . Spark plug wires disconnected and GROUNDED.Check Wht wire and connections to S1 Key Switch.Go to next step. No . test starter motor. No . Park brake LOCKED. replace key switch. S1 S2 A1 M M A1 S2 J S1 (2) Is battery voltage present at interlock module connector X3. System: Cranking Circuit System: Cranking Circuit I S1 S2 K A1 M M (3) Is battery voltage present at starter solenoid 721 Pur wire (K)? Yes .Check 721 Pur wire and connections.

Operator off seat with transmission engaged. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. Ignition timing is controlled by the transistor and is not adjustable. If the operator gets off the seat (seat switch opens) with the PTO engaged or with the transmission engaged. System Operation: The engine is shut off by grounding the ignition coils (T1) and (T2). System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. The ignition system is a transistor-controlled magneto design. When the key switch (S1) is turned to the off position. creating spark to ignite the engine fuel/air mixture. PTO/RIO switch in off position. Electrical Operation and Diagnostics . The magneto relay coil is energized by current from the seat switch circuit or neutral start circuit. With the ignition primary coil grounded. a path to ground is created through the key switch Wht wire (M) solder connection and back to the interlock module through the Wht wire (S2) solder connection. Operating Conditions: • • • • Key switch in start or run position. Engine Shutting Off Function: To shut the engine off by removing power to the ignition coil through the ignition relay. Operating Conditions: • • • Key switch in off position. Park brake locked. Whenever the ignition relay is deenergized. a spark cannot be produced. The seat switch or brake/neutral start switch also energize the ignition relay.ELECTRICAL OPERATION AND DIAGNOSTICS Ignition Circuit Operation Function: To create a spark that ignites the fuel/air mixture in the engine. current flow to the magneto relay coil is stopped. In addition the power circuit current flow is stopped at the key switch. the flywheel magnet induces current into the magneto ignition coil. As the engine turns over (See “Cranking Circuit Operation” on page 269). This de-energizes the magneto relay providing a path to ground for ignition coil through the magneto relay. the fuel shutoff solenoid is also de-energized and fuel flow to the carburetor is stopped. Operator may or may not be on seat. The components are solid state and are not serviced separately except for the 15 amp fuses. which in turn produces current high enough to jump the spark plug(s) gap. Operator off seat with PTO engaged.274 .

Wht Off Run S1 Key Switch Wht Red Wht S1 M A S2 Start Wht Red 2 M S4 PTO/RIO Switch (RIO) (On) (Off) G X1 X3 1 3 7 8 4 Red S5 Brake/Neutral Start Switch (Off) (On) 706 Pur 810 Pnk B A Wht S2 S1 210 Red F2 Fuse . 235E. and 245) E2 Spark Plug 105 Blk 101 Blk V1 and V2 diode used on GT235 and GT235E .15A X2 H 3 Ignition Circuit Electrical Schematic 710 Pur B S X3 1 5 F X4 Grn 940 Wht MIF Start Relay Magneto Relay Ignition Relay PTO Relay D Seat Switch Delay M X4 S2 Seat Switch (Off) U Blk M1 Starting Motor Blk RIO** Switch Delay 4 A X5 X2 X2800 Pnk (On) 414 Yel N1 Voltage Regulator/ Rectifier Grn Red Blk V1 RIO**Latch Relay RIO** Unlatch Relay Solid-state Ignition Module X3 X7 C ELECTRICAL OPERATION AND DIAGNOSTICS Electrical Operation and Diagnostics .275 E1 Spark Plug X2 E Blk T1 Magneto Ignition Coil A1 Ignition Interlock Circuit Board X2 Grn G1 Battery V2 Blk Solid-state Ignition Module Y2 Fuel Shutoff Solenoid Blk T2 Magneto Ignition Coil (235.15A 411 Yel 2 6 6 940 Wht X2 B 451 Yel 711 Pur 805 Pnk 452 Yel X3 X3 X2 X3 F3 Fuse .

Electrical Operation and Diagnostics .Check 101 and 105 Blk wires. Check armature gap and flywheel magnets. If the engine will not start check the magneto circuit first and then the ground circuit. See “Armature Air Gap Adjustment” on page 337 and See “Flywheel Magnet Test” on page 335.Go to next step. isolate the magneto circuit from the ground circuit by separating the engine connector (X4). A1 M M A1 S2 C S1 (1) Is there continuity to ground at A1 Interlock Module connector X2. Engine connector X4 DISCONNECTED.Go to next step. blue spark (A)? Yes .Check spark plug gap and condition of spark plug.Test ignition coil and ignition module.Go to next step. pin E (C)? Yes . Procedure B Test Conditions: • • Key switch in OFF position. The ignition relay must be energized to prevent the ignition coil from being grounded. B System: Ignition Circuit Procedure A Test Conditions: • • • • Key switch in START position. Remember the engine is stopped by grounding the ignition coil through either the key switch or ignition relay. continue with test.ELECTRICAL OPERATION AND DIAGNOSTICS Ignition Circuit Diagnosis When diagnosing an ignition problem. System: Ignition Circuit A System: Ignition Circuit S1 S2 (1) Does spark plug/spark tester indicate a hot. (2) Is a spark present but yellow or weak (B)? No . PTO OFF. If plug is good. Yes . If the engine will not shut off. No . Park brake ON.276 . check the ground circuit first. No . All other functions in OFF position.

No . GT225 G GT235 SN 090001 and GT245 S1 S2 A1 M M A1 G S2 S1 E GT235 and GT235E (3) Is there continuity to ground at interlock module “M” solder joint connection (E)? Yes . If OK.Go to next step. replace interlock module. No . (4) Is there continuity to ground at interlock module X2.Replace A1 Interlock Module. pin B (F)? Yes .Go to next step.Go to next step. No .Check interlock module M an S2 Wht wires and connections. GT235 SN -090000 and GT235E G (5) Measured at ignition coil.Replace interlock module.ELECTRICAL OPERATION AND DIAGNOSTICS System: Ignition Circuit System: Ignition Circuit D S1 S2 A1 S1 S2 M A1 M M M S2 A1 A1 S1 S2 F S1 (2) Is there continuity to ground at interlock module S2 solder joint (D)? Yes .277 . is there continuity to ground at 940 Wht wire (G)? Electrical Operation and Diagnostics .

No . pin B (H)? Yes . X4 and X5 wires and connections. No . Parking brake UNLOCKED. PTO/RIP switch OFF.Go to. Electrical Operation and Diagnostics .“Procedure C” on page 278.Check 940 Wht wire. No .Replace interlock module. Procedure C Test Conditions: • • • • Key switch in RUN position .278 . System: Ignition Circuit S1 S2 A1 M M A1 S2 S1 H (1) Is there continuity to ground at A1 Interlock Module connector X2.See “Cranking Circuit Diagnosis” on page 271.ELECTRICAL OPERATION AND DIAGNOSTICS System: Ignition Circuit Yes .If there is infinity ohms between pin B and ground. Seat switch OFF. see See “Cranking Circuit Diagnosis” on page 271.Engine NOT running.

With the key switch in the run position. a permanent magnet located in the flywheel induces AC current in the stator (G2) windings. Charging output is controlled by the (N1) voltage regulator/rectifier. the voltage regulator/rectifier allows DC current to flow to the battery to charge it through the 205 Red wire. current flows from battery (G1) positive (+) terminal to fusible link. seat switch (S2) (operator on seat). The charging system is a permanent magnet and stator design.ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Operation . As the battery becomes fully charged. and 414 Yel wires. Engine running.7 VDC (Kohler).4 VDC (B&S) or 14. When battery voltage drops.279 . The AC current flows to the regulator/rectifier. The regulator/rectifier converts the AC current to DC current needed to charge the battery. 451. The (H2) discharge light indicates a low voltage condition in the battery and is controlled by the (A2) discharge module. current flows from the voltage regulator/rectifier to the battery positive (+) terminal through the 205 Red wire and F1 fusible link. As the flywheel turns. The 205 Red wire allows the voltage regulator/rectifier to charge the battery. Electrical Operation and Diagnostics . and discharge module (A2). interlock module. If stator output current to the regulator/rectifier stops. 800 Pnk wire. Red wire. When voltage drops below 14. interlock module. The ignition relay contacts receive power from the 15 amp fuse (F3) and provide current to the 805 Pnk wire.GT225 and GT235 (SN -060000) Function: To maintain battery voltage to 12. the regulator/rectifier provides current to the battery discharge light (H2) to illuminate the light. Red wire. the discharge module closes an internal switch providing power to the discharge light.4 volts DC or higher. Operating Conditions: • • Key switch in run position. key switch. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. The ground circuit provides a path to ground for the regulator/rectifier. The components are solid state and are not serviced separately except for the 15 amp fuses. engine connector (X4). 452. 15 amp fuse (F3). the regulator reduces current flow to the battery. 210 Red wire. With the engine running. The discharge module monitors battery voltage through the switched power circuit that follows: The 210 Red wire provides current to the key switch (S1) and protects the charging circuit with a fusible link (F1). System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. energizing the ignition relay closing the contacts.

15A X2 B 2 X4 X3 451 Yel F3 Fuse .280 .15A 6 X2 H X3 3 Red X3 1 X2 F 805 Pnk 452 Yel X3 5 G1 Battery X2 E Start Relay Magneto Relay Ignition Relay PTO Relay X2 C (Off) (On) X2800 Pnk Blk Seat Switch Delay D 414 Yel X2 A S2 Seat Switch (NO) 101 Blk 105 Blk RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay X3 4 W1 Shielded Ground A1 Interlock Circuit Board X2 G MIF Electrical Operation and Diagnostics .ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Electrical Schematic .GT225 and GT235 (SN -060000) 205 Red X4 Off Run Start M G Red W2 Engine Wiring Harness N1 Voltage Regulator/Rectifier 101 Blk Red B S2 A S1 Red U Red S1 Key Switch X1 W7 Stator Wiring Harness Wht Wht + _ H2 Light 600 Brn X4 G G2 Stator 205 Red 210 Red X8 Tan X8 F1 Fusible Link 215 B S Blk A2 Discharge Module Red X8 Red M M1 Starting Motor X3 F2 Fuse .

See “Charge Battery” on page 331.Charge the battery. Electrical Operation and Diagnostics . D B D S1 S2 (4) Does the voltage regulator/rectifier have continuity to ground (D)? M A1 Yes .Check 205 Red wire and connections.See “Procedure B” on page 282.Go to next step. M A1 S2 S1 E (2) Is battery voltage present at S1 Key Switch X1 connector.Check battery negative cable and shielded ground. X1 connector to key switch and connections.Go to next step.Check 101 Blk wire. GT225 GT235 (SN -060000) (1) Is there 12. 210 Red wire? Yes .Go to next step. No .281 . No . No . No .GT225 and GT235 (SN -060000) Procedure A Test Conditions: • Key switch OFF. (5) Does the AH2 discharge light have continuity to ground (E)? Yes .ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Diagnosis .4 volts DC or higher at positive (+) battery terminal? Yes . System: Charging Circuit GT225 GT235 (SN -060000) System: Charging Circuit A C C (3) Is battery voltage present at 205 Red wire (C) of N1 Voltage Regulator/Rectifier? Yes .Check F1 fusible link. No .Go to next step. 210 Red wire.

Go to next step. pin D (C)? Yes . If OK. pin 6 (A)? Yes .Engine NOT running.Go to next step.Check 805 Pnk wire and connections. No . 452. No .Go to next step. S1 S2 System: Charging Circuit System: Charging Circuit A1 M M A1 S1 S2 S2 A1 C M S1 MIF M A1 (3) Is battery voltage present at interlock module connector X2. No . and 414 Yel wires and connections.282 . Seat switch closed (operator ON seat).Check 800 Pnk wire and connections.Check F3 fuse.Go to next step. replace interlock module. D MIF (4) Is battery voltage present at engine connector X4 (D)? B Yes . No . S2 A S1 MIF (1) Is battery voltage present at A1 Interlock Module connector X3. If OK. replace interlock module. E MIF (5) Is battery voltage present at discharge module (E)? Electrical Operation and Diagnostics . MIF (2) Is battery voltage present at S2 Seat Switch (B)? Yes . If OK.Check 451. replace seat switch.ELECTRICAL OPERATION AND DIAGNOSTICS Procedure B Test Conditions: • • Key switch in RUN position .

283 . See “Flywheel Magnet Test” on page 335. If OK. X4 and X5 wires and connections.Engine RUNNING. No .ELECTRICAL OPERATION AND DIAGNOSTICS System: Charging Circuit Yes .GT225 & GT235 (SN -060000): Check 940 Wht wire. GT225 See “Stator Output Test (Kohler Engine)” on page 333.Go to next step. measured at 205 Red wire (A)? Yes . replace voltage regulator/rectifier. No . GT235 See “Stator Output Test (B&S Engine)” on page 333. B MIF (2) Is the voltage measured at stator connector to specification (B)? No . System: Charging Circuit F MIF (6) Is voltage present at the discharge light (F)? Yes . System: Charging Circuit GT225 GT235 (SN -060000) A A (1) Is the regulated amperage to specification.Check stator.See “Procedure C” on page 283. No . If OK.Check 600 Brn wire and connections.Test flywheel magnets. Electrical Operation and Diagnostics . Procedure C Test Conditions: • Key switch in RUN position .Go to next step. replace stator.

4 volts DC or higher. The ignition relay contacts receive power from the 15 amp fuse (F3) and provide current to the 805 Pnk wire. The discharge module monitors battery voltage through the switched power circuit that follows: The 210 Red wire provides current to the key switch (S1) and protects the charging circuit with a fusible link (F1).ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Operation . seat switch (S2) (operator on seat). and discharge module (A2). Engine running. Charging output is controlled by the (N1) voltage regulator/rectifier. 452. engine connector (X4). As the flywheel turns. the voltage regulator/rectifier allows DC current to flow to the battery to charge it through the 205 Red wire. 800 Pnk wire. a permanent magnet located in the flywheel induces AC current in the stator (G2) windings. key switch. The ground circuit provides a path to ground for the regulator/rectifier.GT235 (SN 060001-090000) and GT235E Function: To maintain battery voltage to 12. the regulator/rectifier provides current to the battery discharge light (H2) to illuminate the light. interlock module.7 VDC (Kohler). With the engine running. Red wire. 15 amp fuse (F3). energizing the ignition relay closing the contacts. System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. and 414 Yel wires. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. current flows from battery (G1) positive (+) terminal to fusible link. Operating Conditions: • • Key switch in run position. If stator output current to the regulator/rectifier stops. 210 Red wire. interlock module. Red wire. current flows from the voltage regulator/rectifier to the battery positive (+) terminal through the 205 Red wire and F1 fusible link. the regulator reduces current flow to the battery. the discharge module closes an internal switch providing power to the discharge light. The components are solid state and are not serviced separately except for the 15 amp fuses.4 VDC (B&S) or 14. When battery voltage drops. The AC current flows to the regulator/rectifier. The charging system is a permanent magnet and stator design. With the key switch in the run position. The 205 Red wire allows the voltage regulator/rectifier to charge the battery.284 . When voltage drops below 14. The (H2) discharge light indicates a low voltage condition in the battery and is controlled by the (A2) discharge module. 451. Electrical Operation and Diagnostics . As the battery becomes fully charged. The regulator/rectifier converts the AC current to DC current needed to charge the battery.

15A X2 B 2 X4 X3 451 Yel F3 Fuse .GT235 (SN 060001.15A 6 X2 H X3 3 Red X3 1 X2 F 805 Pnk 452 Yel X3 5 G1 Battery X2 E Start Relay Magneto Relay Ignition Relay PTO Relay X2 C (Off) (On) X2 Blk Seat Switch Delay D 800 Pnk 414 Yel X2 A S2 Seat Switch (NO) 101 Blk 105 Blk RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay X3 4 W1 Shielded Ground A1 Interlock Circuit Board X2 G MIF Electrical Operation and Diagnostics .285 .ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Electrical Schematic .090000) and GT235E X4 595 Red Off Run Start M G W2 Engine Wiring Harness N1 Voltage Regulator/Rectifier X10 Red B S2 A S1 Red Org Tan Yel U Yel Red S1 Key Switch X1 X9 X9 W7 or W8 Stator Wiring Harness Wht Wht G G2 Stator 205 Red 210 Red X10 610 Tan X4 F1 Fusible Link 215 B S 600 Brn + H2 Discharge Light _ X10 800 Pnk 101 Blk M M1 Starting Motor X3 F2 Fuse .

No .Go to next step. System: Charging Circuit System: Charging Circuit A C (3) Is battery voltage present at 205 Red wire (C) of N1 Voltage Regulator/Rectifier? Yes .Go to next step.286 .Go to next step.Check 101 Blk wire.Check battery negative cable and shielded ground. E (5) Does the AH2 discharge light have continuity to ground (E)? Yes . X1 connector to key switch and connections.4 volts DC or higher at positive (+) battery terminal? Yes . 210 Red wire. No . B D S1 S2 A1 (4) Does the voltage regulator/rectifier have continuity to ground (D)? M M Yes .Charge the battery. No . No . 210 Red wire? Yes .See “Procedure B” on page 282.Check F1 fusible link. (1) Is there 12.Go to next step. No .Check 205 Red wire and connections. See “Charge Battery” on page 331.090000) and GT235E Procedure A Test Conditions: • Key switch OFF.ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Diagnosis . A1 S2 S1 (2) Is battery voltage present at S1 Key Switch X1 connector. Electrical Operation and Diagnostics .GT235 (SN 060001.

Electrical Operation and Diagnostics . S1 S2 System: Charging Circuit System: Charging Circuit A1 M M A1 S1 S2 S2 A1 C M S1 MIF M A1 (3) Is battery voltage present at interlock module connector X2. No .Check 805 Pnk wire and connections. and 414 Yel wires and connections.287 .Go to next step.Engine NOT running.ELECTRICAL OPERATION AND DIAGNOSTICS Procedure B Test Conditions: • • Key switch in RUN position . No . replace seat switch. replace interlock module. D MIF (4) Is battery voltage present at engine connector X4 (D)? B Yes . pin 6 (A)? Yes .Go to next step. Seat switch closed (operator ON seat).Check F3 fuse. replace interlock module. If OK. pin D (C)? Yes .Check 800 Pnk wire and connections.Go to next step. 452.Check 451. S2 A S1 MIF (1) Is battery voltage present at A1 Interlock Module connector X3. MIF (2) Is battery voltage present at S2 Seat Switch (B)? Yes . If OK. If OK.Go to next step. No . No .

Check 805 and 800 Pnk wire. (1) Is the regulated amperage to specification.288 . No . replace voltage regulator/rectifier. Procedure C Test Conditions: • Key switch in RUN position . measured at 205 Red wire (A)? Yes . See “Stator Output Test (B&S Engine)” on page 333. F MIF (6) Is voltage present at the discharge light (F)? Yes .See “Procedure C” on page 283.Engine RUNNING.Go to next step.Check 600 Brn wire and connections.Go to next step.Check stator.ELECTRICAL OPERATION AND DIAGNOSTICS System: Charging Circuit System: Charging Circuit E A (5) Is battery voltage present at voltage regulator/ rectifier (E)? Yes . See “Flywheel Magnet Test” on page 335. X4 and X10 wires and connections. replace stator. No . No . Electrical Operation and Diagnostics . If OK.Test flywheel magnets. B MIF (2) Is the voltage measured at stator connector to specification (B)? No . If OK.

4 VDC).GT235 (SN 090001-) and GT245 Function: To maintain battery voltage to 12. not battery voltage. key switch. The 210 Red wire provides current to the key switch (S1) and protects the charging circuit with a fusible link (F1). Operating Conditions: • • Key switch in run position.4 volts DC or higher. a permanent magnet located in the flywheel induces AC current in the stator (G2) windings. 15 amp fuse (F3). seat switch (operator on seat). The AC current flows to the regulator/rectifier. interlock circuit board.ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Operation . As the flywheel turns. New style voltage regulator/rectifier: A battery discharge light warns the operator if the battery voltage drops below the preset threshold (12.289 . 800 Pnk wire. and 414 Yel wire. interlock circuit board. The battery discharge light circuit monitors stator output. The ground circuit provides a path to ground for the regulator/rectifier. energizing the ignition relay closing the contacts. the regulator/rectifier allows DC current to flow to the battery to charge it through the 205 Red wire. and regulator/rectifier (N1). not stator output. Old style voltage regulator/rectifier: A battery discharge light warns the operator if the stator stops charging. Engine running. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. The voltage sensing circuit allows the regulator/rectifier to monitor battery voltage. The ignition relay contacts receive power from the 15 amp fuse (F3) and provide current to the 805 Pnk wire. The battery discharge light circuit monitors battery voltage. the regulator stops current flow to the battery. 451. current flows from battery (G1) positive (+) terminal to fusible link. 452. System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. The regulator/rectifier converts the AC current to DC current needed to charge the battery. Charging output is controlled by a regulator/ rectifier. If the battery voltage is low. engine connector (X4). When the battery is fully charged. Red wire. The charging system is a permanent magnet and stator design. With the key switch in the run position. Electrical Operation and Diagnostics . The components are solid state and are not serviced separately except for the 15 amp fuses. Grn wire. 210 Red wire.

290 .GT235 (SN 090001-) and GT245 205 Red X4 Off Run Start M G W2 Engine Wiring Harness N1 Voltage Regulator/Rectifier Red Red B S2 A S1 Red U Grn Yel Red S1 Key Switch X1 X4 Wht Wht G W11 Stator Wiring Harness X4 205 Red 210 Red G2 Stator 600 Brn + _ 215 F1 Fusible Link B S H2 Discharge Light 101 Blk X3 F2 Fuse .ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Electrical Schematic .15A F-6 X2 X3 F-3 M1 Starting Motor H-H X3 F-1 X2 H-F 805 Pnk 452 Yel X3 F-5 X2 Start Relay Magneto Relay Ignition Relay PTO Relay X2 H-C Red (Off) (On) H-E 105 Blk X2 800 Pnk Seat Switch Delay H-D 414 Yel G1 Battery RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay X2 H-A S2 Seat Switch (NO) X3 F-4 X2 Blk 101 Blk A1 Interlock Circuit Board H-G W1 Shielded Ground MIF Electrical Operation and Diagnostics .15A X2 M H-B F-2 105 Blk X3 451 Yel F3 Fuse .

No . No .Go to next step.Go to next step.See “Procedure B” on page 282.Charge the battery. No .Check 101 Blk wire. (6) Does the AH2 discharge light have continuity to ground (E)? Yes . No . Electrical Operation and Diagnostics . X1 connector to key switch and connections. No .291 . System: Charging Circuit Old New System: Charging Circuit (1) Is the battery fully charged and pass a load test? See “Battery Load Test” on page 331.ELECTRICAL OPERATION AND DIAGNOSTICS Charging Circuit Diagnosis . A Old New D (2) Is there 12. Headlights OFF.Go to next step.Check 205 Red wire and connections.Go to next step. and See “Charge Battery” on page 331.Check battery negative cable and shielded ground.Charge battery and replace as needed.Go to next step.4 VDC or higher (battery voltage) at positive (+) battery terminal (A)? Yes . See “Charge Battery” on page 331. S1 S2 A1 M M E A1 S2 S1 (3) Is battery voltage present at S1 Key Switch X1 connector. 210 Red wire. No .GT235 (SN 090001-) and GT245 Procedure A Test Conditions: • • Key switch OFF. 210 Red wire (B)? Yes . B D (5) Does the voltage regulator/rectifier have continuity to ground (D)? Yes . Yes . C C (4) Is battery voltage present at 205 Red wire (C) of N1 Voltage Regulator/Rectifier? Yes .Check F1 fusible link.

No . No . If OK.292 .Go to next step.Check 451. No .Go to next step. 452.Engine NOT running. E (5) Is battery voltage present at voltage regulator/ rectifier (E)? Electrical Operation and Diagnostics . MIF A1 S2 A S1 (1) Is battery voltage (12. B Old MIF New E (2) Is battery voltage present at S2 Seat Switch (B)? Yes .ELECTRICAL OPERATION AND DIAGNOSTICS Procedure B Test Conditions: • • • Key switch in RUN position . If OK. Headlights OFF. No . replace seat switch.Check F3 fuse. replace interlock module. If OK. A1 S1 S2 System: Charging Circuit System: Charging Circuit M M A1 S2 S1 S2 C S1 MIF A1 M M (3) Is battery voltage present at interlock module connector X2.Go to next step. pin D (C)? Yes .Check 805 Pnk wire and connections. replace interlock module.4 VDC or higher) present at A1 Interlock Module connector X3.Go to next step. and 414 Yel wires and connections.Check 800 Pnk wire and connections. pin 6 (A)? Yes . MIF D (4) Is battery voltage present at engine connector X4 (D)? Yes . Seat switch closed (operator ON seat).

Go to next step. Test voltage regulator/rectifier. 205 Red wire (A). If OK. • Engine RUNNING at low idle then increased to high idle during test.See “Procedure C” on page 283. System: Charging Circuit Unregulated Output F MIF A (6) Is voltage present at the discharge light (F)? Yes . See “Flywheel Magnet Test” on page 335.Engine RUNNING. Procedure C Test Conditions: • Key switch in RUN position . replace voltage regulator/rectifier. No . raise to 14. No .Go to next step. Test Procedure D: Test Conditions: • Engine RUNNING at low idle then increased to high idle during test.2 . • Stator DISCONNECTED from voltage regulator/ rectifier. • • Stator CONNECTED to voltage regulator/rectifier.8 volts? Yes . No . MIF (1) Is the voltage at the connector (A) to the stator at least 26 VAC at low idle and high idle? Yes .293 . • Headlights OFF. System: Charging Circuit Old New No .Check 600 Brn wire and connections. No .Verify engine rpm is set correctly. Check accessory and/or optional components for excess amp draw.Check 805 and 800 Pnk wire.Test flywheel magnets.14.ELECTRICAL OPERATION AND DIAGNOSTICS System: Charging Circuit Yes . X4 and X10 wires and connections. A A (1) Does the voltage at N1 voltage regulator/ rectifier.Stator output is within specification. Headlights OFF. Replace as needed. If OK. See “Regulator/Rectifier Test (Kawasaki Engine)” on page 334. replace stator. Electrical Operation and Diagnostics .Charging circuit is functional.

Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. the inverter is activated. through the inverter and inductor to the GFCI receptacle. for any reason. 706 Pur wire. 210 red wire. and the parking brake locked. a permanent magnet located in the flywheel induces AC current in the stator (G2) windings. The 120 VAC system will operate continuously at 1000 watts output. and up to 1500 watts for brief periods.294 . key switch. the PTO/RIO switch in OFF position. F3 15 amp fuse. Any time the engine stops. Operator may or may not be on seat. Operating at loads greater than 1000 watts continuously may trigger the system to shut down. As the flywheel turns. The 12VDC/120 VAC system is a permanent magnet and stator design. The components are solid state and are not serviced separately except for the 15 amp fuses. Operating Conditions: • • • • • Key switch in start or run position. power is restored. With the engine running. PTO/RIO switch in off position. trimmers and other devices. Output wattage increases with engine speed.GT235E Function: Provides 120 volts. the reset switch must be actuated to reactivate the system. and to the inverter.ELECTRICAL OPERATION AND DIAGNOSTICS 120 Volt Circuit Operation . through fusible link. PTO/RIO switch. and finally the Ground Fault Circuit Interrupt (GFCI) receptacle (X15). to the interlock module. brake/neutral start switch. Electrical Operation and Diagnostics . current flows from the stator. 60 cycle AC to a GFCI receptacle on the equipment to operate power tools such as edgers. 411 Yel wire. Once the reset on/off switch is reset. Once this circuit is closed and the reset on/off switch is switched from the off to the on position. Park brake locked. With the inverter active. Reset switch in on position. The AC current flows to the inverter (A3) and from there to the inductor (L1). System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. current flows from the positive (+) terminal of the battery.

15A 3 X2 B X3 711 Pur 712 Pur Wht Wht Org Org Grn 5 X3 711 Pur 210 Red F X2 H X2 X3 X12 G To 12V X3 1 A3 Inverter Module W9 Inverter Wiring Harness Start Relay Magneto Relay Ignition Relay PTO Relay 120 Volt Circuit Electrical Schematic .GT235E MIF D Seat Switch Delay A Red Red X2 X2 G2 Stator S8 Reset On/Off Switch (Off) (On) Blu G1 Battery RIO**Latch Relay RIO** Unlatch Relay 4 RIO** Switch Delay X13 X3 Blk C ELECTRICAL OPERATION AND DIAGNOSTICS Electrical Operation and Diagnostics .GT235E .Off Run Start M S4 PTO/RIO Switch S5 Brake/Neutral Start Switch (Off) (On) Red M A S2 G Red 2 B A Red (RIO) (On) (Off) S2 1 S1 S1 X3 411 Yel 2 8 4 6 3 7 F2 Fuse .15A 6 X1 F3 Fuse .295 X2 A1 Ignition Interlock Circuit Board E X2 W10 Inductor Wiring Harness L1 Inductor Grn Blk Red X13 Blu Blk Grn Wht X14 Grn X14 X14 Grn Blk X15 GFCI Receptacle 120 Volt System .

Replace GFCI.GT235E NOTE: If a problem occurs and the 120 volt system is suspect. Procedure A Test Conditions: • • • • • Engine running Park brake locked PTO off Reset switch on Stator plugged into inverter module.Go to next step. MIF B (4) Is continuity to ground present at stator ground terminal (D)? Yes .296 .Replace GFCI. System: 120 Volt Circuit A MIF (1) Is approximately 120 VAC present at GFCI outlet (A)? Yes .Go to next step.ELECTRICAL OPERATION AND DIAGNOSTICS 120 Volt Circuit Diagnosis . No .Go to next step.Replace GFCI. it is important to follow the test procedure exactly in the order shown to isolate the faulty component. Electrical Operation and Diagnostics .Go to next step. (3) Does pushing the reset button (C) restore power to the GFCI outlet (A)? Yes . No . D MIF A C System: 120 Volt Circuit No . No . A MIF (2) Does pushing the test button (B) turn off power at the GFCI outlet (A)? Yes .Check frame ground connection.

No . PTO off. 411 Yel and 706 Pur wires and connections.ELECTRICAL OPERATION AND DIAGNOSTICS System: 120 Volt Circuit System: 120 Volt Circuit Yes No . Electrical Operation and Diagnostics . PTO/RIO switch in off position. Park brake locked.Check F3 fuse.Replace switch. • • • • Engine running at 1800 rpm. Procedure C Test Conditions: NOTE: Follow test procedure “120 Volt Stator AC Output Test” on page 346. System: 120 Volt Circuit E MIF (5) Is battery voltage present at X12 connector (E)? Yes .297 .Go to next step. Reset switch on. Procedure B A Test Conditions: • Reset (on/off) switch removed from machine (1) Is the stator output a minimum of 100 volts AC (A)? No .If other tests are normal and output is less than 100 volts. replace the stator. System: 120 Volt Circuit A (1) Does Reset (on/off) switch have continuity across terminals (A) when in the ON position. • Stator to inverter module plug disconnected and plugged into test box (JDG1639).

System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. 800 Pnk wire.298 . This will ground the engine ignition modules. PTO/RIO switch off. ignition and PTO relay coils. 732 Grn wire into the interlock module to energize the PTO relay coil. The PTO/RIO switch is used in the PTO safety circuit to prevent the PTO relay from energizing if the PTO/RIO switch is in the on position when the key switch is turned on. ignition relay. and PTO relay to stop current flow to the PTO clutch (Y1). Power is now available at the PTO/ RIO switch to energize the RIO circuit and the PTO clutch when the PTO/RIO switch is moved to the on position. across the PTO/RIO switch contact to the 710 Pur and 730 Org wires. 451. Second. its contacts close and provide power to the PTO relay common contact terminal. With the ignition relay energized. if the operator gets off the seat. Electrical Operation and Diagnostics . The PTO circuit uses a seat switch (S2). current flows from the 810 Pnk wire. Park brake locked. PTO/RIO switch off. Current flows from the battery (G1) positive (+) terminal to the fusible link (F1). Grn wire to the voltage regulator/rectifier (N1). RIO switch (S3) N. The ground circuit. The PTO/RIO switch is also used in the neutral start circuit to prevent the magneto relay and ignition relay and start relay from energizing if the PTO is engaged.O. and 414 Yel wires. 101 and 105 Blk wires. Operating Conditions: • • • or • • • Key switch in run position. With the PTO/ RIO switch closed (PTO disengaged). if the operator gets off the seat with the PTO engaged. and open the ignition relay causing power to be cut to the PTO relay. turning the key switch off will cut all power.C. First.ELECTRICAL OPERATION AND DIAGNOSTICS PTO Circuit Operation . ignition and start relays. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. current flows through the 15 amp fuse (F3) to the ignition relay N. This then creates a loop to energize the PTO relay.PTO Off Function: To provide power to energize the PTO relay and clutch. contacts (neutral/forward position). current flows to the brake/neutral start switch (S5) and back to the interlock module to energize the magneto. engine connector X4. provides a path to ground for the magneto. Key switch in run position. With the key switch in the run position. The power circuit provides current to the key switch (S1) and protects the PTO circuit with a 15 amp fuse (F3). 452. With the PTO/RIO switch off (PTO disengaged). to the interlock module to energize the ignition relay. The PTO relay contacts close supplying power to the 750 Pur wire. The 750 Pur wire connects back at the PTO/RIO switch to the 710 Pur wire. The components are solid state and are not serviced separately except for the 15 amp fuses. Operator on seat. 210 red wire and key switch. contact terminal. 810 Pnk wire and PTO/ RIO switch (S4). Once the PTO relay is energized it can be de-energized by two methods. Grn wire to fuel shutoff solenoid. seat switch (S2) contacts closed (operator on seat). 805 Pnk wire.

15A 940 Wht X2 B 6 X3 X3 X2 X3 F3 Fuse .15A X2 H 3 711 Pur 731 Blu PTO Circuit Electrical Schematic .299 E1 Spark Plug A1 Ignition Interlock Circuit Board X2 X6 103 Blk G1 Battery Blk T1 Magneto Ignition Coil X2735 Grn X2 X7 Grn Blk Solid-state Ignition Module Blk 105 Blk Y1 PTO Clutch Blk Blk Y2 Fuel Shutoff Solenoid X6 E2 Spark Plug T2 Magneto Ignition Coil (235 Only) 500 Blu 101 Blk 103 Blk .Wht Off Run S1 Key Switch M Start Wht Red Wht S1 M A S2 S4 PTO/RIO Switch Red 2 Wht A G X1 S1 1 2 6 8 4 3 7 Red S5 Brake/Neutral Start Switch (Off) (On) 706 Pur 810 Pnk B (RIO) (On) (Off) 500 Blu Wht S2 X3 411 Yel 750 Pur 710 Pur 451 Yel 711 Pur 805 Pnk 750 Pur 452 Yel 210 Red F2 Fuse .PTO Off B S X3 1 5 F X4 735 Grn Grn MIF Start Relay Magneto Relay Ignition Relay PTO Relay D Seat Switch Delay 940 Wht M X4 S2 Seat Switch (Off) U S3 RIO Switch (On) 414 Yel (Neutral/ Forward) (Reverse) Org Blk M1 Starting Motor Blk RIO** Switch Delay 4 G C E X5 A X2800 Pnk X2 732 Grn 710 Pur N1 Voltage Regulator/ Rectifier Grn Red Blk Solid-state Ignition Module RIO**Latch Relay RIO** Unlatch Relay X3 730 Org ELECTRICAL OPERATION AND DIAGNOSTICS Electrical Operation and Diagnostics .

The PTO/RIO switch will then need to be placed back to the off position to energize the PTO relay and then pulled back to the on position if desired. Power is now available at the PTO/RIO switch to energize the RIO circuit and the PTO clutch when the PTO/RIO switch is moved to the on position. If the operator gets off the seat with the PTO/RIO switch on. 732 Grn wire into the interlock module to energize the PTO relay coil. which stops current flow to the PTO clutch and allows the magneto relay to deenergize.PTO On Function: To provide power to energize or de-energize the PTO clutch when desired by the operator. RIO switch (S3) N. The PTO relay contacts close. System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. See “Reverse Implement Option (RIO) Circuit Operation” on page 306. contacts (neutral/forward position). The PTO/RIO switch is used in the PTO safety circuit to prevent the PTO relay from energizing if the PTO/RIO switch is in the on position when the key switch is turned on. With the PTO/RIO switch on. so the seat circuit must keep the ignition relay energized.300 . The 500 Blu wire supplies power to the PTO clutch and is grounded through the 103 Blk wire. across the PTO/RIO switch contact to the 710 Pur and 730 Org wires. the seat switch (S2) deenergizes the ignition and PTO relays.ELECTRICAL OPERATION AND DIAGNOSTICS PTO Circuit Operation . current flow to the brake/ neutral start switch is stopped. Electrical Operation and Diagnostics . This creates a loop to energize the PTO relay. supplying power to the 750 Pur wire.C. At the same time the 500 Blu wire supplies power to the PTO clutch the 731 Blu wire supplies power to the momentary contacts of the PTO/RIO switch. The components are solid state and are not serviced separately except for the 15 amp fuses. closing its contacts and grounding the ignition system. provides a path to ground for the magneto. If the machine is repositioned in reverse without pulling the PTO/RIO switch into the Reverse Implement Position (RIO) the PTO will be disengaged. Operator on seat. 105 and 101 Blk wires. With the PTO in the on position. power is supplied from the 750 Pur wire across the PTO/RIO switch contacts to the 500 and 731 Blu wires. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. Operating Conditions: • • • Key switch in run position. With the PTO/RIO switch off (PTO disengaged). The 750 Pur wire connects back at the PTO/RIO switch to the 710 Pur wire. current flows from the 810 Pnk wire. The ground circuit. PTO/RIO switch in on position. ignition and PTO relay coils. This circuit is part of the RIO circuit to allow for repositioning of the machine in reverse with the PTO engaged.

Wht Off Run S1 Key Switch Wht Red Wht S1 M A S2 Start M S4 PTO/RIO Switch Red 2 Wht (RIO) (On) (Off) 500 Blu 1 2 8 4 6 3 7 G X1 X3 411 Yel 6 Red 750 Pur 710 Pur 451 Yel 711 Pur 805 Pnk 750 Pur 5 S5 Brake/Neutral Start Switch (Off) (On) 706 Pur 810 Pnk B A Wht S2 S1 210 Red F2 Fuse .301 E1 Spark Plug A1 Ignition Interlock Circuit Board X2 X6 103 Blk G1 Battery Blk T1 Magneto Ignition Coil X2735 Grn X2 X7 Grn Blk Solid-state Ignition Module Blk 105 Blk Y1 PTO Clutch Blk Blk Y2 Fuel Shutoff Solenoid X6 E2 Spark Plug T2 Magneto Ignition Coil (235 Only) 500 Blu 101 Blk 103 Blk .15A 940 Wht X2 B F3 Fuse .PTO On B S X3 1 F X4 735 Grn Grn 940 Wht MIF Start Relay Magneto Relay Ignition Relay PTO Relay D Seat Switch Delay M X4 S2 Seat Switch (Off) U S3 RIO Switch (On) 414 Yel (Neutral/ Forward) (Reverse) Org Blk M1 Starting Motor Blk RIO** Switch Delay 4 G C E X5 A X2800 Pnk X2 732 Grn 710 Pur N1 Voltage Regulator/ Rectifier Grn Red Blk Solid-state Ignition Module RIO**Latch Relay RIO** Unlatch Relay X3 730 Org ELECTRICAL OPERATION AND DIAGNOSTICS Electrical Operation and Diagnostics .15A X2 H 3 X3 X3 X2 X3 452 Yel 731 Blu 711 Pur PTO Circuit Electrical Schematic .

Go to next step. E S2 A1 S1 (5) Is battery voltage present at interlock module connector X2.Go to next step. Operator ON seat (Seat switch closed). D (4) Is battery voltage present at S2 Seat Switch (C)? B S1 S2 Yes .Check 451.Check F1 fusible link. 210 Red wire. and 414 Yel wires and connections. A1 S1 S2 PTO/RIP switch in OFF position. pin 6.Replace interlock module. No . 452.302 .Go to next step. No . X1 connector to key switch and connections. M A1 A1 M S2 S1 S1 S2 (2) Is battery voltage present at A1 Interlock Module “A” solder joint connection (B)? M A1 M Yes . M M System: PTO Circuit S2 A1 A S1 S1 S2 (3) Is battery voltage present at interlock module X3. 451 and 411 Yel wires? Yes . No . M A1 M No . A1 S2 S1 (1) Is battery voltage present at S1 Key Switch X1 connector? Yes . pin D (E)? Electrical Operation and Diagnostics .Replace A1 Interlock Module.ELECTRICAL OPERATION AND DIAGNOSTICS PTO Circuit Diagnosis Procedure A C System: PTO Circuit Test Conditions: • • • Key switch in RUN position .engine NOT running.Go to next step.

System: PTO Circuit H S1 S2 A1 M M (8) Is battery voltage present at X4 engine wiring harness connector.Go to next step. No . No .303 . I S1 S2 A1 (9) Is battery voltage present at 810 Pnk wire at S4 PTO/RIP switch (I)? M M Yes . J (10) Is battery voltage present at S3 RIO switch. 805 Pnk wire (H)? Yes .Check 805 Pnk wire and connections. If OK. replace seat switch. If OK.ELECTRICAL OPERATION AND DIAGNOSTICS System: PTO Circuit Yes . replace interlock module.Check 800 Pnk wire and connections.Verify brake is OFF and drive pedals are in NEUTRAL. S1 (7) Is there battery voltage present at interlock module connector X3. A1 S2 G No . No .Check 810 Pnk wire and connections. No . If OK.Go to next step. 710 Pur and 730 Org wires (J)? Yes . replace PTO/RIP switch. pin (G) 3? Yes .Check 710 Pur and 730 Org wires and connections? Electrical Operation and Diagnostics . No .Replace interlock module. pin F? Yes . A1 S2 F S1 (6) Is battery voltage present at interlock module connector X2.Go to next step.Go to next step.Go to next step.Go to next step.

If OK. • A1 M M System: PTO Circuit A1 S2 K S1 M (11) Is battery voltage present at interlock module connector X2. No .Go to next step. (2) Is battery voltage present at X6 PTO clutch connector. N Electrical Operation and Diagnostics .See “Procedure B” on page 304.engine NOT running. pin 5? (L)? Yes . Operator ON seat (Seat switch CLOSED). replace RIO switch. PTO/RIP switch in ON position. M A1 M A1 S2 S1 (12) Is battery voltage present at interlock module connector X3.Go to next step.ELECTRICAL OPERATION AND DIAGNOSTICS System: PTO Circuit Procedure B Test Conditions: • • S1 S2 Key switch in RUN position . No .Check 732 Grn wire and connections.Go to next step.Check 750 Pur wire and connections. If OK.304 . No . (1) Is battery voltage present at S4 PTO/RIP Switch 750 Pur wire (M)? L S1 S2 Yes .Check 750 Pur wire and connections.Check 500 Blu wire and connections. No . 500 Blu wire? (N)? Yes . pin A (K)? Yes . replace PTO/RIO switch.

305 .4 . Does the resistance measure between 2.2.Replace Y1 PTO clutch. Measure resistance across PTO clutch terminals (P).Go to next step. 103 Blk wire (O)? Yes . Electrical Operation and Diagnostics .ELECTRICAL OPERATION AND DIAGNOSTICS System: PTO Circuit O (3) Is there continuity to ground at PTO clutch connector X6.7 ohms? No . No . P (4) Unplug X6 connector.Check 103 Blk wire and connections.

An operator who deems it necessary. breaking the circuit to the PTO relay. and 414 Yel wires. Because the 750 Pur wire is now de-energized. Power to create this condition comes from the PTO/RIO switch momentary contacts. 800 Pnk wire. Power is now available at the PTO/RIO switch to energize the RIO circuit and the PTO clutch when the PTO/RIO switch is moved to the on position. and chooses to keep the PTO engaged while backing up. Wire 731 Blu is connected to wire 735 Grn which connects to the interlock module to energize the RIO latch relay coil. by pulling up on the PTO/RIO switch momentarily while pressing the reverse pedal. The 500 Blu wire supplies power to the PTO clutch while the 731 Blu wire jumpers to the common terminal of the PTO/RIO switch momentary (RIO position) contacts. Grn wire to the voltage regulator/rectifier (N1). the machine must be place in neutral or forward. The operator can then energize the PTO again if desired. 451. System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. seat switch (S2) contacts (closed . When the machine is placed in reverse the RIO switch is pressed in and its contacts open. the operator must pull up on the PTO/RIO switch while placing the machine in reverse. If the operator chooses to reposition the machine in reverse while the PTO is engaged. RIO Operating Conditions: The key switch must be in the run position. there is no power for the PTO/RIO switch to energize the PTO. Electrical Operation and Diagnostics . power is supplied from the 750 Pur wire across the PTO/ RIO contacts to the 500 and 731 Blu wires. the RIO unlatch relay is energized and breaks the loop to the RIO latch relay. This in turn breaks the circuit to the 750 Pur wire back to the PTO/RIO switch where it connects to the 710 Pur wire to continue the loop back to the RIO switch. engine connector X4. The components are solid state and are not serviced separately except for the 15 amp fuses. operator must be on the seat.ELECTRICAL OPERATION AND DIAGNOSTICS Reverse Implement Option (RIO) Circuit Operation Function: To provide a safety interlock with the machine being repositioned in reverse while the PTO is engaged.306 . 732 Grn wire into the interlock module to energize the PTO relay coil and RIO unlatch relay coil. current flows through the 15 amp fuse (F3) to the ignition relay (normally open) contact terminal. The RIO circuit is powered by either the RIO switch or the PTO/RIO switch. 452. The RIO latch relay takes the place of the RIO switch during reverse movement with the RIO circuit activated. Once the machine is traveling in reverse the operator can release the PTO/RIO switch. must take a deliberate action to actuate the PTO/RIO switch. With the PTO/RIO switch off (PTO disengaged). 805 Pnk wire. Current flows from the battery (G1) positive (+) terminal to the fusible link (F1). 810 Pnk wire and PTO/RIO switch (S4). When the machine is placed back into neutral or forward. RIO switch (normally closed) contacts (neutral or forward position). The PTO relay contacts close supplying power to the 750 and 710 Pur wires at the PTO/RIO switch. and the PTO/RIO switch must be in the RIO (momentary) position while placing the machine in reverse. The 710 Pur wire jumpers back to the interlock module to supply power to the RIO latch relay normally open contact. This in turn disengages power to the PTO/RIO switch disengaging the PTO. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. to the interlock module to energize the ignition relay. across the PTO/RIO switch contact to the 710 Pur and 730 Org wires. the RIO switch supplies power to the PTO relay which in turn supplies power to the PTO/RIO switch to be used when the PTO is engaged. To reenergize these circuits. and the PTO/RIO switch must be placed in the off position. This prepares the machine for the next reverse operation with the PTO engaged. With the machine in neutral or forward. If the machine is placed in reverse the RIO switch is pushed in and its contacts are opened. The RIO latch relay feeds itself across the RIO unlatch relay contacts as well as supplying power to the PTO relay and the PTO loop. With the PTO/RIO switch in to on (PTO engaged) position. 210 red wire and key switch. Grn wire to fuel shutoff solenoid. breaking the circuit to the PTO relay and the RIO unlatch relay. current flows from the 805 Pnk wire. The power circuit provides current to the key switch (S1) and protects the system with a 15 amp fuse (F3). by disengaging the PTO circuit. its contacts close and provide power to the PTO relay (normally open) contact terminal.operator on seat). This creates a loop to energize the PTO relay. With the ignition relay energized. The PTO/RIO switch is used in the PTO safety circuit to prevent the PTO relay from energizing if the PTO/RIO switch is in the on position when the key switch is placed in the on position. With the key switch in the run position.

15A 940 Wht X2 B F3 Fuse .Wht Off Run S1 Key Switch Wht Red Wht S1 M A S2 Start M S4 PTO/RIO Switch Red 2 Wht (RIO) (On) (Off) 500 Blu 1 2 6 8 4 3 7 G X1 X3 411 Yel 6 Red 750 Pur 710 Pur 451 Yel 711 Pur 805 Pnk 750 Pur 5 S5 Brake/Neutral Start Switch (Off) (On) 706 Pur 810 Pnk B A Wht S2 S1 RIO Circuit Electrical Schematic 210 Red F2 Fuse .307 E1 Spark Plug X2735 Grn X2 E G1 Battery Blk T1 Magneto Ignition Coil A1 Ignition Interlock Circuit Board X2 X7 Grn Blk Solid-state Ignition Module Blk 105 Blk Y1 PTO Clutch X6 103 Blk Blk Blk Y2 Fuel Shutoff Solenoid X6 E2 Spark T2 Magneto Plug Ignition Coil (235 Only) 500 Blu 101 Blk 103 Blk .15A X2 H 3 X3 X3 X2 X3 452 Yel 711 Pur 731 Blu B S X3 1 F X4 735 Grn Grn MIF Start Relay Magneto Relay Ignition Relay PTO Relay D Seat Switch Delay 940 Wht M X4 S2 Seat Switch (Off) U S3 RIO Switch (On) 414 Yel (Neutral/ Forward) (Reverse) Org Blk M1 Starting Motor A X5 X2800 Pnk X2 732 Grn 710 Pur N1 Voltage Regulator/ Rectifier Grn Red RIO** Switch Delay Blk Blk Solid-state Ignition Module RIO**Latch Relay RIO** Unlatch Relay 4 G C X3 730 Org ELECTRICAL OPERATION AND DIAGNOSTICS Electrical Operation and Diagnostics .

Check F1 fusible link.Check 451. 210 Red wire. M A1 M No . S1 S2 A1 M M A1 S2 S1 (1) Is battery voltage present at S1 Key Switch X1 connector (A)? Yes . No .ELECTRICAL OPERATION AND DIAGNOSTICS RIO Circuit Diagnosis Procedure A Test Conditions: • • • • Key switch in RUN position . and 414 Yel wires and connections.Go to next step. A1 S2 S1 (2) Is battery voltage present at A1 Interlock Module “A” solder joint connection (B)? Yes .Go to next step. 451 and 411 Yel wires (C)? Yes . D B S1 S2 (4) Is battery voltage present at S2 Seat Switch (D)? Yes .308 . A1 S2 System: RIO Circuit A S1 (3) Is battery voltage present at interlock module X3. No . X1 connector to key switch and connections.engine NOT running.Go to next step. pin 6.Replace interlock module. Operator ON seat (Seat switch CLOSED). M M Transaxle in NEUTRAL. 452.Replace A1 Interlock Module.Go to next step. A1 System: RIO Circuit C S1 S2 PTO/RIP switch in OFF position. Electrical Operation and Diagnostics . No .

Yes . Electrical Operation and Diagnostics . If OK.Check 710 Pur wire and connections.Check 805 and 810 Pnk wires and connections.Check 800 Pnk wire and connections. replace PTO/RIP switch. No .Go to next step. No .Go to next step.Replace interlock module.ELECTRICAL OPERATION AND DIAGNOSTICS System: RIO Circuit E System: RIO Circuit G S1 S2 A1 M M A1 S2 S1 (5) Is battery voltage present at interlock module connector X2. pin F (F)? Yes . No .Go to next step.309 . No . If OK.Go to next step. (7) Is battery voltage present at PTO/RIP switch 805 and 810 Pnk wires (G)? Yes . pin A (H)? (6) Is battery voltage present at interlock module connector X2. replace seat switch. S1 S2 H A1 M M A1 S2 S1 F (8) Is battery voltage present at interlock module connector X2. pin D (E)? Yes .

Procedure B Test Conditions: S1 S2 • • M Key switch in RUN position . (11) Is battery voltage present at interlock module connector X3.engine NOT running. L (1) Is battery voltage present at PTO/RIO switch 731 Blu wire (L)? Yes . pin A (J)? Yes . No .See “Procedure B” on page 310.Go to next step. A1 M • • A1 S2 S1 System: RIO Circuit J (10) Is battery voltage present at interlock module connector X2.ELECTRICAL OPERATION AND DIAGNOSTICS System: RIO Circuit System: RIO Circuit I K S1 S2 A1 M M A1 S2 S1 (9) Is battery voltage present at RIO switch 730 Org wire (I)? Yes . No .Check 730 Org wire and connections. pin 5 (K)? Yes . replace PTO/RIO switch. Operator ON seat.310 .Check 731 Blu wire and connections. Electrical Operation and Diagnostics . PTO/RIP switch in MOMENTARY (RIP) position. No . If OK. re place RIO switch.Check 750 Pur wire and connections. If OK.Go to next step. No . Transaxle in REVERSE.Go to next step.Check 732 Grn wire and connections.

If OK. Electrical Operation and Diagnostics . S1 S2 A1 M M A1 S2 S1 M (3) Is battery voltage present at interlock module connector X3.Check 735 Grn wire and connections.ELECTRICAL OPERATION AND DIAGNOSTICS System: RIO Circuit S1 S2 A1 M M A1 S2 S1 L (2) Is battery voltage present at interlock module connector X2. replace PTO/RIO switch.311 . pin G (L)? Yes .Replace interlock module. pin 5 (M)? No .Go to next step. No .

The switch is closed when engine oil pressure is at or below 28 kPa (4 psi). Current flows from the battery (G1) positive (+) terminal to the fusible link (F1) and key switch. 451 Yel wire and the oil pressure light (H1). the oil pressure switch opens. current flows to the 15 amp fuse (F3). When the engine starts and oil pressure increases above 28 kPa (4 psi). breaking the path to ground and the light goes out. Operating Conditions: • Key switch in run position. • Oil pressure switch closed (engine not running or low oil pressure). The ground circuit provides a path to ground through the oil pressure switch and the 101 Blk wire for the oil pressure light.ELECTRICAL OPERATION AND DIAGNOSTICS Low Oil Pressure Light Circuit Operation Function: To light the low oil pressure light to alert the operator that the oil pressure is too low for continued operation. Electrical Operation and Diagnostics . With the key switch in the run position. The components are solid state and are not serviced separately except for the 15 amp fuses. The power circuit provides current to the key switch (S1) and protects the low oil pressure light circuit with a 15 amp fuse (F3). Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. The low oil pressure light system uses a pressure activated switch to provide a path to ground for the oil pressure light. System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. the oil pressure switch (B1) will be closed. If the engine is not running or oil pressure is at or below 28 kPa (4 psi). The oil pressure switch completes the path to ground and the low oil pressure light comes on.312 .

15A 3 H F 1 X2 X2 X3 452 Yel 451 Yel X1 X3 X3 210 Red 5 Low Oil Pressure Light Circuit Electrical Schematic MIF E Start Relay Magneto Relay Ignition Relay PTO Relay D Seat Switch Delay H1 Engine Oil Pressure Light 620 Tan F1 Fusible Link X2 215 B 721 Pur S X4 X2 X2 A Brn 105 Blk W2 Engine Wiring Harness ELECTRICAL OPERATION AND DIAGNOSTICS Electrical Operation and Diagnostics .313 RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay 4 G C Red M P B1 Engine Oil Pressure Switch X3 X2 X2 H3 Not Used M1 Starting Motor G1 Battery Blk 101 Blk W1 Shielded Ground A1 Ignition Interlock Circuit Board .Off S1 Key Switch Run Wht Start M Wht M S2 2 Wht Wht G Red B A Red A X3 S2 S1 B 6 Wht S1 F2 Fuse .15A X3 451 Yel X2 F3 Fuse .

451Yel wire (D)? B S1 S2 Yes .Replace interlock module. No . (5) Is battery voltage present at engine oil pressure light lead 620 Tan wire (E)? Yes .engine NOT running. No .Go to next step. M A1 S2 S1 D (1) Is battery voltage present at S1 Key Switch X1 connector (A)? Yes .Go to next step. replace interlock module.314 .ELECTRICAL OPERATION AND DIAGNOSTICS Low Oil Pressure Circuit Diagnosis Procedure A Test Conditions: • • Key switch in RUN position .Check F3 fuse. X1 connector to key switch. and connections. F1 fusible link.Check 451 Yel wire and connections. M A1 S1 S2 System: Low Oil Pressure Circuit M System: Low Oil Pressure Circuit A1 S2 A C S1 S1 S2 A1 (3) Is battery voltage present at interlock module connector X3.Check 210 Red wire. No . Engine oil pressure switch lead disconnected. If OK.See “Procedure B” on page 315. (4) Is battery voltage present at H1 Engine Oil Pressure Light. Electrical Operation and Diagnostics . pin 6 (C)? M Yes . M A1 M E A1 S2 S1 (2) Is battery voltage present at A1 Interlock Module “A” solder joint connection (B)? Yes .Go to next step.Go to next step. No .

315 .Check engine oil pressure.Replace engine oil pressure switch.ELECTRICAL OPERATION AND DIAGNOSTICS System: Low Oil Pressure Circuit No . replace engine oil pressure switch.1 ohms of resistance? Yes . If OK. No . System: Low Oil Pressure Circuit Test Conditions: • Key switch in OFF position. (1) Is there continuity to ground at B1 Engine Oil Pressure Switch lead (F) with a maximum of 0.Check 620 Tan wire and connections. Electrical Operation and Diagnostics . replace engine oil pressure light. G System: Low Oil Pressure Circuit F (1) Is there no continuity to ground at engine oil pressure switch lead (G)? No . If OK.See “Procedure C” on page 315.engine running. Procedure B Procedure C Test Conditions: • Key switch in RUN position .

current flows to the 450 Yel wire X8 connector. System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. 412 Yel wire and headlight switch (S6).316 . Yel wire. The ground circuit provides a path to ground for the headlight through wires 104 and 103 Blk. key switch. Operating Conditions • • Key switch in run position. With the headlight switch in the on position. The components are solid state and are not serviced separately except for the 15 amp fuses. With the key switch in the run position. headlights (E3 and E4) and illuminates the lamps. 15 amp fuse (F2). Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. current flows from the battery (G1) positive (+) terminal to the fusible link (F1). Electrical Operation and Diagnostics . Headlight switch in on position.ELECTRICAL OPERATION AND DIAGNOSTICS Headlight Circuit Operation Function: To provide power to the headlights for illumination if desired by the operator. The power circuit provides current to the key switch (S1) and protects the circuit with a 15 amp fuse (F2).

Off Run Start Connections M&G None B&A G&S2 B&A S1&S2 X1 S1 Key Switch 210 Red S6 Headlight Switch W6 Headlight Wiring Harness Yel 450 Yel X8 Yel F1 Fusible Link E3 Left HeadLight E4 Right HeadLight Blk Yel 215 Blk B S Blk X8 M M1 Starting Motor Wht M Wht S2 104 Blk Red Red A Wht S1 F2 Fuse .ELECTRICAL OPERATION AND DIAGNOSTICS Headlight Circuit Electrical Schematic Ignition Switch Circuit Logic Off Run Start M G (On) Red B S2 A 412 Yel S1 (Off) 450 Yel Pos.317 .15A 3 H F X3 1 5 X2 Blk E Start Relay Magneto Relay Ignition Relay PTO Relay D 103 Blk RIO**Latch Relay Seat Switch Delay A X2 X2 W1 Shielded Ground RIO** Unlatch Relay RIO** Switch Delay 4 G C X3 X2 X2 A1 Ignition Interlock Circuit Board 103 Blk 104 Blk MIF Electrical Operation and Diagnostics .15A 2 6 X3 X3 X3 X2 X3 412 Yel X2 X2 G1 Battery B F3 Fuse .

Check fusible link (F1). If OK.Test battery. No . A1 M M S1 S2 System: Headlight Circuit C System: Headlight Circuit A1 A S2 S1 (3) Is battery voltage present at A1 Interlock Module “A” solder joint connection (C)? Yes .ELECTRICAL OPERATION AND DIAGNOSTICS Headlight Circuit Diagnosis Procedure A Test Conditions: • • Key switch in RUN position . See “Battery Test” on page 330.Go to next step. 210 Red wire. pin 2 (D)? M Yes . M A1 S1 S2 M A1 S2 B D S1 S1 S2 A1 (4) Is battery voltage present at interlock module connector X3.Go to next step. (1) Is battery voltage present at battery positive (+) terminal (A)? Yes . E (5) Is battery voltage present at S6 headlight Switch 412 Yel wire (E)? Electrical Operation and Diagnostics .engine NOT running.318 .Check F2 fuse. M A1 S2 S1 (2) Is battery voltage present at S1 Key Switch X1 connector (B)? Yes . replace interlock module. X1 connector to key switch and connections.Replace interlock module.Go to next step? No . Headlight switch in ON position. No .Go to next step. No .

Yes . G (1) Is there a maximum of 0.Check 103 Blk wire shielded ground circuit and connections. Electrical Operation and Diagnostics .See “Procedure B” on page 319. (8) Are the headlights ON? No . (7) Is battery voltage present at X9 headlight wiring harness connectors (G)? No .Check W8 Headlight wiring harness and connections. Procedure B Test Conditions: • Key switch in OFF position.319 .Check 450 Yel wire and connections. Yes .1 ohms resistance between battery negative (-) terminal and 103 Blk wire at headlights (H)? No .Check 412 Yel wire and connections.Go to next step. No . No .Replace headlight switch.Go to next step.Go to next step.ELECTRICAL OPERATION AND DIAGNOSTICS System: Headlight Circuit Yes . System: Headlight Circuit H F (6) Is battery voltage present at 450 Yel wire (F) at headlight switch? Yes .

Operator on seat. current flows to the 15 amp fuse (F3). Current cannot flow to the fuel shutoff solenoid until the ignition relay is energized.320 . Key switch in start or run position. The 451 Yel wire provides current to the 452 and 414 Yel wires. The fuel shutoff solenoid (Y2) uses an electro-magnetic coil to operate a plunger. Operating Conditions: • • or • • PTO/RIO switch in off position. The 411 Yel wire provides current to the PTO/RIO switch (S4). seat switch (S2) (contacts closed). helping to prevent backfire or afterfire at engine shutdown. brake/neutral start switch (S5). The ignition relay coil is energized by current from the seat switch circuit or neutral start circuit.ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Shutoff Solenoid Circuit Operation Function: To energized the fuel shutoff solenoid when the ignition relay is energized. The fuel shutoff solenoid plunger stops fuel flow in the carburetor bowl when the solenoid is de-energized. 711 Pur wire to the interlock module to energize the ignition relay during the neutral or starting operation.O. current is provided to the 805 Pnk wire. the fuel shutoff solenoid stops fuel flow at the same time the spark is stopped. Park brake locked. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. When the ignition relay is de-energized. terminal. With the key switch in the run position. 706 Pur wire. The components are solid state and are not serviced separately except for the 15 amp fuses. Once the ignition relay is energized and its contact close. The ignition relay provides power to the fuel shutoff solenoid. ignition relay N. The ground path for the fuel shutoff solenoid is provided through the frame to the W1 shielded ground. Grn wires of the engine wiring harness (W2) and the fuel shutoff solenoid (Y2). Current flows from the battery (G1) positive (+) terminal to the fusible link (F1). Electrical Operation and Diagnostics . 800 Pnk wire to the interlock module to energize the ignition relay during normal operation. 411 and 451 Yel wires. System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. and key switch. X4 connector.

15A X3 X3 711 Pur 452 Yel 3 7 810 Pnk 8 706 Pur 4 711 Pur X2 B F3 Fuse .15A 3 H F 805 Pnk 1 X2 X2 X1 X3 X3 Fuel Shutoff Solenoid Circuit Electrical Schematic MIF 5 E Start Relay Magneto Relay Ignition Relay PTO Relay D Seat Switch Delay 210 Red F1 Fusible Link X2 S2 Seat Switch (NO) (Off) (On) 805 Pnk 215 810 Pnk A2 Discharge Module B 721 Pur S 105 Blk X2 X2 A 800 Pnk 414 Yel X4 Red X8 Red ELECTRICAL OPERATION AND DIAGNOSTICS Electrical Operation and Diagnostics .Off S1 Key Switch S4 PTO/RIO Switch (RIO*) Wht S2 2 1 411 Yel 2 6 451 Yel 6 (Off) (On) Wht M Run Wht Start M Wht G S5 Brake/Neutral Start Switch (Off) (On) Red B A Red A X3 S2 S1 Wht S1 F2 Fuse .321 RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay 4 G C M Grn W2 Engine Wiring Harness X3 X2 X2 X7 Grn M1 Starting Motor G1 Battery W5 Engine Wiring Harness Y2 Fuel Shutoff Solenoid W6 Engine Wiring Harness Blk 101 Blk W1 Shielded Ground A1 Ignition Interlock Circuit Board .

Check 706 Pur wire and connections.Check F3 fuse.ELECTRICAL OPERATION AND DIAGNOSTICS Fuel Shutoff Solenoid Circuit Diagnosis Procedure A Test Conditions: • • • • Key switch in RUN position . No . PTO/RIP switch OFF. If OK. X1 connector to key switch. If OK.Go to next step.Check 411 Yel wire and connections. A1 S2 System: Fuel Shutoff Solenoid Circuit A S1 (3) Is battery voltage present at interlock module connector X3.Go to next step.Go to next step. No . and connections. 210 Red wire. (5) Is battery voltage present at S5 Brake/Neutral start switch 706 Pur wire (E)? Yes . D (4) Is battery voltage present at S4 PTO/RIO switch 411 Yel wire (D)? Yes .322 . Electrical Operation and Diagnostics . A1 S1 S2 System: Fuel Shutoff Solenoid Circuit C Parking brake locked. B S1 S2 No .Check F1 fusible link.Go to next step. pin 6 (C)? S1 S2 Yes .Replace interlock module.Go to next step. No . replace PTO/RIO switch. M M Operator OFF seat. replace interlock module. No .engine NOT running. M A1 M A1 S2 S1 (1) Is battery voltage present at S1 Key Switch X1 connector? (A)? Yes . A1 M M A1 S2 S1 E (2) Is battery voltage present at A1 Interlock Module “A” solder connection? Yes .

Replace interlock module. No . Operator on seat.323 .Go to next step. PTO/RIP switch OFF. pin D (I)? Yes . Electrical Operation and Diagnostics .Check 414 Yel wire and connections. pin 3 (F)? Yes . M A1 M No .ELECTRICAL OPERATION AND DIAGNOSTICS System: Fuel Shutoff Solenoid Circuit Procedure B Test Conditions: • • S1 S2 Key switch in RUN position. No . replace brake/neutral start switch. Parking brake locked. pin F (G)? Yes .Go to next step. M S1 S2 A1 M A1 S2 I S1 (2) Is battery voltage present at interlock module connector X2. replace seat switch. • A1 • M A1 M System: Fuel Shutoff Solenoid Circuit S2 F S1 (6) Is battery voltage present at interlock module connector X3.Check 711 Pur wire and connections. If OK. H S1 S2 (1) Is battery voltage present at S2 Seat Switch 414 Yel wire (H)? Yes . If OK.Check 800 Pnk wire and connections.See “Procedure B” on page 323. A1 S2 G S1 (7) Is battery voltage present at interlock module connector X2.Go to next step. No .

Check ground circuit. pin E (L) and ground 0. System: Fuel Shutoff Solenoid Circuit A1 M M A1 S2 S1 S2 J S1 A1 M (3) Is battery voltage present at interlock module connector X2.324 . M A1 S2 S1 L K (1) Is the resistance measured between interlock module connector X2. (4) Is battery voltage present at Y2 Fuel Shutoff Solenoid Grn wire (K)? Yes . Electrical Operation and Diagnostics .Go to next step. and 101 and 105 Blk wires.1 ohms or less? No .Replace interlock module. W4 engine wiring harness. replace fuel shutoff solenoid. shielded ground circuit.ELECTRICAL OPERATION AND DIAGNOSTICS System: Fuel Shutoff Solenoid Circuit Procedure C Test Conditions: • S1 S2 Key switch in OFF position. Grn wire and connections.See “Procedure C” on page 324.Check 805 Pnk wire.Check battery negative (-) cable. pin F (J)? Yes . No . If OK. No .

the 800 Pnk wire. wire 451. and 414 Yel.ELECTRICAL OPERATION AND DIAGNOSTICS Hourmeter Circuit Operation Function: To record the number of hours the key switch is in the run position. The power circuit provides current to the key switch (S1) and protects the hourmeter circuit with a 15 amp fuse (F3). to the ignition and magneto relays. Current flows from the battery (G1) positive (+) terminal to the fusible link (F1) and key switch. The ground circuit of 106. and 820 Pnk wires to the P1 hour meter. 810. Electrical Operation and Diagnostics . current flows to the 15 amp fuse (F3). through the closed contacts of the S2 seat switch. Lines within dashed border of the Interlock Module (A1) except for key switch connections are circuit paths on the circuit board and are not wires in the harness. the A1 interlock board. With the key switch in the run position.325 . The components are solid state and are not serviced separately except for the 15 amp fuses. Operating Conditions: • • Key switch in RUN position Operator ON the seat (Seat switch closed) System Operation: NOTE: The key switch is connected to the printed circuit board (A1 Interlock Module) by soldered wire connections. 452. the normally open contacts of the ignition relay. and 101 Blk wires provide a path to ground for the hourmeter. 105. When the ignition relay energizes power flows to the 805.

ELECTRICAL OPERATION AND DIAGNOSTICS Hourmeter Circuit Electrical Schematic Ignition Switch Circuit Logic Off Run Start M G Red B S2 A Position Connections M&G None Off B&A G&S2 Run Start B&A S1&S2 S4 PTO/RIO Switch (RIO*) (On) (Off) 820 Pnk 810 Pnk S1 X1 S1 Key Switch 210 Red 1 2 6 3 7 8 4 F1 Fusible Link 215 820 Pnk B S P1 Hour Meter 810 Pnk M 805 Pnk Red M1 Starting Motor X3 F2 Fuse .15A X2 H-B F-2 X3 451 Yel F3 Fuse .326 .15A F-6 G1 Battery X2 H-H X3 F-3 X3 F-1 X2 805 Pnk H-F X3 X2 452 Yel (Off) (On) 800 Pnk 414 Yel Start Relay Magneto Relay Ignition Relay F-5 PTO Relay Blk X2 H-C H-E X2 Seat Switch Delay H-D X2 H-A S2 Seat Switch (NO) W1 Shielded Ground RIO**Latch Relay RIO** Unlatch Relay RIO** Switch Delay X3 F-4 X2 A1 Interlock Circuit Board H-G MIF Electrical Operation and Diagnostics .

210 Red wire. and 414 Yel wires and connections. E (5) Is battery voltage present at hourmeter (E)? Electrical Operation and Diagnostics . pin 6 (B)? Yes . If OK. Operator on seat. and connections. S2 S1 (1) Is battery voltage present at S1 Key Switch X1 connector? (A)? Yes . C System: Hourmeter Circuit System: Hourmeter Circuit A S1 S2 (3) Is battery voltage present at S2 Seat Switch (C)? Yes .Go to next step.engine NOT running. replace interlock module.Go to next step.Go to next step.Check F3 fuse.327 .Go to next step.ELECTRICAL OPERATION AND DIAGNOSTICS Hourmeter Circuit Diagnosis Procedure A Test Conditions: • • Key switch in RUN position . If OK.Check 800 Pnk wire and connections.Check 451.Check F1 fusible link. No . pin D (D)? Yes . 452. No . replace seat switch. M A1 S1 S2 M A1 S2 D B S1 S2 S1 (4) Is battery voltage present at interlock module connector X2. X1 connector to key switch. M A1 M A1 No . M A1 M A1 No . S2 S1 (2) Is battery voltage present at interlock module connector X3.

Go to next step. No . 105. and 820 Pnk wires and connections.Check 106.328 .Check 805. Electrical Operation and Diagnostics . System: Hourmeter Circuit F (1) Is continuity to ground present at hourmeter (F)? Yes . No .ELECTRICAL OPERATION AND DIAGNOSTICS System: Hourmeter Circuit Yes . replace interlock module. If ok. and 101 Blk wires and connections. Procedure B Test Conditions: • Key switch in off position.Go to next step. 810.

Connect voltmeter positive (red) lead to ground terminal (A) of circuit or component to be tested. or corrosion in the ground circuit. Connect ohmmeter negative (black) lead to negative terminal of battery. poor connections.1 ohms. Maximum allowable resistance in the circuit is 0.329 . corroded. the component is open. Start at the controlling switch of the component that should not be operating. 2. Move forward/reverse pedals to neutral position. Check all terminals and ground connections of the circuit for corrosion. switch(es) closed) so that voltage will be present at the component. Park machine on level surface. 3. Turn key switch to on position. 5.Ohmmeter Method: 1. or severed connections). Results: • If voltage is 0. 2. Resistance reading must be the same or very close to the battery negative terminal reading. Follow the circuit and disconnect wires at connectors until components stop operating. To test for high resistance and open circuits: 1. • If voltage is greater than 1 volt. If a problem is indicated. or no component operation (i. poor. Voltage at the component will be low when the component is in operation.ELECTRICAL TESTS AND ADJUSTMENTS Tests and Adjustments Common Circuit Test Shorted/Grounded Circuit: A shorted circuit on the ground side of a component (i. Ground Circuit Test Reason: To check for open circuits.1 ohms. 3. Lock park brake. Turn component switch on. Lock park brake. Procedure . loose terminal wire crimps.e. improper wire-to-wire or wire to ground contact) may result in blown fusible link and fuses. High Resistance or Open Circuit: High resistance or open circuits usually result in slow. 2. Voltage must be greater than 0.e. Shorted or improper connections will be the last two wires disconnected. dim. Record voltage. Electrical Tests and Adjustments . Check for open wiring. Check both sides of the connectors closely. If the reading is above 0. Raise hood. improper wire-to-wire or wire to ground contact) may result in improper component operation. Connect ohmmeter red lead to ground terminal (A) of circuit or component to be tested that is closest to the battery negative terminal. Raise hood. Move forward/reverse pedals to neutral position. the ground circuit is bad. poor connections. 5. as disconnecting and connection may temporarily solve problem. 4. 4. Turn key switch off. Connect ohmmeter positive (red) lead to negative terminal of battery and record reading. Procedure . disconnect the wiring harness connector to isolate the wire or component and check resistance again. A shorted circuit on the power side of a component or contact of two power circuits (i.e. the problem is in the component or wiring. 2. Some components will have a very small voltage reading on the ground side and still be operating correctly. Work backward from the battery on the ground side of the problem circuit until the resistance reading increases above 0. 7. the problem is between the last two test points. 6. 7.Voltmeter Method: 1. but less than 1 volt. Equipment: • Ohmmeter or Voltmeter NOTE: The voltmeter method checks ground connections under load. To test for a shorted or improperly wired circuit: 1. If terminals are not loose or corroded. 6. or corrosion in the ground circuit. 4. Connect voltmeter negative (black) lead to negative terminal of battery. Park machine on level surface. Be sure that the component circuit is activated (key on. 3. loose terminal wire crimps.1 ohms.

charge battery for 20 minutes at 10 amps. 3.175. Drink large amounts of water or milk. 7.4 volts. and cause blindness if splashed into the eyes. 4. Use a hydrometer to check for a minimum specific gravity of 1. M49596 If you spill acid on yourself: 1. Remove surface charge by placing a small load on the battery for 15 seconds. Apply baking soda or lime to help neutralize the acid. Results: • If all cells are less than 1. 4. • If all cells are more than 1.225 with less than 50 point variation. Filling batteries in a well-ventilated area. 3. Use proper jumpstart procedure. Get medical attention immediately. 3. 5. Avoid the hazard by: 1. If acid is swallowed: 1. Park machine on level surface. 2.4 VDC. • If more than 50 point variation. Flush your skin with water. Turn key switch off. • If all cells are less than 1.ELECTRICAL TESTS AND ADJUSTMENTS Battery Test 8. Install battery. test specific gravity (see Step 9). Wearing eye protection and rubber gloves. Results: • If battery voltage is less than 12. Then drink milk of magnesia. charge battery See “Charge Battery” on page 331. soft water as needed. beaten eggs.225 with less than 50 point variation in each cell. battery terminals and top of battery. Inspect battery terminals and case for breakage or cracks. Equipment: • • Hydrometer Voltmeter or JTO5685 Battery Tester 9. 2. Clean cable ends. Electrical Tests and Adjustments . Avoiding breathing fumes when electrolyte is added. charge battery at 10 amp rate. Reason: To check condition of battery and determine battery voltage. Get medical attention immediately. Avoid spilling or dripping electrolyte. replace battery. It is strong burn skin. eat holes in clothing.4 VDC. or vegetable oil. Procedure: 1. 3. Add clean. Remove battery to workbench.225 with less than 50 point variation. 6. c CAUTION: Avoid injury! Sulfuric acid enough to in battery electrolyte is poisonous. • If battery voltage is more than 12.330 . 2. Lock park brake. charge battery at 10 amp. Use a voltmeter or JTO5685 Battery Tester to check for a minimum battery voltage of 12. If water is added. Check electrolyte level in each battery cell.15 minutes. 5. Flush your eyes with water for 10 . 2. load test battery.

Turn key switch off. Turn load knob (A) counterclockwise to off position. 5. before charging battery.12 hours. Check if battery is accepting 10 amp charge rate after 10 minutes at boost setting. Lock park brake. Park machine on level surface.15 amps for 6 .ELECTRICAL TESTS AND ADJUSTMENTS Charge Battery Reason: To increase battery charge after the battery has been discharged. • If less than 50 point variation between cells. go to Steps 9 and 10. Remove battery. Park machine on level surface. 11. 12.Continue to charge battery until specific gravity is 1. 10.8 hours).331 . 9. • If battery is accepting 10 amp charge after 10 minutes at boost setting. Battery Load Test Equipment: • JTO5685 Battery Tester Procedure: 1. Start charger at slow rate. 8.265 points. Equipment: • Battery charger (variable rate) IMPORTANT: Avoid damage! Decrease charge rate if battery gases or bubbles excessively or becomes too warm to touch. charge battery at 10 .1. replace battery. (Maintenance-free battery: 4 .Load test battery. Results: • If more than 50 point variation between cells. 6.230 . 4. 5. NOTE: If battery was discharged at slow or unknown rate. • If battery is accepting 10 amp charge after 10 minutes at boost setting. Check charger ammeter after 1 minute at each setting. Increase charge rate one setting at a time. Remove battery to workbench. 8. 7. battery terminals and top of battery. 6.25 amps. 2. but battery did need water or all cells were below 1. battery terminals and top of battery. Use boost setting as necessary. Electrical Tests and Adjustments . Lock park brake. and battery did not need water. replace battery. 1.Install battery. C B D E A M49597 7. Turn key switch off. Procedure: NOTE: See “Battery Test” on page 330. 3. 13. M49598 3. 2. Clean cable ends. Results: • If battery will not accept 10 amp charge after 10 minutes at boost setting. Move forward/reverse pedals to neutral position.175. go to Step 10 and 11. Connect variable rate charger to battery. go to Steps 9 and 10. Maintain 10 amp charge rate. 4. Set charger at 15 . Clean cable ends. Connect tester positive (red) cable to battery positive (+) terminal (B).Check specific gravity after 30 minutes (60 minutes for maintenance-free battery).

6.7 volts DC. Lock park brake. Test Equipment: • • JT05712 Current Gun JT05685 Battery Tester Procedure: 1. Set voltmeter for 25 or 50 DC volt scale. 10. 7. Move forward/reverse pedals to neutral position. Connect JT05685 Battery Tester to battery: • Connect tester positive (red) cable to battery positive (+) terminal. Reason: To determine regulated voltage output of the regulator/ rectifier. See “Stator Output Test” procedure for the appropriate engine. Also read amperage. or • Three times ampere hour rating (use black scale). charge battery and retest. 6. 4. 3.14. Turn load knob to maximum counterclockwise position. 2. test stator voltage output.ELECTRICAL TESTS AND ADJUSTMENTS 9. Set Current Gun for DC current. 10.332 . • Connect tester negative (black) cable to battery negative (-) terminal.Repeat Steps 10 and 11 above and read condition of battery at DC Volts scale (E). 8.Start and run engine at fast idle.2 . 12. 11. • If battery does not pass test and has been charged.Start and run engine at fast idle. Turn key switch off.Hold for 15 seconds and turn load knob (A) of tester counterclockwise to off position. Park machine on level surface. Turn key switch off. Put JT05712 Current Gun over small red wire. 10. Lock park brake. • If the DC voltage goes above the maximum specification. Results: • If battery does not pass test and has not been charged. 7. IMPORTANT: Avoid damage! Perform this test quickly to prevent damage to battery tester. Procedure: 1.Turn load knob clockwise until voltage read on the tester voltage scale is 11 volts. replace the regulator/rectifier. • If stator voltage output meets specifications and voltage and ground to the regulator/rectifier is verified. test stator voltage output. 11. 5. Connect voltmeter negative (black) lead to battery negative (-) terminal. 2. Raise hood. Remove surface charge from battery by placing a small load on the battery for 15 seconds. See “Stator Output Test” procedure for the appropriate engine. Connect voltmeter positive (red) lead to battery positive (+) terminal.10 seconds. 9. replace the regulator/rectifier. Results: • If the DC voltage remains below the minimum specification. Results: • If reading does not meet specifications. Connect tester negative (black) cable to battery negative (-) terminal (C). Park machine on level surface. Regulated Voltage Test Regulated Amperage Test Reason: To determine charging output of rectifier/regulator. Voltage should remain between 12. DO NOT apply full load to battery for more than 5 . replace battery. 9. Raise hood. 5.Read voltmeter several times during 5 minutes of running time. Move forward/reverse pedals to neutral position. Test Equipment: • Voltmeter 11. 3. Electrical Tests and Adjustments . 8.Turn load knob (A) of tester clockwise (in) until amperage reading (D) is equal to: • Cold cranking amperage rating of battery (use blue scale). Amperage should read a minimum of 13 amps. 4.

Turn key switch to off position. .2 ohms. Park machine on level surface. 7. Results: • If resistance (or continuity) is measured. Measure stator voltage. test stator with an ohmmeter. Results: • If voltage is less than specification. 3. 7.Measure resistance across stator leads. Raise hood. 6. Equipment: • Fluke Multi-Meter (Set to AC volt scale) Equipment: • Procedure: 1. Measure stator voltage. 6. Voltage should read a minimum of 28 volts AC. 4. 13. Set meter to 50 VAC or Autorange scale. Move forward/reverse pedals to neutral. 11. 9. Results: • If resistance is infinite ohms. Resistance should read 0. stator leads are shorted to ground. v v MIF 8.333 MIF 8. Raise hood. Lock park brake. Disconnect two lead connector between stator and voltage regulator.Change meter to ohms scale. Start and run at fast idle (3350 ± 75 rpm).ELECTRICAL TESTS AND ADJUSTMENTS Stator Output Test (B&S Engine) Reason: To measure AC voltage output of stator. Replace stator. Results: • If voltage is less than specification. Lock park brake. Voltage should read a minimum of 30 volts AC. Electrical Tests and Adjustments . Resistance should read infinite ohms. Procedure: 1. Fluke Multi-Meter (Set to AC volt scale) Stator Output Test (Kohler Engine) Reason: To measure AC voltage output of stator and verify correct resistance of stator. 2. Move forward/reverse pedals to neutral position. 9.1 to 0. Turn key switch to off position. stator is open. 2. Park machine on level surface. 5. Disconnect regulator/rectifier connector. 10. Set multi-meter to 50 VAC or Autorange scale. 5. 12.Stop engine. Replace stator. test flywheel magnet(s) and then replace stator. 3. 4. Start and run at fast idle (3600 ± 50 rpm).Measure resistance from each stator lead to ground.

Equipment: • Fluke Multi-Meter (Set to AC volt scale) Procedure: Procedure: 1. Electrical Tests and Adjustments .ELECTRICAL TESTS AND ADJUSTMENTS Stator Output Test (Kawasaki Engine) Reason: To measure AC voltage output of stator and verify correct resistance of stator. Replace stator. A Regulator/Rectifier Test (Kawasaki Engine) Reason: To determine if voltage regulator/rectifier is defective. Start and run at fast idle (3350 ± 75 rpm). 11. Resistance should read infinite ohms.Stop engine. 5.Measure resistance from each stator lead to ground.2 K ohms ~ infinite E F infinite infinite infinite 110 ohms ~ infinite If resistance measurements do not match any table listing. stator is open. 2.334 . Park machine on level surface. 9. Measure stator voltage. 12. Results: • If resistance is infinite ohms.Measure resistance across stator leads. Disconnect wiring harness from voltage regulator/ rectifier.24 to 0. 13. Raise hood. stator leads are shorted to ground. A B infinite 0 500 ohms ~ infinite 500 ohms ~ infinite C infinite 0 infinite infinite D 7. Lock park brake. 6. replace voltage regulator/rectifier. Equipment: • Voltmeter 1. Turn key switch to off position. Compare readings to table. test stator with an ohmmeter. Park machine safely. Resistance should read 0. Set meter to 50 VAC or Autorange scale.40 ohms. F E v D C B mif 3. Move forward/reverse pedals to neutral position. Voltage should read a minimum of 34 volts AC. Results: • If resistance (or continuity) is measured. 2. 7.Change meter to ohms scale. 10. Replace stator. Disconnect stator connector from regulator/rectifier. 3.5 K ohms ~ infinite 330 ohms ~ infinite 14 K ohms ~ infinite 925 ohms ~ infinite infinite 925 ohms ~ infinite infinite infinite 10 K ohms ~ infinite 10 K ohms ~ infinite 1. Results: • If voltage is less than specification. Measure resistance between each indicated point. 4. Results: MIF + A B infinite C infinite D infinite E 19 ~ 3 K ohms infinite F 3K ohms ~ infinite infinite 8.

A Procedure: 1. See procedure in applicable ENGINE section. 4. Hold a steel tool about 25 mm (1. Remove spark plug high tension leads (D) and ground to engine. See “Battery Test” on page 330. Turn knob on Battery Tester clockwise until the DC voltage is the same as when cranking. Park machine on level surface. Procedure: 1. 3. Connect positive (red) clamp of battery tester to positive (+) terminal of battery and negative (black) clamp to negative (-) terminal of battery. 4. 6.) from flywheel magnet. 3. 6. Disconnect and ground spark plug lead. Lock park brake. IMPORTANT: Avoid damage! Perform the following procedure within 15 seconds to prevent electrical damage to components.335 . Turn knob (C) of battery tester to maximum counterclockwise off position. Remove blower housing. Turn key switch to off position. 2. 4. Maximum starter amperage draw should be 85 amps at 500 rpm. 7. or cranking rpm is low. 5. test starter no-load rpm and amperage. Park machine on level surface. Results: • Replace the flywheel if the magnet does not attract tool. See “Ground Circuit Test” on page 329. Turn key switch off. Move forward/reverse pedals to neutral position. Test battery. B C D M99586 Picture Note: GT235 shown. 9.ELECTRICAL TESTS AND ADJUSTMENTS Flywheel Magnet Test Reason: NOTE: All except model 235E To make sure the flywheel magnet has enough force to induce current in the ignition coil. 7. Electrical Tests and Adjustments . Crank engine and read voltage on DC voltage scale (B) of Battery Tester. Lock park brake. Check engine rpm using JTO7270 HandHeld Digital Tachometer. Turn key switch to off position. Raise hood. 3. 5. Move forward/reverse pedals to neutral position. Read DC amperage (A) on Battery Tester. 2. 8. Results: • If amperage is above specification. Equipment: • Volt/Ohm Meter Procedure: 1. Place PTO/RIO switch in off position. Test Equipment: • • JT05685 Battery Tester JTO7270 Hand-Held Digital Tachometer Starting Motor Solenoid Test Reason: To determine if starting motor solenoid is defective. Test system ground connections. 6.0 in. 5. The tool should be attracted by the magnet. 2. Starter Loaded Amperage Draw Test Reason: To determine the amperage required to crank the engine and check the starter motor operation under load.

• Battery voltage .go to next step. Turn key switch to off position. • Battery voltage . Results: • No battery voltage .336 . 10. 11. Starting motors contain two ceramic magnets that can be broken or cracked if the motor housing is hit. Connect VOM to negative (-) battery terminal (A) and terminal (B) of starting motor. strike starting injury! Do not motor housing Clamp only on the mounting bracket. 1.Check cranking circuit.Momentarily turn ignition key to start position and check for battery voltage. ensure connections are not touching any surface where a ground short may occur. Wrap connections with electrical tape if necessary 7. See “Cranking Circuit Diagnosis” on page 271. Starter solenoid is defective. 6. Results: • No battery voltage. Connect VOM to negative (-) battery terminal (A) and terminal (C) of starting motor. 9. 4. Remove starting motor. IMPORTANT: Avoid damage! When connecting wires and meter. Lock park brake. Required Tools: • • • • • JT05791 Multitester JT02153 Current Clamp 12 Volt Battery JTO7270 Hand-Held Digital Tachometer Jumper Cables B C D MIF • Jumper Wire (To connect the starting motor POS post and the solenoid shift connector) Procedure: 8.Check red cable and connections from battery and starter solenoid terminal (B) for loose connections. Electrical Tests and Adjustments . 12.Connect VOM to negative (-) battery terminal (A) and connector (D) of starting motor shift solenoid. Clamp the starting motor mounting bracket in a vise. 5. 2.Momentarily turn ignition key to start position and check for battery voltage. NOTE: Check that battery is fully charged and of proper size to ensure accuracy of test.go to next step. Park machine on level surface. See “Power Circuit Diagnosis” on page 266. deformed or dented. • Battery voltage . Raise hood. 3. Move forward/reverse pedals to neutral position. Clean any corrosion.ELECTRICAL TESTS AND ADJUSTMENTS A Starting Motor No-load Amperage and RPM Tests Reason: v To determine starting motor condition with no-load. Results: • No battery voltage . c CAUTION: Avoidwith a hammer.Starting motor is possibly defective preform “Starting Motor Loaded Amperage Draw Test”.

012 in. 0. open the jaws and snap them closed several times. 4.012 in.ELECTRICAL TESTS AND ADJUSTMENTS A 17. C E • If amperage reading is above 50 amps or starting motor rpm is less than 6000.20 . . . . Specifications: GT225 Gap .) A M45869 Electrical Tests and Adjustments . 2.30 mm (0. Push armature against flywheel and tighten screws (A) to 7. . . momentarily touch the POS jumper cable lead to the starting motor POS post (G).337 . 11. check for binding or seized bearings.) Armature Screws . .Read the starting motor rpm using the hand-held digital tachometer. .Set the current clamp to 2000A and the multitester to 300mV. and dirty or worn commutator. . Armature Air Gap Adjustment B D Reason: To set the proper air gap between the ignition coil armature and the flywheel magnet. Results: • A good starting motor should have a maximum amperage reading of 50 amps and a minimum rotational reading 6000 rpm.). . . 13.Disconnect and remove the current clamp. 16. 0. momentarily connect the starting motor POS post (D).) GT235 Gap . . .Connect current clamp red lead to the volts jack of the multi tester and the black lead of the current clamp to the com jack on the multi tester. 9. Connect the POS jumper cable to the battery POS post (C) and the starting motor solenoid stud terminal (D). . .0. Repair or replace starting motor.012 in.8 N•m (69 lb-in.0. sticky brushes. . . See specification below. Center flywheel magnet under armature. . The core of the jaws may hold some magnetic force after the current clamp has been used for measurement. . to zero. . 12.0. 3.Clamp jaws of current clamp (E) around the positive jumper cable.30 mm (0.) Procedure: MIF 8. . .20 . . . NOTE: Adjust the DCA zero adjust dial on the current clamp for a zero reading on the multitester. . 1. .Using the jumper cable.20 .Using the jumper wire. to the starting motor solenoid shift connector (F). Connect the NEG jumper cable to the battery NEG post (A) and the frame of the starting motor (B).008 .8 N•m (69 lb-in. . If you cannot adjust the display.0.008 . 7. . .30 mm (0. and read the starting motor amperage draw. 15. . Insert a feeler gauge between flywheel and armature.008 . Equipment: F G • Thickness Gauge 0. 10.0. 14.Place a piece of reflective tape on the starting motor gear shaft. . . Turn flywheel to remove feeler gauge.0.

5. or if no spark. • Terminals should not have continuity with switch off. Move forward/reverse pedals to neutral. 6. C A B D B MIF MIF 6. blue spark. check armature air gap.Watch spark (D) at spark tester. Disconnect light switch connector. 3. A Light Switch Test Reason: To make sure the light switch terminals have continuity when the light switch is on. Turn key switch to run position and start engine. • If spark is weak.2 in. There should be a strong.ELECTRICAL TESTS AND ADJUSTMENTS Spark Test Reason: To check overall condition of ignition system.) with screw (C). 8. Wheels blocked and park brake unlocked. 7. NOTE: Do not adjust spark tester gap beyond 5 mm (0. 2. Electrical Tests and Adjustments . Raise hood. or still no spark. Remove high tension lead (A) from spark plug and connect to spark tester (B). 2. • If continuity is not correct. 4. install a new spark plug and test again. watch spark with engine running. 4. Connect spark tester lead to spark plug. Move forward/reverse pedals to neutral position. Turn key switch to off position. replace light switch.338 . Park machine on level surface. Lock park brake. Results: • If engine will start. • If spark is still weak.2 mm (0. • If spark is still weak.166 in. Adjust spark tester gap to 4.) as damage to ignition system components could occur. Equipment: • D-05351ST Spark Tester Equipment: • Procedure: 1. Ohmmeter or Continuity Tester Procedure: 1. 9. 10. 3. steady. replace ignition armature. adjust as needed. or still no spark. Move light switch to the on and then the off position. Check continuity between terminals (A and B). 5. Results: • Terminals should have continuity with switch on. Turn key switch to off position. Park machine on level surface.

. . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . Turn key switch to off position.A and B . . . . . . . . . . . . .G and H Results: • All other possible combinations have infinite resistance. . . . . . . . . 4. . . . . Electrical Tests and Adjustments . . . . . . . . . . Use an ohmmeter to test switch continuity in off and on positions. . . . . . . . D and E . . . . . . . A and B (D and E) Momentary ON . C A B D G E H MIF F 6. . . . . . . A and C (D and F) ON . . . . . . . . . . . . . . 5. . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . move forward/reverse pedals to neutral position. . . . . . . . . . . . Park machine on level surface. . . . . . . . . Equipment: • Ohmmeter or Continuity Tester Procedure: 1. . . PTO/RIO Switch Continuity: Switch Position . .339 . . . If any continuity is not correct. . . . Lock park brake. . . . . Terminal Continuity OFF . . replace switch. . . Disconnect PTO/RIO switch connector. . . .ELECTRICAL TESTS AND ADJUSTMENTS PTO/RIO Switch Test Reason: To verify PTO/RIO switch functions are operating properly. . . . . . . . . .

Depress plunger and check continuity across switch terminals. replace switch. or continuity is not correct. . Connect leads of ohmmeter or continuity tester to terminals (A) of switch. Check continuity across switch terminals. . . . Procedure: 1. . . . . replace the switch. . C A A B M48379 MIF 6. . . . . . Disconnect seat switch connector. . . Connect meter leads to switch posts (A) and (B). . . 3. . .ELECTRICAL TESTS AND ADJUSTMENTS Seat Switch Test Reason: To verify continuity between seat switch terminals when operator is on the seat (plunger depressed). . . . Move forward/reverse pedals to neutral position. . . . check seat switch bracket and spring for damage. Electrical Tests and Adjustments . . . 9. . There should be no continuity. . . . 2. . . . . . . . continuity between posts A and B Results: • If brake/neutral start switch does not pass both tests. . Press and release plunger (C) of switch. .340 . set zero point before each test. . . . • If the seat switch does not have continuity with plunger depressed. Set ohmmeter for 1x ohms scale. . . . . . Specifications: Switch plunger not pressed . . . . . . . 8. . 4. . . . . . . . . . Compare to specifications. 5. no continuity between posts A and B Switch plunger pressed. . . . Equipment: • Ohmmeter Procedure: 1. Results: • If the seat switch has continuity with the operator on seat. . 7. Test Connections: • Set ohmmeter for 1X scale NOTE: On analog (swing needle) Ohmmeters. . 3. . . . . Equipment: • Ohmmeter or Continuity Tester Brake/Neutral Start Switch Test Reason: To determine proper operation of the brake/neutral start switch. Turn key switch to off position. . Remove connector from brake/neutral start switch. . . . . There should be continuity. 2. Lock park brake. Park machine on level surface. . .

Procedure: c CAUTION: Avoid injury!hot engine partsaway Keep gasoline from sparks. replace the switch. the solenoid will not function properly. B A NOTE: If battery voltage drops below 9 volts when cranking engine or while engine is running. 2. replace solenoid. Connect red ohmmeter lead to terminal of switch (A) and black ohmmeter lead to engine block (B). Test Equipment: • 2 Jumper Wires Procedure: 1. • If solenoid does not click . IMPORTANT: Avoid damage! Do not allow connector of wire to contact the engine or frame as there will be voltage at it during the test. Results: NOTE: Be sure to apply Pipe Sealant with TEFLON ‚to threads of switch anytime it is installed. replace the switch. 6. problem is with the input signal wiring. Move forward/reverse pedals to neutral position. 4. Electrical Tests and Adjustments . Disconnect wire from oil pressure switch.341 . Test Equipment: • Ohmmeter • If switch does not have continuity to ground when the engine is not running. 2. Results: • If solenoid now clicks. 11. check engine oil pressure. 10. 3. or or personal injury can result. 1. 5. Set ohmmeter for 1x scale. problem could be in equipment wiring. or park brake locked. Measure resistance between terminal and engine block. Lock park brake. • If solenoid now clicks. If the oil pressure is to specifications. There should be continuity between terminal and ground. Fuel Shutoff Solenoid Test Reason: To test proper operation of fuel shutoff solenoid. Turn key switch off. There should not be continuity between terminal and ground. Result: M99585 Picture Note: GT235 B&S Engine Shown 7. 9. the solenoid is working properly. 5. the solenoid is working properly. Raise hood.Start and run engine. flame. If solenoid does not click. • If the switch does have continuity to ground with the engine running. Connect a jumper wire from the battery positive (+) terminal to solenoid terminal (A). • If solenoid does not click.go to next step. Park machine on level surface.Measure resistance between terminal and engine block. 4. Listen for an audible click when ignition switch is turned from off to on with PTO/RIO switch in the off position and either the seat switch pressed. Disconnect wire from fuel shutoff solenoid.ELECTRICAL TESTS AND ADJUSTMENTS Oil Pressure Switch Test Reason: To determine the proper operation of the oil pressure switch. The oil pressure switch is located near the oil filter on all models. 3. problem is with the ground wiring. 8. Add a jumper wire from the battery negative (-) terminal to solenoid body (B). See procedure in applicable ENGINE section.

. Set the fuel tank to the right side of the machine between the front and rear wheels. . . B C D M95486 Electrical Tests and Adjustments . . Remove fender deck. set zero point before each test. Move PTO/RIO switch to off position. . . .continuity between posts A and B Switch plunger pressed . . . . Equipment: • Feeler Gauge (Blade type) Test Connections: • Set ohmmeter for 1X scale Procedure: 1. . . . . . . . Remove the rosebud clip holding the fuel line to the frame rail. . . Equipment: • Ohmmeter RIO Switch Adjustment Reason: To set the proper air gap between the RIO switch and the pivot bracket so that the RIO switch is activated at the proper time. . . . . . . . . . 7. Compare to specifications. . . Connect meter leads to posts (A) and (B). . . . A B MIF 2. 3. . . . . . . . Procedure: 1. . 6. .ELECTRICAL TESTS AND ADJUSTMENTS RIO Switch Test Reason: To determine proper operation of RIO switch. no continuity between posts A and B Results: • If RIO switch does not pass both tests. . . . . replace switch A M95320 8. . . C NOTE: On analog (swing needle) Ohmmeters. . Unsnap the transaxle reservoir bottle (A) from the fuel tank and lift the fuel tank up and off of the frame. . . Move forward/reverse pedals to neutral position. . . . . . . See “Fender Deck Removal and Installation” on page 559. 5. . Turn key switch off. Lock park brake. . . . . . . . Press and release plunger (C) of switch. . 2. Park machine on level surface. . 4. . . 3. . . . . . . . Remove connector from RIO switch. Specifications: Switch plunger not pressed . . . .342 .

Specifications: Air Gap .2. 2.7 ohms. Turn key switch OFF. . .ELECTRICAL TESTS AND ADJUSTMENTS 9.Route the fuel line back into position and snap rosebud clip back into frame rail. . . 14. . Move forward/reverse pedals to NEUTRAL position. . 15. Electrical Tests and Adjustments .343 . .) 6. . 12. . 16. Equipment: • • Ohmmeter JT05712 Current Gun Procedure: 1.) 8. . Loosen the M6 locknut (B) and slide the RIO switch and bracket assembly (C) all the way down in the slot (D).Slide switch and bracket assembly (C) up in the slot (D) and set air gap (F) to 1 mm (0.Hold the switch and bracket assembly firmly in place and tighten the M6 locknut (B) to 6 N•m (54 lb-in. Resistance should measure 2. 13. .04 in.Push down on top of pivot bracket (E) and cycle the control arm two (2) times in reverse direction. . . A B F C D M95486 M99547 11. . 7. . . . . . Remove mower deck. . Lock parking brake. M99607A 10.Reassemble machine. . .).4 . . 5. . 3. See “Fender Deck Removal and Installation” on page 559. Park machine on a level surface. 4. Measure resistance across terminals of the connector (A).04 in.Reinstall fender deck. . 1 mm (0. . Electric PTO Clutch Test Reason: E To check condition of PTO clutch coil and to check operation under load. . .Set fuel tank back into position and snap transaxle reservoir bottle into fuel tank. . . Disconnect PTO clutch connector. . . 6 N•m (54 lb-in. . (See procedure in Attachments section. .) Adjustment Screw . Set ohmmeter for 1x ohms scale. . . . . . .).

Measure PTO clutch current draw. GF15BK (Eagle Part Number) AM131987 (John Deere Part Number) Electrical Tests and Adjustments . replace the PTO clutch. or engaging the PTO should also stop power at the outlet. To restore power. The current draw should be 4 amps. B 2.Turn the PTO/RIP switch to the ON position. 13. NOTE: Releasing the parking brake.ELECTRICAL TESTS AND ADJUSTMENTS Ground Fault Circuit Interrupt (GFCI) Test Reason: To ensure proper functioning of GFCI receptacle. and must be replaced. 4. press the reset button. • Normal current draw is approximately 4 amps. Plug a trouble light or radio into the GFCI outlet (A) to verify that electrical power is present. Park machine on level surface with park brake locked and engine running. 11. Results: • If resistance does not meet specifications. Connect PTO clutch connector (C). If the current draw is less than 3 amps.Start and run engine at slow idle. C M82910 9. GFCI receptacle must be replaced with part specified. c CAUTION: an on-board high-voltage generator. Results: • If the device is still being powered. injury or death. Press the GFCI test button (B) to trip the GFCI and stop the flow of electricity.Put JT05712 Current Gun over blue PTO clutch wire (B). A B MX16029 3. Low current draw will cause a weak PTO clutch. the GFCI is not working properly.344 . replace clutch. • If the power goes off. See “120 Volt Circuit Operation . 10. 12. Avoid injury! 120 Volt electric outlet system is Failure to observe all safety messages may result in property damage. Test Equipment: • 120 volt AC light or radio Procedure: 1. the GFCI is working properly. Have the system running and the power reset switch on.GT235E” on page 294.

If meter does not display battery voltage a problem exists with the equipment wiring or interlock switch. Digital multimeter Reset (On-Off) Switch Test Reason: MX16028 To verify proper operation of reset (on-off) switch. B • Digital multimeter Procedure: 1. Test Equipment: 3. Results: • If continuity exists. Disconnect reset (on-off) switch from harness and remove from machine. 3. Results: • Meter should display battery voltage. If the meter does not show continuity. Insert red meter test lead (B) into brake interlock switch wire connector. Set meter to DC volts 2. 3. Disconnect safety interlock circuit purple wire (A) from red inverter wire.ELECTRICAL TESTS AND ADJUSTMENTS Park Brake Interlock Circuit Test Reason: To verify proper operation of safety interlock circuit. Turn equipment key switch to on position. Set meter to diode test. C 2. the meter will make a continuous tone. Attach black meter test lead (C) to negative battery terminal. Test Equipment: • Digital multimeter Test Equipment: • Procedure: 1. lock the park brake and ensure the PTO is off.345 . 2. Connect the leads of the Multi meter between inverter case and the engine frame. MX16027 4. 6. A Inverter Ground Continuity Test Reason: To verify that there is continuity between the inverter case and the engine frame. Verify that there is continuity between the inverter case and the GFCI ground. B MX16026 A Electrical Tests and Adjustments . 5. a problem exists with the system wiring. Attach a meter test lead to each terminal on switch. Set digital multimeter to diode test. NOTE: The 120 volt system may not reset if battery voltage is less than 12 Volts DC. Procedure: 1. Place equipment key switch in off position.

Electrical Tests and Adjustments . 6. Tool with #10 bit Tachometer Procedure: NOTE: To test the inductor. Press button (B) on test box and note AC voltage. Inductor Test Reason: To verify operation of inverter. A B MX16025 2. MX16406 • Connect the multi-meter between the small blade of the GFCI outlet cord plug (positioned as shown) and the small blade socket of the GFCI outlet. There should be continuity. (no continuity). NOTE: Do not exceed 1800 rpm. replace the inverter. 1. Start engine and set speed to 1800 rpm. Measure the continuity across the switch in the on (A) and off (B) positions. Test Equipment: • Digital multimeter 120 Volt Stator AC Output Test Reason: To verify AC output of stator to the inverter. 3. 4. 5. To check the continuity of inductor circuit: Procedure: NOTE: Make all connections before starting engine. (continuity). Results: • With switch in on position meter should make a continuous tone. • • If output is 100 volts or higher. Insert meter test leads into either receptacle in test box.346 . Results: Alternator output should be no less than: 100 volts AC. • With switch in off position meter should display OL. Remove tamper proof screws from harness plug at inverter using Torx® Driver and remove plug. replace the stator. it must be disconnected from the circuit. 1.ELECTRICAL TESTS AND ADJUSTMENTS 4. Set digital multimeter to read AC volts. Insert alternator harness plug (A) into socket in JDG1639 test box. If output is less than 100 volts. NOTE: It may be necessary to remove the inverter from the equipment. Test Equipment: • • • • Digital multimeter JDG1639 Test Box Torx® Driver. Unplug the GFCI outlet cord from the inverter output cord.

There should not be continuity.ELECTRICAL TESTS AND ADJUSTMENTS 2.347 . To check inductor ground isolation: MX16407 • Connect the multi-meter between the small blade of the GFCI outlet cord plug (positioned as shown) and metal bracket of the GFCI outlet. Electrical Tests and Adjustments .

7. 3. Remove spark plug wires to prevent accidental starting of engine during procedure. Ensure fixed key in clutch slides into crankshaft keyway (E). 6.ELECTRICAL REPAIR Repair Electric Clutch Removal and Installation Procedure: 1. New Clutch Break-in Procedure: 1. Electrical Repair . 4. Follow new clutch break-in procedures. 2. Install clutch on crankshaft with pin (D) through slot in clutch coil housing. Park machine on a level surface and turn engine off. 5.Blade Terminals C B M99547 Replacement: 6. Turn PTO/RIO switch on and off 8 . Park machine on level surface.5 second intervals at no-load. Start engine. A A c CAUTION: Avoid injury! Clutch willSupportof fall off crankshaft when bolt is removed. Be sure to bend locking tang back to its original position (B) before installing connector body. Install washer with concave side toward PTO clutch. Remove machine from stands and reconnect spark plug wires. Apply MPG-2® Multi-Purpose Grease to engine crankshaft before installing clutch. 4. Disconnect negative (-) battery cable at battery. 2.348 . 6.10 times in 4 . 3. clutch during removal. Remove mower deck. Connector Body . 4. 3. Install bolt and tighten to 56 N•m (45 lb-ft). Raise and support front of machine on suitable stands. Set throttle control to half-speed. 2. Slide connector body off. Connect PTO clutch connector to main wiring harness. Installation is done in the reverse order of removal: B B RW4218 Use a small screwdriver to depress locking tang (A) terminal. Disconnect clutch wiring connector (A) from main wiring harness. Move forward/reverse pedals to neutral position. Lock park brake. 7. D E M99549 1. Remove bolt washer (B) and clutch (C) from crankshaft. A 5. 5.

Electrical Repair . To remove pin connector from pin body (long connector half) insert tool in center of contact. Use JDG777 Terminal Removal Tool to remove contact from connector body.Sleeve . Remove retainer on wire end of connector with a screwdriver.ELECTRICAL REPAIR Metripack® Connector Removal: B A C D E M56684 2. Open connector body.Pin Body .Mounting Post (optional) . I H G F M56685 A B C D E F G H I .Sleeve Body . M56682 4.Shure-Seal . Hold the removal tool fully seated and pull wire from connector body.349 . 1.Shure-Seal M56690 3.Pin .Wire Retainer . IMPORTANT: Avoid damage! Identify wire number/ color locations with connector terminal letters.Wire Retainer . A M56691 NOTE: To remove sleeve connector from sleeve body (short connector half) insert tool in slot (A) between terminal contact and connector body.

Strip insulation from wire to expose 6 mm (1/4 in.350 . Remove wire from connector body as described above. NOTE: Cables seals are available for three sizes of wire: • • • Large: 1. C. IMPORTANT: Avoid damage! METRIPACK® connectors are keyed A. IMPORTANT: Avoid damage! Proper barb location and orientation for installation of sleeve and pin is shown NOTE: Connector bodies are keyed for proper contact mating.8 mm (18 gauge) wire Small: 0.ELECTRICAL REPAIR Replacement: 1. A C TSO136 3. Install correct size cable seal on wire. Use JDG145 Universal Electrical Plier to remove wire as close as possible to old contact. 2. for proper contact mating. Place proper size contact on wire and use JDG776 Crimper to crimp contact in place with a “W” type crimp. Use JDG776 Crimper to secure cable seal to contact as shown. B. M56686 TSO132 5. M56686 6.) and align cable seal with edge of insulation. Be sure contacts are in proper alignment.5 mm (20 gauge) wire B D M56688 4. Electrical Repair . etc.0 mm (16 gauge) wire Medium: 0. Be sure contacts and wire colors/numbers match and are in proper alignment.

Brush Springs .Brush . Battery or wiring defective.Pinion .Solenoid .Armature . Fields in starter are permanent magnets and are not serviceable.Transfer remaining wires to correct terminal in new connector.Brush Holder .351 . G H Starting Motor Analyze Condition: The starter overheats because of: • • • • • • • • Long cranking. 8. Electrical Repair .Retaining Clip . 9.Place retainer on wire end of connector and snap in place.Shift Lever . and starter drive. If housing or armature is damaged. Shorts. 12.Front Cover . Badly worn brushes or weak brush springs. Armature binding. Push contact into new connector body until fully seated. replace starter. Pull on wire slightly to be certain terminal is locked in place.ELECTRICAL REPAIR Disassembly/Assembly: A M M56689A 7.Case with Field Windings and Brushes 1. Install wire retainer. 11.End Cover . Mark body and covers to aid in alignment for assembly. Excessive voltage drop in cranking system. Dirty or damaged starter drive. . L E D E F B C K J M56683 I 10.Insulator . A B C D E F G H I J K L M M94902 The starter operates poorly because of: NOTE: Starter repair is limited to brushes. end caps.Close connector body. or grounds in armature. opens. Armature binding.Pinion Stopper .

Armature windings are connected in parallel. (See Inspection/Test procedures below.240 in. clean commutator of dust and filings. C NOTE: Shorts between bars are sometimes caused by dirt or copper between bars. If solenoid fails any test. Inspect for this condition.352 . • Test for open circuits between brushes (A).ELECTRICAL REPAIR 2. A B M24861 Locate short circuit by rotating armature on a growler while holding a hacksaw blade or steel strip on armature. 2. • Depress switch arm (A). so each commutator bar must be checked. Test for grounded windings using an ohmmeter. it is defective and must be replaced. There should be continuity. Test solenoid: • Check solenoid terminals (C and D) for continuity. Solvent can damage insulation on windings. replace armature. Points where shaft contacts cover. Replace if necessary. • Test for open circuits between terminal (D) and tang (E). starter armature (G) and case with field windings and brushes (M). Test solenoid (C). • Check either brush (B) to non-painted area of case (C) for continuity. Inspect parts for wear or damage. If case assembly fails any test. 3. There should be continuity when arm is fully depressed. Use only mineral spirits and a brush. E D M51705 3. There should be continuity. There should be no continuity.) Assembly is done in the reverse order of disassembly. There should be no continuity. Test case with field windings and brushes: M50112 If test indicates shorted circuit windings. Separate pinion stopper halves (E) to remove retaining clip (D) to remove starter drive. • Check either brush (A) to non-painted area of case (C) for continuity. 4. Measure brush lengths. it is defective and must be replaced. • Test for open circuits between tang (E) and body (B). Inspect brush springs for wear or damage. 4.). 5. NOTE: Always replace retaining clip (D) with new. There should be no continuity. then (B) for continuity. replace case with field windings and brushes. Apply a very light coating of multipurpose grease to: • Sliding surfaces of armature and solenoid shift lever pivots. Check armature again. Inspection/Test: 1. • Touch probes on each commutator bar. If any one brush length is less than 6 mm (0. Test starter armature: IMPORTANT: Avoid damage! Do not clean armature with solvent. If test still indicates a short circuit. Electrical Repair . There should be no continuity. • • Armature shaft spline. The hacksaw blade will vibrate in area of short circuit.

If the test shows no continuity. • Touch probes on two different commutator bars. a winding is grounded and the armature must be replaced.353 . there is an open circuit and the armature must be replaced.ELECTRICAL REPAIR If test indicates continuity. Electrical Repair . M50113 Test for open circuit windings using an ohmmeter.

354 .ELECTRICAL REPAIR Electrical Repair .

...............378 Cruise Control ............................376 Brake Depressed ..............Maximum............................ and Axles ..... 409 Repair...........................................................355 ...... 405 Tests and Adjustments .Forward (Maximum) ......................362 Reduction Gears....360 Piston Pump ..........................381 Hand Control . 444 Control Pedals and Linkage.. 387 Machine Will Not Move Forward or Reverse ........Neutral...........................................Forward (Maximum) .............................. Differential.......368 Brake Pedal and Linkage .357 Other Materials.............. 395 Erratic Speed ....................................................374 Foot Control ..373 Theory of Operation .........................374 Foot Control .............. 397 Park Brake Does Not Hold Machine On Hill ........ 407 Brake Linkage Adjustment...............POWER TRAIN ..................................376 Foot Control ..................................... 409 Transaxle Disassembly......357 Adjustment Specifications .......................... 400 Brake Switch Will Not Engage .. 449 Brake Rod Removal and Installation ..... 408 Neutral Return Arm Bearing Adjustment .......................357 Hydrostatic Transaxle.................. 391 Machine Creeps.......Off Position. 414 Transaxle Assembly ........... 384 Gear Power Flow ..........................357 Torque Specifications............................................. 446 Cruise Control Lever ......... 428 Traction Drive Belt Tensioner Assembly .........................Reverse (Maximum) ............... 447 Hand Control Lever (Optional).............................................380 Hand Control ...Reverse (Maximum) .................................................................369 Forward and Reverse/Cruise Control Linkage ..............375 Foot Control ..........359 Transaxle Case Halves ......................................Forward..................................................... 405 Forward and Reverse Pedal Height Adjustment ......... 385 Transaxle Brake .......370 Forward and Reverse Pedals and Linkage (Exploded View)...................... 448 Brake Pedal and Linkage..................................... 393 Machine Moves In One Direction Only ...HYDROSTATIC TABLE OF CONTENTS Power Train .......................................................................................... 396 Machine Does Not Achieve Full Ground Speed...................378 Cruise Control ..............374 Controls and Linkage Operation................. 387 Noisy Operation ............Hydrostatic Table of Contents Specifications ..................................................................... 405 Hydrostatic Transaxle Bleeding Procedure 405 Neutral Creep Adjustment ...........................................379 Cruise Control Maximum Speed Position..... 383 Hydrostatic System Operation .......................382 Hydrostatic System Operation .................... 407 Hand Lever Rod Adjustment..............381 Hand Control .............................................................Neutral ..........358 Component Location.........364 Transaxle Brake ........... 404 Transaxle Whines When Brake Is Used ...............................380 Hand Control .......................................................................................... 445 Neutral Return Arm..........................376 Brake Depressed ........374 Foot Control .Reverse.357 Repair Specifications....................................................................377 Brake Linkage ............................................................366 Center Case Assembly............................. 450 Power Train .....371 Cruise Control Lever and Linkage (Exploded View)...................................................................................363 Swash Plate and Neutral Centering Assembly................................ 402 Cruise Control Does Not Maintain Ground Speed..........361 Motor .................................... 445 Intermediate Shaft ......Neutral ........................375 Foot Control .......................................................................................359 Charge Pump ..................... 409 Transaxle Removal and Installation........................................ 408 Cruise/Hand Control Lever Tension Adjustment ..Neutral Position .........................Maximum......................... 386 Diagnostics.............................................................................367 Belt Drive and Idlers ...382 Hand Control ...Hydrostatic Table of Contents .............

POWER TRAIN .356 .HYDROSTATIC TABLE OF CONTENTS Power Train .Hydrostatic Table of Contents .

. . . . . . . . . . . . . .0. . . . . . . .0 mph) Adjustment Specifications Reverse Pedal-to-Foot Mat Height . . .4. . . . . . . . . .) Brake Shoe to Brake Disk Clearance (Maximum) . . . . . .0. . . .999 . . . . . . . . . . . . . . . . . . . . . .) Torque Specifications Center Case Cap Screw Torque . . . . . . . . . . . . . .Kanzaki K71B Travel Speed-Forward . . . . . . . . . . . . . . . . .) Reverse Pedal Set Screw Torque . . . . . . . . . . .003 . 17 . . . . . . . . . . . . . . . . . 17. . . . . . 14.10 . . . . . . . . . . .POWER TRAIN . . . . .) Axle Shaft (Right Hand and Left Hand) Axle Bushing ID . . .) Reduction Pinion Gear/Shaft Clearance (New) . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . .) Differential Gear Assembly Pinion Gear ID. . . . . . . . . . . .97 ± 0. . . . . . . . . . . .37 mm (0. .13 mm (0. . . . . .5 N•m (40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Axle Shaft OD . . . . . . . . . . . .2 km/h (0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .665 . . .005 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ± 2 mm (1. . . . . . . . . . . . . . .50 mm (0. . . . . . .) Clearance Wear Limit (Maximum) . . . . . . 0. . . . . . . . . . . . 0. . . . . . . .669 . . . .592 . . . . .995 . . . . . . . . 20 . . . . . . . .25. . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . 25. . . . . . . . . . . . . . . . . . . .0 mph) Travel Speed-Reverse . . . . . . . . . . . . . . . . . . . . . . .25. . . . . 18 N•m (216 lb-in. . . 0. . . . . . . . . . . . . . . . . . . . .08 . . . .) Pinion Shaft OD . . .0. . . . . . .38 . . . . . . . . . . . . . . . . . . . . . . . . . . .672 in. . . . . . . . . . . . . . . . . . . . . . . . . . .Twin Touch™ Automatic Cruise Control. . . . . .) Reduction Shaft OD . . . . . . . . . . . . . . . . . . . . . . . Belt Drive Transaxle w/ Foot-controlled Variable Speed Drive Transaxle Control . . . . . . . . . . . . . . . .14. . . .0. . . . . . . .060 in.668 in. . . . . . . . . . . 15. . . . . . . . . . . . . . . . . . . .Standard Transaxle .3 N•m (20 lb-in. . . . . . . . . . . .15. . . . . . . . . .97 . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16. . . . . . . . . . . . . . . .) Clearance Wear Limit (Maximum) . . . . .1. . . . . . . . . . . . . . . . . . . . .00 . .60 lb-in. . . . . . . .27 . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . .4 km/h (0 . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . .05 . . . . . . . . . . .) Clearance Wear Limit (Maximum) . . . . . . . . . . . . . . . . .7. . . . . . 4. . . . . . . . . .020 in. . .26 N•m (14 . . . . . . . . .16 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 N•m (150 . .590 in. .52 mm (0. . . . . .180 lb-in. . . . . . . . . . . . . . . . .06 mm (0. . . . . . . . .19 lb-ft) Power Train . . . . . .0. . . . . . . . . .50 mm (0. . . . . . . . . . .) Case Half Cap Screw Torque Same Case . . . . . . . . . . . .006 in. . .50 mm (0. . . . . . . . . .020 in. . . .5 mm (0. . . . . .006 in. . . . . . . . .589 .Hydrostatic Specifications . . . .) Pinion Gear/Shaft Clearance (New) . . . . . . .357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .020 in. . . .17. . . . . . . . .) Repair Specifications Transaxle Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 qt) Reduction Gear Assembly Reduction Pinion Gear ID . . . . . 0 . .99 mm (0. .16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . .08 in. . . . . . . . . . . . . . . . . . . . .11. . . . . . . . . . . . . . .98 mm (0. . . . . . . . . . . .) Shock Absorber/Neutral Switch Bracket Cap Screw Torque . . . . . . . . . .004 . . . . . . . . . .16 mm (0. . . . . . . . .) Drain Plug Torque (Large) . .90 . . . . . . . . . . . . .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. .4 L (4. . . . . . . . . . . . . . .19 lb-ft) Shock Absorber Bracket Cap Screw Torque . . . . . .999 in. . . . . . . . . . . . . . . . . . . . . . .26 N•m (14 . . . . . . . . . . . 20 . . . . . . . 25. 43 N•m (32 lb-ft) Drain Plug Torque (Small) .HYDROSTATIC SPECIFICATIONS Specifications Hydrostatic Transaxle Drive Train .597 in. 0. . . . . . . . . . .6. . .

Loctite is a registered trademark of the Loctite Corp.POWER TRAIN . Teflon is a registered trademark of the DuPont Co.HYDROSTATIC SPECIFICATIONS Other Materials Other Material Part No. TY6305 TY15130 / TY15443 TY9375 / TY9480 (#592 Loctite)1 TY6305/TY9485 (#764 Loctite) Part Name John Deere Clean and Cure Primer Flexible Sealant Pipe Sealant with Teflon® (Medium Strength)2 Cure and Clean Primer Part Use Cleans parts and speeds cure of sealant. Seals transaxle Case Seal Pipe Plug Cleans Transaxle case mating surfaces 1. 2.358 .Hydrostatic Specifications . Power Train .

Plug Power Train .O-Ring .Cap Screw .Snap Ring .O-Ring .HYDROSTATIC COMPONENT LOCATION Component Location Transaxle Case Halves E D F J A B C K H G I C Y B A M L X N W O V U Q R S T M95591 P A B C D E F G H I J K L .Filter M .359 .POWER TRAIN .Hydrostatic Component Location .Seal .Snap Ring .Washer Seal R .Magnet Cover Y .Cap Screw O .Plug S .Bushing P .Fill Cap .Seal .Cap Screw T .Magnet X .Bearing .Lower Case Housing Q .Reservoir Fitting .Cap Screw U .Filter N .Plug V .Upper Case Housing .O-Ring W .

Lower Case Housing Power Train .POWER TRAIN .Filter .Center Case .Case .HYDROSTATIC COMPONENT LOCATION Charge Pump B A C D E F G H I J K M95594 A B C D E .Pin .Charge Pump .Outer Gerotor .Spring .Inner Gerotor F G H I J K .Check Valve .Input Shaft .Hydrostatic Component Location .360 .

Input Shaft .Snap Ring .Upper Case Housing .Spring .POWER TRAIN .Spring .Washer J K L M N O P Q R .Spring .Snap Ring .Piston Power Train .Cylinder Block .Swash Plate .HYDROSTATIC COMPONENT LOCATION Piston Pump F E D C B G A R Q P I J K L O H N M M95593 A B C D E F G H I .Hydrostatic Component Location .Snap Ring .Ring .Bearing .Center Case .Washer .361 .Lower Case Housing .Bearing .

Swash Plate .Washer .POWER TRAIN .Washer .Hydrostatic Component Location .Bearing .Spring .Thrust Bearing .HYDROSTATIC COMPONENT LOCATION Motor F G H I E J K L D C B A M N O P Q R M95587 A B C D E F G H I J .Spring .Gear .Piston .Center Case .Washer .Cylinder Block .Snap Ring .Washer K L M N O P Q R .Output Shaft .Lower Case Housing Power Train .Ring .362 .E-Clip .

and Axles D C B A A B C E S K J G I R H H I J K F Q P M L O N M95589 A B C D E F G H I J K L .363 .Ring Gear .Hydrostatic Component Location . Differential.C-Ring .Spacer .Upper Case Housing .Seal .Bushing .Pinion Shaft .Right Axle Shaft Power Train .Reduction Gear .Side Gear .Piston Pin .Reduction Pinion .Bearing .HYDROSTATIC COMPONENT LOCATION Reduction Gears.Lower Case Housing .POWER TRAIN .Left Axle Shaft M N O P Q R S .Thrust Washer .Bushing .Snap Ring .Bearing .

364 .POWER TRAIN .HYDROSTATIC COMPONENT LOCATION Swash Plate and Neutral Centering Assembly D C B E F A G ah H I J ag af K ad ae ac ab aa L Z Y W X V N M U T S R M N Q P O M95588 Power Train .Hydrostatic Component Location .

HYDROSTATIC COMPONENT LOCATION A .Pin AG.Washer E .Bushing O .Hydrostatic Component Location .Bolt D .Snap Ring W .Swash Plate T .Control Arm C .Upper Case Housing M .Cap Screw L .POWER TRAIN .Cap Screw Power Train .Washer N .Pin I .Spring Pins B .365 .Nut AE.Spring X .E-Clip F .Plate P .O-Rings AC.Shaft Z .Washer AD.Washer H .E-Clip K .Bracket J .Lever AB.Plate R .Bushing S .O-Rings Y .O-Rings AH.Shock Absorber G .Spring V .Pin U .Eccentric AF.Pin AA.Bearing Q .

Brake Shoe Power Train .Ball K .HYDROSTATIC COMPONENT LOCATION Transaxle Brake L A B K J I C H G F E D M95590 A B C D E F G H I J .Upper Case Housing .POWER TRAIN .Seal .Hydrostatic Component Location .Spring Pin .366 .Shims .Brake Disk L .Lever .Cap Screw .Spring .Housing .O-Ring .

367 .POWER TRAIN .HYDROSTATIC COMPONENT LOCATION Center Case Assembly B A B C E D H J G F I M95592 A B C D E F G .Bushing Power Train .Plug H .Cap Screw J .Pin I .Center Case .Plug .Pin .Upper Case Housing .Valve .O-Ring .Hydrostatic Component Location .

Cap .Spring .Belt Guide X .Bushing R .Nut W .E-Clip .Fan N .Hydrostatic Component Location .Felt Washer .Belt T .V-Idler V .368 .Washer .Carriage Bolt .Spacer Z .Carriage Bolt .Bushing Y .HYDROSTATIC COMPONENT LOCATION Belt Drive and Idlers D E F A G C H I Z B J K Y L M Q U X T P N W S V R M95492 O A B C D E F G H I J K L M .POWER TRAIN .Washer .E-Clip O .Drive Sheave Power Train .Carriage Bolt .Nut U .Idler Arm .Nut S .Driven SHeave P .Bushing .Nut .Flat Idler Q .

HYDROSTATIC COMPONENT LOCATION Brake Pedal and Linkage A B D E J C I F G H MIF A B C D E F G H .Freewheeling Arm .Neutral Return Rod J .Brake Shaft .Brake Rod .Hydrostatic Component Location .Freewheeling Interlock Rod .Brake Spring .Brake Pedal I .Neutral Return Arm Power Train .Brake Return Spring .369 .Brake Arm (On Transmission) .POWER TRAIN .

Cruise Control Interlock Rod Power Train .POWER TRAIN .Ball Joint .Neutral Return Arm .Reverse Shaft .Intermediate Plate .370 .Hand Lever Rod .Cruise Control Knob .Forward/Reverse Control Rod .Reverse Pedal .Intermediate Shaft .Transaxle Control Rod .HYDROSTATIC COMPONENT LOCATION Forward and Reverse/Cruise Control Linkage A B C D E F G P O N H I M L J K MIF A B C D E F G H I J .Forward Pedal K L M N O P .Cruise Control Lever .Friction Device .Neutral Return Rod .Pedal Shafts Bracket .Hydrostatic Component Location .

371 .HYDROSTATIC COMPONENT LOCATION Forward and Reverse Pedals and Linkage (Exploded View) B A C D E ad F G ag ab K ae aa Z Y P L Q R Q T Q R Q T P M K ac J af I H V O U V N X W W M99584 Power Train .Hydrostatic Component Location .POWER TRAIN .

Bushing G .Bearing L .Carriage Bolt AC.Spring Locking Pin B .Bearing S .Forward Control Shaft K .372 .Pedal Pad (Forward) O .Carriage Bolt AF.POWER TRAIN .Cotter Pin Power Train .Nut X .Bearing I .Bearing Support R .Pedal Pad (Reverse) V .Washers AA.Forward/Reverse Control Rod E .Pedal (Reverse) P .Pedal (Reverse) Y .Nut D .Washer F .Nut Q .Washers T .Reverse Control Shaft AE.Washer J .Hydrostatic Component Location .HYDROSTATIC COMPONENT LOCATION A .Carriage Bolt N .Nut H .Bearing Retainer M .Carriage Bolt AG.Nut AD.Bracket Z .Strap AB.Cotter Pin U .Ball Joint C .Clamp W .

Knob .Washer AL.Cotter Pin AI .Nut .Bushing .Nut .Nut AG.Bushing AH.Bushing U .Rivet AJ.HYDROSTATIC COMPONENT LOCATION Cruise Control Lever and Linkage (Exploded View) E F G D A B C H V O L am aj ak al I J K Q M N W P U R S T P ai ah ag af ae ac ab aa ad Z V U T Y X M95595 A B C D E F G H I J K L M N O P Q R S .Quick Lock Spring Pin AB.Bushing .Cotter Pin AC.Hydrostatic Component Location .Carriage Bolt Y .Nut X .Rod .Bolt .Cotter Pin .Washer .Lock Washer .Spring Disk .Shaft Z .Rod AE.Rod .Washer AM.Nut .Washer V .Washer AD.POWER TRAIN .Snap Ring W .Ball Joint .Washer AF.Lever .Cap Screw .Nut AK.Bracket T .Washers AA.Spring .373 .Plate Power Train .Washer .

The forward and reverse pedals pivot through the pedal shafts bracket and rotate the pedal control arm forward or rearward (reverse). Foot Pedals: The internal transaxle engagement is controlled by the foot control pedals (forward . See “Brake Depressed . NOTE: With the cruise control lever in the OFF position. the forward/reverse rod pivots the intermediate shaft plate forward. or the brake pedal is fully depressed. The pedal control arm pulls the forward/reverse control rod. and that the forward/reverse controls on the transaxle will return to NEUTRAL when the brake pedal is pressed. the hand lever rod moves freely in the cruise control lever slot. the transaxle control rod moves the intermediate shaft plate to the neutral position. The forward pedal pivots through the pedal shafts bracket and rotates the pedal control arm forward. The transaxle control rod connects the intermediate shaft plate to the transaxle control shaft. The friction device holds the cruise control lever in the set position. In turn. and the forward/reverse rod moves the pedal control arm and pedals to the neutral position. The forward pedal operates independently from the cruise control lever. and ensure that the brake is released when the forward or reverse pedals are engaged. The pedal control arm either pulls or pushes the forward/reverse control rod. Cruise Control (Forward Only): The cruise control system holds the transaxle linkage in a forward position. The transaxle control rod connects the intermediate shaft plate to the transaxle control shaft. Power Train . the transaxle is shifted into forward. the forward/ reverse rod moves (pivots) the intermediate shaft plate forward and rearward. and the cruise control lever is pulled back to a neutral position.reverse . the transaxle control shaft is moved to the forward position and the transaxle engages in forward drive.HYDROSTATIC THEORY OF OPERATION Theory of Operation Controls and Linkage Operation Function: The controls and linkage for the hydrostatic power train provide mechanical means of operating the forward/reverse control lever on the transaxle through the forward and reverse pedals. and the cruise control lever to neutral positions. the transaxle is shifted into reverse. The hand lever rod connects the cruise control lever to the intermediate shaft plate. A spring inside the transaxle returns the transaxle control shaft to the neutral position. rotating the neutral return arm.Neutral Position Function: The function of a properly adjusted linkage in a neutral position ensures that the transaxle control shaft is in the neutral position when the forward or reverse pedals are released. and riding in the inner cam profile of the intermediate shaft plate moves the intermediate shaft plate to the neutral position.brake) through the control linkage. through a mechanical linkage. The intermediate shaft plate moves the transaxle control rod and places the transaxle control shaft in the neutral position. and a means of maintaining forward speed without holding the forward pedal down when using the cruise control lever. They also engage the transaxle brake. When the cruise control is engaged. Foot Control . the hand lever rod moves freely in the cruise control lever slot. a bearing attached to the neutral return arm.Hydrostatic Theory of Operation . Hand Control: An optional hand control may be installed that replaces the forward and reverse pedals. In turn.Maximum” on page 376. The foot pedal controls operate independently from the cruise control lever. As the intermediate shaft plate rotates forward. the transaxle control shaft is shifted into forward.Forward (Maximum) Function: When the forward pedal is depressed. When the brake pedal is depressed.374 . Foot Control . As the intermediate shaft plate rotates forward. the cruise control interlock rod is pulled forward. Brake Pedal: The brake functions. NOTE: With the cruise control lever in the NEUTRAL position. See “Hydrostatic System Operation” on page 383. the hand lever rod is moved forward rotating the intermediate shaft forward. As the transaxle control shaft rotates to the neutral position. As the intermediate shaft plate rotates rearward.POWER TRAIN . As the neutral return arm rotates. to return the intermediate shaft plate and transaxle. Depressing the brake pedal pulls the neutral return rod forward.

Friction Device B .Neutral Return Rod .Neutral Return Arm .Rear Axle Foot Control .Intermediate Shaft Plate E F G H I J .Neutral G B A C F R N N R F F D E R N F R N F J L K M99597 I H A B C D E F .Friction Device .Transaxle Control Arm .Cruise Control Lever (OFF) .Hydrostatic Theory of Operation .375 .POWER TRAIN .Forward Pedal .Brake Pedal (OFF) .HYDROSTATIC THEORY OF OPERATION Foot Control .Transaxle Control Rod .Neutral Position .Intermediate Shaft Plate .Forward (Maximum) B 13° G A C E D F R N F R N F RN F H J I M99598 A .Reverse pedal .Forward Pedal Control Arm .Forward Pedal G H I J K L .Transaxle Control Shaft Power Train .Cruise Control Lever (OFF) C .Independent Movement From Cruise Control Lever D .Neutral Return Arm .Transaxle Control Shaft .Brake Pedal (OFF) .

The pedal control arm pushes the forward/reverse control rod rearward.Friction Device B .Pedal Control Arm E . The reverse pedal has an attached lever that presses down on a bearing on the rear of the pedal control arm. See “Hydrostatic System Operation” on page 383. NOTE: With the cruise control lever in the NEUTRAL position. the transaxle control shaft is shifted into reverse. The transaxle control rod connects the intermediate shaft plate to the transaxle control shaft. When the rear of the pedal control arm is pushed down. Simultaneously.Independent movement from cruise control lever D .Neutral Return Arm H . the hand lever rod moves freely in the cruise control lever slot.Transaxle Control Rod J .376 . pivots the intermediate shaft plate rearward. A . Note: On machines equipped with the optional hand control. rotating the cruise control lever to the neutral position.Transaxle Control Shaft Power Train . the cruise control interlock rod is removed. The brake neutral return rod rotates the neutral return arm. The forward pedal operates independently from the cruise control lever.Brake Pedal (OFF) G . This. a ball bearing (attached to rear of the neutral return arm) travels upward along the inner cam profile of the intermediate shaft plate. the brake neutral return rod is pulled forward. As the ball bearing raises in the inner cam. Foot Control .POWER TRAIN . As the intermediate shaft plate rotates rearward. the transaxle control shaft is moved to the rearward position and the transaxle engages in reverse drive. in turn.Reverse (Maximum) Function: When the reverse pedal is depressed.HYDROSTATIC THEORY OF OPERATION Foot Control . the intermediate shaft plate is moved into the neutral position.Hydrostatic Theory of Operation .Cruise Control Lever (OFF) C . the attached cruise control interlock rod is pulled forward.Reverse (Maximum) B F A C 11° R N F D E R N F R N F G H M99599 I J Brake Depressed . the top of the pedal control arm rotates rearward.Maximum Function: When the brake pedal is depressed.Intermediate Shaft Plate I .Reverse Pedal F . When the neutral arm rotates.

Forcing the transaxle out of the freewheeling mode prevents the operator from starting the engine and trying to drive the machine with the transaxle in the freewheeling mode.Brake Pedal (Maximum) .Pedal Control Arm . See “Cranking Circuit Operation” in the Electrical section.Hydrostatic Theory of Operation . If the transaxle is left in the freewheeling mode (freewheeling rod pulled out).Hand Lever Return . Brake Depressed .Transaxle Control Rod Power Train .Cruise Control Lever (OFF) .Neutral Position .Cruise Control Lever (Maximum Forward) .Neutral Return Arm .Hard Lever Interlock Rod .Friction Device . See “Transaxle Brake” on page 386.Intermediate Shaft Plate .POWER TRAIN .Maximum B A C H I D E G N F N N K M L M99602 J N A B C D E F G H I J K L M N . and the transaxle internal wet brake pads stop the machine. the freewheeling interlock rod (see below) is pulled forward when the brake pedal is depressed and the transaxle is shifted out of the freewheeling mode.Brake Neutral Return Rod . The brake rod rotates the transaxle brake arm forward.Neutral Return .377 .Brake Pedal (OFF) .HYDROSTATIC THEORY OF OPERATION Moving the intermediate shaft plate to the neutral position moves the transaxle control rod and control shaft to the neutral position.

Freewheeling Arm .POWER TRAIN . IMPORTANT: Avoid damage! When cruise control is not in use.Freewheeling Interlock Rod . The friction device holds the cruise control lever in position.Neutral Return Rod . As the intermediate shaft plate rotates forward. the cruise control interlock rod is pulled forward.378 . hand lever should returned manually to the OFF position. Cruise Control Operation: NOTE: Cruise control operates only for forward travel.Brake Shaft .Neutral Return Arm Depressing the brake pedal will return the cruise control lever to the OFF position. and reverse speed of machine will be too slow.Brake Return Spring . the hand lever rod is pushed forward.HYDROSTATIC THEORY OF OPERATION Brake Linkage B D A C E J I F G H MIF A B C D E F G H I J . the transaxle control shaft is shifted into forward. and the cruise control lever is moved farther forward. or. hand lever will restrict travel of reverse pedal linkage. Cruise control may be set by moving the cruise control lever forward until the ground speed of the machine is set. Power Train .Brake Arm (On Transmission) . Use cruise control to maintain travel speed without having to hold the forward travel pedal down.Hydrostatic Theory of Operation . The transaxle control rod connects the intermediate shaft plate to the transaxle control shaft. When the brake pedal is depressed. and the cruise control lever pivots to the neutral position. Otherwise.Brake Pedal . The hand lever rod pushes the top of the intermediate shaft plate forward and pivots the plate forward.Brake Rod . the forward travel pedal may be depressed to attain the ground speed desired and then maintained by moving the cruise control lever forward. Function: As the cruise control lever is moved forward it pivots and the rear of the hand lever rod slides rearward in the slot in the cruise control lever.Brake Spring . When the hand rod lever reaches the rear of the slot.

Intermediate Shaft Plate J .Friction Device B .Forward Pedal G .Pedal Control Arm E .Off Position B G A C E F D R N F R N F R N F H J K M99600 I A .Reverse Pedal F .Transaxle Control Rod K .POWER TRAIN .Cruise Control Lever (OFF) C .Hydrostatic Theory of Operation .379 .HYDROSTATIC THEORY OF OPERATION Cruise Control .Brake Pedal (OFF) H .Independent movement from cruise control lever D .Neutral Return Arm I .Transaxle Control Shaft Power Train .

Hand Control Operation: The hand control is an option. When the hand rod lever reaches the rear of the slot.Intermediate Shaft Plate . The friction device holds the cruise control lever in position. When installed.Forward Pedal . the hand lever rod is pushed forward.Transaxle Control Shaft Depressing the brake pedal will return the cruise control lever to the OFF position.Cruise Control Interlock Rod .POWER TRAIN . As the intermediate shaft plate rotates forward.Hand Lever Rod .HYDROSTATIC THEORY OF OPERATION Cruise Control . and the cruise control lever is moved farther forward.Friction Device . the cruise control interlock rod is pulled forward. IMPORTANT: Avoid damage! When cruise control is not in use. the transaxle control shaft is shifted into forward. and reverse speed of machine will be too slow.Pedal Control Arm . hand lever will restrict travel of reverse pedal linkage. or.Neutral Return Arm .Maximum Speed Position F A B 13° C E D R N F R N F R N F G J I M99601 H A B C D E F G H I J . Cruise control may be set by moving the cruise control lever forward until the ground speed of the machine is set. The hand lever rod pushes the top of the intermediate shaft plate forward and pivots the plate forward. Otherwise. the hand control replaces the forward and reverse foot pedal controls. When the brake pedal is depressed. Power Train . and the cruise control lever pivots to the neutral position. hand lever should returned manually to the OFF position. The transaxle control rod connects the intermediate shaft plate to the transaxle control shaft.380 .Hydrostatic Theory of Operation . Function: As the cruise control lever is moved forward it pivots and the rear of the hand lever rod slides rearward in the slot in the cruise control lever.Brake Pedal (OFF) .Cruise Control Lever (Maximum Forward) . the forward travel pedal may be depressed to attain the ground speed desired and then maintained by moving the cruise control lever forward.

Position of hand lever rod end .Hand Control Lever (Neutral) .HYDROSTATIC THEORY OF OPERATION Hand Control . the transaxle control shaft is shifted into forward.POWER TRAIN . As the intermediate shaft plate rotates forward. When the neutral arm rotates.Transaxle Control Shaft Power Train .Neutral B A C D E R N F RN F H F I M99603 G A B C D E F G H I .Brake Pedal (OFF) . When the hand control is moved to a reverse position. The friction device holds the cruise control lever in position.Neutral Return Arm . the transaxle control shaft is shifted into reverse.Hand Lever Rod . Hand Control . As the intermediate shaft plate rotates rearward.Neutral Function: The transaxle control rod connects the intermediate shaft plate to the transaxle control shaft. the hand lever plate rotates rearward and the hand lever rod pulls the top of the intermediate shaft plate rearward. The brake neutral return rod rotates the neutral return arm.381 .Transaxle Control Rod . rotating the hand control lever to the neutral position.Friction Device .Hydrostatic Theory of Operation .Intermediate Shaft Plate . the attached hand lever rod is pushed backward. When the brake pedal is depressed. the brake neutral return rod is pulled forward.

Hand Lever Rod .Transaxle Control Rod .382 .Intermediate Shaft Plate .Hand Control Lever (Forward) .Transaxle Control Shaft Power Train .Hand Lever Rod .HYDROSTATIC THEORY OF OPERATION Hand Control .Intermediate Shaft Plate .POWER TRAIN .Neutral Return Arm .Transaxle Control Shaft Hand Control .Transaxle Control Rod .Brake Pedal (OFF) E F G H .Forward D A B C N F RN F E H G F M99604 A B C D .Reverse B D A C R N F R N F G H E F M99605 A B C D .Hand Control Lever (Reverse) .Friction Device .Neutral Return Arm .Hydrostatic Theory of Operation .Friction Device .Brake Pedal (OFF) E F G H .

Eccentric (Neutral Adjustment) .Differential Assembly .Pump Rotating Group .Fixed Displacement Swash Plate .Neutral Return Spring .Motor Rotating Group .POWER TRAIN .Hydrostatic Theory of Operation .Motor Output Shaft .Brake Disk .Pump Input Shaft .Filter .Spring .Filter .Directional Control Arm .Variable Displacement Swash Plate .Charge Pump .Ring Gear .Reduction Gear J K L M N O P Q R .Freewheel Lever Power Train .383 .HYDROSTATIC THEORY OF OPERATION Hydrostatic System Operation B C A D E F R G Q H P O I N J M L K MIF A B C D E F G H I .

This bearing acts as a fixed angle swash plate. As system loads increase (climbing a hill for example) oil pressure between the pump and motor increases to meet system needs. When the swash plate is at an angle. Springs inside the pistons force them against the swash plate. As the oil fills the cylinder bore. it no longer adds to the rotary motion of the motor. As the motor continues to rotate. As the pistons are forced back into their bores by the angle of the swash plate. oil is drawn into the cylinders. The pump rotating group is composed of an axial piston pump and a swash plate which provides variable pump displacement. and back to the inlet port of the pump. both directional check valves are closed. the rotary motion is continued. This is due to normal leakage (which provides lubrication). It also provides infinitely variable speed control and the capability of forward or reverse directional travel of the machine. The motor rotating group is splined to the output shaft.Hydrostatic Theory of Operation . through the center case. the pistons are forced in and out of the pump body as the cylinder block turns. The charge pump is composed of a Gerotor pump that draws pressure-free oil from the reservoir through the filter and supplies oil to the pump rotating group. oil lost from the system must be replenished. the swash plate tilts to the forward position. As the pump continues to rotate. by the charge pump. This is known as the low pressure side. Power Train . Since the pump/motor operate in a closed loop system. causing the motor to rotate as the piston follows the angle of the fixed swash plate. the pistons pass from the high pressure port to the low pressure port. The oil path from the pump to the motor (high pressure side) and from the motor back to the pump (low pressure side) switch when the transmission is shifted from forward drive to reverse drive. Since high pressure oil is no longer supplied to the piston. The pump rotating group provides oil under pressure to the motor rotating group. or may be caused by component wear. The motor rotating group is composed of an axial piston motor and an angled bearing housing which provides fixed motor displacement. This rotary motion of the motor output shaft is the beginning of the gear power flow. As the motor rotates. displacing oil. since the pistons next in line to it are now filling with oil. and no oil is displaced. through the filter. the swash plate is held parallel to the pump pistons and cylinder block. the swash plate angle forces the pistons back into their bores. Because there is no demand for oil in the pump. This is known as the high pressure side. As the pistons follow the angled swash plate and move outward in their bores. Because of this.384 .HYDROSTATIC THEORY OF OPERATION Hydrostatic System Operation Function: The hydrostatic system provides a means of transferring power from the input sheave to the gear drive components of the transaxle. Any additional oil required by the system is drawn from the sump. and oil is displaced through ports in the center case. Pressurized oil from the pump forces the forward check valve closed and supplies high pressure oil to the motor rotating group. Oil enters the motor cylinder block through the C-shaped pressure port in the center case.POWER TRAIN . the piston follows the fixed angle swash plate until it is no longer aligned with the pressure port of the center case. The pump input shaft is splined to the pump rotating group and the charge pump. The rotating group of the motor presses against a thrust bearing which is held at a fixed angle in a housing. the pistons in the pump do not move in and out in their bores as the pump rotates. oil is forced out of the piston bores. But. The motor converts hydraulic energy into rotary motion. A certain amount of oil is lost from the pump and motor rotating groups. Theory of Operation: As the input sheave is rotated by the traction drive belt. Neutral: When the directional control arm is in the neutral position. Charge pressure is controlled by the spring holding the charge pump housing on the center case. the piston is forced out. causing the motor to rotate in the opposite direction. This port is located so that high pressure oil enters the cylinder bore at the bottom of the piston stroke. which is output through the motor output shaft. and the machine remains stationary. Forward: As the directional control arm is moved to the forward position. It rotates the pump input shaft. The charge pump keeps a constant pressure and volume of oil supplied to the piston pump.

This causes the reverse check valve to close and supply high pressure oil to the opposite side of the motor rotating group.HYDROSTATIC THEORY OF OPERATION Reverse: The operation in reverse is the same as in forward. They also provide a means of making turns with differential action for smooth operation. and transfer power directly out to the drive wheels. The only difference being that the swash plate is tilted in the opposite direction. pushing a pin (C) against a thrust washer (D) on the motor cylinder block (E). When in reverse. thus causing oil flow through the center case in the opposite direction. allowing high pressure oil to return directly to the reservoir without entering the motor cylinder bores and pistons (G). The forward check valve will open to sump. This causes the output shaft to rotate in the opposite direction. are splined to the axle shafts (I).POWER TRAIN . The output shaft gear meshes with the reduction gear (D) which drives the reduction shaft (E). Power from the motor is transferred to the output shaft. This moves the cylinder block away from the center case (F).Hydrostatic Theory of Operation . When the freewheel lever (A) is engaged.385 . Power is transferred from the ring gear to the differential pinion shaft and differential pinion gears (G). Theory of Operation: The output shaft (A) and output shaft gear (B) are splined to the hydrostatic motor (C). the reverse check valve is closed due to high pressure oil forcing it against the seat. The differential bevel gears (H). Power Train . Freewheel: F Gear Power Flow G I H I E A D B C B A M95571 Function: C D F E G MIF The gear components transfer power from the hydrostatic transaxle motor to the drive axles and wheels. the freewheel shaft (B) turns. The reduction shaft drives the differential ring gear (F). and results in reverse travel of the machine.

Theory of Operation: The transaxle brake is an internal wet disk brake. which moves four angled ramps against four captive steel balls (C). stops machine travel.386 . the brake linkage rotates the brake arm (A). The brake disk is splined to the hydrostatic motor output shaft. and in turn the inner brake shoe (E). in turn. the balls and ramps force the shaft against the brake disk (D). When the brake pedal is depressed.POWER TRAIN . Power Train . The brake arm rotates the brake shaft (B).HYDROSTATIC THEORY OF OPERATION Transaxle Brake A E D B C M95066 Function: The transaxle brake stops the rotation of the transaxle motor shaft. As the shaft rotates. This.Hydrostatic Theory of Operation .

See “Traction Drive Belt Removal and Installation” on page 442. replace faulty or damaged components.Release park brake. (7) Are the brake rod and lever damaged or binding? Yes . not plugged? Yes .Replace sheaves or keys. replace damaged components.Go to next step.Adjust brake linkage. (4) Is the traction belt worn.Go to next step. No . See “Traction Drive Belt Tensioner Assembly” on page 444. Park brake UNLOCKED.Eliminate binding and/or replace damaged components.Go to next step. (6) Is the brake linkage properly adjusted? Yes .Go to next step.Fill reservoir to correct level with specified oil. (3) Is the freewheeling lever disengaged? Yes . No .387 .Check belt tensioning. No . (15) Hydrostatic oil filter is free of debris.Disengage freewheeling lever. No .Replace shock absorber.HYDROSTATIC DIAGNOSTICS Diagnostics Machine Will Not Move Forward or Reverse Test Conditions: • • • • Machine parked on level surface.Go to next step. (13) Idler arm assembly pivots freely. No .Go to next step. and are the keys or keyways damaged? Yes .POWER TRAIN . No . (12) Is the cruise control linkage binding or damaged? Yes .Go to next step.Go to next step. Transaxle in NEUTRAL. replace faulty or damaged components.Hydrostatic Diagnostics . glazed or stretched? Yes . frayed. NOTE: Steps 15 through 22 require removal of transaxle from machine. No . Power Train . No .Eliminate binding. No . no wear in bearing? Yes .Go to next step. No .Lubricate and/or replace assembly. (9) Are the control arm and spring pin intact and present? Yes . No . (16) Freewheel linkage components move freely and are not damaged? Yes .Replace filter. (11) Are the engine and transaxle drive sheaves intact. (14) Belt idler assembly tension spring maintains tension on belt? Yes .Go to next step. (10) Is the shock absorber binding or damaged? Yes .Replace traction belt.Go to next step. (5) Is the traction belt properly tensioned? Yes .Go to next step.Go to next step.Go to next step. See “Transaxle Disassembly” on page 414.Replace control arm and/or spring pin. See “Control Pedals and Linkage” on page 445. No . No .Replace tensioning spring. No . Key switch in STOP position. Symptom: Machine Will Not Move Forward or Reverse (8) Does the forward/reverse pedal linkage move freely? Yes . See “Brake Linkage Adjustment” on page 408.Eliminate binding. No . Symptom: Machine Will Not Move Forward or Reverse (1) Hydrostatic transaxle oil to full mark? Yes . (2) Is the park brake set? Yes .Go to next step.Eliminate binding.

Hydrostatic Diagnostics . (20) Final pinion and ring gear not damaged or worn? Yes . No . Power Train . See “Transaxle Disassembly” on page 414. positively engaged in pump? Yes .Go to next step. or scoring on pistons? Yes . (22) Axle shafts not damaged? No .Go to next step. See “Transaxle Disassembly” on page 414.Correct engagement or replace shaft.Go to next step. No . No .Replace axle shafts. Yes .HYDROSTATIC DIAGNOSTICS Symptom: Machine Will Not Move Forward or Reverse (17) Input pump shaft splines are not worm or damaged. (21) Differential gears not damaged. See “Transaxle Disassembly” on page 414.388 . See “Transaxle Disassembly” on page 414.Replace shaft. No .Replace gears.Go to next step. Yes . No . (19) Motor shaft with gear not damaged or worn.Replace rotating groups and center case.POWER TRAIN . See “Transaxle Disassembly” on page 414. See “Transaxle Disassembly” on page 414. (18) Pump/motor rotating groups not scoring on case/cylinder block mating surfaces.Go to next step.Replace damaged or worn components.

Hydrostatic Diagnostics . M99578.HYDROSTATIC DIAGNOSTICS 11 4 5 3 1 12 3 7 6 9 8 10 M99575.389 .POWER TRAIN . MIF Power Train .

Hydrostatic Diagnostics .HYDROSTATIC DIAGNOSTICS 14 13 4 17 18 20 21 16 22 18 19 15 M95492.POWER TRAIN .390 . MIF Power Train .

(6) Pump/motor rotating groups not scoring on case/cylinder block mating surfaces. No . not plugged? Yes . See “Transaxle Disassembly” on page 414. free up valves or replace valves.Replace filter.Adjust brake linkage. Drain transaxle and fill to correct level with specified oil. See “Brake Linkage Adjustment” on page 408. No .POWER TRAIN . No .Go to next step. No . See “Hydrostatic Transaxle Bleeding Procedure” on page 405. or scoring on pistons? Yes .Clean. No . brake rod and lever not damaged or binding? Yes . clean and not foamy? Yes .HYDROSTATIC DIAGNOSTICS Noisy Operation Test Conditions: • • • • Machine parked on level surface.Go to next step. Transaxle in NEUTRAL. Eliminate binding and/or replace damaged components. Bleed air from system.Hydrostatic Diagnostics . Symptom: Noisy Operation (1) Hydrostatic reservoir oil at full mark.Eliminate binding and/or replace damaged components.Fill reservoir to correct level. No .Replace damaged or worn components. (4) Freewheel linkage and lever move freely and are not damaged? Yes .Release park brake. No . Power Train .391 . See “Transaxle Disassembly” on page 414. (3) Brake linkage adjusted properly. (2) Park brake released? Yes .Go to next step.Go to next step. Symptom: Noisy Operation (7) Check valve spools move freely. No . Park brake UNLOCKED.Go to next step.Go to next step.Replace rotating groups and center case. (8) Final pinion and ring gear not damaged or worn? Yes . Key switch in STOP position.Go to next step. components not damaged? Yes . NOTE: Steps 5 through 8 require removal of transaxle from machine. See “Transaxle Disassembly” on page 414.Go to next step. (5) Hydrostatic oil filter is free of debris. at operating temperature.

MIF Power Train .HYDROSTATIC DIAGNOSTICS 4 1 7 4 6 4 6 5 M99575.392 .POWER TRAIN .Hydrostatic Diagnostics .

(8) Swash plate and control lever not bent or worn? Yes .Go to next step.Go to next step.Replace damaged or worn components. No . transaxle case bearings not worn or damaged.Replace control arm and/or spring pin.POWER TRAIN . NOTE: Steps 8 through 9 require removal of transaxle from machine. (4) Are the control arm and spring pin intact and present? Yes . and thrust washers nor binding? Yes . No .Go to next step. No . See “Transaxle Disassembly” on page 414. See “Forward and Reverse Pedal Height Adjustment” on page 407. See “Control Pedals and Linkage” on page 445. No .Go to next step. No . (6) Is the neutral eccentric properly adjusted for no wheel movement at fast idle? Yes . See “Neutral Creep Adjustment” on page 405.Fill reservoir to correct level with specified oil.Go to next step.Go to next step.Replace damaged or worn components.Go to next step.Go to next step. replace faulty or damaged components.Adjust linkage. See “Transaxle Disassembly” on page 414. No . Symptom: Machine Creeps No .Hydrostatic Diagnostics . (2) Is the forward/reverse pedal linkage properly adjusted? Yes . See “Transaxle Disassembly” on page 414. (5) Is the shock absorber binding or damaged? Yes . (9) Neutral return spring returns swash plate to neutral when forward/reverse pedals are released? No .HYDROSTATIC DIAGNOSTICS Machine Creeps Test Conditions: • • • • Machine parked on level surface. Transaxle in NEUTRAL. (3) Does the forward/reverse pedal linkage move freely? Yes .Replace damaged or worn components. Key switch in STOP position.Replace shock absorber.393 . (7) Variable position swash plate shaft ends. Park brake UNLOCKED.Adjust neutral eccentric. 1 M99575 Power Train .Eliminate binding. Symptom: Machine Creeps (1) Hydrostatic transaxle oil to full mark? Yes . No .

394 .POWER TRAIN .HYDROSTATIC DIAGNOSTICS 3 2 4 5 M99578.Hydrostatic Diagnostics . MIF 8 7 6 9 MIF Power Train .

(2) Does the forward/reverse pedal linkage move freely? 5 1 2 4 3 1 2 M99578. not stuck in open position? No . Park brake UNLOCKED. NOTE: Step 5 requires removal of transaxle from machine. Key switch in STOP position. No .Replace shock absorber. MIF Power Train . See “Transaxle Disassembly” on page 414. Symptom: Machine Moves In One Direction Only (1) Is the forward/reverse pedal linkage properly adjusted? Yes . free up valve or replace valve. replace faulty or damaged components.Go to next step. No .Replace control arm and/or spring pin. See “Forward and Reverse Pedal Height Adjustment” on page 407. Symptom: Machine Moves In One Direction Only Yes . (3) Is the shock absorber binding or damaged? Yes .HYDROSTATIC DIAGNOSTICS Machine Moves In One Direction Only Test Conditions: • • • • Machine parked on level surface.Go to next step. No . (5) Reverse check valve moves freely.395 . See “Control Pedals and Linkage” on page 445.Go to next step.Adjust linkage.Hydrostatic Diagnostics . (4) Is the control arm free of damage? Yes .Clean.Go to next step.POWER TRAIN .Eliminate binding. Transaxle in NEUTRAL. No .

No .Go to next step. No .Go to next step. at operating temperature. (4) Brake linkage adjusted properly. Transaxle in NEUTRAL.POWER TRAIN . See “Traction Drive Belt Tensioner Assembly” on page 444.HYDROSTATIC DIAGNOSTICS Erratic Speed Test Conditions: • • • • Machine parked on level surface. No . Bleed air from system. See “Hydrostatic Transaxle Bleeding Procedure” on page 405. 1 2 3 M99575 Power Train . (2) Is the traction belt worn. See “Transaxle Disassembly” on page 414. Symptom: Erratic Speed (1) Hydrostatic reservoir oil at full mark.Go to next step.Go to next step.Go to next step. Symptom: Erratic Speed (7) Motor shaft with gear not damaged or worn.Replace damaged or worn components. Park brake UNLOCKED.Replace filter. (8) Final pinion and ring gear not damaged or worn? Yes . No . Key switch in STOP position. NOTE: Steps 5 through 8 require removal of transaxle from machine.Go to next step. or scoring on pistons? Yes . Eliminate binding and/or replace damaged components. No .Go to next step. No . (3) Is the traction belt properly tensioned? Yes .396 .Replace shaft. See “Traction Drive Belt Removal and Installation” on page 442. brake rod and lever not damaged or binding? Yes .Fill reservoir to correct level. (5) Hydrostatic oil filter is free of debris.Replace traction belt. glazed or stretched? Yes . No .Check belt tensioning. No .Go to next step.Hydrostatic Diagnostics . (6) Pump/motor rotating groups not scoring on case/cylinder block mating surfaces. clean and not foamy? Yes . frayed.Adjust brake linkage. See “Transaxle Disassembly” on page 414. not plugged? Yes . Drain transaxle and fill to correct level with specified oil. Yes .Replace rotating groups and center case. See “Brake Linkage Adjustment” on page 408. See “Transaxle Disassembly” on page 414.

MIF Yes . No . (3) Hydrostatic reservoir oil at full mark. (4) Is the traction belt worn. No . See “Transaxle Disassembly” on page 414. Drain transaxle and fill to correct level with specified oil. See “Traction Drive Belt Removal and Installation” on page 442. (5) Is the traction belt properly tensioned? Yes . See “Hydrostatic Transaxle Bleeding Procedure” on page 405. 6 8 No . clean and not foamy? Yes . • NOTE: Steps 12 through 15 require removal of transaxle from machine. Symptom: Machine Does Not Achieve Full Ground Speed (1) Transaxle free of debris? Yes .Release park brake. Park brake UNLOCKED. Power Train .Check belt tensioning. MIF No . (6) Is the park brake set? Yes . 5 (7) Swash plate and control lever not bent or worn? Yes . at operating temperature. 6 7 No .Go to next step. No .Replace cooling fan.Go to next step.Replace damaged or worn components.Go to next step.Hydrostatic Diagnostics .Fill reservoir to correct level.HYDROSTATIC DIAGNOSTICS Machine Does Not Achieve Full Ground Speed Test Conditions: • • • 4 Machine parked on level surface. See “Traction Drive Belt Tensioner Assembly” on page 444.Replace traction belt.POWER TRAIN .Go to next step.Go to next step. (2) Cooling fan not damaged. 4 No .Remove debris from transaxle. frayed.Go to next step. glazed or stretched? Yes . Bleed air from system.Go to next step.397 . Transaxle in NEUTRAL. Key switch in STOP position.

(11) Is the shock absorber binding or damaged? Yes . See “Forward and Reverse Pedal Height Adjustment” on page 407.Go to next step. (14) Freewheel linkage and lever move freely and are not damaged? Yes .Go to next step.Go to next step. See “Control Pedals and Linkage” on page 445. (10) Does the forward/reverse pedal linkage move freely? Yes . See “Brake Linkage Adjustment” on page 408. replace faulty or damaged components.Clean. Eliminate binding and/or replace damaged components.Eliminate binding.Go to next step.Hydrostatic Diagnostics .398 . No .Go to next step.Eliminate binding and/or replace damaged components. (13) Pump/motor rotating groups not scoring on case/cylinder block mating surfaces.Adjust brake linkage.HYDROSTATIC DIAGNOSTICS Symptom: Machine Does Not Achieve Full Ground Speed (8) Brake linkage adjusted properly.Replace shock absorber. No . or scoring on pistons? Yes . brake rod and lever not damaged or binding? Yes . No .Go to next step. No . not plugged? Yes .Replace rotating groups and center case.Go to next step. No . No .Replace filter. No . (9) Is the forward/reverse pedal linkage properly adjusted? Yes . (12) Hydrostatic oil filter is free of debris. free up valves or replace valves. See “Transaxle Disassembly” on page 414.Adjust linkage.Go to next step. M95586 1 8 Power Train . See “Transaxle Disassembly” on page 414. No .POWER TRAIN . (15) Check valve spools move freely. components not damaged? Yes .

Hydrostatic Diagnostics .399 . MIF Power Train .POWER TRAIN .HYDROSTATIC DIAGNOSTICS 2 4 5 M95482 14 7 11 8 6 14 13 9 8 15 14 9 13 12 M99578.

No .Eliminate binding and/or replace damaged components. NOTE: Steps 12 through 15 require removal of transaxle from machine. Yes . Yes .Replace damaged or worn components. See “Transaxle Disassembly” on page 414. No .Replace damaged or worn components.Go to next step. (8) Axle shafts not damaged? No . Power Train .POWER TRAIN . See “Transaxle Disassembly” on page 414. Transaxle in NEUTRAL. Symptom: Park Brake Does Not Hold Machine On Hill Yes . Symptom: Park Brake Does Not Hold Machine On Hill (1) Brake pedal and linkage are not damaged. Park brake UNLOCKED. See “Transaxle Disassembly” on page 414. worn.Replace gears. or binding? Yes . worn.Eliminate binding and/or replace damaged components.Go to next step. worn. or binding? Yes . Key switch in STOP position. See “Transaxle Disassembly” on page 414. (5) Reduction shaft and gear not worn or damaged. (2) Park brake lever and linkage are not damaged. No .Hydrostatic Diagnostics . See “Transaxle Disassembly” on page 414.See “Transaxle Disassembly” on page 414.400 .Replace shaft.Go to next step. (7) Differential gears not damaged.Go to next step.HYDROSTATIC DIAGNOSTICS Park Brake Does Not Hold Machine On Hill Test Conditions: • • • • Machine parked on level surface. or binding? Yes .Replace axle shafts. (4) Motor shaft with gear not damaged or worn.Go to next step. No . No .Go to next step. No .Eliminate binding and/or replace damaged components. No .Go to next step. shoe and brake assembly are not damaged. (3) Brake disk. (6) Final pinion and ring gear not damaged or worn? Yes .

MIF Power Train .Hydrostatic Diagnostics .401 .HYDROSTATIC DIAGNOSTICS 2 1 1 3 3 8 4 4 3 M99581.POWER TRAIN .

Go to next step. (5) Does the brake switch have continuity with park brake locked? Yes . See “Brake Linkage Adjustment” on page 408. Eliminate binding and/or replace damaged components. (3) Does the forward/reverse pedal linkage move freely? Yes . No .Go to next step.Adjust brake linkage.POWER TRAIN . (4) Brake linkage adjusted properly. No . No . Key switch in STOP position. See “Brake Switch Test” in the Electrical section.Hydrostatic Diagnostics .HYDROSTATIC DIAGNOSTICS Brake Switch Will Not Engage Test Conditions: • • • • Machine parked on level surface. brake rod and lever not damaged or binding? Yes .Go to next step.Replace shock absorber.Go to next step. Symptom: Brake Switch Will Not Engage (1) Transaxle free of debris? Yes . Transaxle in NEUTRAL. (6) Is the shock absorber binding or damaged? Yes .Test brake switch. Replace switch as needed. See “Forward and Reverse Pedal Height Adjustment” on page 407. No . Park brake UNLOCKED.Go to next step. See “Control Pedals and Linkage” on page 445.Eliminate binding. Power Train .Adjust linkage. replace faulty or damaged components. (2) Is the forward/reverse pedal linkage properly adjusted? Yes .402 . No .Remove debris from transaxle.

403 . M99582.POWER TRAIN . M99578.Hydrostatic Diagnostics . MIF Power Train .HYDROSTATIC DIAGNOSTICS 1 6 4 5 2 3 4 M95586.

Symptom: Cruise Control Does Not Maintain Ground Speed (1) Cruise control lever and linkage move freely.POWER TRAIN . No . (4) Brake linkage adjusted properly. NOTE: Steps 12 through 15 require removal of transaxle from machine. No . See “Control Pedals and Linkage” on page 445.Eliminate binding. replace faulty or damaged components as needed.Hydrostatic Diagnostics .Go to next step.Adjust brake linkage. Park brake UNLOCKED.Adjust linkage. not damaged. No .Eliminate binding. See “Brake Linkage Adjustment” on page 408. Transaxle in NEUTRAL. Symptom: Cruise Control Does Not Maintain Ground Speed (2) Is the forward/reverse pedal linkage properly adjusted? Yes .Go to next step. replace faulty or damaged components. Adjust lever tension 1 3 2 2 3 2 MIF Power Train .Go to next step.Go to next step. and maintain position when set? Yes . See “Forward and Reverse Pedal Height Adjustment” on page 407. brake rod and lever not damaged or binding? Yes . No .HYDROSTATIC DIAGNOSTICS Cruise Control Does Not Maintain Ground Speed Test Conditions: • • • • Machine parked on level surface. Eliminate binding and/or replace damaged components. Key switch in STOP position.404 . (3) Does the forward/reverse pedal linkage move freely? Yes .

2. 2. Alternately depress the forward and reverse pedals. Power Train . If necessary. 1. or park brake is set? Yes . Lock park brake. Turn off engine and lower the machine to the ground. See “Neutral Return Arm Bearing Adjustment” on page 408. Procedure: 1. parking brake released. fill to proper level with John Deere Low Viscosity HY-GARD™ or an equivalent (J20D) transmission oil. c CAUTION:coolinginjury! Keep hands away from Avoid transaxle fan and wheels during procedure to avoid injury.Adjust neutral return arm bearing. Key switch in RUN position. 6. 1 3. Start and run the engine at FAST idle.Hydrostatic Tests and Adjustments . Start and run engine at SLOW idle. Turn key switch to STOP position. Results: • Machine moves without hesitation when forward or reverse pedals are depressed. 3. Transaxle in NEUTRAL. Tests and Adjustments Hydrostatic Transaxle Bleeding Procedure Reason: This procedure is performed to eliminate air from the hydrostatic transaxle after repair or leakage of the transaxle.POWER TRAIN . If necessary. Continue this procedure until the rear wheels rotate both forward and reverse. Check hydrostatic transaxle oil reservoir oil level. Park machine on level surface. fill to correct level with John Deere Low Viscosity HY-GARD™ or an equivalent (J20D) transmission oil. Move forward/reverse pedals to NEUTRAL position. Alternately depress and release the forward and reverse pedals until the machine moves without hesitation. Neutral Creep Adjustment Reason: If the machine creeps forward or backward with the forward/reverse pedals in the neutral position. Check transaxle oil reservoir oil level.405 . Support rear axles with jack stands. M95586 7. Procedure: Symptom: Transaxle Whines When Brake Is Used (1) Transaxle whines when brake is used. Park brake LOCKED. the neutral eccentric must be adjusted.HYDROSTATIC TESTS AND ADJUSTMENTS Transaxle Whines When Brake Is Used Test Conditions: • • • • Machine on level surface. 5. and the engine running. Raise rear wheels off the ground. 4.

5. c CAUTION:coolinginjury! Keep hands away from Avoid transaxle fan and wheels during procedure to avoid injury.Turn the eccentric shaft slowly clockwise until the mark on the eccentric shaft is approximately 1/3 the distance between the forward and reverse stop positions as shown. see steps 15 17. Place a mark (B) on the end of the eccentric shaft (A) as shown to indicate position. This is the forward stop position. 11. NOTE: The eccentric shaft (A) is located on the right side of the transaxle above and forward of the right hand axle 10.Turn the eccentric shaft clockwise until the axle shaft(s) stops rotating.Turn the eccentric shaft slowly counterclockwise until the axle shaft(s) rotates forward. Place a mark on the transaxle case (E). 6. 15.POWER TRAIN . Start and run engine at FAST idle. 12. This is the forward stop position. Place blocks in front of and behind front wheels. Lift rear of machine until wheels are off the ground. 18. Support on suitable stands. 8. 1/3 D 1/3 F 1/3 E 19.HYDROSTATIC TESTS AND ADJUSTMENTS 4.Hold eccentric shaft with wrench and tighten locknut. 17.Place a mark on the end of the eccentric shaft (B) as shown to indicate position. Remove right hand rear wheel. NOTE: If the axle shafts do not rotate in reverse although the eccentric shaft has been turned one full turn. 14.Turn eccentric shaft clockwise until the axle shaft stops.Hydrostatic Tests and Adjustments . NOTE: If axle shafts do not rotate in reverse after turning the eccentric shaft one full turn.Turn the eccentric shaft slowly counterclockwise until the axle shaft(s) stops rotating. This is the neutral position (F). See “Mower Deck Removal and Installation” for the appropriate mower deck in the Attachments section. F A C B MIF 8° E 16.Loosen locknut (C) and turn the eccentric shaft clockwise until the axle shaft(s) rotates in reverse. Power Train . Place a mark (E) on the transaxle case. 20.Hold eccentric shaft with wrench and tighten locknut. MIF 9.Turn eccentric shaft (A) counterclockwise until axle shaft(s) rotate forward. Place a mark on the transaxle case (D). Remove mower deck. adjust neutral as follows: A M95485 A C B 7.406 . This is the reverse stop position.Turn the eccentric shaft clockwise approximately 8× from the forward stop position (F). 13. This will be the neutral position.

± 0. Turn ball joint rod end (H) on end of control rod: • • Lengthen the rod to raise the reverse pedal. This also ensures that the transaxle swash plate and control arm will not act as a mechanical stop for the pedal linkage. adjust foot pedal rod length: A E F D C H B F M99619 5. Align 6 mm alignment hole (B) in hand lever plate with 6 mm hole in frame side. Procedure: 1. Turn key switch to STOP position. Pull hand control lever (A) to rear most position.97 in. 3. E G D M95315 6. Correct reverse pedal height is 50 mm ± 2 mm (1. locate jam nut (D) on forward/reverse control rod (E). Press reverse pedal twice and allow to return to neutral. B 3. 8. 2.08 in. Repeat adjustment procedure until within specification. Press reverse pedal twice and allow pedals to return to NEUTRAL. Remove cotter pin and bushing (E) and disconnect hand lever rod from hand lever. 2.). Unlock park brake. Remove spring clip pin (F) and disconnect forward/ reverse control rod from intermediate shaft plate (G). 5.407 . Loosen jam nut. Reconnect control rod to control lever and retain with spring clip pin. If not within specification. C M99817 1. Insert a 6 mm drill bit through holes.Hydrostatic Tests and Adjustments . Power Train . 7. 4. Loosen jam nut (C) on hand lever rod (D). Park machine on level surface. 4. 2. 3. Check measurement. Proper tool mark location is where sheared steel edge intersects with round portion of pedal bracket. In front of right rear wheel. Measure reverse pedal height (B) from top of foot mat (C) to tooling mark on front edge of pedal bracket as shown.POWER TRAIN .HYDROSTATIC TESTS AND ADJUSTMENTS Forward and Reverse Pedal Height Adjustment Reason: To ensure full travel speeds can be reached in forward and reverse directions. Shorten the rod to lower the reverse pedal. Press reverse pedal (A) twice and allow pedal to return to neutral position. A Hand Lever Rod Adjustment 1.

Ball bearings should not move intermediate shaft. locate and loosen nut (A) on bearing end of neutral return arm (E). Turn key switch to STOP position. 8. This also ensures that the transaxle is not in forward or reverse when park brake is locked. 2. 4. Adjust ball bearings (B) back and forth by sliding carriage bolt in slot in neutral return arm.POWER TRAIN . Procedure: 1.Reconnect rod to hand lever. Inspect transmission brake arm and brake pedal and linkage. Park machine on level surface. MIF 6. Remove mower deck. Remove cotter pin and washer attaching brake rod to transmission brake arm. Loosen two jam nuts (A) and adjust length of brake rod (B) so that rod end fits into hole in transaxle brake arm (C). A A C E B D C B M99616 5. Release park brake and have an assistant depress the brake pedal several times. Park machine on level surface. 7. 5. Underneath machine. Tighten jam nuts. Position bearings so that they are centered in cam profile slot (D) in the intermediate shaft plate (C). Brake Linkage Adjustment 1. 6. Turn rod to adjust length so that centerline of rod end (E) is aligned with alignment mark (F) as shown. Install washer and cotter pin. Be sure that both transmission brake arm and brake pedal are in full rearward (OFF) positions. Neutral Return Arm Bearing Adjustment Reason: To ensure that brake pedal and neutral shaft do not engage forward or reverse when brake pedal is depressed. 7.408 . Power Train . See “Mower Deck Removal and Installation” For the appropriate mower deck in the Attachments section. 10. See “Mower Deck Removal and Installation” for the appropriate mower deck in the Attachments section. Lock park brake. 3. Move forward/reverse pedals or hand control to NEUTRAL position. 4. Disconnect brake rod from transmission brake arm. causing transaxle to whine.HYDROSTATIC TESTS AND ADJUSTMENTS 9. Remove mower deck. If ball bearings move intermediate shaft. 2. 3. Retain with bushing and cotter pin. Turn key switch to STOP position. repeat steps 5 and 6.Hydrostatic Tests and Adjustments .

Raise rear of machine and support on suitable stands. M96061 2. A NOTE: Capacity of the transaxle is approximately 4. 4.6 qt).HYDROSTATIC REPAIR Cruise/Hand Control Lever Tension Adjustment Purpose: To adjust friction mechanism that holds the cruise/hand control lever in position.turn nut clockwise Decrease tension . Locate adjusting nut in right rear wheel well.POWER TRAIN .turn nut counterclockwise X 3. Remove fender deck. Adjust tension so that lever can be easily moved in both forward and rearward direction. Lever should hold transmission linkage in any position set. 2. C A B M95314 Power Train .409 . Have a suitable container ready before removing drain plug. 4. M95337 5. rear of machine must be supported by the frame 3. Turn adjustment nut (A) to change cruise control lever tension: • • Increase tension . IMPORTANT: Avoid damage! During transaxle removal. Mechanism may require adjustment due to wear or operator preference. Remove drain plugs (X). See “Mower Deck Removal and Installation” for the appropriate mower deck in the Attachments section. Remove mower deck.Hydrostatic Repair .4 L (4. Repair Transaxle Removal and Installation Removal: 1. Drain transaxle oil into a suitable container. Procedure: 1. See “Fender Deck Removal And Installation” in Miscellaneous section. Remove rear wheels and tires.

Power Train . I c CAUTION: Avoid injury! Gasoline iswork in a extremely flammable.Lift input sheave (G) off top of transaxle. Using a pry bar (B). and slip belt off of flat idler (C). locate the traction drive belt tensioner sheave (A). H M95324 D 11. M95322 14.On left side of machine.POWER TRAIN .Hydrostatic Repair .Using a transmission jack. Remove sheave. Do not smoke. Lift and remove fuel tank from machine frame. E L K M95321 9. 8. 10. Push hydrostatic transaxle oil reservoir (D) rearward. and transaxle cooling fan (F). Slip belt off of sheave and move aside. Set fuel tank aside. and disconnect it from the fuel tank.410 . G 13. turn belt tensioner to relieve tension on belt. remove cap screw and nut (K) attaching transaxle to angle bracket (L). Wipe-up any spills IMMEDIATELY. including equipment that utilizes pilot lights. support transaxle. Always ventilated area away from open flame or spark producing equipment.HYDROSTATIC REPAIR 6. Remove locknut and washer (E). M95320 J 7.Disconnect neutral switch wiring harness connector (H). M95325 F 12. On underside of machine.Remove cotter pin (I) and disconnect freewheeling valve interlock rod (J) from lever on transaxle.

and nuts (Q). remove cotter pin and washer (U). Power Train .Lower transaxle and remove from frame. 17. M95327 18. washers. and washers and locknuts (Q).On right side of machine.Hydrostatic Repair .On left side of machine. and move into position beneath machine frame. Q S R M95326 T 3. M95328 19. remove cap screw (M). to retain transaxle to machine frame. remove cotter pin and washer (R).Lower transaxle slightly to allow access to cotter pins attaching linkages to transaxle. Raise transaxle into position so that linkages can be connected.HYDROSTATIC REPAIR P N V M W U O M95323 15.411 . 2. retaining transaxle to machine frame. P Installation: 1.Remove four cap screws (P).POWER TRAIN . and disconnect transaxle control rod (S) from control lever (T). spacer (N). M95326 P 16. Q NOTE: The two longer cap screws go in the left holes. and nut (O) attaching transaxle to angle bracket (P). Place transaxle on a transmission jack.On right side of machine. 20. Raise transaxle into position. and disconnect brake link (V) from control lever (W). and install four cap screws (P).

4. including equipment that utilizes pilot lights. On left side of machine. Wipe-up any spills IMMEDIATELY. Slip belt onto input sheave and install input sheave (G) to top of transaxle.412 . E J I M95321 9. spacer (N). Do not smoke.HYDROSTATIC REPAIR L K H M95324 M95322 7. 10. install cap screw (M). On right side of machine. Retain with cotter pin (I). P G N M O M95483 8. Power Train .Hydrostatic Repair . Connect freewheeling valve interlock rod (J) to lever on transaxle. Connect neutral switch wiring harness (H). 6.Install fuel tank to machine frame. M95323 F 5. install cap screw and locknut (K) to attach transaxle to angle bracket (L).POWER TRAIN . M95325 c CAUTION: Avoid injury! Gasoline iswork in a extremely flammable. Always ventilated area away from open flame or spark producing equipment. and locknut (O) to attach transaxle to angle bracket (P). Install transaxle cooling fan (F) and retain with washer and locknut (E).

.Perform transaxle bleeding procedure. .Start engine. locate the traction drive belt tensioner.Attach hydrostatic transaxle oil reservoir (D) to the fuel tank.Remove filler cap on reservoir bottle. Power Train . re-attach fuel hose tie down clamps. 19.Hydrostatic Repair . and a new O-ring to larger drain plug.) D 16. 17. . . . Torque Specification: Drain Plug (Small) . . X M95337 23.5 N•m (40 . This plug will fill the differential gear side. install and tighten filler cap. . turn belt tensioner assembly and slip belt onto flat idler.Raise rear of machine and remove stands. 15. 22.9 L (2 qt) of John Deere Low Viscosity HY-GARD™ or an equivalent (J20D) transmission oil.413 .) Drain Plug (Large) .4 L (2. When oil reaches FULL line on reservoir bottle. .Install rear wheels and tires.6 qt). 12.HYDROSTATIC REPAIR 11. unlock park brake and drive machine forward and backward.Remove fill plug (Y) on left side at rear of transaxle.Install a new seal washer to smaller drain plug.POWER TRAIN . Lightly coat seal washer and O-ring with clean transmission oil and install drain plugs (X) to transaxle case. Using a pry bar.4 L (4. Add approximately 1.Check for oil leaks. 21. . When oil is at bottom of threads in filler. .60 lb-in. Used or damaged O-rings and seals will leak. .6 qt) of John Deere Low Viscosity HY-GARD™ or an equivalent (J20D) transmission oil.On underside of machine.Route seat switch wiring harness in groove in fuel tank next to fuel hose. 20. Tighten to specification. install and tighten fill plug. See “Fender Deck Removal and Installation” in “Miscellaneous” section. 20 N•m (150 . 3 . A Y B M95314 M95484 14. The reservoir bottle tube will fill the hydrostatic transmission side. . See “Hydrostatic Transaxle Bleeding Procedure” on page 405. 24. M95320 13. NOTE: Total transaxle capacity is approximately 4. . .180 lb-in.Install fender deck. . . IMPORTANT: Avoid damage! Replace all O-rings and seals.If removed. Add approximately 2. . . 18.Lower machine to the ground.

Park machine on a level surface.POWER TRAIN . Remove two oil filters (C).HYDROSTATIC REPAIR 25. Remove transaxle from machine. 2.414 . If machine moves with engine running and hydrostatic control in neutral. Thoroughly clean outside surface of transaxle. 5. Remove magnet (D) from lower case half. Remove lower case half. 26. Remove spring (E) from top of pump.Hydrostatic Repair . 4. 27. Loosen hose clamp (A) and remove hydraulic oil reservoir (B).Install mower deck. See “Mower Deck Removal and Installation” for the appropriate mower deck in the Attachments section. M95336 3. perform neutral creep adjustment. Stop engine and check oil level in reservoir bottle. See “Transaxle Removal and Installation” on page 409. E A M95344 8. C Transaxle Disassembly Case Disassembly Procedure: 1. M95339 B 7. Remove 21 cap screws securing case halves. Add oil if needed to bring level up to FULL line. D M95338 6. Turn transaxle over and support it with blocks. Clean using a suitable solvent and a shop towel. See “Neutral Creep Adjustment” on page 405. Power Train .Start engine and release park brake.

and remove two bushings (K).HYDROSTATIC REPAIR Final Drive and Axle Removal Procedure: I F J M95342 1.POWER TRAIN . 4. M95347 G J M95345 2. M95346 3. Remove thrust washers (G) from left and right axles. Slide axles outward. Remove collar (J). Remove differential gear assembly (I). Remove C-ring (H) from left and right axles. 5.415 . Power Train . M95348 K H M95349 6. Remove reduction gear assembly (F) from case.Hydrostatic Repair . NOTE: To remove the C-rings. pull the axles slightly out of the case.

V P U M95355 14.POWER TRAIN .HYDROSTATIC REPAIR L M S R M95353 M95350 7.Inspect bearings for wear or damage. Replace parts as needed if clearance is greater than maximum allowed. Power Train .416 . T N O M95351 M95353 8.Remove snap rings (U) and bearings (V). Remove square keys (N) from grooves in end of shafts.Inspect bearing surfaces of axle shafts for wear or damage.Remove axle shafts. Remove snap rings and washers (O) from end of axle shafts.Remove thrust washers (Q) and wheel hubs (P). 16. 9. Slide axle shafts out of wheel hubs (L) and remove center caps (M) from ends of axles. Replace if needed.Hydrostatic Repair .Remove seals (T) from case. M95352 10.Remove tabbed hub washers (R) and tabbed washers (S). 13. Measure OD of both axle shafts. Q 15. 12. and ID of both bushings. 11.

.99 mm (0.995 . . . and bushing (AA) from reduction gear (AB). .999 in. .Inspect differential gear assembly for wear or damage.Measure ID of bushing and OD of bearing surfaces on pinion gear. . . or replace brake assembly as needed if clearance is greater than maximum allowed. .) Pinion Shaft OD .597 in.5 mm (0. . 0.005 in. Replace if needed. . . . . .020 in. Specifications: Reduction Pinion Gear ID . 19. . . .) Clearance (maximum) .0.) Clearance (maximum) . . . . . Remove brake shoe (D) from case. . .14.90 . . . . .) NOTE: Replace axle shaft seals with new seals when assembling transaxle.060 in. 0.1. .0.) Axle OD .05 . pinion gear (Z). . 1. . .5 mm (0. . .669 . 16. . . . Replace parts as needed if clearance is greater than maximum allowed. . . .25.17. . Remove shim(s). . . 25.HYDROSTATIC REPAIR Specifications: Bushing ID.38 .592 . . Specification: Pinion Gear ID.0. 15. Replace parts as needed. Replace bushing and/or pinion gear if clearance is greater than maximum allowed. Power Train .Measure ID of differential pinion gears (W) and OD of differential pinion shaft (X). . . 14. . .417 . . . . .16. .590 in. . .) Clearance (maximum) . .15.13 mm (0. .) D Z Y M95343 M95419 2. .672 in.0. Specifications Clearance (maximum) . . .020 in.0. measure clearance between brake rotor (B) and brake shoe (C). .020 in. .00 . . . 17. Using a feeler gauge (A).999 .589 . .06 mm (0.Hydrostatic Repair .665 .97 .98 mm (0. .Inspect components for wear or damage. . 18.25.Remove bearing (Y). .) Brake Removal Procedure: B W A X C M95476 M95356 17.5 mm (0. 25.668 in. . 20. . . .) AB AA 1. . .37 mm (0. . .52 mm (0. . . . 0. .POWER TRAIN . . . . . .) Reduction Shaft OD . .5 mm (0. . . .27 . 21.

Replace O-ring (I) in case. Use care when disassembling brake unit to prevent ball from being lost. Remove charge pump case (A).Remove four steel balls (M) from shaft.Inspect housing.Hydrostatic Repair . NOTE: Brake unit contains four steel balls. Remove shaft from housing (P). 5. and brake assembly. A M95357 1. Remove shims (H) and keep for possible use in reassembly. 10. 12. and lever arm for wear or damage. Remove spring (E) from end of brake assembly (F). M95460 Power Train . Remove lever arm (K) from shaft (L).HYDROSTATIC REPAIR H K L G N F P M E M95447 M95444 8. 9.POWER TRAIN . 4. Remove two cap screws (G).418 . balls. B J C M95446 7. Remove spring pin (J). 11. Charge Pump Removal Procedure: 3.Replace seal (N) in housing. Replace parts as needed. I M95451 6.

419 . Center Case Removal Procedure: IMPORTANT: Avoid damage! Before removing center case assembly. D E B F M95363 M95360 5. M95359 4. Press bearing housing (D) and cylinder block (E) against the center case (B) and remove as a single unit. M95362 E 1.HYDROSTATIC REPAIR 2. small pin and washer may fall out. D C A B M95358 3. Clean or replace parts as needed. Inspect check valve (B) in charge pump case (C). IMPORTANT: Avoid damage! When removing center case assembly. Check that ball is in valve cage and moves freely. lint-free cloth or surface. Set assembly on a clean.Hydrostatic Repair . Remove inner rotor (E). 2. be careful to avoid scratching or damaging contact surfaces of center case and cylinder blocks. Remove outer rotor (D). Remove three cap screws (A). Power Train . securing center case assembly (B) to transaxle case (C). Remove pin (F).POWER TRAIN . NOTE: When separating cylinder block from center case. note position and orientation of swash plate.

Inspect spring. 8. M95406 IMPORTANT: Avoid damage! Motor assembly pistons should be installed in same hole they were removed from. Do not remove all pistons at the same time. 5. Inspect cylinder block mating surface (K) for damage or scratches.POWER TRAIN . piston.Hydrostatic Repair . 4. replace center case and both cylinder blocks at the same time. Remove thrust plate (L). E L H M95404 6. Power Train . Separate cylinder block from center case. M95405 7. Slide cylinder block (E) off of motor shaft (H). Do not remove all pistons at the same time. and piston hole for wear or damage. IMPORTANT: Avoid damage! Motor assembly pistons should be installed in same hole they were removed from.420 . Remove bearing cage (M). Remove pin (F) from center case. M M95407 9. Remove washer (G) from end of motor shaft.HYDROSTATIC REPAIR E K F J I G M95364 3. Remove each piston (I) and spring (J) one at a time. NOTE: If any parts of the cylinder block assembly need to be replaced.

remove bearing (S) from shaft. M95414 Power Train . use care to prevent the pistons from falling out. 17. 14.Inspect motor shaft for discoloration. Replace if needed.Remove brake disk (N) and shaft (H) from bearing housing (D). Replace if needed. or damage.Inspect thrust plates and bearing for wear or damage. 16.Inspect bearing for wear or damage.HYDROSTATIC REPAIR D H N Q R M95409 10.Using a press or suitable puller. wear. 15. S D M95408 M95413 11.POWER TRAIN .421 .Hydrostatic Repair . N H M95410 12. NOTE: When removing the cylinder block.Remove brake disk (N) from end of motor shaft (H).Remove E-clip (Q) and gear (R). P M95411 13.Remove thrust plate (P) from bearing housing (D). Check that thrust plate and housing bearing contact surfaces are in good condition.

T 23.Inspect swash plate. replace center case and both cylinder blocks at the same time.422 . U V M95420 21.HYDROSTATIC REPAIR 18.Remove two plastic bushings (T) from upper case half. M95418 20. NOTE: Any pump piston may be installed in any cylinder block hole.POWER TRAIN . Power Train . pistons.Remove pistons and springs. Replace as needed. W X M95422 22. NOTE: If any parts of the cylinder block assembly need to be replaced. IMPORTANT: Avoid damage! Thrust plate bearing and piston contact surfaces must be assembled in same positions as they were removed. Mark thrust plate to ensure correct reassembly.Remove the cylinder block from upper case.Remove thicker thrust plate (U) and thrust bearing (V) from swash plate assembly. M95405 19.Remove thinner thrust plate (W) from swash plate assembly (X). and piston holes for wear or damage. Inspect cylinder block mating surface for damage or scratches.Hydrostatic Repair . Inspect springs. thrust bearing and thrust plates for wear or damage.

D M95427 E F 2.423 . 5.Hydrostatic Repair . remove seal (B). Replace if needed. 3. Remove E-clip (A) from end of pump shaft. Power Train . and disconnect shock absorber (H) from control arm (I). Remove E-clip (G).HYDROSTATIC REPAIR Pump Shaft Removal Procedure: Control Shaft Removal Procedure: I H A J G B M95424 1. K C M95425 2. Remove side cover and swash plate as an assembly. M95416 1. Remove seven cap screws (K) securing side cover to transaxle case.POWER TRAIN . Remove snap ring (C) retaining bearing to case. M95426 4. If needed. Remove spacer (J). Using a suitable puller. Remove pump shaft (D) and bearing (F) from case. replace bearing by removing snap ring (E) and using a press to remove bearing from shaft. 3. Inspect two dowel pins in side cover. Inspect bearing for wear or damage.

Remove eccentric from cover.POWER TRAIN . Remove two spring pins (Q) securing control arm (R) to control shaft (S) and remove arm. V M95431 P O 2. Replace parts as needed. and pivot screw (P) for wear or damage. Control Shaft Disassembly Procedure: M95433 3. Inspect swash plate (V) and spring (T) for damage. 4. and remove swash plate/shaft assembly (V). Power Train . Replace parts as needed.424 . Disconnect spring (T) from eccentric (U).HYDROSTATIC REPAIR L W T M U M95429 4. spring (O). and spring from cover (W) as an assembly. Remove nut (Y) and washer (Z) from eccentric (AA). X T M95430 V 5.Hydrostatic Repair . Remove thrust washer (X) from swash plate. Remove thrust washer (L) from swash plate (M). Inspect neutral switch actuator (N). Switch actuator should move freely without binding. or wear. AA Y R Q Z S M95428 M95434 1. 6. 5.

Replace O-rings (AB) for eccentric shaft and for swash plate control shaft. C C M95437 2.HYDROSTATIC REPAIR 7. Oil Filler Tube Removal Procedure: A B M95436 A 1.Hydrostatic Repair . replace shock absorber. Replace O-ring (C) on oil filler tube. wear. Inspect shock absorber boot (D) for cracking or damage.425 . Remove two cap screws (A) securing shock absorber bracket (B) to transaxle case. Inspect eccentric for wear or damage. Power Train . Replace if needed. or damage. Inspect shock absorber (C) for smooth operation. Shock Absorber Removal Procedure: C AB B M95435 8. Remove shock absorber (C) and bracket as an assembly.POWER TRAIN . Remove cap screw (A) and oil filler tube (B). D M95439 1. M95440 2. If needed.

remove snap ring (A) and spring (B).HYDROSTATIC REPAIR E C F M95442 G 2. If necessary. or come out with control shaft.426 . Remove two cap screws (G) securing shock absorber/ neutral switch bracket (H) to transaxle case. remove spring pin (D) and lever arm (E) from control shaft (F). On inside of case.POWER TRAIN . Remove freewheeling control shaft and lever arm (C) from transaxle case. B G A M95441 M95443 1. Freewheeling Control Shaft Removal Procedure: F M95445 3.Hydrostatic Repair . Remove cotter pin (E) and freewheeling control rod (F). Remove bracket. Power Train . 4. NOTE: Two O-rings (G) may remain in case. G D H E M95438 3.

F G M95455 M95452 4. E C M95459 2. B M95453 5. D M95454 6. replace center case. replace center case. Power Train . Inspect surfaces of valve for wear or scratches. and drive pump cylinders at the same time. Inspect spring (F) and spool (G) for proper operation. Inspect center case to charge pump mating surface (B). and drive pump cylinders at the same time.427 . Using a permanent marking pen. If scratches can be detected by feel (either finger nail or lead pencil). charge pump. mark one of the relief valves (E) for correct installation during assembly. charge pump. Replace parts as needed. 7.Hydrostatic Repair . motor. motor. Inspect spring pins (C).POWER TRAIN . If deep scoring or damage is present. Inspect center case to cylinder block mating surfaces (A). Remove valve assemblies (E) from center case. Remove plug (D) from center case. 3. Replace O-ring. Lubricate plug with clean transmission oil and reinstall. Replace if damaged or loose.HYDROSTATIC REPAIR Center Case Disassembly Procedure: E A M95457 1.

Lightly coat two new O-rings (G) with clean transaxle oil and install onto control shaft. On inside of case. install spring (B) and snap ring (A) to secure freewheeling control shaft to case. clean case half and control shaft cover mating surfaces to remove all traces of old sealant. Power Train . IMPORTANT: Avoid damage! Replace all O-rings and seals. Dry with compressed air. G D E F M95445 2. Used or damaged O-rings and seals will leak. and in good condition. A M95441 5. 4. Using a suitable solvent.POWER TRAIN . be sure all components are clean.428 . Remove two plugs (H) from center case.HYDROSTATIC REPAIR C H I M95456 M95442 8. Transaxle Assembly B IMPORTANT: Avoid damage! Before beginning assembly. assemble lever arm (E) and spring pin (D) to control shaft (F). If necessary. Replace Orings (I). Freewheeling Control Shaft Installation Procedure: 1. Lightly coat plugs and O-rings with clean transaxle oil and reinstall.Hydrostatic Repair . 3. Install freewheeling control shaft and lever arm into transaxle case.

. Power Train . 1. If removed. .19 lb-ft). Install shock absorber/neutral switch bracket (H) to transaxle case. . Retain with pin. Tighten cap screws to 20 . attach shock absorber (C) to bracket. Install a new O-ring (C) onto oil filler tube. 20 . IMPORTANT: Avoid damage! Replace all O-rings and seals. D C C M95437 M95440 3. Retain with two cap screws (G). . . washer and E-clip (D).HYDROSTATIC REPAIR Shock Absorber Installation Procedure: E C B F A G M95436 H M95438 4. .Hydrostatic Repair . Specifications: Cap Screw Torque . . Tighten cap screws to specification.19 lb-ft) Oil Filler Tube Installation Procedure: 1.26 N•m (14 . . Install shock absorber (C) and bracket (B) to transaxle case. 2.26 N•m (14 .429 . Install freewheeling control rod (F) and retain with cotter pin (E).POWER TRAIN . Retain with two cap screws (A). Used or damaged O-rings and seals will leak.

and slide swash plate (V) into cover until swash plate (V) and spring (T) are against thrust washer (W) and cover as shown. Install thrust washer (X) to swash plate.430 . M95431 AA Y 6. Dip eccentric (AA) in clean hydraulic oil. and install oil filler tube (B) to case.Hydrostatic Repair .HYDROSTATIC REPAIR B X A T V M95439 M95433 2. Retain with cap screw (A). install spring (T) to swash plate (V) as shown. and install swash plate assembly into cover. If removed. Power Train . Apply a thin film of clean hydraulic oil to end of swash plate control shaft. Retain with washer (Z) and nut (Y). Control Shaft Assembly Procedure: 3. V 1. lightly coat four new O-rings (AB) with a film of clean hydraulic oil and install into bores for eccentric and control shaft.POWER TRAIN . Used or damaged O-rings and seals will leak. Lightly coat O-ring with clean hydraulic oil. W T AB U M95435 IMPORTANT: Avoid damage! Replace all O-rings and seals. 5. Z M95434 2. Turn eccentric (U) to position shown. If not already done. 4. and install into cover. Slip spring ends over eccentric.

I M J H G M95429 1. Install spacer (J) onto pin on control arm (I). Retain with seven cap screws (K). Apply a bead of sealant to mating surface of cover.431 . Power Train . Install swash plate and cover into case as an assembly. Attach shock absorber (H) to pin and retain with E-clip (G). M95416 4. 2. Install thrust washer (L) to shaft end of swash plate (M).POWER TRAIN . Control Shaft Installation Procedure: L M95427 3.HYDROSTATIC REPAIR K Q R S M95428 7.Hydrostatic Repair . Install outer and inner spring pins (Q) to retain control arm to shaft. Apply a thin film of clean hydraulic oil to shaft end of swash plate. Install control arm (R) to control shaft (S).

IMPORTANT: Avoid damage! Replace all O-rings and seals. Apply a thin film of oil to lip and outside edges of a new seal. NOTE: Valve with small hole goes toward pump side of center case. coat all parts with clean fresh oil. M95453 IMPORTANT: Avoid damage! Be sure valves are installed into holes as marked during disassembly. If removed. If removed. and install plug (D) into center case. Used or damaged O-rings and seals will leak. M95452 2.Hydrostatic Repair . A D B M95424 3. IMPORTANT: Avoid damage! Replace all O-rings and seals. and install seal (B) into case and over pump shaft. Install E-clip (A) onto pump shaft. Used or damaged O-rings and seals will leak. Install internal snap ring (C) into case to retain bearing and pump shaft. install bearing (F) to pump shaft (D) and retain with snap ring (E). M95462 1. Install a new O-ring onto plug. and install pump shaft and bearing into case. E E F M95426 1.432 .POWER TRAIN . Power Train . C M95425 2. install valve assemblies into center case. Apply a thin film of grease to outside of bearing.HYDROSTATIC REPAIR Pump Shaft Installation Procedure: D Center Case Assembly Procedure: NOTE: During assembly. 4.

V M95420 NOTE: When installing the cylinder block. T W M95418 4. Power Train . 7.433 .Hydrostatic Repair . X NOTE: Any piston may be installed in any hole in the pump cylinder block. Install thrust bearing (V) against thin thrust plate and into swash plate assembly. Apply a thin film of clean hydraulic oil to the mating surface of the cylinder block. install 2 plastic bushings (T) into upper case half. Install thick thrust plate (U) against thrust bearing and into swash plate assembly. 2. M95422 1. 3. Apply a thin film of clean hydraulic oil to surfaces of swash plate (X) and thin thrust plate (W). Dip each spring and piston in clean hydraulic oil. and install springs and pistons into cylinder block. Install thrust plate into swash plate assembly. IMPORTANT: Avoid damage! Be sure thick thrust plate is installed with the same side against the thrust bearing that was against it during removal.POWER TRAIN . U M95405 5. M95414 6. Install the cylinder block into the upper case.HYDROSTATIC REPAIR Center Case Installation Procedure: IMPORTANT: Avoid damage! Thrust plate bearing and piston contact surfaces must be assembled in same positions as they were removed. If removed. use care to prevent the pistons from falling out.

Install bearing cage (M). Using a press. M95410 11.434 .POWER TRAIN .Install brake disk and shaft assembly (H) into bearing housing (D). Install gear.Install thrust plate (P) into bearing housing (D). 12. D Q H R M95411 M95409 9.Install E-clip (Q) to retain gear (R). N H M M95407 14. install bearing (S) onto motor shaft.Hydrostatic Repair . 13. Power Train .Install brake disk (N) to end of motor shaft (H).HYDROSTATIC REPAIR P S D M95413 M95408 8. 10.

against the center case (B) and install assembly into transaxle housing. NOTE: When installing the cylinder block.POWER TRAIN .Press bearing housing (D).Apply a thin film of clean hydraulic oil to cylinder block and center case mating surfaces. brake disk (N). and install cylinder block (E) and motor shaft to center case. M95404 16. When installing center case assembly. F D “B” E B G E M95384 N 17. IMPORTANT: Avoid damage! Be sure freewheeling lever does not move during center case installation. use care to prevent the pistons from falling out. and cylinder block (E).Install thrust plate (L).Hydrostatic Repair . IMPORTANT: Avoid damage! Be careful to correctly position bearing housing with "B" marking up.Apply a thin film of clean hydraulic oil to mating surface M95463 22. use care to align freewheeling shaft with hole in underside of center case.Apply a thin film of grease onto thrust washer. 18. Install pin (F) into center case. If bearing housing is installed upside down the transaxle forward and reverse function will be opposite. Damage to short pin may result. F M95474 E H 21. 20. be careful to avoid scratching or damaging contact surfaces of center case and cylinder blocks. 19. NOTE: When installing center case into transaxle housing.Apply a thin film of grease onto short pin. Power Train .HYDROSTATIC REPAIR on underside of center case where pump cylinder block contacts center case.Slide cylinder block and pistons (E) onto motor shaft (H).Turn freewheeling lever (F) so that shaft is in position shown. Install thrust washer (G) onto end of motor shaft and against cylinder block.435 . L M95406 15.

install a new O-ring (I) onto brake assembly. Install brake shoe (D) into case. Tighten to 43 N•m (32 lb-ft).POWER TRAIN . IMPORTANT: Avoid damage! When installing spring pin in brake arm.HYDROSTATIC REPAIR 2. and install balls into shaft.Rotate pump shaft and motor shaft by hand to make sure both turn without binding.436 . IMPORTANT: Avoid damage! Replace all O-rings and seals. Install a new seal (N) into housing (P). install with slit in position shown. Brake Installation Procedure: J M95448 4. IMPORTANT: Avoid damage! Replace all O-rings and seals. I K L M95472 5. Apply a light coating of grease to four steel balls (M). D M95419 1. Retain with spring pin (J). 24. A M95382 K P 23. B 3. If not already done. Install shaft through housing (P) and lever arm (K). N P M M95447 Power Train . Apply a thin film of grease to hole in case and outside of O-ring.Install three cap screws (A) to secure center case assembly (B) to transaxle case (C). Used or damaged O-rings and seals will leak.Hydrostatic Repair . Used or damaged O-rings and seals will leak.

Install inner rotor (E). M95475 1. M95359 E 2. . Power Train . Using a feeler gauge (C). . Rotate brake disk (N) to make sure it moves freely. If brake disk moves freely. and retain with two cap screws (G).) Charge Pump Installation Procedure: 6. Brake Clearance Adjustment Procedure: N H F M95360 1. • Reinstall brake assembly and check rotation of brake disk. . . .437 . measure clearance between brake disk (B) and inner brake shoe (C).5 mm (0. go to next step.HYDROSTATIC REPAIR B G A C M95476 E F M95444 2. . If brake disk will not move: • Remove two cap screws and brake assembly. replace brake assembly. . Install brake assembly (F) into case.POWER TRAIN .060 in. . 7. Remove shims between brake assembly and transaxle housing until clearance is reached. .Hydrostatic Repair . 1. Specification: Clearance (maximum) . If no shims are present. . Install pin (F) into hole in motor shaft. Install spring (E) onto brake assembly. . • Add the smallest shim between brake assembly and case (H) that will allow disk to rotate freely.

Used or damaged O-rings and seals will leak. Retain with snap rings (U). Install tabbed washers and tabbed hub washers. Press seals into case until fully seated.Hydrostatic Repair . case and bushings. Install axle shaft bearings (V) in transaxle housing. Apply grease to inner lip of seals to help avoid damage when installing axles. Install charge pump case (A).HYDROSTATIC REPAIR IMPORTANT: Avoid damage! Replace all O-rings and seals. Install axles through seals. S R A M95357 4. 3. Apply grease to outside of tabbed washer (S) and inside of tabbed hub washer (R). 5. Lightly coat outside of two new axle seals with a suitable grease. T D M95358 3. IMPORTANT: Avoid damage! Be sure charge pump case is installed with openings in direction shown. Install axle seals (T) into case. M95477 Power Train . Final Drive and Axle Installation Procedure: M95353 4.438 .POWER TRAIN . Install outer rotor (D). M95354 2. Apply tape to axle splines before installing axles to help avoid damage to seals. V N P U M95355 1.

Install large washers and snap rings (O) to end of shafts.Slide right axle into case slightly and install collar (J) onto end of right axle shaft. 7. K 13.439 . 12. Install thrust washers (Q). Install wheel hubs (P). to differential gear.Rotate differential gears and axles until all gears mesh. Slide axle shafts through collar (J) and side gears to hold differential gear assembly in case.Install inner axle shaft bushings (K) into transaxle case.HYDROSTATIC REPAIR 6.Slide axle shafts into case slightly to hold bushings in place.Hold side gears (I) in position and install differential gear assembly into case. Power Train .POWER TRAIN . Install square keys (N) into slots in end of shafts. M95347 14. O X W M95356 M95479 9. and pinion gears (W). 11. I J M95349 10. J Q M95352 M95348 8.Hydrostatic Repair . 15.Install two pinion shafts (X).

POWER TRAIN .Install center caps (M) to ends of axles. F M95342 M 21. AA G AB Z Y M95343 20.Install C-rings (H) to retain left and right axles. M95348 16. it may be necessary to move the axles slightly outward. and reduction gear (AB) to pinion gear (Z).Install reduction gear assembly (F) into case.Hydrostatic Repair . Rotate gears if needed to fully seat gear assembly. bushing (AA).440 .Install bearing (Y).HYDROSTATIC REPAIR NOTE: To install the C-rings. Power Train . H E M95344 19.Install thrust washers (G) to left and right axles. M95481 18.Install spring (E) to top of pump. M95345 17.

M95338 4. AC D M95480 NOTE: When installing reduction gear assembly. While turning charge pump and motor shaft by hand. M95473 Power Train .Hydrostatic Repair . pour fresh. hydrostatic pump.HYDROSTATIC REPAIR 2. Install two new oil filters (C). Plug or cap oil filler tube on top of transaxle case. Case Assembly Procedure: 3.POWER TRAIN . be sure flat surface on bushing (AC) is seated properly in case. Install magnet (D) into lower case half. M95339 C M95439 1. clean hydraulic oil into hole in top of charge pump to fill charge pump. and motor with oil.441 .

28 . . . . . Apply a bead of sealant to flanges (A) on upper case half. . D 8. and disconnect it from the fuel tank. Remove fender deck. .POWER TRAIN . . . . . . See “Transaxle Removal and Installation” on page 409. Traction Drive Belt Removal and Installation M95482 5.23 lb-ft) Removal: 1. .HYDROSTATIC REPAIR A B B A A C M95336 7. .19 lb-ft) New Case. Install hydraulic reservoir (B) and secure with hose clamp (A).442 . . . Power Train . 2. 6. Be sure cases seat fully without having to use force. . . See “Fender Deck Removal and Installation” in Miscellaneous section. . See “Mower Deck Removal and Installation” for the appropriate mower deck in the Attachments section. . Remove mower deck. . Retain with 21 cap screws.Hydrostatic Repair .26 N•m (17 . . .32 N•m (20 . and to inner boss (B) that separates pump/motor section (C) and gear lubrication section (D). Torque Specification: Same Case . A M95320 3. Assemble lower case half to upper case half. . . Tighten screws evenly in a crossing pattern to specification. . . 23 . Push hydrostatic transaxle oil reservoir (A) rearward. Install transaxle into machine. . . . Use care to ensure an even bead that extends around all cap screw holes. .

HYDROSTATIC REPAIR c CAUTION: Avoid injury! Gasoline iswork in a extremely flammable.POWER TRAIN . Wipe-up any spills IMMEDIATELY 4. Wear approved eye protection and gloves when removing to minimize the risk of personal injury. Move drag link out of the way.Loosen nut on fixed V-idler (N). On underside of machine. and transaxle cooling fan (F). Set fuel tank aside. Do not smoke. Remove locknut (J) securing drag link (K) to left front wheel steering arm. L I H M95314 9. Always ventilated area away from open flame or spark producing equipment.443 .Hydrostatic Repair . 11.Remove tension spring (M). Remove locknut and washer (E). F K J M95522 8. Power Train . turn belt tensioner assembly and slip belt off of flat idler (M) M95325 7. Slip belt off of input sheave (G). O N M M95554 10. Using a pry bar (L). Lift and remove fuel tank from machine frame. M E M95321 5. including equipment that utilizes pilot lights. locate the traction drive belt tensioner. and turn belt retainer (O) to side to release belt. 6. G c CAUTION:under high tensiondrive belt tension Avoid injury! The spring is when installed. Remove cotter pin (H) and disconnect freewheeling valve interlock rod (I) from lever on transaxle.

See “Mower Deck Removal and Installation” for the appropriate mower deck in the “Attachments” section. 8. Remove fender deck.444 . See “Fender Deck Removal and Installation” on page 559 in “Miscellaneous” section. Using a pry bar (A). 2. Installation: Installation is the reverse of removal.Disconnect PTO clutch wiring harness connector (P). and slip belt off of flat idler (B).HYDROSTATIC REPAIR 4. 10. Remove tensioner assembly from underside of machine.Inspect bushings and felt seal on idler pivot. Replace parts as needed. Power Train . 9. On underside of machine. Replace parts as needed.Inspect idlers for wear or damage. Installation: Installation is the reverse of removal. Remove snap ring (G). M99589 Traction Drive Belt Tensioner Assembly Removal: 1.Remove traction drive belt from the machine. Inspect bearings for smooth operation or damage. M99590 7. G H c CAUTION:under high tensiondrive belt tension Avoid injury! The spring is when installed.POWER TRAIN . Remove cap (F) on tensioner pivot. B D 11. P F M95555 12. turn belt tensioner to relieve tension on belt. E C A M95314 3. 5. 13. Rotate tensioner assembly and remove spring (C). locate the traction drive belt tensioner. 6. Remove mower deck.Hydrostatic Repair . Wear approved eye protection and gloves when removing to minimize the risk of personal injury. Remove nut (D) and V-idler (E). Remove washer and bushing (H).

Disconnect rod. Remove pedal assembly. C A • Perform pedal height adjustment. Loosen four locknuts (D) attaching forward (E) and reverse (F) pedals to control shafts. A E F H D D C E M99607A 2. • When installing bracket and control shafts. and disconnect forward/reverse control rod (B) from intermediate shaft plate (C). 3. Remove cotter pin and washer (D) attaching transaxle control rod (E) to intermediate shaft plate. be sure pedals do not rub against foot mat or fender deck. See “Fender Deck Removal and Installation” in Miscellaneous section. Remove mower deck. Remove four nuts (G) securing bracket (H) to fender deck. Intermediate Shaft B Removal: 1. Replace parts as needed. M95315 B 2.POWER TRAIN . Slide shaft to left side of machine until free of right bushing (H). • When installing forward and reverse pedals. Lower pedal assembly and move toward front of machine. locate and remove spring clip pin (A). G J I G M99587 3. Remove pedals. Rotate shaft until lever is clear of the frame. Pedal Assembly Installation: Installation is the reverse of removal. Remove fender deck.Hydrostatic Repair . 6. Check entire range of pedal motion for interference. See the appropriate “Mower Deck Removal and Installation” procedure in the Attachments section. Slide shaft to right side of machine and remove.445 . Remove snap ring (F) and washer(s) (G) from both ends of intermediate shaft. Behind right rear wheel. H F M99609 4. be sure that arm (I) on end of reverse pedal shaft is in contact with bearing (J) on forward pedal shaft. 4.HYDROSTATIC REPAIR Control Pedals and Linkage Pedal Assembly Removal: 1. See “Forward and Reverse Pedal Height Adjustment” on page 407. 5. Disconnect rod. Power Train . Remove locknut (A) attaching hand lever rod (B) to intermediate shaft plate (C). Inspect components for wear or damage.

perform pedal height adjustment procedure. H I M99608 Neutral Return Arm Removal: 1. Inspect components for wear or damage. 6. Turn arm to clear intermediate shaft plate (I) and remove. Remove two bushings. • When installation is complete.446 . A C G M99612 B 4. Inspect components for wear or damage. Installation: Installation is the reverse of removal. See “Fender Deck Removal and Installation” on page 559 in Miscellaneous section.Hydrostatic Repair .POWER TRAIN . 1 M99808 2 2.HYDROSTATIC REPAIR 5. Disconnect rod from lever. Replace parts as needed. Replace parts as needed. See “Forward and Reverse Pedal Height Adjustment” on page 407. See “Neutral Return Arm Bearing Adjustment” on page 408. NOTE: If forward/reverse control rod end becomes loose during fender deck removal and installation. Remove spring clip pin and washer (D) attaching cruise control interlock rod (E) (if equipped) to cruise control lever (F). Remove nut (G) and cap screw (H) retaining neutral return arm to frame. F 9 10 3 4 8 7 6 5 E D M99611 M99613 3. Installation: Installation is the reverse of removal. 5. perform neutral return arm bearing adjustment. Remove fender deck. Power Train . Rotate retainer (A) and disconnect neutral return rod (B) from neutral return arm (C).

Wipe-up any spills IMMEDIATELY. Remove fender deck. Power Train . B 7.Hydrostatic Repair . Do not smoke. Disconnect rod from lever. Installation: C Installation is the reverse of removal. • See “Hand Lever Rod Adjustment” on page 407. Remove locknut (E) attaching hand lever rod (F) to intermediate shaft plate (G). Remove nut (J). M99611 • See “Cruise/Hand Control Lever Tension Adjustment” on page 409. F E G M99697A A M95320 5. Remove locknut (H) retaining friction device (I). and spring assembly (K) attaching cruise control lever assembly (L) to machine frame. See “Fender Deck Removal and Installation” on page 559 in Miscellaneous section. Lift and remove fuel tank from machine frame. Remove spring clip and washer (B) attaching cruise control interlock rod (C) to cruise control lever (D). 2.POWER TRAIN . 3. Remove cruise control lever. Push hydrostatic transaxle oil reservoir (A) rearward. 4. including equipment that utilizes pilot lights. bushing.HYDROSTATIC REPAIR Cruise Control Lever Removal: 1.447 . and disconnect it from the fuel tank. 8. Set fuel tank aside. Remove friction device. cap screw. Always ventilated area away from open flame or spark producing equipment. I c CAUTION: Avoid injury! Gasoline iswork in a extremely flammable. washer. H J L K M99610 D 6.

including equipment that utilizes pilot lights. Remove locknut (E) retaining friction device (F). Wipe-up any spills IMMEDIATELY. M99615 c CAUTION: Avoid injury! Gasoline iswork in a extremely flammable. • See “Cruise/Hand Control Lever Tension Adjustment” on page 409. Installation: Installation is the reverse of removal. C B D M99607A 4. F I E G A M95320 2. 5. Push hydrostatic transaxle oil reservoir (A) rearward. IMPORTANT: Avoid damage! When removing friction device and hand control lever. Remove nut (G) and pivot assembly (H) attaching hand control lever assembly (I) to machine frame. Remove fender deck.HYDROSTATIC REPAIR Hand Control Lever (Optional) Removal: 1. 3.POWER TRAIN .Hydrostatic Repair . Remove locknut (B) attaching hand lever rod (C) to intermediate shaft plate (D). See “Fender Deck Removal and Installation” on page 559 in Miscellaneous section. • See “Hand Lever Rod Adjustment” on page 407. Power Train . Remove friction device. note location and quantity of washers during removal to ensure correct reassembly. 6. Remove hand control lever. Lift and remove fuel tank from machine frame. Always ventilated area away from open flame or spark producing equipment. Do not smoke.448 . 7. Set fuel tank aside. and disconnect it from the fuel tank.

washer. locate the traction drive belt tensioner.Hydrostatic Repair . On underside of machine. L M M99589 8. and clevis pin (L).449 . 2. Remove mower deck. and disconnect freewheeling interlock rod (J) from brake pedal (K). Rotate retainer (F) and disconnect neutral return rod (G) from neutral return arm (H). Using a suitable spring tool. Remove fender deck. and disconnect brake rod assembly (M) from brake pedal arm (N).POWER TRAIN . Remove cotter pin. See “Fender Deck Removal and Installation” on page 559 in “Miscellaneous” section. Power Train . 4. E MIF 5. See the appropriate “Mower Deck Removal and Installation” Procedure in the “Attachments” section. Rotate tensioner assembly and remove spring (C). and slip belt off of flat idler (B). D 9.HYDROSTATIC REPAIR Brake Pedal and Linkage F Removal: 1. C A N M95314 K I J 3. turn belt tensioner to relieve tension on belt. disconnect brake return spring (D) from brake shaft arm (E). Remove cotter pin and washer (I). 7. Rotate neutral return rod 90° and remove from brake pedal arm. G H B M99609 6. Using a pry bar (A).

• When installation is complete. • When installation is complete. See “Fender Deck Removal and Installation” on page 559 in Miscellaneous section. and disconnect brake rod assembly (B) from brake pedal arm (C).POWER TRAIN . and left brake shaft mounting plate (R). See the appropriate “Mower Deck Removal and Installation” procedure in the Attachments section. Remove lift arm (P). washer. C O R P M99620 10. See “Brake Linkage Adjustment” on page 408. 11.Hydrostatic Repair .Remove locknut (O). and clevis pin (A). Installation: Installation is the reverse of removal. 5. Replace parts as needed.450 . Remove fender deck. remove cotter pin and washer (D). Remove brake rod assembly. 2. Installation: Installation is the reverse of removal. See “Brake Linkage Adjustment” on page 408. Remove cotter pin. Power Train .Inspect components for wear or damage. E D M95328 4. 14. perform brake linkage adjustment procedure. perform brake linkage adjustment procedure. • Be sure to tighten flat idler sheave nut after reconnecting belt to idlers.Remove three nuts and carriage bolts (Q).Remove three nuts and carriage bolts. On left side of machine. spacer and cap screw.Repeat for other side. and disconnect brake link (E) from control lever (F). Inspect components for wear or damage. Replace parts as needed. 13. Remove mower deck. F A B M99589 3.HYDROSTATIC REPAIR Brake Rod Removal and Installation Q Removal: 1. 12. washer. and right brake shaft mounting plate and brake pedal and shaft assembly.

................................453 Component Location....456 Diagnostics .............................................470 Front Wheel Bearing Removal and Installation .........................................................................453 Repair Specifications.............................458 Repair.............................458 Steering Wheel Centering ...........................................................456 Steering System ......467 Front Wheel Spindle Lubrication .......................................455 Theory of Operation .... Disassembly and Inspection...................457 Steering System ..............................459 Steering Gear Removal and Installation.................454 Front Axle .....453 Service Equipment and Tools ..............457 Steering Symptom Diagnosis ......454 Steering Wheel................................471 Steering Table of Contents ..........................................464 Front Axle Assembly and Installation .......453 Torque Specifications................459 Front Axle Removal......................................451 .453 Tests and Adjustments Specifications.........470 Front Wheel Removal and Installation ............................457 Tests and Adjustments .................................................................STEERING TABLE OF CONTENTS Steering Table of Contents Specifications .......................

452 .STEERING TABLE OF CONTENTS Steering Table of Contents .

. . . . . . . . . . . 60 N•m (44 lb-ft) Drag link locknuts. . . . . . . . . . . . . . . . . . .) Briggs & Stratton Exhaust Manifold . . . . . . . . 29 . . . . 6. . . . .05 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Specifications . . . . . . . . . . . . . 22 N•m (192 lb-in. . . . . . . . . . . . . . . . . . . . . . . .002 in. . . . . .) Service Equipment and Tools NOTE: Order tools from your SERVICE-GARD Catalog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special or Required Tools Tool Name Tool No. . . . . . . . . . . . .) Tie rod locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N•m (44 lb-ft) Steering wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some tools may be available from a local supplier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 N•m (22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Use Inside Puller and Slide Hammer Remove steering support needle bearings and front axle pivot bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Kohler Engine Mounting Bolts . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 ± 0. . . . . . . . . . . 0. . . .204 lb-in. . . . . . . . . 0. . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in. . . . . . . . . . . . .453 . . . . . . . . . . . . . . . . . . . . . . . . . . . .05 mm (0. . Snug Only Jam Nuts M10. . .STEERING SPECIFICATIONS Specifications Tests and Adjustments Specifications Lubrication Interval: Spindle grease fitting and kingpin . .9 N•m (61 lb-in. . . . . . . . . . . . . . . .) Kohler Engine Muffler Cap Screws . . . . . . . . . . 30 N•m (22 lb-ft) M12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ± 5 mm (0. . . . . . . . . . . . . . . . . . . . .25 N•m (168 . . . . . .) Spindle Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002 in. . . . .26 lb-ft) Kawasaki Engine Muffler Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 N•m (48 lb-ft) Steering support bolts . . . . . . . . . . . . . . . . . . . . .2 in. . . . . 55 N•m (41 lb-ft) Repair Specifications Axle Beam Pivot Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Torque Specifications Spindle axle pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Every 25 hours (severe conditions) Every 50 hours (normal conditions) Toe-In Adjustment: Front-to-rear difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Support .Steering Wheel .Drag Link .454 .Packing .Steering Arm / Splined Sector Shaft .Ball Joint J K L M N O P Q R .Cotter Pin (secures (C) on late models) .STEERING COMPONENT LOCATION Component Location Steering Wheel A B C D R Q P O N F G M E L K H I J MIF A B C D E F G H I .Packing .Needle Bearing .Needle Bearing .Packing .Shims Steering Component Location .Sector Gear .Packing .Snap Ring (secures (C) on early models) .Bushing .Needle Bearing .Packing .

Axle .Cap .Axle Pivot .Cotter Pin (Early models) G H I J K L M .Bearing .Tie Rod .Drag Link .Lock Nut (Replaces E and F on later models) Steering Component Location .Crown Nut (Early models) .Pad .STEERING COMPONENT LOCATION Front Axle A C B D E F M B B D L G B H K J I MIF A B C D E F .455 .Spindle .Bushing .Grease Fitting .

456 . The steering gear meshes with the sector gear (C). A B C D E G F MIF Steering Theory of Operation . backward . causing the sector gear and steering arm (D) to rotate.left turn. As the steering arm moves. the drag link (E) is moved (forward . Theory of Operation: As the steering wheel is turned.right turn) causing the left spindle (F) to rotate. the steering shaft (A) and gear (B) rotate. causing both spindles to turn at the same time. The spindles are connected by the tie rod (G).STEERING THEORY OF OPERATION Theory of Operation Steering System Function: To allow the operator to change travel direction.

damaged. damaged. No . (2) Spindles move freely without feeling rough spots? Yes . bent or worn? Yes . Key switch in OFF position. Check bushings in center of axle. Parking brake LOCKED.Replace tie rod(s). or binding? Yes .457 .Replace linkage.Steering system OK. System: Steering System (1) Front wheels rotate freely without feeling rough spots? Yes . Check bushings. worn or damaged? Yes . (6) Drag link and steering arm not binding. Key switch in OFF position.Go to next step.Adjust drag link.Replace tie rod(s). Check bushings.Check axle spindle holes and lubrication. bent or worn? No . (3) Gear and sector assembly teeth worn or damaged. (3) Front axle is not binding.Go to next step. No . make sure that tire inflation is correct Test Conditions: • • • • Machine parked on level surface.Go to next step. or binding? Yes . No . Symptom: Steering Wander (1) Gear and sector assembly teeth worn or damaged. Steering Symptom Diagnosis Test Conditions: • • • • Machine parked on level surface. Steering Diagnostics . damaged. No . (2) Steering linkage loose. No .Check front wheel bushings and lubrication.Go to next step. Front axle raised safely off ground.Tighten steering wheel. Parking brake locked.Go to next step.Replace gear and sector assembly.Replace gear and sector assembly.Go to next step. Test Conditions: • • • • Machine parked on level surface.Tighten. No . Front axle raised safely off ground. Check bearings. No . See “Steering Gear Removal and Installation” on page 459.STEERING DIAGNOSTICS Diagnostics Steering System NOTE: Before checking for a steering problem.Go to next step. damaged or worn. repair or replace linkage. (2) Tie rod(s) not binding. See “Steering Gear Removal and Installation” on page 459. Symptom: Lash (Lost Motion) at Steering Wheel (1) Is the steering wheel securely mounted to shaft? Yes . (4) Tie rod(s) binding. bent or worn? Yes .Replace gear and sector assembly. No . damaged or worn? Yes . No .Go to next step. Front axle raised safely off ground. (4) Tie rod(s) not binding. (5) Gear and sector assembly teeth not worn or damaged and not binding? Yes . Key switch in OFF position.Replace tie rod(s). Parking brake LOCKED.Go to next step. and axle pivots freely? Yes . No .

Turn steering wheel to right to expose front end of drag link. See “To Adjust Draglink:” below. 2. Test Conditions: • • • • Machine parked on level surface.Check gear tooth alignment. (2) Gear and sector assembly teeth worn or damaged. lengthen the drag link. damaged. To Adjust Drag Link: 1. Drive the machine in a straight line and note whether the steering wheel is straight. Key switch in OFF position.Go to next step. Steering Tests and Adjustments . Parking brake LOCKED.458 . Front axle raised safely off ground. E C B A D Symptom: Wheels Will Not Track Straight (1) Tie rod(s) binding. Loosen jam nut (A) on front of drag link (B). • If the steering wheel is right (B) when the front tires are straight forward. Parking brake LOCKED. Symptom: Steering Wheel Turns Farther In One Direction (1) Draglink properly adjusted? Yes .Replace bent or damaged components MIF 2. Front axle raised safely off ground. Adjust drag link to align the steering wheel. Key switch in OFF position. shorten the drag link. A B MIF • If the steering wheel is left (A) when the front tires are straight forward. 1. Steering Wheel Centering Purpose: Proper steering wheel centering ensures steering wheel is centered when front wheels are in a straight forward position. See “Steering Wheel Centering” on page 458. See “To Adjust Draglink:” below. bent or worn Yes .STEERING TESTS AND ADJUSTMENTS Tests and Adjustments Test Conditions: • • • • Machine parked on level surface. No . or binding? Yes . rotated left or rotated right. Replace gear and sector assembly.Adjust drag link.

4. . and loosen side screws securing pedestal to frame. M96429 A 3.If the steering wheel is right when the front tires are straight forward. Disconnect front end of drag link (B) from spindle arm (C): • While holding the ball joint stud (D) to prevent it from rotating.459 . lengthen the drag link. C B MX31623 6. See “Fender Deck Removal and Installation” on page 559 in Miscellaneous section. M95522 C D 3. Remove fender deck. Remove pedestal left and right closeout panels. secure ball joint stud to spindle arm with locknut. 7.STEERING REPAIR Repair E Steering Gear Removal and Installation Removal: B 1. remove the locknut (E) securing the front end of the drag link to the spindle arm. Remove steering wheel. Remove choke cable return spring (B). Remove battery.If the steering wheel is left when the front tires are straight forward. While holding ball joint stud. Remove mower deck. 2. Tighten locknut to 60 N•m (44 lbft). Move front wheels until the ball joint stud slips easily into the spindle arm. . shorten the drag link. Remove locknut (A) and bolt securing steering wheel. Steering Repair . See “Mower Deck Removal and installation” for the appropriate mower deck in the Attachments section. 5. Remove choke and throttle control knobs (C). 4. 5. Tighten jam nut to 30 N•m (22 lb-ft). 6. • Turn ball joint rod end to shorten or extend drag link length.

Slide parking brake handle down to bottom of slot and remove from pedestal cover. Remove parking brake rod (D) from handle (E). MX31625 F 11.Lift pedestal cover (G) up and over the steering shaft (H).Remove two flange nuts (F) securing control panel to pedestal frame. 13. M95583 12. J M95576 10.Remove bushing. Steering Repair .STEERING REPAIR G E D H MX31624 I 8. NOTE: It may be necessary to disconnect the wiring harness tie down clips before lifting pedestal cover.Remove snap ring holding bushing (J) in place in pedestal.460 . 9. and rotate it forward over the pedestal frame (I) to expose the entire steering shaft.

3 washers installed above steering gear. N M P R O M96601 16.Remove drag link from spindle arm. 15.461 . shim(s) and packing from the steering shaft.While holding the ball joint stud (K) to prevent it from rotating.Inspect shaft and steering gear assembly. If a new shaft is installed. NOTE: Write down location and number of washers on pinion and sector gear shafts. M95603 24. washer. Replace as necessary. remove the sector gear (P).Rotate steering shaft and steering support and remove from machine.Inspect steering support bearings (R) for damage. 17.Remove the cotter pin (Q). Remove steering arm/ sector shaft and drag link from machine. Replace as necessary. NOTE: If any bearings are replaced. 19.STEERING REPAIR P L Q K M95522 O 14. There may be 0 . remove the locknut (L) securing the front end of the drag link to the spindle arm.Remove steering shaft from steering support.Remove drag link from steering arm. Steering Repair . 22. They are needed to ensure proper pinion gear to sector gear engagement for proper steering response. M95604 20. NOTE: Steering pinion gear cannot be removed from the steering shaft. press bearings in until flush with surface.While raising the steering support.Remove the four nuts (N) and carriage bolts securing the steering support (O) to the frame. Ensure bearing side with lettering is toward outside. Inspect drag link ball joint ends for wear or damage. Lower steering arm/sector shaft through steering support and frame. replace as necessary.Remove the E-clip (M). 21. 23. shim(s) and washer from the steering cam shaft. number and placement of washers may need adjustment. These washers are not interchangeable with other washers on the shaft. 18.

Slide steering shaft through pedestal and place into approximate installed position.STEERING REPAIR Steering Gear Installation: S 8.Ensure steering gear tooth alignment mark (S) and sector gear alignment mark (W) are aligned. Install second packing. spacer(s) and washer onto the steering shaft. Remove cotter pin and washer. Bend ends of cotter pin over. W M95634 10. Before bending cotter pin over. U O M95635 Steering Repair .). 9. 6. check for movement of steering shaft through steering support. Tighten locknuts to 22 N•m (192 lb-in. The mark will be needed to align the sector gear during installation. T S M95602 1. Slide the steering shaft through the steering support. 2. NOTE: Spacer(s) above steering support are installed to eliminate rattle.Install spacer(s). Reinstall washer and cotter pin.Secure steering support to frame with four carriage bolts and locknuts (N). 3. Use a permanent marker to mark (S) the steering gear tooth that matches the alignment mark (T) on the bottom of the steering shaft.462 . NOTE: The steering shaft alignment mark is 90° from cotter pin hole. Ensure steering sector shaft and sector gear alignment marks (V) are matched. 7. N M96601 V 12. 4. Install the second washer (U) and packing on the sector shaft and then slide splined shaft through sector gear. washer and E-ring on steering sector shaft. 5. and add spacers as needed to eliminate movement. NOTE: During installation a felt packing will be installed between washers and any of the bearings in the steering support which hold either the steering shaft or the steering cam shaft. Install washer and packing onto steering shaft. Install cotter pin through hole in steering shaft. Slide the splined sector shaft on the steering arm up through the steering support (O). Set sector gear on top of steering support. 11.

Install steering wheel and secure with locknut (A) and bolt.Install pedestal left and right closeout panels. M95576 27. MX31624 J 20. A M95583 14. M96429 F 21.Install steering column bushing (J). 17. 26. Tighten drag link locknuts (L) to 60 N•m (44 lb-ft).Install throttle and choke knobs.Center steering wheel. Do not tighten locknut to pull washer or head of bolt into steering wheel.Install parking brake handle in pedestal cover. L E D M95522 13.Ensure all electrical connectors are secure.Install battery. 19.Lift pedestal cover up and over the steering shaft.Install snap ring holding bushing in place in pedestal. See “Steering Wheel Centering” on page 458.Install mower deck. 22. 25.463 . Install choke return spring. Ensure pedestal cover slides under two side screws and washers.Install two flange nuts (F) securing control panel to pedestal frame. 24. Tighten screws. 16. See “Fender Deck Removal and Installation” on page 559 in Miscellaneous section. Steering Repair . Snug locknut. 23.Install fender deck.Connect parking brake handle (E) to rod (D).Install drag link to spindle arm and steering arm.STEERING REPAIR 18. 15.

464 . Remove four cap screws (B) and upper heat shield (C). 3. B C A M95517 Kohler Engine 1. Raise front of machine. D B M95518 E 4.Models GT235E. DO NOT touch with bare skin. See “Hood Removal and Installation Models GT225. 2. M95523 D E M95524 Steering Repair . Wear protective eye glasses and clothing. Remove hood. Kohler Engine: c CAUTION: Avoid injury! Engine components may be HOT. GT235” on page 558 or “Hood Removal and Installation . GT245” on page 558 in Miscellaneous section. See “Mower Deck Removal and installation” for the appropriate mower deck in the Attachments section. and support by the frame using suitable stands. Disassembly and Inspection Removal: 1. Remove four screws (A) securing bumper cover (B) to frame.STEERING REPAIR Front Axle Removal. Remove mower deck.

Remove four cap screws (D) and lower heat shield (E). Remove two cap screws securing muffler to frame. 5. Steering Repair . Move drag link out of the way. Loosen four engine mounting bolts. 3.465 . All Machines: H B G M99525 Briggs and Stratton Engine 1. Remove four cap screws (D) and lower heat shield (E). Remove muffler and muffler gasket. M99593 A C 5. Remove four cap screws and upper heat shield (C). Briggs & Stratton Engine: F c CAUTION: Avoid injury! Engine components may be HOT. Remove two nuts (F) and lock washers securing the muffler exhaust tube (G) to the cylinder head. Remove locknut (G) securing drag link (H) to left front wheel steering arm. Remove headlight wiring harness clip (A) from frame. DO NOT touch with bare skin. and raise front of engine slightly. Wear protective eye glasses and clothing. Remove four allen head bolts (F) and lock washers securing muffler to engine. 2. Move brackets out to allow removal of upper heat shield. Remove muffler. M95522 1. D F E G M95525 M95524 4. 3. 4. Loosen (or remove) two flange nuts (B) securing hood support brackets.STEERING REPAIR 2.

. Subtract the ID from the OD. If needed. Be sure boot is in place.) 4. I 3. Remove spindle from axle beam (F). Remove front axle from frame. . 7. . . Measure ID of axle beam pivot bushings. . 4. Inspect tie rod ball joints for smooth operation. remove cotter pin (K). remove nut (N) and washer (O). 2. . replace tie rod. Remove two locknuts (A) securing tie rod ends to spindle steering arms (B). Steering Repair . Remove two cap screws (I) and locknuts securing pivot pin (J) and front axle to frame. Axle Beam Pivot Clearance (Maximum) .05 mm (0. . . . . replace bushings. . Measure axle beam pivot OD. Support front axle and remove pivot pin. . Remove tie rod (C). Disassembly and Inspection: 1. M95539 8. . . . nut (L). Remove E-ring and washer (E) from end of spindle. and washer(s) (M) from end of pivot pin. . . Late models. remove wheels from spindles. C B K M L A M95537 5.STEERING REPAIR IMPORTANT: Avoid damage! Front axle is secured to frame with one pivot pin. 6. If clearance measurement difference is not within specification. Use care when removing pivot pin to prevent beam axle from falling to floor. If necessary. Remove plastic cap (D) from top of spindle. 0. Underneath machine: Early models.002 in. . See “Front Wheel Removal and Installation” on page 470. F E O N M95538 and MX30696 3. . J D M95536 2.466 .

A B F M95536 4. Install tie rod (D). Apply grease to inside of axle pivot.3 mm (0. 0. 11. 5.STEERING REPAIR C G I J H D M95540 9. . 12. M95539 1. Tighten locknuts to 60 N•m (44 lb-ft). Install front axle to machine. If clearance measurement difference is not within specification. Install spindles to front axle beam (A). . Install two cap screws (G) and locknuts to secure pivot pin and front axle to frame. .Subtract the ID from the OD. Specifications: Spindle Clearance (Maximum) . Install plastic cap (C) to top of spindle.Measure ID of spindle bushings. .012 in. 3.) E M95537 2. replace spindle assembly.Measure the OD of the spindles. Inspect thrust surface (G) and rotation wear surface (H) on spindle (I) and steering arm (J). Steering Repair . Tighten cap screws and locknuts to 65 N•m (48 lb-ft). 10. 6. replace bushings. G Front Axle Assembly and Installation NOTE: Be sure bushings in axle beam are in good condition before assembling front axle. Retain with two locknuts (E).467 . Retain with washer and E-ring (B). If excessively worn or grooved. Retain with pivot pin (F).

468 . 2.). Tighten locknut to 60 N•m (44 lb-ft). Raise front of engine slightly.STEERING REPAIR Kohler Engine: IMPORTANT: Avoid damage! Be sure muffler gasket is in place on exhaust tube flange when installing muffler to cylinder head. Steering Repair . Tighten nuts to 20 . Retain with two lock washers and nuts (A). Attach drag link (K) to spindle steering arm (L).204 lb-in. Install two cap screws retaining muffler to frame. Retain with locknut (M). and muffler heat shields. Tighten four engine mounting bolts to 29 . All models: Install washer(s) (H) and nut (I) to pivot pin. DO NOT overtighten screws securing muffler. and install muffler to cylinder head.25 N•m (168 . Early models: Install cotter pin (J) to retain nut to pivot pin.35 N•m (22 26 lb-ft). J H I A M95525 1. B M C M95523 K L M95522 9. 7. 8. H I C M95538 3.

Install two cap screws to secure muffler to frame. C B M99525 4. retain with four cap screws (E). Tighten allen head bolts to 17 N•m (150 lbin. Connect headlight wiring harness clip (C) to frame. Install lower heat shield (B). Install upper heat shield (D). Tighten flange nuts. DO NOT overtighten nuts securing muffler. 3. Steering Repair . Secure muffler to engine cylinder heads with four lock washers and allen head bolts (A). Install upper heat shield and secure with four cap screws.). C A B M95524 4. Install lower heat shield and secure with four cap screws. D M95517 5.STEERING REPAIR Briggs & Stratton Engine: IMPORTANT: Avoid damage! Be sure muffler gaskets are in place on exhaust tube flanges when installing muffler to cylinder heads. Install muffler gaskets and muffler. M99593 E Briggs and Stratton Engine 1. Retain with four cap screws (C).469 . Install (if removed) hood brackets and secure with two flange nuts (B). 2. 5.

and lower machine to the ground. See “Hood Removal and Installation Models GT225. Raise each wheel off of ground so grease can get around spindle. When supporting machine. be sure to place stands so that machine cannot tilt on front axle pivot. Raise front of machine. 4. 5. Turn steering wheel back and forth several times to distribute grease on spindles. Installation: Installation is the reverse of removal. Locate grease fitting (A). Remove wheel. 2.STEERING REPAIR All Machines: 3. See “Mower Deck Removal and installation” for the appropriate mower deck in the Attachments section. Install bumper cover (D) to frame. GT245” on page 558 in Miscellaneous section. 3. GT235” on page 558 or “Hood Removal and Installation . on each side of machine. Retain with four screws (E). 1. 4. Front Wheel Removal and Installation E Removal: c CAUTION: Avoid injury! MACHINE MAY SHIFT SUDDENLY. A M95638 Front Wheel Spindle Lubrication 1. Install hood. Wipe off excess. D M95518 2. remove stands. Steering Repair . Lubricate spindles using John Deere Extreme Pressure Grease or an equivalent. Install mower deck. 3. and support both sides of front axle beam using suitable stands. with one or two shots of John Deere Extreme Pressure Grease or an equivalent until grease comes out of spindle.470 . Raise front of machine. Lubricate front wheel spindle. A M96432 2.Models GT235E. Remove E-ring (A) from end of axle. 1. Remove plastic cap from wheel hub.

471 . wear. Installation: Installation is the reverse of removal. Replace if needed. • Install bearing to wheel hub using a press. Inspect bearings for smooth operation. 2. Using a suitable puller. Remove wheel. IMPORTANT: Avoid damage! f bearings are loose in wheel hub replace wheel. • Apply a small amount of grease to bore of wheel hub or outside of bearing to ease assembly. Steering Repair .STEERING REPAIR Front Wheel Bearing Removal and Installation Removal: 1. remove bearing (A) from wheel hub. or damage. A M95639 3.

STEERING REPAIR Steering Repair .472 .

......................................528 48-Inch Deck Mower Blades ....................................................476 Component Location...476 Tools and Materials .......... 537 48-Inch Deck Spindles.......497 54 ......................................................................................................Inch Mower Deck ..................522 42-Inch Drive Belt...........................Inch Piranha Mower Deck .......................................................................ATTACHMENTS TABLE OF CONTENTS Attachments Table of Contents Specifications .....................512 Tests and Adjustments ....... 546 Jack Sheave .......................475 Rotary Mower Use...........529 54-Inch Deck Mower Blades ....475 Adjustment Specifications ..................... 549 Idlers ....Inch Mower Deck .............................................................................514 Mower Level Front-To-Rear ....524 54-Inch Mower Drive Belt .........517 44-Inch Mower Deck Removal and Installation .......................................................................................................511 Mower Decks Troubleshooting Chart ......................................................................525 38-Inch Deck Mower Blades ..........476 Tools....................515 Repair.Inch Mower Deck ........477 38 .....475 Repair Specifications......................516 42-Inch Convertible Mower Deck Removal and Installation .523 44-Inch Piranha Mower Drive Belt.... 534 44-Inch Deck Spindles.......524 54-Inch Convertible Mower Drive Belt............... 543 54-Inch Convertible Deck Spindles...................................521 38-Inch Drive Belt....516 38-Inch Mower Deck Removal and Installation ..............526 44-Inch Deck Mower Blades ...................................................................................................486 48 ............................................................................................530 54-Inch Convertible Deck Mower Blades .491 54 ................Inch Mower Deck .............................504 Diagnostics ...525 42-Inch Deck Mower Blades .477 42 ........523 48-Inch Mower Drive Belt .............................................511 Mower Drive Checks .............532 38-Inch Deck Spindles.................................................... 533 42-Inch Deck Spindles..............514 Mower Level Side-to-side.......................................519 54-Inch Mower Deck Removal and Installation 520 54-Inch Convertible Mower Deck Removal and Installation ..................................................... 540 54-Inch Deck Spindles..........473 .............................. 549 Attachments Table of Contents .......518 48-Inch Convertible Mower Deck Removal and Installation .............481 44 ...Inch Convertible Mower Deck ....

474 .ATTACHMENTS TABLE OF CONTENTS Attachments Table of Contents .

ATTACHMENTS SPECIFICATIONS
Specifications Adjustment Specifications
Side-to-Side Blade Height Difference (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 mm (0.125 in.) Front-to-Rear Blade Height Difference 38, 44, 48 and 54-Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 mm (0.125 - 0.375 in.) front lower then rear 42C Mower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 mm (0.125 - 0.375 in.) front lower then rear

Repair Specifications
38-Inch Deck Spindle Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6 N•m (230 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 N•m (94 lb-ft) Lower Seal Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 mm (0.31 in.) Blade Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Cutting Edge Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) 42-Inch Convertible Mower Deck Spindle Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (230 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 N•m (94 lb-ft) Lower Seal Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 mm (0.31 in.) below hub flange Blade Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft) Cutting Edge Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) 44-Inch Piranha™ Mower Deck Spindle Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (230 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 N•m (94 lb-ft) Lower Seal Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 mm (0.31 in.) below hub flange Blade Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft) Cutting Edge Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

Attachments Specifications - 475

ATTACHMENTS TOOLS AND MATERIALS
48-Inch Convertible and 54-Inch Mower Decks Gauge Wheels Roller Shaft Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Idlers and Sheaves Jack Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft) Tensioning Idler Sheave Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Spindle Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (230 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 N•m (120 lb-ft) Lower Seal Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 mm (0.31 in.) below hub flange Blade Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft) Cutting Edge Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

Rotary Mower Use
MOWER 38" Side Discharge 42C Convertible 44" Piranha Mulching 48C Convertible 54" Side Discharge 54C Convertible GT225 Optional Standard Optional Optional Not Recommended Not Recommended GT235 Optional Optional Optional Standard Standard Standard

Tools and Materials Tools
Order tools according to information given in the U.S. SERVICEGARD™ Catalog or in the European Microfiche Tool Catalog (MTC). Special or Required Tools Tool Name Blade Height Gauge Rotary Blade Balancer Torque Wrench Tool No. TY15272 JT07076 Tool Use Use to check mower side-to-side level Use to balance blades Use to install mower blades

Attachments Tools and Materials - 476

ATTACHMENTS COMPONENT LOCATION
Component Location 38 - Inch Mower Deck
Overall View

F

C

E

G

B

D H I J A

S P R Q

O N L K

M M99532

A B C D E F G H I

- Tensioning Spring - Belt Tensioning Handle - Belt Shield - Secondary Idler Arm - Primary Drive Belt - Pivot Lock Lever - Front Draft Rod - Secondary Drive Belt Idler Sheave - Secondary Drive Belt

J K L M N O P Q R S

- Spindle (2 used) - Primary Jack Sheave Arm - Primary Jack Sheave - Primary Belt Tensioning Spring - Spring - J-Pin Assembly (2 used) - Primary Drive Belt Tensioning Rod - Bushing - Gauge Wheel (3 used) - Gauge Wheel Shaft

Attachments Component Location - 477

ATTACHMENTS COMPONENT LOCATION
Component View
D

G K C E F H I J

B

A X

L

M N W V U R Q O P

T S M45878

A B C D E F G H I J K L M N O P Q R S

- Front Draft Arm Hangers - PTO Drive Sheave - PTO Clutch - Traction Drive Sheave - Secondary Drive Belt - Secondary Drive Belt Idler Tensioning Spring - Primary Drive Belt - Spring Locking Pin - Secondary Belt Idler Arm Assembly - Hinge Assembly - Discharge Chute - Right J-Pin Assembly - Rear Draft Arm Attaching Bracket - Belt Tensioning Rod - Primary Jack Sheave Arm Assembly - Primary Belt Tensioning Spring - Rear Draft Arm Attaching Bracket - Left J-Pin Assembly - Rear Gauge Wheel Assembly

T - Spindle U - Blade V - Quick-Release Belt Tensioning Handle W - Front Gauge Wheel Assembly X - Drilled Pin

Attachments Component Location - 478

ATTACHMENTS COMPONENT LOCATION
Draft Arms and Gauge Wheels

A

G

F E C B D

K L J M H N O

I M82894A

A B C D E F G H I J K

- Pivot - Spacer (2 used) - Clevis (2 used) - Front Draft Rod - Rear Draft Arm (Left) - Lift Link Assembly (2 used) - Rear Draft Arm (Right) - Gauge Wheel (3 used) - Bushing (3 used) - Pin (3 used) - Clip (3 used)

L M N O

- Strap (3 used) - Spring Pin (3 used) - Cotter Pin (2 used) - “J” Pin Assembly (2 used)

Attachments Component Location - 479

ATTACHMENTS COMPONENT LOCATION
Idlers and Sheaves

K G B H L

D

I M

A

E F J

C

N

P

Q

O

R S

M54670

A B C D E F G H I J

- Idler Tensioning Spring - Secondary Idler Arm - Idler Arm Bushing - Spacer - Ball Bearing - Idler Sheave - Ball Bearing (2 used) - Spacer - Primary Jack Sheave - Primary Jack Sheave Arm

K L M N O P Q R S

- Cap - Snap Ring - Bushings - Quick-Release Belt Tensioning Handle - Retainer - Primary Tensioning Spring Assembly - Spring Pin - Bushing - Flange Nut

Attachments Component Location - 480

ATTACHMENTS COMPONENT LOCATION
42 - Inch Mower Deck
Overall View
A

B

C

E

D G O H I N F

M

L K J M99542

A B C D E F G H I J K L M N O

- Gauge Wheel - Shield - Secondary Drive Belt - Spindle Sheave - Chute Guard - Inner Discharge Chute - Flat Idler Sheave - Secondary Spring Arm - Idler Spring - Jack Sheave Pivot Arm - Jack Sheave - Tensioner Spring - “J” Pin Assembly - Tensioner Rod - Tensioner Handle

Attachments Component Location - 481

ATTACHMENTS COMPONENT LOCATION
Draft Arms

H G I J K B C A D E F M F E D C N O P N B L

N O P N M99559

A B C D E F G H I J K L M N O P

- Pivot - Locknut - Bushing - Flanged Bushing - Spacer - Cap Screw - Rear Draft Arm (Right) - Lift Link (2 used) - Nut (2 used) - Link (2 used) - Locknut (2 used) - Rear Draft Arm (Left) - Front Draft Rod - Nut - Clevis - Spacer

Attachments Component Location - 482

ATTACHMENTS COMPONENT LOCATION
Idlers and Sheaves
A B

C

D

E

G C

F I I P

H K J

L Q J J

M

N O J M99543

A B C D E F G H I

- Cap Screw - Washer - Bearing - Jack Sheave - Spacer - Secondary Spring Arm - Cap - E-Clip - Washer

J K L M N O P Q

- Bushing - Carriage Bolt - Shield - Flat Idler Sheave - Bushing - Nut - Idler Arm - Jack Sheave Pivot Arm

Attachments Component Location - 483

ATTACHMENTS COMPONENT LOCATION
Gauge Wheels
D H

E C A B F G I F

A

J

L

K

M99544

A B C D E F G H I J K L

- Locknut - Washer - Gauge Wheel - Pin - Carriage Bolt - Bushing - Wave Washer - Spring Locking Pin - Bracket (Welded) - Carriage Bolt - Gauge Wheel Arm - Bushing

Attachments Component Location - 484

ATTACHMENTS COMPONENT LOCATION
Spindle - Cross Section

P

A O B

N

M C D E L F

K

J

I H G

MIF

A B C D E F G H I J K L M N O P

- Nut - Upper Seal Ring - Upper Bearing - Spindle Shaft - Lower Bearing - Seal Depth - 7.8 mm (0.310 in.) - Blade - Cap Screw - Lower Seal Ring - Lower Seal - Lower Seal - Spacer - Spindle Sheave - Upper Seal - Lubrication Fitting - Grease Notch

Attachments Component Location - 485

Rear Draft Arm Attaching Bracket .PTO Drive Sheave Attachments Component Location .Blade T .486 .Primary Belt Tensioning Spring P .Secondary Drive Belt .Secondary Drive Belt Idler .Discharge Chute O .Rear Draft Arm Bracket R .Fixed Idler Sheave W .Primary Drive Belt X .Left Rear Gauge Wheel S .ATTACHMENTS COMPONENT LOCATION 44 .J-Pin Assembly .Greasable Spindle .PTO Clutch .Front Draft Arm Hangers .Deflector .Right Front Gauge Wheel .Inch Piranha Mower Deck Component View B G C F E D A X W V H I J U T K L N O P M Q R S M99533 A B C D E F G H I J K L M N .Left Front Gauge Wheel U .Jack Sheave Assembly Q .Traction Drive Sheave .Quick-Release Belt Tensioning Handle V .Right Rear Gauge Wheel .Secondary Drive Belt Tensioning Spring .Greasable Spindles .

Jack Sheave .Primary Drive Belt .Idler Sheave .Gauge Wheel .Deflector L M N O P Q R S .Rear Draft Arm Attaching Bracket .Secondary Drive Belt Idler Arm .Idler Pivot Arm .Right Hand Belt Cover .ATTACHMENTS COMPONENT LOCATION Overall View K J I H G F E M N L O D C B L P Q A S M82734AE R A B C D E F G H I J K .Fixed Idler Sheave .Belt Tensioning Handle Attachments Component Location .487 .Secondary Drive Belt Tensioning Spring .Primary Belt Tensioning Spring .Spindle (Driven Sheave) .Left Hand Belt Cover .Secondary Drive Belt .Front Draft Rod .Lock Lever .Primary Belt Tensioning Rod .

Seal Depth .Upper Seal Ring .Upper Seal .Spacer .310 in.Blade .Nut .7.Grease Notch A B C D E F G H I J K L M N O P Q .Lubrication Fitting Attachments Component Location .Lower Seal .Cap Screw .Upper Bearing .Lower Seal Ring .Spindle Sheave .Spindle Housing .Spindle Shaft .488 .ATTACHMENTS COMPONENT LOCATION Spindle .Blade Washer .Blade Washer .8 mm (0.) .Cross Section R Q O P A B C D N M E F L K J M99535 I H G R .Lower Bearing .

Jack Sheave Arm .Belt Tensioning Handle .Bushing K L M N O P Q R S .Spacer .Bushing .ATTACHMENTS COMPONENT LOCATION Idlers and Sheaves A B C I J H G K P L Q M N O S F D E R M82736A A B C D E F G H I J .Secondary Drive Belt Idler Sheave Attachments Component Location .Ball Bearing (2 used) .Bushing .Jack Sheave .489 .Primary Belt Tensioning Rod .Clevis .Spacer .Secondary Drive Belt Tensioning Spring .Shield .Primary Belt Tensioning Spring .Fixed Idler Sheave .Bushing .Secondary Drive Belt Idler Arm .Spacer .

Gauge Wheel (4 used) .Spring Pin (4 used) .Front Draft Rod .Lift Link Assembly (2 used) .Rear Draft Arm (Left Hand) .Bushing (4 used) .Spacer (2 used) .Cotter Pin (2 used) .Rear Draft Arm (Right Hand) K L M N O .Strap (4 used) Attachments Component Location .Clip (4 used) .ATTACHMENTS COMPONENT LOCATION Draft Arms and Gauge Wheels A G E F C D B J K M L I H O N M82735AO A B C D E F G H I J .Clevis (2 used) .Pin (4 used) .J-Pin Assembly (2 used) .490 .Pivot .

J-Pin Assembly .Blade .Greasable Spindle Access .Secondary Drive Belt Idler Tensioning Spring .Secondary Drive Belt Idler Sheave .Discharge Chute Attachments Component Location .Rear Draft Arm Attaching Bracket .Left Rear Gauge Wheel Assembly .Primary Drive Belt .Inch Mower Deck Mower Deck Component Location A T B C D E G F H I J S R Q P K O N M L MIF A B C D E F G H I J K L .491 .Jack Sheave Assembly .Left Front Gauge Wheel .Left Front Gauge Wheel .Front Draft Arm Hangers .Secondary Drive Belt .Primary Belt Tensioning Spring .Right Rear Gauge Wheel .Hinge Assembly .Fixed Secondary Belt Idler Sheave .Quick-Release Belt Tensioning Handle M N O P Q R S T .Primary Belt Tensioning Rod .ATTACHMENTS COMPONENT LOCATION 48 .

Pivot .Clevis (2 used) .Cotter Pin (2 used) .Spacer (2 used) .492 .J-Pin Assembly (2 used) Attachments Component Location .Rear Draft Arm (Left Hand) .Front Draft Rod .Lift Link Assembly (2 used) .ATTACHMENTS COMPONENT LOCATION Draft Arms A G C F B D E H I I M80845 A B C D E F G H I .Rear Draft Arm (Right Hand) .

Washer (4 used) .Washer K L M N O P Q .Roller Shaft .Pin (4 used) Attachments Component Location .Bushing (2 used) .Cap .Nut .Bushing (2 used) .Carriage Bolt .ATTACHMENTS COMPONENT LOCATION Gauge Wheels A G B Q D E F H I J K L M N B A P C O M95458 A B C D E F G H I J .Gauge Wheel Bar (4 used) .493 .Rear Gauge Wheel (2 used) .Front Rollers .Flange Nut (4 used) .Front Gauge Wheel (2 used) .Grease Fitting .Bushing .Lock Washer .

Bushing AE.Spacer .Nut .Fixed Idler Sheave .Secondary Idler Arm AC.Tensioner Rod Attachments Component Location .Jack Sheave .Shield .Tensioner Handle .Secondary Spring Arm Y .Cap X .Washer S .Nut .Carriage Bolt .Cap Screw .Washer V .Hook (Welded) AA.Carriage Bolt AF.Spacer .Ball Bearing (2 used) .Jack Sheave Arm .Cotter Pin R .Bracket AG.ATTACHMENTS COMPONENT LOCATION Jacksheave and Idlers F X T G W V H U A B I C T J D K E L M S T AG AF A AE R AD T AB B AC AA Y Z R AH AI AB A N O P M82803A R Q A B C D E F G H I J K L M N O P Q .Bushing U .E-Ring W .Cap Screw .Carriage Bolt AB.Washer .Shaft T .Primary Belt Tensioning Spring AH.Nut .Spring Pin AI .Spring Z .Tensioning Idler Sheave AD.494 .Jack Sheave Tensioning Arm .

Ball Bearing (2 used) .Bushing Attachments Component Location .Secondary Spring Arm .Bushing O P Q R S T U .Jack Sheave Arm .Cap .Cross Section A B C D E F G O H P I Q R S G B T J L K M N U M45998AE A B C D E F G H I J K L M N .Secondary Idler Arm .495 .Spacer .Tensioning Idler Sheave .Fixed Idler Sheave .Nut .Carriage Bolt .Shield .Nut .Jack Sheave Tensioning Arm .Cap Screw .Carriage Bolt .Jack Sheave .Shaft .ATTACHMENTS COMPONENT LOCATION Jack Sheave and Idlers .Spacer .E-Ring .

Lower Bearing .) .Lower Seal .Spindle Housing .Upper Seal .Lower Seal Ring .Spindle Shaft .Upper Bearing .Upper Seal Ring .Lubrication Fitting Attachments Component Location .ATTACHMENTS COMPONENT LOCATION Spindle .Blade .Seal Depth .Spacer .7.Cross Section Q P A B O N C D E M L F K J I H G MIF Q .Blade Washer .Nut .29 in.3 mm (0.Spindle Sheave . A B C D E F G H I J K L M N O P .496 .Cap Screw .Grease Notch NOTE: Upper seal ring (2) is installed with grease notch (17) facing toward upper bearing (3).

Secondary Drive Belt .Jack Sheave Assembly .Primary Belt Tensioning Spring .Left Rear Gauge Wheel Assembly R .Left Front Gauge Wheel U .Front Draft Arm Hangers Attachments Component Location .Inch Mower Deck Component View B C E F G H D A W V U I J K L O P S R Q N M T M45782 A B C D E F G H I J K L M N O P Q .Primary Belt Tensioning Rod .Discharge Chute .ATTACHMENTS COMPONENT LOCATION 54 .Secondary Drive Belt Idler Sheave .PTO Clutch .J-Pin Assembly S .Right Rear Gauge Wheel .Primary Drive Belt .PTO Drive sheave .Secondary Drive Belt Idler Tensioning Spring .Fixed Secondary Belt Idler Sheave T .Quick-Release Belt Tensioning Handle W .Greasable Spindles .Hinge Assembly .497 .Blade V .Traction Drive Sheave .J-Pin Assembly .Rear Draft Arm Attaching Bracket .

Secondary Drive Belt Idler Tensioning Spring AE.Right Rear Draft Arm AC.Secondary Idler Sheave Arm T .Secondary Drive Belt Idler Sheave U .Tensioning Spring Arm .Clevis .Gauge Wheel Shaft (Bolt) V .Rear Gauge Wheel (2 used) X .Spring .Front Draft Rod AA.Primary Belt Tensioning Spring .Spindle (3 used) .Left Rear Draft Arm Attachments Component Location .J-Pin Assembly Y .Bushing .Right Belt Shield AD.Secondary Drive Belt .Front Rollers Z .Jack Sheave Tensioning Arm .ATTACHMENTS COMPONENT LOCATION Overall View E Z B AH F C D AA AF A AE AB AE Z AD AC AA Y J X M R K L N O P G H I Q T S U V W M99523 A B C D E F G H I J K L M N O P Q R S .Bushing .Bushing .Jack Sheave Arm .Primary Belt Tensioning Rod .Front Gauge Wheel (2 used) AB.Quick Release Belt Tensioning Handle .498 .Seal .J-Pin Assembly .Gauge Wheel Arm .Jack Sheave .Left Belt Shield AF.Bushing (3 used) W .Grease Fitting (Early models) .

J-Pin Assembly (2 used) Attachments Component Location .Clevis (2 used) .Pivot .Spacer (2 used) .Lift Link Assembly (2 used) .ATTACHMENTS COMPONENT LOCATION Draft Arms A G C F B D E G H I M80845 A B C D E F G H I .Front Draft Rod .499 .Rear Draft Arm (Right) .Cotter Pin (2 used) .Rear Draft Arm (Left) .

Grease Fitting (2 used) .Roller Shaft .Bushing (3 used) .Carriage Bolt .Washer (4 used) .Flange Nut (4 used) .Gauge Wheel Shaft (3 used)) .Bushing .ATTACHMENTS COMPONENT LOCATION Gauge Wheels G H A D E C B F I J K L M N O P Q M80846 A B C D E F G H I J K .J-Pin Assembly (4 used .Front Rollers .Rear Gauge Wheel (2 used) .Front Gauge Wheel (2 used) .Seal (2 used) .Bushing (4 used) .500 .Gauge Wheel Arm .Nut Attachments Component Location .Cap L M N O P Q .

Jack Sheave .Spring Z .Shield .Carriage Bolt AF.Primary Belt Tensioning Spring AH.Shaft T .Spacer .Cap Screw .Tensioning Idler Sheave AD.Cap Screw .Bushing AE.Tensioner Handle .Carriage Bolt AB.Nut .Cotter Pin S .Jack Sheave Tensioning Arm .Tensioner Rod Attachments Component Location .Ball Bearing (2 used) .Secondary Spring Arm Y .Nut .Washer .Washer R .Hook (Welded) AA.Jack Sheave Arm .Washer V .Cap X .Spring Pin AI .Carriage Bolt .Nut .ATTACHMENTS COMPONENT LOCATION Jack Sheave and Idlers Y F X T G W V U H A B T I C D T AD A J T E K L M AH T A N AG AF AE R AB B AC AA Z S AD AI O P M82803A Q R A B C D E F G H I J K L M N O P Q .Secondary Idler Arm AC.Spacer .E-Ring W .Bracket AG.501 .Fixed Idler Sheave .Bushing U .

Cap Screw .E-Ring .Secondary Spring Arm .Ball Bearing (2 used) .Nut .502 .Secondary Idler Arm .Jack Sheave Tensioning Arm .Shield .Carriage Bolt .Jack Sheave .Tensioning Idler Sheave .Cap .Fixed Idler Sheave .Carriage Bolt .Bushing Attachments Component Location .Bushing .Nut .Spacer .Jack Sheave Arm .ATTACHMENTS COMPONENT LOCATION Jack Sheave and Idlers .Cross Section A C D F G O H E P I Q R S G B T J L K M N U M45998 A B C D E F G H I J K L M .Shaft N O P Q R S T U .Spacer .

Spindle Shaft G .Lower Seal Ring N .Seal Depth (7.Washer L .Lubrication Fitting C .8 mm (0.Spindle Sheave .Grease Notch (Upper-Face Towards Bearing and Lower-Face Away From Bearing) B .Blade J .ATTACHMENTS COMPONENT LOCATION Spindle .Nut (4 Used) I .503 .310 in.Nut D .Hub .Cap Screw M .) O P Q R .Upper Bearing F .Upper Seal Attachments Component Location .Upper Seal Ring E .Lower Seal K .Lower Bearing H .Cross Section A B C D R Q E P F O G N H K M L J I MIF A .Spacer .

Primary Belt Tensioning Rod .Secondary Drive Belt Idler Sheave .Left Belt Shield .Right Belt Shield .Secondary Drive Belt .Left Front Gauge Wheel .Right Front Gauge Wheel .Quick-Release Belt Tensioning Handle .Front Rollers .504 .Blade Attachments Component Location .Spring .Rear Draft Arm Attaching Bracket .Secondary Drive Belt Idler Tensioner Spring .Discharge Chute .Jack Sheave Assembly O P Q R S T U V .Left Rear Gauge Wheel .J-Pin Assembly .Right Rear Gauge Wheel .ATTACHMENTS COMPONENT LOCATION 54 .Inch Convertible Mower Deck Component View G H I J D C E F B A L K M O N Q V U R T S P MIF A B C D E F G H I J K L M N .Primary Belt Tensioning Spring .Hinge Assembly .J-Pin Assembly .Fixed Secondary Belt Idler Sheave .

J-Pin Assembly (2 used) .Hinge Assembly .Right Front Gauge Wheel .Left Rear Gauge Wheel Attachments Component Location .Fixed Idler Sheave .Rollers .Left Belt Shield .Secondary Drive Belt Idler Sheave .Rear Draft Arm Attaching Bracket .Right Belt Shield .Tensioning Spring Arm .ATTACHMENTS COMPONENT LOCATION Overall View E A B C D F G H I J K L U V W T S R Q P O N M MIF A B C D E F G H I J K L M N O P Q R .505 .Secondary Drive Belt .Jack Sheave Assembly T .J-Pin Assembly (3 used) .Secondary Drive Belt Idler Tensioning Spring .Left Gauge Wheel .Primary Belt Tensioning Spring U .Discharge Chute .Right Rear Gauge Wheel .Primary Belt Tensioning Rod V .Spring S .Quick Release Belt Tensioning Handle W .Spindle (3 used) .

Clevis (2 used) .Cotter Pin Attachments Component Location .Front Draft Rod .Spring .506 .Bushing .Rear Draft Arm (Left) F G H I J K L .Washer (2 used) .Spacer (2 used) .Pivot .J-Pin .Rear Draft Arm (Right) .Lift Link Assembly (2 used) .ATTACHMENTS COMPONENT LOCATION Draft Arms D B C G B A F E F H I L I K J MIF A B C D E .

Pin .J-Pin (4 used) .Cap Q .Front Roller (2 used) .507 .Flange Nut P .ATTACHMENTS COMPONENT LOCATION Gauge Wheel G F E B C D A 17 M N L H M N K P O O L J I P K MIF A B C D E F G H I J K L M N .Gauge Wheel Arm (Front) Attachments Component Location .Bushing (2 per wheel) .Roller Shaft .Grease Fitting (Early models) O .Washer .Gauge Wheel Arm (Rear) .J-Pin Spring .Seal .Bushing (Flat) .Carriage Bolt .Gauge Wheel .Flange Nut .

Carriage Bolt .Plug .Primary Belt Tensioning Rod X .Jack Sheave Arm Q .ATTACHMENTS COMPONENT LOCATION Jack Sheave and Idlers G H A B F I J K E L C M AF D AE AD N O S AC AB AA P R Q T U V W Z X Y MIF A B C D E F G H I J K L M N O P .Jack Sheave .Spacer .Belt Tensioning Spring U .Bushing (4 used) .Tensioning Idler Sheave Arm (Secondary .Tensioning Spring Arm (Secondary) .Cotter Pin Z .Quick Release Belt Tensioning Handle AA.Tensioning Idler Sheave AF.Shaft AB.Shield .Bearing .508 .Jack Sheave Tensioning Arm R .Shield Attachments Component Location .Ball Bearing (2 used) .Carriage Bolt .Snap Ring .Spacer .Bushing AD.Fixed Idler Sheave .Cotter Pin V .Washer (2 used) W .Clevis .Spring T .Washer Y .Bushing S .Nut AC.Bearing AE.

Cross Section B C D A E M N L F I H K G J MIF A B C D E F G H .Cap .Fixed Idler Sheave .Carriage Bolt .Nut .Jack Sheave Arm .509 .Spacer .Shaft .Jack Sheave .Bolt .Jack Sheave Tensioning Arm .Bolt .ATTACHMENTS COMPONENT LOCATION Jack Sheave and Idlers .Secondary Tensioner Idler Sheave Arm Attachments Component Location .Tensioning Idler Sheave .Nut I J K L M N .

ATTACHMENTS COMPONENT LOCATION Spindle .Lower Seal .Spindle Housing .Lower Bearing .7.Upper Seal .Spindle Shaft .Lower Seal Ring .Nut .Seal Depth .Lubrication Fitting .Upper Bearing .Spacer .510 .3 mm (0.Blade .Upper Seal Ring .) .Blade Washer .29 in.Grease Notch Attachments Component Location .Spindle Sheave .Cap Screw .Cross Section Q P A B O N C D E M L F K J I MIF H G A B C D E F G H I J K L M N O P Q .

(5) Are gauge wheels adjusted correctly? No . Symptom: deck cut unevenly or with striping (1) Are blades bent? Yes . or “54-Inch Convertible Deck Mower Blades” on page 532.See “Mower Level Side-to-side” on page 514. Yes .See “Mower Level Front-To-Rear” on page 515.Replace belt. Yes .Replace or reattach spring.Go to next step. or “54-Inch Convertible Deck Mower Blades” on page 532. worn. “42-Inch Deck Mower Blades” on page 526. (4) Is the primary belt Quick-Release belt tensioning handle locked in place? No . glazed. or stretched? Yes . No . No . No . Yes .Adjust wheels. “42-Inch Drive Belt” on page 523.Go to next step. worn.Go to next step. (4) Are blades dull? Symptom: Mower deck vibrates (1) Are blades out of balance? Yes .See “38-Inch Deck Mower Blades” on page 525.Go to next step. “42-Inch Deck Mower Blades” on page 526.See “Jack Sheave” on page 549. “44-Inch Piranha Mower Drive Belt” on page 523. “44-Inch Deck Mower Blades” on page 528. “48-Inch Deck Mower Blades” on page 529. “42-Inch Deck Mower Blades” on page 526.Engage. or “54-Inch Convertible Deck Mower Blades” on page 532. or stretched? Yes . “42-Inch Deck Mower Blades” on page 526. “48-Inch Mower Drive Belt” on page 524.Go to next step. “44-Inch Deck Mower Blades” on page 528.Go to next step.511 . Yes . or “54-Inch Convertible Mower Drive Belt” on page 525. (2) Is blade level side-to-side out of adjustment. See “38-Inch Drive Belt” on page 522. (5) Is the secondary drive belt tensioning spring weak or unhooked. glazed. frayed.Go to next step. “48-Inch Deck Mower Blades” on page 529. “54-Inch Deck Mower Blades” on page 530. “48-Inch Deck Mower Blades” on page 529. Yes . “54-Inch Deck Mower Blades” on page 530. (3) Are drive sheaves damaged? Yes . No . “54-Inch Mower Drive Belt” on page 524. (2) Is the primary drive belt broken. No .Go to next step.See “Jack Sheave” on page 549. or “54-Inch Convertible Deck Mower Blades” on page 532.Lock in place.Go to next step. frayed.ATTACHMENTS DIAGNOSTICS Diagnostics Mower Decks Troubleshooting Chart Symptom: Mower blades don’t run (1) Is the PTO clutch engaged? No . Attachments Diagnostics . “44-Inch Deck Mower Blades” on page 528. No .See “38-Inch Deck Mower Blades” on page 525.See “38-Inch Deck Mower Blades” on page 525. No . (2) Are blades bent? Yes .Replace belt. No .Go to next step. Symptom: Mower deck vibrates Yes . “54-Inch Deck Mower Blades” on page 530. (3) Is the secondary drive belt broken.See “38-Inch Deck Mower Blades” on page 525. “44-Inch Deck Mower Blades” on page 528. “48-Inch Deck Mower Blades” on page 529.Go to next step. Yes . (6) Are drive sheaves damaged? Yes . (3) Is blade level front-to-back out of adjustment. “54-Inch Deck Mower Blades” on page 530.

No . No . No .Install. (2) Is the secondary drive belt broken.Replace. frayed. or stretched? Yes .Go to next step. See “38-Inch Drive Belt” on page 522. Yes . (3) Is the primary belt Quick-Release belt tensioning handle locked in place? No . Key switch in OFF position. Parking brake engaged.Tighten cap screw. No . or stretched? Yes . (5) Are drive sheaves damaged? Yes . “54-Inch Mower Drive Belt” on page 524. System: Jack sheave (1) Is belt on sheave? Attachments Diagnostics . worn. or “54-Inch Convertible Mower Drive Belt” on page 525.Go to next step. (Replace key. (1) Is the primary drive belt broken. (3) Is belt on sheave? Yes .Check jack sheave and PTO sheave. System: PTO clutch and drive sheave (1) Is PTO clutch and drive shave tight on crankshaft? (Key not damaged or missing?) Yes .Replace belt.Replace or reattach spring. or stretched? Yes . or stretched? Yes .Go to next step.Go to next step.) (2) Is air gap properly adjusted? Yes .Replace sheave. System: Primary drive belt.Go to next step. worn. “54-Inch Mower Drive Belt” on page 524.Go to next step. glazed. if necessary. worn. frayed. (4) Is the secondary drive belt tensioning spring weak or unhooked? Yes . (3) Is the primary belt Quick-Release belt tensioning handle locked in place? No . No .Replace belt. glazed.Go to next step.Go to next step.See “Jack Sheave” on page 549.Go to next step. worn. No . Mower Drive Checks Test Conditions: • • • • Machine parked on a level surface. (1) Is primary drive belt damaged. frayed. Symptom: Belt jumps off sheaves.See “Jack Sheave” on page 549. glazed.Go to next step. frayed. damaged or worn? No .Replace belt.512 . Yes . (4) Is sheave binding. worn. broken or turned over? Yes . No .Lock handle in place.Repair and adjust as needed.Go to next step. Symptom: Belt jumps off sheaves. (5) Are drive sheaves damaged? Yes . or “54-Inch Convertible Mower Drive Belt” on page 525. No . “44-Inch Piranha Mower Drive Belt” on page 523.Replace or reattach spring. glazed. Yes . (4) Is the secondary drive belt tensioning spring weak or unhooked? Yes . See “38-Inch Drive Belt” on page 522.ATTACHMENTS DIAGNOSTICS Symptom: Belt Slips (1) Is the primary drive belt broken. (5) Does sheave angle match belt angle? No . (2) Is the secondary drive belt broken. “42-Inch Drive Belt” on page 523. No . “44-Inch Piranha Mower Drive Belt” on page 523. PTO disengaged. “42-Inch Drive Belt” on page 523.Go to next step. “48-Inch Mower Drive Belt” on page 524.Lock handle in place. “48-Inch Mower Drive Belt” on page 524.Replace belt.

Replace blade. System: Spindle sheave System: Primary belt tension spring and rod (1) Is primary belt tension spring or rod damaged.Go to next step.Go to next step. damaged or worn? No . Yes . No . 48 and 54-inch only (1) Is idler binding. Yes . broken or turned over? Yes . bent or not running straight? No . No .513 . System: Secondary drive belt tensioning spring (1) Is secondary drive belt tensioning spring damaged. System: Blade (1) Is blade bent.Go to next step.Replace sheave. (3) Does sheave angle match belt angle? Yes . System: Secondary drive belt idler and pivot arm (1) Is secondary drive belt idler and pivot arm binding. No . No . worn.Replace idler. Yes .Replace spring or rod.Tighten hardware. Yes .Go to next step. System: Fixed idler .Tighten System: Secondary drive belt idler and pivot arm No . No . System: Secondary drive belt (1) Is secondary drive belt damaged. (2) Is belt tensioning handle in tension position? No .Replace idler. or replace as needed.Replace as needed.Replace sheave and bearing. (2) Is spindle sheave damaged. worn or damaged? No .Install.Go to next step. Yes .Go to next step.Install. (1) Is spindle sheave tight on spindle with key in place? Yes .Tighten nut and install key as needed.Go to next step. (2) Is sheave binding. locating idler parallel to belt? Yes . damaged or worn? No . damaged or worn? Yes . (3) Is belt on sheave? Yes . Yes .Repair. (4) Does Sheave angle matches belt angle? No . worn or weak? Yes .Move to tension position.Replace spring.Go to next step. (2) Blade tight on spindle.ATTACHMENTS DIAGNOSTICS System: Jack sheave Yes . (2) Is belt in place? Yes . System: Spindle and housing (1) Have bearings failed? No . (2) Is blade sharp and balanced? Yes .Go to next step.Replace belt. Attachments Diagnostics .Replace jack sheave arm. No . System: Jack sheave arm (1) Is jack sheave arm binding.Go to next step.44. (2) Is belt in place? No .Install.Install.Go to next step. worn or weak? Yes . (3) Is pivot arm bent. damaged or worn? No .Go to next step.Check jack sheave and PTO sheave. (4) Is nut at correct torque? No .Go to next step.Replace pivot arm.

). level surface. Move forward/reverse pedals to NEUTRAL position. 6.5 mm (2. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Attachments Tests and Adjustments .Tighten or replace as needed.514 . Set mower cutting height to 63. Wait for all moving parts to STOP. 2. Equipment: • TY15272 Blade Height Gauge Tests and Adjustments Mower Level Side-to-side System: Mower deck lift linkage (1) Is mower deck lift linkage mounting hardware tight. 7. Raise gauge wheels to highest setting so they are not on the ground during leveling.Adjust.Check engine adjustments and condition. 1. Repair or replace parts as needed. No . not worn? Yes .Sharpen and balance. Reason: To set mower deck for an even side-to-side cut. (4) Is blade correctly adjusted front to back? No . System: Engine (1) Is engine is running at correct rpm? No .Go to next step. Rotate mower blades so that tips (A) point toward outside edges of mower deck. Rotate blade by hand to check for bent blade or spindle.Adjust engine fast idle and governor. Measurement Procedure: c CAUTION:PARTS.Adjust.Inform operator that engine should be running at fast idle when mowing. Engage parking brake. 5. c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. No . (3) Is blade level side to side? Yes . Wear gloves or handling blades to minimize the risk of personal injury. 3. No . 4.injury! engine.5 in. A C B M40161 8. Check tires for correct sizes and inflation pressures at all four wheels.ATTACHMENTS TESTS AND ADJUSTMENTS System: Blade No . Shake deck slightly to ensure deck is settled to lowest point on hangers. Park machine on a hard.

3.) Results: • If the mower side-to-side height difference is greater than specification. . 3. Loosen nut (D). M39912 Attachments Tests and Adjustments . 6. NOTE: Adjustable lift links (F) are on both sides of the mower. Check for correct tire sizes and inflation pressures at all four wheels. Shake deck slightly to ensure deck is settled to lowest point on hangers.3 mm (0. M99566 1. Rotate mower blades so that the tips point toward the front and rear of the machine. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Equipment: • TY15272 Blade Height Gauge Measurement Procedure: c CAUTION:PARTS. level surface. Set mower cutting height to 2.Subtract one measurement from the other. 2. Rotate blade by hand to check for bent blade or spindle.ATTACHMENTS TESTS AND ADJUSTMENTS 9. 7.5 in. . Repair or replace parts as needed. Wait for all moving parts to STOP. DO NOT adjust deck too high or it will not lock in the transport (RAISE) position. Turn locknut (E) to raise or lower right side of mower deck until blade tip heights are within specification. Cutting height can be made to closely match knob setting by adjusting these lift links. Wear gloves or handling blades to minimize the risk of personal injury. . 2. Specification: Maximum blade outside tip-to-outside tip height difference . . 1. E c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. . .injury! engine. Engage parking brake. use same blade tip when verifying measurements and checking front-to-rear deck height. DO NOT hold blade with bare hands. adjust lift link on right side of mower deck.125 in. Park machine on a hard. 5. 0. 10. Raise gauge wheels to highest setting so they are not on the ground during leveling. NOTE: Whenever possible. . Move forward/reverse pedals to NEUTRAL position. 8. 4. .515 . 4. . . . . Tighten nut (D). measure height of outside tips of blade (C). Adjustment Procedure: D F Mower Level Front-To-Rear Reason: To set the mower blade for the best cut and most efficient operation. Using a TY15272 Blade Height Gauge (B) or other suitable measuring tool. Turn locknuts (on both sides of mower deck) equally until blade tip heights closely match set mower cutting height. .

0. . .) Results: • If the blade front-to-rear height difference is out of specification. Wait for all moving parts to STOP. Adjustment Procedure: A Repair 38-Inch Mower Deck Removal and Installation c CAUTION:PARTS. 3. . Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. . 5. M54688 A 4. Attachments Repair . .375 in.375 in. 10. Turn FRONT nuts (B) clockwise to raise front of mower deck or counterclockwise to lower front of mower deck. Turn mower depth control knob to blank mark.Inch Mowers) Front-to-Rear Blade Height Difference . Specifications: (38. Rotate blade by hand 180°.9 mm (0. . Move lift lever all the way forward and lock in the full LOWER position. The front tip of the blade should be lower than the rear. . . Put wood blocks under each side of mower deck. 3. 44 . 48C and 54 . Pull out and push down on lock lever (B) to disconnect front draft rod assembly (C) from frame. B B M82726 C 1. . Loosen REAR nuts (A) on front draft rod. . 6 .ATTACHMENTS REPAIR 9. . .516 . Remove drive belt from PTO and mower jack sheave.)] for best possible bagger performance.Check and adjust the blade height on the opposite side of the mower deck. then measure from the rear blade tip to ground. 3 . Measure blade tip height (front and rear). . 4.375 in. adjust as follows.9 mm (0.250 . .Inch Piranha. . Tighten REAR nuts to lock deck height. 1. .) 42C Mower Front-to-Rear Blade Height Difference . M95512 6.injury! engine. 2. adjust front-to-rear height difference to maximum specification [9 mm (0. NOTE: On 38. and 42-Inch decks equipped with a bagger. Disconnect tensioner handle (A) from bracket and pull handle out to relieve belt tension.125 . 2.0. Using a TY15272 Blade Height Gauge or other suitable measuring tool. Deck should be in contact with the blocks. Pull lift lever rearward and lock mower deck in the RAISE position. measure from front blade tip to ground.

ATTACHMENTS REPAIR 42-Inch Convertible Mower Deck Removal and Installation C c CAUTION:PARTS. With no weight on spring will pull lift lever rearward when lock button is pressed. Disconnect tensioner handle (A) from bracket (B). Installation: Installation is the reverse of removal. c CAUTION: Avoid injury! SUDDENdraft arms. c CAUTION: Avoid injury! SUDDEN DRAFT ARM MOVEMENT.Slide mower deck out the right side of the machine. 1. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Put wood blocks under each side of mower deck.injury! engine. M54690 7. 2. Pull handle out to relieve belt tension. NOTE: It may be necessary to lift up on rear of mower deck to pull out J-pins. Remove draft rod assembly (C) from machine. 10. C M82728 D Attachments Repair . Pull out J-pin (D) on each side of mower deck and turn pin to unlock position. 9. Turn mower depth control knob to blank mark. LIFT LEVER MOVEMENT. 4. Remove drive belt from PTO and mower jack sheave. Do not remove mower deck J-pins unless lift lever is moved all the way forward and locked. 5.517 . 3. Pull lift lever all the way rearward to the RAISE position. Deck should be in contact with the blocks. Draft arms will raise suddenly if mower deck is disconnected without locking lift mechanism in the DOWN position. Move lift lever all the way forward and lock in the full LOWER position. Use caution when releasing lift spring tension to minimize the risk of personal injury. Wait for all moving parts to STOP. B A D M99567 M54691 8. Pull lift lever rearward and lock mower deck in the RAISE position.

F D M54691 8. Pull out and rotate lock lever (C) on pivot (D) to disconnect front draft rod assembly. c CAUTION: Avoid injury! SUDDEN LIFT ARM if MOVEMENT. Pull lift lever rearward and lock mower deck in the RAISE position. Put wood blocks under each side of mower deck. Pull handle out to relieve belt tension. and press in release button. Turn mower depth control knob to blank mark. Move lift lever all the way forward and lock in the full LOWER position.Slide mower deck out the right side of the machine. Installation: Installation is the reverse of removal.518 . NOTE: It may be necessary to lift up on rear of mower deck to pull out J-pins (F). and lock in the RAISE position.ATTACHMENTS REPAIR 6. Wait for all moving parts to STOP. C M82728 7. Remove drive belt from PTO and mower jack sheave. 6. 9. Push lift lever forward against spring tension.injury! engine. Disconnect tensioner handle (A) from bracket (B). 44-Inch Mower Deck Removal and Installation c CAUTION:PARTS. Attachments Repair . Move lift lever rearward. Pull out J-pin (F) on each side of mower deck and turn pin to unlock position. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Do not remove mower deck J-pins unless lift lever is moved all the way forward and locked. Draft arms will raise suddenly mower deck is disconnected without locking lift mechanism in the DOWN position. Pull out and rotate lock lever (C) on pivot (D) to disconnect front draft rod assembly. 2. 1. E 3. 7. M54690 4. B A M82732 5. Remove draft rod assembly (E) from machine. Remove two wing nuts and rear deflector. Deck should be in contact with the blocks. 10.

Deck should be in contact with the blocks. LIFT LEVER MOVEMENT.519 C M82728 6. Do not remove mower deck J-pins unless lift lever is moved all the way forward and locked. M82733 9.injury! engine. c CAUTION: Avoid injury! SUDDEN LIFT ARM if MOVEMENT. Remove drive belt from PTO and mower jack sheave. Installation: Installation is the reverse of removal. Disconnect tensioner handle (A) from bracket (B). Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. B A M95465 F 4. and lock in the RAISE position. 5. Pull out J-pin (F) on each side of mower deck and turn pin to unlock position.Slide mower deck out the right side of the machine. Put wood blocks under each side of mower deck. 10. 11. Attachments Repair . 1. Use caution when releasing lift spring tension to minimize the risk of personal injury. and press in release button. With no weight on spring will pull lift lever rearward when lock button is pressed.ATTACHMENTS REPAIR 48-Inch Convertible Mower Deck Removal and Installation c CAUTION:PARTS. c CAUTION: Avoid injury! SUDDENdraft arms. 8. Wait for all moving parts to STOP. Pull handle out to relieve belt tension. 3. M54690 E 2. Remove draft rod assembly (E) from machine. Pull out and push down on lock lever (C) to disconnect front draft rod assembly. . Pull lift lever rearward and lock mower deck in the RAISE position. Move lift lever rearward. Draft arms will raise suddenly mower deck is disconnected without locking lift mechanism in the DOWN position.Push lift lever forward against spring tension. Turn mower depth control knob to blank mark. NOTE: It may be necessary to lift up on rear of mower deck to pull out J-pins. Move lift lever all the way forward and lock in the full LOWER position.

Remove draft rod assembly (D) from machine.injury! engine. Deck should be in contact with the blocks. 1. B A M82731 4. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Use caution when releasing lift spring tension to minimize the risk of personal injury. E M82740 8. Remove drive belt from PTO and mower jack sheave.Slide mower deck out the left side of the machine. Pull out J-pin (E) on each side of mower deck and turn pin to unlock position. Pull out and rotate lock lever (C) on pivot (D) to disconnect front draft rod assembly. Disconnect tensioner handle (A) from bracket (B). D c CAUTION: Avoid injury! SUDDENdraft arms. 10. 5. 9. Installation: Installation is the reverse of removal. Move lift lever all the way forward and lock in the full LOWER position. Pull handle out to relieve belt tension.520 . Draft arms will raise suddenly if mower deck is disconnected without locking lift mechanism in the DOWN position.ATTACHMENTS REPAIR c CAUTION: Avoid injury! SUDDEN DRAFT ARM MOVEMENT. NOTE: It may be necessary to lift up on rear of mower deck to pull out J-pins. 3. Pull lift lever rearward and lock mower deck in the RAISE position. D M54690 7. 2. Wait for all moving parts to STOP. Pull lift lever all the way back to full raised position. With no weight on spring will pull lift lever rearward when lock button is pressed. 54-Inch Mower Deck Removal and Installation c CAUTION:PARTS. LIFT LEVER MOVEMENT. Attachments Repair . C M82728 6. Turn mower depth control knob to blank mark. Do not remove mower deck J-pins unless lift lever is moved all the way forward and locked. Put wood blocks under each side of mower deck.

C MX9575 6. With no weight on spring will pull lift lever rearward when lock button is pressed. Remove Avoid ROTATING BLADES/ MOVING STOP E ignition key. Remove drive belt from PTO and mower jack sheave. and press in release button. Attachments Repair . 54-Inch Convertible Mower Deck Removal and Installation c CAUTION:PARTS. 3. c CAUTION: Avoid injury! SUDDEN LIFT ARM if MOVEMENT.Slide mower deck out the right side of the machine. Pull out and rotate lock lever (C) on pivot (D) to disconnect front draft rod assembly. A B MX9574 F 4. Turn mower depth control knob to blank mark. M82740 8. 5. Remove draft rod assembly (E) from machine.injury! engine. Wait for all moving parts to STOP. Push lift lever forward against spring tension. Move lift lever rearward. Pull out and push down on pivot (C) to disconnect front draft rod assembly (D). LIFT LEVER MOVEMENT. Pull lift lever rearward and lock mower deck in the RAISE position. 9. M54690 1. and lock in the RAISE position.ATTACHMENTS REPAIR 10. Deck should be in contact with the blocks. Do not remove mower deck J-pins unless lift lever is moved all the way forward and locked NOTE: It may be necessary to lift up on rear of mower deck to pull out J-pins. Put wood blocks under each side of mower deck. Draft arms will raise suddenly mower deck is disconnected without locking lift mechanism in the DOWN position. Disconnect tensioner handle (A) from bracket (B). Pull handle out to relieve belt tension. Installation is the reverse of removal. Use caution when releasing lift spring tension to minimize the risk of personal injury. 7. c CAUTION: Avoid injury! SUDDENdraft arms.521 . Move lift lever all the way forward and lock in the full LOWER position. 2. Pull out J-pin (F) on each side of mower deck and turn pin to unlock position.

Installation: Installation is the reverse of removal. Remove belt cover.Slide mower deck out the right side of the machine. Use caution when releasing lift spring tension to minimize the risk of personal injury. Remove draft rod assembly from machine. Remove mower drive belt (B). 2.522 . Pull out and push down on pivot to disconnect front draft rod assembly (D). A M54674 3. LIFT LEVER MOVEMENT. E MX9577 8. Installation is the reverse of removal. Remove mower deck.ATTACHMENTS REPAIR 10. Attachments Repair . 38-Inch Drive Belt c CAUTION:PARTS. With no weight on spring will pull lift lever rearward when lock button is pressed. Remove spring (A). Draft arms will raise suddenly mower deck is disconnected without locking lift mechanism in the DOWN position. 4. Pull out J-pin (E) on each side of mower deck and turn pin to unlock position. c CAUTION: Avoid injury! SUDDEN LIFT ARM if MOVEMENT. 9. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Wait for all moving parts to STOP D Removal: MX9576 1. and press in release button. Push lift lever forward against spring tension. B 7.injury! engine. Do not remove mower deck J-pins unless lift lever is moved all the way forward and locked NOTE: It may be necessary to lift up on rear of mower deck to pull out J-pins. Move lift lever rearward. c CAUTION: Avoid injury! SUDDENdraft arms. and lock in the RAISE position.

Installation: Installation is the reverse of removal. Remove mower drive belt (D).injury! engine. IMPORTANT: Avoid damage! When installing. Remove cap screws (A) and belt cover (B). Remove mower deck. Wait for all moving parts to STOP Removal: 1.523 . Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. A A A B B A M82738 M99568 1. 3. D D B C C M82745 E M99569 3. 2. be sure to install spring hook (E) on secondary spring arm (F) as shown. Remove two cap screws (A) and belt cover (B).ATTACHMENTS REPAIR 42-Inch Drive Belt Removal: 44-Inch Piranha Mower Drive Belt c CAUTION:PARTS. Remove mower drive belt (D). Remove Avoid ROTATING BLADES/ MOVING STOP ignition key.injury! engine. 2. Wait for all moving parts to STOP c CAUTION:PARTS. Remove spring (C) using a spring puller. Installation: Installation is the reverse of removal. Attachments Repair . Remove spring (C) using a spring puller. 4.

Replace mower drive belt (D). 4. Installation: Installation is the reverse of removal. Disconnect spring (C) using a spring puller. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Remove nuts (A) and belt covers (B) from both the right and left side of the mower deck. 3. M74255 D C M95468A Attachments Repair . 4. c CAUTION:PARTS.injury! engine. Replace mower drive belt (D). Wait for all moving parts to STOP. Remove mower deck.ATTACHMENTS REPAIR 48-Inch Mower Drive Belt 3. Disconnect spring (C) using a spring puller. Remove cap screws (A) and belt cover (B). Remove mower deck. Installation is the reverse of removal.524 . Removal: 1. B 54-Inch Mower Drive Belt Removal/Installation: 1. D A C M95466 2. A B A A M95467 B M74253 2.

525 . 3.injury! engine. Disconnect spring (C) using a spring puller. Remove mower deck. 4. washer (B). and blade (C). c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. Remove cap screws (A) and belt cover (B). Installation: C M95468A Installation is the reverse of removal. Wait for all moving parts to STOP. Remove mower deck. Attachments Repair . 4. Inspect blade for cracks. 3. Sharpen and balance as necessary. Replace mower drive belt (D). Remove cap screw (A). Wear gloves or removing/installing blades. Tighten cap screw to 75 N•m (55 lb-ft). A M82898A D 2. Remove Avoid ROTATING BLADES/ MOVING STOP B ignition key. Replace blade if necessary. wear or damage. • • Install blade with bent tips up.ATTACHMENTS REPAIR 54-Inch Convertible Mower Drive Belt Removal/Installation: 1. 38-Inch Deck Mower Blades Removal/Installation: c CAUTION:PARTS. IMPORTANT: Avoid damage! Make sure that concave side of washer faces blade. DO NOT hold blade with bare hands. 1. Installation is the reverse of removal. A C M95467 B 2.

Set blade on JT07076 Rotary Blade Balancer (A) and turn blade to the horizontal position. 8. SHARP EDGES. 3. If blade is not balanced.ATTACHMENTS REPAIR Sharpen: c CAUTION: Avoid injury! FLYING SPARKS/ METAL FRAGMENTS. Attachments Repair . Blade should also touch in same way. 1. Turn blade to opposite tip. DO NOT hold blade with bare hands. Wear gloves or removing/installing blades to minimize the risk of personal injury. Recheck balance. Lightly grind bevel of the heavy end.059 in. A c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES.526 . Clean blade and remove any accumulated grass/dirt with scraper or wire brush and wipe blade clean. 1. 2. if needed. Wear gloves or handling blades.5 mm (0. or power sharpener. MIF 6. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Adjust balancer track (B) to just touch blade tip.) (C).) cutting edge (B) rather than a razor-type edge to prevent excessive chipping of the cutting edge. 42-Inch Deck Mower Blades Removal/Installation: c CAUTION:PARTS.40 mm (0. 5. Blade should have 0. 9. M29627 3.016 in. Wait for all moving parts to STOP. heavy end will drop. Wear approved eye protection and gloves when sharpening blades to minimize the risk of personal injury. 7. Do not alter original bevel (A). file. Sharpen blades using grinder.injury! engine. Balance: c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. Remove mower deck. NOTE: If excessive browning of ends of mown grass occurs or if mower is to be used on tough grasses it may be necessary to grind the blade to a sharp edge. IMPORTANT: Avoid damage! Install new blade if difference between blade tips and balancer track measures over 1. B A B C M29529 4. 2. Balance blades. DO NOT hold blade with bare hands. 1. WITHOUT changing the original angle of blade. Sharpen blade.

) (C). sharpen blade. WITHOUT changing the original angle of blade. Lightly grind bevel of the heavy end. file or power sharpener. Remove cap screw (A). Blade should also touch in same way. blade (C). 6. Blade should have 0.) cutting edge (B) rather than a razor-type edge to prevent excessive chipping of the cutting edge. Replace if needed. and that the concave side of washer faces the blade. If needed. See “Sharpen Blades” above.527 . See “Balance Blades” below. NOTE: If excessive browning of ends of mown grass occurs or if mower is to be used on tough grasses it may be necessary to grind the blade to a sharp edge. C M29528 4. 4.5 mm (0. Recheck balance. Tighten cap screw to 74 N•m (55 lb-ft). IMPORTANT: Avoid damage! Install new blade if difference between blade tips and balancer track measures over 1. Adjust balancer track (B) to just touch blade tip. washer (B). 3. A M29527 IMPORTANT: Avoid damage! Make sure deflector cup is in place between spindle and blades. Do not alter original bevel (A). 2. Installation: Installation is the reverse of removal. Sharpen: 1. Clean blade and remove any accumulated grass/dirt with scraper or wire brush and wipe blade clean. Inspect blade for cracks. 3. A B B MIF 2.40 mm (0. heavy end will drop. DO NOT hold blade with bare hands. B A M74256 2.ATTACHMENTS REPAIR Balance Blades: D c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. Sharpen and balance as needed. Turn blade to opposite tip. wear or damage. Set blade on JT07076 Rotary Blade Balancer (A) and turn blade to the horizontal position.059 in. 9.016 in. 5. 7. 8. Wear gloves or C handling blades to minimize the risk of personal injury. and cup (D). Sharpen blades using grinder. 1. 3. • • Install blade with bent tips up. Attachments Repair . Balance blades. If blade is not balanced.

c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. Sharpen blade. wear or damage. Wear C approved eye protection and gloves when sharpening blades to minimize the risk of personal injury. Remove cap screw (A). Blade should have 0. if required.) cutting edge (B) rather than a razor-type edge to prevent excessive chipping of the cutting edge. A B B MIF A 2. 1. 1. Wear gloves or removing/installing blades to minimize the risk of personal injury. Replace if needed. and cup (E).016 in. and that the concave side of washer faces the blade. Sharpen and balance as needed.ATTACHMENTS REPAIR 44-Inch Deck Mower Blades Removal/Installation: 1. Sharpen blades using grinder. SHARP EDGES. Inspect blade(s) for cracks. blade(s) (C). M82739A Picture Note: Mulching Configuration NOTE: If excessive browning of ends of mown grass occurs or if mower is to be used on tough grasses it may be necessary to grind the blade to a sharp edge. spacer (D) (if equipped). washer (B). M99534 Picture Note: Rear Discharge Configuration 2.528 . D Balance Blades: C B A c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. DO NOT hold blade with bare hands. 3. 3. Installation: Installation is the reverse of removal. Balance blades. Tighten cap screw to 68 N•m (50 lb-ft). 2. 4. DO NOT hold blade with bare hands. Wear gloves or handling blades. Attachments Repair . Remove mower deck. See “Sharpen Blades” above. Do not alter original bevel (A). IMPORTANT: Avoid damage! Make sure deflector cup is in place between spindle and blades. Clean blade and remove any accumulated grass/dirt with scraper or wire brush and wipe blade clean. file or power sharpener.40 mm (0. • • Install blade with bent tips up. Sharpen Blades: E c CAUTION: Avoid injury! FLYING SPARKS/ METAL FRAGMENTS.

IMPORTANT: Avoid damage! Make sure deflector cup is in place between spindle and blades. Turn blade to opposite tip. Set blade on JT07076 Rotary Blade Balancer (A) and turn blade to the horizontal position. M29527 3. Adjust balancer track (B) to just touch blade tip. Recheck balance. and that the concave side of washer faces the blade. Tighten cap screw to 68 N•m (50 lb-ft). Blade should also touch in same way. 7. 4.) (C). washer (B). blade (C). Sharpen and balance as needed. IMPORTANT: Avoid damage! Install new blade if difference between blade tips and balancer track measures over 1. D C B A M74256 B 2.ATTACHMENTS REPAIR 48-Inch Deck Mower Blades A Removal/Installation: 1. 6. Inspect blade for cracks.059 in. 9. and cup (D). c CAUTION: Avoid injury!injury. Remove cap screw (A). WITHOUT changing the original angle of blade. heavy end will drop. Remove mower deck. • • Install blade with bent tips up.5 mm (0. 3.529 . Attachments Repair . Wear glovesand Blades are sharp could cause personal or wrap blade with rag when removing/installing blades. M29528 C 4. 8. wear or damage. 5. DO NOT hold blade with bare hands. Installation: Installation is the reverse of removal. Lightly grind bevel of the heavy end. Replace blade if needed. If blade is not balanced.

Turn blade to opposite tip. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. wear or damage. D A C B A M74256 M29527 3. 9.injury! engine. 5. 54-Inch Deck Mower Blades Removal/Installation: c CAUTION: Avoid injury!injury. c CAUTION:PARTS. 2.40 mm (0.) cutting edge (B) rather than a razor-type edge to prevent excessive chipping of the cutting edge. Wear glovesand Blades are sharp could cause personal or wrap blade with rag when handling blades. Wait for all moving parts to STOP. 6.016 in. MIF 2. 1.5 mm (0. Clean blade and remove any accumulated grass/dirt with scraper or wire brush and wipe blade clean. washer (B). WITHOUT changing the original angle of blade.ATTACHMENTS REPAIR Sharpen: c CAUTION: Avoid injury! FLYING SPARKS/ METAL FRAGMENTS.530 . Inspect blade for cracks.059 in. Recheck balance. 3. 1. heavy end will drop. NOTE: If excessive browning of ends of mown grass occurs or if mower is to be used on tough grasses it may be necessary to grind the blade to a sharp edge. Do not alter original bevel (A). 8. DO NOT hold blade with bare hands.) (C). 3. Attachments Repair . Sharpen blades using grinder. and blade (C). SHARP EDGES. Replace blade if needed. 2. if required. Blade should also touch in same way. C M29528 B B A 4. 1. If blade is not balanced. Remove cap screw (A). Wear approved eye protection and gloves when sharpening blades to minimize the risk of personal injury. Balance blades. Set blade on JT07076 Rotary Blade Balancer (A) and turn blade to the horizontal position. Blade should have 0. Lightly grind bevel of the heavy end. Remove mower deck. Balance: 7. Sharpen blade. Adjust balancer track (B) to just touch blade tip. IMPORTANT: Avoid damage! Install new blade if difference between blade tips and balancer track measures over 1. file or power sharpener.

Sharpen blades using grinder. heavy end will drop. 1. Lightly grind bevel of the heavy end. Blade should also touch in same way. Balance: 4. 9.5 mm (0. C NOTE: If excessive browning of ends of mown grass occurs or if mower is to be used on tough grasses it may be necessary to grind the blade to a sharp edge. Turn blade to opposite tip. IMPORTANT: Avoid damage! Install new blade if difference between blade tips and balancer track measures over 1. Balance blades.531 . file or power sharpener. Set blade on JT07076 Rotary Blade Balancer (A) and turn blade to the horizontal position. M29528 5. 7. Sharpen blade.40 mm (0. 1.) (C). c CAUTION: Avoid injury! Wear gloves or wrap blade with a shop towel when handling blades to minimize the risk of personal injury. 8.016 in. 6. IMPORTANT: Avoid damage! Make sure deflector cup (D) is in place between spindle and blade. SHARP EDGES. Installation is the reverse of removal. Do not alter original bevel (A).) cutting edge (B) rather than a razor-type edge to prevent excessive chipping of the cutting edge. Adjust balancer track (B) to just touch blade tip. Wear approved eye protection and gloves when sharpening blades to minimize the risk of personal injury. If blade is not balanced. A MIF B 2. Sharpen and balance as needed. Clean blade and remove any accumulated grass/dirt with scraper or wire brush and wipe blade clean. Recheck balance. • • Install blade with bent tips up. Attachments Repair . 2. M29527 3. Blade should have 0. 3.059 in. if required.ATTACHMENTS REPAIR 4. DO NOT hold blade with bare hands. Tighten cap screw to 68 N•m (50 lb-ft). WITHOUT changing the original angle of blade. A Sharpen: c CAUTION: Avoid injury! FLYING SPARKS/ METAL FRAGMENTS.

Wear approved eye protection and gloves when sharpening blades to minimize the risk of personal injury. Tighten cap screw to 68 N•m (50 lb-ft). Remove mower deck. Sharpen blade. Remove cap screw (A). Inspect blade for cracks. DO NOT hold blade with bare hands. 2. Removal/Installation: 1. Sharpen and balance as needed. IMPORTANT: Avoid damage! Install new blade if difference between blade tips and balancer track measures over 1. file or power sharpener. Set blade on JT07076 Rotary Blade Balancer (A) and turn blade to the horizontal position.ATTACHMENTS REPAIR 54-Inch Convertible Deck Mower Blades c CAUTION:PARTS.016 in. Blade should have 0. M29527 3. SHARP EDGES. Sharpen blades using grinder. IMPORTANT: Avoid damage! Make sure deflector cup (D) is in place between spindle and blade. Wear gloves or handling blades to minimize the risk of personal injury. 3.059 in.) (C).532 . Attachments Repair . 4. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Replace blade if needed. Sharpen: c CAUTION: Avoid injury! FLYING SPARKS/ METAL FRAGMENTS. and blade (C). washer (B). C B A 2. if required. A B MIF c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. Balance: D 1.) cutting edge (B) rather than a razor-type edge to prevent excessive chipping of the cutting edge. NOTE: If excessive browning of ends of mown grass occurs or if mower is to be used on tough grasses it may be necessary to grind the blade to a sharp edge. Wait for all moving parts to STOP. 3. Balance blades. Installation is the reverse of removal.40 mm (0. Clean blade and remove any accumulated grass/dirt with scraper or wire brush and wipe blade clean. wear or damage.injury! engine. M74256 2. Do not alter original bevel (A). • • Install blade with bent tips up.5 mm (0. 1.

7. Replace parts as needed. M29528 4. spindle sheave. Disassemble and replace parts. • Tighten mounting nuts to 26 N•m (230 lb-in.533 . E F G H I J M99520 A . 6. sheave. Blade should also touch in same way. Turn blade to opposite tip. Remove cap screw.ATTACHMENTS REPAIR B A M54873 4. Remove nut. NOTE: If only the nut. wear. washer. 2. or damage. washers (A) and spindle (B). Wear gloves or wrap blade with a shop towel when removing/installing blades to minimize the risk of personal injury. and fan. D IMPORTANT: Avoid damage! SHARP EDGES. 9. Remove mower deck. Adjust balancer track (B) to just touch blade tip. 5. Remove four nuts. 8.Key B . 5. WITHOUT changing the original angle of blade.Nut C . Recheck balance.Sheave Attachments Repair . If blade is not balanced.). or replace entire spindle assembly as needed. 3. Disassembly: 38-Inch Deck Spindles Removal: A B C 1. heavy end will drop. DO NOT hold blade with bare hands. Installation: Installation is the reverse of removal. use a block of wood to prevent the blade from turning. or fan need to be replaced. Inspect spindle for smooth operation. Lightly grind bevel of the heavy end. Remove mower drive belt. and mower blade.

Lubricate spindle with multipurpose EP-2 grease or equivalent at lubrication fitting. and nut. Remove shaft from housing using a press. Using a press or a suitable driver and a soft-faced mallet. IMPORTANT: Avoid damage! When installing spindle sheave nut. 6. DO NOT hold end of spindle shaft in a vise. Wait for all moving parts to STOP. Remove nut. fan.Ball Bearing . Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Install blade and washer to spindle. Wear gloves or removing/installing blades to minimize the risk of personal injury.Shaft 9.ATTACHMENTS REPAIR D E F G H I J . MIF c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES.Shoulder . Remove cap screw. 5. 4. Hold the blade with a soft jaw vise or. Install spindle shaft. Install blade. Attachments Repair . Remove mower drive belt. DO NOT hold blade with bare hands. Assembly: 1. Remove second bearing using a press. and washer. spindle sheave. or suitable driver and a mallet. install lower bearing tight against spindle hub shoulder. from either side of the housing. Remove bearings only if replacement is necessary. Remove cap screw. 8. Install spacer. and must be removed one at a time.Housing . 1. and blade. Tighten nut to 140 N•m (103 lb-ft).Housing 6.Upper Bearing .Spacer . 1.Fan . Inspect all parts for wear or damage. NOTE: If only the nut or spindle sheave need to be replaced. washer. Replace parts as needed. key.Washer . A B C D E F . A B 42-Inch Deck Spindles F C E D c CAUTION:PARTS. 8. and blade. Install fan. Using a press or a suitable driver and a soft-faced mallet. Remove one bearing using a suitable puller.534 . End of the spindle shaft will be damaged. 7. NOTE: Bearings are seated against shoulder in housing. sheave.injury! engine. Remove mower blade. 2. Secure with cap screw. resulting in improper blade operation. 2. 4. with a block of wood. 3. Remove nut and sheave. Make sure that the concave side of washer faces the blade.Lower Bearing . 3. 5.Spacer .Shoulder . and cap screw onto spindle shaft. install upper bearing tight against spindle hub shoulder. 7. and replace parts as needed. washer. washer. Secure the spindle assembly by the blade in a soft jaw vise. Remove spacer. if spindle is in the mower deck. 2. Remove mower deck. or pin punch and hammer. or suitable driver and mallet.Ball Bearing . 3. use a block of wood to prevent the blade from turning.

and spindle (B).Bearing . . Spindle shaft will be damaged.Sheave .Cap Screw . 6.ATTACHMENTS REPAIR A B C D E F G E M54685 M D E H L 4.Seal . Repair or replace components as needed. Using a suitable puller or press. 1. DO NOT hold end of spindle shaft in a vise.Washer . • Tighten blade cap screw to 73 N•m (54 lb-ft). Secure with cap screw.) A B C D E F G H I J K L M M44948 c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES.Seal Ring . Wear gloves or removing/installing blades to minimize the risk of personal injury.Shoulder in housing 4.Nut . and remove two seal rings. remove spindle shaft from housing. K • Tighten spindle retaining nuts to 26 N•m (230 lb-in. DO NOT hold blade with bare hands.Lubrication Fitting . Remove nut.Spindle Shaft . resulting in improper blade operation.Housing .Spacer . make sure concave side of blade washer faces blade. Remove spindle from deck. (See “Removal/ Installation”. sheave.535 . wear. Install blade and washer to spindle. Secure the spindle assembly by the blade in a soft jaw vise. 3. 5. Attachments Repair . Note location of notched side. Installation: Installation is the reverse of removal. washer. or damage. 7. 2. 5. Remove four nuts and washers (A).). and blade. Check spindle for smooth bearing operation. I • When installing blade. Remove cap screw. J Disassembly/Inspection: IMPORTANT: Avoid damage! When removing spindle sheave nut. and lubrication fitting.Blade .

or suitable driver and a mallet. install upper seal (C) tight against bearing.Inspect all parts for wear or damage. 3. 6.) below hub flange (J). 11. C 2.ATTACHMENTS REPAIR IMPORTANT: Avoid damage! Bearings are seated against shoulder in housing. from either side of the housing. Remove one bearing (B) using a suitable puller. Install lower seal (I) with lip toward bearing using a press. install upper bearing (A) tight against spindle hub shoulder (B). until seal is 7. or pin punch and hammer. Install spacer (F). Install upper seal ring (D) inside seal lip with grease notch (E) toward bearing. and must be removed one at a time. 10. Remove bearings only if replacement is necessary. just enough so the lower seal can be installed. 5.Remove second bearing using a press. and cannot be removed with a press. Attachments Repair . Assembly: I G M44951 J I B M44952 D C A M44949 4. M44950 B A 1. Using a press or a suitable driver and a soft-faced mallet.536 .29 in. D 8. H A B K F MIF 9. 12. Replace parts as needed. Remove seals using a suitable seal puller.3 mm (0. Remove bearings only if replacement is necessary. NOTE: Install upper seal (C) with lip toward bearing.Remove spacer (C). Using a press or a suitable seal driver and a soft-faced mallet. Install lower bearing (G) in hub using a press. NOTE: Bearings are seated against shoulder (A) in housing.

3. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. washer (N). 10. Install blade (M). M54685 4. or damage. and lubrication fitting (R). Repair or replace components as needed. DO NOT hold blade with bare hands. 2. and blade. 1.injury! engine. Tighten nut to 127 N•m (94 lb-ft). Make sure that the concave side of washer faces the blade. wear. Spindle shaft will be damaged. 5. c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. with a block of wood. make sure concave side of blade washer faces blade. and cap screw (O) onto spindle shaft. Q P 44-Inch Deck Spindles Removal/Installation: c CAUTION:PARTS. resulting in improper blade operation. 11.537 .Lubricate spindle with EP-2 grease or equivalent at lubrication fitting.Hold the blade with a soft jaw vise or. Install lower seal ring (K) inside seal lip with grease notch away from bearing. Install spindle shaft (L). M A N O M44948 B 8. 1.Remove cap screw. washer. IMPORTANT: Avoid damage! When installing spindle sheave nut. if spindle is in the mower deck. Tighten spindle retaining nuts to 26 N•m (230 lb-in. When installing blade. nut (Q). Attachments Repair . 2. 9.). Remove mower deck. Install spindle sheave (P). Remove four nuts and washers (A) and spindle (B). DO NOT hold end of spindle shaft in a vise. Check spindle for smooth bearing operation. Tighten blade cap screw to 122 N•m (90 lb-ft). Wait for all moving parts to STOP. Remove mower drive belt. 12. Remove mower blade(s). Wear gloves or removing/installing blades to minimize the risk of personal injury. Installation: Installation is the reverse of removal.ATTACHMENTS REPAIR 7. R L 3. See “Disassembly/Inspection” procedure below.

Remove cap screw and washer 5. Replace parts as needed.Washer MIF 10. Remove nut. (Mulching Deck) Remove two blades.Shoulder in housing 3.Seal Ring . 13. and must be removed one at a time.Remove spacer (C). from either side of the housing. use a block of wood to prevent the blade from turning. Attachments Repair .) 4.Remove second bearing using a press.Blade . or screw-type puller. A B C D E F G E M D C B H L C K A J K L M .Bearing . or pin punch and hammer. 6. Remove nut and sheave.Inspect all parts for wear or damage. 1. and remove two seal rings.One blade and a spacer.Sheave . DO NOT hold hex end of spindle shaft in a vise. NOTE: Bearings (A) are seated against shoulder (B) in housing. Install blade(s).Two blades.Remove one bearing (A) using a suitable puller. and lubrication fitting. See “Removal/Installation” above.Cap Screw .Spindle Shaft . or suitable driver and mallet. NOTE: If only the nut or spindle sheave need to be replaced and the spindle is still in the deck. 11. Hex end of the spindle shaft will be damaged. NOTE: Two blade configurations are available: Mulching . Using a suitable puller or press. and replace parts as needed. Rear Discharge . 12. and spacer (if equipped) to spindle. resulting in improper blade operation. (Rear Discharge Deck) Remove blade and spacer. Secure the spindle by the blade in a soft jaw vise. 7. Remove spindle from deck. Remove seals using a suitable seal puller.Housing . I J M44948 A B A B C D E F G H I .Spacer .ATTACHMENTS REPAIR Disassembly/Inspection: IMPORTANT: Avoid damage! When removing spindle sheave nut. remove spindle shaft from housing. Note location of notched side. 9.538 . sheave.Nut . 2. (Rear Discharge configuration shown.Lubrication Fitting . Remove bearings only if replacement is necessary.Seal . 8.

6.539 . install upper bearing (A) tight against spindle hub shoulder (B). 5. Attachments Repair .ATTACHMENTS REPAIR Assembly: J B I D C A M44952 M44949 4. 3. 7. Install spacer (F). Install spindle shaft (L).8 mm (0. Using a press or a suitable seal driver and a soft-faced mallet. Q E D P M44950 1. L R K F H M N O I G M44951 M44948 8. Using a press or a suitable seal driver and a soft-faced mallet. Install lower seal with lip toward bearing using a press. just enough so the lower seal (I) can be installed. until seal is 7. NOTE: Install upper seal with lip toward bearing. Install lower bearing (G) in hub using a press.) below hub flange (J).31 in. Install upper seal ring (D) inside seal lip with grease notch (E) toward bearing. install upper seal (C) tight against bearing. Install lower seal ring (K) inside seal lip with grease notch away from bearing. 2.

Installation: installation is done in the reverse order of removal. Make repairs as necessary. • Install blade (D) with blade wing toward top of mower deck. 2. washer (E). 12. and tighten blade cap screw to 156 N•m (115 lb-ft). 6. If nut will not loosen. blade (D). 4. MX9609 5. 9. Remove four nuts and washers (G) and spindle (H). spindle sheave (B). Install spindle sheave (P). and blade cap screw (F). Remove mower drive belt. resulting in improper blade operation. Hold the blade (D) with a block of wood.Install washer (N). c CAUTION: Avoid injury! Wear gloves or wrap blade with a shop towel when removing/ installing blades to minimize the risk of personal injury. Use a piece of wood to prevent the blade from turning. See Disassembly/ Inspection procedure. and lubrication fitting (C). remove nut and then blade cap screw.540 . 1. 11. • Tighten spindle sheave flange nut (A) to 163 N•m (120 lb-ft). and deflector (R). washer. H 3. blade and spacer or blades. DO NOT hold hex end of spindle shaft in a vise. Wait for all moving parts to STOP. Remove mower deck. 10. with a block of wood. Tighten nut to 127 N•m (94 lb-ft).injury! engine. 48-Inch Deck Spindles c CAUTION:PARTS.Hold the blade with a soft jaw vise or if spindle is in the mower deck. tighten blade cap screw to 156 N•m (115 lb-ft).Lubricate spindle with multipurpose grease at lubrication fitting. (Rear Discharge Deck) Install blade (M) and spacer.(Mulching Deck) Install two blades. Remove cap screw (F). and lubrication fitting (R). Remove nut (A). • Loosen blade cap screw and then tighten to 73 N•m (54 lb-ft).Remove cap screw. nut (Q). Make sure that the concave side of washer faces the blade.ATTACHMENTS REPAIR IMPORTANT: Avoid damage! When installing spindle sheave nut. and cap screw (O) onto spindle shaft. A B D • Install washer (E). IMPORTANT: Avoid damage! Make sure the hex shaped hole in sheave is aligned with the hex end of the spindle shaft. 13. 14. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Hex end of the spindle shaft will be damaged. C R E F MX9610 Attachments Repair . Tighten cap screw to 67 N•m (50 lb-ft). DO NOT hold blade with bare hands.

Place spacer (M) into housing. Support the assembly using a 1-13/16-in. 3. 3. Pipe must extend beyond housing so the assembly is supported by the pipe NOT by spindle housing. disk against the upper bearing and a pipe approximately the same diameter against the disk. 4. IMPORTANT: Avoid damage! When using disk drivers. Push spacer (M) to one side and remove lower bearing (K) with a punch or a press. Pull spindle shaft (Q) and deflector (R) out of spindle hub (H). Remove upper bearing (N) with a punch or press. Center spacer on upper bearing. P N M H P O N M L MX9612 K I MIF 2.ATTACHMENTS REPAIR Disassembly/Inspection: Assembly: NOTE: Inspect all parts for wear or damage. Replace parts as necessary. MX9610 1. 2.541 . Install upper bearing (K) tight against spindle hub shoulder (L) using a 1-13/16 disk and press. support both the inner and outer races of the upper and lower bearings when installing the lower bearing. Turn housing over. Remove spacer (M). 4. Attachments Repair . Install lower bearing (N) in housing using a 1-13/16 in. disk and press. A J K L H P Q C O I M N D B I E F J K L MX9611 1. Remove seal rings (I and P) noting location of notched sides (down). 5. Press bearing until it is seated against spacer.

29 in.3 mm (0.Install sheave. . . If this is not possible. . 156 N•m (115 lb-ft) 7. Be careful not to turn lip of seal inside out when installing seal ring. Refer to cross section for correct seal installation. . . with grease notch toward bearing. MX9613 O T 5. . place blade in a vice and attach spindle assembly. . .Lubricate spindle with multipurpose grease at lubrication fitting. . . . . Tighten blade cap screw to 156 N•m (115 lb-ft) first. Specifications: Spindle Retaining Nuts . 13. 73 N•m (54 lb-ft) Spindle Sheave Flange Nut . flange nut.ATTACHMENTS REPAIR IMPORTANT: Avoid damage! Do NOT install hexagon end of spindle shaft in a vice to install spindle sheave flange nut. P S MX9810 M44950 9. . Tighten nut after the spindle is installed in the mower deck. Be careful not to turn lip of seal inside out when installing seal ring. . disk and a press. NOTE: The spindle housing must be attached to the deck shell BEFORE installing spindle sheave. tight against bearing using a 1-13/16 disk and press. . inside seal lip. 6.) Blade Cap Screw .Install spindle shaft (Q) in housing (H). Install spindle assembly in mower deck. . and tighten blade cap screw to 156 N•m (115 lb-ft). Attachments Repair . 11. . 14. 16. . . . .Install washer (E). being sure to index components to spindle shaft. . . . Install lower seal (O) with lip toward bearing using a 1-13/16 in. 26 N•m (230 lb-in. L I J K MX9611 15. 8.Loosen blade cap screw and then tighten to 73 N•m (54 lb-ft). 10. but do not torque at this time. then tighten spindle sheave flange nut. and blade cap screw (F). Install lower seal ring (P). . Install upper seal (J) with lip toward bearing. Install to a depth of 7. .Install blade (D) with blade wing toward top of mower deck.542 . . . and lubrication fitting. Use a piece of wood to prevent the blade from turning. .) below hub flange (T). Press until the seal is tight against the bearing. . with grease notch (S) away from bearing. . inside seal lip. Remove blade to install assembly in mower deck. 12. Tighten flange nut securely.Tighten spindle sheave flange nut to 163 N•m (120 lbft). . . Install upper seal ring (I). .

Install blade. Remove cap screw. DO NOT hold hex end of spindle shaft in a vise. make sure concave side of blade washer faces blade.injury! engine. Remove mower drive belt. 3. Remove mower blade(s). Check spindle for smooth bearing operation. DO NOT hold blade with bare hands. Wait for all moving parts to STOP. or damage. c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. Hex end of the spindle shaft will be damaged. A 4 5 6 7 B 13 M54685 5 4 3 12 8 4. spindle sheave. • Tighten spindle retaining nuts to 26 N•m (230 lb-in. (See “Disassembly/Inspection” procedure. NOTE: If only the nut or spindle sheave need to be replaced and the spindle is still in the deck. Remove nut. and cap screw onto spindle shaft.) Installation is the reverse of removal. • Tighten blade cap screw to 122 N•m (90 lb-ft). Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. Attachments Repair . 2. Repair or replace components as needed. Secure the blade in a soft-jaw vise. Remove four nuts and washers (A).ATTACHMENTS REPAIR 54-Inch Deck Spindles Removal/Installation: Disassembly/Inspection: c CAUTION:PARTS. Remove spindle from deck. washer and blade. 5. 9 10 11 • When installing blade. Remove mower deck. washer. Wear gloves or handling blades to minimize the risk of personal injury. 4. wear.). 1 2 3 c CAUTION: wrap blade with a shop towel when Avoid injury! SHARP EDGES. resulting in improper blade operation.543 . (See “Removal/ Installation”. DO NOT hold blade with bare hands. 1. and lubrication fitting.) 2. and replace parts as needed. IMPORTANT: Avoid damage! When removing spindle sheave nut. 5. 3. use a block of wood to prevent the blade from turning. Remove nut and sheave. M44948 1. Wear gloves or removing/installing blades to minimize the risk of personal injury. and spindle (B).

NOTE: Bearings (A and G) are seated against shoulder (B) in housing.Remove spacer (C). Note location of notched side. 3. Install upper seal ring (D) inside seal lip with grease notch (E) toward bearing. and must be removed one at a time. NOTE: Install upper seal with lip toward bearing. remove spindle shaft from bearings and housing. 10.544 . Remove seals using a suitable seal puller.Inspect all parts for wear or damage.ATTACHMENTS REPAIR 6. Remove bearings only if replacement is necessary. or screw-type puller. Using a press or a suitable seal driver and a soft-faced mallet. 7. from either side of the housing. 2. Using a press or a suitable seal driver and a soft-faced mallet. 11. or pin punch and hammer. and remove two seal rings. Remove one bearing using a suitable puller. Attachments Repair . Replace parts as needed. install upper bearing (A) tight against spindle hub shoulder (B). install upper seal (C) tight against bearing. 12.Remove second bearing using a press. or a suitable driver and a mallet. 9. Using a suitable puller or press. Assembly: B D C A M44949 A B C E D B G M44950 MIF 1. 8.

Install lower seal (I) with lip toward bearing using a press. IMPORTANT: Avoid damage! Do not press lower bearing (G) tight against hub shoulder (H). The bearing and seal must be installed to a specific dimension for proper sealing of spindle. 12. Install spindle shaft. just enough so the lower seal can be installed. Install lower bearing (G) in hub using a press.Remove cap screw. M44948 IMPORTANT: Avoid damage! When installing spindle sheave nut. Tighten cap screw to 122 N•m (90 lb-ft). 6.8 mm (0. Hex end of the spindle shaft will be damaged. until seal is 7. Install spacer (F). 7. Install lower seal ring (K) inside seal lip with grease notch away from bearing. washer and blade. Install spindle sheave. 8.Lubricate spindle with multipurpose grease at lubrication fitting. washer. resulting in improper blade operation.) below hub flange (J). with a block of wood.31 in. nut.ATTACHMENTS REPAIR 1 H F 2 3 4 5 6 K I G 7 5 M44951 13 4 3 8 J I 12 11 9 M44952 10 4. 11. IMPORTANT: Avoid damage! Make sure the hex shaped hole in spindle sheave is aligned with the hex portion of the spindle shaft. 10. DO NOT hold hex end of spindle shaft in a vise. and cap screw onto spindle shaft. Install blade. Attachments Repair . and lubrication fitting.Hold the blade with a soft-jaw vise or if spindle is in the mower deck. Tighten nut to 163 N•m (120 lbft). 9. 5.545 .

ATTACHMENTS REPAIR 54-Inch Convertible Deck Spindles Removal/Installation: G c CAUTION:PARTS. Remove mower drive belt. blade (D). MX9609 5. Disassembly/Inspection: E F MX9610 I K H P R Q M N 3. See Disassembly/ Inspection procedure. Remove nut (A). Installation is done in the reverse order of removal. • Tighten spindle sheave flange nut (A) to 163 N•m (120 lb-ft). Hold the blade (D) with a block of wood. and blade cap screw (F). remove nut and then blade cap screw. Use a piece of wood to prevent the blade from turning. 6. Attachments Repair . If nut will not loosen.injury! engine. and tighten blade cap screw to 156 N•m (115 lb-ft). Make repairs as necessary. Remove mower deck. Pull spindle shaft (Q) and deflector (R) out of spindle hub (H). A B D C R • Install washer (E). 4. spindle sheave (B). Remove cap screw (F). • Install blade (D) with blade wing toward top of mower deck. • Loosen blade cap screw and then tighten to 73 N•m (54 lb-ft). H c CAUTION: Avoid injury! Wear gloves or wrap blade with a shop towel when removing/ installing blades to minimize the risk of personal injury. Wait for all moving parts to STOP. DO NOT hold blade with bare hands. washer (E). 1. 2. Remove Avoid ROTATING BLADES/ MOVING STOP ignition key. and lubrication fitting (C). MX9610 1.546 . tighten blade cap screw to 156 N•m (115 lb-ft). Remove four nuts and washers (G) and spindle (H). and deflector (R).

Turn housing over. O T I J MX9613 K M9611 1. Press bearing until it is seated against spacer. disk and a press.3 mm (0. disk against the upper bearing and a pipe approximately the same diameter against the disk. Remove seal rings (I and P) noting location of notched sides (down). Attachments Repair .547 . 5. 5. Assembly: L 2. 4.ATTACHMENTS REPAIR P N L M H P K I MIF M MX9612 O N 2.29 in. Place spacer (M) into housing. 3. Center spacer on upper bearing. Install upper bearing (K) tight against spindle hub shoulder (L) using a 1-13/16 disk and press. Install lower bearing (N) in housing using a 1-13/16 in. Remove spacer (M). Refer to cross section for correct seal installation. Inspect all parts for wear or damage. 6. 4. Remove upper bearing (N) with a punch or press. 3. Pipe must extend beyond housing so the assembly is supported by the pipe NOT by spindle housing. disk and press. Install lower seal (O) with lip toward bearing using a 1-13/16 in. Replace parts as necessary.) below hub flange (T). Install to a depth of 7. Support the assembly using a 1-13/16-in. Push spacer (M) to one side and remove lower bearing (K) with a punch or a press.

. . but do not torque at this time. . Install spindle assembly in mower deck. 26 N•m (230 lb-in. . Remove blade to install assembly in mower deck. . IMPORTANT: Avoid damage! Do NOT install hexagon end of spindle shaft in a vice to install spindle sheave flange nut. then tighten spindle sheave flange nut. NOTE: The spindle housing must be attached to the deck shell BEFORE installing spindle sheave. .Tighten spindle sheave flange nut to 163 N•m (120 lbft). . . Specifications: Spindle Retaining Nuts . Tighten blade cap screw to 156 N•m (115 lb-ft) first. . Press until the seal is tight against the bearing. . . and blade cap screw (F). flange nut. . and lubrication fitting.Lubricate spindle with multipurpose grease at lubrication fitting.Install washer (E). Attachments Repair . Install upper seal (J) with lip toward bearing.Install sheave. . . 156 N•m (115 lb-ft) 8.Install blade (D) with blade wing toward top of mower deck. . Tighten nut after the spindle is installed in the mower deck. Install upper seal ring (I). . . tight against bearing using a 1-13/16 disk and press. L I J K MX9611 14. Tighten flange nut securely. . 11. Be careful not to turn lip of seal inside out when installing seal ring.Loosen blade cap screw and then tighten to 73 N•m (54 lb-ft). . . .548 . with grease notch toward bearing. . . being sure to index components to spindle shaft. 7. place blade in a vice and attach spindle assembly. . 12. 16. inside seal lip. . 73 N•m (54 lb-ft) Spindle Sheave Flange Nut . If this is not possible. with grease notch (S) away from bearing. 15.) Blade Cap Screw . . Use a piece of wood to prevent the blade from turning. F MX9610 9. .Install spindle shaft (Q) with deflector (R) in housing (H). inside seal lip. Install lower seal ring (P). Be careful not to turn lip of seal inside out when installing seal ring. . . .ATTACHMENTS REPAIR A B H D P S R Q E M44950 C 6. . 10. 13. and tighten blade cap screw to 156 N•m (115 lb-ft). . .

or suitable driver and mallet. Remove one bearing (B) using a suitable puller. Remove second bearing using a press. and must be removed one at a time. 1. Inspect all parts for wear or damage. or suitable driver and mallet. from either side. Be sure to install spacer between bearings.549 . Attachments Repair . Remove spacer (C). or a pin punch and hammer. Idlers Disassembly and Assembly: Idler sheaves are welded and contain a non-serviceable bearing. Replace as needed. A B C A B MIF 2. replace entire idler sheave. 3. If bearing replacement is needed. Remove bearings only if replacement is necessary. Assembly: • Install bearings tight against shoulder (A) in jack sheave using a press.ATTACHMENTS REPAIR Jack Sheave Disassembly: NOTE: Bearings are seated against shoulder (A) in jack sheave. 4.

ATTACHMENTS REPAIR Attachments Repair .550 .

......556 Lift Assist Spring Adjustment Early Models......570 Miscellaneous Table of Contents .......................566 Spring and Adjuster Removal and Installation .....556 Mower Deck Lift and Depth Stop Theory of Operation ..............................................................................555 Theory of Operation .................553 Other Materials..........554 Mower Deck Foot Pedal Lift ...............................551 ...561 Mower Deck Lift (Foot Pedal)......................557 Repair...........559 Fuel Tank Removal and Installation ................556 Tests and Adjustments ...........556 Hood Latch Adjustment ...............................................561 Mower Deck Lift (Handle).................556 Lift Assist Spring Adjustment Later Models.......570 Height Adjuster Assembly Removal and Installation ................................................MISCELLANEOUS TABLE OF CONTENTS Miscellaneous Table of Contents Specifications ..........558 Seat and Support Removal and Installation ........................................................... GT245 .............553 Torque Specifications.....558 Hood Removal and Installation Models GT225.......................557 Checking Wheel Bolt Torque........................................................................................................559 Fender Deck Removal and Installation ...............................................554 Mower Deck Handle Lift ....553 Component Location................................................ GT235...................................558 Hood Removal and Installation Models GT235E............................

552 .MISCELLANEOUS TABLE OF CONTENTS Miscellaneous Table of Contents .

. .59 lb-ft) Other Materials Other Material Part No. . . . . . . . . . . . . . . .81 N•m (29 . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDM J13E4 Part Name John Deere Extreme Pressure Grease Part Use Lubricate Spindles Miscellaneous Specifications .553 . . . . . . . . . . . . . . . . . . . . .MISCELLANEOUS SPECIFICATIONS Specifications Torque Specifications Front Axle Pivot Pin Cap Screws . . .87 N•m (30 . . . . . 42 . . . . . . .64 lb-ft) Drag Link Locknut . . . .

Depth Stop Arm .Lift Assist Spring .Latch .554 .Latch Strike Miscellaneous Component Location .MISCELLANEOUS COMPONENT LOCATION Component Location Mower Deck Handle Lift C B A D E J L K I Latch F H G M95621 A B C D E F G H I J K L .Lift Link .Mower Deck Lift Arm .Lift Button .Mower Deck Cutting Height Adjusting Knob .Mower Depth Stop Cam .Lift Handle Assembly .Latch Rod .Return Button Spring and Cup .

555 .Mower Deck Lift Arm .Lift Assist Spring .Pedal Latch Handle .Mower Depth Stop Cam .Latch .MISCELLANEOUS COMPONENT LOCATION Mower Deck Foot Pedal Lift F G C D B A H I E K J mif A B C D E F G H I J K .Lift Pedal Assembly .Latch Rod .Lift Link .Latch Strike .Depth Stop Arm Miscellaneous Component Location .Mower Deck Cutting Height Adjustment Knob .

Move latch up or down and tighten cap screw for proper adjustment. The lift shaft rotates forward raising the lift arms and attachment. The lift assist spring can be locked out by pushing the lift handle fully forward. Open hood and loosen cap screw (A) to adjust hood latch (B) on both sides of machine.MISCELLANEOUS THEORY OF OPERATION Theory of Operation Mower Deck Lift and Depth Stop Theory of Operation Function: To provide a means of controlling the cutting height of the deck and to allow the deck to be raised to a transport position. This allows the attachment to return to a specific height each time the attachment is lowered. A slot in the lift link allows the lift shaft and arms that hold the attachment to move without any effect from the lift assist spring. To Adjust Spring Tension: NOTE: The long adjusting bolt (B) is located behind front bumper on left side of frame.Early Models Purpose: The weight of the mower deck affects ease of lifting. Adjust lift assist spring tension when installing a different deck to machine. Tests and Adjustments Hood Latch Adjustment Hood should stay latched down when latches are properly adjusted. M96440 2. Also attached to the lift link is the lift assist spring.556 . When the lift handle is lowered. 48C Mower: The yellow spring plug should be half way between the (+) and (-) windows. Lift Assist Spring Adjustment . Three Spindle Mower Decks: 44 Piranha: The yellow spring plug should be half way between the (+) and (-) windows. This results in full implement weight on the ground. The depth stop cam has different cam heights which are selected by using the cutting height knob. The lift link is attached to the lift shaft. B A B M95619 1. M95562 Miscellaneous Theory of Operation . 54-Inch Mower: The yellow spring plug should be visible in the (+) window. Theory of Operation: As the lift lever is pulled rearward (to raise attachment). it pulls the lift link forward. The lift handle locks in the fully raised position with a latch and strike. the lift arms lower the attachment until the depth stop arm on the lift shaft contacts the depth stop cam. Spring tension helps pull the link forward. Two Spindle Mower Deck: A The yellow spring plug (A) should be visible in the (-) window. reducing the effort required to lift the attachment.

C B M96442a 2. Late Style: NOTE: The weight of the mower affects ease of lifting. Adjust lift assist spring tension when installing a different deck to machine.Decreases spring tension and moves indicator toward rear of machine for lighter mowers. and (E) until snug. Miscellaneous Tests and Adjustments . Lift Assist Spring Adjustment .557 . (C).MISCELLANEOUS TESTS AND ADJUSTMENTS E D MX30481 1. adjust the lift assist spring so the indicator is aligned with the correct mower deck mark. • Turn long adjusting bolt (B) clockwise to increase spring tension and move yellow spring plug (C) toward the front of the machine or into the (+) window. Checking Wheel Bolt Torque NOTE: Check wheel bolt torque often during the first 100 hours of operation. The slotted opening has indicator marks for different size decks. Make sure yellow indicator (D) is aligned with the proper mark for the mower deck installed.Later Models Purpose: The weight of the mower deck affects ease of lifting. Adjust the lift assist spring for your particular mower deck model. • Counterclockwise . Finish tightening to 55 N•m (41 lb-ft). • Turn the long adjusting bolt counterclockwise to decrease spring tension and move yellow spring plug toward the rear of the machine or into the (-) window.Increases spring tension and moves indicator toward front of machine for heavier mowers. If not. A D C B E M99521 Tighten rear wheel bolts evenly in proper sequence (A). Turn adjusting bolt (E) at front of machine frame to adjust lift assist spring: • Clockwise . (B). (D).

Miscellaneous Repair . GT245 Removal: 1. M95514 2. Lift hood slightly and move toward front of machine. 5.Models GT225. disconnect electrical connector (A) for headlights. M95514 6. Installation: Installation is the reverse of removal. E A D M95516 4.Models GT235E. 3. Remove hood. Remove hood.MISCELLANEOUS REPAIR Repair F Hood Removal and Installation . On right side of the machine frame. disconnect electrical connector (A) for headlights. On right side of the machine frame. A C M95515 3. Open hood. Slide two bushings (E) toward center of machine and out of hinge brackets (F).558 . B B Hood Removal and Installation . GT235 Removal: 1. Install quick lock spring pins to inner holes (D) on pivot pins. near the right front pivot. Lift hood slightly and move toward front of machine. 2. NOTE: It may be necessary to lift up slightly on hood when sliding bushings. Remove two quick lock spring pins (B) from pivot pins (C). near the right front pivot. Installation: Installation is the reverse of removal. Open hood.

Lift seat and disconnect wiring harness (A) from seat switch (B). A A M95319 B C 1. and nut. M95317 4. Under footrest area. 2.559 . 3.MISCELLANEOUS REPAIR Seat and Support Removal and Installation Removal: B Fender Deck Removal and Installation Removal: 1. locate and remove two nuts (D) attaching front of fender deck (E) to machine frame (F). Remove seat and seat support. c injury may Avoid Injury! Serious personal by CAUTION: result if gasoline vapor is ignited a spark or open flame. lock washer. Remove four nuts (C). Miscellaneous Repair . C M95315 3. Remove lift adjust stop knob. Remove spring clip pin (A) and disconnect forward/ reverse control rod (B) from control lever (C). Installation: Installation is the reverse of removal. Remove cruise control lever knob. E D M95318 F 2.

Replace fuel filler cap. Obtain an assistant. 7.560 . Obtain an assistant. Miscellaneous Repair . B H A M95319 M95319 4. M95318 5. 6. route seat switch wiring harness through hole in fender deck and seat support.MISCELLANEOUS REPAIR Installation: G c injury may Avoid Injury! Serious personal by CAUTION: result if gasoline vapor is ignited a spark or open flame. 9. Install two cap screws (C) to rear of fender deck attaching fender deck to machine frame. Replace fuel filler cap. Remove fuel filler cap. 1. C IMPORTANT: Avoid damage! Use caution when removing fender deck from machine to prevent damage to seat switch wiring harness. and lift and remove fender deck from machine. 3. Connect seat switch wiring harness (A) to seat switch (B). and install fender deck to machine. I M95318 5. Disconnect wiring harness (H) from seat switch (I). 2. Remove two cap screws (G) from rear of fender deck attaching fender deck to machine frame. IMPORTANT: Avoid damage! When installing fender deck. Position forward/ reverse control rod toward rear of machine to prevent interference when installing fender deck to frame. 8. Remove fuel filler cap.

2. 9. lock washer. 7. Installation: Installation is the reverse of removal. Use caution when releasing lift spring tension to minimize the risk of personal injury. Wipe-up any spills IMMEDIATELY. safe container. 4. G H 3. 1. See “Fender Deck Removal and Installation” on page 559. perform pedal height adjustment procedure.) c MOVEMENT. DO NOT expose or spark. Pull transaxle reservoir (B) from back of fuel tank and lift fuel tank off of machine. See “Mower Deck Removal and Installation” for the appropriate mower deck in the Attachments section. and press in release button. A I B M99673 2. Install lift adjust stop knob. and lock in the RAISE position. M953115 Mower Deck Lift (Handle) Removal: 1. push lift lever forward against spring tension. Install two nuts (D) to carriage bolts attaching front of fender deck (E) to machine frame (F). injury can result. 3. Miscellaneous Repair .MISCELLANEOUS REPAIR Fuel Tank Removal and Installation Procedure: E D F c CAUTION: Avoid to flameGasoline isSerious injury! explosive. Store in a properly marked. and nut. If lift lever is not in rearward position. NOTE: If forward/reverse control rod end becomes loose during fender deck removal and installation. 8. Remove fender deck. M95317 6.561 . (See “Forward and Reverse Pedal Height Adjustment” in “Hydrostatic Power Train” section. WithInjury! SUDDEN LIFT LEVER CAUTION: Avoid no weight on lift arms. Disconnect and plug fuel line (A). spring will pull lift lever rearward when lock button is pressed. Move lift lever rearward. Wipe up any spilled fuel. Install cruise control lever knob. Connect forward/reverse control rod (G) to transaxle control lever (H) and retain with spring clip pin (I). Under footrest area. Remove mower deck. Remove fender deck. Turn steering wheel to left until wheels stop.

Loosen lift spring adjusting bolt (A) until all tension is removed from lift assist spring. E B C D F C B D M95564 Right Side Shown 1. Miscellaneous Repair . Remove snap ring and washer (C) attaching lift strap (B) to lift lever (D). 3. remove four screws and bumper cover. and spacer and cap screw (C). Remove lift rod (E) and lift link (F). Move lift lever to forward (Lower) position. Installation of lift arms is the reverse of removal. 2. Remove locknut and washer (B).562 . Repeat for other side. 3. M95563 2. Disconnect rear of lift assist spring (A) from lift strap (B). Lift Arms Removal and Installation: M95570 1. Remove lift arm (D). Detach lift strap from pin on lift lever. Lift Shaft Removal and Installation: A A B M95562 5.MISCELLANEOUS REPAIR NOTE: For easier access to adjusting bolt (A).

Rotate lift strap (B) 90° and remove from lift shaft assembly (E). Remove two nuts and carriage bolts (F) attaching left side of lift shaft assembly to frame. Lift and support the front of the fuel tank. Remove lift shaft assembly (E).563 .MISCELLANEOUS REPAIR E I F M95567 B M95566 7. Slip the wiring harness (J) over the left side of the lift shaft assembly. Miscellaneous Repair . NOTE: Lower cap screw supports brake linkage. 4. M95569 9. Installation of the lift shaft is the reverse of removal. Remove lower nut and push cap screw (H) toward center of machine until clear of lift shaft assembly. J M95568 G 8. Locate the wiring harness tie down clip (I) and disconnect it from the machine frame. Remove upper nut and carriage bolt (G) attaching right side of lift shaft assembly to frame. It is not necessary to remove the lower cap screw when removing the lift shaft assembly. H E M95565 6. 5.

2. 3. Remove steering wheel. M95576 8. Remove snap ring (E) from end of lift shaft (F).564 . E A B F M95574 6. Remove screw (A) and left closeout panel (B). Loosen two screws (G) attaching control panel (H) to pedestal (I). See “Steering Gear Removal and Installation” on page 459 in Steering section. Remove throttle and choke control knobs. G C D M95575 7. Remove screw (C) and right closeout panel (D). Remove two nuts (J) attaching control panel to pedestal.MISCELLANEOUS REPAIR Lift Lever Removal and Installation: 1. M95573 H I 4. Miscellaneous Repair . Remove battery. J M95572 5.

Disconnect wiring harness tie down clip (R) from machine frame (S) in front of pedestal (I). M95582 16. 14. 10.Disconnect sides of park brake handle from control panel and remove handle from park brake rod (M).Disconnect wiring harness tie down clip (T) from machine frame behind pedestal (I).565 . 12.Remove two nuts (N) attaching left side of pedestal to machine frame.Remove locknut (P) and latch strike (Q). Miscellaneous Repair .Lift control panel (H) off of pedestal (I).Disconnect wiring harness tie down clip (O) from pedestal (I). Remove spring (K) from park brake handle (L).MISCELLANEOUS REPAIR L O M I K Q P M95579 M95577 13. I N I T M95578 11. Lift and rotate control panel and lay it on top of pedestal as shown. 9. H R S I M95581 15.

Remove battery. If lift pedal is not in locked position. 5. W 20. Use caution when releasing lift spring tension to minimize the risk of personal injury. Remove fender deck. M95584 19.MISCELLANEOUS REPAIR U X I Y Z M95580 17. Remove mower deck. M95583 18. c CAUTION: Avoid injury! SUDDEN LIFT PEDAL MOVEMENT. Turn steering wheel to left until wheels stop. Disconnect negative (-) battery cable and then disconnect positive (+) battery cable.Inspect bushing (Y) and latch assembly (Z). spring will pull lift pedal rearward when lift lock is engaged.Slide snap ring (V) on steering shaft away from pedestal and steering bushing (W). 3. See Mower Deck Removal and Installation for the appropriate deck in the Attachments section. 2. Mower Deck Lift (Foot Pedal) Removal: 1.Raise pedestal until lift lever and shaft (X) can be removed from machine.566 . With no weight on lift arms. Support pedestal and remove lift lever and shaft. V Installation of the lift lever is the reverse of removal. 4.Remove two nuts (U) attaching right side of pedestal (I) to machine frame. Miscellaneous Repair . Replace parts as needed. push lift pedal forward and lock in the RAISE position.

C B L M F D E G A I MX30459A MX30461 Picture Note: Left side of Machine.567 . 5. spacer and cap screw (C). 3.MISCELLANEOUS REPAIR Lift Shaft Removal and Installation: K I J A M95562 H MX30460 NOTE: For easier access to adjusting bolt (A). Remove spring (A) from lift arm (F). Remove lift rod (B) and lift link (G). Disconnect rear of lift assist spring (H) from lift strap (I). 3. Loosen lift spring adjusting bolt. Release lift pedal to (LOWER) position. 4. Detach lift strap from pin on lift lever. 4. located under left side of front fender. until all tension is removed from lift assist spring. 1. Miscellaneous Repair . Remove lift arm (F). remove four screws and bumper cover. Lift Arms Removal and Installation: 1. 6. 2. Installation: Installation of lift arms is the reverse of removal. washer (D). 2. Remove locknut (E). Repeat for other side. Remove snap ring (K) attaching lift strap (I) to lift lever (J). Remove two nuts and carriage bolts (M) attaching left side of lift shaft assembly to frame. Rotate left lift strap (I) 90° and remove from lift shaft assembly (L).

Lift Pedal and Lift Lock Handle Removal and Installation: 1. Remove lower nut and push cap screw (O) toward center of machine until clear of lift shaft assembly.568 . MX30464 2.MISCELLANEOUS REPAIR N Q O M95568 MX30462 NOTE: Lower cap screw supports brake linkage. It is not necessary to remove the lower cap screw when removing the lift shaft assembly. 10. 6. Remove upper nut and carriage bolt (N) attaching right side of lift shaft assembly to frame. if necessary. Locate the wiring harness tie down clip (P) and disconnect it from the machine frame. Remove screw (A) and left closeout panel (B). Remove battery P B M99567 A 7. Remove lift shaft assembly (L). Lift and support the front of the fuel tank. Slip the wiring harness (Q) over the left side of the lift shaft assembly.Installation of the lift shaft is the reverse of removal. Miscellaneous Repair . 8. L MX30463 9.

8. Installation of the lift pedal and lift lock handle is the reverse of removal. Remove snap ring and shims (E). Slide Lift foot pedal (F) off. Miscellaneous Repair .MISCELLANEOUS REPAIR C D I MX30465 3.569 . Remove lift pedal stop (I). Remove lift rod (H) from the back side of the park brake handle (J). Remove spring (G) from lift rod (H). H G H M95575 7. 6. Remove screw (C) and right closeout panel (D). MX30466 5. MX30469 F J E M95596 4.

Clip 2.Shaft . Replace parts as necessary. Hold spring and loosen tension adjuster (A) until spring comes off. Miscellaneous Repair . See “Hood Removal and Installation Models GT225. Remove four screws (B) and bumper cover (C). 2. Remove fender deck.570 . B C M95518 3. Height Adjuster Assembly Removal and Installation Removal: 1. 4. Installation: Installation is the reverse of removal. Installation: Installation is the reverse of removal. Remove hood. See “Fender Deck Removal and Installation” on page 559. Inspect all parts for wear or damage. GT245” on page 558.Adjuster .MISCELLANEOUS REPAIR Spring and Adjuster Removal and Installation Removal: NOTE: The following steps are for removal of the lift assist spring and tension adjuster bolt.Detent Wire . or “Hood Removal and Installation . D C B A A M54681 M95562 1. Remove adjuster bolt from front of machine. A B C D .Models GT235E. GT235” on page 558.

. . . . . . . . . . . . .363 Belt Drive and Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363 Electrical . . . . . . . . .174 Kawasaki (FH601V) Carburetor Externally Vented . Spindle . . . . . . . . . . . .367 Cruise Control Linkage (Exploded View) . . . . . . . . . . Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mower Blades . . 48-Inch Convertible Mower Deck Component Location Draft Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mower Drive Belt . . . . . . Mower Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Kawasaki (FH580V) Carburetor . . . . . . . . . . . . . Spindles . . . . . . . . .Cross Section . . . . . . . . .500 Jack Sheave and Idlers . . . Jack Sheave and Idlers . . . . . . . .240 Electrical . Mower Drive Belt . . . Overall View . . . . . . . . . . . . . . . . . . . . . . . . Jack Sheave and Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindles . . . . . . . . . . . . . . . . . . . . . . . . .530 Mower Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mower Drive Belt . . . . . . . . . . . Mower Drive Belt . . . . . . . . . . . . . . . . . . . .76 Kawasaki Engine (FH580V) . . . . . . . . . . . . . . . . . . . . . Spindles . . . . . .26 Component Location . . . . . . . . .4 Choke Adjustment B&S Engine . . . . . . . . . . . . . . . . .373 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jack Sheave and Idlers . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . Overall View . . . . .175 Internally Vented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Kawasaki (FH601V) . . . . . . . . . . . . .5 B Belt Traction Drive Removal and Installation . . . . . . . . Idlers and Sheaves . . . . Spindle . . . . . . . . . . . . . . . . . . . Draft Arms and Gauge Wheels . . . . . . Mower Deck Component Location . Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .241 Engine Kawasaki (FH580V) . . . . . . Gauge Wheels . . . . . . . . . . . . . . . .501 Jack Sheave and Idlers . . . . . . . . . . . . . . . . . . . . . . . .Cross Section . . . . . . . . . . . . . . . . . .543 479 480 477 549 525 522 516 533 A 482 484 483 481 485 526 523 534 486 490 489 487 488 528 523 518 537 Avoid Harmful Asbestos Dust . . . . Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176 Kohler Air Intake System . . . . . . .Cross Section . Mower Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 Electrical . . . . . . . . . . . . . . . Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449 C California Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498 Removal & Installation . . . . . . . . . . . . . . . . . . . . . . Spindle . . .GT235 . . . . . . . . . . . . . . . . .408 Brake Pedal and Linkage Brake Rod Removal and Installation .5 Avoid Injury Rotating Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .499 Mower Blades . . . . . . . . .35 Forward & Reverse Pedals . . . . . . . . . . . . Jack Sheave and Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX Numerics 38-Inch Mower Deck Component Location Draft Arms and Gauge Wheels . . .524 Overall View . . . . . .370 Axles . . . . . . . . . . . . 54-Inch Mower Deck Component Location Gauge Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Kawasaki Engine (FH601V) . . . . . . . . . . . . . .450 Removal & Installation . . . . . . . . . . . . . . . . Removal & Installation . . . . . . . . . . . . . . . . . . . . Removal and Installation . . .Cross Section . . . . . . .369 Center Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jack Sheave Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 492 493 494 495 491 496 529 524 519 540 507 508 509 510 506 532 525 505 521 546 Index . . . . .444 Brake Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge Wheels . . . . . . . . . . . . . . . . . . . . . . . . . .503 Draft Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368 Brake Pedal and Linkage . . . . . . . . . . . . . .GT235E .Cross Section . . . . .GT245 . . . . . . . . . . . . . . . . . . . Augers And PTO Shafts . . . . . . . . . . . Mower Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . 44-Inch Piranha Mower Deck Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-Inch Convertible Mower Deck Component Location Draft Arms . . . . . . . . . . . . . . . . . . . . . Removal & Installation . . . . . . . . . . . . . . Mower Blades . . . . .180 Kohler Engine . . .502 Spindle . . . . . . . .Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idlers and Sheaves . . . . . . . . . . Spindles . . . .442 Traction Drive Tensioner Removal and Installation . . . . . . . . . . . . . . . . . . .520 Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-Inch Convertible Mower Deck Component Location Gauge Wheels . . . . . . . . . . . . . . . . . . . . . . . . . .GT225 . . . . . . Idlers and Sheaves . . . . . . . . . . . Draft Arms . . . . Mower Blades . . . . . . . . . . . . . . . .

. . . . . . . . . 296 120 Volt Circuit Electrical Schematic . . . . . . . . . . .GT225 and GT235 (SN -060000) . . . . . .320 General Specifications . .GT235E . . . . . . . . . . . .302 PTO Circuit Electrical Schematic . . . . . . . . . . . .346 D Diagnosis Attachments . . . . . . . . . . . . . . . . . . . . . .271 Cranking Circuit Electrical Schematic . . . . . . . . . .INDEX (Exploded View) . . . . . . . . . . 281 Charging Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GT235E . . . . . . . . . . . . . . .GT235 (SN 060001-) and GT235E . . . . . . . .300 PTO Clutch . . .261 Power Circuit Diagnosis . . . . . . . . . . . . . . . 511 B&S Engine . . . . . . . . . . . 54-Inch Convertible . . . . . . . . . . . . . . . . . . . . . . . . Mower Deck Handle Lift . .GT235E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306 Reading Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . .GT245 . . . .GT225 and GT235 (SN -060000) . . . . . .284 Charging Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel . . . . . . . . . . .233 Cranking Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PTO Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318 Headlight Circuit Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Kohler Engine . . . . . . . . . . . .GT235 . . . . . . . . . . . . . . . 54-Inch . . . . . .2 . . . . . . . . . .334 Repair Connector Body . . . . . . . . . . . . . . . .348 Metripack Connector . .60 Tests & Adjustments 120 Volt Stator AC Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266 Power Circuit Electrical Schematic . . . . .351 Starting Motor Kohler Engine . . . . . .327 Hourmeter Circuit Electrical Schematic . . . . . . . . . . . . . . . . . 25 Steering . . . . . . . . . . . .270 Cranking Circuit Operation .301 PTO Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lever Tension Adjustment . .348 Electric Clutch Removal and Installation . . . . . . . .265 Power Circuit Operation . . . . . .274 Engine Shutting Off . . . . . . . . . . .312 PTO Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 555 554 477 481 486 491 497 504 361 363 455 454 364 366 359 445 271 447 409 370 Charging Circuit Operation . . . . . . . . . . . . Transaxle Brake . . . . . . . . . . . . . . . . . . .GT235 (SN 060001-) and GT235E . . . . . . . . . . .313 Low Oil Pressure Light Circuit Operation . . . . . . . . . . . . . . . . 44-Inch Piranha . . . . . . . . . . . .GT235 (SN 060001-) and GT235E . . . . .321 Fuel Shutoff Solenoid Operation . .317 Headlight Circuit Operation . . . . . . . 295 120 Volt Circuit Operation . . 457 Dispose of Waste Properly . . . . . . . . . . . . . . . . . . . . . .GT225 and GT235 (SN -060000) . . . . . . . . . . . .343 Fuel Shutoff Solenoid Circuit Diagnosis . . . . . . Cruise Control Linkage . . . . . . . . . . . . . . . . . . . . . .299 PTO Circuit Electrical Schematic . . . . . . . . . . . . . . Reduction Gears . . . . . . . .234 Headlight Circuit Diagnosis .269 Diagnostic Information . . . .274 Low Oil Pressure Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . 387 Kawasaki Engine (FH580V) . . . . . . . . . . . . . . . . . . Mower Deck Foot Pedal Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Pedals & Linkage Removal & Installation . . . . . . . . . . . . . . .307 RIO Circuit Operation . . . . . . . 290 Charging Circuit Operation . .241 Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PTO Off . . . . . . . . . .241 Conductors for 12 Volt Circuit . . . 286 Charging Circuit Diagnosis . . . . . . . . . . . . Transaxle Case Halves . . . .241 Component Location . . . . . . . . . . . . . . . . . . . . . . Steering Front Axle . . . . . . .308 RIO Circuit Electrical Schematic . . . . . . . . . . . . . . 280 Charging Circuit Electrical Schematic .GT235E . . . . 279 Index . . .349 Starting Motor . . . . . . . . . . . .PTO On .PTO On . . . . .314 Low Oil Pressure Light Circuit Electrical Schematic . . . . . .326 Hourmeter Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275 Ignition Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276 Ignition Circuit Electrical Schematic . . Cruise Control Lever Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348 Electric PTO Clutch Test .231 Regulator/Rectifier Test . . . . . . . . . . . . . . . . . . . . .232 Electric PTO Clutch Break-in Procedure . . . . . . . . . . . . . . . . . 291 Charging Circuit Electrical Schematic . .264 RIO Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . .GT235 (SN 060001090000) and GT235E . . . . . . . . . . . . . .Blade Terminals . . . . . . . . . . . . . .GT245 . . . . . Swash Plate & Neutral Centering Assembly . Piston Pump . . . . . . . . . . . . . . . . . . . . . . . 42-Inch Convertible . . . . . . . . . . . . . . . . Mower Decks 38-Inch . . . . . . . . . . . . . . . . . . . . . . . 126 Kawasaki Engine (FH601V) . . . . 6 E Electric PTO Clutch Test . . . . . . .233 Component Location . . 48-Inch Convertible . . . . . . . . . . . . . . . .289 Common Circuit Tests . . 285 Charging Circuit Electrical Schematic . . . .298 PTO Circuit Operation . . . . . . . . . . . . . . . . 294 Charging Circuit Diagnosis . . . . . . . . . . . . . . . .316 Hourmeter Circuit Diagnosis . . . . . . . .GT245 .325 Ignition Circuit Electrical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cranking Circuit Diagnosis . . . . . . . . . . . . . . . .322 Fuel Shutoff Solenoid Circuit Electrical Schematic . . . . . . . . . . . . . . 70 Hydrostatic Power Train . . 343 Electrical 120 Volt Circuit Diagnosis . . . .

. . . . . . . . . . . . . . . . 340 Charging Battery . . . . . . . . 331 Battery Test . . . . . . . .101 Cylinder Bore Inspection . 263 Wire Color Abbreviation Chart . . . . . . . . . . . . . . . . . . . . . . . . .259 Electrical . . . . . . . . . 331 Common Circuit Test . . . 338 Oil Pressure Switch Test . 257 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 329 Flywheel Magnet Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .261 Main Schematic (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 W2 Engine Wiring Harness . . . . . . . . . . . . . . . .GT245 Fuel Shutoff Solenoid . . . .GT235 and GT245 W2 Engine Wiring Harness . . . . . . . . . . . . . . . . . . . . .92 Cylinder Bore Cleaning . . . . . . . . . . . .109 Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 Starter Loaded Amperage Draw Test . . .246 Main Schematic (4 of 4) . . . . . . . . . . . . . . . . . . . . . .263 W8 Stator Wiring Harness . . . . . . . . . . . . 339 Park Brake Interlock Switch Test . . . . . . . . . . . 232 Electrical . . . . . . . . . . . . .87 Removal and Installation . . . . . . .261 W10 GFCI Wiring Harness . 330 Brake/Neutral Start Switch Test . . .GT225 A2 Discharge Module . . . . . . . . . . . . . . . . . 334 Kohler Engine . . . . . . . . 346 Inverter Ground Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 W11 Stator Wiring Harness . . . . . . . . . . . . . . 345 Light Switch Test . . . . . . . . . . . . . . . 340 Spark Test . . . . . . . . . . . . . .260 W2 Engine Wiring Harness Color Code Chart . . . . . . . . . . . . . . . .83 Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Breather Valve Service . . . . . .101 Cylinder Head Inspection and Repair .259 W2 Engine Wiring Harness . . . . . . . . . . . . . . . . . . . . .260 W5 Engine Wiring Harness . . . . . . . . . . .103 Fuel Shutoff Solenoid Test . . . . . .INDEX Armature Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Starting Motor No-Load Amp & RPM Test . . . . . . 336 Starting Motor Solenoid Test . . . . . . 333 Stator Regulated Amperage Test . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Index . . 258 W6 Headlight Wiring Harness Color Code Chart . . . . .239 Voltage Regulator/Rectifier . . . . . . 242 Schematic and Wiring Harness Legend . . . . . . . . . . . . . . . . . . . . . 261 Main Schematic (1 of 4) . . . . . . . . . . . . . . 344 Ground Circuit .259 W3 Engine Wiring Harness Color Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Inductor Continuity Test . . . . . . . . . . . . . . . . . . . . . .263 W3 Engine Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . . . . . . . . . .76 Compression Test . . . . . . . . . . . . . . . . . . . . . . .GT235E Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . .259 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Connecting Rod Inspection . . . . . . . . . 345 Seat Switch Test . . . . . . . . . . . 337 Battery Load Test .83 Blower Housing Removal and Installation . . . . . . . . . . . . 335 Stator Output Test B & S Engine . . . . . . . . . . . .263 W4 Engine Wiring Harness . . . . . . . . . . 261 Component Location . . . . . . . . . . . . . . . . . . 232 Voltage Regulator/Rectifier Kohler Engine . . . . . . 257 W3 Engine Wiring Harness Color Code Chart . . .263 W3 Engine Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 Kawasaki Engine . . . . . . . . . . . . . . . . . . . . .250 Schematic and Wiring Harness Legend . . . . . . . . . . . .259 W3 Engine Wiring Harness Color Code Chart . . .263 W3 Engine Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258 W2 Engine Wiring Harness (SN 060001-) . . 341 PTO/RIP Switch Test . . . . . . . . . . . . .260 W3 Engine Wiring Harness Color Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 Stator Regulated Voltage Test . 250 Schematic and Wiring Harness Legend . . . . . . . . .260 Engine B&S Air Cleaner Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 257 W2 Engine Wiring Harness Color Code Chart . . . . . . 238 Voltage Regulator/Rectifier . . . . . . . . . . . . . . . . . . . . . . .261 W2 Engine Wiring Harness (SN -060000) . . . . . . . 332 Theory of Operation Information . . . . . . . . . . . . . . . . . 342 Reset Switch Test . . . . . . . . . . . . . . .258 W2 Engine Wiring Harness Color Code Chart . . . . . . . 257 W5 Engine Wiring Harness . . . . . . 341 GFCI Test . . 335 Fuel Shutoff Solenoid Test .85 Inspection . . . . . .88 Disassembly . . . .260 Electrical . . . . . . .251 Schematic and Wiring Harness Legend . . . . . . 262 W3 Engine Wiring Harness . . . . . 255 W1 Main Wiring Harness Color Code Chart . . . . . . . . . 263 W4 Engine Wiring Harness . . . . . . . . . . .GT235 Fuel Shutoff Solenoid . . . . .105 Cylinder Air Guides Removal and Installation . . . . . .98 Crankshaft Removal and Installation . . . . . . . . . . . . . . . . . .101 Cylinder Bore Honing . . .79 Choke Cable Adjustment . . .258 W2 Engine Wiring Harness Color Code Chart . . . . . . . . . . . . . . . .261 Main Schematic (1 of 4) . . . . . . .263 W7 Stator Wiring Harness . . . . . . . . . . . . . .90 Flywheel Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 W1 Main Wiring Harness (1 of 2) . . . . . . . . . . . . . . . . . . . .95 Engine Removal and Installation . . . . . . . . . . . . . . . . 246 Main Schematic (SN 060001-) (4 of 4) . . . . . . . . 237 Voltage Regulator/Rectifier . . . . . . . . . . . . . 342 RIO Switch Test . . . . . . . . . . . . . . . . . . . 262 W6 Headlight Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238 Voltage Regulator/Rectifier . . . . . . . . . 261 Main Schematic (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 W9 Inverter Wiring Harness . . . . . . . . . . . . . . . . . . . 240 Fuel Shutoff Solenoid . . . . . . . . . . . . 345 RIO Switch Adjustment . .

. .161 Lubrication System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Piston. . . . . . . . . . . . . . .130 Special or Required Tools . . . . . . . . . . . . . . . . 148 Cylinder Head Removal & Installation . . . . . . . . . . . . . . . . . . . 67 Starting Motor Assembly . . . . . . . . . . . . . 108 Oil Pressure Test . . . . . . . . . . . . . . . . . . . . 141 General Specifications . . . . . . . 118 Cylinder Head Assembly Repair Specifications . . . . . . . Rings and Rod. . . .161 Oil Pump Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Starting Motor Disassembly and Inspection . . . . . .162 Test and Adjustment Specifications . . . . . . . . 129 Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 Troubleshooting . . . . . . . . . . 142 Fuel Pump Removal & Installation .151 Removal & Installation . .163 Removal and Installation . . . . . . . . . .119 Oil Pump Removal & Installation .126 Valves Lap . . . . . . . . .166 Valve Clearance Check and Adjustment . . . . . . .127 Stator Removal & Installation . . . . . 155 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 Recondition Seats . . . . . 139 Disassembly & Assembly . . . . . . . . . . 155 Cylinder Bore Deglaze . . . . . . . . . . . . . . . . 123 Choke Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Specifications . . . . . . . . . 158 Crankshaft Wear Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Choke Plate Check and Adjustment . . 133 Crankcase Cover Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 Muffler Removal & Installation . .143 Repair Specifications . . . . . . . . . . . .224 Blower Housing Removal & Installation . . . . . . . . . . . . . . . . . .171 Camshaft & Tappets Removal & Installation . . . . . . . . . . . . . 119 Camshaft & Tappets Removal & Installation . . . . .132 Throttle Cable Adjustment . . . .4 Adjustment . . . . . . . . 109 Piston Inspection . . . . . . . .188 Armature Removal and Installation . . . . . . . . . . . . . . . . .137 Cylinder Compression Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Kawasaki (FH580V) Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . 131 Flywheel Removal & Installation . . . . . . . . . . . . . . . .INDEX Governor Adjustment . . 158 Cylinder Bore Resize . . . . . . . 122 Connecting Rod Wear Analysis . . . .138 Oil Filter Manifold Removal & Installation . . . . . . . . .161 Governor Shaft Removal & Installation . . . 118 Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . .121 Slow Idle Adjustment . . . . . . . . . . . . . . . . .217 . . . . . . . . . . . . . . . . . . . . . . . .149 Valves & Valve Lifter Repair Specifications . . . . . . . . . . . . . .159 Other Materials . .133 Engine Oil Pressure Test . . . . . . . 97 Resizing Cylinder Bore .118 Kawasaki (FH601V) Air Cleaner Removal and Installation . . . . . . . .138 Tools and Materials .121 Piston & Connecting Rod Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston & Rings Repair Specifications . . . . . . . . . . . . . . 117 Governor Index . . . . . . . . . . . . . . 92 Magneto Bearing Inspection . . . Remove & Install . 155 Crankcase Vacuum . . .146 Service Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Carburetor Component Location . . . . . . . . . .136 Starting Motor No-Load Amp Draw and RPM Test . . . . . . . . . . 139 Armature Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Valve Inspection and Repair . . . . . . . . . . . . . . . . . 110 PTO and Cam Bearing Inspection . 95 Valve Removal . . .120 Torque Specifications .128 Throttle Control Lever & Cable Removal & Installation . . . . . . . . . . . . . . . . . . . . . .204 Camshaft Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 159 Cylinder Bore. . . . . . . . . . . . . . . . . . . . . . . . . . 82 Intake Manifold Removal and Installation . . 143 Camshaft Repair Specifications . . . . . .120 Starting Motor Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . .118 Rocker Arm Assembly Removal & Installation . . . . . . . . . . . .128 Tests and Adjustments Armature Air Gap Adjust . . . . . 119 Crankshaft & Main Bearings Removal & Installation . . . . . . . . . . . . . . . . . . . . 112 Throttle Cable Adjustment . . . . . . . . . . . . . . . . . . . . . 81 Valve Guide Ream . . . . . . . 142 Breather Removal and Installation . . . . . . . 76 Valve Clearance Adjustment . . . . . . . . . . . . .130 Governor Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 Spark Test . . . . . . . . . . . . . . 162 Blower Housing Removal & Installation .202 Breather Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Oil Pump Removal . . . . .120 Troubleshooting . . 80 Ignition Armature Air Gap Adjustment . . . . . . . . 150 Crankshaft Repair Specifications . . . . . . . . . . . . . . . . 157 Crankshaft Oil Seals Removal & Installation . . . . . . . . . . . . . . . . . . .117 Tests & Adjustments . . . .135 Spark Plug Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . 147 Fast Idle Adjustment . . . . . . . . . . . . .135 Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 Repair Specifications . . . . . . . . . . . . . . . . . . . . . . .5 Cylinder Compression Pressure Test . . . . . . . . . . .21 Carburetor Inspection . . . Removal and Installation . . . . . . . . . . . . . . . . . . .183 Engine Oil Pressure Test . . . . . . . . . . . .26 Connecting Rod Repair Specifications . . . .187 Tools and Materials . . . . . Cylinder Bore Deglaze . . . . . . . . . . . . . . . Piston & Rings Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 Throttle Control Lever & Cable Removal & Installation . . . . . . . . . . . . . . . . Fuel Pump Removal & Installation . . . . . . . .30 Balancer Shaft Inspection . .60 Cylinder Bore. . . . . . . . . . . . . . . . . . . . Connecting Rod Wear Analysis . . . . . . . . . . . . Piston & Connecting Rod Removal & Installation . . . . . . . . .181 Spark Plug Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .180 Slow Speed Idle Adjustment .170 Kohler Air Intake System Components . . . . . . . . . . . . . . . . . . . . . Oil Pump Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Camshaft End Play Measurement . . . . . . . . . . . . . . . .186 Starting Motor No-Load Amp Draw and RPM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Removal & Installation . . . . . .36 Removal & Installation . . . . . . . . . . . . . . . . . . . .20 Cylinder Block Inspection . . . . . . . Disassembly & Assembly . . .59 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX Carburetor (Externally Vented) Components . . . . . . . . . . . . . . . . . . . Stator Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Parts Kits . . . . . Choke Plate Check and Adjustment . . . . . . . . . . . . . Carburetor (Internally Vented) Components . . . .172 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Crankshaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Removal & Installation . . .211 Valves & Valve Lifter Repair Specifications . . . . . . . . . . . . Disassembly & Assembly . .184 Fast Idle Speed Adjustment . . . Crankshaft Oil Seals Removal & Installation . . . . . . . . . . . . . . . . . . . Crankshaft Wear Analysis . . . .35 Choke Adjustment . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . .50 Inspection . .35 Automatic Compression Release (ACR) . . . . . . Tests and Adjustments Armature Air Gap Adjust . . .172 Torque Specifications . . . .228 Throttle Cable . . . . . . . .58 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Manifold Removal & Installation . . . Rocker Arm Assembly Removal & Installation . . . Starting Motor Disassembly and Assembly . . . . . . . . Removal & Installation . . . . . . . . . . . . . Cylinder Head Removal & Installation . . . . . . Intake Manifold Removal and Installation . . .21 Breather Inspection . . . . Muffler Removal & Installation . . . . Component Location . . . . . . . . . . . . . . . . . Cylinder Bore Resize . . . . . . . . . . . Tests & Adjustments . .21 Cylinder Head Inspection . . . Piston & Rings Repair Specifications . . .58 Crankshaft Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal & Installation . . . . . . . . . Special or Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212 Recondition Seats . .49 Repair Specifications . . . . Oil Pump Repair Specifications . Crankshaft & Main Bearings Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Removal & Installation . . . . . . . . . . . . . . . . . Crankcase Cover Removal & Installation . . . . .59 Inspection . . . . .42 . . . . . . . . . . . . . . . Crankcase Vacuum Test .43 Removal & Installation . . . Cylinder Head Assembly Repair Specifications . . . . . . . . . . . . . . .186 Spark Test .179 Valve Clearance Check and Adjustment . . . . . . . . . . . . . . . . . .177 Valves Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Repair Specifications . . . . . . . . . .185 Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Specifications . . . . . . Test and Adjustment Specifications . . . . . . . . . . . . . . . . . . . . . . .181 Fuel Pump Test .22 Crankcase Oil Seal Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 191 189 176 197 196 174 217 212 171 219 220 217 220 221 170 170 210 209 203 202 169 223 223 204 187 223 171 221 173 213 205 170 208 173 172 225 225 178 224 169 179 187 180 184 Index . . . . . . . Governor Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Inspection . . . .47 Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Bore. . .59 Cylinder Bore Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal & Installation . . . . . Governor Shaft Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . .409 Hand Lever Rod Adjustment . . . . . . . . . . . . . . . . . . Fuel Pump Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Specifications . . . . . . . . . . . . . .471 Removal & Installation . . . . . . . . . . .448 Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407 Handle Chemical Products Safely . . . . . . . . . . . . . . . .367 Cruise Control Linkage . . . . . . . Piston Assembly . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . .369 Case Halves . . . . . . . .13 Hydrostatic Power Train Component Location Axles . . . . . . Valve Seats Recondition . . . . . . . . . . . . . . . . . . . . . . .371 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470 Fuel Shutoff Solenoid Circuit Diagnosis .558 Hydraulic oil . . . Inspection . . . . . . . . . . . . . . .234 Grease Anti-Corrosion . . . . . . . . . . . . . . . . . . . . . .322 Fuel Tank Removal & Installation . . . . . . . . . .464 Front Wheel Bushing Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .559 Flywheel Removal B&S Engine . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .556 Removal and Installation . . .90 Kawasaki Engine (FH580V) . . . . . . . . . . . . . . . . .205 Kohler Engine . . .373 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . Slow Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measurement . . . . . . . . . . . .11 General Specifications Electrical . . . . . . . . . . . . . . . . . . . . . . .407 Front Axle Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Disassemble . . . . . . .368 Brake Pedal and Linkage . . . . . . . . . . . . . . . . . . . Flywheel Removal & Installation . . . . . . . . . . . . . . .40 Forward & Reverse Pedals Height Adjustment . . . . . . . . .370 (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 28 38 27 40 35 32 37 19 27 53 52 22 51 50 41 46 47 48 33 48 48 56 54 54 57 55 53 54 55 42 38 20 42 20 27 60 41 19 26 23 45 45 46 20 43 63 Engine Removal and Installation B&S Engine . . . . . . . . . . . . . . . Relief Valve Inspection . . . . . . . . . Voltage Regulator/Rectifier . Oil Pickup Inspection . Governor Adjustment . . . . . . . Ignition Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves & Springs Removal/Installation . . . . . . Side Clearance Measurement . . . . . .6 Handling And Servicing Batteries . . . . . . . Fuel Flow Test . . .142 Kawasaki Engine (FH601V) . . Seal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Test . . . . . . . .561 G Gasoline specifications 4-cycle engines . . . . . . . . . . Cylinder Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Installation . . . . . . . . . . . .143 Kawasaki Engine (FH601V) . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363 Forward & Reverse Pedals . .6 . . . . . . . . . . . . Rocker Arms Removal and Installation . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator Removal and Installation . . . . . . . . Throttle Cable Adjustment . . . Hydraulic Valve Lifters Inspection . . .INDEX Repair Specifications . . . . . . . . . . . . . . . . . . . . Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel & Air Repair . . . . . . .203 Kohler Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Repair .318 Hood Latch Adjustment . . . . . . . Piston Ring End Gap Measurement .38 F Fender Deck Removal and Installation . . .363 Belt Drive and Idlers . . . . . . . . . . . . . . . . . . . . . Fast Idle Speed Adjustment . . . . . . . . . . . . . . . . Repair Specifications . . . . . . . . . . . Inspection . . Test & Adjustments Specifications . . . Rocker Arms Repair Specifications . . . . Starting Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . Push Rod Inspection .359 Center Case . . . . . . . . . Torque Specifications . . . . . .103 Kawasaki Engine (FH580V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 H Hand Control Lever (Optional) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470 Spindle Lubrication . . . . .1 Headlight Circuit Diagnosis . . . . . .

. . . . . . . . . . . . . .556 Mower Deck Lift Removal & Installation . .561 Spring Removal & Installation . . . . . . . . . . . . . . .14 P PTO Circuit Diagnosis . . . . . . . . . .475 Usage Table . . . . . . 12 Grease .554 Mower Deck Lift Height Adjuster Removal & Installation . . . . . . 187 Kohler Engine . . . . . . . . . . . . . . . . . . . .445 Cruise Control Lever Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302 Park Machine Safely . . . . . . . . . . . . . . . . . . . 13 Mower Deck Foot Pedal Lift Component Location . . . .476 I Ignition Air Gap Adjustment B&S Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334 Remove Paint Before Welding or Heating . . . . . . . . 4 Inch Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Lubrication Alternative Lubricants . 464 Front Wheel Bushing Removal & Installation . . . . 561 Hood Removal and Installation .450 Control Pedals & Linkage Removal & Installation . 12 Engine Oil-Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX Piston Pump . . . 559 Front Axle Removal & Installation . . . . . . . . . . . . . . 384 Hydrostatic transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 Transaxle Brake . . . . . . .566 Mower Decks Adjustment Specifications . . . . 470 Fuel Tank Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 Cruise Control Lever Removal and Installation . . 14 Synthetic Lubricants . . . . . . . . . . . . . 407 Hand Lever Rod Adjustment . . . . . . . . . 409 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . .266 Prevent Acid Burns . . . . . . . . . . . . .348 M Machine serial number locations . . . . . . . . . . . . . . . . . . . . .570 Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446 L Live With Safety . . . . . . . . . . . . . . 6 Low Oil Pressure Circuit Diagnosis . . . . . . 363 Swash Plate & Neutral Centering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine Oil-North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Forward & Reverse Pedal Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .570 Mower Deck Lift Removal & Installation . . . . . . . . . . . . . .308 Regulator/Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .566 Repair . .2 Prevent Battery Explosions . . . . 137 Kawasaki Engine (FH601V) . . . . . . . . . . . . . . 558 Index . . . . . . . . . . . . . . . . . . . . . . . .554 Mower Deck Lift Height Adjuster Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 Neutral Return Arm Bearing Adjustment . . 14 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .561 Spring Adjustment . . . . . . . . . . . . . . .4 Repair Brake Pedal & Linkage Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . 471 Removal & Installation . . . . . 13 Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 R RIO Circuit Diagnosis . . . . . . . . . . . . .556 Spring Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Illuminate Work Area Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . .555 Mower Deck Handle Lift Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Miscellaneous Fender Deck Removal and Installation .558 Seat & Support Removal & Installation . . . . 13 Anti-Corrosion Grease . . . . . 407 Intermediate Shaft . . 385 Hydrostatic System . . . . . . . . . . . . . . . . .559 Specifications . . . . . . . .447 Electrical Connector Body Blade Terminals . . . . . . . . . . . . . . 82 Kawasaki Engine (FH580V) . 10 N Neutral Creep Adjustment . . . . . . . . . . . . . . 15 Metric Fastener Torque Values Standard . . . . . . . . . 386 Gear Power Flow . . . . . . . . . . . . . . . . . . .449 Brake Rod Removal and Installation . . . . . .3 Power Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Theory of Operation Brake . . . . . . . . . . . . . . . . . . 13 O Oil filters . . . . . . . . . .553 Mower Deck Foot Pedal Lift Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .570 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .555 Mower Deck Handle Lift Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 Reduction Gears .405 Neutral Return Arm Bearing Adjustment . . . . .570 Removal & Installation . . . . . . . . . . . . . . . . . . . . 408 Specifications . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . 67 Kawasaki Engine (FH580V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332 Forward & Reverse Pedal Height Adjustment . . . .346 Inverter Ground Continuity Test . . 446 Traction Drive Belt Removal and Installation . . .405 Tests and Adjustments Electrical Electric PTO Clutch Test . . . . . . 470 Fuel Tank Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Engine B&S . . . . . . . . . . . . .129 Kawasaki Engine (FH601V) . . . . . . . . . . . . . . . . . . . 1 Support Machine Properly . . . . . . . . .335 Fuel Shutoff Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Lubrication Interval . . . . . . . . . . . . . . . . . 453 Steering Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .556 Neutral Return Arm Bearing Adjustment . . . . . . . . . . . . . 453 Torque Specifications . . . . . . . 414 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 Torque Specifications . . . . . . . .407 Hand Control Lever Tension . . . . . . . . . . . . . . . . . . . . . .340 Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 Metripack Connector . . . . . . . . . . . . . . . . . .330 Brake/Neutral Start Switch Test . . . . . . 553 Steering Lubrication Interval . . . 559 Service Machines Safely . . . 459 Toe-In Adjustment . .26 Mower Deck Lift Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX Electric Clutch Removal and Installation . . . . . . . . . . .338 Oil Pressure Switch Test . . . . . . . . . . . . . . 462 Steering Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 471 Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Hand Control Lever (Optional) Removal and Installation . . . . . . . . . . . . . . . 453 Starting Motor Kohler Engine . . . . . . . . . . . . . . . . . . . . . . . . .179 Kohler Engine . . . 464 Front Wheel Bushing Removal & Installation . . . . . . .333 Stator Regulated Amperage Test . . . . . . . . . . . . . . . . . . . . . . .345 Light Switch Test . . . . . . . . . . . . . . . . . . . . . . .340 Charging Battery . . . . . . . . . . . . . . 448 Intermediate Shaft Removal and Installation . . . . . . . . . . . . . . . . . . . . .341 GFCI Test . . . . . . . . . . . . . . . . . . . . . . .342 Reset Switch Test . . . . . . . . . . . . 60 Steering Diagnosis . . . . . . . . . . . . . . . . . . . . . . . .76 Kawasaki Engine (FH580V) . . . . . . . . . . . . .344 Ground Circuit . . . . .346 Armature Air Gap Adjustment . . . . . . . . . . . . . 444 Transaxle Assembly . . . . . . . . . . . . . . .331 Common Circuit Test . . . 409 Replace Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Kohler Engine . . . . .556 Kawasaki Engine (FH580V) . . .338 Starter Loaded Amperage Draw Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 Miscellaneous Front Axle Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335 Stator Output Test B & S Engine . . . . . . . . . . . . . . . . . . . . . . .334 Kohler Engine . . . . . . . . . . . . . . . . . . . . .345 RIO Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . .345 Seat Switch Test . . . . . . . . .409 Hand Lever Rod Adjustment . . . . . . . . . . . . . . . . . . . . . .337 Battery Load Test . . . 138 Kawasaki (FH601V) . . . . . . . . . . . . . . . . . . . . . . . . . 187 Kohler . . . . . . . . . . . . . . . . . . . . . . . . . .332 Stator Regulated Voltage Test .180 Kohler Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Electrical 120 Volt Stator AC Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329 Inductor Continuity Test . . . . . . . . . . . . . . . . 428 Disassembly . 442 Traction Drive Belt Tensioner Removal and Installation . . . . . . 20 Hydrostatic Power Train . . . . . . . . . . . . . . . . . . . 453 Toe-In Adjustment . . . . . . . 357 Miscellaneous .343 S Seat & Support Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . .336 Starting Motor Solenoid Test . . . . . . . . . . . . . . . . 82 Kawasaki (FH580V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 . . . . . . . . . 561 Mower Deck Lift Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Starting Motor . . . . 453 Index . . . . . . .329 Flywheel Magnet Test . . . .342 RIO Switch Test . . . .76 Choke B&S Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408 Regulator/Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333 Kawasaki Engine . . . .339 Park Brake Interlock Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Kawasaki Engine (FH601V) . . . . . . . . . . . . . . . .341 PTO/RIP Switch Test . . . . . . . .335 Starting Motor No-Load Amp & RPM Test . .4 T Tests & Adjustments B&S Engine . . . . . . . . . . . . . . . .407 Hood Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Kawasaki Engine (FH601V) . . . 566 Neutral Return Arm Removal and Installation . . . . . . . . . . . . . . . . 3 Service Tires Safely . . . . . . . . . . . . . .334 Transaxle . . . . . . . . . . . . . . . . . . .331 Battery Test . . . . . 5 Specifications Engine Repair B&S Engine . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard . . . . . . . . . 13 U Understand Signal Words . . . . . . . . . 4 Work In Ventilated Area . . . . . . . . . . . hydrostatic . . . . . . . . . . . . . 10 Metric Fasteners. . . . . . . . . . . 428 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 Mower Deck Lift . . . . 414 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556 Torque Values Inch Fastener . . . . . . . . . . . . . . . . . . . 444 Transaxle Assembly . . .INDEX Theory of Operation Hydrostatic Power Train Brake . 442 Belt Tensioner Removal and Installation . . . . . . . . . . . . . . 1 4 3 4 W Wear Protective Clothing . . . . . 385 Hydrostatic System . . . . . . . . . . . . . . . . . . 4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 Gear Power Flow . . . . . . . . . . . . . . Use Proper Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . Using High Pressure Washers . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wheel Bolt Torque. 9 Traction Drive Belt Removal and Installation .9 . . . . . . . . . . . . . . . . . . . . . . . . . . . Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557 Work In Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Transmission oil. . . . . .

INDEX Index .10 .