TM 112919

Z225, Z245, Z235, Z255
EZtrak Residential Mower

Diagnostic and Repair
TECHNICAL MANUAL
EZtrak Mower models Z225, Z245 (SN. 100001-); Z235, Z255 (SN. 130001- )
TM112919 28 JAN 16 (ENGLISH)
John Deere Commercial and Consumer Equipment Lawn and Garden

Pinted by Belgreen
TM112919-TECHNICAL MANUAL (g) by Belgreen v2.5
Table of contents
FOREWORD
Section 10 - GENERAL INFORMATION
Group 05 - Safety
Group 10 - General Specifications
Group 15 - Fuel and Lubricants
Group 20 - Machine Specifications
Section 20 - SINGLE CYLINDER ENGINE REPAIR
Group 10 - Engine Single Cylinder
Section 30 - V-TWIN ENGINE REPAIR
Group 10 - Repair Engine V-Twin
Section 40 - ELECTRICAL REPAIR
Group 10 - Component Location
Group 20 - Wiring Harness
Section 50 - POWER TRAIN REPAIR
Group 20 - Repair
Section 60 - ATTACHMENTS REPAIR
Group 20 - Repair
Section 70 - MISCELLANEOUS REPAIR
Group 20 - Repair
Section 220 - SINGLE CYLINDER DIAGNOSIS, TESTS, AND ADJUSTMENTS
Group 10 - Diagnosis
Group 20 - Tests and Adjustments
Section 230 - V-TWIN ENGINE DIAGNOSIS, TESTS, AND ADJUSTMENTS
Section 240 - ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS
Group 10 - Theory of Operation
Group 40 - Wiring Schematics
Group 50 - Connector Information
Section 250 - POWER TRAIN DIAGNOSIS, TESTS, AND ADJUSTMENTS
Section 260 - ATTACHMENTS DIAGNOSIS, TESTS, AND ADJUSTMENTS
Section 299 - SERVICE TOOLS AND KITS
Group 10 - Service Tools
<- Go to Global Table of contents TM112919-TECHNICAL MANUAL

GENERAL INFORMATION (g) by Belgreen v2.0
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified
in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text
of the manual.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for
personal injury.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
Operation and tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are
summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service
parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of
troubleshooting, general maintenance, and basic type of failures and their causes.
<- Go to Section TOC Section 10 page 1 TM112919-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Table of contents
Group 05 - Safety ..................................................................................................................................... 1
Recognize Safety Information ............................................................................................................... 1
Understand Signal Words ..................................................................................................................... 1
Follow Safety Instructions ..................................................................................................................... 1
Practice Safe Maintenance ................................................................................................................... 3
Use Proper Tools ................................................................................................................................... 3
Handle Fluids Safely—Avoid Fires ......................................................................................................... 4
Drain Gasoline When Storing Machine ................................................................................................. 4
Prevent Acid Burns ............................................................................................................................... 6
Prevent Battery Explosions ................................................................................................................... 6
Handling Batteries Safely ..................................................................................................................... 7
Prepare for Emergencies ...................................................................................................................... 9
Park Machine Safely ............................................................................................................................. 9
Support Machine Properly .................................................................................................................... 9
Wear Protective Clothing .................................................................................................................... 11
Work in Clean Area ............................................................................................................................. 11
Service Machines Safely ..................................................................................................................... 12
Work In Ventilated Area ...................................................................................................................... 12
Illuminate Work Area Safely ............................................................................................................... 12
Replace Safety Signs .......................................................................................................................... 13
Use Proper Lifting Equipment ............................................................................................................. 13
Follow Tire Recommendations ............................................................................................................ 13
Decommissioning: Proper Recycling and Disposal of Fluids and Components ................................... 14
Protect Against High Pressure Spray .................................................................................................. 15
Live With Safety ................................................................................................................................. 15
Group 10 - General Specifications ....................................................................................................... 16
Service Recommendations for O-Ring Boss Fittings ........................................................................... 16
Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 18
Metric Cap Screw Torque Values—Grade 7 ........................................................................................ 19
Metric Bolt and Screw Torque Values ................................................................................................. 20
Unified Inch Bolt and Screw Torque Values ........................................................................................ 21
Group 15 - Fuel and Lubricants ........................................................................................................... 22
Summary of References ..................................................................................................................... 22
Gasoline Engine Oil ............................................................................................................................. 23
Oil Filters ............................................................................................................................................ 24
Gasoline Fuel for 4-Cycle Engines ...................................................................................................... 24
Transaxle Oil ....................................................................................................................................... 24
Grease ................................................................................................................................................ 24
Mixing of Lubricants ........................................................................................................................... 25
Alternative and Synthetic Lubricants .................................................................................................. 25
Lubricant Storage ............................................................................................................................... 25
Gasoline and Engine Storage .............................................................................................................. 27
Carburetor Cleaning ........................................................................................................................... 29
Carburetor Cleaning Methods ............................................................................................................. 30
Group 20 - Machine Specifications ...................................................................................................... 31
Machine Specifications Z225 and Z245 (S.N. -130000) ...................................................................... 31
Machine Specifications Z235 and Z255 (S.N. 130001- ) ..................................................................... 33
Product Identification Number Location (S.N. -130000) ..................................................................... 34
Product Identification Number Location (S.N. 130001- ) .................................................................... 34

Section 10 - GENERAL INFORMATION Group 05: Safety
Group 05 - Safety
Recognize Safety Information
Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe operating practices.
Understand Signal Words
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.
Follow Safety Instructions

Safety Messages
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.
Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety
signs. Replacement safety signs are available from your John Deere dealer.
There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in
this operator′s manual.
Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or
safety and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

Practice Safe Maintenance
Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts.
Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the
key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any
buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding
on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on
machine.
Use Proper Tools

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.
Handle Fluids Safely—Avoid Fires
Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Drain Gasoline When Storing Machine

Storing Gasoline
Gasoline stored in fuel tank can explode.

Never store equipment with gasoline in the tank inside a building where fumes may reach an open flame or spark.
Always drain gasoline from fuel tank and carburetor bowl when storing machine. Allow engine to cool before storing.

Prevent Acid Burns
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 the hazard 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 15—30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.
Prevent Battery Explosions

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).
Handling Batteries Safely
Caution

Caution
Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
Always remove grounded (-) battery clamp first and replace grounded clamp last.
Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in clothing, and cause blindness if
splashed into eyes.
Avoid hazards by:
Filling batteries in a well-ventilated area

Wearing eye protection and rubber gloves
Avoiding use of air pressure to clean batteries
Avoiding breathing fumes when electrolyte is added
Avoiding spilling or dripping electrolyte
Using correct battery booster or charger procedure.
If acid is spilled on skin or in eyes:
1. Flush skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush eyes with water for 15—30 minutes. Get medical attention immediately.
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 qt.).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State
of California to cause cancer and reproductive harm. Wash hands after handling.

Prepare for Emergencies
First Aid Kit
Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Park Machine Safely
Remove the Key
Before working on the machine:
Lower all equipment to the ground.

Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.
Support Machine Properly

Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the
machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices
can settle or leak down.
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.
When implements or attachments are used with a machine, always follow safety precautions listed in the implement or
attachment operator′s manual.

Wear Protective Clothing
Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating
machine.
Work in Clean Area
Clean Work Area
Before starting a job:
Clean work area and machine.

Make sure you have all necessary tools to do your job.
Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.
Service Machines Safely
Moving Parts
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.
Work In Ventilated Area
Engine exhaust fumes
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.
Illuminate Work Area Safely

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.
Replace Safety Signs
Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
Use Proper Lifting Equipment
Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.

Follow Tire Recommendations
Read OM
Keep your machine in proper working order.

Use only prescribed tire sizes with correct ratings and inflate to the pressure specified in this manual.
Use of other than prescribed tires may decrease stability, affect steering, result in premature tire failure, or cause other
durability or safety issues.
Decommissioning: Proper Recycling and Disposal of Fluids and

Components
Recycle Waste
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or
component. These measures include the following:
Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the
removal or handling of objects and materials.
Follow instructions for specialized components.
Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other
electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.
Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides.
Handle and dispose of these components appropriately.
Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use
leak-proof containers when draining fluids. Do not use food or beverage containers.
Do not pour waste fluids onto the ground, down a drain, or into any water source.

Section 10 - GENERAL INFORMATION Group 10: General Specifications
Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids
(example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or
components in other than specially designed incinerators may be prohibited by law and could result in exposure to
harmful fumes or ashes.
Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service
center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.
Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in
part or completely.
Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to
recycle or dispose of waste.
Protect Against High Pressure Spray
High Pressure Spray
Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.
If an accident occurs, see a doctor immediately. Any high pressure spray 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.
Live With Safety
Safety Systems
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all
guards and shields.

Group 10 - General Specifications

Service Recommendations for O-Ring Boss Fittings
Straight Fitting
Straight Fitting
[1] - Inspect O-ring boss seat for dirt or defects.
[2] - Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into
O-ring groove of fitting. Remove tape.
[3] - Tighten fitting to torque value shown on chart.
Angle Fitting
Angle Fitting
[1] - Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.
[2] - Turn fitting into threaded boss until back-up washer contacts face of boss.
[3] - Turn fitting head-end counterclockwise to proper index (maximum of one turn).
[4] -
→NOTE:
Do not allow hoses to twist when tightening fittings.
Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.

Straight Fitting or Special Nut Torque Chart
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size N˙m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
→NOTE:
Torque tolerance is ± 10%.

Service Recommendations For Flat Face O-Ring Seal Fittings

[1] - Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.
[2] - Lubricate O-rings and install into grove using petroleum jelly to hold in place.
[3] - Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place.
[4] - Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup
wrench on straight hose couplings.
IMPORTANT:
Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an
actuating device.
Tighten fittings to 50% of listed torque value if used in aluminum housing.
O-ring Seal Fitting Torque
FLAT FACE O-RING SEAL FITTING TORQUE*
Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. N˙m lb·ft N˙m lb·ft
6.35 0.250 9/16-18 16 12 12 9
9.52 0.375 11/16-16 24 18 24 18
12.70 0.500 13/16-16 50 37 46 34
15.88 0.625 1-14 69 51 62 46
19.05 0.750 1 3/16-12 102 75 102 75
22.22 0.875 1 3/16-12 102 75 102 75
25.40 1.000 1 7/16-12 142 105 142 105
31.75 1.250 1 11/16-12 190 140 190 140
38.10 1.500 2-12 217 160 217 160
*Torque tolerance is +15 -20% unless otherwise specified.
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N˙m lb·ft
3/8-24 5/8 9/16 12 9
7/16-20 5/8 5/8 21 15
1/2-20 3/4 11/16 26 19
9/16-18 3/4 3/4 34 25
3/4-16 7/8 15/16 73 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 285 210
*Torque tolerance is +15 -20% unless otherwise specified.

Metric Cap Screw Torque Values—Grade 7

→NOTE:
When bolting aluminum parts, tighten to 80% of torque specified in table.
Metric Cap Screw Torque Values—Grade 7
Size N˙m (lb-ft)
M6 9.5—12.2 (7—9)
M8 20.3—27.1 (15—20)
M10 47.5—54.2 (35—40)
M12 81.4—94.9 (60—70)
M14 128.8—146.4 (95—108)
M16 210.2—240 (155—177)

Metric Bolt and Screw Torque Values
Metric Bolt and Screw
Metric Torque Values
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Lubricated Lubricated Lubricated Lubricated

[ “Lubricated” [ “Lubricated” [ “Lubricated” [ “Lubricated”
Dry Dry Dry Dry
means coated with means coated with means coated with means coated with
[ “Dry” means [ “Dry” means [ “Dry” means [ “Dry” means
a lubricant such as a lubricant such as a lubricant such as a lubricant such as
Bolt or plain or zinc plain or zinc plain or zinc plain or zinc
engine oil, engine oil, engine oil, engine oil,
Screw plated without plated without plated without plated without
fasteners with fasteners with fasteners with fasteners with
any lubrication, or any lubrication, or any lubrication, or any lubrication, or
Size phosphate and oil
M6 to M18
phosphate and oil
M6 to M18
phosphate and oil
M6 to M18
phosphate and oil
M6 to M18
coatings, or M20 coatings, or M20 coatings, or M20 coatings, or M20
fasteners with fasteners with fasteners with fasteners with
and larger and larger and larger and larger
JDM F13B, F13E or JDM F13B, F13E or JDM F13B, F13E or JDM F13B, F13E or
fasteners with JDM fasteners with JDM fasteners with JDM fasteners with JDM
F13H zinc flake F13H zinc flake F13H zinc flake F13H zinc flake
F13C, F13F or F13J F13C, F13F or F13J F13C, F13F or F13J F13C, F13F or F13J
coating. ] coating. ] coating. ] coating. ]
zinc flake coating. zinc flake coating. zinc flake coating. zinc flake coating.
] ] ] ]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N˙m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of the
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts
bolt or screw. DO NOT use these values if a different torque value or
with identical property class. Replace fasteners with the same or higher property class.
tightening procedure is given for a specific application. For stainless steel
If higher property class fasteners are used, tighten these to the strength of the original.
fasteners or for nuts on U-bolts, see the tightening instructions for the
Make sure fastener threads are clean and that you properly start thread engagement.
specific application. Tighten plastic insert or crimped steel type lock nuts by
When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts
turning the nut to the dry torque shown in the chart, unless different
or wheel nuts, unless different instructions are given for the specific application.
instructions are given for the specific application.

Section 10 - GENERAL INFORMATION Group 15: Fuel and Lubricants
Unified Inch Bolt and Screw Torque Values
Unified Inch Bolt and Screw
Unified Inch Bolt and Screw Torque Values
SAE Grade 2
[ Grade 2 applies for hex cap screws
(not hex bolts) up to 6 in. (152 mm)
SAE Grade 1 long. Grade 1 applies for hex cap screws SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
over 6 in. (152 mm) long, and for all
other types of bolts and screws of any
length. ]
Lubricated Lubricated Lubricated Lubricated

Bolt or [ “Lubricated” [ “Lubricated” [ “Lubricated” [ “Lubricated”
Screw Dry Dry Dry
means coated means coated with Dry means coated with means coated with
[ “Dry” means [ “Dry” means [ “Dry” means
Size with a lubricant
plain or zinc
a lubricant such as [ “Dry” means a lubricant such as
plain or zinc
a lubricant such as
plain or zinc
such as engine engine oil, plain or zinc plated engine oil, engine oil,
plated without plated without plated without
oil, fasteners with fasteners with without any fasteners with fasteners with
any lubrication, or any lubrication, or any lubrication, or
phosphate and oil phosphate and oil lubrication, or 1/4 phosphate and oil phosphate and oil
1/4 to 3/4 in. 1/4 to 3/4 in. 1/4 to 3/4 in.
coatings, or 7/8 coatings, or 7/8 in. to 3/4 in. fasteners coatings, or 7/8 in. coatings, or 7/8 in.
fasteners with fasteners with fasteners with
in. and larger and larger with JDM F13B, and larger and larger
JDM F13B, F13E or JDM F13B, F13E or JDM F13B, F13E or
fasteners with fasteners with JDM F13E or F13H zinc fasteners with JDM fasteners with JDM
F13H zinc flake F13H zinc flake F13H zinc flake
JDM F13C, F13F or F13C, F13F or F13J flake coating. ] F13C, F13F or F13J F13C, F13F or F13J
coating. ] coating. ] coating. ]
F13J zinc flake zinc flake coating. zinc flake coating. zinc flake coating.
coating. ] ] ] ]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N˙m lb.-ft. N˙m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N˙m lb.-ft. N˙m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N˙m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt or Replace fasteners with the same or higher grade. If higher grade fasteners
screw. DO NOT use these values if a different torque value or tightening procedure is are used, tighten these to the strength of the original. Make sure fastener
given for a specific application. For plastic insert or crimped steel type lock nuts, for threads are clean and that you properly start thread engagement. When
stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel
specific application. Shear bolts are designed to fail under predetermined loads. Always bolts or wheel nuts, unless different instructions are given for the specific
replace shear bolts with identical grade. application.

Group 15 - Fuel and Lubricants

Summary of References
Gasoline Engine Oil
Oil Filters
Gasoline Fuel for 4-Cycle Engines
Transaxle Oil
Grease
Mixing of Lubricants
Alternative and Synthetic Lubricants
Lubricant Storage
Carburetor Cleaning
Carburetor Cleaning Methods

Gasoline Engine Oil
Oil Viscosities for Air Temperature Ranges
Use oil viscosity based on the expected air temperature range during the period between oil changes.
Using single viscosity grade oils such as SAE 30 or SAE 40 can reduce oil consumption in air cooled engines.
John Deere Turf-Gard ™ is preferred.
The following oils are also recommended:
John Deere Plus-4 ™

John Deere Plus-50 ™ II
Other oils may be used if they meet one or more of the following:
ILSAC GF-5
API Service Category SN
API Service Category SM
API Service Category SL
API Service Category SJ
ACEA Oil Sequence A5

ACEA Oil Sequence C4
Oil Filters
Filtration of oils is critical to proper operation and lubrication.
Always change filters regularly as specified in this manual.
Use filters meeting John Deere performance specifications.
Gasoline Fuel for 4-Cycle Engines

Use unleaded gasoline with a minimum octane rating of 87 AKI (anti-knock index) or 90 RON (research octane number).
Gasoline fuels specified to EN 228 or ASTM D4814 are recommended.
Fuel blends of unleaded gasoline with a maximum 10% ethanol or 15% MTBE (methyl tertiary-butyl ether) are also acceptable.
CAUTION:
Reduce the risk of fire. Handle fuel carefully. DO NOT fill the fuel tank when the engine is running or hot.
Stop engine and allow it to cool for several minutes before filling fuel tank. Fill fuel tank only to the
bottom of the filler neck.
Refuel outdoors. DO NOT smoke while you fill the fuel tank or service the fuel system.
Store fuel in properly identified polyethylene containers.
When storing fuel, add John Deere Gasoline Conditioner and Stabilizer (or equivalent) at the specified concentration.
IMPORTANT:
DO NOT use methanol or fuel blends that contain methanol.
Avoid spilling fuel. Gasoline can damage plastic and painted surfaces.
DO NOT mix oil with gasoline.
Transaxle Oil
The transaxles are filled at the factory. Do not mix oil types.
The following oil is preferred:
20W50 SL Rated Oil
JD Hy-Gard ™ may be used if oil is unavailable.
Grease

Greases for Air Temperature Ranges
Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.
John Deere SD Polyurea Grease is preferred.
The following greases are also recommended:
John Deere HD Lithium Complex Grease

John Deere HD Water Resistant Grease
John Deere GREASE-GARD ™
Other greases may be used if they meet the following:
NLGI Performance Classification GC-LB
IMPORTANT:
Some types of grease thickeners are not compatible with others. Consult your grease supplier before
mixing different types of grease.
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain
specifications and performance requirements.
Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.
Consult your John Deere dealer to obtain specific information and recommendations.
Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual.
Some John Deere brand coolants and lubricants may not be available in your location.
Consult your John Deere dealer to obtain information and recommendations.
Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.
The temperature limits and service intervals shown in this manual apply to both conventional and synthetic lubricants.
Re-refined base stock products may be used if the finished lubricant meets the performance requirements.
Lubricant Storage
Your equipment can operate at top efficiency only when clean lubricants are used.
Use clean containers to handle all lubricants.
Store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their

side to avoid water and dirt accumulation.

Make certain that all containers are properly marked to identify their contents.
Properly dispose of all old containers and any residual lubricant they may contain.

Gasoline and Engine Storage

Fuel:
If you have been using “Stabilized Fuel”, add stabilized fuel to tank until the tank is full.
→NOTE:
Filling the fuel tank reduces the amount of air in the fuel tank and helps reduce deterioration of fuel.
If you are not using “Stabilized Fuel”:
[1] - Park machine safely in a well-ventilated area.
[2] -
→NOTE:
Try to anticipate the last time the machine will be used for the season so very little fuel is left in the fuel
tank.
Turn on engine and allow to run until it runs out of fuel.
[3] - For machines with a key switch, turn key to off position.
[4] - Mix fresh fuel and fuel stabilizer in separate container. Follow stabilizer instructions for mixing.
[5] - Fill tank with stabilized fuel.
[6] - Run engine for a few minutes to allow fuel mixture to circulate through carburetor on gas engine or fuel injectors on gas
engine or diesel engine.
Engine:
Engine storage procedure should be used when machine is not to be used for longer than 60 days.
[1] - Change engine oil and filter while engine is warm.
[2] - Service air filter if necessary.
[3] - Clean debris from engine air intake screen.
[4] - On gas engines:
a. Remove spark plugs. Put 30 mL (1 oz.) of clean engine oil in cylinder(s).

b. Install spark plugs, but do not connect spark plug wires.
c. Crank the engine five or six times to allow oil to be distributed.
[5] - Clean the engine and engine compartment.
[6] - Remove battery.
[7] - Clean the battery and battery posts. Check the electrolyte level, if the battery is not maintenance free.
[8] - Close fuel shutoff valve, if machine is equipped.
[9] - Store the battery in a cool, dry place where it will not freeze.
[10] -
→NOTE:
The stored battery should be charged every 90 days.
Charge the battery.
[11] -

IMPORTANT:
Prolonged exposure to sunlight could damage the hood surface. Store the machine inside or use a cover
if stored outside.
Store the machine in a dry, protected place. If machine is stored outside, put a waterproof cover over it.

Carburetor Cleaning
Debris, corrosion, rust, or varnish can build up in the internal air/fuel passages. Many times the contamination is located in an
area of the carburetor that is not visible. In most cases proper cleaning can resolve these issues.
Carburetors and carburetor components can be cleaned by using one of several types of commercial cleaning methods: aerosol
sprays, caustic dip tanks, and ultrasonic cleaners.
→NOTE:
Some cleaning chemicals may be flammable and have toxic fumes. Always follow the chemical
manufacturer’s recommendations. Always wear personal protection gear such as safety glasses
protective gloves and work in a well ventilated area. Do not use drill or hard wire to clean carburetor
passage ways.
Cleaning Procedure
Always follow the solvent manufacturer’s recommendations for material compatibility because some solvents may attack
metal, plastic or rubber components.
[1] - Clean debris off the outside of the carburetor before disassembly.
[2] - Completely disassemble the carburetor per the instructions in the Technical Manual and visually inspect.
[3] - Determine if carburetor is repairable, excessive corrosion may determine this is not practical.
[4] - If repairable, clean any remaining dirt and old gaskets from the carburetor.
The preferred method of cleaning is to use an ultrasonic cleaner.
IMPORTANT:
Wires and metal instruments should not be used. Light damage or deposits on the surface of the float
valve seat can be removed using a cotton swab with a mild abrasive such as toothpaste or 800 grit
lapping compound.
Carburetor Assembly
When the carburetor is ready for assembly, lay out all the necessary components on a clean surface. Be aware that even clean
shop rags may contain dirt and metal shavings. Assemble the carburetor in accordance with the instructions in the Technical
Manual. Keep the following in mind:
Check the throttle shaft for excessive play or movement and any signs of binding.
Never use oil on the throttle shaft because it attracts dirt which can cause premature wear of the throttle shaft seals.
If the throttle shaft was removed use new screws and follow the service manual torque specifications.
Always check the float and float valve for binding with the float valve installed in its proper position.
Replacement of all gaskets and seals is necessary when servicing any carburetor.
Inspect the carburetor insulator for damage and replace if necessary. Be sure to install the insulator using the correct
orientation.
Clean and flush the complete fuel system.
Fuel lines must be replaced if they are brittle, cracked, excessively soft or damaged.
Replace the fuel filter and air filter after cleaning the carburetor.

Section 10 - GENERAL INFORMATION Group 20: Machine Specifications
Carburetor Cleaning Methods

Ultrasonic Cleaning Systems
Ultrasonic cleaners use environmentally friendly cleaning solution and sound waves to penetrate deep into carburetor
passages. Heating the solution is an option on ultrasonic cleaners that significantly increases the effectiveness of the system.
Ultrasonic cleaner systems work by creating sound wave pulses that are transmitted through a cleaning solution. Manufactures
of ultrasonic cleaners claim the pulses create small bubbles that loosen and pulverizes contaminates. Select a chemical
solution that is designed specifically for carburetor cleaning.
Generally, chemicals will need to be diluted with water prior to use. When choosing a chemical, consider dilution rates to help
determine which chemical is the most cost effective. Consider disposal of cleaning solution before ordering chemicals. Check
with local authorities on recommended disposal methods before disposing of any cleaning solution. Ultrasonic cleaners come in
many sizes. Most 5.7— 7.6 L (1.5-2 gal.) tanks will be sufficient for carburetors used by John Deere gas engines.
If an Ultrasonic Cleaner is used, place carburetor in and run for 30 minutes at 43.4° C (110° F) in the proper solution mix. If the
solution is too strong or the carburetor is left in the cleaner for too long, the aluminum body will have a residue on the surface
from the aluminum oxidizing.
Rinse the parts in water and dry with compressed air (up to 210 kPa [30 psi]).
CAUTION:
Compressed air can cause debris to fly a long distance
Clear work area of bystanders

Wear eye protection when using compressed air for cleaning purposes.
Reduce compressed air pressure to 210 kPa (30 psi).
Wash off and blow ports out in carburetor body, fuel transfer tubes, and discharge port. Blow compressed air through
carburetor passages in the opposite direction of the air and fuel flow (into the smallest passages to flush debris out of the
larger passages). This will prevent debris lodging in difficult to clean areas.
Aerosol Cleaner
Personal safety, environmental concerns and cleaning effectiveness make this method the least desirable. This method can be
used on carburetor components that may be damaged by caustic cleaners (rubber seals or other non-metallic components).
When cleaning with aerosol sprays, it is always best to spray in the opposite direction of the air/fuel circuit (into the smallest
passages to flush debris out of the larger passages). This will prevent debris lodging in difficult to clean areas.
CAUTION:
Vapors from solvents can be explosive and flammable. Follow the instructions on the container label for
safe use of the solvent.
Work in a well-ventilated area.

Wear protective clothing when handling solvent.
Do not smoke while handling solvents.
Keep solvent away from flames or sparks
Caustic Dip Tanks

Caustic dip tanks use aggressive chemicals to dissolve carbon based contamination. This method is effective for most
carburetor cleaning needs.
Rotating the parts in the tank will ensure the cleaning solution flushes out any air pockets left in the passages. Follow the
recommendation on the cleaner for submersion times. Disadvantages of the caustic dip tanks are that some carburetor parts
may be damaged if left in solution too long.
Personal safety and chemical disposal are additional concerns. Because the chemical is caustic, exposure may cause injury or
death. Disposal of used solution can be difficult because most cleaners are considered hazardous waste.

Group 20 - Machine Specifications

Machine Specifications Z225 and Z245 (S.N. -130000)
→NOTE:
Specifications and design subject to change without notice.
General Specifications
Z225 Z245
Ground Speed:
Forward 0—11.3 km/h (0—7.0 mph)
Reverse 0—5.6 km/h (0—3.5 mph)
Engine:
Make Briggs & Stratton
Engine Power Information http://www.briggsandstratton.com
Type Gas
Model Intek 31P777 44L777
Cylinders single cylinder v-twin
Low Idle Speed (Governed) 2200 ± 300 rpm 1750 ± 100 rpm
Low Idle Speed 1750 ± 100 rpm 1300 ± 100 rpm
High Idle Speed 3350 ± 100 rpm 3350 ± 100 rpm
Displacement 0.502 L (30.63 in. 3 ) 0.724 L (44.2 in. 3 )
Bore 90.42 mm (3.56 in.) 79.25 mm (3.12 in.)
Stroke 77.72 mm (3.06 in.) 73.40 mm (2.89 in.)
Lubrication Pressurized
Crankcase Capacity 1.4 L (1.5 qt.) 1.8 L (1.9 qt.)
Crankcase (with Filter) — 1.9 L (2.0 qt.)
Cooling Air Cooled
Air Cleaner Paper Element Paper with Foam Element
Engine Shut Off Key Switch
Fuel System:
Type Mechanical Vacuum Pump
Tank Capacity 10.2 L (2.7 gal.)
Electrical System:
Type 12 Volt Negative Ground
Stator Output 6—16.6 amp regulated at 12.2—13.8 VDC
Battery 12-volt
Battery Type BCI Group U1
Spark Plug Torque 20 N·m (180 lb.-in.)
Spark Plug Gap 0.76 mm (0.030 in.)
Ignition Coil Air Gap 0.25—0.35 mm (0.010—0.014 in.) 0.20—0.30 mm (0.008—0.012 in.)
Power Train:
Transaxle Hydro-Gear EZT
Transaxle Type Hydraulic Infinite Variable Speed
Drive 2 Transaxles (Mirror Image of Each Other)
Brake Type External Disc
Transaxle Oil Capacity (approximate) 1550—1650 ml (53.4—55.8 oz.)

Transaxle Oil 20W50 SL Rated Oil

Machine Specifications Z235 and Z255 (S.N. 130001- )

→NOTE:
Specifications and design subject to change without notice.
General Specifications
Z235, Z255
Ground Speed:
Forward 0—11.3 km/h (0—7.0 mph)
Reverse 0—5.6 km/h (0—3.5 mph)
Engine:
Make Briggs & Stratton
Engine Power Information http://www.briggsandstratton.com
Type Gas
Intek 406777—Z235
Model
Intek 407777—Z255
Cylinders v-twin
Dead Idle Speed 1300 ± 100 rpm
Low Idle Speed 1750 ± 100 rpm
High Idle Speed 3350 ± 100 rpm
Displacement 0.656 L (40 in. 3 )
Bore 70.9 mm (2.79 in.)
Stroke 73.40 mm (2.89 in.)
Lubrication Pressurized
Crankcase Capacity 1.8 L (1.9 qt.)
Crankcase (with Filter) 1.9 L (2.0 qt.)
Cooling Air Cooled
Air Cleaner Paper Element
Engine Shut Off Key Switch
Fuel System:
Type Mechanical Vacuum Pump
Tank Capacity 7.9 L (2.1 gal.)
Electrical System:
Type 12 Volt Negative Ground
Stator Output 6—16.6 amp regulated at 12.2—13.8 VDC
Battery 12-volt
Battery Type BCI Group U1
Spark Plug Torque 20 N·m (180 lb.-in.)
Spark Plug Gap 0.76 mm (0.030 in.)
Ignition Coil Air Gap 0.25—0.35 mm (0.010—0.014 in.) 0.20—0.30 mm (0.008—0.012 in.)
Power Train:
Transaxle Hydro-Gear EZT
Transaxle Type Hydraulic Infinite Variable Speed
Drive 2 Transaxles (Mirror Image of Each Other)
Brake Type External Cogged
Transaxle Oil Capacity (approximate) 1550—1650 ml (53.4—55.8 oz.)
Transaxle Oil 20W50 SL Rated Oil

SINGLE CYLINDER ENGINE REPAIR (g) by Belgreen v2.0
Product Identification Number Location (S.N. -130000)

LEGEND:
A PIN Label
PIN Location
Product identification number (A), also called serial number or chassis number, is located on the rear of the frame.
Engine identification number is located on engine valve cover.
Product Identification Number Location (S.N. 130001- )

LEGEND:
A PIN Label
PIN Location
Product identification number (A), also called serial number or chassis number, is located on the right rear of the engine pan.
Engine identification number is located on engine valve cover.

Section 20 - SINGLE CYLINDER ENGINE REPAIR

Table of contents
Group 10 - Engine Single Cylinder ........................................................................................................ 1
Summary of References ....................................................................................................................... 1
Specifications ....................................................................................................................................... 2
Service Equipment and Tools ............................................................................................................... 4
Remove and Install Upper Blower Housing ........................................................................................... 4
Service Air Cleaner ............................................................................................................................... 5
Remove Carburetor .............................................................................................................................. 7
Install Carburetor .................................................................................................................................. 8
Disassemble Carburetor ..................................................................................................................... 10
Inspect Carburetor .............................................................................................................................. 12
Assemble Carburetor .......................................................................................................................... 14
Service Breather Valve ....................................................................................................................... 16
Remove Engine .................................................................................................................................. 18
Install Engine ...................................................................................................................................... 21
Remove Cylinder Head ....................................................................................................................... 22
Install Cylinder Head .......................................................................................................................... 25
Inspect and Repair Cylinder Head ...................................................................................................... 27
Remove Valves ................................................................................................................................... 29
Reface Valves ..................................................................................................................................... 30
Install Valves ...................................................................................................................................... 31
Remove and Install Governor ............................................................................................................. 31
Piston and Rings ................................................................................................................................. 33
Inspect Cylinder Bore ......................................................................................................................... 35
Hone Cylinder Bore ............................................................................................................................. 36
Clean Cylinder Bore ............................................................................................................................ 37
Resize Cylinder Bore ........................................................................................................................... 38
Inspect Piston and Connecting Rod .................................................................................................... 40
Assemble and Install Connecting Rod and Piston ............................................................................... 42
Remove and Install Flywheel .............................................................................................................. 46
Remove and Install Stator .................................................................................................................. 47
Remove Crankshaft ............................................................................................................................ 49
Remove Balance System .................................................................................................................... 51
Install Balance System ....................................................................................................................... 52
Install Crankshaft and Cam Gear ........................................................................................................ 53
Inspect Magneto and Cam Bearing ..................................................................................................... 54
Inspect PTO Journal ............................................................................................................................ 56
Inertia Starting Motor Components .................................................................................................... 58
Remove and Install Starting Motor ..................................................................................................... 58
Disassemble Inertia Starting Motor .................................................................................................... 60
Assemble Inertia Starting Motor ......................................................................................................... 64
Replace Inertia Pinion Gear ................................................................................................................ 67

Section 20 - SINGLE CYLINDER ENGINE REPAIR Group 10: Engine Single Cylinder
Group 10 - Engine Single Cylinder

Specifications
Remove and Install Upper Blower Housing
Service Air Cleaner
Remove Carburetor
Install Carburetor
Disassemble Carburetor
Inspect Carburetor
Assemble Carburetor
Service Breather Valve
Remove Engine
Install Engine
Remove Cylinder Head
Install Cylinder Head
Inspect and Repair Cylinder Head
Remove Valves
Reface Valves
Install Valves
Remove and Install Governor
Piston and Rings
Inspect Cylinder Bore
Hone Cylinder Bore
Clean Cylinder Bore
Resize Cylinder Bore
Inspect Piston and Connecting Rod
Assemble and Install Connecting Rod and Piston
Remove and Install Flywheel
Remove and Install Stator
Remove Crankshaft
Remove Balance System
Install Balance System
Install Crankshaft and Cam Gear
Inspect Magneto and Cam Bearing
Inspect PTO Journal
Inertia Starting Motor Components
Remove and Install Starting Motor
Disassemble Inertia Starting Motor
Assemble Inertia Starting Motor
Replace Inertia Pinion Gear

Specifications
Item Measurement Specification
Blower Housing Screws Torque 10 N·m
(85 lb·in)
Fuel Pump Screws Torque 4 N·m
(35 lb·in)
Carburetor Mounting Studs Torque 8 N·m
(70 lb·in)
Air Cleaner Base Hardware Torque 4.5 N·m
(40 lb·in)
Throttle Valve Screws Torque 4.5 N·m
(40 lb·in)
Fuel Shutoff Solenoid Torque 5 N·m
(44 lb·in)
Breather Cover Screws Torque 3 N·m
(25 lb·in)
Engine Mounting Bolts

Engine Mounting Bolts Torque 47 N·m
(35 lb·ft)
Engine Mounting Bolt and Nut Torque 25 N·m
(220 lb·in)
PTO Clutch Cap Screw Torque 75 N·m
(55 lb·ft)
Exhaust Pipe Flange Bolts Torque 10.2 N·m
(90 lb·in)
Cylinder Head Bolts Torque 28.2 N·m
(250 lb·in)
Valve Cover Screws Torque 6 N·m
(55 lb·in)
Intake Manifold Bolts Torque 11 N·m
(100 lb·in)
Valve Margin
Valve Margin Thickness 0.8 mm
(0.030 in)
Valve Margin Wear Limit Thickness 0.4 mm
(0.0156 in)
Valve Seat Width 0.8—1.6 mm
(0.031—0.063 in)
Valve Guide (Intake and Exhaust) Reject ID 6.09 mm
(0.240 in)
Rocker Arm Studs Torque 17 N·m
(150 lb·in)
Oil Sump Cover Screws Torque 20 N·m
(180 lb·in)
Piston Ring End Gap

Top Compression Ring Gap (maximum) 0.64 mm
(0.025 in)
Center Compression Ring Gap (maximum) 0.76 mm
(0.030 in)
Oil Control Ring Gap (maximum) 0.76 mm
(0.030 in)
Cylinder Bore

Standard Bore ID 90.42 mm
(3.560 in)
Standard Bore (maximum) ID 90.51 mm
(3.563 in)
Oversize Bore ID 90.98 mm
(3.582 in)
Cylinder Out of Round Maximum 0.04 mm
(0.002 in)
Cylinder Oversized Maximum 0.08 mm
(0.003 in)
Connecting Rod and Piston Pin Wear Limits

Crankpin Bearing ID 38.15 mm
(1.502 in)
Piston Pin Bearing ID 20.35 mm
(0.801 in)
Piston Pin OD 20.29 mm
(0.799 in)
Piston Pin Wear OD (maximum) 0.01 mm
(0.001 in)
Connecting Rod Screws Torque 17 N·m
(150 lb·in)
Flywheel Bolt Torque 136 N·m
(100 lb·ft)
Flywheel Fan Screws Torque 16 N·m
(140 lb·in)
Stator Cap Screws Torque 3.4 N·m
(30 lb·in)
Crankshaft Wear Limits

PTO Journal Diameter 41.20 mm
(1.622 in)
Magneto Journal Diameter 34.95 mm
(1.376 in)
Crankshaft Pin Diameter 38.02 mm
(1.497 in)
Eccentric Journal Diameter 55.93 mm
(2.202 in)
Cam Gear Wear Limits

Camshaft PTO Journal Diameter 12.65 mm
(0.498 in)
Camshaft Magneto Journal Diameter 12.65 mm
(0.498 in)
Cam Lobe Diameter 30.07 mm
(1.184 in)
Compression Bearing Diameter 12.8 mm
(0.504 in)
Crankshaft Journal and Counterweight Bearing

Crankshaft Eccentric Journal (Wear Limit) OD 55.93 mm
(2.202 in)
Counterweight Link Bearing (Wear Limit) ID 56.13 mm
(2.210 in)
Crankcase Cover Bolts Torque 20 N·m

(180 lb·in)
Magneto Bearing Wear Limit ID 35.13 mm
(1.383 in)
Cam Bearing Wear Limit ID 12.80 mm
(0.504 in)
PTO Journal and Oil Seal

PTO Journal Wear Limit ID 41.37 mm
(1.629 in)
Oil Seal Depth Flush
Starting Motor
Starter (Inertia) Minimum Brush Length 3.2 mm
(0.125 in)
Though Bolts Torque 6 N·m
(50 lb·in)
Mounting Bolts Torque 16 N·m
(140 lb·in)
Service Equipment and Tools

→NOTE:
Order tools according to information given in the SERVICEGARD ™ Catalog. Some tools may be available
from a local supplier.
Thickness Gauge
0.15 mm (0.006 in.)
Use to measure piston ring side gap.
C-Ring Removal Tool
JDG1087
Use to remove retainer C-ring from inertia starting motor pinion gear.
C-Ring Installer Tool
JDG1086
Use to install retainer C-ring to inertia starting motor pinion gear.
Remove and Install Upper Blower Housing

LEGEND:
A Screws
B Screws

Blower Housing Screen
[1] - Remove two screws securing the fuel pump to blower housing.
[2] - Remove 4 screws (A) and the fan screen in place.
[3] - Remove the air cleaner cover and air cleaner.
[4] - Remove 4 screws (B) holding the outer blower housing in place.
[5] - Lift outer blower housing up and off of engine.
[6] - Remove the screw holding the dipstick tube in place.
[7] - Install in reverse order of removal.
[8] - Tighten screws to specification.

(85 lb.-in.)
Fuel Pump Screws Torque 4 N·m
(35 lb.-in.)
Service Air Cleaner

LEGEND:
A Nut
B Cover
Air Cleaner Cover
[1] - Remove nuts (A). Remove cover (B) to service high flow air cleaner.
[2] -
LEGEND:
C Filter Element
D Elbow
Filter Element
Inspect the paper filter element (C) without removing it.

[3] - If the paper filter element is very dirty or damaged, replace with new element:
a. Pull air cleaner from intake tube (D).

b. Clean air cleaner base very carefully, preventing any dirt from falling into carburetor.
c. Install new paper filter element.
[4] - Install air cleaner cover and secure with two nuts.

Remove Carburetor
LEGEND:
A Fuel Line
B Wire Connector
Carburetor and Solenoid
[1] - Park machine safely.
[2] -
CAUTION:
Gasoline is extremely flammable. Do not smoke. Always work in a well ventilated area away from open
flame or spark producing equipment; including equipment that utilizes pilot lights.
Disconnect fuel line (A) and drain fuel in line into an approved container.
[3] - Disconnect wire connector (B) to fuel shutoff solenoid.
[4] - Remove upper blower housing. (See Remove and Install Upper Blower Housing .)
[5] -
LEGEND:
C Breather Tube
D Nuts
Carburetor Breather Tube

Disconnect breather tube (C). Remove nuts (D) securing the air cleaner base.
[6] -

LEGEND:
E Studs
F Choke Linkage
G Governor Linkage
H Spring
Carburetor Disconnect and Remove

While supporting the carburetor in one hand, loosen and remove the two studs (E) holding the carburetor to the intake
manifold.
[7] - Carefully pull the carburetor away from the intake manifold and rotate the carburetor to disengage the choke linkage (F),
governor link (G) and governor link spring (H).
[8] - Remove carburetor and gasket.
Install Carburetor
LEGEND:
A Outer Hole
B Choke Link
C Slot
Carburetor Linkage
[1] -
CAUTION:
Before starting or running engine, static adjustment of the governor must be made. Failure to make
static adjustments first, could result in engine overspeeding, and may result in engine or equipment
damage, personal injury and/or property damage.
Connect governor link and governor link spring to throttle lever.
[2] - Install choke link to outer hole (A) of choke lever on carburetor.
[3] - Position gasket in place on the carburetor and slide choke link (B) into slot (C) in choke control bracket.
[4] - Making certain that the gasket is in place, install the carburetor bolts and tighten to specification.

Carburetor Mounting Studs Torque 8 N·m
(70 lb.-in.)
[5] - Install the air cleaner base and breather tube. Tighten the base screw and nuts to specification.
Air Cleaner Base Hardware Torque 4.5 N·m
(40 lb.-in.)
[6] - Install air cleaner base support bracket.
[7] - Install fuel line and fuel line clamp.
[8] - Install air cleaner pre-cleaner, air filter, and cover.

Disassemble Carburetor
LEGEND:
A Valve Assembly
Float and Fuel Inlet Valve Assembly
[1] - Remove fuel shutoff solenoid and fuel bowl washer.
[2] - Remove float bowl and float bowl gasket from carburetor.
[3] - With a small punch, drive the float hinge pin out of float hinge. Remove float and fuel inlet valve assembly (A).
[4] -
Float Valve
LEGEND:
B Good Valve
C Damaged Valve
Inspect the float valve for excessive wear or damage.
The tip should be smooth, without any grooves, scratches, or tears (B). The rod at the opposite end of the needle should
move smoothly when pushed in and released.
If either the valve or the valve seat is worn or damaged (C), replace the float assembly and carburetor as a set.
[5] -

LEGEND:
D Gasket
E O-Ring
Fuel Transfer Plate

Lift the fuel transfer plate from the carburetor body.
[6] - Remove the rubber gasket (D) and the o-ring (E).
[7] -
LEGEND:
F Jet
Jet
Using a punch of close diameter, press the jet (F) out of the pick-up tube.
[8] -
LEGEND:
G Choke Shaft
H Choke Valve
I Return Spring
J Foam Washer
Choke Shaft
Allow the spring to rotate choke shaft (G) to wide open position.
[9] - Pull choke valve (H) out of choke shaft and lever.
[10] - Remove choke shaft and lever, return spring (I), and foam washer (J).
[11] -
LEGEND:
K Lever
L Screw
M Throttle Valve
N Foam Seal
Throttle Shaft Lever

Rotate throttle shaft and lever (K) closed. Mark throttle valve with a marker for installation. Remove two throttle valve screws
(L).
[12] - Remove throttle valve (M), throttle shaft with lever, and foam seal (N).
[13] - Remove and replace the pilot screw in accordance with the following procedure, if necessary:
Carefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its
original position later.
Remove the limiter, being careful not to turn the pilot screw at this time.
urn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage. Record the
number of turns needed to close the screw.
Turn out the pilot screw to replace it with a new one.
[14] -
LEGEND:
O Tapered End
P Pilot Screw
Pilot Screw
Inspect the tapered portion (O) of the pilot screw (P) for wear or damage.
If the pilot screw is worn or damaged on the taper portion of it, replace it.
Check the spring for a weakened condition; replace it, if necessary
[15] - Install the new pilot screw until the screw is gently seated. Then open the screw the same number of turns as recorded
prior to removal.
Align the limiter with the mark on the carburetor body to install, taking care not to turn the pilot screw.

Inspect Carburetor
[1] -
IMPORTANT:
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 in carburetor cleaner. DO NOT soak rubber, neoprene or plastic
parts in cleaner.
Check 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] - Carefully blow through all passages with dry, compressed air
[4] - Inspect idle mixture needle for bent or grooved point. Replace if grooved or bent.

Assemble Carburetor
Carburetor Components
LEGEND:
A Shaft Seal
B Screw
C Throttle Valve Plate
D Throttle Shaft
E Choke Valve Plate
F Choke Shaft
G Shaft Seal
H Spring
I Idle Speed Screw
J Spring
K Idle Needle Valve
L Limiter Cap
M Plug
N Rubber Gasket
O O-ring
P Fuel Transfer Plate
Q Fuel Inlet Valve
R Float
S Pin
T Sediment Bowl
U Screw
V Seal Washer
W Fuel Shutoff Solenoid
X O-ring
Y Jet
Z Gasket - Intake
IMPORTANT:
When assembling the carburetor use new seals and gaskets.
→NOTE:
A high altitude jet is available.
prior to removal.
[2] -
LEGEND:
A Foam Seal
B Throttle Shaft
C Speed Tab
D Throttle Valve
E Throttle Valve Screw
Carburetor Body
Install the foam seal (A) onto the throttle shaft (B) and insert the shaft into the carburetor body so that the idle speed tab (C)
contacts the idle speed screw and the flat portion of the shaft is facing outward.
[3] - Place the throttle valve (D) on the throttle shaft with mark from removal facing outward and secure with two throttle
valve screws (E). Tighten to specification.
(40 lb.-in.)
[4] -
LEGEND:
F Foam Seal
G Choke Shaft
H Spring Anchor
I Choke Lever Stop
J Choke Valve
K Fuel Inlet
Seal, Spring and Choke Shaft

Insert spring inside foam seal (F). Slide seal and spring onto choke shaft (G) with straight end of spring up toward choke shaft
lever.
[5] - Insert choke shaft into carburetor body until hook of spring hooks on spring anchor (H).
[6] - Lift choke shaft up slightly. Turn counterclockwise until stop (I) on lever clears spring anchor. Push shaft down.
[7] - Insert choke valve (J) into choke shaft with dimples away from fuel inlet (K) side of carburetor. Dimples help to hold and
align choke valve on shaft.
[8] -
LEGEND:
L Rubber Gasket
M O-Ring
N Jet
Fuel Transfer Plate

Install the rubber gasket (L) and the o-ring (M).
[9] - Using a punch of close diameter, press the jet (N) into the pick-up tube with the o-ring end.
[10] - Place the fuel transfer plate onto the carburetor body.
[11] - Insert inlet needle valve in slot on float.
[12] - Place float and needle in carburetor and install float hinge pin, centering hinge pin.
[13] - Place bowl gasket on carburetor body.
[14] - Place bowl on carburetor and install float bowl washer and fuel shutoff solenoid and tighten to specification.
(44 lb.-in.)

LEGEND:
A Screws
Breather Valve Cover
[1] - Remove flywheel. (See Remove and Install Flywheel .)
[2] - Remove breather tube from breather.
[3] - Remove 2 screws (A) from breather cover. Remove cover and gasket. Discard old gasket.
[4] -
LEGEND:
B Reed Valve
Breather Reed Valve

Check the breather reed valve (B). Replace the reed if worn or bent.
[5] - Install breather using a new gasket. Tighten the screws to specification.
Breather Cover Screws Torque 3 N·m
(25 lb.-in.)
[6] - Install breather tube in breather.
[7] - Install flywheel.

Remove Engine
LEGEND:
A Clamp
B Throttle Cable
Throttle Cable
[2] - Disconnect battery negative (—) cable.
[3] - Remove upper and lower engine guards. (See Remove Engine Guards (S.N. -130000) .)
[4] - Remove muffler heat shielding. (See Muffler and Heat Shield, Single Cylinder .)
[5] - Remove 2 nuts from exhaust studs and two screws securing muffler bracket.
[6] - Remove muffler with exhaust pipe.
[7] - Remove clamp (A) and disconnect throttle cable (B) from slider.
[8] -
CAUTION:
Gasoline is extremely flammable. Do not smoke. Always work in a well ventilated area away from open
flame or spark producing equipment; including equipment that utilizes pilot lights.
LEGEND:
C Fuel Pump
Fuel Pump
Disconnect fuel line from tank to fuel pump (C) and plug line.
[9] -

LEGEND:
D Engine Harness
E Starter Terminal
Main Engine Harness

Disconnect main engine harness (D) and wire from starter terminal (E).
[10] -
LEGEND:
F Wire
G Wire Clip
PTO Clutch
Disconnect wire (F) to PTO clutch and remove from wire clip (G).
[11] - Remove belt from PTO clutch. (See Replace Mower Drive Belt (42C) (S.N. -130000) .)
[12] -
LEGEND:
H Washer
PTO Clutch
Remove bolt and washer (H) securing PTO clutch assembly to engine crankshaft.

[13] - Remove tension on transaxle belt. (See Remove Traction Belt (S.N. -130000) .) Remove belt from crankshaft sheave and
remove sheave from crankshaft.
[14] -
LEGEND:
I Nut
Engine Mounting Boss

Remove bolt and nut (I) from right front engine mounting boss.
[15] -
LEGEND:
J Bolt
Engine Mount Bolts

Remove 3 remaining engine mount bolts (J). Remove engine from machine.

Install Engine
LEGEND:
A Bolts
Engine to Frame Bolts
[1] - Install engine onto machine frame.
[2] - Install 3 bolts (A) securing engine to frame. Tighten bolts to specification.
Engine Mounting Bolts Torque 47 N·m
(35 lb.-ft.)
[3] -
LEGEND:
B Nut
C Fuel Pump
D Throttle/Choke Cable
Fuel Pump and Throttle Cable

Install the remaining mounting bolt. Attach the ground wires and negative battery cable. Install the nut (B) and tighten to
specification.
Engine Mounting Bolt and Nut Torque 25 N·m
(220 lb.-in.)
[4] - Connect fuel line from fuel tank to fuel pump (C).
[5] - Connect throttle/choke cable (D) and adjust. (See Adjust Throttle and Choke Cable .)
[6] -

LEGEND:
E Connector
F Starter Terminal
Engine Wire Harness Connector

Connect engine wire harness connector (E) and cable to starter terminal (F).
[7] - Install engine crankshaft key and sheave.
[8] - Install traction drive belt engine and transaxle sheaves. (See Install Traction Belt (S.N. -130000) .)
[9] -
LEGEND:
K Slot
L Cap Screw
PTO Clutch
Install PTO clutch with anti rotation pin in slot (K) in machine frame.
[10] - Secure with washer and cap screw (L). Tighten cap screw to specification.
PTO Clutch Cap Screw Torque 75 N·m
(55 lb.-ft.)
[11] - Install muffler and exhaust pipe and secure with mounting bolts (N). Tighten mounting bolts to specification. (See Muffler
and Heat Shield, Single Cylinder .)
Exhaust Pipe Flange Bolts Torque 10.2 N·m
(90 lb.-in.)
[12] - Install engine guards. (See Remove Engine Guards (S.N. -130000) .)
[13] - Check engine oil and fill as necessary.
[14] - Connect battery negative (—) cable.


LEGEND:
A Cap Screws
Valve Cover Cap Screws
[1] - Disconnect spark plug lead and remove spark plug.
[2] - Remove air cleaner assembly, carburetor and blower housing.
[3] - Remove intake manifold and governor control bracket and linkage.
[4] - Remove valve cover cap screws (A).
[5] -
→NOTE:
Mark the push rods for reassembly in their original position. The exhaust valve push rod is steel and is
marked with a red stripe. The intake valve push rod is aluminum.
LEGEND:
B Adjustment Nuts
C Rocker Arms
D Pivots
E Push Rods
Rocker Arms and Push Rods

Remove rocker arm adjustment nuts (B), rocker arms (C), rocker arm pivots (D), and push rods (E).
[6] -

Cylinder Head Bolts

Remove cylinder head bolts in sequence shown.
[7] -
Cylinder Head and Gasket

Remove cylinder head, cylinder head gasket and push rods.


LEGEND:
A Alignment Sleeves
[1] - Clean gasket surfaces.
[2] -
IMPORTANT:
Do not use sealer of any kind on gaskets.
Place new gasket and cylinder head on cylinder. Align head with alignment sleeves (A) located in the cylinder.
[3] - Apply thin coat of clean engine oil to threads. Install 8 cylinder heads bolts.
[4] -
IMPORTANT:
Do not tighten each bolt to final torque in a single step. Incorrect tightening may cause a warped cylinder
head. Step-tighten all bolts to 1/3 of the final torque value, then 2/3 of the final torque value.

Cylinder Head Bolts

Tighten all bolts down evenly by hand. Tighten cylinder head bolts in sequence shown in three even increments to
specification.
Cylinder Head Bolts Torque 28.2 N·m
(250 lb·in)
[5] -
IMPORTANT:
The exhaust valve push rod is steel and is marked with a red stripe. The intake valve push rod is
aluminum.
LEGEND:
B Nuts
C Rocker Arms
D Pivots
E Push Rods
Rocker Arms and Push Rods

Install push rods (E), rocker arm pivots (D), rocker arms (C), and arm support nuts (B). Tighten to specification.
[6] - Adjust valve clearance. (See Adjust Valve Clearance .)
[7] -
Valve Cover
Install valve cover with new gasket. Tighten to specification using the crossing pattern shown.
(55 lb·in)
[8] - Install intake manifold. Tighten bolts to specification.

Intake Manifold Bolts Torque 11 N·m
(100 lb·in)
[9] - Install blower housing.
[10] - Install governor control bracket and linkage.
[11] - Install carburetor and adjust governor linkage. (See Adjust Governor - Static .)
[12] - Install air cleaner assembly.
[13] - Install spark plug and plug wire.

LEGEND:
A Straight Edge
Cylinder Head Measure
[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.
[2] - Inspect cylinder head for broken fins or cracks.
[3] - Remove all gasket material from cylinder head.
[4] - Using a surface plate or straight edge (A), check cylinder head mounting surface for distortion in several areas. If
mounting surfaces are distorted more than 0.1 mm (0.004 in.) , replace cylinder head.
[5] - Inspect valve guides. The rejection dimension for both intake and exhaust valve guides is 6.09 mm (0.240 in.) .

Remove Valves
LEGEND:
A Retainer Locks
B Retainer
C Valve Spring
D Valve
Valve Removal
[1] - Place cylinder head on workbench with support to hold valves in place.
[2] - Move rocker arms out of the way and remove valve caps from valve stems.
[3] - Depress the valve spring retainer and spring with thumbs to compress spring until valve spring retainer locks can be
removed.
[4] - Release pressure and remove the valve spring retainer locks (A), valve spring retainer (B), valve spring (C), and valve (D)
from the cylinder head.
[5] - Repeat procedure on other valve.

Reface Valves
LEGEND:
A Seal
B Valve Margin
C 0.8 mm (0.030 in.)
D Valve Seat Width
E 45°
Valve Stem Seal
Valve and Valve Seat
[1] - To remove valve stem seals (A), grasp seal with pliers and pull up on seal while turning.
[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.
[3] - Valve margin (B) should be 0.8 mm (0.031 in.) (C). If wear limit or less, resurface or replace valve.
Valve Margin
Valve Margin Thickness 0.8 mm
(0.030 in.)
Valve Margin Wear Limit Thickness 0.4 mm
(0.0156 in.)
[4] - Valve seat width (D) should be 0.8—1.6 mm (0.031—0.063 in.) .

Valve Seat Width 0.8—1.6 mm
(0.031—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.
[6] - Inspect valve springs and replace if broken or worn.

[7] - Inspect valve guides by inserting plug gauge into valve guide. If plug gauge inserts 6.4 mm (0.250 in.) or more, the
guide must be replaced. If plug gauge is not available, the rejection dimension for both intake and exhaust valve guides is 6.05
mm (0.238 in.) .
Valve Guide (Intake and Exhaust) Reject ID 6.09 mm
(0.240 in.)
Install Valves
[1] - If rocker arm studs were removed, coat with hardening sealant before installation.
[2] - Install rocker arm studs. Tighten to specification.

Rocker Arm Studs Torque 17 N·m
(150 lb.-in.)
[3] - Valve stems and guides must be free of foreign material and burrs or valve sticking will occur, damaging the valve stem
seals.
[4] - Oil the ID of the valve stem seal with engine oil. Install on valve stem. Press seal down over intake valve guide.
[5] -
→NOTE:
Be sure valve guide lubricant is not on valve face, valve seat, or exposed end of valve stem.
Lightly coat valve stems with valve guide lubricant. Install valve into valve guide.
[6] - Place valve spring over valve stem.
[7] - Place retainer on spring.
[8] - Compress valve spring with thumbs until valve stem extends through end of retainer. Continue to press until the valve
spring retainer locks can be put into the groove on the valve stem. Be sure locks are fully engaged in valve stem groove.
[9] - Gradually release pressure on the valve spring until the retainer locks seat into the retainer.
[10] - Install cylinder head on engine block. (See Install Cylinder Head .)
[11] - Set valve clearance. (See Adjust Valve Clearance .)
Remove and Install Governor

[1] - Drain oil from sump.
[2] - Remove all rust, foreign material and burrs from crankshaft.
[3] - Remove sump screws. Remove sump and sump gasket.
[4] - Inspect governor gear and bearing, flyweight pivots, and governor cup for wear or damage.
[5] - Before installing sump, be sure that governor cup is in line with governor shaft paddle.
[6] -

LEGEND:
E Screw
Sump Cover
Install sump and gasket. Use non-hardening sealant on the threads of screw #9 (E).
[7] - Tighten screws to specification using the pattern illustrated above.

(180 lb.-in.)
[8] - Complete installation of remaining governor linkage and carburetor.
[9] - Adjust governor. (See Adjust Governor - Static .)

Piston and Rings

LEGEND:
A Retainer
B Notch
Piston Pin Removal
[1] - Remove air filter and bracket, upper blower housing, flywheel, alternator, carburetor and governor linkage.
[2] -
→NOTE:
Remove carbon or ridge at the top of the cylinder bore. This will prevent breaking the rings when
removing the piston and connecting rod.
Remove starter, cylinder head and crankcase cover.
[3] - Remove the connecting rod cap. Then push the piston and connecting rod out through the top of the cylinder.
[4] - To remove connecting rod from piston, rotate piston pin retainer (A) until one end is exposed in the notch (B) in the piston
pin bore.
[5] - With a needle nose pliers, grasp end of piston pin retainer. Pull in and up to remove.
[6] - From opposite side of piston, push piston pin out of piston and connecting rod. Piston pin is a push fit in piston and rod.
Deposits may build up on piston pin and require the piston pin to be pressed out.
[7] -
IMPORTANT:
New piston rings must be installed whenever the engine is disassembled for major servicing or overhaul,
providing that cylinder bore is within specifications.
LEGEND:
A Piston Ring Expander
Piston Ring Expander

Remove top and center compression rings using ring expander (A).

[8] -
→NOTE:
Measure cylinder bore before checking piston and rings. If cylinder bore requires re-sizing, it will not be
necessary to check piston and rings since a new oversized piston assembly will be used.
If cylinder bore is more than 0.08 mm (0.003 in.) oversize, or 0.04 mm (0.002 in.) out of round, it must be resized.
[9] -
→NOTE:
Oil control ring (B) is shown being spiraled into compression ring groove.
LEGEND:
B Oil Control Ring
Oil Control Ring Install

Spiral top oil control ring from oil ring groove into center compression ring groove. Repeat into top compression ring groove,
and then off piston. Repeat for bottom oil control ring.
[10] -
→NOTE:
If the cylinder is not to be resized and the piston shows no signs of wear or scoring, replace only the
piston rings.
Insert old rings one at a time approximately 25.4 mm (1.0 in.) down into the cylinder bore.
[11] -
CAUTION:
Wear gloves or cover rings with a rag. The top and bottom edges of the ring may be extremely sharp.
Personal injury could occur. Never reuse worn piston rings.

LEGEND:
A Gauge
B Piston Ring
Ring End Gap Measure

Check ring end gap with feeler gauge (A). If ring (B) gap is greater than 0.64 mm (0.025 in.) for the top compression ring and
0.76 mm (0.030 in.) for the center compression ring and the oil ring, the ring is worn and should be replaced.
[12] -
→NOTE:
Before installing new piston rings, recondition the cylinder using a rigid hone with finishing stones. This
will restore the cross hatch angle in the cylinder bore. The correct cylinder cross hatch ensures proper
lubrication and piston ring rotation.
A worn ring will usually show scratches caused by abrasives and/or have a shiny appearance. Never reuse worn piston rings.
Cylinder Specifications
Cylinder Out of Round Maximum 0.04 mm
(0.002 in.)
Cylinder Oversized Maximum 0.08 mm
(0.003 in.)
Piston Ring End Gap

Top Compression Ring Gap (maximum) 0.64 mm
(0.025 in.)
Center Compression Ring Gap (maximum) 0.76 mm
(0.030 in.)
Oil Control Ring Gap (maximum) 0.76 mm
(0.030 in.)

Cylinder Bore
[1] - Always inspect cylinder after engine has been disassembled. Visual inspection will show if there are any cracks, stripped
bolt holes, broken fins or if the cylinder walls are damaged. Use a telescoping gauge (D), and dial caliper, or an inside
micrometer to determine the size of the cylinder bore. Measure at right angles and at six locations from the top (A), middle (B)
and bottom (C).
[2] - If the cylinder bore is more than 0.08 mm (0.003 in.) oversize, or 0.04 mm (0.002 in.) out of round, it must be resized,
or replaced.
Cylinder Bore ID
Standard Bore ID 90.42 mm
(3.560 in.)
Standard Bore (maximum) ID 90.51 mm
(3.563 in.)
Oversize Bore ID 90.98 mm
(3.582 in.)
[3] - If cylinder bores are within specification and show no signs of scoring or other damage, new pistons rings may be installed
providing the cylinder bores are reconditioned using a rigid hone with finishing stones. This will restore the proper cross hatch
angle in the cylinder bores. The proper cylinder cross hatch ensures proper lubrication and piston ring rotation.
Hone Cylinder Bore

LEGEND:
A 45° Cross Hatch

Cylinder Bore Hone Pattern
[1] -
→NOTE:
To produce the proper cross hatch finish use a drill speed of approximately 200 rpm and 40 - 60 strokes
per minute. Lubricate hone liberally to prevent build up on finishing stones.
The cylinder finish, (cross hatch) should be applied after cylinder bore has been resized to within 0.038 mm (0.0015 in.) of
the desired size or when reconditioning a cylinder bore. The finishing stones will produce the correct cross hatch necessary for
proper lubrication and piston ring rotation. The correct hatch angle is approximately 45° (A).
[2] - 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. Be careful not to hone oversize or it will be necessary to resize the cylinder.
(See Resize Cylinder Bore .)
Clean Cylinder Bore

IMPORTANT:
nsure that the entire cylinder and crankcase are thoroughly cleaned after honing. First wash the cylinder
and crankcase carefully in a solvent such as kerosene or commercial solvent. Then thoroughly wash
cylinder and crankcase using a stiff brush with soap and hot water, Rinse thoroughly with hot running
water. Repeat washing and rinsing until all traces of honing grit are gone. Honing grit is highly abrasive
and will cause rapid wear to all of the internal components of the engine unless it is completely removed.
When cylinder and crankcase have been thoroughly cleaned, use a clean white rag or napkin and wipe the cylinder bore. If
honing grit is present it will appear as a gray residue on rag. If any honing grit is evident, rewash and rinse entire cylinder and
crankcase and check again. When there is no trace of honing grit on rag, the cylinder is properly cleaned. Then oil cylinder bore
to prevent rusting.


LEGEND:
A Hone
B Ring Travel
C Cylinder Bore
D Cylinder Bore Bottom
E Cylinder Bore Top
F Cylinder Bore Length
G Ring Travel
H Wear Area
Cylinder Bore Resize
[1] - If the cylinder bore is not within specifications, it will have to be resized using a boring bar or hone. Always resize to
exactly 0.51 mm (0.020 in.) over standard size. (See Specifications for dimension.)
[2] - If this is done accurately, the service oversize rings and pistons will fit perfectly and proper clearances will be maintained.
[3] -
IMPORTANT:
If a boring bar is used, a hone must be used after the boring operation to produce the proper cylinder
cross hatch. (See Hone Cylinder Bore .)
If a hone is used to resize the cylinder bore, place hone (A) in middle of cylinder bore (C). Tighten adjusting knob with finger
until stones fit snugly against cylinder wall. DO NOT FORCE.
[4] - Connect drive shaft to hone. Be sure that cylinder and hone are centered and aligned with drive shaft and drill spindle.
Lubricate hone as recommended by hone manufacturer.
[5] - The recommended drill speed is 300 to 700 rpm maximum and 40 - 60 strokes per minute.
[6] - Because cylinder bores normally wear (H) only in the area of ring travel (B), the cylinder bore will be round above and

below ring travel (G).
[7] - Start drill and, as hone spins, move it up and down at the bottom of the cylinder bore (D).
[8] - Gradually increase the length of the strokes until hone travels full length of cylinder bore (F). Do not travel more than
19.05 mm (0.750 in.) to 25.4 mm (1.0 in.) above cylinder bore (E).
[9] - Lubricate hone frequently to prevent build up on stones.
[10] - As cutting tension decreases, stop hone and tighten adjusting knob following hone manufacturer’s recommendations.
[11] - Check cylinder bore size frequently.
[12] - Check cylinder bores at top and bottom for burrs. Remove burrs. Cylinder head and crankcase cover surfaces must be
free of burrs and gasket material.
[13] - After cylinder bore has been brought to proper resizing dimension, a cross hatch must be applied to bore.

Inspect Piston and Connecting Rod

Inspect Piston
LEGEND:
A Thickness Gauge
Ring Gap
[1] - Clean carbon from top two ring grooves.
[2] - Place a new ring in each piston groove.
[3] - If a 0.15 mm (0.006 in.) or larger feeler gauge (A) can be inserted in any ring groove, the ring grooves are worn and the
piston should be replaced.
→NOTE:
Before installing new piston rings, the cylinder bore should be reconditioned using a rigid hone with
finishing stones. This will restore the proper cross hatch angle in the cylinder bores. The correct cylinder
cross hatch ensures proper lubrication and piston ring rotation.
Inspect Connecting Rod

LEGEND:
A Crankpin Bearing
B Piston Pin Bearing
Connecting Rod Bores
[1] - If the crankpin bearing (A) in the connecting rod is scored, or the crankpin bearing (A) or piston pin bearing (B) exceeds
reject size, the rod must be replaced.
Connecting Rod and Piston Pin Wear Limits

Crankpin Bearing ID 38.15 mm
(1.502 in.)
Piston Pin Bearing ID 20.35 mm
(0.801 in.)
Piston Pin OD 20.29 mm
(0.799 in.)
Piston Pin Wear OD (maximum) 0.01 mm
(0.001 in.)

[2] - Replace connecting rod if either bore is worn.
[3] -
LEGEND:
C Piston Pin Bore
Piston Pin Bore

If piston pin bore (C) is worn 0.01 mm (0.001 in.) out of round or below reject size, it must be replaced.

Assemble and Install Connecting Rod and Piston
Piston Notch
LEGEND:
A Arrow
[1] - The piston pin is a slip fit in both the piston and the connecting rod.
[2] - Install a piston pin lock in groove on one side of piston.
[3] - Piston must be installed with notch or arrow (A) toward flywheel side of cylinder. Dot on piston can face either direction.
[4] - Insert piston pin from opposite side of piston until pin stops against piston pin lock. Then install other piston pin lock. Be
sure that both locks are seated in grooves.
[5] -
Rings
LEGEND:
A Oil Expander
B Lower Scraper Ring
C Upper Scraper Ring
D Center Compression Ring
E Upper Compression Ring
Install oil expander (A) first. Spiral the lower scraper (B) into the top ring groove, then into second ring groove and finally into
position below the expander. Repeat procedure when placing the upper scraper ring above the expander.
[6] - Position gap of oil ring expander, and scraper rings approximately 120° apart from each other.
[7] -

→NOTE:
The paint stripes on the piston rings must be installed with the stripes to the right of the ring gap.
Rings
Using the ring expander tool, install the center compression ring (D) in the middle ring groove. Make sure that the paint stripes
are to the right of the ring gap.
[8] - Using ring expander, install the top compression ring (E) with the paint stripe to the right of the ring gap. Rotate the ring
so the compression ring end gaps are 180° apart.
[9] - Apply oil to piston rings and piston skirt.
[10] -
Ring Compressor
Place piston and ring compressor upside down on bench and push down until head of piston and edge of ring compressor are
even.
[11] -

Ring Compressor
Tighten ring compressor until rings are fully compressed. Then loosen ring compressor slightly so that compressor can be
rotated on piston skirt while holding connecting rod.
[12] - Thoroughly clean and then oil cylinder bore.
[13] -
→NOTE:
The pistons have offset piston pin bores. Position the notch or arrow (E) on piston facing toward the
flywheel side (F) of engine.
Piston Pin Bores

LEGEND:
E Arrow/notch
F Flywheel Side of Engine
Rotate crankshaft until crankpin journal is at bottom of stroke. The rotation permits complete entry of compressed rings,
piston, and rod assembly, when pushed into cylinder.
[14] - Clean and oil crankshaft crankpin.
[15] - Pull connecting rod against crankpin.
[16] -

LEGEND:
G Connecting Rod
H Screw
I Screw
Connecting Rod
Install rod cap with the notch in the connecting rod (G) engaged to the tab on the connecting rod.
[17] -
IMPORTANT:
The connecting rod screws MUST be tightened in the sequence listed. Failure to use a torque wrench in
the correct sequence can result in breakage or scoring.
Install connecting rod screws. Tighten the screw (H) closest to the piston first, the screw (I) farthest from the piston second.
Connecting Rod Screws Torque 17 N·m
(150 lb·in)
[18] - Check for binding by rotating the crankshaft two revolutions. Rod must be free to slide sideways on crankpin.

Remove and Install Flywheel

LEGEND:
A Flywheel Puller
B Flywheel Notch
Flywheel Puller
[1] - Remove blower housing and rotating screen.
[2] - Remove 2 screws securing fan. Remove fan.
[3] - Loosen ignition coil screws and move ignition coil away from flywheel, or remove ignition coil completely.
[4] -
→NOTE:
If the engine crankshaft rotates while loosening the flywheel bolt, secure the flywheel with a strap
wrench.
Use an impact wrench and 24 mm (15/16 in.) socket to loosen flywheel bolt. Do not remove at this time. Unscrew bolt about
6.5 (0.25 in.) for use with flywheel puller.
[5] -
IMPORTANT:
Do not use a flywheel puller that pulls against flywheel teeth.
Install flywheel puller (A), turning puller screws into flywheel puller holes evenly. Tighten lower puller nuts equally against
flywheel to secure screws.
[6] - Tighten upper puller nuts to press puller against flywheel bolt until flywheel separates from engine input shaft.
[7] - Remove puller, flywheel bolt, washer and flywheel.
[8] - Inspect flywheel for cracks, broken fins, burrs on the taper or keyway and distortion of the keyway. Check taper of
crankshaft for burrs, rust or other damage. Replace crankshaft if damaged.
[9] - Inspect flywheel key for wear or damage. Replace if necessary.
[10] -
CAUTION:
Improperly installed flywheel can cause machine damage and serious personal injury.
Before installing flywheel, clean taper and crankshaft taper removing all oil, dirt or grease.
[11] - Align keyway. Install key and flywheel.
[12] -

IMPORTANT:
If used in this application, install spring washer with cup side down as shown.
Flywheel Bolt and Spring Washer

Install flywheel bolt.
[13] - Place strap wrench on flywheel. While holding flywheel, tighten flywheel bolt to specification.
Flywheel Bolt Torque 136 N·m
(100 lb.-ft.)
[14] - Align boss on back of fan with notch (B) in flywheel.
[15] - Install fan and secure with 2 screws.

Fan Screws Torque 16 N·m
(140 lb.-in.)

LEGEND:
A Cap Screws
Stator
Remove:
[2] - Remove engine blower housing.
[3] - Remove the flywheel. (See Remove and Install Flywheel .)

[4] - Disconnect the stator wires from the voltage regulator/rectifier.
[5] - Lift the wire retainer tab and route the stator wires to the top of the shroud.
[6] - Remove the 4 mounting cap screws (A) and remove stator from crankcase.
Install:
[1] - Place stator onto crankcase.
[2] - Align the four mounting holes with the threaded holes in the crankcase and the stator wires routed under the retainer tab.
[3] - Install and tighten the 4 cap screws to specification.

(30 lb.-in.)
[4] - Connect stator wires to the voltage regulator/rectifier.
[5] - Install the flywheel.
[6] - Install flywheel fan. Tighten fan cap screws to specification.

Flywheel Fan Cap Screws Torque 16 N·m
(140 lb.-in.)
[7] - Install engine blower housing.

Remove Crankshaft
LEGEND:
A Timing Marks
Cam Gear and Timing Marks
[1] - Drain oil from crank case.
[2] - Remove flywheel. (See Remove and Install Flywheel .)
[3] -
IMPORTANT:
DO NOT remove dowel pins.
→NOTE:
Before crankcase cover is removed, it is recommended that any rust, paint or burrs be removed from
power take off end of crankshaft. This will eliminate or reduce chances of damaging the crankcase cover
bearing.
Remove crankcase cover. If crankcase cover sticks, tap lightly with soft hammer on alternate sides near dowel pins.
[4] - Tip engine over onto flywheel side of crankcase.
[5] - Support engine to prevent end of crankshaft from resting on workbench.
[6] -
IMPORTANT:
If engine is rotated from this position, tappets will fall out. Tappets must not be mixed.
Rotate crankshaft until timing marks (A) are aligned. With cam gear in this position, the valve tappets will remain clear of cam
lobes.
[7] - Lift out cam shaft.
[8] - Remove piston and connecting rod assemblies.
[9] - Remove crankshaft from crankcase.
[10] -
IMPORTANT:
The various wear points on the crankshaft must be measured.

LEGEND:
B Magneto Journal
C Crankpin
D PTO Journal
E Eccentric Journal
Crankshaft Wear Surfaces

Measure various wear points on the crankshaft, including the magneto journal (B), crankpin (C), PTO journal (D), and eccentric
journals (E).
[11] - Replace crankshaft if worn or if journals are scored. Keyways should be checked to be sure they are not worn or spread.
Remove burrs from keyway edges to prevent damaging the bearing or oil seal. Check oil galleries for blockage or obstructions.
Crankshaft Wear Limits

PTO Journal Diameter 41.20 mm
(1.622 in.)
Magneto Journal Diameter 34.95 mm
(1.376 in.)
Crankshaft Pin Diameter 38.02 mm
(1.497 in.)
Eccentric Journal Diameter 55.93 mm
(2.202 in.)
[12] -
LEGEND:
F Magneto Journal
G PTO Journal
H Exhaust Cam Lobe
I Intake Cam Lobe
J Compression Release
Cam Gear
Check timing gear for chipped or cracked teeth and keyway for wear. Replace timing gear, if damaged. If timing gear is
chipped or cracked, also check cam gear for damage.
[13] - Inspect cam gear teeth, lobes (H and I) and journals (F and G) for wear and nicks. Replace cam gear if journals or lobe

diameter do not meet specification.

Cam Gear Wear Limits

Camshaft PTO Journal Diameter 12.65 mm
(0.498 in.)
Camshaft Magneto Journal Diameter 12.65 mm
(0.498 in.)
Cam Lobe Diameter 30.07 mm
(1.184 in.)
Compression Bearing Diameter 12.8 mm
(0.504 in.)
Remove Balance System

LEGEND:
A Crankshaft
B Counterweight Links
C Alignment Plug
D Counterweight
E Woodruff Key
F Crankshaft Gear
Crankshaft and Balance System
[1] - Remove crankshaft.
[2] - Remove the crankshaft gear (F) from the crankshaft (A). If the gear is tight pry it off using two screwdrivers, being careful
not to damage the gear.
[3] - Remove the woodruff key (E) from the crankshaft.
[4] - Remove and discard the plastic alignment plug (C) from the Mag side of the counterweight (D). Slide the counterweight
from the counterweight links (B).
[5] - Remove the counterweight links from the crankshaft.
[6] -
Crankshaft, Links, and Counterweight

Check counterweight pins, counterweight link bearing surfaces, and crankshaft eccentric surfaces for wear.

[7] - If counterweight link bearing surfaces are discolored, scored or worn to or over reject size, the links must be replaced.
Balance System Wear Limits

Crankshaft Eccentric Journal OD 55.93 mm
(2.202 in.)
Counterweight Link Bearing ID 56.13 mm
(2.210 in.)
Install Balance System

LEGEND:
A Chamfer
Counterweight Links
[1] - Lubricate bearing surfaces with new engine oil.
[2] -
→NOTE:
Both counterweight links must be installed with the chamfer (A), facing the crankshaft throw. The sides
of the link without a chamfer face the outside of the engine.
Slide the counterweight links onto the crankshaft eccentrics.
[3] - Slide the counterweight into the counterweight links.
[4] -
→NOTE:
The plastic alignment plug aids in the assembly of the counter-weight assembly. Replace this plug
whenever it is removed from the counterweight.
Press a new plastic alignment plug into the Mag. side of the counterweight.
[5] - Install the woodruff key to the crankshaft.
[6] - Install the crankshaft gear to the crankshaft. The flange of the gear must face the counterweight link.

Install Crankshaft and Cam Gear

[1] - Install intake and exhaust valve tappets.
[2] - Place seal protector in magneto crankshaft seal.
[3] - Place crankshaft and balancer assembly into block and start magneto journal into magneto bearing.
[4] - Install connecting rod on crankshaft.
[5] - Install cam gear, making sure tappets clear cam lobes.
[6] - Timing marks must be aligned.
[7] - Install governor and oil slinger assembly. (See Remove and Install Governor .)
[8] -
Crankcase Cover Bolts

Install cover and gasket on crankcase being sure screw #9 has non hardening sealant (A) on the threads.
[9] - Protect the oil seal while assembling crankcase cover. Do not use force to assemble.
[10] - Tighten cover bolts to specification using the sequence shown.

Crankcase Cover Bolts Torque 20 N·m
(180 lb.-in.)
[11] - Install cylinder head. (See Install Cylinder Head .)
[12] - Install flywheel. (See Remove and Install Flywheel .)
[13] - Install intake manifold and carburetor assembly. (See Install Carburetor .)
[14] - Install governor lever and governor springs.
[15] - Install oil fill tube and dipstick assembly.
[16] - Perform static governor adjustment. (See Adjust Governor - Static .)
[17] - Install engine shrouding. (See Remove and Install Upper Blower Housing .)
[18] - Install air filter assembly.

Inspect Magneto and Cam Bearing
Magneto Bearing Measure
[1] - When checking the main magneto bearing, it should be replaced if scored or if not within specification.
(1.383 in.)
[2] -
LEGEND:
A Bushing Driver
B Cylinder Block
C Bearing
D Support
Bushing Driver
Place cylinder support (D) under cylinder block (B). Use a bushing driver (A) to press bearing (C) out toward the inside of the
block.
[3] - Lubricate outside surface of bearing and place on inside of block.
[4] -

LEGEND:
E Split Line
F Stake Grooves
Bearing Install
Position bearing with split line (E) away from stake grooves (F).
[5] - Press bearing in until 2.78 mm (0.109 in.) below surface of block.
[6] -
LEGEND:
G Stake Locations
Stake Locations
Stake new bearing into position at locations shown (G).
[7] - When installing new magneto side oil seal, properly support cylinder. Press in seal until it is 1.5 mm (0.059 in.) below
mounting surface.
[8] -

Cam Gear Bearing

Measure cam gear bearing.
Cam Bearing Wear Limit ID 12.80 mm
(0.504 in.)
[9] - If bearing is worn beyond specification the, cylinder, crankcase cover, or sump must be replaced.
Inspect PTO Journal
PTO and Cam Bearing
[1] - From the inside, press the oil seal out of the PTO journal.
[2] - Inspect PTO bearing and cam bearing. The crankcase cover must be replaced if PTO bearing or cam bearing is scored or if
dimensions exceed reject size.
PTO Journal and Oil Seal

PTO Journal Wear Limit ID 41.37 mm
(1.629 in.)
Oil Seal Depth Flush

[3] - Replace the crankcase cover or sump if the journal is worn beyond specification.
[4] - Support crankcase cover and install new oil seal. Press in seal until it is flush with mounting surface.


LEGEND:
A C-Ring
B Retainer
C Spring
D Drive Gear
E Helix Starter Clutch
F Wave Washer
G Drive End Head
H Armature
I Through Bolt
J Housing
K Brush Holder
L End Cap
Starting Motor Components

LEGEND:
A Positive Cable
Positive Cable
Remove:
[1] - Disconnect the negative (—) battery cable from the battery.
[2] - Disconnect battery positive (+) cable (A) from starting motor.
[3] - Remove upper blower housing. (See Remove and Install Upper Blower Housing .)
[4] -
→NOTE:
Flywheel and plate (below and surrounding stator) may be removed for ease of starting motor removal.
LEGEND:
B Bolts
Starting Motor Bolts

Remove starting motor bolts (B) and starter.
Install:
[1] - Install starting motor bolts and tighten to specification.

Starting Motor Bolts Torque 16 N·m
(140 lb.-in.)
[2] - Install plate (below and surrounding stator) and flywheel (if removed).
[3] - Install upper blower housing. (See Remove and Install Upper Blower Housing .)
[4] - Connect positive cable to the starter.
[5] - Connect the negative (—) battery cable to the battery.


[1] -
IMPORTANT:
DO NOT clamp motor housing in a vise or strike with a steel hammer. Starting motors contain two
powerful magnets that can be broken or cracked if the motor housing is deformed or dented.
LEGEND:
A Drive End Head
B End Cap
C Bolts
Starting Motor - Inertia

Remove pinion gear assembly.
[2] - Mark drive end head (A) and end cap (B) and housing using a marker. This will assure proper orientation of the drive end
head and end cap when assembling starter.
[3] - Remove bolts (C) and inspect bushing for wear. If worn, replace drive head end assembly.
[4] -
Armature and Housing

Hold the armature and bearing end cap against a work surface while sliding housing off the armature. (This allows the
armature to remain in the bearing end cap and brush holder for inspection of brush contact to armature.)
[5] -

LEGEND:
B End Cap
D Brush Holder
E Armature
Armature and Brush Holder

While holding brush holder (D) and armature (E), remove bearing end cap (B) from armature.
[6] -
IMPORTANT:
DO NOT use emery cloth to clean the commutator. The particles from the cloth will become embedded in
the commutator and cause rapid brush wear.
LEGEND:
D Brush Holder
E Armature

Remove brush holder (D) from armature commutator (E).
[7] -

→NOTE:
The bearing housing and armature should not be soaked in a cleaning solution. Fine sandpaper, such as
crocus cloth, can be used to clean the armature. The commutator may also be machined with the use of a
diamond cutting tool to no less than 31.24 mm (1.23 in.) outside diameter.
Commutator
Slots between the commutator bars should be cleaned as shown using a broken piece of hacksaw blade.
[8] - If it is suspected that the armature field coil, magnets or motor housing is defective, a new part should be tried in the
motor. If proper testing equipment is available, check the suspected armature or field coil to determine if it is defective (opens
or grounds).
[9] -
LEGEND:
F Brushes
G New Length
H Worn Length
Starting Motor Brushes

The brushes (F) should be checked for proper seating, weak brush springs, dirt, oil or corrosion.
[10] - Comparing to normal length when new (H), if brushes are worn to 3.2 mm (0.125 in.) (G), replace brushes. When all
parts have been thoroughly cleaned, lightly lubricate the bearings.

(0.125 in.)

Brush Retainers
LEGEND:
A Retainers
[1] -
→NOTE:
Brush retainers (A) can be made from standard size paperclips. Straighten and cut to length 2-1/2 in.
Bend into a U-shape with sides of 1 in. and bottom 1/2 in. in length.
Place brushes in their slots and hold brushes with retainers.
[2] -

Place armature commutator in brush holder and remove brush retainers.
[3] -

Armature and End Plate

Install bearing end plate on armature commutator journal making sure plate indexes with brush holder.
[4] -
LEGEND:
B Notch
Starting Motor Housing

Slide motor housing over armature with the notch (B) toward brush holder.
[5] -

Starting Motor - Inertia Washers

Place wave washer on armature shaft with concave side up. Then place flat washer on armature.
[6] - Place drive end cap on starting motor housing making sure that marks on drive end head and end cap line up with
housing mark.
[7] -
Starting Motor - Inertia Bolts

Install through bolts in starting motor. Check for binding of armature shaft using starting motor clutch. Tighten through bolts to
specification.
Through Bolts Torque 6 N·m
(50 lb.-in.)
[8] - Install starting motor drive.
[9] - Install starting motor and tighten bolts to specification.

(140 lb.-in.)


LEGEND:
A C-ring
B JDG1087 Tool
C Retainer
D Drive Pins
Pinion Removal Tool
Pinion Tool Compress
[3] - Remove upper bower housing and flywheel.
[4] -
CAUTION:
To prevent eye injury, always wear eye protection when removing C-ring.
→NOTE:
The starting motor does not have to be removed from the engine to replace the pinion gear.
Position C-ring (A) using screw driver tip so C-ring removal tool (B) can be aligned properly.
[5] - Install C-ring removal tool, JDG1087 over retainer (C) and compress spring.
C-Ring Removal Tool
JDG1087

[6] -
LEGEND:
D Retainer
G Spring
H Flat Washer
I Wave Washer
J Clutch
K Helix
Pinion Gear Components

Screw in handle until drive pins (D) on tool forces off the C-ring from starting motor shaft.
[7] - Remove retainer (D), spring (G), flat washer (H), wave washer (I), pinion gear, and starting motor clutch (J).
[8] - Before installing starting motor clutch, apply lithium based lubricant sparingly around base of helix (K).
[9] -
Starting Motor Helix Install

Place starting motor clutch on starting motor shaft. Rotate clutch until it drops into place.
[10] -

V-TWIN ENGINE REPAIR (g) by Belgreen v2.0
LEGEND:
G Spring
I Wave Washer
Pinion Gear and Spring

Install pinion gear with beveled side of teeth up. Install return spring (G) making sure spring is in recess of starting motor gear.
[11] - Place wave washer (I) with concave side up on starting motor clutch spline.
[12] -
LEGEND:
L JDG1086 Tool
JDG1086 C-ring Install Tool

Place retainer and new C-ring on starting motor shaft.
[13] - Align one of the slots on the JDG1086 C-ring install tool (L) with open end of C-ring.
JDG1086
[14] - Use a hammer to drive snap ring down until it engages groove in starting motor shaft. Then make sure retainer is all the
way up against the snap ring.

Section 30 - V-TWIN ENGINE REPAIR

Table of contents
Group 10 - Repair Engine V-Twin .......................................................................................................... 1
Specifications ....................................................................................................................................... 2
Essential or Recommended Tools ......................................................................................................... 4
Remove and Install Air Cleaner (S.N. -130000) .................................................................................... 4
Remove and Install Air Cleaner (S.N. 130001- ) ................................................................................... 5
Remove and Install Upper Blower Housing (S.N. -130000) ................................................................... 6
Remove and Install Upper Blower Housing (S.N. 130001- ) .................................................................. 7
Remove Single Barrel Carburetor ......................................................................................................... 9
Install Single Barrel Carburetor .......................................................................................................... 10
Disassemble Single Barrel Carburetor ................................................................................................ 11
Inspect Single Barrel Carburetor ........................................................................................................ 13
Assemble Single Barrel Carburetor ..................................................................................................... 15
Remove Two Barrel Carburetor .......................................................................................................... 18
Install Two Barrel Carburetor .............................................................................................................. 19
Repair Two Barrel Carburetor ............................................................................................................. 21
Assemble Two Barrel Carburetor ........................................................................................................ 27
Remove Engine (S.N. -130000) .......................................................................................................... 33
Install Engine (S.N. -130000) .............................................................................................................. 37
Remove Engine (S.N. 130001- ) ......................................................................................................... 41
Install Engine (S.N. 130001- ) ............................................................................................................. 44
Remove Cylinder Air Guides ............................................................................................................... 46
Install Cylinder Air Guides .................................................................................................................. 47
Remove Cylinder Head ....................................................................................................................... 48
Install Cylinder Head .......................................................................................................................... 51
Inspect and Repair Cylinder Head ...................................................................................................... 53
Remove Valve .................................................................................................................................... 54
Inspect and Repair Valve .................................................................................................................... 56
Lap Valves .......................................................................................................................................... 56
Install Valve ........................................................................................................................................ 57
Remove Piston, Rings and Rod ........................................................................................................... 59
Check Piston Ring End Gap ................................................................................................................ 60
Inspect Piston and Rod ....................................................................................................................... 62
Assemble Piston and Rod ................................................................................................................... 64
Install Piston and Rod ......................................................................................................................... 66
Inspect Cylinder Bore ......................................................................................................................... 69
Hone Cylinder Bore ............................................................................................................................. 69
Clean Cylinder Bore ............................................................................................................................ 70
Resize Cylinder Bore ........................................................................................................................... 71
Remove Flywheel ............................................................................................................................... 72
Install Flywheel ................................................................................................................................... 73
Remove and Install Stator .................................................................................................................. 74
Remove and Inspect Crankshaft and Camshaft .................................................................................. 76
Crankshaft and Camshaft Component Location ................................................................................. 78
Install Crankshaft and Camshaft ......................................................................................................... 78
Inspect Magneto Bearing .................................................................................................................... 81
Inspect PTO and Cam Bearing ............................................................................................................ 82
Service Breather Valve ....................................................................................................................... 83
Remove Oil Pump ............................................................................................................................... 86

Install Oil Pump .................................................................................................................................. 89

Inertia Starting Motor Components .................................................................................................... 91
Remove and Install Starting Motor ..................................................................................................... 91
Disassemble Inertia Starting Motor .................................................................................................... 93
Assemble Inertia Starting Motor ......................................................................................................... 97
Replace Inertia Pinion Gear .............................................................................................................. 100

Section 30 - V-TWIN ENGINE REPAIR Group 10: Repair Engine V-Twin
Group 10 - Repair Engine V-Twin

Remove and Install Air Cleaner (S.N. -130000)
Remove and Install Air Cleaner (S.N. 130001- )
Remove and Install Upper Blower Housing (S.N. -130000)
Remove and Install Upper Blower Housing (S.N. 130001- )
Remove Two Barrel Carburetor
Install Two Barrel Carburetor
Repair Two Barrel Carburetor
Assemble Two Barrel Carburetor
Remove Engine (S.N. -130000)
Install Engine (S.N. -130000)
Remove Engine (S.N. 130001- )
Install Engine (S.N. 130001- )
Remove Cylinder Air Guides
Install Cylinder Air Guides
Remove Valve
Inspect and Repair Valve
Lap Valves
Install Valve
Remove Piston, Rings and Rod
Check Piston Ring End Gap
Inspect Piston and Rod
Assemble Piston and Rod
Install Piston and Rod
Hone Cylinder Bore
Clean Cylinder Bore
Remove Flywheel
Install Flywheel
Remove and Inspect Crankshaft and Camshaft
Crankshaft and Camshaft Component Location
Install Crankshaft and Camshaft
Inspect Magneto Bearing
Inspect PTO and Cam Bearing
Remove Oil Pump
Install Oil Pump

Specifications
(80 lb·in)
Carburetor to Intake Manifold Studs Torque 7 N·m
(65 lb·in)
Air Cleaner Elbow to Carburetor Torque 7 N·m
(65 lb·in)
Intake Manifold Cap Screws Torque 9 N·m
(80 lb·in)
(45 lb·in)
Engine Mounting Cap Screws Torque 48 N·m
(35 lb·ft)
PTO Clutch Bolt Torque 68 N·m
(50 lb·ft)
Oil with Filter Capacity 1.9 L
(2 qt)
Air Guide Screws Torque 7 N·m
(62 lb·in)
Cylinder Head Bolts

Cylinder Head Bolt Increments Torque 9 N·m
(80 lb·in)
Cylinder Head Bolt Final Torque 25 N·m
(220 lb·in)
Rocker Arm Screws Torque 11 N·m
(100 lb·in)
(100 lb·in)
Spark Plug Torque 20 N·m
(180 lb·in)
Cylinder Head (maximum) Out-of-Flat 0.1 mm
(0.004 in)
Valve Guide (maximum) ID 6.09 mm
(0.240 in)
Valve Specifications:
Valve Guide Wear Limits ID 6.10 mm
(0.240 in)
Valve Stem Wear Limits Intake OD 5.92 mm
(0.233 in)
Valve Stem Wear Limits Exhaust OD 5.92 mm
(0.233 in)
Valve Seat Width Width 1.2—1.6 mm
(0.047—0.063 in)
Valve Margin (minimum) Width 0.4 mm
(0.016 in)
Valve Guide Depth Distance 7.10 mm
(0.280 in)
Valve Face Angle Angle 45°
Valve Seat Narrowing Angle Angle 30°
Valve Spring Free Length (minimum) Length 33.50 mm
(1.319 in)

Piston Specifications
Compression and Oil Ring End Gap Gap 0.76 mm
(0.030 in)
Crankpin Bearing Wear Limit ID 38.15 mm
(1.502 in)
Piston Pin Bearing Wear Limit ID 17.15 mm
(0.675 in)
Piston Pin Wear Limit OD 17.07 mm
(0.672 in)
Piston Pin Bore Wear Limit ID 17.15 mm
(0.675 in)
Connecting Rod Bolts Torque 13 N·m
(115 lb·in)
Cylinder Bore Specifications

Cylinder Bore — 40 Series ID 75.41—75.44 mm
(2.969—2.970 in)
Cylinder Bore Wear Limit — 40 Series ID 75.51 mm
(2.973 in)
(3.119—3.120 in)
(3.124 in)
Cylinder Bore Out-of-Round 0.076 mm
(0.003 in)
Flywheel Nut Torque 203 N·m
(150 lb·ft)
Fan Retainer Cap Screw Torque 16 N·m
(140 lb·in)
(30 lb·in)
Wear Limit Specifications:

PTO Journal ID 41.22 mm
(1.623 in)
Magneto Journal ID 34.95 mm
(1.376 in)
Crankshaft Crankpin ID 38.02 mm
(1.497 in)
Crankshaft End Play 0.051—0.76 mm
(0.002—0.03 in)
Cam Gear PTO journal ID 12.64 mm
(0.498 in)
Cam Gear Magneto Journal ID 12.64 mm
(0.498 in)
Cam Lobes (Intake) Height 31.12 mm
(1.225 in)
Cam Lobes (Exhaust) Height 31.06 mm
(1.223 in)
Magneto Bearing ID 35.13 mm
(1.383 in)
PTO End Bearing Diameter 41.38 mm
(1.629 in)

Cam Bearing Diameter 12.75 mm
(0.502 in)
Crankcase Cover Bolts Torque 22.6 N·m
(200 lb·in)
Breather Cover Screw Torque 6 N·m
(55 lb·in)
Oil Pump Cover Screws Torque 6 N·m
(50 lb·in)
(200 lb·in)
Oil pressure Pressure 103—345 kPa
(15—50 psi)
Starting Motor
(0.125 in)
Through Bolts Torque 6 N·m
(50 lb·in)
(140 lb·in)
Essential or Recommended Tools

→NOTE:
Order tools from the SERVICEGARD ™ Catalog.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from the SERVICEGARD ™ Catalog.
RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools may be available from local suppliers
or may be fabricated.
Lapping Tool
n/a
Valve Lapping
Briggs & Stratton Flywheel Tool
19203
Remove Flywheel

→NOTE:
C-Ring Removal Tool

JDG1087
JDG1086
Remove and Install Air Cleaner (S.N. -130000)

[1] -

IMPORTANT:
DO NOT use petroleum solvents, such as kerosene, to clean foam pre-cleaner. They may cause foam to
deteriorate. DO NOT oil paper cartridge. DO NOT use pressurized air to clean or dry paper cartridge.
Replace the paper cartridge if it is dirty.
Remove cover assembly.
[2] - Remove filter cartridge. Clean by tapping gently on a flat surface. Replace if dirty. Remove foam pre-cleaner.
[3] - Wash pre-cleaner in liquid detergent and water.
[4] - Squeeze it dry in a clean cloth.
[5] - Saturate it in clean engine oil. Wrap it in a clean, absorbent cloth. Squeeze to remove excess oil.
[6] - Installation is the reverse of removal.
Remove and Install Air Cleaner (S.N. 130001- )

LEGEND:
A Cover
B Knobs
Air Cleaner Cover
[1] - Park machine safely and let engine cool.
[2] - Clean dirt and debris from the air cleaner cover (A).
[3] - Loosen two knobs (B) and remove cover.
[4] -
IMPORTANT:
Avoid damage! Dirt and debris can enter the engine through a damaged filter element:
• Do not wash paper element.
• Do not attempt to clean paper element by tapping against another object.
• Do not use pressurized air to clean element.
• Replace element only if it is very dirty, damaged or the seal is cracked.
IMPORTANT:
Avoid damage! To prevent engine damage, do not allow any foreign objects to fall into the carburetor air
intake.
→NOTE:
During filter cartridge removal, any material or foreign object that enters the air intake must be removed
before replacement of the cartridge.

LEGEND:
C Filter Cartridge
Air Cleaner
Lift out filter cartridge (C) and inspect it for damage.
[5] - Clean air cleaner housing carefully. Prevent any dirt from falling into carburetor.
[6] - Install cartridge. Make sure cartridge and seal are properly seated and sealing the carburetor air intake area.
[7] - Install air cleaner cover and tighten knobs. Do not overtighten.
Remove and Install Upper Blower Housing (S.N. -130000)

LEGEND:
A Screen Tabs
Screen Tabs
Remove:
[1] - Press inward on the stationary screen tabs (A) and remove the stationary screen.
[2] - Remove air cleaner cover and air cleaner elements.
[3] -
LEGEND:
B Screw
C Screw
D Screw

Engine guards removed for clarity.

Remove 4 screws (B) securing the rotating screen to the fan.
[4] - Remove 2 screws (C) holding the upper blower housing to the air intake.
[5] - Loosen the 6 screws (D) (3 on each side) holding the upper blower housing to the engine block.
[6] - Remove upper blower housing.
Install:
[1] -
IMPORTANT:
Upper blower housing must be assembled so that the slot in the blower housing aligns with the ridge in
the air intake. Failure to assemble correctly will prevent the air filter from sealing and cause engine
damage.
Install in reverse order of removal.

(80 lb.-in.)
Remove and Install Upper Blower Housing (S.N. 130001- )

LEGEND:
A Screen Tabs
Screen Tabs
Remove:
[1] - Press inward on the stationary screen tabs (A) and remove the stationary screen.
[2] - Remove air cleaner cover and air cleaner elements.
[3] -
LEGEND:
B Screws
C Screws
D Screws
E Fuel Pump
F Screws

Blower Housing
Remove screws (B) securing the rotating screen to the fan.
[4] - Remove screws (C) holding the upper blower housing to the air intake.
[5] - Remove screws (D) holding fuel pump (E) to blower housing.
[6] - Loosen screws (F) (3 on each side) holding the upper blower housing to the engine block.
Install:
[1] -
IMPORTANT:
Upper blower housing must be assembled so that the slot in the blower housing aligns with the ridge in
the air intake. Failure to assemble correctly prevents the air filter from sealing.
Install in reverse order of removal.

Screws Torque 9 N·m
(80 lb.-in.)

Remove Single Barrel Carburetor

LEGEND:
A Fuel Shutoff Solenoid
B Choke Link
C Throttle Link
Fuel Shutoff Solenoid
[2] - Disconnect fuel shutoff solenoid (A) and choke link (B). Throttle link (C) can be unhooked when carburetor and intake
manifold are being removed.
[3] -
CAUTION:
Fuel vapors are explosive and flammable:
Do not smoke while handling fuel.

Keep fuel away from flames or sparks.
Shut off engine before servicing.
Cool engine before servicing.
Clean up spilled fuel immediately.
LEGEND:
D Fuel Inlet Line
E Breather Hose
F Vapor Hose
G Screw
Single Barrel Assembly

Disconnect and plug the fuel inlet line (D).
[4] - Disconnect breather hose (E) and fuel vapor hose (F) from carburetor inlet elbow.
[5] - Remove four cap screws (G) from intake manifold flanges.
[6] - Disconnect the throttle link from the governor arm while carefully pulling the carburetor and manifold assembly away
from the engine.
[7] -
LEGEND:
H Nut
Air Cleaner Elbow

Remove two nuts (H) holding the air cleaner elbow to the carburetor.
[8] - Separate air cleaner elbow, carburetor body, and intake manifold.
Install Single Barrel Carburetor

[1] - Connect choke link while assembling spacer, gaskets, and carburetor to intake manifold.
[2] - Slide carburetor body and air cleaner elbow onto studs mounted on air intake manifold. Tighten nuts to specification.
Carburetor Assembly Stud Nuts Torque 7 N·m
(65 lb·in)
[3] - Connect throttle link to throttle lever.
[4] - Clean gasket mating surfaces and install new gaskets on intake manifold
[5] - Install manifold and carburetor assembly to cylinder block with four cap screws.
[6] - Tighten to specification.

(80 lb·in)
[7] - Connect and adjust throttle and choke cable. (See Adjust Throttle and Choke Cable .)
[8] - Connect fuel line.

Disassemble Single Barrel Carburetor

LEGEND:
A Valve Assembly
Float and Fuel Inlet Valve Assembly
[1] - Remove fuel shutoff solenoid and fuel bowl washer.
[2] - Remove float bowl and float bowl gasket from carburetor.
[3] - With a small punch, drive the float hinge pin out of float hinge. Remove float and fuel inlet valve assembly (A).
[4] -
Float Valve
LEGEND:
B Good Valve
C Damaged Valve
Inspect the float valve for excessive wear or damage.
The tip should be smooth, without any grooves, scratches, or tears (B). The rod at the opposite end of the needle should
move smoothly when pushed in and released.
If either the valve or the valve seat is worn or damaged (C), replace the float assembly and carburetor as a set.
[5] -

LEGEND:
D Gasket
E O-ring
Fuel Transfer Plate

Lift the fuel transfer plate from the carburetor body.
[6] - Remove the rubber gasket (D) and the O-ring (E).
[7] -
LEGEND:
F Jet
Jet
Using a punch of close diameter, press the jet (F) out of the pick-up tube.
[8] -
LEGEND:
G Choke Shaft
H Choke Valve
I Return Spring
J Foam Washer
Choke Shaft
Allow the spring to rotate choke shaft (G) to wide open position.
[9] - Pull choke valve (H) out of choke shaft and lever.
[10] - Remove choke shaft and lever, return spring (I), and foam washer (J).
[11] -
LEGEND:
K Lever
L Screw
M Throttle Valve
N Foam Seal
Throttle Shaft Lever

Rotate throttle shaft and lever (K) closed. Mark throttle valve with a marker for installation. Remove two throttle valve screws
(L).
[12] - Remove throttle valve (M), throttle shaft with lever, and foam seal (N).
[13] - Remove and replace the pilot screw in accordance with the following procedure, if necessary:
Carefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its
original position later.
Remove the limiter, being careful not to turn the pilot screw.
Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage. Record the
number of turns to close the screw.
Turn out the pilot screw to replace it.
[14] -
LEGEND:
O Tapered End
P Pilot Screw
Pilot Screw
Inspect the tapered portion (O) of the pilot screw (P) for wear or damage.
If the pilot screw is worn or damaged on the taper portion of it, replace it.
Check the spring for a weakened condition; replace it, if necessary
before removal.

Inspect Single Barrel Carburetor

[1] -
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 in carburetor cleaner. DO NOT soak rubber,
neoprene, or plastic parts in cleaner.
Check 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] - Carefully blow through all passages with dry, compressed air
[4] - Inspect idle mixture needle for bent or grooved point. Replace if grooved or bent.

Assemble Single Barrel Carburetor
Carburetor Components
LEGEND:
A Throttle Shaft Seal
B Throttle Shaft
C Throttle Valve Plate
D Throttle Valve Plate Screws
E Carburetor Body
F Gasket - Intake
G Choke Valve Plate
H Choke Shaft Seal
I Choke Shaft
J Float
K Pin
L Fuel Inlet Valve
M Rubber Gasket
N Fuel Transfer Plate
O Jet
P Fuel Bowl Screws
Q Fuel Bowl
R Fuel Shutoff Solenoid
IMPORTANT:
Avoid Damage! When assembling the carburetor use new seals and gaskets.
→NOTE:
A high altitude jet is available.
before removal.
[2] -
LEGEND:
A Foam Seal
B Throttle Shaft
C Speed Tab
D Throttle Valve
E Throttle Valve Screw
Carburetor Body
Install the foam seal (A) onto the throttle shaft (B) and insert the shaft into the carburetor body so that the idle speed tab (C)
contacts the idle speed screw and the flat portion of the shaft is facing outward.
[3] - Place the throttle valve (D) on the throttle shaft with mark from removal facing outward and secure with two throttle
valve screws (E). Tighten to specification.
(40 lb.-in.)
[4] -
LEGEND:
F Foam Seal
G Choke Shaft
H Spring Anchor
I Choke Lever Stop
J Choke Valve
K Fuel Inlet
Seal, Spring, and Choke Shaft

Insert spring inside foam seal (F). Slide seal and spring onto choke shaft (G) with straight end of spring up toward choke shaft
lever.
[5] - Insert choke shaft into carburetor body until hook of spring hooks on spring anchor (H).
[6] - Lift choke shaft up slightly. Turn counterclockwise until stop (I) on lever clears spring anchor. Push shaft down.
[7] - Insert choke valve (J) into choke shaft with dimples away from fuel inlet (K) side of carburetor. Dimples help to hold and
align choke valve on shaft.
[8] -

LEGEND:
L Rubber Gasket
M O-ring
N Jet
Fuel Transfer Plate

Install the rubber gasket (L) and the O-ring (M).
[9] - Using a punch of close diameter, press the jet (N) into the pick-up tube with the O-ring end.
[10] - Place the fuel transfer plate onto the carburetor body.
[11] - Insert inlet needle valve in slot on float.
[12] - Place float and needle in carburetor and install float hinge pin, centering hinge pin.
[13] - Place bowl gasket on carburetor body.
[14] - Place bowl on carburetor and install float bowl washer and fuel shutoff solenoid and tighten to specification.
(44 lb.-in.)

Remove Two Barrel Carburetor

LEGEND:
A Fuel Shutoff Solenoid
B Choke Link
C Throttle Link
[1] -
→NOTE:
Cyclonic carburetor shown. ELS carburetor similar.
Remove upper blower housing.
[2] - Disconnect fuel shutoff solenoid (A) and choke link (B). Throttle link (C) can be unhooked when carburetor and intake
manifold are being removed.
[3] -
CAUTION:

LEGEND:
D Fuel Inlet Line
E Breather Hose
F Vapor Hose
G Screw
Fuel Inlet Line

Disconnect and plug the fuel inlet line (D).

[4] - Disconnect breather hose (E) and fuel vapor hose (F) from carburetor inlet elbow.
[5] - Remove 4 cap screws (G) from intake manifold flanges.
[6] - Disconnect the throttle link from the governor arm while carefully pulling the carburetor and manifold assembly away
from the engine.
[7] -
LEGEND:
H Nut
Air Cleaner Elbow

Remove 4 nuts (H) holding the air cleaner elbow to the carburetor.
[8] -
LEGEND:
I Stud
Carburetor Studs
Remove four special studs (I) holding the carburetor and gaskets to the intake manifold.
[9] - Remove carburetor.
Install Two Barrel Carburetor

[1] - Connect choke link while assembling spacer, gaskets and carburetor to intake manifold.
[2] - Secure carburetor to intake using mounting studs. Tighten to specification.

Carburetor to Intake Manifold Studs Torque 7 N·m
(65 lb.-in.)
[3] - Install air cleaner elbow. Tighten 4 nuts to specification.

Air Cleaner Elbow to Carburetor Torque 7 N·m

(65 lb.-in.)
[4] - Connect throttle link to throttle lever.
[5] - Install new gaskets on intake manifold. Install manifold and carburetor assembly to cylinder block with four cap screws.
Tighten to specification.
(80 lb.-in.)
[6] - Connect and adjust throttle and choke cable. (See Adjust Throttle and Choke Cable, V-Twin .)
[7] - Connect fuel line.

Repair Two Barrel Carburetor
Cyclonic Carburetor Shown. ELS Similar

LEGEND:
A Fuel Bowl
B Fuel Shutoff Solenoid
C Choke Shaft
D Choke Return Spring
E Foam Seal
F Choke Valve
G Carburetor Body
H Top Plate
I Gasket
J Discharge Nozzle
K Gasket
L Throttle Shaft
M Foam Seal
N Throttle Valve Plates
O Emulsion Tube Gasket
P Emulsion Tube Body
Q Main Jets
R Inlet Valve
S Float Pin
T Float
U Float Bowl O-Ring
Components
Disassemble

LEGEND:
A Screw
B Fuel Shutoff Solenoid
Fuel Bowl
[1] -
→NOTE:
Cyclonic carburetor shown. ELS similar.
Remove 2 screws (A) holding the fuel bowl to the carburetor body. Remove fuel bowl and drain the remaining gasoline into a
suitable container.
[2] - Remove fuel shutoff solenoid (B).
[3] - Mark choke valve so it can be installed in its original position.
[4] -
LEGEND:
C Choke Valve
D Choke Shaft
E Foam Seal
Choke Valve/Shaft
Remove 2 screws securing the choke valve (C) to the choke shaft (D). Pull choke shaft and foam seal (E) out of carburetor
body.
[5] - Mark the throttle valves so they can be installed in their original position.
[6] -

LEGEND:
F Throttle Valves
G Throttle Shaft
H Screw
Thottle Valve
Remove 4 screws securing the throttle valves (F) to the throttle shaft (G). Pull throttle shaft and foam seal out of carburetor
body.
[7] - Remove 3 screws (H) securing the cover plate and gasket to the carburetor body.
[8] -
LEGEND:
I Cover Plate
J Gasket
Cover Plate and Gasket

Remove the cover plate (I) and gasket (J).
[9] -

LEGEND:
K Float Hinge Pin
Float Hinge Pin

With a small punch, push out float hinge pin (K).
[10] -
LEGEND:
L Float
M Fuel Inlet Valve
Float and Fuel Inlet Valve

Remove float (L) and fuel inlet valve (M) as an assembly.
[11] -
LEGEND:
N Screw
O Discharge Nozzle
Discharge Nozzle
Remove the screw (N) holding the discharge nozzle (O) into the carburetor body.
[12] - Remove the discharge nozzle and the rubber gasket.

[13] -
LEGEND:
P Screw
Q Emulsion Tube Body Marks
Emulsion Tube Body

Remove 2 screws (P) and emulsion tube body (Q).
[14] -
LEGEND:
R Emulsion Tube Body
Emulsion Tube Body

Mark one jet and the emulsion tube body (R) so it may be installed in the same location during assembly.
[15] -
Main Jets
Use a small punch or similar tool and push main jets out of emulsion tube body.
[16] -
CAUTION:
Be sure to wear eye protection when cleaning parts with compressed air.
Clean metal parts with carburetor cleaner and blow out passages with compressed air.
[17] - Inspect moving parts for wear, nicks, and burrs. Inspect float for leaks or damage. Inspect mating surfaces for nicks,
burrs, foreign material, and cracks. Replace parts that are worn or damaged.
[18] -
Throttle and Choke Shafts

Place carburetor on 6.35 mm (0.250 in.) raised flat surface. Check throttle and choke shafts and shaft bores for wear. Wear
between shafts and shaft bores should not exceed 0.25 mm (0.010 in.) .
[19] - Measure the movement of the shaft with a feeler gauge or dial indicator while moving the shaft up and down.
[20] -
LEGEND:
S Shaft Bore Wear
Shaft and Bores

If movement exceeds 0.25 mm (0.010 in.) check shaft and shaft bores for wear (S). If shaft is worn, replace shaft. If shaft
bores are worn, replace carburetor.

Assemble Two Barrel Carburetor

LEGEND:
A Discharge Nozzle
B Screw
C Emulsion Tube Body
D Screw
Carburetor Body
[1] -
CAUTION:
Be sure to wear eye protection when cleaning parts with compressed air.
→NOTE:
Use new seals and gaskets when assembling carburetor.
Install the rubber gasket and discharge nozzle (A) into the carburetor body. Tighten screw (B) securely.
[2] - Install the rubber gasket and emulsion tube body (C) to the carburetor body. Tighten securely with 2 screws (D).
[3] -
LEGEND:
E Fuel Inlet Valve
F Float Tang
Fuel Inlet Valve

Hook the fuel inlet valve (E) into the float tang (F). Slip float over emulsion tube body aligning fuel inlet valve into seat.
[4] -

LEGEND:
G Float Hinge Pin
Float Hinge Pin

Push float hinge pin (G) into place.
[5] -
LEGEND:
G Shaft
H Throttle Valves
I Screw
Throttle Shaft
Slide foam seal onto throttle shaft. Slide shaft (G) into carburetor body
[6] - Using the marks from disassembly, install throttle valves (H) in their original positions. Tighten screws securely.
[7] - Place the cover gasket and cover plate on the carburetor body. Tighten securely with three screws (I).
[8] - Install choke plate and shaft.
a.
Choke Shaft
Install foam seal onto spring.

→NOTE:
The spring can be installed in either direction.
Choke Shaft Spring and Seal

Slide spring and seal onto choke shaft.
LEGEND:
J Spring
c.
Choke Shaft End Spring
Hook one end of the spring (J) on the choke shaft end.
LEGEND:
J Spring
K Spring End
d.
Choke Shaft into Carburetor
Slide the choke shaft into the carburetor and rotate it so the other end of the spring (K) goes against the post cast into
the carburetor.

LEGEND:
J Spring
K Spring End
e.
Choke Shaft into Carburetor
Push the choke shaft into the carburetor and rotate the choke shaft to tension the spring (J). Rotate the shaft enough so
the flats in the carburetor throat face out and the choke plate can be installed (approximately 180 degrees).
f.
Choke Plate
Hold the choke shaft end and and install the choke plate. Secure the plate with the two round head screws.
g.
Choke Plate
Release the choke shaft end and check that the choke plate opens fully, and can be closed fully by rotating the shaft end
90 degrees.
[9] -

LEGEND:
L O-Ring
Carburetor O-Ring
Install O-ring (L) in groove on bottom of carburetor body
[10] -
LEGEND:
M O-Ring
Fuel Bowl O-Ring

Install new O-ring (M) on bottom of fuel bowl.
[11] -
LEGEND:
N Screw
O Fuel Shutoff Solenoid
Fuel Bowl
Place fuel bowl over the emulsion tube body. Tighten screws (N) securely

[12] - Install fuel shutoff solenoid (O) with washer. Tighten to specification.
(45 lb.-in.)

Remove Engine (S.N. -130000)

LEGEND:
A Starter Terminal
B Engine Wire Harness Connector
C Clutch Wire Harness Connector
Starter Terminal
[2] - Raise seat and disconnect negative (—) battery cable.
[3] - Drain engine oil into a suitable container. (Oil capacity with filter is approximately 1.9 L (2.0 US qt) .
[4] - Remove engine guards. (See Remove Engine Guards (S.N. -130000) .)
[5] - Disconnect wire from starter terminal (A).
[6] - Unplug main wire harness to engine wire harness connector (B).
[7] - Unplug main wire harness to clutch wire harness connector (C).
[8] -
LEGEND:
D Nut
Ground Wires
Remove the cap screw and nut (D) securing ground wires and engine to frame. Remove ground wires.
[9] -

CAUTION:

LEGEND:
E Fuel Line
Fuel line and Pump

Disconnect hose clamp and slide fuel line (E) off hose barb on fuel pump. Plug the fuel line.
[10] -
LEGEND:
F Retaining Clamp
Throttle Cable
Loosen retaining clamp (F) for the throttle cable. Disconnect cable.
[11] -

LEGEND:
G Nut
H Washer
Muffler Shield
Remove cap screw and nut (G) and cap screw, nut and washer (H) on each side of muffler shield. Remove muffler shield.
[12] -
CAUTION:
Spring is under tension. Wear eye protection and gloves.
LEGEND:
I Hole
J Hole
K Idler Sheave
Mower Belt Tensioner Arm

Use a 3/8 in. square drive wrench in hole (I) in mower belt tensioner arm. Pull tensioner arm in direction of left arrow to relieve
tension on mower belt. Slide belt off of sheaves. Carefully release the tension arm to the relaxed position.
[13] - Place a half inch drive wrench in hole (J) in drive belt tensioner arm. Rotate the tension arm in direction of right arrow to
release tension on the drive belt. Remove the drive belt from the idler sheave (K). Carefully release the tension arm to the
relaxed position.
[14] - Remove belts from clutch sheave and drive sheave on engine crankshaft.
[15] -
CAUTION:
Be prepared to support clutch if there is sudden release of clutch from engine crankshaft.

LEGEND:
L Screw
M Screw
Electric Clutch and Engine Sheave

Remove cap screw (L) and washer securing electric clutch and engine sheave assemblies to engine output shaft. Remove
electric clutch.
[16] - Remove the drive sheave and key from the engine crankshaft.
[17] - Remove 3 cap screws (M) securing engine to frame.
[18] - Remove engine.

Install Engine (S.N. -130000)

LEGEND:
A Screw
B Drive Sheave
C Anti-rotation Pin
D Screw
Engine Mounting Cap Screws
[1] - Set engine in machine frame.
[2] - Install 3 engine mounting cap screws (A). Tighten cap screws to specification.
(35 lb.-ft.)
[3] - Install the key and drive sheave (B) onto the engine output shaft.
[4] - Install the electric PTO clutch assembly so that the anti-rotation pin (C) is in the slot. The PTO clutch pin should be able to
move freely within the slot.
[5] - Secure electric PTO clutch with washer and cap screw (D). Tighten cap screw to specification.
(50 lb.-ft.)
[6] -
CAUTION:
LEGEND:
E Hole
F Hole
G Idler Pulley Sheave
Traction Drive Belt

Place traction drive belt on engine sheave and transmission sheaves and idler pulleys. Place a half inch drive wrench in hole (E)
in drive belt tensioner arm. Rotate the tensioner arm in direction of right arrow until drive belt can be placed on idler pulley
sheave (G). Carefully release the tension arm to the relaxed position.
[7] - Place mower deck drive belt in position on all but one of the sheaves. Use a 3/8 in. square drive wrench in hole (F) in
mower belt tensioner arm. Pull tensioner arm in direction of left arrow until belt can be installed on sheave. Carefully release
the tension arm to the relaxed position.
[8] -
CAUTION:

LEGEND:
H Fuel Pump Fitting
Fuel Pump
Remove plug from fuel line and connect to the fuel pump fitting (H), secure with hose clamp.
[9] -
LEGEND:
I Starter Motor Terminal
J Engine Wire Harness Connector
K Clutch Wire Harness Connector
Starter Motor Terminal

Connect wire to the starting motor terminal (I).

[10] - Connect the main wire harness to engine wire harness connector (J).
[11] - Connect the main wire harness to clutch wire harness connector (K).
[12] -
LEGEND:
L Nut
Ground Wires and Engine to Frame

Install the cap screw and nut (L) securing ground wires and engine to frame.
[13] -
LEGEND:
M Hole
N Cable Clamp
Throttle Cable and Control

Attach throttle cable to hole (M) in throttle control. Route cable housing through cable clamp (N). Adjust cable and tighten
clamp. (See Adjust Throttle and Choke Cable, V-Twin .)
[14] -
LEGEND:
N Washer
P Washer

Muffler Shield
Install cap screw, washer and nut (O) on each side of muffler shield. Install cap screw, washer, and nut (P) securing back of
muffler shield to frame.
[15] - Install the engine guards.
[16] - Refill crankcase with engine oil.

(2 qt.)
[17] - Connect negative (—) battery cable.

Remove Engine (S.N. 130001- )

LEGEND:
A Starter Terminal
D Screw
E Screws
F Muffler Shield
Engine and Clutch Wire Harness Connector
[2] - Raise seat.
[3] - Remove battery access cover and disconnect negative (—) battery cable.
[4] - Drain engine oil into a suitable container. (Oil capacity with filter is approximately 1.9 L (2.0 US qt) .
[5] - Remove engine guards. (See Remove Engine Guards (S.N. 130001- ) .)
[6] - Disconnect wire from starter terminal (A).
[7] - Unplug main wire harness to engine wire harness connector (B).
[8] - Unplug main wire harness to clutch wire harness connector (C).
[9] - Remove the cap screw (D) securing ground wires to engine block. Remove ground wires.
[10] - Loosen two screws (E) and remove muffler shield (F).
[11] -
CAUTION:

LEGEND:
G Fuel Line
H Clamp
I Vent Line

Fuel and Vent Line

Remove fuel line (G) from clips.
[12] - Disconnect hose clamp (H) and slide fuel line off hose barb on fuel pump. Plug the fuel line.
[13] - Remove vent line (I) from barb fitting.
[14] -
LEGEND:
J Clamp
Throttle Cable Clamp

Loosen retaining clamp (J) for the throttle cable. Disconnect cable.
[15] -
LEGEND:
K Mower Drive Belt
L Clutch Sheave
M Hole
N Idler Sheave
O Traction Drive Belt
P Engine Sheave
Belts
Pull mower drive belt (K) toward rear of machine to remove from clutch sheave (L).
[16] -
CAUTION:
Insert a 3/8 in. ratchet or breaker bar into the square hole (M) on the idler arm. Rotate the spring-loaded idler arm to relieve
belt tension on the idler sheave (N). Remove the traction drive belt (O) from the idler sheave. Release the spring tension from
the arm and remove the tool.
[17] - Remove the traction drive belt from the engine sheave (P).
[18] -
CAUTION:
Be prepared to support clutch if there is sudden release of clutch from engine crankshaft.

LEGEND:
Q Bolt
R Bolts
Idler arm and pulley removed for clarity.

Remove bolt (Q) and washer securing electric clutch and engine sheave assemblies to engine output shaft. Remove electric
clutch.
[19] - Remove the drive sheave and key from the engine crankshaft.
[20] - Remove 4 bolts (R) securing engine to frame.
[21] - Remove engine.

Install Engine (S.N. 130001- )

LEGEND:
R Bolts
Q Bolt
Idler arm and pulley removed for clarity.
[1] - Set engine in machine frame.
[2] - Install 4 engine mounting bolts (R). Tighten bolts to specification.

(35 lb.-ft.)
[3] - Install the key and drive sheave onto the engine output shaft.
[4] - Install the electric PTO clutch assembly so that the anti-rotation pin is in the slot. The PTO clutch pin must be able to
move freely within the slot.
[5] - Secure electric PTO clutch with washer and bolt (Q). Tighten bolt to specification.
(50 lb.-ft.)
[6] -
CAUTION:
LEGEND:
K Mower Drive Belt
L Clutch Sheave
M Hole
N Idler Sheave
O Traction Drive Belt
P Engine Sheave
Belts
Place traction drive belt (O) on engine sheave (P) and transmission sheaves. Insert a 3/8 in. drive wrench in hole (M) in drive
belt tensioner arm. Rotate the tensioner arm until the drive belt can be placed on idler pulley sheave (N). Carefully release the
tension arm to the relaxed position.
[7] - Place mower deck drive belt (K) in position on clutch sheave (L).

[8] -
LEGEND:
J Clamp
Throttle Cable Clamp

Attach throttle cable to hole in throttle control. Route cable housing through cable clamp (J). Adjust cable and tighten clamp.
(See Adjust Throttle and Choke Cable, V-Twin .)
[9] -
CAUTION:

LEGEND:
G Fuel Line
H Clamp
I Vent Line
Fuel and Vent Line

Connect vent line (I) to barb fitting.
[10] - Remove plug from fuel line and connect to the fuel pump fitting with hose clamp (H).
[11] - Place fuel line (G) inside clips.
[12] -

LEGEND:
A Starter Terminal
D Screw
E Screws
F Muffler Shield
Engine and Clutch Wire Harness Connector

Position muffler shield (F) in place over screws (E). Tighten screws.
[13] - Install screw (D) securing ground wires to engine block.
[14] - Connect the main wire harness to clutch wire harness connector (C).
[15] - Connect the main wire harness to engine wire harness connector (B).
[16] - Connect wire to the starting motor terminal (A).
[17] - Install the engine guards.
[18] - Refill crankcase with engine oil.

(2 qt.)
[19] - Connect negative (—) battery cable.
Remove Cylinder Air Guides

LEGEND:
A Screw
Cylinder Air Guides
[1] - Remove upper blower housing. (See Remove and Install Upper Blower Housing (S.N. -130000) or Remove and Install
Upper Blower Housing (S.N. 130001- ) .)
[2] - Remove carburetor. (See Remove Two Barrel Carburetor .)
[3] - Remove 2 screws holding the fuel pump to the cylinder block.
[4] - Disconnect the fuel line to the carburetor and the pulse line to the valve cover.
[5] - Remove the remaining screw from the bottom of the air guide. Remove the air guide.

[6] - Remove 3 screws holding the left side air guide to the cylinder block.
[7] - Remove 2 screws (A) holding the front air guide in place.
Install Cylinder Air Guides

[1] - Install air guides in reverse order. Tighten air guide screws to specification.
Air Guide Screws Torque 7 N•m
(62 lb.-in.)
[2] - Install carburetor. (See Install Two Barrel Carburetor .)
[3] - Install carburetor linkage.
[4] - Install air filter assembly.
[5] - Install upper blower housing. (See Remove and Install Upper Blower Housing (S.N. -130000) or Remove and Install Upper
Blower Housing (S.N. 130001- ) .)


LEGEND:
A Cap Screw
B Valve Cover
Valve Cover
[1] -
IMPORTANT:
Avoid Damage! Mark all parts when disassembling cylinder heads to prevent interchanging.
Remove carburetor and associated components. (See Remove Two Barrel Carburetor .)
[2] - Disconnect spark plug leads. Remove spark plugs.
[3] - Loosen governor lever nut.
[4] - Remove governor control bracket and governor lever.
[5] - Remove cylinder air guides. (See Remove Cylinder Air Guides .)
[6] - Remove cap screws (A), and valve cover (B). Repeat for second cylinder, if being removed.
[7] -
LEGEND:
C Rocker Arms
D Push Rod
E Valve Spring
Valve Spring
Release valve spring pressure from rocker arms (C) by rocking the arm against spring pressure and allowing push rod (D) to
drop out of the rocker arm socket. Push rod will move out of position, releasing valve spring (E) pressure.
[8] -

IMPORTANT:
Avoid Damage! Exhaust valve push rods are aluminum. Intake valve push rods are steel. Mark push rods
for correct reinstallation.
LEGEND:
F Screws
G Rocker Arm Support
H Rocker Arm
Rocker Arms
Remove rocker support screws (F), rocker arm supports (G), and rocker arms (H). Lift out push rods.
[9] -
LEGEND:
I Cylinder Head Bolt
Cylinder Head Bolts

Remove 5 cylinder head bolts (I) in sequence shown.
[10] -

LEGEND:
J Cylinder Head
K Gasket
Remove cylinder head (J) and gasket (K). Discard cylinder head gasket.


LEGEND:
I Cylinder Head Bolt
Cylinder Head Bolts
[1] - Clean gasket surfaces.
[2] -
IMPORTANT:
Avoid Damage! Do not use sealer of any kind on gaskets.
Place new gasket and the cylinder head on cylinder. Align head with the alignment sleeves in the cylinder.
[3] - Apply a small amount of clean engine oil to threads. Install 5 cylinder head cap screws.
[4] -
IMPORTANT:
Avoid Damage! Do not tighten one bolt down completely before all the others have been tightened to the
second stage. Uneven tightening may warp the cylinder head.
Tighten cylinder head bolts (I) down evenly by hand. Then, using torque wrench, tighten cylinder head bolts in sequence
shown, in
Cylinder Head Bolt Increments Torque 9 N·m
(80 lb.-in.)
increments to
Cylinder Head Bolt Final Torque 25 N·m
(220 lb.-in.)
.
[5] -
IMPORTANT:
Avoid Damage! Intake valve push rods are aluminum. Exhaust valve push rods are steel. Do not
interchange push rods.
Insert push rods into recess in tappets.
[6] -

LEGEND:
F Screws
G Rocker Arm Support
H Rocker Arm
Rocker Arms
Assemble rocker arms (H), supports (G) and screws (F) and install on cylinder head. Tighten screws to specification.
Rocker Arm Screws Torque 11 N·m
(100 lb.-in.)
[7] -
LEGEND:
I Valve Spring
J Rocker Arm
K Rocker Arm Socket
L Rocker Arm Screws
Assemble Rocker Arms

Compress valve spring (I) with rocker arm (J). Insert push rod into rocker arm socket (K). Be sure push rods remain seated in
recess in tappets.
[8] - Adjust valves. (See Adjust Valve Clearance, V-Twin .)
[9] -

LEGEND:
A Cap Screw
B Valve Cover
Valve Cover
Install new gasket and valve cover (B). Tighten valve cover screws (A) to specification.
(100 lb.-in.)
[10] - Install intake and exhaust manifold, carburetor, governor control bracket, cylinder air guides, blower housing and air
cleaner assembly.
[11] - Install spark plugs. Tighten to specification.

(180 lb.-in.)
[12] - Install spark plug leads.
[13] - Adjust governor. (See Adjust Governor - Static, V-Twin , and Adjust Governor - Dynamic, V-Twin (S.N. -130000) or Adjust
Governor - Dynamic, V-Twin (S.N. 130001- ) .)
Cylinder Head Mounting Surface
[1] -

IMPORTANT:
Avoid Damage! Remove combustion chamber deposits using a soft, hand wire brush or scraper.
Remove combustion chamber deposits from combustion chamber and around valves using a soft, hand wire brush or scraper.
With piston at top dead center (TDC), remove combustion chamber deposits from top of piston.
[2] - Inspect cylinder head for broken fins or cracks. Repeat procedure for other cylinder head and cylinder.
[3] - Be sure that all gasket material is removed from cylinder head.
[4] - Using a surface plate or straight edge (A), check cylinder head mounting surface for distortion in several areas. If
mounting surfaces are distorted more than specification, replace cylinder head.
Cylinder Head (maximum) Out-of-Flat 0.1 mm
(0.004 in.)
[5] -
→NOTE:
Valve guides are not serviceable.
Inspect valve guides by inserting plug gauge into valve guide. If plug gauge inserts 6.4 mm (0.25 in.) or more, the cylinder
head must be replaced. Measure valve guides if plug gauge is not available. Replace cylinder if inside dimension specification
is larger than reject dimension for both intake and exhaust valve guides.
Valve Guide (maximum) ID 6.09 mm
(0.240 in.)
Remove Valve
LEGEND:
A Rocker Screw
B Valve Spring Compressor
C Split Retainer
Cylinder Head Rocker Screws and Valve Spring
[1] -
IMPORTANT:
Avoid Damage! Mark push rods for reassembly in their original position. Intake push rods are aluminum.
Exhaust push rods are steel. Do not interchange the push rods.
To remove the valves, place cylinder head on workbench with support to hold valves in place.
[2] - Reinstall rocker screws (A) into cylinder head. Do not tighten. Slip end of valve spring compressor (B) under the screw of

the valve spring. Press down on tool handle to compress valve spring and remove split retainers (C).
[3] - Gradually release pressure. Remove retaining washer and spring.
[4] - Remove rocker screws.
[5] - Repeat procedure on other cylinder head.
[6] -
Intake Valve Stem Seal

LEGEND:
D Valve Stem Seal
Remove intake valve stem seal (D) by grasping with pliers and pulling up while turning.

Inspect and Repair Valve

LEGEND:
B Valve Margin Dimension
C Valve Margin
D Resurface Dimension
E Valve Seat Width
Valve Face
[1] - Faces on valves may be resurfaced with a valve grinder to 45° (D). Recondition valve seats using Valve Seat Cutter.
Valves and seats should then be lapped with Valve Lapping Tool and Valve Lapping Compound. See “Lap Valves”. Remove
grinding marks and assure a good seal between valve and seat. Thoroughly clean lapping compound from valve seat and valve
face.
[2] - Valve margin (C) should be 0.8 mm (0.031 in.) (B). If 0.4 mm (0.016 in.) or less, resurface or replace valve.
[3] - Valve seat width (E) should be 0.8 - 1.2 mm (0.031 - 0.047 in.) .
[4] - 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.
[5] - Measure valve stem diameter 40 mm (1.6 in.) from end of valve. Replace if less than 5.92 mm (0.233 in.) in diameter.
[6] - Inspect valve springs and replace if broken or worn. Replace if free length is less than 33.50 mm (1.319 in.) .
[7] -
→NOTE:
Valve guides are not serviceable.
Inspect valve guides by inserting plug gauge into valve guide. If plug gauge inserts 6.35 mm (0.250 in.) or more, the cylinder
head must be replaced. If plug gauge is not available, the rejection dimension for both intake and exhaust valve guides is 6.09
mm (0.240 in.) .
Valve Specifications:
Valve Guide Wear Limits ID 6.10 mm
(0.240 in.)
Valve Stem Wear Limits Intake OD 5.92 mm
(0.233 in.)
Valve Stem Wear Limits Exhaust OD 5.92 mm
(0.233 in.)
Valve Seat Width Width 1.2—1.6 mm
(0.047—0.063 in.)
Valve Margin (minimum) Width 0.4 mm
(0.016 in.)
Valve Guide Depth Distance 7.10 mm
(0.280 in.)
Valve Face Angle Angle 45°
Valve Seat Narrowing Angle Angle 30°
Valve Spring Free Length (minimum) Length 33.50 mm
(1.319 in.)

Lap Valves
Valve Seat
[1] -
IMPORTANT:
Avoid Damage! Valves and seats should be lapped if they do not make good contact
Apply light coat of lapping compound to valve face, then turn valve in seat using vacuum cup tool.
[2] - Check valve every eight strokes until a uniform ring appears around surface of valve face.
[3] - Wash parts in solvent to remove lapping compound.
[4] - Check position of lap mark on face - lap mark must be on or near center of valve face.
Install Valve
LEGEND:
A Rocker Screw
B Valve Spring Compressor
C Split Retainer
Cylinder Head Rocker Screws and Valve Spring
[1] -
IMPORTANT:
Avoid Damage! Replace valve stem seals whenever valves are removed.
Install a new intake valve stem seal using a valve guide driver.
[2] - Lightly coat valve stems with valve guide lubricant. Install valves.

[3] - Install springs and valve spring retainers over valve stems. Temporarily install rocker studs (A) in cylinder head.
[4] - Use valve spring compressor (B) to compress spring and install split retainers (C). Repeat procedure for other valves.
[5] - Remove rocker studs.
[6] - Install cylinder head(s) and follow cylinder head assembly procedures. (See Install Cylinder Head .)

Remove Piston, Rings and Rod
Remove Piston from Rod
[1] - Remove air filter and bracket, upper blower housing, flywheel, alternator, carburetor, intake manifold and governor
linkage.
[2] - Remove starting motor, cylinder heads and crankcase cover.
[3] -
→NOTE:
Remove any carbon or ridge at the top of the cylinder bore. This will prevent breaking the rings when
removing the piston and connecting rod from the engine.
Remove the connecting rod cap. Then push the piston and connecting rod out through the top of the cylinder.
[4] - To remove connecting rod from piston, remove piston pin locks with screwdriver. Piston pin is a push fit in piston and rod.
Deposits may build up on piston pin and require the piston pin to be pressed out.
[5] -
IMPORTANT:
Avoid Damage! Remove top and center compression rings using ring expander (A). New piston rings must
be installed whenever the engine is disassembled for major servicing or overhaul, providing that cylinder
bores are within specifications.
→NOTE:
Measure cylinder bores before checking pistons and rings. 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.

Piston Ring Expander

LEGEND:
A Piston Ring Expander
Check cylinder bore to determine if it must be resized. (See Inspect Cylinder Bore .)
[6] -
IMPORTANT:
Avoid Damage! When servicing pistons, rings, piston pins or rods, each rod, piston, piston pin and ring
set must be kept as a set for the cylinder that it was removed from. Mark each set before removing from
the engine.
→NOTE:
Oil control ring (B) is shown being spiraled into compression ring groove.
Spiral Oil Control Ring

LEGEND:
B Oil Control Ring
Spiral top oil control ring (B) from oil ring groove into center compression ring groove. Repeat into top compression ring
groove, and then off piston. Repeat for bottom oil control ring.
→NOTE:
If the cylinder is to be resized, there is no reason to check the piston, since a new oversized piston
assembly must be used. If however, the cylinder is not to be resized and the piston shows no signs of
wear or scoring, only the piston rings must be replaced.
Check Piston Ring End Gap

LEGEND:
A Feeler Gauge
B Compression and Oil Ring
Check End Gap with Feeler Gauge
[1] - Insert old rings one at a time approximately 25.4 mm (1.0 in.) down into a cylinder bore.
[2] -
CAUTION:
Avoid Injury! Note that the top and bottom edges of the ring may be extremely sharp. Never reuse worn
piston rings.
→NOTE:
Before installing new piston rings, the cylinder bore should be reconditioned using a rigid hone with
finishing stones. This will restore the proper cross hatch angle in the cylinder bores. The correct cylinder
cross hatch ensures proper lubrication and piston ring rotation.
Check end gap with feeler gauge (A). If ring gap is greater than specifications for compression and oil ring (B), the ring is worn
and should be replaced.
Compression and Oil Ring End Gap Gap 0.76 mm
(0.030 in.)
[3] - A worn ring will usually show scratches caused by abrasives and/or have a shiny appearance. Never reuse worn piston
rings.

Inspect Piston and Rod

LEGEND:
A Feeler Gauge
Piston Ring Grooves
[1] - Clean carbon from top two ring grooves.
[2] - Place a new ring in each piston groove.
[3] - If a 0.10 mm (0.004 in.) or larger feeler gauge (A) can be inserted in the compression ring grooves, or a 0.20 mm (0.008
in.) or larger feeler gauge can be inserted in the oil ring grooves, the compression and ring grooves are worn and the piston
should be replaced.
[4] -
LEGEND:
B Crankpin Bearing
C Piston Pin Bearing
Crankpin and Piston Pin Bearing

If the crankpin bearing (B) in the connecting rod is scored, the rod must be replaced. Reject sizes of crankpin bearing and
piston pin bearing (C) are as specified.
Crankpin Bearing Wear Limit ID 38.15 mm
(1.502 in.)
Piston Pin Bearing Wear Limit ID 17.15 mm
(0.675 in.)
[5] - Replace connecting rod if either bore is worn.
[6] -

LEGEND:
D Piston Pin Bore
Piston Pin and Piston Pin Bore

Reject sizes for piston pin and piston pin bore (D) are as specified.
Piston Pin Wear Limit OD 17.07 mm
(0.672 in.)
Piston Pin Bore Wear Limit ID 17.15 mm
(0.675 in.)
[7] - If piston pin is worn 0.01 mm (0.0004 in.) out of round or below reject size, it must be replaced.

Assemble Piston and Rod

LEGEND:
A Rod Location
B Piston Marking
Connecting Rod-to-Piston
[1] - The piston pin is a slip fit in both piston and connecting rod. Use a thin nose pliers or screwdriver and install a piston pin
lock in groove on one side of piston. Refer to figure to determine correct location of rod (“Out 1” cylinder number one, or “Out
2” cylinder number two) (A) in relation to notch or circle (B) on piston. Insert piston pin from opposite side of piston until pin
stops against piston pin lock. Then install other piston pin lock. Be sure that both locks are seated in grooves.
[2] -
Rings
LEGEND:
A Oil Expander
B Lower Scraper Ring
C Upper Scraper Ring
D Center Compression Ring
E Upper Compression Ring
Install oil expander (A) first. Spiral the lower scraper (B) into the top ring groove, then into second ring groove and finally into
position below the expander. Repeat procedure when placing the upper scraper ring above the expander.
[3] - Position gap of oil ring expander, and scraper rings approximately 120° apart from each other.
[4] -
→NOTE:
The paint stripes on the piston rings must be installed with the stripes to the right of the ring gap.

Rings
Using the ring expander tool, install the center compression ring (D) in the middle ring groove. Make sure that the paint stripes
are to the right of the ring gap.
[5] - Using ring expander, install the top compression ring (E) with the paint stripe to the right of the ring gap. Rotate the ring
so the compression ring end gaps are 180° apart.
[6] - Apply oil to piston rings and piston skirt.

Install Piston and Rod

LEGEND:
A Projection
Ring Compressor Projections
→NOTE:
Approximate location of projections (A) on ring compressor shown. These will be inserted to the cylinder
bore when assembling piston to cylinder.
[1] -
LEGEND:
B Ring Compressor Tool
Ring Compressor Tool

Apply oil to piston rings and piston skirt. Compress rings with ring compressor tool (B). Place piston and ring compressor upside
down on bench. Push down until head of piston and edge of ring compressor are even. Tighten ring compressor until rings are
fully compressed. Then loosen ring compressor very slightly so that compressor can be rotated on piston skirt while holding
connecting rod.
[2] -
→NOTE:
The pistons have offset piston pin bores. When the circle on piston (C) is facing toward the flywheel side
(D) of engine, the words “OUT-1” on the side of the connecting rod for cylinder No. 1 and “OUT-2” on the
side of the connecting rod for cylinder No. 2 (E) should face toward the PTO side (F) of the crankcase.

LEGEND:
C Piston Mark
D Flywheel Side
E Connecting Rod Mark
F PTO Side
Piston and Rod Position

Thoroughly clean and oil cylinder bore. Rotate crankshaft until crankpin journal is at bottom of stroke. This permits complete
entry of compressed rings, piston and rod assembly, when pushed into cylinder. If other piston and rod assembly was removed,
repeat procedure for that cylinder.
[3] -
Piston and Rod Assembly

Clean and oil crankshaft crankpin.
[4] - Pull connecting rod against crankpin.
[5] -

LEGEND:
G Match Mark
H Bolts
Rod Cap Match mark

Install rod cap with match marks (G) aligned.
[6] -
→NOTE:
Failure to use a torque wrench can result in loose connecting rods causing breakage, or tight connecting
rods causing scoring.
Install connecting rod bolts (H) and tighten to specifications.

Connecting Rod Bolts Torque 13 N·m
(115 lb.-in.)
[7] - Rotate crankshaft two revolutions to check for binding. Rod should also be free to slide sideways on crankpin.

Size of Cylinder Bore

LEGEND:
A Telescoping Gauge
B Top
C Middle
D Bottom
[1] - Always inspect cylinder after engine has been disassembled. Visual inspection shows if there are any cracks, stripped bolt
holes, broken fins or if the cylinder walls are damaged. Determine the size of the cylinder bore using a telescoping gauge (A)
and a dial caliper, or use an inside micrometer. Measure at right angles at six locations from the top (B), middle (C) and bottom
(D).
[2] - Measure cylinder bore. Compare measurements to specifications.

Cylinder Bore Specifications

(2.969—2.970 in)
(2.973 in)
(3.119—3.120 in)
(3.124 in)
Cylinder Bore Out-of-Round 0.076 mm
(0.003 in)
[3] - Install new rings when cylinder bores are within specification and show no signs of scoring or other damage. Cylinder
bores are reconditioned using a rigid hone with finishing stones. Reconditioning is necessary to restore the crosshatch angle in
the cylinder bores, and ensure proper lubrication and piston ring rotation.
Hone Cylinder Bore

LEGEND:
A 45° Cross Hatch
Cylinder Bore Honing
[1] -
→NOTE:
To produce the proper cross hatch finish use a drill speed of approximately 200 rpm and 40 to 60 strokes
per minute. Lubricate the hone liberally to prevent build up on finishing stones.
Apply the cross hatch cylinder finish after cylinder bore has been resized to within 0.04 mm (0.0015 in.) of the desired size,
or when reconditioning a cylinder bore. The finishing stones produce the correct cross hatch for necessary for proper
lubrication and piston ring rotation. The correct cross hatch (A) is approximately 45° .
[2] -
IMPORTANT:
Be careful not to hone oversize or it will be necessary to resize the cylinder.
The cylinder bores need to be reconditioned to restore the cross hatch when new piston rings are installed in a cylinder bore
that is within specification.
[3] - Wash the cylinder head and crankcase thoroughly. (See Clean Cylinder Bore .)
[4] - Oil the cylinder bore to prevent rust.
Clean Cylinder Bore

IMPORTANT:
Make sure that the entire cylinder and crankcase are thoroughly cleaned after honing.
[1] - Wash the cylinder head and crankcase carefully in a solvent such as kerosene or commercial solvent.
[2] - Thoroughly wash cylinder and crankcase using a stiff brush with soap and hot water.
[3] - Rinse thoroughly with hot running water.
[4] - Repeat washing and rinsing until all traces of honing grit are gone. Honing grit is highly abrasive and will cause rapid wear
to all internal components of the engine unless it is completely removed.
[5] - When the cylinder and crankcase are thoroughly cleaned, use a clean white rag or napkin to wipe the cylinder bore.
a. If honing grit is present it will appear as a gray residue on the rag. If any residue is evident, rewash and rinse entire
cylinder and crankcase and check again.
b. When there is no trace of honing grit on the rag, the cylinder is properly cleaned.
[6] - Oil the cylinder bore to prevent rust.


LEGEND:
A Ring Travel
B Above Ring Travel
C Below Ring Travel
D Bottom of Cylinder Bore
E Cylinder Bore Full Length
Cylinder Bore Resize
Verify the available piston oversize for the engine. Resize the cylinder to exactly that dimension over the standard bore size.
If this is done accurately, the service oversize rings and pistons will fit correctly, maintaining the proper clearances.
[1] - If a hone is used to resize the cylinder bore, place hone in middle of cylinder bore. Tighten adjusting knob until hone fits
snugly against cylinder wall. DO NOT force hone adjustment.
[2] -
Connect drive shaft to hone. Be sure that cylinder and hone are centered and aligned with drive shaft and drill spindle.
Lubricate hone as recommended by manufacturer.
[3] - The recommended drill speed is 300 to 700 rpm maximum, and 40 to 60 stokes per minute.
[4] - Because cylinder bores normally wear only in the area of ring travel (A), the cylinder bore will be round above (B) and
below (C) ring travel.
[5] - Start drill, and as hone spins, move it up and down at the bottom of the cylinder bore (D).
[6] - Gradually increase the length of the strokes until the hone travels full length of cylinder bore (E), with a starting point
below the wearing of ring travel (C). Do not travel more than 19—25 mm (0.75—1.0 in.) above or below cylinder bore.

[7] - Lubricate hone frequently to prevent build up on stones.
[8] - As tension decreases, stop hone in bottom of cylinder and tighten adjustment knob following hone manufacturer’
instructions.
[9] - Check cylinder bore size frequently.
[10] - Check cylinder bore at top and bottom for burrs. Remove burrs. Cylinder head and crankcase cover surfaces must be
free of burrs and gasket material.
[11] - After cylinder bore has been brought to proper resize dimension, a cross hatch must be applied to bore. (See Hone
Cylinder Bore .)
Remove Flywheel
LEGEND:
A Flywheel Puller
Remove Flywheel
[1] - Remove blower housing and rotating screen.
[2] - Remove 2 screws securing fan. Remove fan.
[3] - Loosen ignition coil screws and move ignition coils away from flywheel, or remove ignition coils completely.
[4] -
→NOTE:
If the engine crankshaft rotates while loosening the flywheel nut, secure the flywheel with a strap
wrench.
Use an impact wrench and 32 mm (1-1/4 in.) socket to loosen flywheel nut. Do not remove at this time.
[5] - Unscrew nut until it extends just beyond engine input shaft threads.
[6] -
IMPORTANT:
Avoid Damage! Do not use a flywheel puller that pulls against flywheel teeth.
Protect threads during flywheel removal.
Install B&S 19203 flywheel puller (A), turning puller screws into flywheel puller holes evenly. Tighten lower puller nuts equally
against flywheel to secure screws.
19203
Remove Flywheel
[7] - Tighten upper puller nuts to press puller against flywheel nut until flywheel separates from engine input shaft.
[8] - Remove puller, flywheel nut, washer and flywheel.

[9] - Inspect flywheel for cracks, broken fins, burrs on the taper or keyway and distortion of the keyway. Check taper of
crankshaft for burrs, rust or other damage. Replace crankshaft if damaged.
[10] - Inspect flywheel key for wear or damage. Replace if necessary.
Install Flywheel
[1] -
CAUTION:
Avoid Injury! Improperly installed flywheel can cause machine damage and serious personal injury
Before installing flywheel, clean taper and crankshaft taper removing all oil, dirt or grease.
[2] - Align keyway. Install key and flywheel.
[3] -
IMPORTANT:
If used in this application, install spring washer with cup side down as shown.
Flywheel Bolt and Spring Washer

Install flywheel nut.
[4] - Place strap wrench on flywheel. While holding flywheel, tighten flywheel nut to specification.
Flywheel Nut Torque 203 N·m
(150 lb.-ft.)
[5] - Install fan and secure with 2 screws. Tighten screws to specification.
Fan Retainer Cap Screw Torque 16 N·m
(140 lb.-in.)


LEGEND:
A Cap Screws
B Ignition Coils
Flywheel Fan
Remove:
[2] - Remove engine blower housing.
[3] - Remove two cap screws (A) securing fan. Remove fan.
[4] - Loosen ignition coil screws and move ignition coils (B) away from flywheel, or remove ignition coils completely.
[5] - Remove the flywheel. (See Remove Flywheel .)
[6] -
LEGEND:
C Stator Wires
D Screw
E Cap Screws
Stator and Engine Shield

Disconnect the stator wires (C) from the voltage regulator/rectifier.
[7] - Loosen the shield mounting screw (D) and route the stator wires to the top of the shield.
[8] - Remove the 4 mounting cap screws (E) and remove stator from crankcase.
Install:
[1] - Place stator onto crankcase.
[2] - Align the four mounting holes with the threaded holes in the crankcase and the stator wires routed under the retainer tab.
[3] - Install and tighten the 4 cap screws to specification.

(30 lb.-in.)

[4] - Connect stator wires to the voltage regulator/rectifier.
[5] - Install the flywheel. (See Install Flywheel .)
[6] - Install flywheel fan. Tighten fan cap screws to specification.

Flywheel Fan Cap Screws Torque 16 N·m
(140 lb.-in.)
[7] - Install engine blower housing.

Remove and Inspect Crankshaft and Camshaft

LEGEND:
A Governor Lever
B Control Bracket
Governor Lever and Link
[1] - Remove governor lever (A) and disconnect governor link and springs. Remove governor control bracket (B). Remove oil fill
tube and dipstick assembly.
[2] - Remove exhaust manifold, intake manifold, and cylinder heads.
[3] - Remove oil pump. (See Remove Oil Pump .)
[4] -
IMPORTANT:
Avoid Damage! DO NOT remove dowel pins.
→NOTE:
Remove rust, paint, or burrs from the PTO end of the crankshaft before the crankcase cover is removed.
LEGEND:
C Crankcase Cover
D Dowel Pins
Crankcase Cover
Remove crankcase cover (C). If crankcase cover sticks, tap lightly with soft hammer on alternate sides near dowel pins (D).
[5] - Tip engine over onto flywheel side of crankcase.
[6] - Support engine to prevent end of crankshaft from resting on workbench.
[7] -

IMPORTANT:
Avoid Damage! If engine is rotated from this position, tappets fall out. Tappets must not be mixed.
LEGEND:
E Timing MARKS
Crankshaft Timing MARKS

Rotate crankshaft until timing marks (E) are aligned. With cam gear in this position, the valve tappets remain clear of cam
lobes.
[8] - Lift out cam gear, governor gear, and thrust washer.
[9] - Mark the connecting rods and caps to prevent interchanging when reassembling.
[10] - Remove piston and connecting rod assemblies.
[11] - Remove crankshaft from crankcase.
[12] -
IMPORTANT:
Avoid Damage! The various wear points on the crankshaft must be measured.
Replace crankshaft if worn or if journals are scored. Check keyways to be sure that they are not worn or spread. Remove burrs
from keyway edges to prevent damaging the bearing or oil seal. Check oil galleries for blockage or obstructions.
[13] - Check gear teeth for chipped or cracked teeth. Replace if needed.
[14] -
→NOTE:
Always replace tappets if the camshaft is replaced. Pre-lubricate tappets and cam lobes with
multipurpose grease.
Inspect cam gear teeth, lobes, and journals for wear and nicks.

PTO Journal ID 41.22 mm
(1.623 in.)
Magneto Journal ID 34.95 mm
(1.376 in.)
Crankshaft Crankpin ID 38.02 mm
(1.497 in.)

Crankshaft End Play 0.051—0.76 mm
(0.002—0.03 in.)
Cam Gear PTO journal ID 12.64 mm
(0.498 in.)
Cam Gear Magneto Journal ID 12.64 mm
(0.498 in.)
Cam Lobes (Intake) Height 31.12 mm
(1.225 in.)
Cam Lobes (Exhaust) Height 31.06 mm
(1.223 in.)
Crankcase Cover Bolts Torque 22.6 N·m
(200 lb.-in.)
Crankshaft and Camshaft Component Location

LEGEND:
A Gear Teeth
B PTO Journal
C Exhaust Lobes
D Intake Lobes
E Oil Gallery
F Mag. Journal
Camshaft
LEGEND:
A Mag. Journal
B Oil Galleries
C Crankpin
D Timing Gear Teeth
E PTO Journal
F Keyway
G Oil Galleries
H Threads and Keyway
Crankshaft
Install Crankshaft and Camshaft

LEGEND:
E Timing Marks
Crankshaft Timing Marks
[1] - Remove any old gasket material from mating surfaces. Place new crankcase cover gasket on crankcase.
[2] - Install crankshaft and camshaft, aligning timing marks (E) accordingly.
[3] - Lubricate thrust washer, governor gear and governor cup and install.
[4] - Install oil pump. (See Install Oil Pump .)
[5] - Take care to protect the oil seal while assembling crankcase cover. No force should be used.
[6] -
Cover Bolts
Tighten cover bolts to specification in the sequence shown.
[7] - Install cylinder heads. (See Install Cylinder Head .)
[8] - Install flywheel. (See Install Flywheel .)
[9] - Install intake manifold and carburetor assembly. (See Install Two Barrel Carburetor .)
[10] - Install governor lever and governor springs.
[11] - Install oil fill tube and dipstick assembly.

[12] - Install engine shrouding. (See Remove and Install Upper Blower Housing (S.N. -130000) or Remove and Install Upper
[13] - Install air cleaner assembly.
[14] - Perform static and dynamic governor adjustments.

Inspect Magneto Bearing
Magneto Bearing
[1] - Replace the main magneto bearing if scored or not within wear limit.
(1.383 in.)
[2] - To remove the magneto bearing, first remove oil seal.
[3] -
LEGEND:
A Mark Tool
B Bushing Driver Tool
Remove Magneto Bearing

To remove magneto bearing, place cylinder on a suitable cylinder support. Insert suitable bushing driver tool (B) and mark (A)
tool to indicate proper depth when installing new bushing. Press out old bushing, from oil seal side.
[4] -
→NOTE:
Be sure oil holes in bushing are aligned with oil gallery holes in bearing.

LEGEND:
D Oil Holes
Cylinder Support
To install magneto bearing, place cylinder on a suitable cylinder support. Position new bushing against counterbore bearing in
crankcase and carefully align oil holes (D) in bushing with oil gallery holes in bearing. Press in new bushing to correct depth
with a suitable bushing driver tool.
[5] -
LEGEND:
C Round Punch
Stake Bearing
Stake bearing on both sides with a round punch (C) to prevent bearing from turning.
[6] -
→NOTE:
Always install new oil seal whenever engine is disassembled for major servicing or when repairing
bearings. Always use the correct seal protector to prevent damaging oil seal. Always lubricate seal lips
with fresh engine oil before assembling engine components.
Install new oil seal using a suitable cylinder support. Press in new oil seal until it is flush with cylinder.
Inspect PTO and Cam Bearing

PTO Bearing and Cam Bearing
[1] - Remove oil pump. (See Remove Oil Pump .)
[2] - Remove oil seal.
[3] - Inspect PTO bearing and cam bearing. The cylinder or crankcase cover must be replaced if PTO bearing is worn or scored.
If cam bearing is worn or scored, the crankcase cover must be replaced.

PTO End Bearing Diameter 41.38 mm
(1.629 in.)
Cam Bearing Diameter 12.75 mm
(0.502 in.)
[4] -
→NOTE:
Install new oil seal whenever engine is disassembled for major servicing or when repairing bearings. Use
the correct seal protector to prevent damaging oil seal. Lubricate seal lips with new engine oil before
assembling engine components.
Install new PTO oil seal using a cylinder support. Press in seal until it is flush with mounting surface.

LEGEND:
A Breather Valve Assembly
B Breather Tube
Breather Valve Assembly
→NOTE:
A leak at the seal between the tube and crankcase cover, or at the seal at the upper end of the dipstick,
can result in a loss of crankcase vacuum and a discharge of oil or smoke through the muffler.
The engine utilizes a breather valve to control and maintain a vacuum in the crankcase. 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. This vacuum prevents
oil leakage past piston rings, valve guides, oil seals, governor shaft and gaskets.
[1] - Before breather valve assembly (A) can be removed for inspection, the air cleaner assembly, support bracket, blower
housing and intake manifold must be removed as well.
[2] -
IMPORTANT:
Avoid Damage! Do not use force on reed valve.
The reed valve is spring loaded and must make a complete seal around the vent hole in breather body. Check to see that reed
valve (B) is not deformed.
[3] - When installing breather, make sure breather gasket is located properly.
[4] - Place gasket and breather on engine block. Install screw and tighten to specification.
Breather Cover Screw Torque 6 N·m
(55 lb.-in.)
[5] -
LEGEND:
C Breather Tube

Breather Valve
The breather is vented through the air cleaner to prevent dirt from entering the crankcase. Check breather tube (C) for cracks,
holes or hardening. Replace if damaged.
[6] - Reinstall all removed components.

Remove Oil Pump
Full Pressure Lubrication System
This engine is equipped with a full pressure lubrication system with an oil filter.
The camshaft driven oil pump supplies lubrication to all bearing journals.
The oil pump draws oil through a screened pick up in the engine base and pumps the oil through the oil filter. 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.
A pressure relief valve located in the oil pump housing limits the maximum oil pressure in the system.
An oil gallery in the crankshaft supplies oil from the magneto bearing to the crankpin, lubricating the connecting rods.
[1] - Drain oil from sump and filter.
[2] - Remove rust, foreign material and burrs from the bottom of the crankcase and the crankshaft.
[3] -

LEGEND:
A O-ring
B Outer Rotor
C Drive Shaft
D Inner Rotor
E Cover
F Screws
Oil Pump Cover

Remove 3 screws (F) securing the oil pump cover. Remove the cover (E) and O-ring (A).
[4] - Remove the inner (D) and outer (B) rotors and drive shaft (C).
[5] - Inspect surfaces of the rotors, pump housing, cover and shaft for wear and scoring. Remember to inspect O-ring groove
(F) before assembly; clean, if necessary.
[6] - Inspect pump housing for debris. Clean as needed.
[7] - Replace any worn or damaged components.
[8] - If debris is found, the sump should be removed for cleaning and replacement of the oil screen.
[9] -
Sump Cover
Using the pattern shown, loosen 10 cap screws securing the sump cover to the cylinder block 1/2 turn at a time until screws
are loosened. Then remove the cap screws. This will prevent damage to the sump cover.
[10] -

LEGEND:
G Punch
Oil Pump Slots

Using a punch (G) through the slots in the oil pump housing, press the oil screen out of the sump.
[11] -
Oil Sump Screen Filter

Press a new screen filter into the sump with the hole in the back of the screen oriented away from the governor shaft.
[12] - Clean all gasket surfaces of old gasket material.

Install Oil Pump

[1] - Install sump and gasket.
[2] -
Cover
Tighten all screws using the pattern indicated, to specification.
Oil Pump Cover Screws Torque 6 N·m
(50 lb.-in.)
[3] -
LEGEND:
A O-ring
B Inner Rotor
C Drive Shaft
D Outer Rotor
E Cover
F Screws
Oil Pump Cover

Install the oil pump drive shaft (C), ensuring that it engages with camshaft.
[4] - Lightly coat the rotors with new motor oil. Install the inner (D) then the outer (B) rotor.
[5] - Insert the O-ring (A) into the O-ring groove in the sump and secure cover (E) with the 3 screws (F). Tighten the screws to
specification.

(200 lb.-in.)
[6] - Complete installation of remaining governor linkage and carburetor.
[7] - Adjust governor. (See Adjust Governor - Static, V-Twin .)
→NOTE:
Engine oil pressure will vary with oil viscosity, ambient air temperature differences, operating
temperatures and engine load.
[8] - Check that engine oil pressure meets specification.

Oil pressure Pressure 103—345 kPa
(15—50 psi)


LEGEND:
A Spring
B Gear
C Clutch
D Brush Holder
E Through Bolt
F End Cap
G Nut, Starter Cable
H Nut, Brush Retainer
I Housing
J Drive End Cap
K Cap Screw
L Armature
M C-ring
N Cap
O Washer
Starting Motor Components

LEGEND:
A Positive Cable
Positive Cable
Remove:
[2] - Disconnect battery positive (+) cable (A) from starting motor.
[3] - Remove upper blower housing. (See Remove and Install Upper Blower Housing (S.N. -130000) , or Remove and Install
Upper Blower Housing (S.N. 130001- ) .)
[4] -
→NOTE:
Flywheel and plate (below and surrounding stator) may be removed for ease of starting motor removal.

LEGEND:
B Bolts
Starting Motor Bolts

Remove starting motor bolts (B) and starter.
Install:
[1] - Install starting motor bolts and tighten to specification.

Starting Motor Bolts Torque 16 N·m
(140 lb.-in.)
[2] - Install plate (below and surrounding stator) and flywheel (if removed).
[3] - Install upper blower housing. (See Remove and Install Upper Blower Housing (S.N. -130000) , or Remove and Install Upper
[4] - Connect positive cable to the starter.
[5] - Connect the negative (—) battery cable to the battery.


[1] -
IMPORTANT:
DO NOT clamp motor housing in a vise or strike with a steel hammer. Starting motors contain two
powerful magnets that can be broken or cracked if the motor housing is deformed or dented.
LEGEND:
A Drive End Head
B End Cap
C Bolts
Starting Motor - Inertia

Remove pinion gear assembly.
[2] - Mark drive end head (A) and end cap (B) and housing using a marker. This will assure proper orientation of the drive end
head and end cap when assembling starter.
[3] - Remove bolts (C) and inspect bushing for wear. If worn, replace drive head end assembly.
[4] -
Armature and Housing

Hold the armature and bearing end cap against a work surface while sliding housing off the armature. (This allows the
armature to remain in the bearing end cap and brush holder for inspection of brush contact to armature.)
[5] -

LEGEND:
B End Cap
D Brush Holder
E Armature

While holding brush holder (D) and armature (E), remove bearing end cap (B) from armature.
[6] -
IMPORTANT:
DO NOT use emery cloth to clean the commutator. The particles from the cloth will become embedded in
the commutator and cause rapid brush wear.
LEGEND:
D Brush Holder
E Armature

Remove brush holder (D) from armature commutator (E).
[7] -

→NOTE:
The bearing housing and armature should not be soaked in a cleaning solution. Fine sandpaper, such as
crocus cloth, can be used to clean the armature. The commutator may also be machined with the use of a
diamond cutting tool to no less than 31.24 mm (1.23 in.) outside diameter.
Commutator
Slots between the commutator bars should be cleaned as shown using a broken piece of hacksaw blade.
[8] - If it is suspected that the armature field coil, magnets or motor housing is defective, a new part should be tried in the
motor. If proper testing equipment is available, check the suspected armature or field coil to determine if it is defective (opens
or grounds).
[9] -
LEGEND:
F Brushes
G New Length
H Worn Length
Starting Motor Brushes

The brushes (F) should be checked for proper seating, weak brush springs, dirt, oil or corrosion.
[10] - Comparing to normal length when new (H), if brushes are worn to 3.2 mm (0.125 in.) (G), replace brushes. When all
parts have been thoroughly cleaned, lightly lubricate the bearings.

(0.125 in.)

Brush Retainers
LEGEND:
A Retainers
[1] -
→NOTE:
Brush retainers (A) can be made from standard size paperclips. Straighten and cut to length 2-1/2 in.
Bend into a U-shape with sides of 1 in. and bottom 1/2 in. in length.
Place brushes in their slots and hold brushes with retainers.
[2] -

Place armature commutator in brush holder and remove brush retainers.
[3] -

Armature and End Plate

Install bearing end plate on armature commutator journal making sure plate indexes with brush holder.
[4] -
LEGEND:
B Notch
Starting Motor Housing

Slide motor housing over armature with the notch (B) toward brush holder.
[5] -

Starting Motor - Inertia Washers

Place wave washer on armature shaft with concave side up. Then place flat washer on armature.
[6] - Place drive end cap on starting motor housing making sure that marks on drive end head and end cap line up with
housing mark.
[7] -
Starting Motor - Inertia Bolts

Install through bolts in starting motor. Check for binding of armature shaft using starting motor clutch. Tighten through bolts to
specification.
Starting Motor Through Bolts Torque 6 N·m
(50 lb.-in.)
[8] - Install starting motor drive.
[9] - Install starting motor and tighten bolts to specification.

Starting Motor Mounting Bolts Torque 16 N·m
(140 lb.-in.)


LEGEND:
A Plate
Stator and Plate
[3] - Remove upper blower housing and flywheel.
→NOTE:
The plate (A) surrounding and below the stator does not have to be removed.
[4] -
CAUTION:
To prevent eye injury, always wear eye protection when removing C-ring.
LEGEND:
B JDG1087 Tool
C C-ring
D Retainer
E Drive Pins
F Handle
JDG1087 C-ring Removal Tool

Compress Spring
Position C-ring (C) using screw driver tip so C-ring removal tool (B) can be aligned properly.
[5] - Install JDG1087 C-ring removal tool over retainer (D) and compress spring.
C-Ring Removal Tool
JDG1087
[6] - Screw in handle (F) until drive pins (E) on tool forces off the C-ring from starting motor shaft.
[7] -
LEGEND:
C C-ring
D Retainer
G Wave Washer
H Spring
I Piion Gear
J Clutch
K Splines
Starting Motor Pinion Components

Remove retainer (D), wave washer (G), spring (H), pinion gear (I) and starting motor clutch (J).
[8] -
→NOTE:
Do not use mineral spirit based lubricants to lubricate helix.
Before installing pinion gear, apply a lithium based lubricant sparingly around splines (K) on motor clutch (J).
[9] - Place starting motor clutch on starting motor shaft. Rotate clutch until it drops into place.
[10] -

LEGEND:
H Spring
I Pinion Gear
Pinion Gear and Spring

Install pinion gear (I) with beveled side of teeth up, then install return spring (H) making sure spring is in recess of starting
motor gear.
[11] -
LEGEND:
G Wave Washer
Wave Washer and Clutch Spline

Place wave washer (G) with concave side up on starting motor clutch spline.
[12] -
LEGEND:
L JDG1086 Tool

ELECTRICAL REPAIR (g) by Belgreen v2.0
JDG1086 C-Ring Install Tool

Place retainer and new C-ring on starting motor shaft.
[13] - Align one of the slots on the JDG1086 C-ring install tool (L) with open end of C-ring.
JDG1086
[14] - Use a hammer to drive snap ring down until it engages groove in starting motor shaft. Then make sure retainer is all the
way up against the snap ring.
[15] - Install flywheel, upper blower housing and reconnect negative (—) battery cable.

Section 40 - ELECTRICAL REPAIR

Table of contents
Group 10 - Component Location ............................................................................................................ 1
Electrical Component Location (S.N. -130000) ..................................................................................... 2
Electrical Component Location (S.N. 130001-170000) ......................................................................... 3
Electrical Component Location (S.N. 170001- ) .................................................................................... 4
Group 20 - Wiring Harness ..................................................................................................................... 5
Wiring Harness Legend ......................................................................................................................... 5
W1 Main Wiring Harness (S.N. -120000) ............................................................................................... 7
W1 Main Wiring Harness Color Codes (S.N. -120000) ........................................................................... 9
W1 Main Wiring Harness (S.N. 120001-130000) ................................................................................. 10
W1 Main Wiring Harness Color Codes (S.N. 120001-130000) ............................................................. 12
W1 Main Wiring Harness (S.N. 130001-170000) ................................................................................. 13
W1 Main Wiring Harness Color Codes (S.N. 130001-170000) ............................................................. 16
W1 Main Wiring Harness (S.N. 170001- ) ............................................................................................ 17
W1 Main Wiring Harness Color Codes (S.N. 170001- ) ........................................................................ 20
W2 Engine Wiring Harness ................................................................................................................. 22
W3 Lighting Kit Wiring Harness (S.N. -130000) .................................................................................. 23
W3 Lighting Kit Wiring Harness (S.N. 130001- ) ................................................................................. 24

Section 40 - ELECTRICAL REPAIR Group 10: Component Location

Electrical Component Location (S.N. -130000)
Electrical Component Location (S.N. 130001-170000)
Electrical Component Location (S.N. 170001- )

Electrical Component Location (S.N. -130000)
Electrical Component Location (SN -130000)

LEGEND:
A SW1 Key Switch
B SW6 PTO Switch
C P1 Hourmeter
D SW4 Park Brake Switch
E SW3 Left Handle Neutral Lock Switch
F SW5 Seat Switch
G SW2 Right Handle Neutral Lock Switch
H K2 Interlock Relay
I Fuses
J K1 Start Relay
K C4M Connector to Engine Wiring Harness
L Connector to Y2 PTO Clutch
M M1 Starting Motor
N G1 Battery
O W2 Engine Ground


LEGEND:
A C1 Power Connector
B SW3 Left Handle Neutral Lock Switch
C SW5 Seat Switch
E C3F Connector to Headlight Harness
F P1 Hourmeter
G SW1 Key Switch
H SW6 PTO Switch
I SW2 Right Handle Neutral Lock Switch
J SW7 Headlight Switch Connector (option)
K Fuses
L K2 Interlock Relay
M G1 Battery
N K1 Start Relay
O W2 Engine Ground
P Connector to Y2 PTO Clutch
Q C4M Connector to Engine Wiring Harness
R M1 Starting Motor

Section 40 - ELECTRICAL REPAIR Group 20: Wiring Harness
Electrical Component Location (S.N. 170001- )
Electrical Component Location (S.N. 170001-)

LEGEND:
A C1 Power Connector
B SW3 Left Handle Neutral Lock Switch
C SW5 Seat Switch
E C3F Connector to Headlight Harness
F P1 Hourmeter
G SW1 Key Switch
H SW6 PTO Switch
I SW2 Right Handle Neutral Lock Switch
J SW7 Headlight Switch Connector (option)
K Fuses
L K2 Interlock Relay
M G1 Battery
N K1 Start Relay
O W2 Engine Ground
P Connector to Y2 PTO Clutch
Q C4M Connector to Engine Wiring Harness
R M1 Starting Motor
S L6 Low Fuel Light
T Thermistor (Low Fuel sending Unit)

Group 20 - Wiring Harness

Wiring Harness Legend
W1 Main Wiring Harness (S.N. -120000)
W1 Main Wiring Harness Color Codes (S.N. -120000)
W1 Main Wiring Harness (S.N. 120001-130000)
W1 Main Wiring Harness Color Codes (S.N. 120001-130000)
W1 Main Wiring Harness (S.N. 170001- )
W1 Main Wiring Harness Color Codes (S.N. 170001- )
W2 Engine Wiring Harness
W3 Lighting Kit Wiring Harness (S.N. -130000)
W3 Lighting Kit Wiring Harness (S.N. 130001- )
Wiring Harness Legend

Components
DEFINITIONS:
D1, D2 Diode
D3 Diode (S.N. 120001- )
E1 Spark Plug
F1 Fuse 20A
F2 Fuse 20A
F3 Fuse 7.5A
F4 Fuse 7.5A (option)
G1 Battery
G2 Stator
K1 Start Relay
K2 Interlock Relay
L1 Left Headlight (option)
L2 Right Headlight (option)
L6 Low Fuel Light (S.N. 170000- )
M1 Starting Motor
N1 Voltage Regulator/Rectifier
P1 Hourmeter
SW1 Key Switch
SW2 Left Handle Neutral Lock Switch
SW3 Right Handle Neutral Lock Switch
SW4 Park Brake Switch
SW5 Seat Switch
SW6 PTO Switch
SW7 Headlight Switch (option) (S.N. 130001- )
SW99 Headlight Switch (option) (S.N. -130000)
T1, T2 Ignition Coil
W2 Engine Ground
Y1 Fuel Shutoff Solenoid
Y2 PTO Clutch
Connectors:
DEFINITIONS:
C1 Power Connector (S.N. 130001- )
C3F W1 Main Wiring Harness to W3 Lighting Kit Wiring Harness (S.N. 130001- )
C3M W3 Lighting Kit Wiring Harness to W1 Main Wiring Harness (S.N. 130001- )
C4E W2 Engine Wiring Harness to W1 Main Wiring Harness
C4M W1 Main Wiring Harness to W2 Engine Wiring Harness
SWA Fuel Level Sensor Tab (S.N. 170000- )
SWB Fuel Level Sensor Tab (S.N. 170000- )
Wiring Harnesses:
DEFINITIONS:
W1 Main Wiring Harness

DEFINITIONS:
W3 Lighting Kit Wiring Harness (option)

W1 Main Wiring Harness (1 of 2)

LEGEND:
K1 Start Relay
P1 Hour Meter
SW1 Key Switch
SW2 Left Handle Neutral Switch
SW5 Seat Switch
SW6 PTO Switch


LEGEND:
C4M Engine Harness Connector
G1 Battery
M1 Starter Motor
S3 Right Handle Neutral Switch
W2 Engine Ground
Y2 PTO Clutch

W1 Main Wiring Harness Color Codes (S.N. -120000)

W1 Color Codes (SN -120000)
Size Number Color Wire Connection Points
13.0 100A Bare G1, W2
0.8 100C Blk Y2, SP100
1.0 100D Blk W2, SP100
0.8 100E Blk SW5, SP100
0.8 100F Blk SW4, SP100
0.8 100G Blk SW1, SP100
0.8 100H Blk P1, SP100
0.8 100R Blk K2, SP100
2.0 201 Red F2, C4M
13.0 202A Red G1, K1
3.0 202B Red K1, SP202
3.0 202C Red F2, SP202
3.0 202D Red F1, SP202
1.0 220A Red F1, SW1
0.8 220B Red SW1, SW1
1.0 400A Yel SW1, SP400
0.8 400B Yel F3, SP400
0.8 400C Yel K2, SP400
0.8 400E Yel F4, SP400
0.8 420 Yel C4M, P1
0.8 475A Yel F3, SW6
0.8 475B Yel P1, SW6
0.8 601A Wht C4M, SP601
0.8 601B Wht SW3, SP601
0.8 601C Wht SW2, SP601
0.8 601D Wht SW4, SP601
0.8 601E Wht SW6, SP601
0.8 601F Wht SW1, SP601
0.8 601G Wht P1, SP601
0.8 602A Pnk SW4, SW6
0.8 602B Pnk SW4, K2
0.8 603A Grn SW2, SW3
0.8 603B Grn SW2, SW4
0.8 603C Grn SW4, K1
0.8 604 Pnk SW6, Y2
0.8 605 Wht SW5, K2
0.8 700 Pur SW3, K1
0.8 701 Grn SW2, SW3
0.8 702 Grn SW2, SW6
0.8 703 Grn SW1, SW6
13.0 705 Red K1, M1


LEGEND:
K1 Start Relay
P1 Hour Meter
SW1 Key Switch
SW5 Seat Switch
SW6 PTO Switch


LEGEND:
G1 Battery
M1 Starter Motor
S3 Right Handle Neutral Switch
W2 Engine Ground
Y2 PTO Clutch


W1 Color Codes (SN 120001-130000)
13.0 100A Bare G1, W2
0.8 100C Blk Y2, SP100
1.0 100D Blk W2, SP100
0.8 100E Blk SW5, SP100
0.8 100G Blk SW1, SP100
0.8 100H Blk P1, SW1
0.8 100R Blk K2, SP100
2.0 201 Red F2, C4M
13.0 202A Red G1, K1
3.0 202B Red K1, SP202
3.0 202C Red F2, SP202
3.0 202D Red F1, SP202
1.0 220A Red F1, SW1
1.0 400A Yel SW1, SP400
0.8 400B Yel F3, SP400
0.8 400E Yel F4, SP400
0.8 419A Yel SW2, P1
0.8 419B Yel SW2, SW4
0.8 420A Yel K2, C4M
0.8 420B Yel SW5, D3
0.8 420C Yel K2, D3
0.8 475A Yel F3, SW6
0.8 475B Yel P1, SW6
0.8 601A Wht C4M, SP601
0.8 601B Wht K2, SP601
0.8 601F Wht SW1, SP601
0.8 601G Wht P1, SP601
0.8 604 Pnk SW6, Y2
0.8 605 Wht SW4, SW6
0.8 608A Pnk SW5, SW4
0.8 608B Pnk SW4, SW4
0.8 608C Pnk SW3, SW4
0.8 701 Grn SW2, SW3
0.8 702A Grn SW6, D3
0.8 702B Grn SW1, SW6
0.8 703 Grn SW1, K1
0.8 704 Wht K1, K2
13.0 705 Red K1, M1


LEGEND:
C3F Light Kit Harness Connector
SW3 Right Handle Neutral Switch
SW5 Seat Switch


LEGEND:
G1 Battery
K1 Start Relay
P1 Hour Meter
SW1 Key Switch
SW6 PTO Switch
SW7 Hazard Switch


LEGEND:
C1 Power Connector
M1 Starter Motor
W2 Engine Ground
Y2 PTO Clutch


W1 Color Codes (S.N. 130001-170000)
13.0 100A Bare G1, W2
0.8 100C Blk Y2, SP100
1.0 100D Blk W2, SP100
0.8 100E Blk K2, SP100
0.8 100G Blk SW1, SP100
0.8 100H Blk P1, SW1
0.8 100N Blk C1, SP100
0.8 100P Blk SP100, C3F
0.8 100R Blk K2, SP100
2.0 201 Red F2, C4M
13.0 202A Red G1, K1
3.0 202B Red K1, SP202
3.0 202C Red F2, SP202
3.0 202D Red F1, SP202
1.0 220A Red F1, SW1
1.0 400A Yel SW1, SP400
0.8 400B Yel F3, SP400
0.8 400E Yel F4, SP400
0.8 419A Yel SW2, P1
0.8 419B Yel SW2, SW4
0.8 420A Yel K2, C4M
0.8 420B Yel SW5, D3
0.8 420C Yel K2, D3
0.8 475A Yel F3, SW6
0.8 475B Yel P1, SW6
0.8 601A Wht C4M, SP601
0.8 601B Wht K2, SP601
0.8 601F Wht SW1, SP601
0.8 601G Wht P1, SP601
0.8 604 Pnk SW6, Y2
0.8 605 Wht SW4, SW6
0.8 608A Pnk SW5, SW3
0.8 608B Pnk SW4, SW4
0.8 608C Pnk SW3, SW4
0.8 701 Grn SW2, SW3
0.8 702A Grn SW6, D3
0.8 702B Grn SW1, SW6
0.8 703 Grn SW1, K1
0.8 704 Wht K1, K2
13.0 705 Red K1, M1
0.8 800 Blu C1, SW7
0.8 900A Yel SW7, F4
0.8 901B Yel SW7, C3F


LEGEND:
C3F Light Kit Harness Connector
SW3 Right Handle Neutral Switch
SW5 Seat Switch


LEGEND:
G1 Battery
K1 Start Relay
L6 Low Fuel Light
P1 Hour Meter
SW1 Key Switch
SW6 PTO Switch
SW7 Hazard Switch


LEGEND:
C1 Power Connector
M1 Starter Motor
SWA Fuel Level Sensor
SWB Fuel Level Sensor
W2 Engine Ground
Y2 PTO Clutch

W1 Main Wiring Harness Color Codes (S.N. 170001- )

W1 Color Codes (S.N. 170001-)
13.0 100A Bare G1, W2
0.8 100C Blk Y2, SP100
1.0 100D Blk W2, SP100
0.8 100E Blk K2, SP100
0.8 100G Blk SW1, SP100
0.8 100H Blk P1, SW1
0.8 100N Blk C1, SP100
0.8 100P Blk SP100, C3F
0.8 100R Blk K2, SP100
0.8 100AD Blk SWB, SP100
2.0 201 Red F2, C4M
13.0 202A Red G1, K1
3.0 202B Red K1, SP202
3.0 202C Red F2, SP202
3.0 202D Red F1, SP202
1.0 220A Red F1, SW1
1.0 400A Yel SW1, SP400
0.8 400B Yel F3, SP400
0.8 400E Yel F4, SP400
0.8 400R Yel L6B, SP400
0.8 419A Yel SW2, P1
0.8 419B Yel SW2, SW4
0.8 420A Yel K2, C4M
0.8 420B Yel SW5, D3
0.8 420C Yel K2, D3
0.8 475A Yel F3, SW6
0.8 475B Yel P1, SW6
0.8 600A Org L6A, SWA
0.8 601A Wht C4M, SP601
0.8 601B Wht K2, SP601
0.8 601F Wht SW1, SP601
0.8 601G Wht P1, SP601
0.8 604 Pnk SW6, Y2
0.8 605 Wht SW4, SW6
0.8 608A Pnk SW5, SW3
0.8 608B Pnk SW4, SW4
0.8 608C Pnk SW3, SW4
0.8 701 Grn SW2, SW3
0.8 702A Grn SW6, D3
0.8 702B Grn SW1, SW6
0.8 703 Grn SW1, K1
0.8 704 Wht K1, K2
13.0 705 Red K1, M1
0.8 800 Blu C1, SW7
0.8 900A Yel SW7, F4

0.8 901B Yel SW7, C3F

Engine Wiring Harness

LEGEND:
C4E Main Harness Connector
T1 Ignition Coil
T2 Ignition Coil

W3 Lighting Kit Wiring Harness (S.N. -130000)
Lighting Kit Wiring Harness

LEGEND:
L1 Left Hand Headlight
L2 Right Hand Headlight
SW99 Light Switch
W2 Engine Ground

POWER TRAIN REPAIR (g) by Belgreen v2.0
W3 Lighting Kit Wiring Harness (S.N. 130001- )
Lighting Kit Wiring Harness

LEGEND:
C3M Main Harness Connector
L1 Left Hand Headlight
L2 Right Hand Headlight

Section 50 - POWER TRAIN REPAIR

Table of contents
Power Train Components (S.N. -130000) .............................................................................................. 2
Power Train Components (S.N. 130001- ) ............................................................................................. 3
Control Linkage Components (S.N. -130000) ........................................................................................ 4
Control Linkage Components (S.N. 130001- ) ....................................................................................... 6
Transaxle Components (S.N. -130000) ................................................................................................. 8
Transaxle Components (S.N. 130001- ) .............................................................................................. 10
Fan Pulley (S.N. -130000) ................................................................................................................... 11
Fan Pulley (S.N. 130001- ) .................................................................................................................. 12
Transaxle Mounts (S.N. -130000) ....................................................................................................... 13
Transaxle Mounts (S.N. 130001- ) ...................................................................................................... 14
Group 20 - Repair ................................................................................................................................... 15
Specifications ..................................................................................................................................... 15
Disassemble Park Brake (S.N. -130000) ............................................................................................. 15
Inspect Park Brake (S.N. -130000) ...................................................................................................... 16
Assemble Park Brake (S.N. -130000) .................................................................................................. 18
Remove Traction Belt (S.N. -130000) ................................................................................................. 19
Install Traction Belt (S.N. -130000) ..................................................................................................... 19
Remove Traction Belt (S.N. 130001- ) ................................................................................................ 20
Install Traction Belt (S.N. 130001- ) .................................................................................................... 21
Remove and Install Transaxle (S.N. -130000) ..................................................................................... 22
Remove and Install Transaxle (S.N. 130001- ) .................................................................................... 24
Replace Neutral Return Shaft Seal ..................................................................................................... 25
Replace Transaxle Hub Nut ................................................................................................................ 27

Section 50 - POWER TRAIN REPAIR Group 10: Component Location

Power Train Components (S.N. -130000)
Power Train Components (S.N. 130001- )
Control Linkage Components (S.N. -130000)
Control Linkage Components (S.N. 130001- )
Transaxle Components (S.N. -130000)
Transaxle Components (S.N. 130001- )
Fan Pulley (S.N. -130000)
Fan Pulley (S.N. 130001- )
Transaxle Mounts (S.N. -130000)
Transaxle Mounts (S.N. 130001- )

Power Train Components (S.N. -130000)
Power Train Components

LEGEND:
A Right Control Lever
B Left Control Lever
C Engine Drive Sheave
D Control Lever Shock Absorber
E Fan and Pulley Input Shaft
F Bypass Release Rod
G Wheel Hub
H Forward/Reverse Control Arm
I Direction Return Assembly
J Return Spring
K Left Transaxle Case
L Drive Belt Tension Spring
M Control Linkage
N Adjustment Yoke End
O Tracking Adjustment Bolt
P Right Transaxle Case
Q Drive Belt

Power Train Components (S.N. 130001- )
Power Train Components

LEGEND:
A Right Control Lever
B Left Control Lever
C Fan and Pulley Input Shaft
D Bypass Release Rod
E Drive Belt
F Engine Drive Sheave
G Drive Belt Tension Spring
H Forward/Reverse Control Arm
I Direction Return Assembly
J Return Spring
K Wheel Hub
L Left Transaxle
M Control Linkage
N Adjustment Yoke End
O Right Transaxle
P Control Lever Shock Absorber
Q Tracking Adjustment Bolt

Control Linkage Components (S.N. -130000)
Control Linkage Components

LEGEND:
A Handlebar
B Plug
C Linkage
D Screw, M8x45
E Nut, M8
F Spring Clip
G Bracket
H Flange Nut
I Linkage
J Bolt, M10x20
K Flange Nut
L Gas Operated Cylinder
M Ball Stud
N Linkage
O Link End
P Cap Screw, M8x45
Q Bushing
R Screw, M6x12
S Bracket
T Lock Nut
U Switch
V Strap
W Screw
X Bolt, M8x25

Y Flange Nut
Z Self-Locking Screw, M8x30

Control Linkage Components (S.N. 130001- )
Control Linkage Components

LEGEND:
A Handlebar
B Plug
C Upper Steering Arm
D Locknut, M8
E Shoulder Bolt
F Spring Washer
G Spring locking Pin
H Right Steering Linkage
I Spring locking Pin
J Link
K Bolt, M8x35
L Left Steering Linkage
M Link End
N Bolt, M8x90
O Pin
P Gas Operated Cylinder
Q Shoulder Bolt
R Nut, M8
S Pivot Shaft
T Bushing
U Lower Steering Arm
V Locknut, M12

Transaxle Components (S.N. -130000)
Transaxle Components (with Park Brake)

LEGEND:
A Bypass Release Rod
B Pushnut
C Arm, Bypass
D Pushnut
E Vent Tube
F Vent Cap
G Plug
H Fitting
I Nut
J Spacer (2 used)
K Wheel Hub
L Lock Nut
M Hub Cap
N Bolt
O Brake Pad (2 used)
P Brake Rotor
Q Plate, Backing
R Bolt
S Caliper
T Bolt (2 used)
U Spacer
V Pin, Actuating (2 used)
W Spring, Compression
X Bolt
Y Plate
Z Extension Spring
AA Washer
AB Castle Nut
AC Cotter Pin
AD Spacer
AE Control Arm, Neutral
AF Washer
AG Socket Head Cap Screw
AH Control Arm, Speed and Direction
AI Bushing
AJ Washer, Plastic (2 used)
AK Return Arm (Small Blade)
AL Washer
AM Return Arm (Large Blade)
AN Washer
AO Torx Washer Head Cap Screw
AP Spring

Transaxle Components (S.N. 130001- )
Transaxle Components (with Park Brake)

LEGEND:
A Seal
B Snap Ring, Internal
C Kit, Bypass Arm
D Kit, Breather
E Snap Ring, Internal
F Seal
G Axle Tube
H Kit, Hub
I Cap
J Extension Spring
K Kit, Neutral Return
L Seal
M Kit, Brake
N Seal

Fan Pulley (S.N. -130000)

LEGEND:
A Lock Nut
B Screw Hex Head
C Fan
D Pulley
Fan Pulley

Fan Pulley (S.N. 130001- )

LEGEND:
A Locknut
B Washer
C Pulley
D Fan
E Spacer
Fan Pulley

Transaxle Mounts (S.N. -130000)
Transaxle Mounts
LEGEND:
A Bracket
B Bolt
C Nut
D Nut
E Nut
F Bolt
G Bolt
H Bracket

Section 50 - POWER TRAIN REPAIR Group 20: Repair
Transaxle Mounts (S.N. 130001- )
Transaxle Mounts
LEGEND:
A Bolt, M8x70
B Locknut, M8
C Bolt, M8x60
D Bracket
E Bolt, M10x60
F Bracket
G Screw, M8
H Wireform, LH Steer Guard (Shown)
- Wireform, RH Steer Guard
I Locknut, M10

Group 20 - Repair
Disassemble Park Brake (S.N. -130000)
Inspect Park Brake (S.N. -130000)
Assemble Park Brake (S.N. -130000)
Remove Traction Belt (S.N. -130000)
Install Traction Belt (S.N. -130000)
Remove Traction Belt (S.N. 130001- )
Install Traction Belt (S.N. 130001- )
Remove and Install Transaxle (S.N. -130000)
Remove and Install Transaxle (S.N. 130001- )
Replace Neutral Return Shaft Seal
Replace Transaxle Hub Nut
Specifications
Park Brake Rotor Released Clearance 0.5—1.0 mm
(0.02—0.04 in.)
Wheel Lug Nut Torque 102 N·m
(75 lb.-ft.)
Transaxle-to-Frame Mounting Hardware Torque 40 N·m
(30 lb.-ft.)
Hub Lock Nut Torque 339 N·m
(250 lb.-ft.)
Disassemble Park Brake (S.N. -130000)

LEGEND:
A Bolt
B Bolt
C Caliper
D Park Brake Rotor
E Splined Shaft
Park Brake
[2] - Block front wheels.
[3] - Raise and support rear of machine sufficiently to remove rear wheels.
[4] - Pull hydrostatic bypass release rods rearward and secure in release position.
[5] - Remove hex head bolt (A).
[6] - Loosen flanged hex head bolt (B), allowing caliper (C) with attached brake actuating components to rotate downward
about bolt (B).
[7] - Remove park brake rotor (D) from splined shaft (E).
[8] - Clean splined shaft (E) of any dirt or corrosion.

[9] -
LEGEND:
F Park Brake Pad
G Transaxle Housing
Inboard Park Brake Pad

Remove inboard park brake pad (F) from recess in transaxle housing (G).
[10] -
LEGEND:
C Caliper
H Brake Pad
I Backing Plate
Brake Pad and Backing Plate

Remove outboard park brake pad (H) and backing plate (I) from recess in caliper (C).
Inspect Park Brake (S.N. -130000)

LEGEND:
A Actuating Pins
B Caliper
Park Brake Actuating Pins
[1] - Inspect park brake rotor for unusual wear or oil contamination. Replace rotor if damaged.
[2] - Clean park brake rotor hub internal splines of any dirt or corrosion.
[3] - Clean brake rotor if oil is present.

[4] - Inspect park brake pads for wear or evidence of oil contamination. Replace brake pads if oil contamination is evident.
[5] - Check to see that park brake actuating pins (A) slide freely in bores of caliper (B).

Assemble Park Brake (S.N. -130000)

LEGEND:
A Bolt
B Bolt
C Caliper
D Park Brake Rotor
E Splined Shaft
Park Brake Rotor
[1] - Make sure that park brake rotor and pads are clean and free of oil.
[2] - Insert inboard park brake pad in transaxle housing recess.
[3] - Install park brake rotor (D) to splined shaft (E) while holding inboard brake pad in place.
[4] - Place outboard park brake backing plate (I) and brake pad (H) into recess in caliper (C).
[5] - Rotate caliper and actuating assembly on bolt (B) to align holes for bolt (A).
[6] - Insert bolt (A) and turn in finger tight.
[7] - Tighten hex head bolt (A) and flanged head bolt (B) securing park brake caliper in place.
[8] -
LEGEND:
D Park Brake Rotor
H Outboard Brake Pad
K Cotter Pin
L Castle Nut
Park Brake Rotor

With park brake control in the released position, check clearance between park brake rotor (D) and outboard brake pad (H).
[9] - If park brake rotor to pad clearance is not within specification, remove cotter pin (K) and adjust position of castle nut (L)
as required.
(0.02—0.04 in.)
a. Turn castle nut out to closest position allowing insertion of cotter pin.
b. Insert and secure cotter pin in castle nut.

[10] - Engage park brake control and check brake for function.
[11] - Disengage park brake control and check park brake for drag and clearance within specification.
[12] - Install tire and wheel assemblies.
[13] - Lower machine from supports.
[14] - Tighten wheel lugs to specification.

(75 lb.-ft.)
[15] - Return hydrostatic bypass release rods to operating position.
Remove Traction Belt (S.N. -130000)

LEGEND:
A Square Hole
B Idler Arm
C Idler Sheave
D Drive Belt
E Belt Guide
F Belt Guide
G Transaxle Sheaves
H Intermediate Sheaves
I Engine Sheave
Idler Arm
[2] - Remove mower deck.
[3] - Insert a 1/2 in. ratchet or breaker bar into the square hole (A) on the idler arm (B), rotate the spring-loaded idler arm to
relieve belt tension on the idler sheave (C) and remove the drive belt (D) from the idler sheave. Release the spring tension
from the arm and remove the tool.
[4] - Remove the bolt, nut and belt guide (E).
[5] - Remove belt guide (F).
[6] - Remove the drive belt (D) from the transaxle sheaves (G), intermediate sheaves (H) and engine sheave (I).
Install Traction Belt (S.N. -130000)

LEGEND:
A Square Hole
B Idler Arm
C Idler Sheave
D Drive Belt
E Belt Guide
F Belt Guide
G Transaxle Sheaves
H Intermediate Sheaves
I Engine Sheave
Idler Arm
[1] - Position belt onto engine sheave (I), intermediate sheaves (H) and transaxle sheaves (G).
[2] - Install belt guides (E, F).
[3] -
→NOTE:
The transaxle drive belt is self-adjusted using the spring tensioner and does not require a tension
adjustment.
Rotate the spring-loaded idler arm (B) and install the belt on the idler sheave (C).
[4] - Insert electric clutch wiring harness connector to main wiring harness.
[5] - Make sure that drive belt is properly located in all sheave grooves, and reinstall tensioning spring to belt tensioner arm.
[6] - Tighten any loose transaxle mounting bolts to specification.

(30 lb.-ft.)
Remove Traction Belt (S.N. 130001- )

LEGEND:
A Clutch Connector
B Hole
C Idler Arm
D Idler Sheave
E Drive Belt
F Transaxle Sheaves
G Engine Sheave
Idler Arm
[3] - Disconnect electric clutch wiring connector (A) from main wiring harness connector.

[4] -
CAUTION:
Avoid injury! Components are installed under spring tension. Wear eye protection and use proper tools
when installing and removing components with spring tension.
Insert a 3/8 in. ratchet or breaker bar into the square hole (B) on the idler arm (C), rotate the spring-loaded idler arm to relieve
belt tension on the idler sheave (D) and remove the drive belt (E) from the idler sheave. Release the spring tension from the
arm and remove the tool.
[5] - Remove the drive belt (E) from the transaxle sheaves (F).
[6] - Remove the drive belt (E) from the engine sheave (G).
Install Traction Belt (S.N. 130001- )

LEGEND:
A Clutch Connector
B Hole
C Idler Arm
D Idler Sheave
E Drive Belt
F Transaxle Sheaves
G Engine Sheave
Idler Arm
[1] - Position replacement belt onto engine sheave (G), and transaxle sheaves (F).
[2] -
CAUTION:
Rotate the spring-loaded idler arm (C) and install the belt on the idler sheave (D).
[3] - Connect electric clutch wiring harness connector (A) to main wiring harness.
[4] - Install mower deck.

Remove and Install Transaxle (S.N. -130000)

LEGEND:
A Spring Cotter
B Control Linkage
C Nut
Control Linkage
[2] - Raise the rear wheels off the ground and support the frame with jack stands.
[3] - Remove the rear wheel(s).
[4] - Remove traction drive belt. (See Remove Traction Belt (S.N. -130000) .)
[5] - Remove spring cotter (A) and disconnect control linkage (B).
[6] - Remove bolt and nut (C) from front transaxle bracket.
[7] - Remove parking brake cable.
[8] -
LEGEND:
D Bolt
E Nut
F Nut
Bottom Bracket
Remove nuts and carriage bolts (D) from bottom bracket.
[9] - Support transaxle and remove bolts and nuts (E) and (F).
[10] - Lower transaxle from machine.
Install Transaxle:
Installation is the reverse order of removal.

Tighten transaxle mounting hardware to specification.
Install traction drive belt. (See Install Traction Belt (S.N. -130000) .)
Tighten wheel lugs to specification.

(30 lb.-ft.)
(75 lb.-ft.)

Remove and Install Transaxle (S.N. 130001- )

LEGEND:
A Nut
B Bolt
C Guard
D Screws
E Spring Locking Pin
F Bypass Rod
Left side shown with engine guard removed for clarity.
[3] - Remove the rear wheel(s).
[4] - Remove traction drive belt. (See Remove Traction Belt (S.N. 130001- ) .)
[5] - Remove nut (A) and bolt (B) holding the steer guard (C) to the transaxle.
[6] - Remove two screws (D) holding the steer guard to the frame. Remove guard.
[7] - Remove spring locking pin (E) from bypass rod (F).
[8] -
LEGEND:
G Spring
H Arm
I Brake Link
J Nuts and Bolts
K Bracket
Park Brake Spring

Disconnect park brake return spring (G) from park brake arm (H) on transaxle.
[9] - Pull back on park brake link (I) to remove from arm on transaxle.
[10] - Remove nuts and bolts (J) from center support bracket (K).
[11] -

LEGEND:
L Spring Locking Pin
M Control Linkage
N Nuts
O Bolts
Transaxle Mounting Bolts

Remove spring locking pin (L) and disconnect control linkage (M).
[12] - Support transaxle and remove nuts (N) and bolts (O).
[13] - Lower transaxle from machine.
Install Transaxle:
Installation is the reverse order of removal.

Tighten transaxle mounting hardware to specification.
Install traction drive belt. (See Install Traction Belt (S.N. 130001- ) .)
Tighten wheel lugs to specification.
(30 lb.-ft.)
(75 lb.-ft.)
Replace Neutral Return Shaft Seal

LEGEND:
A Spring
B Seal
Seal
[2] - Support machine and remove wheel.
[3] - Remove the return to neutral (RTN) control arm by removing the spring (A) and TORX ™ head screw (Inspect the parts
before assembly for hidden damage).
[4] -
→NOTE:
Position drain pan under transaxle.

Remove seal (B) from transaxle.
[5] - Lubricate new seal and install.
[6] - Reassemble all parts in reverse order.
[7] - Tighten screw to specification.

RTN TORX Head Screw Torque 26 N·m
(230 lb-in.)
[8] - Adjust RTN. (See Adjust Return To Neutral (RTN) .)
[9] -
LEGEND:
C Fill Plug
Plug
Check oil level at fill plug (C). Add 20W50 oil as required to fill transaxle to 19—38 mm (0.75—15 in.) below top of fill port.
[10] - Purge transaxle oil. (See Purge Transaxle Hydraulic System .)
[11] - Check oil level. Adjust level as required.
[12] - Install wheel.

Replace Transaxle Hub Nut
Shown with and without spacers.

LEGEND:
A Nut
[1] -
IMPORTANT:
If removing lock nut with pin, bend pin out from threads before removing nut. Discard and replace nut.
Do not reuse nut.
→NOTE:
If hub flange is being replaced: new hub flange may have a groove on the outside.
Remove and discard hub lock nut (A).
[2] -
LEGEND:
A Lock Nut
B Lock Nut with Pin
Lock Nuts
Replace lock nut (A) with lock nut (B) that has pin.

ATTACHMENTS REPAIR (g) by Belgreen v2.0
[3] - Tighten lock nut to specification.

Hub Lock Nut Torque 339 N·m
(250 lb.-ft.)

Section 60 - ATTACHMENTS REPAIR

Table of contents
Deck and Lift Components, 42C (S.N. -130000) ................................................................................... 2
Deck and Lift Components, 42C (S.N. 130001- ) .................................................................................. 3
Deck and Lift Components, 48TD (S.N. -130000) ................................................................................. 4
Deck and Lift Components, 48TD (S.N. 130001- ) ................................................................................ 5
Deck Spindles and Sheaves, 42C (S.N. -130000) .................................................................................. 6
Deck Spindles and Sheaves, 42C (S.N. 130001- ) ................................................................................. 8
Deck Spindles and Sheaves, 48TD ..................................................................................................... 10
Deck Lift Assembly Components (S.N. -130000) ................................................................................ 12
Deck Lift Assembly Components (S.N. 130001- ) ............................................................................... 14
Spindle Section, 42 and 48 Decks MY09 ............................................................................................. 15
Spindle Section, 42 and 48 Decks MY10— .......................................................................................... 16
Group 20 - Repair ................................................................................................................................... 17
Specifications ..................................................................................................................................... 17
Install Mounting Post Bracket to Machine (S.N. -130000) ................................................................... 17
Install Bagger Chute ........................................................................................................................... 19
Remove Bagger Chute ........................................................................................................................ 20
Install Weight Kit ................................................................................................................................ 22
Remove Mower Deck (42C) (S.N. -130000) ........................................................................................ 23
Install Mower Deck (42C) (S.N. -130000) ............................................................................................ 25
Remove Mower Deck (42C) (S.N. 130001- ) ....................................................................................... 27
Install Mower Deck (42C) (S.N. 130001- ) ........................................................................................... 29
Remove Mower Deck (48TD) (S.N. -130000) ...................................................................................... 31
Install Mower Deck (48TD) (S.N. -130000) .......................................................................................... 33
Remove Mower Deck (48TD) (S.N. 130001- ) ..................................................................................... 35
Install Mower Deck (48TD) (S.N. 130001- ) ......................................................................................... 37
Replace Mower Drive Belt (42C) (S.N. -130000) ................................................................................. 39
Replace Mower Drive Belt (42C) (S.N. 130001- ) ................................................................................ 41
Replace Mower Drive Belt (48TD) ....................................................................................................... 43
Remove and Install Mower Blade ....................................................................................................... 45
Sharpen and Balance Blades .............................................................................................................. 46
Disassemble Spindle, 42 and 48 Inch ................................................................................................. 48
Assemble Spindle, 42 and 48 Inch ...................................................................................................... 50

Section 60 - ATTACHMENTS REPAIR Group 10: Component Location

Deck and Lift Components, 42C (S.N. -130000)
Deck and Lift Components, 42C (S.N. 130001- )
Deck and Lift Components, 48TD (S.N. -130000)
Deck and Lift Components, 48TD (S.N. 130001- )
Deck Spindles and Sheaves, 42C (S.N. -130000)
Deck Spindles and Sheaves, 42C (S.N. 130001- )
Deck Spindles and Sheaves, 48TD
Deck Lift Assembly Components (S.N. -130000)
Deck Lift Assembly Components (S.N. 130001- )
Spindle Section, 42 and 48 Decks MY09
Spindle Section, 42 and 48 Decks MY10—

Deck and Lift Components, 42C (S.N. -130000)
Deck and Lift Assembly 42 Inch

LEGEND:
A “J” Hook
B Pin, Height Adjustment
C Lift Handle
D Cross Bar, Lift
E Lift Arm
F Lift Rod
G Trunnion
H Lift Arm
I Belt Tension Arm and Spring
J Front Hanger

Deck and Lift Components, 42C (S.N. 130001- )
Deck and Lift Assembly 42C

LEGEND:
A Lift Handle
C Cable, Lift
D Trunnion
E Draft Arm
F Belt Tension Arm and Spring
G Front Hanger
H Spring, Lift Assist

Deck and Lift Components, 48TD (S.N. -130000)

LEGEND:
A “J” Hook
C Lift Handle
D Deck Lift Bar
E Lift Arm
F Pin, Attachment
G Trunnion
H LH Lift Arm
I Belt Tension Arm and Spring
J Idler Pulley
K Front Hanger

Deck and Lift Components, 48TD (S.N. 130001- )

LEGEND:
A Lift Handle
C Cable, Lift
D Belt Tension Arm and Spring
E Trunnion
F Draft Arm
G Front Hanger
H Spring, Lift Assist

Deck Spindles and Sheaves, 42C (S.N. -130000)
Deck Spindles and Sheaves 42C

LEGEND:
A Belt
B Flange Nut
C Bushing
D Tension Arm Assembly
E Spring
F Lock Nut (2 used)
G Idler Pulley
H Bushing (2 used)

I Belt Guide
J Bolt
K Pin (2 used)
L Clip (2 used)
M Belt Shield
N Screw (11 used)
O Belt Guide
P Shoulder Bolt (2 used)
Q Wheel (2 used)
R Flange Nut (2 used)
S Spindle Assembly (2 used)
T Seal (2 used)
U Blade (2 used)
V Washer (2 used)
W Lock Nut (2 used)
X arriage Bolt (2 used)
Y Hinge Bracket
Z Shield
AA Discharge Chute
AB Pin
AC Torsion Spring
AD Nut (2 used)
AE Spring
AF Push Pin
AG Spindle Sheave (2 used)
AH Flange Nut (2 used)
AI Idler Pulley
AJ Bolt

Deck Spindles and Sheaves, 42C (S.N. 130001- )
Deck Spindles and Sheaves 42C

LEGEND:
A Discharge Chute
B Push Retainer
C Screw (5 used)
D Belt Shield, Right
E Belt
F Bolt, M8x25
G Bushing
H Bolt, M10x40
I Idler Pulley

J Bushing
K Flange Nut, M10
L Spring
M Tension Arm Assembly
N Idler Pulley
O Belt Guide
P Bolt, M10x50
Q Pin (2 used)
R Spring Locking Pin (2 used)
S Belt Shield, Left
T Belt Guide
U Quick Coupler
V Port Plate, Deck Wash
W Screw
X Washer
Y Shoulder Bolt
Z Wheel (2 used)
AA Flange Nut, M10
AB Washer (2 used)
AC Nut (2 used)
AD Blade (2 used)
AE Spindle Assembly (2 used)
AF Carriage Bolt (2 used)
AG Hinge Bracket
AH Locknut, M8
AI Torsion Spring
AJ Pin
AK Torsion Spring
AL Shield
AM Flange Nut (2 used)
AN Spindle Sheave (2 used)

Deck Spindles and Sheaves, 48TD

S.N. -130000 is shown; S.N. 130001- is similar

LEGEND:
A Belt
B Lock Nut M10 (2 used)
C Idler
D Bushing
E Screw M10 X 75
F Bushing
G Extension Spring
H Idler
I Arm
J Guide
K Screw M10 X 50
L Pin Fastener (2 used)
M Spring Locking Pin (2 used)
N Shield
O Screw (7 used)
P Quick Coupler
Q Screw, M6 X 12
R Washer 6.6 X 22 X 2mm
S Port Plate, Deck Wash
T Shield
U Screw M10 X 35
V Pulley
W Bushing
X Washer 11 X 34 X 3mm
Y Nut (3 used)
Z Pulley (3 used)
AA Screw (12 used)
AB Chute
AC Push Nut
AD Pin Fastener
AE Torsion Spring
AF Spring
AG Chute
AH Lock Nut M8 (2 used)
AI Hinge
AJ Bolt M8 X 20 (2 used)
AK Screw (2 used)
AL Gage Wheel (2 used)
AM Lock Nut M10 (2 used)
AN Bushing (3 used)
AO Bearing (3 used)
AP Spacer (3 used)
AQ Lubrication Fitting (3 used)
AR Spindle Housing (3 used)
AS Bearing (3 used)
AT Spacer (3 used)
AU Spindle (3 used)
AV Blade (3 used)
AW Washer (3 used)
AX Lock Nut(3 used)

Deck Lift Assembly Components (S.N. -130000)
Deck Lift Assembly Components

LEGEND:
A Grip
B Lift Handle
C M8X20 Hex Head Bolt (4 used)
D M8 Hex Nut (6 used)
E M8X75 Hex Head Bolt (2 used)
F Rockshaft
G Lift Rod (2 used)
H Lift Link (2 used)
I M10 Hex Nut (2 used)
J Drilled Pin (2 used)
K Spring Lock (3 used)
L Lift Arm (2 used)
M Draft Link (Z245)
N M12 Hex Nut (4 used)
O Trunnion (2 used)
P Bracket (2 used)
Q M8X20 Carriage Bolt (4 used)
R M8 Hex Nut
S M8X16 Carriage Bolt (2 used)
T M8 Hex Nut
U M8X80 Carriage Bolt
V Spacer
W Flat Washer
X M8 Hex Nut
Y Lift Quadrant
Z Deck Height Stop/Tracking Adjustment Tool
AA Draft Link (Z225)
AB Flat Washer
AC Bracket (1 used)

Deck Lift Assembly Components (S.N. 130001- )
Deck Lift Assembly Components

LEGEND:
A Lift Quadrant
B Bolt
C Locknut, M8
D Deck Height Stop/Tracking Adjustment Tool
E Carriage Bolt
F Bracket
G Locknut, M8
H Spring Locking Pin
I Cable, Lift
J Drilled Pin
K Draft Arm
L Nut
M Trunnion
N Spring Locking Pin
O Rod, Front Draft
P Spring, Lift Assist
Q Lift Handle
R Grip

Spindle Section, 42 and 48 Decks MY09
Spindle Section - 42 and 48 Decks

LEGEND:
A Nut
B Spindle Sheave
C Upper Seal Ring
D Upper Bearing
E Spacer
F Spindle Housing
G Blade
H Washer
I Nut
J Spacer
K Lower Bearing
L Cap Screw (4 used)
M Lubrication Fitting
N Spindle Shaft
O Deck
Spindles up to Model Year 2009 (MY09) can be differentiated by the side mount lubrication fitting, cast finish sides and four
mounting cap screws through the top of the deck.

Section 60 - ATTACHMENTS REPAIR Group 20: Repair
Spindle Section, 42 and 48 Decks MY10—
Spindle Section - 42 and 48 Decks MY10

LEGEND:
A Spindle Sheave Nut
B Spindle Sheave
C Upper Seal Ring
D Upper Bearing
E Spacer
F Spindle Housing
G Deflector Cup
H Blade
I Washer
J Blade Lock Nut (5/8 in.)
K Lower Bearing
L Stud (4 used)
M Spindle Mounting Nut
N Spindle Shaft
O Lubrication Fitting
P Deck
Model Year 2010 (MY10-) spindles can be differentiated by the top mount lubrication fitting, smooth sides and mounting studs
with nuts on the top of the deck.

Group 20 - Repair
Install Mounting Post Bracket to Machine (S.N. -130000)
Install Bagger Chute
Remove Bagger Chute
Install Weight Kit
Remove Mower Deck (42C) (S.N. -130000)
Install Mower Deck (42C) (S.N. -130000)
Remove Mower Deck (42C) (S.N. 130001- )
Install Mower Deck (42C) (S.N. 130001- )
Remove Mower Deck (48TD) (S.N. -130000)
Install Mower Deck (48TD) (S.N. -130000)
Remove Mower Deck (48TD) (S.N. 130001- )
Install Mower Deck (48TD) (S.N. 130001- )
Replace Mower Drive Belt (42C) (S.N. -130000)
Replace Mower Drive Belt (42C) (S.N. 130001- )
Replace Mower Drive Belt (48TD)
Remove and Install Mower Blade
Sharpen and Balance Blades
Disassemble Spindle, 42 and 48 Inch
Assemble Spindle, 42 and 48 Inch
Specifications
Blade Nuts
Blade Nut Torque (12 mm) Torque 68 N·m
(50 lb.-ft.)
Blade Nut Torque (5/8 in.) Torque 88 N·m
(65 lb.-ft.)
48TD Deck Sheave Nut Torque 47 N·m
(35 lb.-ft.)
Spindle Mounting Cap Screws Torque 30 N·m
(22 lb.-ft.)
Spindle Mounting Nuts Torque 30 N·m
(22 lb.-ft.)
Spindle Sheave Nut Torque 115 N·m
(85 lb.-ft.)
Install Mounting Post Bracket to Machine (S.N. -130000)

LEGEND:
A Bolt
B Bolts
C U-Bolts
D Machine Frame
E Exhaust Shield
F U-Bolt
Exhaust Shield
[1] -

→NOTE:
Allow engine to cool before beginning kit installation. Some components are in proximity to muffler.
Remove exhaust shield bolt (A) through frame and loosen front bolts (B) as necessary to install the two flat section U-bolts (C)
around machine frame (D) from the front. Slide each U-bolt toward the center until they line up with the two slots in the
exhaust shield (E).
[2] - Reinstall exhaust shield bolt (A) and tighten. U-bolts should now be trapped by the exhaust shield and engine.
[3] - Install standard U-bolt (F) from main hopper kit and continue with hopper installation instructions for installing remaining
components.

Install Bagger Chute

LEGEND:
A Pin
B Hole
C Hook
D Hole
E Hook
F Slot
Discharge Opening
Lower Discharge Chute
Install Lower Chute
[1] -
→NOTE:
If you have a 42 in. deck and bagging performance is not acceptable, purchase AM136660 lip kit.
→NOTE:
Prior to installing lower chute clean out toe guard on deck to allow chute to fit correctly.
The mulch plug, if installed, must be removed before installing the bagger discharge chute.
Raise and hold plastic discharge chute on mower deck.
[2] - Raise inner metal deflector, and position lower bagger discharge chute in front of mower deck discharge opening.
[3] -

CAUTION:
Prevent possible thrown objects. The discharge chute assembly must fit tight against the chute hinge
bracket and completely cover the mower deck discharge opening.
→NOTE:
Bagger discharge chute must fit on the outside of the mower deck discharge opening.
At the front of the discharge opening, slide pin (A) through hole (B) in gage wheel bracket.
[4] - Hook front rubber strap hook (C) over the top of the gage wheel bracket and insert through hole (D).
[5] - Rotate rear side of lower discharge chute toward mower deck, and insert rear strap hook (E) on discharge chute into slot
(F) on deck.
Install Upper Chute
[1] -
LEGEND:
A Upper Discharge Chute Top
B Flexible Chute
Upper Discharge Chute

Slide top (A) of upper discharge chute into flexible chute (B) of hopper assembly.
[2] -
LEGEND:
C Upper Discharge Chute Bottom
D Lower Chute Top
E Notch
F Bolt
G Strap Latch
Upper Discharge Chute

Slide bottom (C) of upper discharge chute over top (D) of lower chute, aligning notch (E) with bolt (F).
[3] - Hook rubber strap latch (G) on to bolt (F) in lower chute.

Remove Bagger Chute

LEGEND:
A Strap Latch
B Upper Chute
C Lower Chute
Remove Upper Chute
[1] - Unhook rubber strap latch (A) connecting upper chute (B) to lower chute (C). Remove upper chute (B).
[2] -
LEGEND:
D Strap Hook
E Hole
Rubber Strap Hook

Release front rubber strap hook (D) from hole (E) in gage wheel bracket.
[3] -
LEGEND:
F Strap Hook
G Deck Slot
Rubber Strap Hook from Deck

Release rear rubber strap hook (F) from slot (G) on deck.
[4] - Lift discharge chute deflector and remove lower chute from mower.

Install Weight Kit

LEGEND:
A Bolts
B Frame
C Retainers
Frame Bolts
[1] -
→NOTE:
There is an additional weight in kit needed to bring the amount of weights installed on a Z225 model to
four.
Remove installed M8 bolts, and install two included M8x130 bolts (A) from under frame, through holes in frame (B). Install two
retainers (C) to secure bolts to frame.
[2] -
LEGEND:
D Weight
E Kit Weights
F Knobs
Weights
Install included weight (D) in addition to all specified weights (E) in hopper kit, with recessed holes in weights facing machine
frame.
[3] - Secure with two knobs (F) from hopper kit.

Remove Mower Deck (42C) (S.N. -130000)

LEGEND:
A Pin
B Handle
Deck Lift Handle
[2] - Allow engine and muffler to cool completely.
[3] -
CAUTION:
Avoid injury! Rotating blades are dangerous. Before adjusting or servicing mower:
• Disconnect spark plug wire(s) or battery negative (-) cable to prevent engine from starting accidently.
• Always wear gloves when handling mower blades or working near blades.
Raise mower deck to the transport lock position.
[4] - Remove lock pin (A), push handle (B) to its lowest position and install pin just above lever to lock deck in lowered position.
[5] - Remove foot plate.
[6] -
CAUTION:
Avoid injury! Component is spring-assisted and under tension. Injury can occur if spring-assisted
component is released suddenly.
LEGEND:
C Hole
D Sheave
Mower Drive Belt

Disconnect mower drive belt:
a. Install 3/8-inch ratchet into square hole (C) in tension arm. Rotate counterclockwise to release tension on belt, while

removing mower belt from left spindle sheave (D).

b. Remove belt from engine sheave.
[7] -
LEGEND:
F Stud End
G Bracket
Front Draft Bracket

Remove spring locking pin (E) and, remove stud end (F) from front draft bracket (G).
[8] -
LEGEND:
Rear Draft Bracket

Remove spring locking pin (H) and pin from each side of rear mower bracket.
[9] - Raise draft arms to transport lock position:
a. Pull and raise mower lift lever fully upward.

b. Install pin just below lift lever to lock into raised position.
[10] - Rotate front caster wheels to maximize clearance.
[11] -
→NOTE:
Do not operate the machine without the mower deck: Machine can become unstable without the mower
deck attached. Move machine only by hand.
Slide mower out from under the machine.

Install Mower Deck (42C) (S.N. -130000)

LEGEND:
Rear Draft Bracket
[1] -
CAUTION:
Park machine safely.
[3] - Raise mower lift lever fully upward into transport lock position.
[4] - Slide mower deck under machine.
[5] - Lower mower lift lever, and install pin and spring locking pin (H) onto each side of rear mower bracket.
[6] -
LEGEND:
F Stud
G Bracket
Front Draft Bracket

Install stud (F) onto front draft bracket (G). Secure with spring locking pin (E).
[7] -
CAUTION:

LEGEND:
C Hole
D Sheave
Mower Drive Belt

Connect mower drive belt:
a. Install belt onto engine sheave.

b. Install 3/8 in. ratchet into square hole (C) in tension arm. Rotate counterclockwise to release tension on belt, while
installing mower belt onto left spindle sheave (D). Make sure belt is properly seated on all sheaves.
[8] - Install foot plate.

Remove Mower Deck (42C) (S.N. 130001- )

LEGEND:
A Pin
B Handle
C Bolt
Deck Lift Handle
[3] -
CAUTION:
[5] - Remove bolt (C) to remove foot plate.
[6] -
CAUTION:
LEGEND:
D Bolts
E Shield
F Hole
G Sheave
Mower Drive Belt


a. Remove two bolts (D) and remove right hand spindle shield (E).
b. Install 3/8-inch ratchet into square hole (F) in tension arm. Rotate counterclockwise to release tension on belt, while
removing mower belt from right spindle sheave (G).
c. Remove belt from engine sheave.
[7] -
LEGEND:
I Stud End
J Bracket
Front Draft Bracket

Remove spring locking pin (H) and, remove stud end (I) from front draft bracket (J).
[8] -
LEGEND:
K Spring Locking Pin
Rear Draft Bracket

Remove spring locking pin (K) and pin from each side of rear mower bracket.

[11] -
→NOTE:

Install Mower Deck (42C) (S.N. 130001- )

LEGEND:
A Pin
B Handle
C Bolt
Deck Lift Handle
[3] - Raise mower lift lever fully upward into transport lock position.
[4] - Remove two bolts to remove mower right hand spindle belt shield. Take belt out of V-sheave to allow more belt slack for
installation of belt onto clutch.
[8] -
LEGEND:
Rear Draft Bracket

Install pin and spring locking pin (K) onto each side of rear mower bracket.
[9] -

LEGEND:
I Stud
J Bracket
Front Draft Bracket

Install stud (I) onto front draft bracket (J). Secure with spring locking pin (H).
[10] -
CAUTION:
LEGEND:
D Bolts
E Shield
F Hole
G Sheave
Mower Drive Belt


b. Install 3/8 in. ratchet into square hole (F) in tension arm. Rotate counterclockwise to release tension on belt, while
installing mower belt onto right spindle sheave (G). Make sure belt is properly seated on all sheaves.
[11] - Install right hand spindle belt shield (E).

Remove Mower Deck (48TD) (S.N. -130000)

LEGEND:
A Pin
B Handle
Deck Lift Handle
[3] -
CAUTION:
[6] -
CAUTION:
LEGEND:
C Hole
D Sheave
Mower Drive Belt

a. Install 3/8-inch ratchet onto square hole (C) in tension arm. Rotate clockwise to release tension on belt, while removing
mower belt from center spindle sheave (D).
[7] -
LEGEND:
E Spring Locking Pins
F Draft Rod
G Draft Bracket
H Deck Bracket
Front Draft Bracket

Remove spring locking pins (E), and remove front draft rod (F) from draft bracket (G) and mower deck bracket (H).
[8] -
LEGEND:
I Spring Locking Pin
Rear Draft Bracket

Remove spring locking pin (I) and pin from each side of rear mower bracket.
[9] - Raise draft arms to transport position:

[11] -
→NOTE:

Install Mower Deck (48TD) (S.N. -130000)

LEGEND:
I Spring Locking Pin
Rear Draft Bracket
[3] -
CAUTION:
Raise mower lift lever fully upward into transport lock position.
[5] - Lower mower lift lever, and install pin and spring locking pin (I) onto each side of rear mower bracket.
[6] -
LEGEND:
E Spring Locking Pins
F Draft Rod
G Draft Bracket
H Deck Bracket
Front Draft Bracket

Install front draft rod (F) onto mower deck bracket (H) and onto draft bracket (G). Secure each stud end with spring locking pin
(E).
[7] -
CAUTION:

LEGEND:
C Hole
D Sheave
Mower Drive Belt


→NOTE:
Left and right spindle sheaves are hidden by belt covers. Failure to seat belt properly on sheaves
can result in belt damage.
Install 3/8-inch ratchet into square hole (C) in tension arm. Rotate clockwise to release tension on belt, while installing
mower belt onto center spindle sheave (D). Make sure belt is properly seated on all sheaves.

Remove Mower Deck (48TD) (S.N. 130001- )

LEGEND:
A Pin
B Handle
C Bolt
Deck Lift Handle
[3] -
CAUTION:
[6] -
CAUTION:
LEGEND:
D Hole
E Sheave
Mower Drive Belt

a. Install 3/8-inch ratchet into square hole (D) in tension arm. Rotate clockwise to release tension on belt, while removing
mower belt from center spindle sheave (E).
[7] -
LEGEND:
F Spring Locking Pin
G Stud End
H Bracket
Front Draft Bracket

Remove spring locking pin (F) and, remove stud end (G) from front draft bracket (H).
[8] -
LEGEND:
Rear Draft Bracket

Remove spring locking pin (K) and pin from each side of rear mower bracket.

[11] -
→NOTE:

Install Mower Deck (48TD) (S.N. 130001- )

LEGEND:
Rear Draft Bracket
[3] -
CAUTION:
Raise mower lift lever fully upward into transport lock position.
[5] - Lower mower lift lever, and install pin and spring locking pin (K) onto each side of rear mower bracket.
[6] -
LEGEND:
G Stud End
H Bracket
Front Draft Bracket

Install front draft rod onto mower deck bracket (H). Secure stud end (G) with spring locking pin (F).
[7] -
CAUTION:

LEGEND:
D Hole
E Sheave
Mower Drive Belt


→NOTE:
Left and right spindle sheaves are hidden by belt covers. Failure to seat belt properly on sheaves
can result in belt damage.
Install 3/8-inch ratchet into square hole (D) in tension arm. Rotate clockwise to release tension on belt, while installing
mower belt onto center spindle sheave (E). Make sure belt is properly seated on all sheaves.

Replace Mower Drive Belt (42C) (S.N. -130000)

LEGEND:
A Bolts
B Cover
C Bolt
D Sheaves
Left Belt Shield
Belt Guide and Sheaves
[3] - Remove mower deck. (See Remove Mower Deck (42C) (S.N. -130000) .)
[4] -
CAUTION:
Remove drive belt:
a. Remove two bolts (A) and left belt cover (B).

b. Loosen bolt (C) on belt guide.
c. Loosen hardware on two sheaves (D), and remove belt from all sheaves.
[5] - Inspect belt for wear or damage; replace as necessary.
[6] - Clean top surface of mower deck and sheaves.
[7] - Install belt on mower deck as shown.
[8] - Install and tighten bolt (C) on belt guide.
[9] -

LEGEND:
E Belt Guide
F Hole
G Arm
Shown without sheave for clarity only.

Make sure that the belt guide (E) is indexed properly into hole (F) on tension arm (G).
[10] - Tighten sheave hardware to specification.

42C Deck Sheave Nut and Sheave Bolt Torque 47 N·m
(35 lb.-ft.)
[11] - Make sure that the belt is properly seated on all sheaves, and install belt shield.
[12] - Install mower deck. (See Install Mower Deck (42C) (S.N. -130000) .)

Replace Mower Drive Belt (42C) (S.N. 130001- )

LEGEND:
A Bolts
B Shields
C Bolt
D Sheaves
Belt Shields
Belt Guide and Sheaves
[3] - Remove mower deck. (See Remove Mower Deck (42C) (S.N. 130001- ) .)
[4] -
CAUTION:
Remove drive belt:
a. Remove four bolts (A) and belt shields (B).

b. Loosen bolt (C) on belt guide.
c. Loosen hardware on two sheaves (D), and remove belt from all sheaves.
[8] - Install and tighten bolt (C) on belt guide.
[9] -

LEGEND:
E Belt Guide
F Hole
G Arm

Make sure that the belt guide (E) is indexed properly into hole (F) on tension arm (G).
[10] - Tighten sheave hardware to specification.

42C Deck Sheave Nut and Sheave Bolt Torque 47 N·m
(35 lb.-ft.)
[11] - Make sure that the belt is properly seated on all sheaves, and install belt shield.
[12] - Install mower deck. (See Install Mower Deck (42C) (S.N. 130001- ) .)

Replace Mower Drive Belt (48TD)

LEGEND:
A Bolts
B Belt Covers
C Nut
D Bolt
Belt Covers
Remove Belt
[3] - Remove mower deck. (See Remove Mower Deck (48TD) (S.N. -130000) or Remove Mower Deck (48TD) (S.N. 130001- ) .)
[4] -
CAUTION:
Components are installed under spring tension. Wear eye protection and use proper tools when
installing and removing components with spring tension.
Remove drive belt:
Remove seven bolts (A) and left and right belt covers (B).
Loosen nut (C) and bolt (D) on sheaves, and remove belt from all sheaves.
[8] -

LEGEND:
E Belt Guide
F Hole
G Tension Arm

Make sure belt guide (E) is indexed properly into hole (F) on tension arm (G).
[9] - Tighten sheave nut (C) and bolt (D) to specification.

48TD Deck Sheave Nut and Sheave Bolt Torque 47 N·m
(35 lb.-ft.)
[10] -
IMPORTANT:
Failure to seat belt properly on sheaves may result in belt damage.
Make sure belt is properly seated on all sheaves, and install belt shields.
[11] - Install mower deck. (See Install Mower Deck (48TD) (S.N. -130000) or Install Mower Deck (48TD) (S.N. 130001- ) .)

Remove and Install Mower Blade

LEGEND:
A Nut
B Washer
C Blade
Remove Mower Blade
Remove Mower Blades
[1] -
CAUTION:
Rotating blades are dangerous. Before adjusting or servicing mower:
Disconnect spark plug wire(s) or battery negative (-) cable to prevent engine from starting
accidently.
Always wear gloves when handling mower blades or working near blades.
Park machine safely
[3] - Block mower blade with a piece of wood to prevent it from spinning.
[4] - Remove mower blade(s):
Loosen and remove nut (A), washer (B), and blade (C).
[5] - Inspect blades; sharpen, balance or replace blades as necessary. Clean and inspect deflector cup.
Install Mower Blades

LEGEND:
A Nut
B Washer
C Blade
D Spindle Shaft
Install Mower Blade
[1] - Align the splined center hole in the blade (C) with the splined spindle shaft (D) and put the blade onto the mower spindle
shaft with cutting edge toward ground.
[2] - Install washer (B), with cupped side towards blade, and install nut (A) to secure blade onto splined spindle shaft.
[3] - Block mower blade with a piece of wood to prevent spinning and tighten nut to specification.
Blade Nuts
Blade Nut Torque (12 mm) Torque 68 N·m
(50 lb.-ft.)
Blade Nut Torque (5/8 in.) Torque 88 N·m
(65 lb.-ft.)
Sharpen and Balance Blades
Sharpen Blade
LEGEND:
A Bevel
B Cutting Edge
[1] -
CAUTION:
Wear gloves when handling blade.
Clean blade.
[2] - Sharpen blade using grinder, file or power sharpener.
[3] - Do not alter original bevel (A). Blade should have 0.40 mm (0.016 in.) cutting edge (B) rather than a razor-type edge.
[4] -

Balance Blade
Put blade on nail in a vise or vertical wall stud.
[5] - Turn blade to horizontal position. If the blade is not balanced, the heavy end will drop.
[6] - Grind bevel of heavy end. Do not change blade bevel angle.

Disassemble Spindle, 42 and 48 Inch

LEGEND:
B Spindle Sheave
C Seal Ring
D Bearing
E Spacer
F Spindle Housing
G Bearing
H Seal Ring
I Spindle
J Washer
K Nut
L Lubrication Fitting
M Screws (4 used)
Spindle to Model Year 2009 shown.
CAUTION:
Wear gloves or wrap blade with rag to prevent personal injury.
IMPORTANT:
Do not install hexagon end of spindle shaft in a vise. The hexagon end of the spindle shaft may be
damaged resulting in improper blade operation.
Spindle to Model Year 2009
[1] - If only the spindle sheave nut (A) and spindle sheave (B) need to be replaced, and the spindle is still in the deck, use a
block of wood to prevent the blade from turning. Use an impact wrench to remove nut (A). Remove spindle nut and sheave.
[2] - To disassemble the spindle:
Use a block of wood to prevent the blade from turning and remove spindle sheave nut (A), spindle sheave (B), and
lubrication fitting (L).
Remove nut (K), washer (J), and blade.
Remove four screws (M) securing spindle housing to deck.
Pull spindle shaft (I) out of spindle housing.
Remove seal rings (C and H).
→NOTE: Remove bearings only if replacement is necessary.
Bearings (D and G) are seated against spindle hub shoulder and cannot be removed with a press. Remove bearings using
a punch.
Remove spacer (E).
[3] - Inspect all parts for wear or damage. Replace parts as necessary.

LEGEND:
B Spindle Sheave
C Seal Ring
D Bearing
E Spindle Housing
F Spacer
G Bearing
H Lubrication Fitting
I Spindle
J Deflector Cup
K Washer
L Nut
M Nuts (4 used)
Spindle Starting Model Year 2010 shown.
Spindle Starting Model Year 2010
[1] - If only the spindle sheave nut (A) and spindle sheave (B) need to be replaced, and the spindle is still in the deck, use a
block of wood to prevent the blade from turning. Use an impact wrench to remove nut (A). Remove spindle nut and sheave.
[2] - To disassemble the spindle:
Use a block of wood to prevent the blade from turning and remove spindle sheave nut (A), spindle sheave (B), and
lubrication fitting (H).
Remove blade nut, washer, and blade.
Remove four screws or nuts securing spindle housing to deck.
Pull spindle shaft and seal rings out of spindle housing.
Remove seal rings (C and H).
→NOTE: Remove bearings only if replacement is necessary.
Bearings (D and G) are seated against spindle hub shoulder and cannot be removed with a press. Remove bearings using
a punch.
Remove spacer.
[3] - Inspect all parts for wear or damage. Replace parts as necessary.

Assemble Spindle, 42 and 48 Inch

LEGEND:
B Spindle Sheave
C Seal Ring
D Bearing
E Spacer
F Spindle Housing
G Bearing
H Seal Ring
I Spindle
J Washer
K Nut
L Lubrication Fitting
M Screws (4 used)
Spindle to Model Year 2009 shown.

LEGEND:
B Spindle Sheave
C Seal Ring
D Bearing
E Spindle Housing
F Spacer
G Bearing
H Lubrication Fitting
I Spindle
J Deflector Cup
K Washer
L Nut
M Nuts (4 used)
Spindle Starting Model Year 2010 shown.
CAUTION:
Wear gloves or wrap blade with rag to prevent personal injury.
IMPORTANT:
If bearing has an open side, the open side should orient to inside of spindle.
[1] - Press top bearing into spindle housing, install spacer, press second bearing into housing.
[2] - Install seal ring(s) and spindle.
[3] - Install blade. (See Remove and Install Mower Blade .)

MISCELLANEOUS REPAIR (g) by Belgreen v2.0
[4] - Position spindle housing into deck from the bottom, attach with mounting hardware. Tighten screws or nuts to
specification.
Spindle Mounting Cap Screws Torque 30 N·m
(22 lb.-ft.)
Spindle Mounting Nuts Torque 30 N·m
(22 lb.-ft.)
[5] - Place spindle sheave (B) onto end of spindle and secure with nut (A). While holding blade nut, tighten spindle nut to
specification.
Spindle Sheave Nut Torque 115 N·m
(85 lb.-ft.)
[6] - Loosen blade nut and retighten to specification.

Blade Nut (12 mm) Torque 68 N·m
(50 lb.-ft.)
Blade Nut (5/8 in.) Torque 88 N·m
(65 lb.-ft.)

Section 70 - MISCELLANEOUS REPAIR

Table of contents
Fuel System Components (S.N. -130000) ............................................................................................. 2
Fuel System Components (S.N. 130001-170000) ................................................................................. 4
Fuel System Components (S.N. 170001- ) ............................................................................................ 5
Park Brake Components (S.N. -130000) ............................................................................................... 6
Park Brake Components (S.N. 130001- ) .............................................................................................. 7
Muffler and Heat Shield, Single Cylinder .............................................................................................. 8
Muffler and Heat Shield, V-Twin (S.N. -120000) ................................................................................... 9
Muffler and Heat Shield, V-Twin (S.N. 120001-130000) ..................................................................... 10
Muffler and Heat Shield, V-Twin (S.N. 130001- ) ................................................................................ 10
Seat and Pan Components (S.N. -130000) ......................................................................................... 11
Seat and Pan Components (S.N. 130001- ) ........................................................................................ 12
Group 20 - Repair ................................................................................................................................... 13
Specifications ..................................................................................................................................... 13
Remove and Install Seat (S.N. -130000) ............................................................................................. 13
Remove and Install Seat (S.N. 130001- ) ............................................................................................ 14
Remove and Install Control Console (S.N. -130000) ........................................................................... 16
Remove and Install Control Panel (S.N. -130000) ............................................................................... 16
Repair Park Brake (S.N. -130000) ....................................................................................................... 18
Repair Park Brake (S.N. 130001- ) ...................................................................................................... 21
Remove and Install Foot Plate (S.N. -130000) .................................................................................... 23
Remove and Install Foot Plate (S.N. 130001- ) ................................................................................... 23
Remove Engine Guards (S.N. -130000) .............................................................................................. 24
Remove Engine Guards (S.N. 130001- ) ............................................................................................. 24
Front Caster Wheels (S.N. -130000) ................................................................................................... 26
Front Caster Wheels (S.N. 130001- ) .................................................................................................. 29

Section 70 - MISCELLANEOUS REPAIR Group 10: Component Location

Fuel System Components (S.N. -130000)
Fuel System Components (S.N. 130001-170000)
Fuel System Components (S.N. 170001- )
Park Brake Components (S.N. -130000)
Park Brake Components (S.N. 130001- )
Muffler and Heat Shield, Single Cylinder
Muffler and Heat Shield, V-Twin (S.N. -120000)
Muffler and Heat Shield, V-Twin (S.N. 120001-130000)
Muffler and Heat Shield, V-Twin (S.N. 130001- )
Seat and Pan Components (S.N. -130000)
Seat and Pan Components (S.N. 130001- )

Fuel System Components (S.N. -130000)
Fuel System
LEGEND:
A Cap
B Filler Neck
C Retainer
D Hose Clamp (2 used)
E Hose
F Hose

G Pad (2 used)
H Valve
I Bushing
J Tank
K Pickup Tube
L Bushing
M Bracket, Rear
N Bracket, Front
O Screw

Fuel System Components (S.N. 130001-170000)
Fuel System
LEGEND:
A Hose
B Hose
C Hose Clamp
D Pickup Tube
E Cap
F O-ring
G Tank

Fuel System Components (S.N. 170001- )
Fuel System Components S.N. 170001-

LEGEND:
A Hose
B Hose
C Hose Clamp
D Pickup Tube
E Cap
F O-ring
G Tank
H Low Fuel Thermistor

Park Brake Components (S.N. -130000)
Park Brake
LEGEND:
A Park Brake Control
B Hex Head Bolt, M6X16
C Switch
D Drilled Pin
E Cable Assembly
F Locknut, M8
G Hex Head Bolt, M8X20
H Right Hand Park Brake Actuator
I Spring Lock
J Left Hand Park Brake Actuator

Park Brake Components (S.N. 130001- )
Park Brake
LEGEND:
A Park Brake Handle
B Brake Handle Support
C Screw, M5
D TORX Screw, M5
E Cable Assembly
F Spring
G Brake Actuator Link
H Grommet

Muffler and Heat Shield, Single Cylinder
Muffler and Heat Shield (Single Cylinder)

LEGEND:
A Muffler
B Screw, M8x75
C Washer
D Screw
E Heat Shield
F Screw, M6x12
G Lock Nut
H Flange Nut
I Screw, M6x16
J Heat Shield
K Screw, M6x12

Muffler and Heat Shield, V-Twin (S.N. -120000)
Muffler and Heat Shield (V-Twin)

LEGEND:
A Muffler
B Screw, M8x75
C Washer
D Screw
E Heat Shield
F Screw, M6x12
G Lock Nut
H Flange Nut
I Screw
J Heat Shield

Muffler and Heat Shield, V-Twin (S.N. 120001-130000)

LEGEND:
A Muffler
B Heat Shield
C Screw
D Heat Shield
E Flange Nut
F Screw
Muffler and Heat Shield, V-Twin (S.N. 130001- )

LEGEND:
A Muffler
B Heat Shield

Seat and Pan Components (S.N. -130000)
Seat and Pan

LEGEND:
A Seat
B Arm Rest (Z245)
C Screw, M10x20
D Compression Spring
E Screw
F Washer
G Bolt
H Plug
I Bolt
J Lock Nut, M10
K Pan
L Latch
M Lock Nut, M8
N Spring
O Bolt
P Seat Slide Track Kit
Q Nut

Section 70 - MISCELLANEOUS REPAIR Group 20: Repair
Seat and Pan Components (S.N. 130001- )
Seat and Pan

LEGEND:
A Seat
B Arm Rest (Z255)
C Screw
D Screw
E Compression Spring
F Bracket
G Bolt
H Pivot Pin
I Seat Pan

Group 20 - Repair
Remove and Install Seat (S.N. -130000)
Remove and Install Seat (S.N. 130001- )
Remove and Install Control Console (S.N. -130000)
Remove and Install Control Panel (S.N. -130000)
Repair Park Brake (S.N. -130000)
Repair Park Brake (S.N. 130001- )
Remove and Install Foot Plate (S.N. -130000)
Remove and Install Foot Plate (S.N. 130001- )
Remove Engine Guards (S.N. -130000)
Remove Engine Guards (S.N. 130001- )
Front Caster Wheels (S.N. -130000)
Front Caster Wheels (S.N. 130001- )
Specifications
Park Brake Lever Application Force (nominal) 44 N
(10 lb.)
Park Brake Clearance 0.55—1.0 mm
(0.020—0.040 in.)
Wheel Lug Torque 105 N·m
(75 lb.-ft.)
Wheel Caster Lock Nut Torque 47 N•m
(35 lb-ft)
Yoke Flange Bolt Torque 47 N•m
(35 lb-ft)
Tire Pressure
Front Tire (S.N. -130000) Pressure 69 kPa
(10 psi)
Front Tire (S.N. 130001-) Pressure 205 kPa
(30 psi)
Rear Tire Pressure 69 kPa
(10 psi)
Remove and Install Seat (S.N. -130000)

LEGEND:
A Bolt
B Seat Switch
C Platform Assembly
Platform Assembly
Remove

[2] - Adjust seat to the fully rearward position.
[3] - Raise seat platform assembly (C).
[4] - Disconnect connector at seat switch (B).
[5] - Remove four bolts (A) retaining seat to base (B) onto platform.
[6] - Remove seat.
Install
LEGEND:
A Bolt
B Seat Switch
C Platform Assembly
Platform Assembly
[1] - Raise seat platform assembly (C).
[2] - Adjust seat platform to the fully rearward position.
[3] - Align seat with holes in platform. Install four bolts (A) securing seat.
[4] - Route harness connector up and onto seat switch (B).
[5] - Lower seat.
Remove and Install Seat (S.N. 130001- )

LEGEND:
A Seat Switch
B Bolts
C Seat Pan
Seat
Remove
[2] - Rotate seat forward.
[3] - Disconnect connector at seat switch (A).
[4] - Remove four bolts (B) retaining seat to seat pan (C).
[5] - Remove seat.
Install
LEGEND:
A Seat Switch
B Bolts
C Seat Pan
Seat
[1] - Align seat with holes in seat pan (C). Install four bolts (B) securing seat.
[2] - Route harness connector up and onto seat switch (A).
[3] - Lower seat.

Remove and Install Control Console (S.N. -130000)

LEGEND:
A Bolt
Control Console to Frame
Control Console to Frame
Remove
[2] - Disconnect negative battery cable.
[3] - Remove 4 bolts (A) securing control console to frame. Remove control console assembly and move to the side of the
machine.
[4] - If the console is to be completely removed, disconnect cables and wiring at console.
Install
Installation is the reverse of removal.

Remove and Install Control Panel (S.N. -130000)

LEGEND:
A Bolt
Control Panel to Console
Removal:
[2] - Disconnect negative battery cable.
[3] - Remove bolt (A) securing control panel to console.
[4] - If control panel is to be completely removed, disconnect cables and wiring at console.
Installation:
Installation is the reverse of removal.

Repair Park Brake (S.N. -130000)

LEGEND:
A Control Cable
B Control Cable
C Sheath Entrance
D Hex Nut
E Bolt
F Cable Bracket
G Retainer
H Drilled Pin
I Control Lever Link
Park Brake Control Cable
Park Brake Controls

Remove left fender and control console for access to park brake control and cable assemblies.
[1] -
→NOTE:
Left side fender and control console has throttle and wiring harness components attached. Exercise care
when removing and relocating fender assembly so as not to damage these components.
[4] - Remove rear wheels for access to park brakes.
[5] -
→NOTE:
Failure of park brakes to release may have several causes. Investigate the cause of service problems to
determine remedy. If a park brake cable is damaged or broken, cables are replaced as an assembly.
Apply and release park brake control while watching brake control components to determine problem areas.
[6] - Remove left fender and control console for access to park brake components. (See Remove and Install Control Console
(S.N. -130000) .)
[7] - Rotate seat assembly forward.
[8] - Lift fender assembly and position assembly on top of engine and seat location. Exercise care so as not to damage throttle
or wiring harness components attached to the fender assembly.
[9] - If service problems result from sticking of left or right park brake control cable (A) or (B), lubricate cable(s) at upper cable
sheath entrance (C).
[10] - If service problems result from bent or broken park brake control cable, replace cable assembly
[11] - At park brake cable control end, remove hex nut (D) and hex head bolt (E) securing cable bracket (F).
[12] - Remove retainer (G) and drilled pin (H) securing cables (A) and (B) to control lever link (I).
[13] -

LEGEND:
J Retainer
K Tension Spring
L Actuating Arm
Park Brake Cable Tension Spring

Remove retainer (J) securing park brake cable tension spring (K) to brake actuating arm (L).
[14] - Remove tension spring from brake actuating arm.
[15] -
LEGEND:
M Cable Housing Ferrule
N Engine Platform
O Platform Slot
P Platform Hole
Park Brake Cable Housing Ferrule

Grasp park brake cable housing ferrule (M) and pull upward, removing ferrule from engine platform (N).
[16] - Slide park brake cable through platform slot (O) toward platform hole (P).
[17] - Withdraw park brake cable and tension spring assembly through platform hole (O).
[18] - Repeat park brake cable removal procedure for opposite side assembly.
[19] - Install new park brake control cable assembly in reverse order of removal.
[20] - Engage park brake control and check for proper function.
(10 lb.)
[21] - Disengage park brake control and check park brake for clearance within specification.
Park Brake Clearance 0.55—1.0 mm
(0.020—0.040 in.)


Wheel Lug Torque 105 N·m
(75 lb.-ft.)
[26] - Adjust park brake. (See Adjust Park Brake (S.N. -130000) .)

Repair Park Brake (S.N. 130001- )

LEGEND:
A Retainer
B Connector
C Pivot Pins
D Panels
Seat and Access Panels
Park Brake Control
[3] - Raise and support rear of machine.
[4] - Rotate seat assembly forward. Release harness retainer (A) and disconnect seat switch connector (B).
[5] - Remove seat by pulling pivot pins (C).
[6] - Remove access panels (D).
[7] -
LEGEND:
E Slot
F Handlebars
G Rivets
H Panel
Style Panel
Slide harness through slot (E) in panel and place in storage compartment.
[8] - Remove one of the handlebars (F), tube portion only, from the steering controls.
[9] - Remove seven rivets (G) and lift off style panel (H).
[10] -
→NOTE:
Failure of park brakes to release can have several causes. Investigate the cause of service problems to
determine remedy. Replace park brake cable if damaged or broken.
Apply and release park brake control while watching brake control components to determine problem areas.
[11] - If service problems result from bent or broken park brake control cable, replace cable assembly.
[12] -

LEGEND:
I Screws
J Bracket
K Screw
L Retainer
M Handle
N Cable End
Park Brake Handle

Remove two screws (I) that hold cable assembly bracket (J) to plastic frame piece. Pull up bracket to free it from frame.
[13] - Remove one screw (K) that holds park brake handle retainer (L). Remove retainer.
[14] - Pull handle (M) forward and remove cable end (N) from handle.
[15] -
LEGEND:
O Brake Link
P Cable End
Park Brake Link

Remove PTO clutch.
[16] - Pull brake link (O) rearward to disengage from transmissions
[17] - Detach brake link from cable by sliding cable end (P) off brake link.
[18] -
LEGEND:
Q Ferrule
R Engine Pan
Brake Cable to Engine Pan

Grasp park brake cable housing ferrule (Q) and pull sharply upward, removing ferrule from engine pan (R). Cable end passes
between the plastic frame and engine pan.
[19] - Install new park brake control cable assembly in reverse order of removal.
[20] - Engage park brake control and check for proper function.

(22 lb.)
Remove and Install Foot Plate (S.N. -130000)

LEGEND:
A Mat
B Bolt
C Finger Pull
D Tabs
Mower Deck Foot Plate
Remove:
[2] - Remove foot plate mat (A).
[3] - Remove hex head bolt (B) securing foot plate to frame.
[4] - Grasp finger pull (C) and rotate foot plate forward.
Install:
[1] - Place tabs (D) of foot plate into slots in frame and lower plate to installed position.
[2] - Replace and tighten hex head bolt (B).
[3] - Replace foot plate mat (A).
Remove and Install Foot Plate (S.N. 130001- )

LEGEND:
A Bolt
B Finger Pull
C Tabs
Mower Deck Foot Plate
Remove:

[2] - Remove bolt (A).
[3] - Rotate foot plate up using finger pull (B).
Install:
[1] - Place tabs (C) of foot plate into slots in frame.
[2] - Lower foot plate.
[3] - Install bolt (A).
Remove Engine Guards (S.N. -130000)

LEGEND:
A Bolt
Upper Engine Guard
[1] - Park machine safely and allow to cool.
[2] - Remove bolts (A) from upper engine guard and remove guard.
[3] -
LEGEND:
B Bolt
C Bolt
Engine Guard Bolts and Nuts

On each side of machine, remove bolts (B) and (C) and nuts.
[4] - Remove lower engine guard.
Remove Engine Guards (S.N. 130001- )

LEGEND:
A Nuts
B Tabs
Engine Guard Nuts
[1] - Park machine safely and allow the engine to cool.
[2] - Remove nuts (A) on each side of the machine.
[3] - Lift up on the engine guard assembly to remove from frame..
[4] - Tilt the top of the engine guard assembly back to disengage tabs (B) from muffler heat shield.
[5] - Remove engine guard assembly.

Front Caster Wheels (S.N. -130000)

Disassemble:
LEGEND:
A Bolt
B Cap
Caster Assembly
[2] - Jack up front of machine and place on safety stands.
[3] - Support caster assembly and remove flange bolt (A) and cap (B).
[4] - Remove caster from machine.
[5] -
LEGEND:
C Bearing
Inspect Bearing
Inspect bearings (C) at top and bottom of frame. Replace worn or damaged bearings.
[6] -

LEGEND:
D Nut
E Wheel Assembly
Caster Wheel Bolt

Remove nut (D) and pull bolt out of caster.
[7] - Remove wheel assembly (E).
[8] -
LEGEND:
F Shield
G Bearing
Caster Wheel Shield and Bearing

Remove shield (F) and bearing (G). Inspect shields, wheel, and bearings for wear or damage. Replace worn or damaged parts.
[9] -
LEGEND:
H Bearing Wear Areas
I Bolt Holes
Bearing Wear Areas

Inspect bearing wear areas (H), and bolt holes (I) for wear or damage. Replace if necessary.
Assemble:
Apply grease to caster shaft and bolt before assembling.

Assemble in the reverse order of disassembly.
Tighten caster lock nut and bolt to specification.

Front Caster Wheel Lock Nut Torque 47 N•m
(35 lb-ft)
Tighten flange bolt securing yoke to specification.

Front Caster Yoke Flange Bolt Torque 47 N•m
(35 lb-ft)

Front Caster Wheels (S.N. 130001- )

Disassemble:
LEGEND:
A Bolt
B Cap
C Bushings
D Nut
E Wheel
Front Caster Assembly
[2] - Jack up front of machine and place on safety stands.
[3] - Support caster assembly and remove flange bolt (A) and cap (B).
[4] - Remove caster from machine.
[5] - Inspect bushings (C) at top and bottom of frame. Replace worn or damaged bushings.
[6] - Remove nut (D) and pull bolt out of caster.
[7] - Remove wheel assembly (E).
[8] -
LEGEND:
F Shield
G Bearing
Caster Wheel Shield and Bearing

Remove shield (F) and bearing (G). Inspect shields, wheel, and bearings for wear or damage. Replace worn or damaged parts.
[9] -

SINGLE CYLINDER DIAGNOSIS, TESTS, AND ADJUSTMENTS (g) by Belgreen v2.0
LEGEND:
H Bushing Wear Areas
I Bolt Holes
Bushing Wear Areas

Inspect bushing wear areas (H), and bolt holes (I) for wear or damage. Replace if necessary.
Assemble:
Apply grease to caster shaft and bolt before assembling.

Assemble in the reverse order of disassembly.
Tighten caster lock nut and bolt to specification.
Front Caster Wheel Lock Nut Torque 47 N•m
(35 lb-ft)
Tighten flange bolt securing yoke to specification.

Front Caster Yoke Flange Bolt Torque 47 N•m
(35 lb-ft)

Section 220 - SINGLE CYLINDER DIAGNOSIS, TESTS, AND

ADJUSTMENTS
Table of contents
Group 10 - Diagnosis ............................................................................................................................... 1
Diagnose Engine Starting (Single Cylinder) .......................................................................................... 1
Diagnose Carburetor, Air, Fuel (Single Cylinder) .................................................................................. 2
Engine Will Not Crank (Single Cylinder) ................................................................................................ 3
Engine Cranks But Will Not Start (Single Cylinder) ............................................................................... 4
Engine Runs Erratically (Single Cylinder) .............................................................................................. 5
Engine Runs Then Dies (Single Cylinder) .............................................................................................. 5
Engine Backfires or Misses (Single Cylinder) ........................................................................................ 5
Engine Overheats (Single Cylinder) ...................................................................................................... 5
Engine Has Loss of Power (Single Cylinder) .......................................................................................... 7
Group 20 - Tests and Adjustments ........................................................................................................ 8
Specifications ....................................................................................................................................... 8
Adjust Throttle and Choke Cable .......................................................................................................... 9
Test Fuel Shutoff Solenoid .................................................................................................................. 10
Adjust Governor - Static ..................................................................................................................... 10
Adjust Governor - Dynamic ................................................................................................................. 12
Adjust Governed Idle .......................................................................................................................... 13
Adjust Low Idle ................................................................................................................................... 14
Adjust Valve Clearance ....................................................................................................................... 15
Adjust Armature Air Gap ..................................................................................................................... 16
Test Crankcase Vacuum ..................................................................................................................... 17
Test Cylinder Leakdown ..................................................................................................................... 19

Section 220 - SINGLE CYLINDER DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 10: Diagnosis
Diagnose Engine Starting (Single Cylinder)
CAUTION:
The engine may start to rotate at any time. Keep hands away from all moving parts when testing.
CAUTION:
Do not rotate engine with starter if the spark plug is removed. Gasoline spray from the open cylinder
may be ignited by ignition spark and cause an explosion or fire.
→NOTE:
To test specific electrical components, see Electrical section and refer to either Diagnostics or Tests and
Adjustments for further guidance.
→NOTE:
Perform a visual inspection first to determine if battery cables are tight and not corroded. The battery
must be sufficient size to turn the engine over at minimum cranking speed of 350 rpm.

Diagnose Carburetor, Air, Fuel (Single Cylinder)

Defects in carburetors would be apparent very early in the life of the engine. The majority of fuel system problems are related
to stale or improper fuel or dirt. This section is to help you diagnose fuel system problems.
Other engine failures such as plugged exhaust or improper valve clearance can cause symptoms similar to faulty fuel supply.
Verify the quality of the engines mechanical and electrical systems.
Initial Checklist
How old is the fuel?

Does the fuel have a foul smell?
Is the fuel cloudy, dark or dirty?
Is the fuel tank cap air vent clean and open?
Is a clean, correct air filter installed?
Has the ignition system been verified?
Is the air filter and carburetor attached properly?
Is the intake manifold loose and/or leaking?
Is the fuel shutoff solenoid operating properly?
Is the governor throttle linkage moving properly?
Is the float operating properly?
If the carburetor is externally vented, is the vent line unrestricted?
Engine Surge
An engine that surges may have an improper air/fuel mixture or a misadjusted or worn governor.
Attempt to manually control the throttle at low and high idle to determine which system is causing the surge. If the engine
speed can be held constant check the governor system. If the engine surge cannot be controlled manually, check the fuel
system.
Fuel system issues may consist of:
Improper air/fuel mixture caused by air leaks around the throttle shaft, intake and/or insulator gaskets.
Minor restrictions inside the carburetor passages from varnish and debris buildup in the idle circuit. Properly cleaning the
carburetor will likely fix the problem.
Rich Air/Fuel Mixture

There are several possible causes of a rich running condition such as: improper or stale fuel, short-tripping, air filter, choke
adjustment and/or vent tube location.
→NOTE:
Verify the ignition system. A rich running condition can have the same symptoms as an improperly
operating ignition system.
Float Valve
Fuel level in the float bowl is regulated by the float and the float valve. A worn float valve tip provides too much fuel and will
cause a rich condition.
Improper or Stale Fuel
Poor fuel quality can cause an engine to appear to be running rich. Improper or stale fuel can cause engine components to stick
or deteriorate.
Short-Tripping
A common misdiagnosis comes from short-tripping machines (engines that are started for short periods of time). Short-tripping
causes the engine to develop black, sooty spark plugs and contamination in the oil. Over time, short-tripping can lead to glazed
cylinder walls. To prevent this, every time the engine is started, allow the engine to reach operating temperature and load the
machine.
Air Filters
→NOTE:
Late model carburetors are internally vented to meet emissions standards.
Engines with externally vented carburetors with a dirty air filter will exhibit rich running conditions. When a dirty air filter

restricts air flow to the carburetor, the low pressure in the venturi drops even further, resulting in a higher pressure differential
between the fuel bowl and the venturi. Therefore, a dirty air filter can enrich the air/fuel mixture to the point that performance
will drop.
Engines with internally vented carburetors will not exhibit rich running conditions with a dirty air filter. When a dirty air filter
restricts air flow to the throat of the carburetor, an equal reduction will be applied to the bowl vent. Internally vented
carburetors maintain the pressure differential between the bowl and the venturi resulting in a consistent air/fuel mixture over
the life of the air filter.
Vent Tube Location
With an externally vented carburetor, a rich or lean run condition could also be caused by the location of the float bowl vent
tube. The purpose of the vent tube is to allow atmospheric pressure into and out of the float bowl. Air from the cooling fan at
the vent tube opening can cause a pressure increase or decrease on the fuel in the float bowl and cause the engine to run rich
or lean. Check for bulletins and relocate the float bowl vent tube to a location away from any source of turbulence.
Engine Will Not Crank (Single Cylinder)
66
Engine Will Not Crank (Single Cylinder)
Symptom Problem Solution
Engine Will Not
Battery a. Charge and test battery. (See Battery Charge , and Battery Load Test .)
Crank
b. Replace the battery if it will not take or hold a charge.
Starting motor does not rotate

a. Cranking circuit problem. (See Cranking Circuit Operation (S.N. -120000) , or Cranking Circuit Operation (S.N.
when ignition switch is turned to
120001-130000) .)
start position.
b. Key switch malfunction. (See Key Switch Test .)
c. Starting relay malfunction. (See Start Relay Test .)

Engine Cranks But Will Not Start (Single Cylinder)

66
Engine Cranks But Will Not Start (Single Cylinder)
Engine
Cranks But Engine cranks slowly. Charge and test battery. (See Battery Charge , and Battery Load Test .)
Will Not Start
Replace the battery if it will not hold a charge.
Starting motor is binding. (See the appropriate starting motor amperage draw test in the Electrical Tests and
Adjustments section.)
Poor or no spark at spark plug. Replace spark plug.
Ignition air gap incorrect. (See Adjust Armature Air Gap .)
Magneto shorted to ground, flywheel magnet weak.
Choke or throttle not adjusted

Adjust cable. (See Adjust Throttle and Choke Cable .)
properly.
Fuel supply. Check air cleaner, fuel mixture, possible contaminated fuel, or stuck float needle.
Dirty carburetor. (See Carburetor Cleaning .)
Check fuel shutoff valve, fuel lines, fuel pump, and engine vacuum.
Fuel shutoff solenoid does not open

Check fuel solenoid and ignition circuit. (See Fuel Shutoff Solenoid Test, B&S , and Ignition Interlock Circuit
when ignition switch is turned to
Operation (S.N. -120000) or Ignition Interlock Circuit Operation (S.N. 120001-130000) .)
start/run.
Valve clearance improper. Check and adjust valve clearance. (See Adjust Valve Clearance .)
Remove spark plug and drive belts. Turn the engine over by hand. If the engine is hard to turn over by hand
Internal components binding.
repair or replace engine.

Engine Runs Erratically (Single Cylinder)

66
Engine Runs Erratically (Single Cylinder)
Engine Runs
Lean fuel mixture. Check fuel cap air vent.
Erratically
Check fuel supply system.
Check carburetor for proper operation. (See Remove Carburetor , Inspect Carburetor , and Install Carburetor .)
Check for dirty or varnished carburetor. (See Inspect Carburetor , and Carburetor Cleaning .)
Check throttle and choke cable. (See Adjust Throttle and Choke Cable .)
Check for a possible air leak at the intake manifold or carburetor connections and repair as needed.
Check for debris in the idle circuit. Check to see if the problem is governor or carburetor: Hold the throttle plate
Engine does not idle properly
closed to force engine to idle. If the engine continues to run - check governor. If the engine stalls - suspect idle circuit.
(hunts or surges)
Clean idle circuit.
Engine idles, does not run

properly at wide open throttle Check for dirt between needle valve and seat. Check float bowl for dirt or corrosion. Clean bowl. Check valve tip.
(WOT)
Check for sticking float. Check float for proper adjustment.
Check air passage and pilot jet for debris or varnish. Clean carburetor. (See Carburetor Cleaning .)
Governor not moving freely or

Disassemble engine, inspect, and repair governor as needed.
out of adjustment.
Adjust governor. (See Adjust Governor - Static .)
Engine Runs Then Dies (Single Cylinder)

66
Engine Runs Then Dies (Single Cylinder)
Engine Runs
Fuel supply system. Clean fuel cap vent.
Then Dies
Check for dirt in bowl sucked into main jet. (See Inspect Carburetor .)
Drain fuel tank and lines and check for restrictions or collapsed lines. Check fuel pump. Add fresh fuel
to tank.
Check for proper operation of fuel shutoff solenoid. (See Fuel Shutoff Solenoid Test, B&S .)
Weak or discharged battery. Charge or load test battery. (See Battery Charge or Battery Load Test .)
Electrical connections on battery, starter, or

Check and tighten cables.
ignition are loose.
Engine loses spark. Check and repair ignition system to get good spark. (See Spark Test .)
Choke not being used or adjusted properly. Adjust choke linkage. (See Adjust Throttle and Choke Cable .)
Engine Backfires or Misses (Single Cylinder)

66
Engine Backfires or Misses (Single Cylinder)
Engine
Backfires Or Spark plug. Check for good spark. (See Spark Test .)
Misfires
Ignition circuit not functioning

Check plug wires, coils, and air gap. (See Adjust Armature Air Gap .)
properly.
Flywheel key damaged or sheared. Inspect key. (See Remove and Install Flywheel .)
Poor compression. Test compression. (See Test Cylinder Leakdown .)
If leakage is excessive, check for the following: loose cylinder head bolts, blown head gasket, burned valves, or
valve seats, warped cylinder head, warped valve stems. (See Inspect and Repair Cylinder Head and Reface
Valves .)
Improper valve lift. Check camshaft. (See Remove Crankshaft and Inspect Magneto and Cam Bearing .)
Fuel supply system. Check fuel lines and filter for restrictions. Check fuel pump. Check gas cap vent.
Check fuel shutoff solenoid for proper operation. (See Fuel Shutoff Solenoid Test, B&S .)
Engine Overheats (Single Cylinder)

66
Engine Overheats (Single Cylinder)
Engine Overheats Engine shroud debris. Remove shroud and clean around cooling fins.

Flywheel or fan damaged; flywheel key partially

Check flywheel, flywheel key, and fan for damage. (See Remove and Install Flywheel .)
sheared affecting timing.
Check carburetor for proper operation. (See Remove Carburetor , Inspect Carburetor and Install
Carburetor running too lean.
Carburetor .)
Also check for air leak at intake manifold.

Section 220 - SINGLE CYLINDER DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 20: Tests and Adjustments
Engine Has Loss of Power (Single Cylinder)

66
Engine Has Loss of Power (Single Cylinder)
Loss of
Oil level too high or low. Check oil level; drain or add oil to proper level.
Power
Engine is overheated. Clean debris from engine shroud and air cooling fins.
Check flywheel, flywheel key, and fan for damage. (See Remove and Install Flywheel .)
Spark plug. Check for good spark. (See Spark Test .)

Check plug wires, coils, fuses, and air gap. (See Adjust Armature Air Gap .)
properly.
Flywheel key damaged or sheared. (See Remove and Install Flywheel .)
Fuel not getting to carburetor. Check fuel lines and filter for restrictions. Check fuel pump. Check gas cap vent.
Air filter restricted. Clean or replace air filter.
Poor compression. Test compression. (See Test Cylinder Leakdown .)
valve seats, warped cylinder head, warped valve stems. (See Inspect and Repair Cylinder Head and Reface Valves
.)
Also check for worn cylinder bore or piston rings. (See Inspect Cylinder Bore and Inspect Piston and Connecting
Rod .)


Adjust Throttle and Choke Cable
Test Fuel Shutoff Solenoid
Adjust Governor - Static
Adjust Governor - Dynamic
Adjust Governed Idle
Adjust Low Idle
Adjust Valve Clearance
Adjust Armature Air Gap
Test Crankcase Vacuum
Test Cylinder Leakdown
Specifications
Throttle Cable Clamp Torque 3 N·m
(25 lb.-in.)
Governor Lever Nut Torque 4.5 N·m
(40 lb.-in.)
Engine Top No Load (High Idle) Speed 3350 ± 100 rpm
Governed Idle Speed 2200 ± 300 rpm
Carburetor Low Idle Speed 1750 ± 50 rpm
Intake Valve Clearance 0.08—0.13 mm
(0.003—0.005 in.)
Exhaust Valve Clearance 0.13—0.18 mm
(0.005—0.007 in.)
Valve Adjustment Nut Torque 7 N·m
(60 lb.-in.)
(180 lb.-in.)
(60 lb.-in.)
Armature Air Gap Gap 0.25—0.35 mm
(0.010—0.014 in.)
Armature Mounting Screws Torque 2.8 N·m
(25 lb.-in.)
Crankcase Vacuum (minimum)

Water Movement Distance 25.4 cm
(10 in.)
Hg (mercury) Movement Distance 18.7 mm
(0.74 in.)

→NOTE:
Jumper Wires
Not Applicable
To apply momentary power for tests.
Pulse Tachometer
JT07270
To measure engine speed.

Digital Tachometer
JT05719
Feeler Gauge
Not Applicable
To measure clearances.
Plug
8741-F66
To perform vacuum test.
Barbed Fitting
JTO5703
Hose
JTO5699
Vacuum Gauge
JTO3503
Adjust Throttle and Choke Cable

Reason:
To make sure the throttle cable moves the throttle and choke through its full range of movement.
Procedure:
LEGEND:
A Rod
B Clamp
Choke Control Rod
[1] - Move throttle lever all the way forward to Start (Choke) position.
[2] - Locate choke control rod (A) on right side of engine at top of throttle control plate.
[3] - With your fingers or a needle nose pliers, try and move choke rod (A) toward carburetor (top arrow).
[4] - If choke control rod moves toward carburetor, choke is not completely closing and throttle cable needs to be adjusted.
[5] - Loosen throttle cable clamp (B).

[6] - Slide the throttle cable as far as it will go to the right.
[7] - Tighten throttle cable clamp (B) to specification.

Throttle Cable Clamp Torque 3 N·m
(25 lb.-in.)
Test Fuel Shutoff Solenoid

Reason:
To test proper operation of fuel shutoff solenoid.
Procedure:
LEGEND:
A Wire
Solenoid Wire
[2] - Listen for an audible click when ignition switch is turned from OFF to ON.
Results:
If solenoid clicks when ignition switch is turned from OFF to ON, the solenoid is working properly.
If solenoid does not click, check machine wiring. (See Fuel Shutoff Circuit Operation (S.N. -120000) or Fuel Shutoff Circuit
Operation (S.N. 120001-130000)
Test solenoid. (See Fuel Shutoff Solenoid Test, B&S .)
Adjust Governor - Static

Adjustment Condition
Engine off
CAUTION:
Reason:
To remove any slack in governor linkage that would allow engine to overspeed.

Procedure:
LEGEND:
A Nut
Governor Lever Nut
[1] - Loosen governor lever pinch bolt nut (A).
[2] - Move throttle lever to HIGH.
[3] -
IMPORTANT:
Governor Lever
LEGEND:
B Arm
C Socket
Do not bend governor link or distort governor arm.
Hold governor lever (B) in HIGH position. Using a 3/16 in. socket (C), turn governor shaft clockwise until it stops.
[4] - Hold governor lever and shaft in position. Tighten governor lever pinch bolt nut to specification.
Governor Lever Nut Torque 4.5 N·m
(40 lb.-in.)

Adjust Governor - Dynamic

Full throttle, no load.
CAUTION:
Reason:
To verify the engine speed settings are within limits.
Procedure:
LEGEND:
A Tool
B Anchor
C Slots
Adjust Engine RPM
Governor Adjusting Tool
[1] - With engine running, set throttle lever to HIGH.
[2] - Measure engine rpm using JT07270 Pulse Tachometer or JT05719 Digital Tachometer.
Pulse Tachometer
JT07270
Digital Tachometer
JT05719
[3] -
IMPORTANT:
Do not bend governor link or distort governor arm.
→NOTE:
A tool can be made from a 5/16 in. Allen wrench. Slots (C) are cut into each end 6 mm (0.25 in.) across
the width of the wrench.
Insert the governor adjusting tool (A) and bend the upper governor spring anchor (B) to adjust the top no load engine rpm to
specification.
Engine Top No Load (High Idle) Speed 3350 ± 100 rpm
[4] - Bend the anchor UP (counter clockwise) to lengthen the spring and increase the rpm, or DOWN (clockwise) to shorten the
spring and reduce the engine rpm.
Adjust Governed Idle

Reason:
To set the governed idle speed.
Procedure:
LEGEND:
A Tang
B Slide
Governed Idle
[1] - Start engine and run at 1/2 throttle for 5 minutes to bring engine to operating temperature.
[2] - Move throttle lever to LOW position and check engine speed with JT07270 Pulse Tachometer or JT05719 Digital
Tachometer.
Pulse Tachometer
JT07270
Digital Tachometer
JT05719
[3] - Tang (A) is a stop for remote control slide (B). If governed idle is not within specification, bend tang (A) to the right to
increase rpm or to the left to decrease rpm. Make sure slide is against tab when checking rpms.
Governed Idle Speed 2200 ± 300 rpm

Adjust Low Idle

Reason:
To set the carburetor mixture screw for proper operation of the carburetor.
Procedure:
LEGEND:
A Tab
B Idle Speed Screw
C Idle Mixture Screw
Low Idle Speed
IMPORTANT:
To obtain correct adjustment, the procedure must be performed in the sequence shown.
[1] - Start engine. Run at 1/2 throttle for 5 minutes to bring engine to operating temperature.
[2] - Move throttle to LOW.
[3] - Hold throttle closed so that tab (A) is against idle speed screw (B). Turn idle speed screw (B) until rpm reaches
specification.
Carburetor Low Idle Speed 1750 ± 50 rpm
Use JT07270 Pulse Tachometer or JT05719 Digital Tachometer to measure rpm.

Pulse Tachometer
JT07270
Digital Tachometer
JT05719
[4] - Adjust idle mixture screw (C) slowly until best idle is obtained.
[5] - Check rpm and adjust if necessary

Adjust Valve Clearance

LEGEND:
A Cover
B Spark Plug Wire
Valve Cover Bolts
→NOTE:
Correct position of crankshaft is necessary to eliminate interference by the compression release
mechanism when adjusting valve clearance.
[1] - Park machine safely and allow engine to cool.
[2] - Remove four bolts and valve cover (A).
[3] - Disconnect spark plug wire (B) and remove spark plug.
[4] - Place thumb or finger over spark plug hole and turn crankshaft (clockwise viewed from top, counter clockwise viewed
from bottom) until air pressure is felt in spark plug hole (engine is on compression stroke).
[5] -
LEGEND:
C Spark Plug Opening
Spark Plug Opening

Insert a screwdriver through the spark plug opening (C). Slowly continue to turn the crankshaft until the piston has pushed the
screwdriver to the top of it’s stroke and has started to move down again approximately 6.35 mm (0.25 in.).
[6] -

LEGEND:
D Feeler Gauge
E Set Screw
F Nut
Valve Clearance
Check valve clearance with a feeler gauge (D) between valve stem and rocker arm.
[7] - If not within specification, adjust as necessary by loosening set screw (E) and adjusting nut (F) until slight drag is felt on
feeler gauge.
Intake Valve Clearance 0.08—0.13 mm
(0.003—0.005 in.)
Exhaust Valve Clearance 0.13—0.18 mm
(0.005—0.007 in.)
Hold nut with wrench and tighten set screw to specification.

Valve Adjustment Nut Torque 7 N·m
(60 lb.-in.)
[8] - Recheck clearance and make adjustments if necessary.
[9] - Install spark plug and tighten to specification.

(180 lb.-in.)
[10] - Install valve cover with new gasket. Tighten screws to specification.
(60 lb.-in.)
Adjust Armature Air Gap

Reason:
To set the ignition air gap for proper operation.
Procedure:

LEGEND:
A Magnet
B Screws
C Gauge
Armature Air Gap
[1] - Remove blower housing.
[2] - Rotate flywheel until magnet (A) is away from armature.
[3] - Loosen the armature mounting screws (B). Slide armature away from flywheel as far as possible.
[4] - Tighten one screw enough to hold the armature in place.
[5] - Rotate flywheel until magnet is directly under armature.
[6] - Place a 0.30 mm (0.012 in.) feeler gauge (C) between armature and magnet.
[7] - Loosen the mounting screw so magnet will pull armature against feeler gauge and bring air gap into specification.
(0.010—0.014 in.)
[8] - Tighten both mounting screws (B) to specification.

Armature Mounting Screws Torque 2.8 N·m
(25 lb.-in.)
[9] - Rotate flywheel while pulling feeler gauge out from between the armature and the magnet.
Test Crankcase Vacuum

Reason:
To determine operation of breather, condition of seals, gaskets, rings, piston, and cylinder wall.
Equipment
JT03503 Crankcase Vacuum Test Kit
Procedure:
[2] - Raise hood and remove oil dipstick.
[3] - Place Plug and Barbed Fitting in dipstick tube until tight.
[4] - Cover barbed fitting with a plug or finger and start engine.
[5] - Quickly remove plug or finger from barbed fitting and attach Hose and Vacuum Gauge

[6] - Run engine at HIGH idle and record reading on gauge.
[7] - Run engine at LOW idle. Do not turn engine off.
[8] - Disconnect hose and quickly place plug or finger over barbed fitting.
[9] - Turn engine off.
[10] - Remove plug and install oil dipstick.
Results:
If crankcase vacuum is less than specification, check:


(10 in.)
(0.74 in.)
Breather reed valve clearance and condition.

Seals and gaskets for leakage.
Valve cover gasket for leakage.
Rings, piston and cylinder wall for wear or damage.
Valve and valve seats for wear or damage.
Head warp.

V-TWIN ENGINE DIAGNOSIS, TESTS, AND ADJUSTMENTS (g) by Belgreen v2.0
Test Cylinder Leakdown

Reason:
To check sealing of piston rings and cylinder bore.
Procedure:
[2] -
CAUTION:
Touching hot surfaces can burn skin. The engine, components, and fluids will be hot if the engine has
been running. Keep hands and body away from hot surfaces when servicing or working near the engine
and components.
Warm engine to operating temperature, then stop engine.
[3] - Remove valve cover bolts (A) and valve cover. Remove spark plug wire (B) and spark plug (C).
[4] -
CAUTION:
Before attaching adapter hose to tester, make sure another person is holding on tight to the breaker bar
and the engine is at TDC. When compressed air is applied, there will be considerable torque forcing
piston and crankshaft to turn.
With adapter hose disconnected, attach hose from air source to tester and adjust regulator knob (D) until needle on gauge is in
the set zone.
[5] - With another person holding firmly to breaker bar, connect adapter hose (E) to tester. Watch and record gauge reading
while listening for air leaks at carburetor inlet and exhaust outlet. Pressure should hold steady or reduce only slightly
[6] - Remove test equipment and install spark plug. Tighten spark plug to specification.
(180 lb.-in.)
[7] - Install valve cover with new gasket. Tighten screws to specification.
(60 lb.-in.)
Results:
→NOTE: A small amount of air escaping from the crankcase breather is normal.
Excessive air escaping from the crankcase breather indicates worn piston rings or cylinder wall, or a leaking head gasket.
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. The engine is still usable but an overhaul
should be considered.
Gauge reading in the Red (high) area indicates excessive compression loss. Engine overhaul is necessary.

Section 230 - V-TWIN ENGINE DIAGNOSIS, TESTS, AND ADJUSTMENTS

Table of contents
Group 10 - Diagnosis ............................................................................................................................... 1
Diagnose Engine Starting, V-Twin ........................................................................................................ 1
Diagnose Carburetor, Air and Fuel, V-Twin ........................................................................................... 2
Engine Will Not Crank, V-Twin .............................................................................................................. 3
Engine Cranks But Will Not Start, V-Twin .............................................................................................. 4
Engine Runs Erratically, V-Twin ............................................................................................................ 5
Engine Runs Then Dies, V-Twin ............................................................................................................ 5
Engine Backfires or Misses, V-Twin ....................................................................................................... 5
Engine Overheats, V-Twin .................................................................................................................... 5
Engine Has Loss of Power, V-Twin ........................................................................................................ 7
Specifications ....................................................................................................................................... 9
Adjust Throttle and Choke Cable, V-Twin ........................................................................................... 10
Test Fuel Shutoff Solenoid, V-Twin ..................................................................................................... 11
Adjust Governor - Static, V-Twin ......................................................................................................... 12
Adjust Governor - Dynamic, V-Twin (S.N. -130000) ............................................................................ 13
Adjust Governor - Dynamic, V-Twin (S.N. 130001- ) ........................................................................... 16
Test Crankcase Vacuum, V-Twin ........................................................................................................ 19
Test Cylinder Leakdown, V-Twin ......................................................................................................... 20
Test Cylinder Balance, V-Twin ............................................................................................................ 22
Adjust Armature Air Gap, V-Twin ........................................................................................................ 23
Adjust Valve Clearance, V-Twin .......................................................................................................... 25
Test Engine Oil Pressure, V-Twin ........................................................................................................ 27

Section 230 - V-TWIN ENGINE DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 10: Diagnosis
Diagnose Engine Starting, V-Twin
CAUTION:
The engine may start to rotate at any time. Keep hands away from all moving parts when testing.
CAUTION:
Do not rotate engine with starter if the spark plug is removed. Gasoline spray from the open cylinder
may be ignited by ignition spark and cause an explosion or fire.
→NOTE:
To test specific electrical components, see Electrical section and refer to either Diagnostics or Tests and
Adjustments for further guidance.
→NOTE:
Perform a visual inspection first to determine if battery cables are tight and not corroded. The battery
must be sufficient size to turn the engine over at minimum cranking speed of 350 rpm.

Diagnose Carburetor, Air and Fuel, V-Twin

Defects in carburetors would be apparent very early in the life of the engine. The majority of fuel system problems are related
to stale or improper fuel or dirt. This section is to help you diagnose fuel system problems.
Other engine failures such as plugged exhaust or improper valve clearance can cause symptoms similar to faulty fuel supply.
Verify the quality of the engines mechanical and electrical systems.
Initial Checklist
How old is the fuel?

Does the fuel have a foul smell?
Is the fuel cloudy, dark or dirty?
Is the fuel tank cap air vent clean and open?
Is a clean, correct air filter installed?
Has the ignition system been verified?
Is the air filter and carburetor attached properly?
Is the intake manifold loose and/or leaking?
Is the fuel shutoff solenoid operating properly?
Is the governor throttle linkage moving properly?
Is the float operating properly?
If the carburetor is externally vented, is the vent line unrestricted?
Engine Surge
An engine that surges may have an improper air/fuel mixture or a misadjusted or worn governor.
Attempt to manually control the throttle at low and high idle to determine which system is causing the surge. If the engine
speed can be held constant check the governor system. If the engine surge cannot be controlled manually, check the fuel
system.
Fuel system issues may consist of:
Improper air/fuel mixture caused by air leaks around the throttle shaft, intake and/or insulator gaskets.
Minor restrictions inside the carburetor passages from varnish and debris buildup in the idle circuit. Properly cleaning the
carburetor will likely fix the problem.
Rich Air/Fuel Mixture

There are several possible causes of a rich running condition such as: improper or stale fuel, short-tripping, air filter, choke
adjustment and/or vent tube location.
→NOTE:
Verify the ignition system. A rich running condition can have the same symptoms as an improperly
operating ignition system.
Float Valve
Fuel level in the float bowl is regulated by the float and the float valve. A worn float valve tip provides too much fuel and will
cause a rich condition.
Improper or Stale Fuel
Poor fuel quality can cause an engine to appear to be running rich. Improper or stale fuel can cause engine components to stick
or deteriorate.
Short-Tripping
A common misdiagnosis comes from short-tripping machines (engines that are started for short periods of time). Short-tripping
causes the engine to develop black, sooty spark plugs and contamination in the oil. Over time, short-tripping can lead to glazed
cylinder walls. To prevent this, every time the engine is started, allow the engine to reach operating temperature and load the
machine.
Air Filters
→NOTE:
Late model carburetors are internally vented to meet emissions standards.
Engines with externally vented carburetors with a dirty air filter will exhibit rich running conditions. When a dirty air filter

restricts air flow to the carburetor, the low pressure in the venturi drops even further, resulting in a higher pressure differential
between the fuel bowl and the venturi. Therefore, a dirty air filter can enrich the air/fuel mixture to the point that performance
will drop.
Engines with internally vented carburetors will not exhibit rich running conditions with a dirty air filter. When a dirty air filter
restricts air flow to the throat of the carburetor, an equal reduction will be applied to the bowl vent. Internally vented
carburetors maintain the pressure differential between the bowl and the venturi resulting in a consistent air/fuel mixture over
the life of the air filter.
Vent Tube Location
With an externally vented carburetor, a rich or lean run condition could also be caused by the location of the float bowl vent
tube. The purpose of the vent tube is to allow atmospheric pressure into and out of the float bowl. Air from the cooling fan at
the vent tube opening can cause a pressure increase or decrease on the fuel in the float bowl and cause the engine to run rich
or lean. Check for bulletins and relocate the float bowl vent tube to a location away from any source of turbulence.
Engine Will Not Crank, V-Twin
66
Engine Will Not Crank (V-Twin)
Engine Will Not
Battery a. Charge and test battery. (See Battery Charge , and Battery Load Test .)
Crank
b. Replace the battery if it will not take or hold a charge.
Starting motor does not rotate

a. Cranking circuit problem. (See Cranking Circuit Operation (S.N. -120000) , Cranking Circuit Operation (S.N.
when ignition switch is turned
120001-130000) , or Cranking Circuit Operation (S.N. 130001- ) .)
to start position.
b. Key switch malfunction. (See Key Switch Test .)
c. Starting relay malfunction. (See Start Relay Test .)

Engine Cranks But Will Not Start, V-Twin

66
Engine Cranks But Will Not Start (V-Twin)
Engine
Cranks But Engine cranks slowly. Charge and test battery. (See Battery Charge , and Battery Load Test .)
Will Not Start
Replace the battery if it will not hold a charge.
Starting motor is binding. (See Starting Motor Amperage Draw Test: Loaded, B&S .)
Poor or no spark at spark plug. Replace spark plug.
Ignition air gap incorrect. (See Adjust Armature Air Gap, V-Twin .)
Magneto shorted to ground, flywheel magnet weak.
Choke or throttle not adjusted

Adjust cable. (See Adjust Throttle and Choke Cable, V-Twin .)
properly.
Fuel supply. Check air cleaner, fuel mixture, possible contaminated fuel, or stuck float needle.
Dirty carburetor. (See Carburetor Cleaning .)
Check fuel shutoff valve, fuel lines, fuel pump, and engine vacuum.
Fuel shutoff solenoid does not open Check fuel solenoid and ignition circuit. (See Fuel Shutoff Solenoid Test, B&S , and Ignition Interlock Circuit
when ignition switch is turned to Operation (S.N. -120000) , Ignition Interlock Circuit Operation (S.N. 120001-130000) , or Ignition Interlock Circuit
start/run. Operation (S.N. 130001- ) .)
Valve clearance improper. Check and adjust valve clearance. (See Adjust Valve Clearance, V-Twin .)
Remove spark plug and drive belts. Turn the engine over by hand. If the engine is hard to turn over by hand repair
Internal components binding.
or replace engine.

Engine Runs Erratically, V-Twin

66
Engine Runs Erratically (V-Twin)
Engine Runs
Lean fuel mixture. Check fuel cap air vent.
Erratically
Check fuel supply system.
Check carburetor for proper operation. (See Remove Two Barrel Carburetor , Repair Two Barrel Carburetor , and Install
Two Barrel Carburetor .)
Check for dirty or varnished carburetor. (See Repair Two Barrel Carburetor , and Carburetor Cleaning .)
Check throttle and choke cable. (See Adjust Throttle and Choke Cable, V-Twin .)
Check for a possible air leak at the intake manifold or carburetor connections and repair as needed.
Check for debris in the idle circuit. Check to see if the problem is governor or carburetor: Hold the throttle plate closed
Engine does not idle properly
to force engine to idle. If the engine continues to run - check governor. If the engine stalls - suspect idle circuit. Clean
(hunts or surges)
idle circuit.
Engine idles, does not run

properly at wide open throttle Check for dirt between needle valve and seat. Check float bowl for dirt or corrosion. Clean bowl. Check valve tip.
(WOT)
Check for sticking float. Check float for proper adjustment.
Check air passage and pilot jet for debris or varnish. Clean carburetor. (See Carburetor Cleaning .)
Governor not moving freely or

Disassemble engine, inspect, and repair governor as needed.
out of adjustment.
Adjust governor. (See Adjust Governor - Static, V-Twin .)
Engine Runs Then Dies, V-Twin

66
Engine Runs Then Dies (V-Twin)
Engine Runs
Fuel supply system. Clean fuel cap vent.
Then Dies
Check for dirt in bowl sucked into main jet. (See Repair Two Barrel Carburetor and Carburetor Cleaning .)
Drain fuel tank and lines and check for restrictions or collapsed lines. Check fuel pump. Add fresh fuel to
tank.
Check for proper operation of fuel shutoff solenoid. (See Fuel Shutoff Solenoid Test, B&S .)
Weak or discharged battery. Charge or load test battery. (See Battery Charge or Battery Load Test .)
Electrical connections on battery, starter,

Check and tighten cables.
or ignition are loose.
Engine loses spark. Check and repair ignition system to get good spark. (See Spark Test .)
Choke not being used or adjusted

Adjust choke linkage. (See Adjust Throttle and Choke Cable, V-Twin .)
properly.
Engine Backfires or Misses, V-Twin

66
Engine Backfires or Misses (V-Twin)
Engine
Backfires Or Spark plug. Check for good spark. (See Spark Test .)
Misfires
Fuel supply system. Check fuel lines and filter for restrictions. Check fuel pump. Check gas cap vent.

Check plug wires, coils, and air gap. (See Adjust Armature Air Gap, V-Twin .)
properly.
Flywheel key damaged or sheared. Inspect key. (See Remove Flywheel .)
Poor compression. Test compression. (See Test Cylinder Leakdown, V-Twin .)
valve seats, warped cylinder head, warped valve stems. (See Inspect and Repair Cylinder Head and Inspect and
Repair Valve .)
Improper valve lift. Check camshaft. (See Remove and Inspect Crankshaft and Camshaft .)
Engine Overheats, V-Twin

66
Engine Overheats (V-Twin)
Engine Overheats Engine shroud debris. Remove shroud and clean around cooling fins.

Check carburetor for proper operation. (See Remove Two Barrel Carburetor , Repair Two Barrel
Carburetor running too lean.
Carburetor and Install Two Barrel Carburetor .)
Also check for air leak at intake manifold.
Flywheel or fan damaged; flywheel key

Check flywheel, flywheel key, and fan for damage. (See Remove Flywheel and Install Flywheel .)
partially sheared affecting timing.

Section 230 - V-TWIN ENGINE DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 20: Tests and Adjustments
Engine Has Loss of Power, V-Twin

66
Engine Has Loss of Power (V-Twin)
Loss of
Oil level too high or low. Check oil level; drain or add oil to proper level.
Power
Engine is overheated. Clean debris from engine shroud and air cooling fins.
Check flywheel, flywheel key, and fan for damage. (See Remove Flywheel and Install Flywheel .)
Spark plug. Check for good spark. (See Spark Test .)

Check plug wires, coils, fuses, and air gap. (See Adjust Armature Air Gap, V-Twin .)
properly.
Flywheel key damaged or sheared. (See Remove Flywheel and Install Flywheel .)
Fuel not getting to carburetor. Check fuel lines and filter for restrictions. Check fuel pump. Check gas cap vent.
Air filter restricted. Clean or replace air filter.
Poor compression. Test compression. (See Test Cylinder Leakdown, V-Twin .)
valve seats, warped cylinder head, warped valve stems. (See Inspect and Repair Cylinder Head and Inspect and
Repair Valve .)
Also check for worn cylinder bore or piston rings. (See Inspect Cylinder Bore and Inspect Piston and Rod .)


Adjust Throttle and Choke Cable, V-Twin
Test Fuel Shutoff Solenoid, V-Twin
Adjust Governor - Static, V-Twin
Adjust Governor - Dynamic, V-Twin (S.N. -130000)
Adjust Governor - Dynamic, V-Twin (S.N. 130001- )
Test Crankcase Vacuum, V-Twin
Test Cylinder Leakdown, V-Twin
Test Cylinder Balance, V-Twin
Adjust Armature Air Gap, V-Twin
Adjust Valve Clearance, V-Twin
Test Engine Oil Pressure, V-Twin

Specifications
Throttle and Choke Cable Clamp Torque 3 N·m
(25 lb.-in.)
Governor Lever Nut Torque 15 N·m
(130 lb.-in.)
Dead Idle Speed (S.N. -130000) rpm 1300 ± 100
Dead Idle Speed (S.N. 130001- ) rpm 1300 ± 100
Governed Low Idle Speed (S.N. -130000) rpm 1750 ± 100
Low Idle Speed (S.N. 130001- ) rpm 1750 ± 100
High Idle Speed (S.N. -130000) rpm 3350 ± 100
High Idle Speed (S.N. 130001- ) rpm 3350 ± 100
Throttle Cable Clamp Screw Torque 3 N·m
(25 lb.-in.)

(10 in.)
(0.74 in.)
(0.008—0.012 in.)
Armature Mounting Screws Torque 3 N·m
(25 lb.-in.)
Valve Adjuster Nut Torque 7 N·m
(62 lb.-in.)
Valve Clearance 0.10—0.13 mm
0.004—0.005 in.)
(180 lb.-in.)
(100 lb.-in.)
Engine Oil Pressure 103—345 kPa
(15—50 psi)

→NOTE:
Pulse Tachometer
JD07270
Photo Tachometer
JT05719
Crankcase Vacuum , Test Kit
JT03503
Cylinder Leak Tester
JT03502

To check for engine air leaks.

Spark Tester
D053515T
To check spark.
Pulse Tachometer
JT07270
Use to measure engine rpm.
Oil Pressure Adapter with O-ring
JT07262
To measure oil pressure.
Connector
JT05487
Hose Assembly
JT03017
Coupler
JT03262
Gauge
JT07034
Adjust Throttle and Choke Cable, V-Twin

Reason:
To ensure that the combined throttle and choke cable moves both throttle and choke through their full range of movement.
Procedure:
LEGEND:
A Clamp
B Hole Location
Throttle and Choke Cable Clamp
[2] - Move the throttle lever up into the Choke position, then back down to the Full throttle position (in the detent).
[3] - Loosen the throttle and choke cable housing clamp (A).

[4] - Line up the holes in the lever and bracket at (B).
[5] -
LEGEND:
C Rivet
D Cable
Insert Rivet
Insert rivet (C) into holes. Keep tool perpendicular to lever.
[6] -
→NOTE:
Make sure throttle plate hole is aligned, and throttle lever is in detent position while removing slack and
clamping.
Pull slack in the cable (D) away from carburetor, and tighten clamp on cable to specification.
Throttle and Choke Cable Clamp Torque 3 N·m
(25 lb.-in.)
[7] - Remove rivet, and check to make sure the throttle lever moves freely up into choke position.
Test Fuel Shutoff Solenoid, V-Twin

Reason:
To test proper operation of fuel shutoff solenoid.
Procedure:
LEGEND:
A Wire
Solenoid Wire

[2] - Listen for an audible click when ignition switch is turned from OFF to ON.
Results:
If solenoid clicks when ignition switch is turned from OFF to ON, the solenoid is working properly.
If solenoid does not click, check machine wiring. (See Fuel Shutoff Circuit Operation (S.N. -120000) , Fuel Shutoff Circuit
Operation (S.N. 120001-130000) , or Fuel Shutoff Circuit Operation (S.N. 130001- )
Test solenoid. (See Fuel Shutoff Solenoid Test, B&S .)
Adjust Governor - Static, V-Twin

Engine off.
All linkages must be installed to make adjustment.
CAUTION:
Reason:
To remove any slack in governor linkage that would allow engine to overspeed.
Procedure:
LEGEND:
A Bolt and Nut
B Lever
C Shaft
Governor Lever
[1] - Remove engine guards. (See Remove Engine Guards (S.N. -130000) or Remove Engine Guards (S.N. 130001- ) .)
[2] - Loosen governor lever bolt and nut (A).
[3] - Push on governor lever (B) until throttle is wide open.
[4] - Do not bend governor link or distort governor lever.
[5] - Hold lever in this position and rotate governor shaft (C) clockwise as far as it will go. Hold lever and shaft in position and
tighten governor lever bolt and nut to specification.
Governor Lever Nut Torque 15 N·m
(130 lb.-in.)

Adjust Governor - Dynamic, V-Twin (S.N. -130000)

Adjustment Condition:
Engine running.
Procedure:
LEGEND:
A Dead Idle Stop Screw
Dead Idle Screw
[1] -
→NOTE:
All belts must be removed from PTO before dynamic governor adjustment. Engine must be run with bare
PTO shaft.
Make sure that the governor has been statically adjusted before performing dynamic adjustment.
[2] - Start and run engine for approximately 5 minutes to allow engine to warm up.
[3] - Using JD07270 Pulse Tachometer or JT05719 Photo Tachometer with the engine running
Pulse Tachometer
JD07270
Photo Tachometer
JT05719
, hold throttle lever on carburetor against dead idle stop screw (A). Record engine speed, and if needed, adjust stop screw until
idle is to specification.
Dead Idle Speed (S.N. -130000) rpm 1300 ± 100
[4] -

LEGEND:
B Throttle Cable
C Governed Idle Tang
Governed Idle Tang

With engine not running, remove throttle cable (B) from speed control bracket on engine. Restart engine, rotate control swivel
to clockwise stop position. Measure the governed low idle speed. Bend the governed idle tang (C) to obtain specified governed
low idle speed.
Governed Low Idle Speed (S.N. -130000) rpm 1750 ± 100
[5] -
LEGEND:
D Pin or Rivet
E Cable Clamp Screw
Throttle Swivel Plate

Throttle cable reinstallation procedure. Engine not running.
a. Rotate speed control swivel counterclockwise to align hole in control swivel with hole in control bracket.
b. Insert 1/8 inch diameter pin or rivet (D) through both holes to lock into high speed position.
c. Move throttle lever to the HIGH speed detent position (throttle cable not connected to engine).
d. With speed control swivel, at engine, locked into place with pin, reinstall throttle cable to speed control swivel.
e. Tighten casing clamp screw (E) to lock throttle cable into place.
(25 lb.-in.)
f. Remove pin or rivet from speed control swivel.
[6] - Start engine, move throttle lever to HIGH idle detent position, and record the engine speed. Adjust high idle speed, if
needed, to specification by bending the high idle tang (lower end of high idle spring).

High Idle Speed (S.N. -130000) rpm 3350 ± 100
[7] - Stop engine and remove key, then reinstall belts.

Adjust Governor - Dynamic, V-Twin (S.N. 130001- )

Adjustment Condition:
Engine running.
Procedure:
LEGEND:
A Dead Idle Stop Screw
Dead Idle Screw
[1] -
→NOTE:
All belts must be removed from PTO before dynamic governor adjustment. Engine must be run with bare
PTO shaft.
Make sure that the governor has been statically adjusted before performing dynamic adjustment.
[2] - Start and run engine for approximately 5 minutes to allow engine to warm up.
[3] - Using JD07270 Pulse Tachometer or JT05719 Photo Tachometer with the engine running
Pulse Tachometer
JD07270
Photo Tachometer
JT05719
, hold throttle lever on carburetor against dead idle stop screw (A). Record engine speed, and if needed, adjust stop screw until
idle is to specification.
Dead Idle Speed (S.N. 130001- ) rpm 1300 ± 100
[4] -

LEGEND:
B Idle Tang
Idle Tang
Start engine, move the throttle lever to the LOW idle position. Measure the low idle speed. Bend the idle tang (B) to obtain
specified low idle speed.
Low Idle Speed (S.N. 130001- ) rpm 1750 ± 100
[5] -
LEGEND:
C Pin or Rivet
D Cable Clamp Screw
Throttle Swivel Plate

With the engine running, move the throttle lever to HIGH idle position. Ensure that a 1/8 inch pin can be inserted through holes
in the speed control swivel and through control bracket. If not, procede to the following adjustment procedure:
a. Loosen throttle cable screw.

b. Position speed swivel so a 1/8 inch diameter pin or rivet (C) can be inserted through both holes to lock into high speed
position.
c. Move throttle lever to the HIGH speed detent position (throttle cable not connected to engine).
d. With speed control swivel, at engine, locked into place with pin, reinstall throttle cable to speed control swivel.
e. Tighten casing clamp screw (D) to lock throttle cable into place.
(25 lb.-in.)
f. Remove pin or rivet from speed control swivel.
[6] - Start engine, move throttle lever to HIGH idle detent position, and record the engine speed. Adjust high idle speed, if
needed, to specification by bending the high idle tang (lower end of high idle spring).

High Idle Speed (S.N. 130001- ) rpm 3350 ± 100
[7] - Stop engine and remove key, then reinstall belts.

Test Crankcase Vacuum, V-Twin

Reason:
To determine operation of breather, condition of seals, gaskets, rings, piston, and cylinder wall.
Procedure:
[2] - Raise hood and remove oil dipstick.
[3] - Place 8741-F66 Plug and JTO5703 Barbed Fitting in dipstick tube until tight.
Plug
8741-F66
Barbed Fitting
JTO5703
[4] - Cover barbed fitting with a plug or finger and start engine.
[5] - Quickly remove plug or finger from barbed fitting and attach JTO5699 Hose and JTO3503 Vacuum Gauge.
Hose
JTO5699
Vacuum Gauge
JTO3503
[6] - Run engine at high idle and record reading on gauge.
[7] - Run engine at low idle. Do not turn engine off.
[8] - Disconnect hose and quickly place plug or finger over barbed fitting.
[9] - Turn engine off.
[10] - Remove plug and install oil dipstick.
Results:
If crankcase vacuum is less than specification, check:


(10 in.)
(0.74 in.)
Breather reed valve clearance and condition.

Seals and gaskets for leakage.
Valve cover gasket for leakage.
Rings, piston and cylinder wall for wear or damage.
Valve and valve seats for wear or damage.
Head warp.

Test Cylinder Leakdown, V-Twin

Reason:
To check sealing of piston rings and cylinder bore.
IMPORTANT:
Check and adjust the valves to ensure the valves have not been adjusted too tight. If either valve is off
its seat, the leak test will be invalid.
→NOTE:
If the directions that come with the tester being used are different than the following, use the directions
that came with the tester.
Procedure:
LEGEND:
A Knob
B Air Line
Connect Cylinder Leak Tester
[1] - Warm the engine to operating temperature, then stop engine.
[2] -
CAUTION:
With spark plugs removed, the magnetos must be grounded to the engine to prevent a spark that could
ignite anything combustible.
Remove spark plugs. 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.
[3] - Remove the air cleaner element from engine so you can listen for air leaks through the carburetor.
[4] - Remove the valve covers.
[5] - Remove the rotating screen.
[6] -
IMPORTANT:
The piston must be positioned at Top Dead Center (TDC) to ensure that the intake valves are away from
the compression relief balls. If not, the intake valve will be open and the leak test will be invalid.
Turn the crankshaft until piston is at TDC on the compression stroke (both valves closed).
[7] - Screw the adaptor into the spark plug hole but do not attach it to the JT03502 Cylinder Leak Tester at this time.


JT03502
To check for engine air leaks.
[8] - Pull back the locking ring and rotate the regulator knob (A) fully counterclockwise. Connect an air line (B) to the tester.
[9] -
IMPORTANT:
The air supply must have enough supply pressure to calibrate the tester, refer to tester documentation
for requirements.
Pull back the locking ring and rotate the regulator knob clockwise until the gauge needle rests in the SET range of the gauge.
Push the locking ring towards the tester to lock it.
[10] -
LEGEND:
C Hose
D Tester
E Breaker Bar
Cylinder Leak Measurement

Connect the adaptor hose (C) to the tester (D), and record the needle position while holding the flywheel in position with a
breaker bar (E).
Results:
→NOTE:
A small amount of air escaping from the crankcase breather is normal.
Excessive air escaping from the crankcase breather indicates worn piston rings or cylinder wall, or leaking head gasket.
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. The engine is still usable but an overhaul
should be considered.
Gauge reading in the Red (high) area indicates excessive compression loss. Engine overhaul is necessary.

Test Cylinder Balance, V-Twin

Reason:
If the engine is hard starting, runs rough, misses or lacks power, run a cylinder balance test to determine if both cylinders are
operating to their full potential.
Procedure:
LEGEND:
A Tester
B Spark Plug
C Lead
Connect Spark Tester
[1] - Disconnect spark plug high tension lead.
[2] - Connect D053515T Spark Tester

Spark Tester
D053515T
To check spark.
(A) to spark plug (B) and high tension lead (C).
[3] - Start engine and note spark at tester. Shut engine off.
[4] - Repeat steps 1—3 for second cylinder.
[5] - Connect JT07270 pulse tachometer.

Pulse Tachometer
JT07270
[6] - Start engine and run at top no load speed. Note rpm on tachometer.
[7] -

LEGEND:
D Screwdriver
Ground Cylinder
Ground out one cylinder with screwdriver (D). Note rpm on tachometer.
[8] - Remove screwdriver and allow engine to recover.
[9] - Ground second cylinder with screwdriver. Note rpm on tachometer.
Results:
If the difference between the two cylinders is less than 75 rpm, the cylinders are considered equal.
If the difference between the two cylinders is greater than 75 rpm, the cylinder with the least rpm loss is weakest, and is
the potential problem.
Adjust Armature Air Gap, V-Twin

Reason:
To set the ignition air gap for proper operation.
Procedure:
LEGEND:
A Magnet
B Screws
C Gauge
Armature Air Gap
[1] - Remove blower housing.
[2] - Rotate flywheel until magnet (A) is away from armature.
[3] - Loosen the armature mounting screws (B). Slide armature away from flywheel as far as possible.
[4] - Tighten one screw enough to hold the armature in place.
[5] - Rotate flywheel until magnet is directly under armature.

[6] - Place a 0.25 mm (0.010 in.) feeler gauge (C) between armature and magnet.
[7] - Loosen the mounting screw so magnet will pull armature against feeler gauge and bring air gap into specification.
(0.008—0.012 in.)
[8] - Tighten both mounting screws (B) to specification.

Armature Mounting Screws Torque 3 N·m
(25 lb.-in.)
[9] - Rotate flywheel while pulling feeler gauge out from between the armature and the magnet.
[10] - Repeat procedure for the remaining ignition armature.

Adjust Valve Clearance, V-Twin

→NOTE:
Correct position of crankshaft is necessary to eliminate interference by the compression release
mechanism when adjusting valve clearance.
[1] - Key switch must be OFF.
[2] - Engine must be cold for accurate adjustment.
[3] - Remove both valve covers.
[4] - Remove spark plugs.
[5] - Identify cylinder #1. It is the cylinder on the starting motor side.
[6] - Turn crankshaft until cylinder #1 piston is at top-dead-center (TDC) on the compression stroke.
a. Rotate the flywheel clockwise and watch the action of the valves. The compression stroke is after the intake valve closes
and the piston is approaching the top of the cylinder.
b. Insert a dowel or blunt pencil through the spark plug opening until it touches the top of the piston. Slowly turn the
flywheel and find the TDC of the piston travel.
c. Using a paint pen, make a small mark on the flywheel and the blower housing to indicate cylinder #1 TDC.
d. Using the dowel or pencil, rotate the flywheel so that the piston travels 6.4 mm (0.25 in.) downward and past TDC.
e. Mark the blower housing with this location. This is where the valve settings must be performed. This ensures that the
automatic compression release lobes on the camshaft do not affect the adjustment
[7] -
LEGEND:
A Feeler Gauge
B Hex Wrench
C Open End Wrench
Adjusting Valve Clearance

Start with the #1 cylinder. Loosen the valve adjusting nut.
[8] - Check valve clearance with a 0.10 mm (0.004 in.) feeler gauge (A) between valve stem and rocker arm. Do not insert the
feeler gauge farther than needed, as contact between gauge and other parts of the rocker can cause inaccurate readings.
[9] - With the feeler gauge in place, turn the adjuster using a 5 mm hex bit socket (B) while holding the nut with a 13 mm box
wrench (C) until the feeler gauge is snug. Do not remove the feeler gauge yet.
[10] - Tighten the adjuster nut finger tight, then to specification.

Valve Adjuster Nut Torque 7 N·m
(62 lb.-in.)
[11] - Remove the feeler gauge and recheck clearance using the 0.1 mm (0.004 in.) feeler gauge, and then a 0.13 mm (0.005
in.), and 0.15 mm (0.006 in.) feeler gauge.

The 0.1 mm (0.004 in.) feeler gauge should be somewhat loose.

The 0.13 mm (0.005 in.) feeler gauge should be snug.
The 0.15 mm (0.006 in.) feeler gauge should not fit.
[12] - If this is the case, the valve is set properly. If this is not the case, repeat steps until the adjustment is to specification.
Valve Clearance 0.10—0.13 mm
0.004—0.005 in.)
[13] -
→NOTE:
The flywheel will need to be turned 270 degrees to find the TDC of the compression stroke. Be careful not
to set the valves for the #2 cylinder on TDC of the exhaust stroke.
Repeat procedure for the #2 cylinder.
[14] - Install spark plugs. Tighten to specification.

(180 lb.-in.)
[15] - Install valve covers. Tighten to specification.

(100 lb.-in.)

Test Engine Oil Pressure, V-Twin

Reason:
To verify that the engine has enough oil pressure to lubricate the internal engine components.
Test Conditions
Perform test procedure with engine level.

Disconnect spark plug wires and allow engine to cool.
Procedure:
LEGEND:
JTO7262 Oil Pressure Adapter with O-ring (Only required
A
on engines without test ports)
B JTO5487 Connector
C JTO3017 Hose Assembly
D JTO3262 Coupler
E JTO7034 Gauge
Oil Pressure Tester
[1] - Drain engine oil from oil filter.
[2] - Remove oil filter and wipe filter base clean.
[3] - Install pre-assembled JTO7262 Adapter, JTO5487 Connector, JTO3017 Hose Assembly, JTO3262 Coupler, and JTO7034
Gauge on to oil filter base. ONLY hand-tighten adapter to oil filter base.
JTO7262
Connector
JTO5487
Hose Assembly
JTO3017
Coupler
JTO3262
Gauge
JTO7034
[4] - Check crankcase oil level and adjust to full mark.
[5] - Monitor oil pressure during cranking, if oil pressure is below 28 kPa (4 psi), STOP engine immediately and correct cause
before continuing.
ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS (g) by Belgreen v2.0
[6] - Connect spark plug wires.
[7] -
CAUTION:
Engine components are HOT. DO NOT touch with bare skin. Wear protective eye glasses and clothing.
Warm-up engine by running at MEDIUM idle for five minutes.
[8] - Record oil pressure readings at LOW and HIGH idle.
[9] - Stop engine and allow to cool.
[10] - Remove adapter, connector, hose assembly, coupler, and gauge.
[11] - Install new oil filter.
[12] - Run engine for 30 seconds and stop engine.
[13] - Check crankcase oil level and adjust to full mark.
Results:
Oil pressure readings should be within specification.

Engine Oil Pressure 103—345 kPa
(15—50 psi)
If not, inspect the following and replace as needed:

Oil pump assembly
Oil suction screen
Oil passages
Bearing wear
Oil Seals

Section 240 - ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS

Table of contents
Group 10 - Theory of Operation ............................................................................................................. 1
Power Circuit Operation (S.N. -120000) ................................................................................................ 2
Cranking Circuit Operation (S.N. -120000) ........................................................................................... 4
Ignition Interlock Circuit Operation (S.N. -120000) ............................................................................... 6
Fuel Shutoff Circuit Operation (S.N. -120000) ...................................................................................... 8
PTO Circuit Operation (S.N. -120000) ................................................................................................... 9
Charging Circuit Operation (S.N. -120000) ......................................................................................... 10
Headlight Circuit Operation (option) (S.N. -120000) ........................................................................... 11
Hour Meter Circuit Operation (S.N. -120000) ...................................................................................... 11
Power Circuit Operation (S.N. 120001-130000) .................................................................................. 13
Cranking Circuit Operation (S.N. 120001-130000) ............................................................................. 15
Ignition Interlock Circuit Operation (S.N. 120001-130000) ................................................................. 17
Fuel Shutoff Circuit Operation (S.N. 120001-130000) ........................................................................ 20
PTO Circuit Operation (S.N. 120001-130000) ..................................................................................... 23
Charging Circuit Operation (S.N. 120001-130000) ............................................................................. 24
Headlight Circuit Operation (option) (S.N. 120001-130000) ............................................................... 25
Hour Meter Circuit Operation (S.N. 120001-130000) .......................................................................... 26
Power Circuit Operation (S.N. 130001- ) ............................................................................................. 28
Cranking Circuit Operation (S.N. 130001- ) ........................................................................................ 31
Ignition Interlock Circuit Operation (S.N. 130001- ) ............................................................................ 33
Fuel Shutoff Circuit Operation (S.N. 130001- ) ................................................................................... 36
PTO Circuit Operation (S.N. 130001- ) ................................................................................................ 39
Charging Circuit Operation (S.N. 130001- ) ........................................................................................ 40
Headlight Circuit Operation (option) (S.N. 130001- ) .......................................................................... 41
Hour Meter Circuit Operation (S.N. 130001- ) ..................................................................................... 42
Low Fuel Light Circuit Operation (S.N. 170001- ) ................................................................................ 44
Group 20 - Diagnosis ............................................................................................................................. 45
Switched Power .................................................................................................................................. 45
Cranking Power .................................................................................................................................. 48
Test Procedure D: Spark Test ............................................................................................................. 51
Test Procedure A ................................................................................................................................ 56
Test Procedure A ................................................................................................................................ 57
Test Procedure B ................................................................................................................................ 58
Test Procedure A ................................................................................................................................ 59
Test Procedure B ................................................................................................................................ 61
Switched Power .................................................................................................................................. 63
Cranking Power .................................................................................................................................. 67
Test Procedure C: ............................................................................................................................... 71
Diagnose Fuel Shutoff Circuit (S.N. 120001-130000) ......................................................................... 75
Test Procedure A ................................................................................................................................ 76
Test Procedure B ................................................................................................................................ 77
Test Procedure A ................................................................................................................................ 78
Test Procedure B ................................................................................................................................ 80
Switched Power .................................................................................................................................. 82
Cranking Power .................................................................................................................................. 86
Test Procedure C: ............................................................................................................................... 90
Diagnose Fuel Shutoff Circuit (S.N. 130001- ) .................................................................................... 94
Test Procedure A ................................................................................................................................ 95
Test Procedure B ................................................................................................................................ 96

Test Procedure A ................................................................................................................................ 97

Test Procedure B ................................................................................................................................ 99
Procedure Low Fuel Light Always ON ................................................................................................ 101
Group 30 - Tests and Adjustments .................................................................................................... 103
Summary of References ................................................................................................................... 103
Specifications ................................................................................................................................... 103
Service Equipment and Tools ........................................................................................................... 103
Ground Circuit Test ........................................................................................................................... 104
Battery Voltage and Specific Gravity Tests ...................................................................................... 105
Battery Charge ................................................................................................................................. 107
Battery Load Test ............................................................................................................................. 107
Spark Test ........................................................................................................................................ 108
Regulated Voltage Test .................................................................................................................... 109
Regulated Amperage Test ................................................................................................................ 110
Starting Motor Amperage Draw Test: Loaded, B&S .......................................................................... 112
Starting Motor Amperage Draw Test: No Load, B&S ......................................................................... 114
Stator Output Test, B&S ................................................................................................................... 115
Flywheel Stator Magnets Test .......................................................................................................... 116
Flywheel Ignition Magnet Test .......................................................................................................... 116
Diode Test ........................................................................................................................................ 117
PTO Switch Test ................................................................................................................................ 119
Electric PTO Clutch Test ................................................................................................................... 120
Key Switch Test ................................................................................................................................ 120
Start Relay Test ................................................................................................................................ 122
Relay Test ......................................................................................................................................... 123
Fuel Shutoff Solenoid Test, B&S ....................................................................................................... 123
Seat Switch Test ............................................................................................................................... 124
Headlight Switch (S.N. -130000) ....................................................................................................... 125
Headlight Switch (S.N. 130001- ) ...................................................................................................... 126
Park Brake and Neutral Switch Test ................................................................................................. 127
Group 40 - Wiring Schematics ........................................................................................................... 129
Schematic Legend ............................................................................................................................ 129
Main Electrical Schematic (S.N. -120000) ......................................................................................... 130
Main Electrical Schematic (S.N. 120001-130000) ............................................................................. 132
Main Electrical Schematic (S.N. 130001-170000) ............................................................................. 134
Main Electrical Schematic (S.N. 170001- ) ........................................................................................ 136
Group 50 - Connector Information .................................................................................................... 138
Load Center (S.N. -120000) .............................................................................................................. 139
Load Center (S.N. 120001-130000) .................................................................................................. 140
Load Center (S.N. 130001- ) ............................................................................................................. 141
Hour Meter Connector ...................................................................................................................... 142
Key Switch Connector ....................................................................................................................... 143
Left Handle Neutral Switch Connector .............................................................................................. 145
Right Handle Neutral Switch Connector ............................................................................................ 146
Park Brake Switch Connector ........................................................................................................... 147
Seat Switch Connector ..................................................................................................................... 148
PTO Switch Connector ...................................................................................................................... 149
Light Switch Connector ..................................................................................................................... 150
Headlight Harness Connector, C3F (W1 Main Harness) (S.N. 130001- ) ........................................... 150
Headlight Harness Connector, C3M (W3 Light Kit Harness) (S.N. 130001- ) ..................................... 151
Headlight Connector ......................................................................................................................... 152

Power Connector (S.N. 130001- ) ..................................................................................................... 152

Engine Connector ............................................................................................................................. 154
PTO Clutch Connector ....................................................................................................................... 155
Start Relay Connectors ..................................................................................................................... 156
Regulator/Rectifier Connectors ......................................................................................................... 156

Section 240 - ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 10: Theory of Operation

Power Circuit Operation (S.N. -120000)
Cranking Circuit Operation (S.N. -120000)
Ignition Interlock Circuit Operation (S.N. -120000)
Fuel Shutoff Circuit Operation (S.N. -120000)
PTO Circuit Operation (S.N. -120000)
Charging Circuit Operation (S.N. -120000)
Headlight Circuit Operation (option) (S.N. -120000)
Hour Meter Circuit Operation (S.N. -120000)
Power Circuit Operation (S.N. 120001-130000)
Cranking Circuit Operation (S.N. 120001-130000)
Ignition Interlock Circuit Operation (S.N. 120001-130000)
Fuel Shutoff Circuit Operation (S.N. 120001-130000)
PTO Circuit Operation (S.N. 120001-130000)
Charging Circuit Operation (S.N. 120001-130000)
Headlight Circuit Operation (option) (S.N. 120001-130000)
Hour Meter Circuit Operation (S.N. 120001-130000)
Power Circuit Operation (S.N. 130001- )
Cranking Circuit Operation (S.N. 130001- )
Ignition Interlock Circuit Operation (S.N. 130001- )
Fuel Shutoff Circuit Operation (S.N. 130001- )
PTO Circuit Operation (S.N. 130001- )
Charging Circuit Operation (S.N. 130001- )
Headlight Circuit Operation (option) (S.N. 130001- )
Hour Meter Circuit Operation (S.N. 130001- )
Low Fuel Light Circuit Operation (S.N. 170001- )

Power Circuit Operation (S.N. -120000)

Function:
To provide unswitched and switched power to the primary electrical components whenever the battery is properly connected.
The power circuits are either unswitched (always on), switched (key switch in RUN position), or secondary (controlled).
Operating Conditions, Unswitched Circuits:
Voltage must be present at the following components with the key switch in the OFF position:
G1 positive battery terminal

K1 start relay
F1 and F2 fuses
N1 voltage regulator/rectifier - Red wire
SW1 key switch - terminals B and S1
The 202A Red wire connects the positive battery terminal to the start relay. The relay terminal acts as the 12 volt DC tie point
for the electrical system.
The 202B/C/D Red wires supply power to the F1 and F2 fuses. Fuse F1 protects the circuit to the key switch and switched power
circuit, while fuse F2 protects the charging circuit and voltage regulator/rectifier.
Proper starting motor operation depends on the high current supplied through the battery cables.
The ground cable connection is equally as important as the positive cable connection in maintaining electrical system integrity.
All cables, wires and their connections must be in good condition for the machine’s electrical system to work properly.
Operating Conditions, Switched Circuits:
With the key switch in RUN position and PTO switch OFF, voltage should be present at the following components:
SW1 key switch - terminal A

F3 and F4 fuses
K2 Interlock Relay - 400C Yel wire
SW99 Headlight switch - 900 Yel wire
SW6 PTO switch - 475A/B Yel wires
P1 hour meter - 475B and 420 Yel wires
Y1 fuel shutoff solenoid - Gry/420 Yel wires
The key switch provides power to the switched circuits, which are protected by fuses F3 and F4.
The ground circuit is equally important as the power circuit connections. Proper systems operation depends on good wires and
connections in order to carry the current needed to operate the various components.

Power Circuit Schematic (S.N. -120000)

Cranking Circuit Operation (S.N. -120000)

Function:
To energize the starting motor to crank the engine.
Operating Conditions:
Park brake locked.

PTO switch OFF.
Motion control handles in NEUTRAL position.
Key switch in START position.
Theory of Operation:
→NOTE:
This circuit will crank the engine. However, in order for the engine to run, the ignition and fuel shutoff
circuits must also function properly.
Unswitched power is supplied to the key switch via fuse F1. (See Power Circuit Operation (S.N. -120000) .)
Turning the key switch to START applies power to switch terminal S1.
The key switch START signal must pass via the 700-series of wires and the (closed) neutral and PTO switches before reaching
the start relay coil. The circuit for the coil is completed by a ground path through the (closed) park brake switch.
With the start relay energized, the main contacts close, supplying battery power to the starting motor. The spinning motor
engages the flywheel, cranking the engine.
If the ignition and fuel shutoff circuits are functioning properly, the engine should start and run. (See Ignition Interlock Circuit
Operation (S.N. -120000) , and Fuel Shutoff Circuit Operation (S.N. -120000) .

Cranking Circuit Schematic (S.N. -120000)

Ignition Interlock Circuit Operation (S.N. -120000)

Function:
To shut off the engine should the machine be placed in an unsafe operating mode.
The engine will stop when:
Key switch is in OFF position;
- OR -
Park brake locked, and

Motion control handles in DRIVE position (whether machine is in motion or not);
- OR -
Park brake unlocked, and

Operator off seat;
- OR -
PTO engaged, and

Operator off seat.
The ignition system is a transistor-controlled magneto design. Ignition timing is controlled by the transistor and is not
adjustable. As the engine turns over, the flywheel magnet induces current into the magneto ignition coil. The coil creates the
high voltage needed to jump the spark plug gap, which ignites the fuel/air mixture in the cylinder.
The engine is shut off by grounding the primary winding of the ignition coil. With the ignition coil grounded, a spark cannot be
produced. Grounding is done through a sequence of connections involving the 601-series Wht wires and the key switch, park
brake switch, neutral switches, seat switch, PTO switch and interlock relay.
Key Switch:
With the key switch in the OFF position, the switch creates a ground path from the 100G Blk wire to the 601-series Wht wires
and the ignition coil.
Park Brake Switch:
Both motion control handles must be in the NEUTRAL position when the park brake is locked. The 603A/B Grn wires connect the
neutral switches to the park brake switch. When the park brake is locked, the park brake switch grounds the 603-series Grn
wires via the 100F Blk wire. Should either motion control handle be shifted into DRIVE, the neutral switch(es) connect the
ignition coil/601-series Wht wires to the (now grounded) 603-series Grn wires.
Another set of park brake switch contacts are used in conjunction with the interlock relay.
Interlock Relay:
The 602A/B Pnk wires connect the park brake and PTO switches to one side of the interlock relay contacts; the other contact is
grounded by the 100R Blk wire. Activating the seat switch (operator on-seat) energizes the interlock relay coil, allowing the
relay contacts to open. If the relay is released, the contacts ground the 602A/B Pnk wires.
When the operator is off-seat and the park brake is unlocked, the park brake switch connects the ignition coil and 601-series
Wht wires to the 602B Pnk wire (now grounded by the relay).
Attempting to engage the PTO while the operator is off-seat will also connect the (now grounded) 602A/B Pnk wires to the
ignition coil/601-series Wht wires via the PTO switch.

Ignition Interlock Circuit Schematic (S.N. -120000)

Fuel Shutoff Circuit Operation (S.N. -120000)

Function:
To energize the fuel shutoff solenoid when the key switch is placed in the RUN position.
Key switch in RUN or START
The fuel shutoff solenoid uses an electromagnetic coil to operate a plunger. The switched power system is used to activate the
solenoid coil. When the solenoid is de-energized, the plunger stops fuel flow within the carburetor.
With the key switch in the RUN or START position, power is supplied to the hour meter by way of Yel wires 400A/B, fuse F3 and
Yel wires 475A/B. The hour meter joins the 475B wire to Yel wire 420 and connector C4. The engine harness Gray wire routes
the power to the fuel shutoff solenoid; the Black wire provides the ground path.
Fuel Shutoff Circuit Schematic (S.N. -120000)

PTO Circuit Operation (S.N. -120000)

Function:
To energize the PTO clutch.
Key switch in RUN position

PTO switch On
The PTO is an electromechanical device (electric clutch) controlled by a 12 VDC input from the switched power circuit.
The engine crankshaft drives the PTO clutch. When the PTO switch is in the ON position, 12 VDC is applied to the clutch. The
clutch sheave is then engaged with the engine crankshaft.
PTO Circuit Schematic (S.N. -120000)

Charging Circuit Operation (S.N. -120000)

Function:
To maintain battery voltage at 12.6 volts or higher.
The engine must be running in order for the charging system to operate. (See Ignition Interlock Circuit Operation (S.N.
-120000) , and Fuel Shutoff Circuit Operation (S.N. -120000) for those conditions required by the engine.)
Key switch in RUN position, engine running
The charging system is of the permanent magnet-and- stator design.
The engine crankshaft spins the flywheel. A permanent magnet located in the flywheel induces alternating current (AC) in the
stator windings. The regulator/rectifier converts this alternating current into the direct current (DC) needed to charge the
battery.
Battery charging is managed by the voltage regulator. The regulator will increase or decrease the current as needed, charging
the battery to 13.5—14.7VDC.
Connector C4, fuse F2 and the 201/202-series Red wires link the regulator/rectifier to the battery.
Charging Circuit Schematic (S.N. -120000)


Function:
To illuminate the (optional) headlight(s).

Light switch ON
Turning the key switch to the RUN position supplies switched power to fuse F4, the 900A Yel wire and the light switch. The light
switch applies power to the headlights over the 901B/C Yel wires.
The headlights are grounded directly to the W2 engine ground point by the 100K/L Blk wires.
Headlight Circuit Schematic (S.N. -120000)
Hour Meter Circuit Operation (S.N. -120000)

Function:
To power the hour meter and accumulate time only when the engine is running.

Key switch in the RUN position with the engine running.
The hour meter records the total number of hours of engine operation.
The 475A/B Yel wires supply switched power to the hour meter, with the 100H/D Blk wires providing the ground path. To
energize the fuel shutoff solenoid, the hour meter connects power from the 475B wire to the 420 Yel wire.
In order to count time, the hour meter must receive pulses from the ignition coil(s). The 601-series Wht wires carry these
pulses during engine operation. Turning key switch to OFF or engaging the ignition interlock system shunts these pulses to
ground, stopping the engine. With the pulses removed, the hour meter ceases to increment time.

Power Circuit Operation (S.N. 120001-130000)

Function:

K1 start relay
F1 and F2 fuses
SW1 key switch - terminal B
The 202A Red wire connects the positive battery terminal to the start relay. The relay terminal acts as the 12 volt DC tie point
for the electrical system.
The ground cable connection is equally as important as the positive cable connection in maintaining electrical system integrity.
All cables, wires and their connections must be in good condition for the machine’s electrical system to work properly.
With the key switch in RUN position, PTO switch OFF, drive handles in neutral position voltage, and park brake locked, battery
voltage should be present at the following components:

F3 and F4 fuses
SW99 headlight switch - 900 Yel wire
P1 hour meter - 475B and 419A Yel wires
SW2 left neutral switch - 419A/B Yel and 701 Grn wires
SW3 right neutral switch - 701 Grn and 608C Pnk wires
SW4 park brake switch - 419B Yel and 608C/B/A Pnk wires
SW5 seat switch - 608A Pnk wire

Power Circuit Schematic (S.N. 120001-130000)

Cranking Circuit Operation (S.N. 120001-130000)

Function:
Park brake locked

PTO switch OFF
Motion control handles in NEUTRAL position
Key switch in START position
The K1 start relay must be energized to provide power to the starter motor. The K1 start relay coil ground circuit and power
circuit are both switched. Both circuits must be completed to crank the engine.
Unswitched power is supplied to the key switch via fuse F1. (See Power Circuit Operation (S.N. 120001-130000) .) Turning the
key switch to RUN or START applies power to switch terminal A.
Power from the key switch terminal A passes through the 400A and 400B Yel wires, F3 fuse, and 475A and 475B Yel wires to
the P1 hour meter.
The hour meter passes power through to the 419A Yel wire, SW2 left neutral switch, 701 Grn wire, SW3 right neutral switch
(both in the neutral position), and 608C Pnk wire to the SW4 park brake switch.
With the park brake engaged, power passes through to the 605 Wht wire, and SW6 PTO switch terminal 3. With the PTO switch
in the OFF position power is passed though to switch terminal 9, the 702B Grn wire, and SW1 key switch terminal S2
Turning the key switch to START provides power to switch terminal S1, 703 Grn wire and K1 start relay coil.
The circuit for the start relay coil is completed with a ground path through the (closed) K2 interlock relay contacts. The
interlock relay coil is energized when power is passed though to the PTO switch terminal 9. Power is provided via the 702A Grn
wire, D3 diode, and 402C Yel wires.
The D3 diode prevents the start relay from being energized if the SW6 PTO switch is in the ON position and the operator is on
the seat.
Operation (S.N. 120001-130000) , and Fuel Shutoff Circuit Operation (S.N. 120001-130000) .)

Cranking Circuit Schematic (S.N. 120001-130000)

Ignition Interlock Circuit Operation (S.N. 120001-130000)

Function:
- OR -

Operator off seat;
- OR -

- OR -
PTO engaged, and

Operator off seat.
produced.
There are two controlled paths to ground for the ignition coils. One is through the key switch (Off position). The other path is
through the K2 interlock relay contacts.
Key Switch:
Interlock Relay:
The K2 interlock relay must be energized to prevent the ignitions coils from having a path to ground. The 601A/B Wht wires
connect the ignition coils to one side of the interlock relay contacts; the other contact is grounded by the 100R Blk wire.
The relay coil has a ground path through the 100E and 100D Blk wires. The intelock relay is controlled with battery power
through the following component and circuit combinations:
With the park brake contacts closed (A-C closed with park brake unlocked), and the seat switch closed (operator on seat),
power is provided to energize the interlock relay coil through the 420 Yel wires, keeping the relay contacts open. If the
relay is released, the contacts ground the 601A/B Wht wires. When the park brake is unlocked and the operator is off-
seat, the power circuit to the interlock relay coil is open and the ignition coils obtain a path to ground.
When the park brake is locked, both motion control handles must be in the NEUTRAL position, and the PTO switch must
be in the OFF position, OR, the operator must be on the seat. With the park brake contacts closed (B-D closed with park
brake locked), power to energize the interlock relay must come through both neutral switches (motion control handles in
neutral). Power can go through the park brake switch (B-D contacts), 605 Wht wire, PTO switch (3-9 closed with PTO
switch off), 702A Grn wire, D3 diode, and the 420 Yel wires. Power can also go through the 608B/A Pnk wires, seat switch
closed contacts (operator on seat), and 420 Yel wires.
Should either motion control handle be shifted into DRIVE, with the park brake switch locked, the interlock relay coil will
deenergize, grounding the ignition coils.
Attempting to engage the PTO while the operator is off the seat will also deenergize the interlock relay coil.

Ignition Interlock Circuit Schematic (S.N. 120001-130000) 1 of 2

Ignition Interlock Circuit Schematic (S.N. 120001-130000) 2 of 2

Fuel Shutoff Circuit Operation (S.N. 120001-130000)

Function:

Park brake locked, and operator on seat
Motion control handles in NEUTRAL position, park brake locked, and PTO OFF - or- operator on seat
One or both motion control handles in DRIVE position, park brake OFF, and operator on seat
The fuel solenoid is energized with the same power as the K2 interlock coil. The circuit functions the same as the ignition
interlock circuit. (See Ignition Interlock Circuit Operation (S.N. 120001-130000) .)

Fuel Shutoff Circuit Schematic (S.N. 120001-130000) 1 of 2

Fuel Shutoff Circuit Schematic (S.N. 120001-130000) 2 of 2

PTO Circuit Operation (S.N. 120001-130000)

Function:

PTO switch On
PTO Circuit Schematic (S.N. 120001-130000)

Charging Circuit Operation (S.N. 120001-130000)

Function:
120001-130000) , and Fuel Shutoff Circuit Operation (S.N. 120001-130000) for those conditions required by the engine.)
battery.
Charging Circuit Schematic (S.N. 120001-130000)


Function:

Light switch ON
Turning the key switch to the RUN position supplies switched power to fuse F4, the 900 Yel wire and the light switch. The light
switch applies power to the headlights over the 901B/C Yel wires.
The headlights are grounded directly to the W2 engine ground point by the 100K/L Blk wires.
Headlight Circuit Schematic (S.N. 120001-130000)

Hour Meter Circuit Operation (S.N. 120001-130000)

Function:
To power the hour meter and accumulate time only while the engine is running.
The hour meter records the total hours of engine operation.
The 475A/B Yel wires supply switched power to the hour meter, with the 100H/G/D Blk wires forming the ground path. Power
from wire 475B is available to the 419-series Yel wires provided the hour meter remains connected.
In order to count time, the hour meter receive pulses from the ignition coils. The 601-series Wht wires carry these pulses
during engine operation. Turning the key switch to OFF or engaging the ignition interlock system shunts these pulses to
ground, stopping both the engine and the hour meter.
Diodes D1 and D2 prevent any electrical interaction between the two ignition coils.

Hour Meter Circuit Schematic (S.N. 120001-130000)

Power Circuit Operation (S.N. 130001- )

Function:

K1 start relay
F1 and F2 fuses
SW1 key switch - terminal B
The 202A Red wire connects the positive battery terminal to the start relay. The relay terminal acts as the 12 VDC tie point for
the electrical system.
The ground cable connection is equally important as the positive cable connection in maintaining electrical system integrity.
All cables, wires, and their connections must be in good condition for the machine’s electrical system to work properly.
With the key switch in RUN position, PTO switch OFF, drive handles in neutral position voltage, and park brake locked, battery
voltage should be present at the following components:

F3 and F4 fuses
SW7 headlight switch - 900A Yel wire
P1 hour meter - 475B and 419A Yel wires
SW2 left neutral switch - 419A/B Yel and 701 Grn wires
SW3 right neutral switch - 701 Grn and 608A/C Pnk wires
SW4 park brake switch - 419B Yel and 608C/B Pnk wires
SW5 seat switch - 608A Pnk wire
(S.N. 170001- ) L6 Low Fuel Light and R1 Thermistor

Power Circuit Schematic (S.N. 130001-170000)

Power Circuit Schematic (S.N. 170001- )

Cranking Circuit Operation (S.N. 130001- )

Function:
Park brake locked

PTO switch OFF
Motion control handles in NEUTRAL position
Key switch in START position
The K1 start relay must be energized to provide power to the starter motor. The K1 start relay coil ground circuit and power
circuit are both switched. Both circuits must be completed to crank the engine.
Unswitched power is supplied to the key switch via fuse F1. (See Power Circuit Operation (S.N. 130001- ) .) Turning the key
switch to RUN or START applies power to switch terminal A.
Power from the key switch terminal A passes through the 400A and 400B Yel wires, F3 fuse, and 475A and 475B Yel wires to
the P1 hour meter.
The hour meter passes power through to the 419A Yel wire, SW2 left neutral switch, 701 Grn wire, SW3 right neutral switch
(both in the neutral position), and 608C/B Pnk wires to the SW4 park brake switch.
With the park brake engaged, power passes through to the 605 Wht wire, and SW6 PTO switch terminal 3. With the PTO switch
in the OFF position power is passed through to switch terminal 9, the 702B Grn wire, and SW1 key switch terminal S2
Turning the key switch to START provides power to switch terminal S1, 703 Grn wire and K1 start relay coil.
The circuit for the start relay coil is completed with a ground path through the (closed) K2 interlock relay contacts. The
interlock relay coil is energized when power is passed though to the PTO switch terminal 9. Power is provided via the 702A Grn
wire, D3 diode, and 402C Yel wires.
The D3 diode prevents the start relay from being energized if the SW6 PTO switch is in the ON position and the operator is on
the seat.
Operation (S.N. 130001- ) , and Fuel Shutoff Circuit Operation (S.N. 130001- ) .)

Cranking Circuit Schematic (S.N. 130001- )

Ignition Interlock Circuit Operation (S.N. 130001- )

Function:
- OR -

Operator off seat;
- OR -

- OR -
PTO engaged, and

Operator off seat.
The engine will continue to run when:
Motion control handles in NEUTRAL position, and

PTO disengaged, and
Operator off seat.
produced.
There are two controlled paths to ground for the ignition coils. One is through the key switch (Off position). The other path is
through the K2 interlock relay contacts.
Key Switch:
Interlock Relay:
The K2 interlock relay must be energized to prevent the ignitions coils from having a path to ground. The 601A/B Wht wires
connect the ignition coils to one side of the interlock relay contacts; the other contact is grounded by the 100R Blk wire.
The relay coil has a ground path through the 100E and 100D Blk wires. The intelock relay is controlled with battery power
through the following component and circuit combinations:
With the park brake contacts closed (B-D closed with park brake unlocked), and the seat switch closed (operator on seat),
power is provided to energize the interlock relay coil through the 420 Yel wires, keeping the relay contacts open. If the
relay is released, the contacts ground the 601A/B Wht wires. When the park brake is unlocked and the operator is off-
seat, the power circuit to the interlock relay coil is open and the ignition coils obtain a path to ground.
When the park brake is locked, both motion control handles must be in the NEUTRAL position, and the PTO switch must
be in the OFF position, OR, the operator must be on the seat. With the park brake contacts closed (A-C closed with park
brake locked), power to energize the interlock relay must come through both neutral switches (motion control handles in
neutral), and the 608C/B Pnk wires. Power can then go through the park brake switch (A-C contacts), 605 Wht wire, PTO
switch (3-9 closed with PTO switch off), 702A Grn wire, D3 diode, and the 420 Yel wires. Power can also go through the
608A Pnk wire, seat switch closed contacts (operator on seat), and 420 Yel wires.
Should either motion control handle be shifted into DRIVE, with the park brake switch locked, the interlock relay coil will
deenergize, grounding the ignition coils.

Attempting to engage the PTO while the operator is off the seat will also deenergize the interlock relay coil.
Ignition Interlock Circuit Schematic (S.N. 130001- ) 1 of 2

Ignition Interlock Circuit Schematic (S.N. 130001- ) 2 of 2

Fuel Shutoff Circuit Operation (S.N. 130001- )

Function:

Park brake locked, and operator on seat
Motion control handles in NEUTRAL position, park brake locked, and PTO OFF - or- operator on seat
One or both motion control handles in DRIVE position, park brake OFF, and operator on seat
interlock circuit. (See Ignition Interlock Circuit Operation (S.N. 130001- ) .)

Fuel Shutoff Circuit Schematic (S.N. 130001- ) 1 of 2

Fuel Shutoff Circuit Schematic (S.N. 130001- ) 2 of 2

PTO Circuit Operation (S.N. 130001- )

Function:

PTO switch On
PTO Circuit Schematic (S.N. 130001- )

Charging Circuit Operation (S.N. 130001- )

Function:
130001- ) , and Fuel Shutoff Circuit Operation (S.N. 130001- ) for those conditions required by the engine.)
battery.
Charging Circuit Schematic (S.N. 130001- )

Headlight Circuit Operation (option) (S.N. 130001- )

Function:

Light switch ON
Turning the key switch to the RUN position supplies switched power to fuse F4, the 900A Yel wire and the light switch. The light
switch applies power to the headlights over the 901B/C/D Yel wires.
The headlights are grounded to the W2 engine ground point by the 100K/L/P/D Blk wires.
Headlight Circuit Schematic (S.N. 130001- )

Hour Meter Circuit Operation (S.N. 130001- )

Function:
To power the hour meter and accumulate time only while the engine is running.
The hour meter records the total hours of engine operation.
The 475A/B Yel wires supply switched power to the hour meter, with the 100H/G/D Blk wires forming the ground path. Power
from wire 475B is available to the 419-series Yel wires provided the hour meter remains connected.
In order to count time, the hour meter receive pulses from the ignition coils. The 601-series Wht wires carry these pulses
during engine operation. Turning the key switch to OFF or engaging the ignition interlock system shunts these pulses to
ground, stopping both the engine and the hour meter.
Diodes D1 and D2 prevent any electrical interaction between the two ignition coils.

Hour Meter Circuit Schematic (S.N. 130001- )

Section 240 - ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 20: Diagnosis
Low Fuel Light Circuit Operation (S.N. 170001- )

Function:
To alert the operator that the equipment is low on fuel.
The low fuel indicator light receives switched power from the key switch. It is connected to ground through a thermistor
mounted in the fuel tank. The thermistor is normally open. When the fuel level falls below the thermistor the contacts close.
The contacts complete the circuit to ground and the low fuel indicator light turns on.
Low Fuel Light Circuit

Diagnose Power Circuit (S.N. -120000)
65
Power Circuit (S.N. -120000)
Refer to Power Circuit Operation (S.N. -120000) for theory and circuit schematic.
Unswitched Power
( 1 ) Start Relay
Action:
Test Conditions
Test Conditions:
• Battery properly connected

• Key switch OFF
Carefully lift red boot from start relay to expose battery cable terminal. (See Start Relay Connectors .) Is battery voltage
present at terminal?
Result:
YES:Re-seat boot. Go to next step.

NO:Check for loose or corroded connections at battery terminals, engine ground and start relay. If ok, test the battery. (See
Battery Voltage and Specific Gravity Tests .)
( 2 ) Key Switch
Action:
Is battery voltage present at key switch terminals B and S2? (See Key Switch Connector .)
Result:
YES:Go to next step.

NO:Test fuse F1. Check Red wires 220A/B, 202B/D. (See Load Center (S.N. -120000) , and Main Electrical Schematic (S.N.
-120000) .)
( 3 ) Voltage Regulator
Action:
Unplug the red regulator wire from engine harness. Is battery voltage present at harness connector?
Result:
YES:Reattach red wire. Go to next step.

NO:Test fuse F2. Check connector C4, Red wires 201, 202B/C.
Switched Power
( 1 ) Key Switch (connected)
Action:

Test Conditions
Test Conditions:
• Key switch in RUN position, engine not running

• Park brake locked
Is battery voltage present at the key switch terminal, 400A Yel wire?
Result:

NO:Test fuse F1 and unswitched power circuit. If ok, test the key switch and replace as necessary. (See Key Switch Test .)
( 2 ) PTO Switch
Action:
Is battery voltage present at PTO switch terminal 2, 475A/B Yel wires? (See PTO Clutch Connector .)
Result:

NO:Test fuse F3. Check Yel wires 400A/B, 475A.
( 3 ) Hourmeter Connector
Action:
Disconnect the harness from the hour meter. Is battery voltage present at connector 475B Yel wire? (See Hour Meter Connector
.)
Result:
YES:Reconnect the hour meter. Go to next step.

NO:Check the 475B Yel wire and connections.
( 4 ) Fuel Shutoff Solenoid
Action:
Unplug the harness from the fuel shutoff solenoid. Is battery voltage present at the connector Gray wire?
Result:
YES:Reconnect the solenoid. Go to next step.

NO:Check the solenoid connector Gray wire. Check connector C4/420 Yel wire. Confirm that hour meter is fully seated into
harness. If ok, replace hour meter.
( 5 ) K2 Relay
Action:
→NOTE:
When replacing relay, make sure it is oriented correctly. Center terminal (side with 3 terminals, should be
on top.
Remove K2 relay. Is battery voltage present at load center pin B9? (See Load Center (S.N. -120000) .)
Result:
YES:Install relay. Go to next step.

NO:Check the 400C/A Yel wires.

( 6 ) Light Switch (option)
Action:
Is battery voltage present at the light switch 900 Yel wire? (See Light Switch Connector .)
Result:
YES:Test complete.
NO:Check fuse F4. Check Yel wires 900, 400A/E.

Diagnose Cranking Circuit (S.N. -120000)

65
Cranking Circuit (S.N. -120000)
Refer to Cranking Circuit Operation (S.N. -120000) for theory and circuit schematic.
Cranking Power
( 1 ) Starting Motor
Action:
Test Conditions
Test Conditions:
• PTO switch OFF

• Motion control handles (switches) in neutral position
• Key switch to START position during each test
Is battery voltage present at the starting motor 705 Red wire?
Result:
YES:Cranking circuit is operational. If engine does not crank, test the starting motor. (See Starting Motor Amperage Draw Test:
No Load, B&S .)
NO:Check 705 Red wire/connections. Go to next step.
( 2 ) Start Relay
Action:
Carefully lift red boot from start relay to expose terminal, 202A/B Red wires. Is battery voltage present at terminal? (See Start
Relay Connectors .)
Result:

( 3 ) (continued)
Action:
Does start relay make a strong audible click when the key switch is turned to START?
Result:
YES:Connect voltmeter across battery and starter terminals. Energize relay and note meter reading. If value always exceeds
0.5 volt, replace relay.
NO:Unplug 700 Pur and 603C Grn wires from relay. Measure resistance of coil (3.5 ohms ±25%) across terminals. If ok, go to
next step.
( 4 ) Key Switch
Action:
Is battery voltage present at key switch terminal (S1), 703 Grn wire? (See Key Switch Connector .)
Result:

NO:Check fuse F1. Test the unswitched power circuit. Test key switch. (See Key Switch Connector .)
( 5 ) PTO Switch
Action:
Is battery voltage present at PTO switch terminal 3, 703 Grn wire? (See PTO Switch Connector .)
Result:

NO:Check 703 Grn wire.
( 6 ) (continued)
Action:
Is voltage present at terminal 9, 702 Grn wire?
Result:

NO:Test PTO switch. (See PTO Switch Test .)
( 7 ) Left Handle Neutral Switch
Action:
Is battery voltage present at the left neutral switch (plunger depressed), 702 Grn wire? (See Left Handle Neutral Switch
Connector .)
Result:

NO:Check the 702 Grn wire.
( 8 ) (continued)
Action:
Is voltage present at 701 Grn wire?
Result:

NO:Test the switch. (See Park Brake and Neutral Switch Test .)
( 9 ) Right Handle Neutral Switch
Action:
Is battery voltage present at the right neutral switch (plunger depressed), 701 Grn wire? (See Right Handle Neutral Switch
Connector .)
Result:

NO:Check the 701 Grn wire.
OK:
( 10 ) (continued)
Action:
Is voltage present at 700 Pur wire?

Result:

NO:
OK:Test the switch. (See Park Brake and Neutral Switch Test .)
( 11 ) Start Relay
Action:
Is battery voltage present at the start relay 700 Pur wire? (See Start Relay Connectors .)
Result:

NO:Check the 700 Pur wire.
( 12 ) (continued)
Action:
Key switch OFF. Park brake set. Is there continuity between ground and the 603C Grn wire?
Result:
YES:Release park brake. If continuity still exists, check 603-series Grn wires for short to ground. Test park brake switch. (See
Park Brake and Neutral Switch Test .)
NO:Go to next step.
( 13 ) Park Brake Switch
Action:
Is continuity to ground present at the park brake switch (plunger depressed), 603C/B Grn wires? (See Park Brake Switch
Connector .)
Result:
YES:Check the 603C Grn wire.

NO:Go to next step.
( 14 ) (continued)
Action:
Is continuity to ground present at the 100F Blk wire?
Result:
YES:Test the switch. (See Park Brake and Neutral Switch Test .)
NO:Check the 100F/D Blk wires.

Diagnose Ignition Interlock Circuit (S.N. -120000)

65
Ignition Interlock Circuit (S.N. -120000)
Refer to Ignition Interlock Circuit Operation (S.N. -120000) for theory and circuit schematic.
Engine Connector and Test Lamp
→NOTE:
Disconnect main harness connector C4M from engine harness. Connect a small test lamp across C4M
terminals 1 (201 Red wire) and 2 (601A Wht wire). Leave lamp in place during Test Procedures A, B & C.
Test Procedure A: Key Switch Circuit Test

( 1 ) Test Lamp
Action:
Test Conditions
Test Conditions:
• Key switch OFF

• PTO switch OFF
• Test lamp in place
Is test lamp lit?
Result:

NO:Check 601A/F Wht and 100G/D Blk wires. Test key switch. (See Key Switch Test .)
( 2 ) Test Lamp
Action:
Turn key switch to RUN. Is test lamp off?
Result:
YES:Circuit functional; go to Test Procedure B.

NO:Go to next step.
( 3 ) Test Lamp

Action:
Remove interlock relay from fuse block. Park brake OFF. Is test lamp off?
Result:
YES:Test neutral switches. (See Park Brake and Neutral Switch Test .)
NO:Go to next step.
( 4 ) Test Lamp
Action:
Park brake locked. Is test lamp off?
Result:
YES:Go to Test Procedure B.

NO:Test 601-Wht wires for short to ground.
Test Procedure B: Interlock Relay Circuit Test

( 1 ) Interlock Relay Socket
Action:
Test Conditions
Test Conditions:
• Test Procedure A completed.

• Interlock relay removed from fuse block
• PTO switch OFF
Is battery voltage at fuse block terminal B9? (See Load Center (S.N. -120000) .)
Result:

NO:Check 400C Yel wire. Test power circuit.
Action:
Is continuity to ground present at terminal A8?
Result:

NO:Check 100R/D Blk wires.
Action:
Is continuity to ground present at terminal A7?
Result:
YES:Test seat switch. Check 605 Wht wire for short to ground. (See Seat Switch Test .)
NO:Go to next step.
Action:
Is continuity to ground present at terminal A7 while the seat switch is being depressed?
Result:

NO:Test seat switch. Check 100E/D Blk and 605 Wht wires. (See Seat Switch Test .)
OK:
Action:
Connect jumper wire from terminal A8 to terminal B7. Is test lamp lit?
Result:
YES:Test park brake switch. (See Park Brake and Neutral Switch Test .) Test PTO switch. (See PTO Switch Test .)
NO:Go to next step.
( 6 ) Test Lamp
Action:
Park brake OFF. Is test lamp lit?
Result:

NO:Test park brake switch. Check 602B Pnk and 601D Wht wires. (See Park Brake and Neutral Switch Test .)
( 7 ) Test Lamp
Action:
Remove jumper wire. Is test lamp lit?
Result:
YES:Check 602-Pnk wires for short to ground.

NO:Go to next step.
( 8 ) Test Lamp
Action:
Reconnect the jumper wire from terminal A8 to terminal B7. Park brake locked. PTO switch ON. Is test lamp lit?
Result:

NO:Test PTO switch. Check 602A Pnk and 601E Wht wires. (See PTO Switch Test .)
( 9 ) Test Lamp
Action:
Remove jumper wire and install interlock relay. Park brake OFF (or PTO On). Does the test lamp go from lit to off when the seat
switch is depressed?

Result:
YES:Go to Test Procedure C.

NO:Test interlock relay. (See Relay Test .)
Test Procedure C: Neutral Switch Circuit Test

( 1 ) Test Lamp
Action:
Test Conditions
Test Conditions:
• Test Procedure A and B completed.

• PTO switch OFF
Left control handle to Drive. Is test lamp now lit?
Result:

NO:
OK:Check 601C Wht, 603B Grn and 100F Blk wires and connections. Test park brake and left neutral switches. (See Park Brake
and Neutral Switch Test .)
( 2 ) Test Lamp
Action:
Park brake OFF. Is test lamp off?
Result:

NO:Check 603-Grn wires for short to ground. Test park brake switch.
( 3 ) Test Lamp
Action:
Park brake locked. Left control handle to Neutral, Right control handle to Drive. Is test lamp now lit?
Result:
YES:Move control handles to Neutral. Key switch OFF. Remove test lamp. Install interlock relay. Reattach connector C4M to
engine harness. Go to Test Procedure D.
NO:Check 601B Wht and 603A Grn wires. Test right neutral switch. (See Park Brake and Neutral Switch Test .)
Test Procedure D: Spark Test

( 1 ) Spark Plug
Action:

Test Conditions
Test Conditions:
• Machine parked safely

• Ignition spark tester installed between spark plug and spark plug lead
• Fuel shutoff solenoid disconnected to prevent starting
• Operator on seat
• PTO switch OFF
• Key switch in START position, engine cranking during test.
Does the spark tester indicate a hot, blue spark? (See Spark Test .) Repeat procedure for opposite spark plug (if V-twin).
Result:
YES:Check spark plug gap and condition of spark plug. If plug is good, continue testing ground circuit.
NO:Test ignition coil. Check armature air gap. (See Adjust Armature Air Gap , or Adjust Armature Air Gap, V-Twin .)

Diagnose Fuel Shutoff Circuit (S.N. -120000)

65
Fuel Shutoff Circuit (S.N. -120000)
Refer to Fuel Shutoff Circuit Operation (S.N. -120000) for theory and circuit schematic.
Test Procedure A
( 1 ) Fuel Shutoff Solenoid
Action:
Test Conditions
Test Conditions:
• PTO switch OFF

• Key switch to RUN, engine not running
Does the fuel shutoff solenoid make a click sound when the key switch is turned from Off to RUN?
Result:
YES:Fuel shutoff circuit is functioning properly. Test the fuel shutoff solenoid. (See Fuel Shutoff Solenoid Test, B&S .)
NO:Go to next step.
( 2 ) Solenoid Harness Connector
Action:
Unplug connector from the fuel solenoid. Is battery voltage present across the harness connector terminals?
Result:
YES:Replace the fuel shutoff solenoid.

NO:Check the solenoid connector Gray wire, connector C4 and the 420 Yel wire to hour meter. Confirm that hour meter is fully
seated.
NO:Check the solenoid connector Black wire to ground. Check battery ground connections.
( 3 ) Hourmeter Harness Connector
Action:
Disconnect the harness from the hourmeter. Is battery voltage present at connector 475B Yel wire? (See Hour Meter Connector
.)
Result:

NO:Check fuse F3, Yel wires 475A/B and 400A/B. Test power circuits.
( 4 ) (continued)
Action:
Is continuity to ground present at the connector 100H Blk wire?
Result:
YES:Replace hourmeter.
NO:Check 100H/D Blk wires to W2 engine ground.

Diagnose PTO Circuit (S.N. -120000)

65
PTO Circuit (S.N. -120000)
Refer to PTO Circuit Operation (S.N. -120000) for theory and circuit schematic.
Test Procedure A
( 1 ) Clutch Connector
Action:
Test Conditions
Test Conditions:

• PTO switch ON
Unplug the PTO clutch from the main wiring harness. Is battery voltage present across the harness connector terminals? (See
PTO Clutch Connector .)
Result:
YES:PTO clutch circuit is functional. Test the PTO clutch. (See Electric PTO Clutch Test .)
NO:Go to next step.
( 2 ) (continued)
Action:
Is battery voltage present at the clutch connector 604 Pnk wire?
Result:

NO:Check the 604 Pnk wire and connections.
( 3 ) (continued)
Action:
Is continuity to ground present at 100C Blk wire?
Result:
YES:Connect the PTO clutch. Go to next step.

NO:Check the 100C/D Blk wires and connections.
( 4 ) PTO Switch
Action:
Is battery voltage present at PTO switch terminal 2, 475A/B Yel wires? (See PTO Switch Connector .)
Result:
YES:Test the PTO switch. (See PTO Switch Test .) Replace the switch as necessary.
NO:Check fuse F3. Check the 400A/B and 475A Yel wires and connections. Test the power circuit.

Diagnose Charging Circuit (S.N. -120000)

65
Charging Circuit (S.N. -120000)
Refer to Charging Circuit Operation (S.N. -120000) for theory and circuit schematic.
Test Procedure A
( 1 ) Battery
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
• Battery fully charged
• Stator connected
• Power circuits functioning properly. See appropriate power circuit section.
• Key switch to RUN, running at low idle then to high idle during test
Does the voltage measured across battery terminals (A) rise from approximately 12.5 VDC to 13.5 VDC or higher when the
throttle is moved from low idle to high idle?
Result:
YES:Charging system is working properly. Test complete.

NO:Test fuse F2.
NO:Check for poor connections between battery, starting motor solenoid and voltage regulator/rectifier.
NO:Test voltage regulator/rectifier. (See Regulated Voltage Test .)
Test Procedure B
( 1 ) Stator Connector
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
• Stator unplugged from voltage regulator/ rectifier
• Key switch to RUN, running at high idle during test
• Voltmeter set to VAC
Is the voltage measured across stator leads a minimum 30 volts AC? (See Regulator/Rectifier Connectors .)
Result:
YES:Connect stator. Test complete.

NO:If no or low output is found, test flywheel stator magnets. (See Flywheel Stator Magnets Test .) If magnets are OK, then
replace stator.

Diagnose Headlight Circuit (S.N. -120000)

65
Headlight Circuit (S.N. -120000)
Refer to Headlight Circuit Operation (option) (S.N. -120000) for theory and circuit schematic.
Test Procedure A
( 1 ) Headlights Connectors
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
• Light switch position as directed
Light switch OFF. Remove lamp from headlight assembly. Unplug harness connector from lamp. Attach an ohmmeter across
lamp terminals. Does the meter indicate continuity?
Result:

NO:Replace lamp; light switch ON. If lamp does not light, unplug connector and proceed to next step.
( 2 ) (continued)
Action:
Light switch ON. Is battery voltage present at the connector Yel wire? (See Headlight Connector .)
Result:
YES:Check 100-Blk wire for continuity to ground.

NO:Go to next step.
( 3 ) Fuse Block
Action:
Remove and inspect fuse F4. Is fuse open?
Result:
YES:Check headlight harness 900/901-Yel wires for grounded circuit.

YES:Verify that the proper fuse is installed (7.5 Amp). (See Load Center (S.N. -120000) .)
NO:Install fuse. Go to next step.
( 4 ) Light Switch
Action:
Light switch ON. Is battery voltage present at the light switch 901-Yel wires? (See Light Switch Connector .)
Result:
YES:Check 901-Yel wires from the light switch to the lamp connector.
NO:Go to next step.
( 5 ) (continued)

Action:
Is there battery power at the switch 900 Yel wire?
Result:
YES:Test light switch. (See Headlight Connector .)

NO:Check the 900 Yel wire from switch to fuse block location B4. Check for power on the 400E Yel wire at fuse block location
B3.

Diagnose Hour Meter Circuit (S.N. -120000)

65
Hour Meter Circuit (S.N. -120000)
Refer to Hour Meter Circuit Operation (S.N. -120000) for theory and circuit schematic.
Test Procedure A
Action:
Test Conditions
Test Conditions:

• Connector unplugged from hour meter
Unplug connector from hour meter. Is battery voltage present at the connector 475B Yel wire? (See Hour Meter Connector .)
Result:

NO:Test fuse F3. Check 475A/B Yel wires and connections.
( 2 ) (continued)
Action:
Result:
YES:Go to test procedure B.

NO:Check 100H/D Blk wires to W2 engine ground.
Test Procedure B
CAUTION:
Keep clear of moving engine parts.
→NOTE:
The hour meter receives pulses from the engine magneto ignition coil(s). A 12 VAC output should be
present at the connector when the engine is started. The output will drop to approximately 1—4 VAC3
within 15 to 20 seconds.
[ Readings will vary with engine and the type of meter being used. ]
Action:

Test Conditions
Test Conditions:

• PTO switch OFF
• Jumper wire across 475B and 420 Yel wires
• Operator on the seat
• Meter leads to 100H Blk and 601G Wht wires
• Key switch to RUN, engine running at low idle
Is 12 VAC present at hour meter connector 601G Wht wire (D) when the engine is started, that then drops to approximately
1—4 VAC within 15 to 20 seconds? (See Hour Meter Connector .)
Result:
YES:Replace hour meter. Remove jumper and reattach the hour meter connector.
NO:Check 601-series Wht wires and connections.

Diagnose Power Circuit (S.N. 120001-130000)

65
Power Circuit (S.N. 120001-130000)
Refer to Power Circuit Operation (S.N. 120001-130000) for theory and circuit schematic.
Unswitched Power
( 1 ) Start Relay
Action:
Test Conditions
Test Conditions:

• Key switch OFF
Result:
YES:Re-seat boot. Go to next step.

( 2 ) Key Switch
Action:
Is battery voltage present at key switch terminals B? (See Key Switch Connector .)
Result:

NO:Test fuse F1. Check Red wires 220A, 202B/D. (See Load Center (S.N. 120001-130000) , and Main Electrical Schematic (S.N.
120001-130000) .)
Action:
Result:

NO:Test fuse F2. Check connector C4, Red wires 201, 202B/C.
Switched Power
Action:
Test Conditions
Test Conditions:

Is battery voltage present at the key switch terminal, 400A Yel wire? (See Key Switch Connector .)

Result:

NO:Test fuse F1 and unswitched power circuit. If ok, test the key switch and replace as necessary. (See Key Switch Test .)
( 2 ) PTO Switch
Action:
Result:

NO:Test fuse F3. Check Yel wires 400A/B, 475A.
Action:
.)
Result:

( 4 ) Left Neutral Switch
Action:
Is battery voltage present at the left neutral switch 419A/B Yel wires? (See Left Handle Neutral Switch Connector .)
Result:

NO:Verify that the hour meter is securely connected. Check the 419A Yel wire.
Action:
Is battery voltage present at the park brake switch 419B Yel wire? (See Park Brake Switch Connector .)
Result:

NO:Check the 419B Yel wire.
( 6 ) (continued)
Action:
→NOTE:
There are two separate paths for voltage to get to terminal C of the park brake switch. One is through
the switch, the other is through both neutral switches. With the park brake locked the path through the
switch is open. (See Power Circuit Operation (S.N. 120001-130000) .)
Is battery voltage present at the 608A/B Pnk wires?

Result:

NO:Check that both motion control handles are in the neutral position and the neutral switches are closed. Check the 608B/C
Pnk wires and 701 Grn wire.
( 7 ) (continued)
Action:
Move one of the motion control handles out of the neutral position: Is battery voltage present at the 608A/B Pnk wires?
Result:
YES:Lock the park brake. Check that the motion control handle is releasing the switch, adjust the switch if needed. Go to next
step.
NO:Return the motion control handle to the neutral position. Go to next step.
( 8 ) (continued)
Action:
Move the other motion control handle out of the neutral position: Is battery voltage present at the 608A/B Pnk wires?
Result:
YES:Check that the motion control handle is releasing the switch, adjust the switch if needed. Go to next step.
( 9 ) (continued)
Action:
Unlock the park brake and move one of the motion control levers out of the neutral position: Is battery voltage present at the
park brake switch 419B Yel wire?
Result:

NO:Check that the park brake is set and the switch properly adjusted. Test park brake switch. (See Park Brake and Neutral
Switch Test .)
OK:
( 10 ) Seat Switch
Action:
Is battery voltage present at the seat switch 608A Pnk wire? (See Seat Switch Connector .)
Result:

NO:Check the 608A Pnk wire.
Action:
Is battery voltage present at the light switch 900 Yel wire? (See Light Switch Connector .)
Result:
YES:Test complete.

NO:Check fuse F4. Check Yel wires 900, 400A/E.

Diagnose Cranking Circuit (S.N. 120001-130000)

65
Cranking Circuit (S.N. 120001-130000)
Refer to Cranking Circuit Operation (S.N. 120001-130000) for theory and circuit schematic.
Cranking Power
Action:
Test Conditions
Test Conditions:
• PTO switch OFF

Result:
No Load, B&S .)
( 2 ) Start Relay
Action:
Relay Connectors .)
Result:

( 3 ) (continued)
Action:
Result:
NO:Unplug 703 Grn and 704 Wht wires from relay. Measure resistance of coil (3.5 ohms ±25%) across terminals. If ok, go to
next step.
( 4 ) (continued)
Action:
Is there continuity between ground and the 704 Wht wire?
Result:
YES:Release park brake. If continuity still exists, check 704 Wht wire for short to ground. Test K2 interlock relay. (See Relay
Test .)
NO:Remove K2 interlock relay. Check for continuity to ground at relay socket B7, terminal 87 100R Blk wire. If continuity to

ground is present check for battery voltage at relay socket B9, terminal 86, 420C Yel wire. (See Load Center (S.N.
120001-130000) .)
( 5 ) Start Relay
Action:
With park brake released, sit on seat. Is there continuity between ground and the 704 Wht wire?
Result:
YES:Interlock relay functions properly. Go to next step.

NO:Go to next step.
( 6 ) (continued)
Action:
Is battery voltage present at the start relay 703 Grn wire?
Result:

NO:Make sure test conditions are met. Check the 703 Grn wire.
( 7 ) Key Switch
Action:
Result:

NO:Check fuse F1. Test the unswitched power circuit.
( 8 ) PTO Switch
Action:
Is battery voltage present at PTO switch terminal 2, 475A Yel wire? (See PTO Switch Connector .)
Result:

NO:Check fuse F3.
Action:
.)
Result:
YES:Connect the hour meter. Go to next step.

Action:
Is battery voltage present at the left neutral switch 419A Yel wires? (See Left Handle Neutral Switch Connector .)

Result:

( 11 ) (continued)
Action:
Is voltage present at 701 Grn wire on left neutral switch?
Result:

( 12 ) Right Neutral Switch
Action:
Connector .)
Result:

NO:Check the 701 Grn wire and test the switch.
( 13 ) (continued)
Action:
Is voltage present at 608C Pnk wire?
Result:

Action:
Is voltage at the park brake switch (plunger depressed), 605 Wht wire? (See Park Brake Switch Connector .)
Result:

NO:Check 608C Pnk wire.
( 15 ) PTO Switch
Action:
Is battery voltage present at PTO switch terminal 3 605 Wht wire? (See PTO Switch Connector .)
Result:

NO:Check the 605 Wht wire.
( 16 ) (continued)

Action:
Is battery voltage present at the PTO switch terminal 9, 702A Grn wire?
Result:

( 17 ) Fuse Block
Action:
Check connection point at B1 diode, load center D3 420B/C Yel wires for voltage. Is battery voltage present? (See Load Center
(S.N. 120001-130000) .)
Result:
YES:End test.
NO:Remove diode D3 and check for voltage. If voltage is at D3 continue to inspect 420C/D Yel wires for proper connection.
Test diode D3 to determine proper function. (See Diode Test .)

Diagnose Ignition Interlock Circuit (S.N. 120001-130000)

65
Ignition Interlock Circuit (S.N. 120001-130000)
Refer to Ignition Interlock Circuit Operation (S.N. 120001-130000) for theory and circuit schematic.
→NOTE:
Disconnect main harness connector C4M from engine harness. Connect a small test light across C4M
terminals 1 (201 Red wire) and 2 (601A Wht wire). Leave light in place during Test Procedures A, B & C.
Test Procedure A:
( 1 ) Key Switch Circuit Test
Action:
Test Conditions
Test Conditions:
• Power Circuits functional. (See Power Circuit Operation (S.N. 120001-130000) .)

• Key switch OFF
• PTO OFF
• Drive control handles switches in NEUTRAL
With test conditions in place, is test light lit?
Result:

NO:Check continuity of 601 Wht wires and 100 Blk wires.
NO:Test key switch. (See Key Switch Test .)
( 2 ) (continued)
Action:
Remove interlock relay from fuse block. (See Load Center (S.N. 120001-130000) .) Key switch to RUN. Is test light off?
Result:
YES:Circuit functional; go ahead to Test Procedure B.

NO:Test key switch. (SEE Key Switch Test .)

NO:Check 601-series Wht wires for short to ground.

NO:Unplug hour meter from harness. Hour meter is defective if light goes out.
Test Procedure B:
( 1 ) Park Brake and Neutral Switch Circuit Test
Action:
Test Conditions
Test Conditions:
• Test Procedure A completed

• PTO OFF
• Park brake locked unless directed
• Hour meter attached to harness
• Drive control handle switches in NEUTRAL unless directed
• Key switch in RUN position; engine not running
Unplug connector from seat switch. Attach voltmeter between ground and the connector 608A Pnk wire. (See Seat Switch
Connector .) Is battery voltage present?
Result:

NO:Confirm drive handles are fully spread apart with neutral switches activated.
NO:Test both neutral switches. (See Park Brake and Neutral Switch Test .)
NO:Check continuity of 608 Pnk wires and 701 Grn wires.
( 2 ) (continued)
Action:
Is voltage removed from 608A Pnk wire (See Seat Switch Connector .) when either drive control handle is out of neutral
position?
Result:
YES:Return handles to neutral. Go to next step.

NO:Confirm that park brake is fully locked.
NO:Test park brake switch. (See Park Brake and Neutral Switch Test .)
( 3 ) (continued)
Action:
Is voltage present at the PTO switch, terminal 3, 605 Wht wire? (SEE PTO Switch Connector .)
Result:

NO:Check continuity of 605 Wht wire.
( 4 ) (continued)
Action:
Move drive control handle out of neutral position. Release park brake (brake off). Is voltage present at the PTO switch, terminal
3, 605 Wht wire? (See PTO Switch Connector .)

Result:
YES:Test park brake switch. (See Park Brake and Neutral Switch Test .)
NO:Go to next step.
( 5 ) (continued)
Action:
Is voltage present at the 608A Pnk wire? (See Seat Switch Connector .)
Result:
YES:Circuit functional; go ahead to Test Procedure C.

Test Procedure C:
( 1 ) PTO Switch, Seat Switch, and Interlock Relay Circuit Test
Action:
Test Conditions
Test Conditions:
• Test Procedures A and B completed

• Drive control handle switches in NEUTRAL unless directed
• PTO OFF unless directed
• Interlock relay removed from fuse block unless directed
→NOTE:
Use care when probing the fuse block
Using a small jumper wire, temporarily connect fuse block terminal A8 to ground. (See Load Center (S.N. 120001-130000) .) Is
test light now lit?
Result:
YES:Disconnect jumper from ground. Go to next step.

NO:Check continuity of 601B Wht wire.
( 2 ) (continued)
Action:
Jumper fuse block terminal A8 to terminal A7. (See Load Center (S.N. 120001-130000) .) Is test light now lit?
Result:
YES:Disconnect jumper from A7. Go to next step.

NO:Check continuity of 100E Blk wire.
( 3 ) (continued)
Action:
Jumper fuse block terminal A8 to terminal B7. (See Load Center (S.N. 120001-130000) .) Is test light now lit?
Result:
YES:Remove jumper wire. Go to next step.

NO:Check continuity of 100R Blk wire.
( 4 ) (continued)
Action:
Is battery voltage present at fuse block terminal B2 (diode D3 anode)? (See Load Center (S.N. 120001-130000) .)
Result:

NO:Check continuity of 702A Grn wire.
NO:Test PTO switch. (SEE PTO Switch Test .)
( 5 ) (continued)
Action:
Is voltage at fuse block terminal B1 (diode D3 cathode) approximately 0.7V less than the battery? (See Load Center (S.N.
120001-130000) .)
Result:

NO:(Same voltage or no voltage) - Test diode. (See Diode Test .)
( 6 ) (continued)
Action:
Is voltage at seat switch connector 420B Yel wire approximately 0.7V less than the battery? (See Seat Switch Connector .)
Result:

NO:Check continuity of 420B Yel wire.
( 7 ) (continued)
Action:
Is voltage at fuse block terminal B9 approximately 0.7V less than the battery? (See Load Center (S.N. 120001-130000) .)
Result:

NO:Check continuity of 420C Yel wires.
( 8 ) (continued)
Action:
Is voltage at the C4M connector 420A Yel wire approximately 0.7V less than the battery? (See Engine Connector .)
Result:

NO:Check continuity of 420A Yel wire.
( 9 ) (continued)
Action:
Reinstall interlock relay. (See Load Center (S.N. 120001-130000) .) With park brake locked and PTO off, is test light off?

Result:

( 10 ) (continued)
Action:
Move PTO switch to ON. Is test light now lit?
Result:

( 11 ) (continued)
Action:
Reattach seat switch connector and activate seat switch. Does the test light turn off?
Result:
YES:Tests complete. Turn key switch OFF. Remove all test items and reassemble machine.
NO:Test seat switch. (See Seat Switch Test .)
Diagnose Fuel Shutoff Circuit (S.N. 120001-130000)
65
Fuel Shutoff Circuit (S.N. 120001-130000)
Refer to Fuel Shutoff Circuit Operation (S.N. 120001-130000) for theory and circuit schematic.
interlock circuit.
Refer to Ignition Interlock Circuit Operation (S.N. 120001-130000) for operation.

Diagnose PTO Circuit (S.N. 120001-130000)

65
PTO Circuit (S.N. 120001-130000)
Refer to PTO Circuit Operation (S.N. 120001-130000) for theory and circuit schematic.
Test Procedure A
Action:
Test Conditions
Test Conditions:

• PTO switch ON
Result:
NO:Go to next step.
( 2 ) (continued)
Action:
Result:

( 3 ) (continued)
Action:
Result:

( 4 ) PTO Switch
Action:
Result:

Diagnose Charging Circuit (S.N. 120001-130000)

65
Charging Circuit (S.N. 120001-130000)
Refer to Charging Circuit Operation (S.N. 120001-130000) for theory and circuit schematic.
Test Procedure A
( 1 ) Battery
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
Does the voltage measured across battery terminals (A) rise from approximately 12.5 VDC to 13.5 VDC or higher when the
throttle is moved from low idle to high idle.
Result:

NO:Test fuse F2.
Test Procedure B
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
• Stator unplugged from voltage regulator/rectifier
Result:

replace stator.

Diagnose Headlight Circuit (S.N. 120001-130000)

65
Headlight Circuit (S.N. 120001-130000)
Refer to Headlight Circuit Operation (option) (S.N. 120001-130000) for theory and circuit schematic.
Test Procedure A
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
Result:

( 2 ) (continued)
Action:
Result:
YES:Check 100-Blk wire for continuity to ground.

NO:Go to next step.
( 3 ) Fuse Block
Action:
Result:
YES:Check headlight harness 900/901-Yel wires for grounded circuit.

YES:Verify that the proper fuse is installed (7.5 Amp). (See Load Center (S.N. 120001-130000) .)
( 4 ) Headlight Switch
Action:
Light switch ON. Is battery voltage present at the headlight switch 901-Yel wires? (See Light Switch Connector .)
Result:
YES:Check 901-Yel wires from the light switch to the lamp connector.
NO:Go to next step.
( 5 ) (continued)

Action:
Is there battery power at the headlight switch 900 Yel wire?
Result:
YES:Test headlight switch. (See Headlight Switch (S.N. -130000) .)

NO:Check the 900 Yel wire from switch to fuse block location B4. Check for power on the 400E Yel wire at fuse block location
B3.

Diagnose Hour Meter Circuit (S.N. 120001-130000)

65
Hour Meter Circuit (S.N. 120001-130000)
Refer to Hour Meter Circuit Operation (S.N. 120001-130000) for theory and circuit schematic.
Test Procedure A
Action:
Test Conditions
Test Conditions:

Result:

( 2 ) (continued)
Action:
Result:

NO:Check 100H/G/D Blk wires to W2 engine ground.
Test Procedure B
CAUTION:
→NOTE:
present at the connector when the engine is started. The output will drop to approximately 1—4 VAC
Action:

Test Conditions
Test Conditions:

• PTO switch OFF
• Jumper wire across 475B and 419A Yel wires
Is 12 VAC present at hour meter connector 601G Wht wire when the engine is started, that then drops to approximately 1—4
VAC within 15 to 20 seconds? (See Hour Meter Connector .)
Result:

Diagnose Power Circuit (S.N. 130001- )

65
Power Circuit (S.N. 130001- )
Refer to Power Circuit Operation (S.N. 130001- ) for theory and circuit schematic.
Unswitched Power
( 1 ) Start Relay
Action:
Test Conditions
Test Conditions:

• Key switch OFF
Result:
YES:Reseat boot. Go to next step.

NO:Check for loose or corroded connections at battery terminals, engine ground, and start relay. If OK, test the battery. (See
( 2 ) Key Switch
Action:
Is battery voltage present at key switch terminals B? (See Key Switch Connector .)
Result:

NO:Test fuse F1. Check Red wires 220A, 202B, and 202D. (See Load Center (S.N. 130001- ) , and Main Electrical Schematic
(S.N. 130001-170000) , or Main Electrical Schematic (S.N. 170001- ) .)
Action:
Result:

NO:Test fuse F2. Check connector C4, Red wires 201, 202B, and 202/C.
Switched Power
Action:
Test Conditions
Test Conditions:

Is battery voltage present at the key switch terminal, 400A Yel wire? (See Key Switch Connector .)

Result:

NO:Test fuse F1 and unswitched power circuit. If OK, test the key switch and replace as necessary. (See Key Switch Test .)
( 2 ) PTO Switch
Action:
Is battery voltage present at PTO switch terminal 2, 475A, and 475B Yel wires? (See PTO Switch Connector .)
Result:

NO:Test fuse F3. Check Yel wires 400A, and 400B, and 475A.
Action:
.)
Result:

Action:
Is battery voltage present at the left neutral switch 419A and 419B Yel wires? (See Left Handle Neutral Switch Connector .)
Result:

Action:
Is battery voltage present at the park brake switch 419B Yel wire? (See Park Brake Switch Connector .)
Result:

NO:Check the 419B Yel wire.
( 6 ) (continued)
Action:
→NOTE:
There are two separate paths for voltage to get to terminal B of the park brake switch. One is through
the switch, the other is through both neutral switches. With the park brake locked the path through the
switch is open. (See Power Circuit Operation (S.N. 130001- ) .)
Is battery voltage present at the 608C Pnk wire?

Result:

NO:Check that both motion control handles are in the neutral position and the neutral switches are closed. Check the 608C Pnk
wire and 701 Grn wire.
( 7 ) (continued)
Action:
Move one of the motion control handles out of the neutral position: Is battery voltage present at the 608C Pnk wire?
Result:
YES:Lock the park brake. Check that the motion control handle is releasing the switch, adjust the switch if needed. Go to next
step.
( 8 ) (continued)
Action:
Move the other motion control handle out of the neutral position: Is battery voltage present at the 608C Pnk wire?
Result:
YES:Check that the motion control handle is releasing the switch, adjust the switch if needed. Go to next step.
( 9 ) (continued)
Action:
Unlock the park brake and move one of the motion control levers out of the neutral position: Is battery voltage present at the
park brake switch 419B Yel wire?
Result:

NO:Check that the park brake is set and the switch properly adjusted. Test park brake switch. (See Park Brake and Neutral
Switch Test .)
OK:
( 10 ) Seat Switch
Action:
Is battery voltage present at the seat switch 608A Pnk wire? (See Seat Switch Connector .)
Result:

NO:Check the 608A Pnk wire.
Action:
Is battery voltage present at the light switch 900A Yel wire? (See Light Switch Connector .)
Result:

NO:Check fuse F4. Check Yel wires 900A, 400A, and 400E.
( 12 ) Low Fuel Light (S.N. 170001- )
Action:
Is battery voltage present at the low fuel light 400R Yel wire? (See Low Fuel Light Circuit Operation (S.N. 170001- ) .)
Result:
YES:Test complete.
NO:Check splice SP400 and wire 400R Yel.

Diagnose Cranking Circuit (S.N. 130001- )

65
Cranking Circuit (S.N. 130001- )
Refer to Cranking Circuit Operation (S.N. 130001- ) for theory and circuit schematic.
Cranking Power
Action:
Test Conditions
Test Conditions:
• PTO switch OFF

Result:
No Load, B&S .)
( 2 ) Start Relay
Action:
Relay Connectors .)
Result:

( 3 ) (continued)
Action:
Result:
NO:Unplug 703 Grn and 704 Wht wires from relay. Measure resistance of coil (3.5 ohms ±25%) across terminals. If ok, go to
next step.
( 4 ) (continued)
Action:
Is there continuity between ground and the 704 Wht wire?
Result:
YES:Release park brake. If continuity still exists, check 704 Wht wire for short to ground. Test K2 interlock relay. (See Relay
Test .)
NO:Remove K2 interlock relay. Check for continuity to ground at relay socket B7, terminal 30 100R Blk wire. If continuity to

ground is present check for battery voltage at relay socket B9, terminal 86, 420C Yel wire. (See Load Center (S.N. 130001- ) .)
( 5 ) Start Relay
Action:
With park brake released, sit on seat. Is there continuity between ground and the 704 Wht wire?
Result:
YES:Interlock relay functions properly. Go to next step.

NO:Go to next step.
( 6 ) (continued)
Action:
Is battery voltage present at the start relay 703 Grn wire?
Result:

NO:Make sure test conditions are met. Check the 703 Grn wire.
( 7 ) Key Switch
Action:
Result:

NO:Check fuse F1. Test the unswitched power circuit.
( 8 ) PTO Switch
Action:
Is battery voltage present at PTO switch terminal 2, 475A Yel wire? (See PTO Switch Connector .)
Result:

NO:Check fuse F3.
Action:
.)
Result:
YES:Connect the hour meter. Go to next step.

Action:
Is battery voltage present at the left neutral switch 419A Yel wires? (See Left Handle Neutral Switch Connector .)

Result:

( 11 ) (continued)
Action:
Is voltage present at 701 Grn wire on left neutral switch?
Result:

( 12 ) Right Neutral Switch
Action:
Connector .)
Result:

NO:Check the 701 Grn wire and test the switch.
( 13 ) (continued)
Action:
Is voltage present at 608C/A Pnk wires?
Result:

Action:
Is voltage at the park brake switch (plunger released), 605 Wht wire? (See Park Brake Switch Connector .)
Result:

NO:Check 608C/B Pnk wires.
( 15 ) PTO Switch
Action:
Is battery voltage present at PTO switch terminal 3 605 Wht wire? (See PTO Switch Connector .)
Result:

NO:Check the 605 Wht wire.
( 16 ) (continued)

Action:
Is battery voltage present at the PTO switch terminal 9, 702A Grn wire?
Result:

( 17 ) Fuse Block
Action:
Check connection point at B1 diode, load center D3 420B/C Yel wires for voltage. Is battery voltage present? (See Load Center
(S.N. 130001- ) .)
Result:
YES:End test.
NO:Remove diode D3 and check for voltage. If voltage is at D3 continue to inspect 420C/B Yel wires for proper connection. Test
diode D3 to determine proper function. (See Diode Test .)

Diagnose Ignition Interlock Circuit (S.N. 130001- )

65
Ignition Interlock Circuit (S.N. 130001- )
Refer to Ignition Interlock Circuit Operation (S.N. 130001- ) for theory and circuit schematic.
→NOTE:
Disconnect main harness connector C4M from engine harness. Connect a small test lamp across C4M
terminals 1 (201 Red wire) and 2 (601A Wht wire). Leave lamp in place during Test Procedures A, B & C.
Test Procedure A:
( 1 ) Key Switch Circuit Test
Action:
Test Conditions
Test Conditions:
• Power Circuits functional. (See Power Circuit Operation (S.N. 130001- ) .)

• Key switch OFF
• PTO OFF
• Drive control handles/switches in NEUTRAL
With test conditions in place, is test lamp lit?
Result:

NO:Check continuity of 601A/F Wht and 100G/D Blk wires.
( 2 ) (continued)
Action:
Remove interlock relay from fuse block. (See Load Center (S.N. 130001- ) .) Key switch to RUN. Is test lamp off?
Result:
YES:Circuit functional; go ahead to Test Procedure B.


NO:Check 601-series Wht wires for short to ground.

NO:Unplug hour meter from harness. Hour meter is defective if lamp goes out.
Test Procedure B:
( 1 ) Park Brake and Neutral Switch Circuit Test
Action:
Test Conditions
Test Conditions:
• Test Procedure A completed

• PTO OFF
• Hour meter attached to harness
• Drive control handles/switches in NEUTRAL unless directed
Unplug connector from seat switch. Attach voltmeter between ground and the connector 608A Pnk wire. (See Seat Switch
Connector .) Is battery voltage present?
Result:

NO:Confirm drive handles are fully spread apart with neutral switches activated.
NO:Test both neutral switches. (See Park Brake and Neutral Switch Test .)
NO:Check continuity of 608A Pnk and 701 Grn wires.
( 2 ) (continued)
Action:
Is voltage removed from 608A Pnk wire (See Seat Switch Connector .) when either drive control handle is out of neutral
position?
Result:
YES:Return handles to neutral. Go to next step.

NO:Confirm that park brake is fully locked.
( 3 ) (continued)
Action:
Is voltage present at the PTO switch, terminal 3, 605 Wht wire? (See PTO Switch Connector .)
Result:

NO:Check continuity of 605 Wht wire.
( 4 ) (continued)
Action:
Move drive control handle(s) out of neutral position. Release park brake (brake off). Is voltage present at the PTO switch,
terminal 3, 605 Wht wire? (See PTO Switch Connector .)

Result:
YES:Test park brake switch. (See Park Brake and Neutral Switch Test .)
NO:Go to next step.
( 5 ) (continued)
Action:
Is voltage present at the 608A Pnk wire? (See Seat Switch Connector .)
Result:
YES:Circuit functional; go ahead to Test Procedure C.

Test Procedure C:
( 1 ) PTO Switch, Seat Switch, and Interlock Relay Circuit Test
Action:
Test Conditions
Test Conditions:
• Test Procedures A and B completed

• Drive control handles/switches in NEUTRAL unless directed
• PTO OFF unless directed
• Interlock relay removed from fuse block unless directed
→NOTE:
Use care when probing the fuse block
Using a small jumper wire, temporarily connect fuse block terminal A8 to ground. (See Load Center (S.N. 130001- ) .) Is test
lamp now lit?
Result:
YES:Disconnect jumper from ground. Go to next step.

NO:Check continuity of 601B Wht wire.
( 2 ) (continued)
Action:
Jumper fuse block terminal A8 to terminal A7. (See Load Center (S.N. 130001- ) .) Is test lamp now lit?
Result:
YES:Disconnect jumper from A7. Go to next step.

NO:Check continuity of 100E Blk wire.
( 3 ) (continued)
Action:
Jumper fuse block terminal A8 to terminal B7. (See Load Center (S.N. 130001- ) .) Is test lamp now lit?
Result:
YES:Remove jumper wire. Go to next step.

NO:Check continuity of 100R Blk wire.
( 4 ) (continued)
Action:
Is battery voltage present at fuse block terminal B2 (diode D3 anode)? (See Load Center (S.N. 130001- ) .)
Result:

NO:Check continuity of 702A Grn wire.
( 5 ) (continued)
Action:
Is voltage at fuse block terminal B1 (diode D3 cathode) approximately 0.7V less than the battery? (See Load Center (S.N.
130001- ) .)
Result:

NO:(Same voltage or no voltage) - Test diode. (See Diode Test .)
( 6 ) (continued)
Action:
Is voltage at seat switch connector 420B Yel wire approximately 0.7V less than the battery? (See Seat Switch Connector .)
Result:

NO:Check continuity of 420B Yel wire.
( 7 ) (continued)
Action:
Is voltage at fuse block terminal B9 approximately 0.7V less than the battery? (See Load Center (S.N. 130001- ) .)
Result:

NO:Check continuity of 420C Yel wire.
( 8 ) (continued)
Action:
Is voltage at the C4M connector 420A Yel wire approximately 0.7V less than the battery? (See Engine Connector .)
Result:

NO:Check continuity of 420A Yel wire.
( 9 ) (continued)
Action:
Reinstall interlock relay. (See Load Center (S.N. 130001- ) .) With park brake locked and PTO off, is test lamp off?

Result:

( 10 ) (continued)
Action:
Move PTO switch to ON. Is test lamp now lit?
Result:

( 11 ) (continued)
Action:
Reattach seat switch connector and activate seat switch. Does the test lamp turn off?
Result:
YES:Tests complete. Turn key switch OFF. Remove all test items and reassemble machine.
NO:Test seat switch. (See Seat Switch Test .)
Diagnose Fuel Shutoff Circuit (S.N. 130001- )
65
Fuel Shutoff Circuit (S.N. 130001- )
Refer to Fuel Shutoff Circuit Operation (S.N. 130001- ) for theory and circuit schematic.
interlock circuit.
Refer to Ignition Interlock Circuit Operation (S.N. 130001- ) for operation.

Diagnose PTO Circuit (S.N. 130001- )

65
PTO Circuit (S.N. 130001- )
Refer to PTO Circuit Operation (S.N. 130001- ) for theory and circuit schematic.
Test Procedure A
Action:
Test Conditions
Test Conditions:

• PTO switch ON
Result:
NO:Go to next step.
( 2 ) (continued)
Action:
Result:

( 3 ) (continued)
Action:
Result:

( 4 ) PTO Switch
Action:
Result:

Diagnose Charging Circuit (S.N. 130001- )

65
Charging Circuit (S.N. 130001- )
Refer to Charging Circuit Operation (S.N. 130001- ) for theory and circuit schematic.
Test Procedure A
( 1 ) Battery
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
Does the voltage measured across battery terminals rise from approximately 12.5 VDC to 13.5 VDC or higher when the throttle
is moved from low idle to high idle.
Result:

NO:Test fuse F2.
Test Procedure B
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
• Stator unplugged from voltage regulator/rectifier
Result:

replace stator.

Diagnose Headlight Circuit (S.N. 130001- )

65
Headlight Circuit (S.N. 130001- )
Refer to Headlight Circuit Operation (option) (S.N. 130001- ) for theory and circuit schematic.
Test Procedure A
Action:
Test Conditions
Test Conditions:

• PTO switch OFF
Result:

( 2 ) (continued)
Action:
Result:
YES:Check 100K/L Blk wires for continuity to ground.

NO:Go to next step.
( 3 ) Fuse Block
Action:
Result:
YES:Check 900A/901B Yel wires and headlight harness 901C/D Yel wires for grounded circuit.
YES:Verify that the proper fuse is installed (7.5 Amp). (See Load Center (S.N. 130001- ) .)
( 4 ) Headlight Switch
Action:
Light switch ON. Is battery voltage present at the headlight harness connector (C3F) 901B Yel wire? (See Headlight Harness
Connector, C3F (W1 Main Harness) (S.N. 130001- ) .)
Result:
YES:Check 901C/D Yel wires from C3M connector to the lamp connector. (See Headlight Harness Connector, C3M (W3 Light Kit
Harness) (S.N. 130001- ) .)
NO:Go to next step.

( 5 ) (continued)
Action:
Is there battery power at the headlight switch 900A Yel wire?
Result:
YES:Test headlight switch. (See Headlight Switch (S.N. 130001- ) .)

NO:Check the 900A Yel wire from switch to fuse block location B4. Check for power on the 400E Yel wire at fuse block location
B3.

Diagnose Hour Meter Circuit (S.N. 130001- )

65
Hour Meter Circuit (S.N. 130001- )
Refer to Hour Meter Circuit Operation (S.N. 130001- ) for theory and circuit schematic.
Test Procedure A
Action:
Test Conditions
Test Conditions:

Result:

( 2 ) (continued)
Action:
Result:

NO:Check 100H/G/D Blk wires to W2 engine ground.
Test Procedure B
CAUTION:
→NOTE:
present at the connector when the engine is started. The output will drop to approximately 1—4 VAC
Action:

Test Conditions
Test Conditions:

• PTO switch OFF
• Jumper wire across 475B and 419A Yel wires
Is 12 VAC present at hour meter connector 601G Wht wire when the engine is started, that then drops to approximately 1—4
VAC within 15 to 20 seconds? (See Hour Meter Connector .)
Result:

Diagnose Low Fuel Light Circuit (S.N. 170001- )

65
Low Fuel Light Circuit (S.N. 170001- )
Refer to Low Fuel Light Circuit Operation (S.N. 170001- ) for theory and circuit schematic.
Procedure: Low Fuel Light Always Off

( 1 ) Light
Action:
Test Conditions
Test Conditions
• Machine parked safely.

• Park brake locked.
• Battery fully charged.
• Fuel tank empty.
• Key switch to RUN, engine not running.
• Power circuit OK. See Diagnose Power Circuit (S.N. 130001- ), Section 240, Group 20.
Remove and check light. Is light good?
Result:

NO:Replace light.
( 2 ) Light Socket
Action:
Is battery voltage present at socket, 400A Yel?
Result:
YES:Install light.
NO:Check connections to socket, and SP400. Check 400A Yel wire.
( 3 ) Fuel Level Assembly
Action:
Disconnect 600A Org wire from fuel level assembly center tab. Is battery voltage present at wire?
Result:
YES:Check continuity from side tab of fuel level assembly to ground.

NO:Check connections and continuity of 600A Org.
( 4 ) Continued
Action:
Is continuity to ground present at side tab of fuel level assembly?
Result:
YES:Circuit OK, Replace fuel tank assembly.

NO:Check connections to thermistor, engine ground, and SP100. Check continuity of wires 100AD Blk, and 100A Blk.
Procedure Low Fuel Light Always ON

( 1 ) Fuel Level Sensor

Section 240 - ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 30: Tests and Adjustments
Action:
Test Conditions
Test Conditions
• Machine parked safely.

• Park brake locked.
• Battery fully charged.
• Fuel tank full (fuel must cover Thermistor located approximately 15 cm (6 in.) below fuel cap).
• Key switch to RUN, engine not running.
Disconnect wire 600A Org from fuel level sensor. Is low fuel light on?
Result:
YES:600A Org wire is shorted to ground. Turn off key switch. Check connections to sensor and low fuel light socket. Inspect
600A Org wire. Check continuity to ground. Repair or replace as needed.
NO:Replace fuel tank assembly.


Ground Circuit Test
Battery Voltage and Specific Gravity Tests
Battery Charge
Battery Load Test
Spark Test
Regulated Voltage Test
Regulated Amperage Test
Starting Motor Amperage Draw Test: Loaded, B&S
Starting Motor Amperage Draw Test: No Load, B&S
Stator Output Test, B&S
Flywheel Stator Magnets Test
Flywheel Ignition Magnet Test
Diode Test
PTO Switch Test
Electric PTO Clutch Test
Key Switch Test
Start Relay Test
Relay Test
Fuel Shutoff Solenoid Test, B&S
Seat Switch Test
Headlight Switch (S.N. -130000)
Headlight Switch (S.N. 130001- )
Park Brake and Neutral Switch Test
Specifications
Battery (Minimum) Voltage 12.4 VDC
Battery (Minimum) Electrolyte Specific Gravity 1.225 with less than 50 point variation
Minimum Load Reading Amperage 3—9 amps at 11 volts
Starting Motor, Loaded (Maximum Draw) Amperage 100 amp
Starting Motor, No Load (Maximum Draw) Amperage 35 amp
Stator output at full throttle (minimum) Voltage 30 VAC
PTO Clutch Resistance 3.0 ohm ± 10%
Relay Coil Resistance 80 ohms ±10%

Solenoid Type “L” Resistance 37 ohms ±15%
Solenoid Type “S” Resistance 28 ohms ±15%

→NOTE:
Order tools according to information given in the ServiceGard ™ Catalog. Some tools may be available
Battery Tester
JTO5685 or equivalent
To load test battery.
Current Gun
JT05712
To measure current.
Current Clamp
JT02153

To measure current.
Multimeter
JT05791A
To perform electrical tests.
Ground Circuit Test

Reason:
To check for opens, loose terminal wire crimps, poor connections, or corrosion in the ground circuit. The voltmeter method
checks ground connections under load.
Ohmmeter Procedure:
[1] - Turn key switch to OFF position. Engage park brake.
[2] - Connect ohmmeter negative (BLACK) lead to negative (-) terminal of battery. Put meter positive (+) (RED) lead on
negative (-) terminal of battery and record reading. Reading should be 0.1 ohm or less.
[3] - Put meter RED lead on ground terminal of circuit or component to be tested that is closest to the battery negative (-)
terminal. Resistance reading must be very close to or the same as the battery negative (-) terminal reading. Work backwards
from the battery on the ground side of the problem circuit until the resistance reading increases above 0.1 ohms. The problem
is between the last two test points. If a problem is indicated, disconnect the wiring harness connector to isolate the wire or
component and check resistance again. Maximum allowable resistance in the circuit is 0.1 ohms. Check both sides of
connectors closely as disconnecting and connecting may temporarily solve problem.
Voltmeter Procedure:
[1] - Put transmission in neutral. Engage park brake. Put PTO switch in OFF position. Turn key switch to on position.
[2] - Connect voltmeter negative (-) (BLACK) lead to the negative (-) terminal of battery.
[3] - Put meter positive (+) (RED) lead on ground terminal of component to be tested. Be sure that the component circuit is
activated (key switch on, switches closed) so voltage is present at the component. Record voltage. Voltage must be greater
than 0 but less than 1 V. Some components have a small voltage reading on the ground side and still be operating correctly.
Results:
If resistance is above 0.1 ohms, check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the
ground circuit.
If voltage is 0, the component is open.
If voltage is greater than 1 V, the ground circuit is bad. Check for open wiring, loose terminal wire crimps, poor
connections, or corrosion in the ground circuit.

Battery Voltage and Specific Gravity Tests
Battery Voltage test
Reason:
To check voltage and determine condition of battery.
Procedure:
CAUTION:
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into the eyes. Avoid the hazard by:
Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added.
Avoid spilling or dripping electrolyte.
Use proper jump-start procedure.
If you spill acid on yourself:
Flush your skin with water.

Apply baking soda or lime to help neutralize the acid.
Flush your eyes with water for 10—15 minutes. Get medical attention immediately.
Drink large amounts of water or milk.

Then drink milk of magnesia, beaten eggs, or vegetable oil.
Get medical attention immediately.
[1] - Clean battery terminals and top of battery. Inspect battery terminals and case for breakage or cracks.
[2] - Check electrolyte level in each battery cell. Add clean, soft water as needed. If water added, charge battery for 20
minutes at 10 amps.
[3] - Remove surface charge by placing a small load on the battery for 15 seconds.
[4] - Check battery voltage with voltmeter or JT05685 Battery Tester or equivalent.
Battery Tester
JT05685 or equivalent
Electrical Tests and Adjustments
[5] - Check specific gravity of each cell with a hydrometer.

Results:
Battery voltage less than 12.4 VDC, charge battery to specification.

Battery (Minimum) Voltage 12.4 VDC
Battery voltage more than 12.4 VDC, test specific gravity to specification.
Battery (Minimum) Electrolyte Specific Gravity 1.225 with less than 50 point variation
All cells less than 1.175, charge battery at 10 A rate.

All cells less than 1.225 with less than 50 point variation, charge battery at 10 A rate.
All cells more than 1.225 with less than 50 point variation, load test battery.
More than 50 point variation: replace battery.

Battery Charge
Reason:
To increase battery charge after battery has been discharged.
Procedure:
Battery Charger
[1] - Connect variable rate charger to battery.
[2] -
→NOTE:
Maximum charge time at boost setting is 10 minutes. Allow an additional 5 minutes for each 10 degrees
below 21°C (70°F).
Start charger at slow rate. Increase charge rate one setting at a time. Check charger ammeter after 1 minute at each setting.
Maintain 10 A charge rate. Use boost setting as necessary.
[3] - Check if battery is accepting a 10 A charge after 10 minutes at boost setting.
Battery will not accept 10 A charge after 10 minutes at boost setting: replace battery.
Battery is accepting 10 A charge after 10 minutes at boost setting, and battery did not need water: go to steps 6 and 7.
Battery is accepting 10 A charge after 10 minutes at boost setting, but battery did need water or all cells were below
1.175: go to steps 4 and 5.
[4] -
IMPORTANT:
Decrease charge rate if battery gases or bubbles excessively or becomes too warm to touch.
Set charger at 15—25 amps.
[5] -
→NOTE:
If battery was discharged at slow or unknown rate, charge at 10—15 amps for 6—12 hours
(Maintenance—free battery: 12—24 hours). If battery was discharged at fast rate, charge at 20—25 amps
for 2—4 hours (Maintenance—free battery: 4—8 hours).
Check specific gravity after 30 minutes (60 minutes for maintenance—free battery).
More than 50 point variation between cells: replace battery.

Less than 50 point variation between cells: go to steps 6 and 7.
[6] - Continue charging battery until specific gravity is 1.230—1.265 points.
[7] - Load test battery. (See “Battery Load Test”.)

Battery Load Test

Reason:
JT05685 Battery Tester or Equivalent
To check condition of battery under load.
→NOTE:
See “Battery Charge” before applying a load to battery.
→NOTE:
Use the procedures given with the tester.
Procedure:
[1] - Turn load knob of JT05685 battery tester or equivalent clockwise until amperage reading is equal to:
Battery Tester
Electrical Tests and Adjustments
One half (1/2) cold cranking amperage rating (use blue scale).
OR
Three times ampere hour rating (use black scale).
[2] - Hold for 15 seconds and turn load knob of tester off.
[3] - Read battery voltage.
Results:
If the battery does not indicate 9.6 V or more, replace battery.
Spark Test
Reason:
To determine condition of the ignition system.
Equipment:
D05351ST Spark Tester

Tester, Spark
D05351ST
Use to test the condition of the spark plug while engine is operating.
Procedure:
LEGEND:
A High Tension Lead
B Spark Tester
C Screw
D Spark
Spark Test
[2] - Remove high tension lead (A) from spark plug and connect to spark tester (B).
[3] - Connect spark tester lead to spark plug.
[4] -
→NOTE:
Do not adjust spark tester gap beyond 5.0 mm (0.200 in.) as damage to ignition system components
could occur.
Adjust spark tester gap to 4.2 mm (0.166 in.) with screw (C).
[5] - Start engine and watch spark (D) at tester.
Results:
If engine starts, watch spark with engine running. Look for a strong, steady, blue spark.
If spark is weak, or if no spark, install new spark plug and test again.
If spark is still weak, or still no spark, run tests on individual components to find cause of malfunction.
Regulated Voltage Test

[1] - Park machine safely
[2] - Raise seat.
[3] - Remove surface charge from battery by placing a small load on the battery for 15 seconds.
[4] - Set voltmeter to 50 DC volt scale.
[5] - Connect voltmeter positive (red) lead to battery positive (+) terminal.
[6] - Connect voltmeter negative (black) lead to battery negative (—) terminal.
[7] - Start and run engine at high idle. Read voltmeter several times during 5 minutes of running time.
[8] - Voltage should remain between 12.2—14.7 volts DC.

Regulated Amperage Test
Regulated Amp Test Setup

LEGEND:
A JT05712 Current Clamp
B Load Knob
C Scale
Reason:
To determine charging output of rectifier/regulator.
Procedure:
[2] - Connect JT05712 Current Clamp (A) to voltmeter and put around positive (red) battery cable going to regulator.
Current Gun
JT05712
To measure current.
[3] - Set current clamp for DC current.
[4] -
→NOTE:
Turn load knob (B) fully counterclockwise (out) into OFF position BEFORE making any test connections.
Connect battery tester to battery.

Current Clamp
To load and measure battery.

[5] - Turn load knob (B) clockwise (in) until voltage on voltage tester scale reads 11 volts for 5 seconds only to partially drain
battery.
[6] - Quickly turn load knob completely counter-clockwise (out) to OFF position.
[7] - Start and run engine at high idle. Battery voltage should read between 12.2—15.0 VDC.
[8] - Turn load knob clockwise (in) until voltage on tester voltage scale (C) reads 11 volts and observe reading on amps scale.
[9] - Quickly turn load knob completely counter-clockwise (out) to OFF position.
[10] - After load test, voltage scale (B) should return to voltage level prior to test.
Results:
If reading does not meet specifications, test stator voltage output.

Minimum Load Reading Amperage 3—9 amps at 11 volts
If stator voltage output meets specifications and voltage and ground to the regulator/rectifier is verified, replace the
regulator/rectifier.

Starting Motor Amperage Draw Test: Loaded, B&S

LEGEND:
A Current Clamp
B Positive Battery Cable
Starting Motor Amperage Draw Test, Loaded
Reason:
To determine amperage needed to crank the engine.
Procedure:
[1] - Ensure transmission is in neutral and park brake is set.
[2] - Remove spark plug lead and ground to engine.
[3] - Connect JT02153 current clamp RED lead to the VOLTS jack of the JT05791 multimeter and the BLACK lead of the current
clamp to the COM jack on the multimeter.
Current Clamp
JT02153
To measure current.
Multimeter
JT05791
To read current in millivolts.
[4] - Clamp jaws of current clamp (A) around the positive battery cable (B).
[5] -
→NOTE:
If using a multimeter other than JT05791, use a meter that will read millivolts. Millivolts = current in
amps; 1mV= 1 amp.
Set the current clamp to 2000A and the multimeter to 300mV.
[6] -
→NOTE:
The core of the jaws may hold some magnetic force after the current clamp has been used for
measurement. If you cannot zero adjust the display, open the jaws and snap them closed several times.

Adjust the DCA ZERO ADJUST dial on the current clamp for a zero reading on the multimeter.
[7] - Crank the engine and read the starting motor amperage draw.
Result:
If amperage is above specification check starting motor for binding or damaged wires or windings.
Starting Motor, Loaded (Maximum Draw) Amperage 100 amp
If starting motor is good, check internal engine and PTO drive for binding or damage.

Starting Motor Amperage Draw Test: No Load, B&S

Reason:
To determine starting motor condition under no load conditions.
Procedure:
LEGEND:
A Current Clamp
Starting Motor Amperage Draw Test, No Load
CAUTION:
Do not clamp starting motor housing in vise or strike with a hammer. Clamp only on the mounting
bracket. Starting motors contain two ceramic magnets that can be broken or cracked if the motor
housing is hit, deformed or dented.
[1] - Remove starting motor from machine and clamp the starting motor mounting bracket in a vise.
[2] - Connect JT02153 current clamp (A) RED lead to the VOLTS jack of the JT05791A multimeter and the BLACK lead of the
current clamp to the COM jack on the multimeter.
Current Clamp
JT02153
To measure current.
Multimeter
JT05791A
To read current in millivolts.
[3] - Connect the negative jumper cable to the battery negative post and the frame of the starting motor.
[4] - Connect the positive jumper cable to the positive post of the battery.
[5] - Connect current clamp RED lead to the VOLTS jack of the multimeter and the BLACK lead of the current clamp to the COM
jack on the multimeter.
[6] - Clamp jaws of current clamp around the positive jumper cable.
[7] -
→NOTE:
If using a multimeter other than JT05791A, use a meter that will read millivolts. Millivolts = current in
amps; 1mV = 1 amp.
Set the current clamp to 2000A and the multimeter to 300mV.
[8] -
→NOTE:
The core of the jaws may hold some magnetic force after the current clamp has been used for
measurement. If you cannot zero adjust the display, open the jaws and snap them closed several times.
Adjust the DCA ZERO ADJUST dial on the current clamp for a zero reading on the multimeter.
[9] - Momentarily touch the positive jumper cable lead to the starting motor positive post and read the starting motor
amperage draw.
Result:
If amperage is above specification, check starting motor for binding or damage.

Starting Motor, No Load (Maximum Draw) Amperage 35 amp
Stator Output Test, B&S
Stator Connector
LEGEND:
A Connector
Reason:
To measure AC voltage output of stator and verify correct resistance of stator.
Procedure:
[2] - Disconnect connector from stator.
[3] - Set multi-meter for AC volts.
[4] - Attach RED test lead to either pin on stator side of stator connector (A).
[5] - Attach meter leads:
On single wire lead models, attach BLACK test lead to engine ground.
On two wire lead models, attach BLACK test lead to other connector pin.
[6] - Set parking brake, start engine and run at full throttle.
[7] - Check output.

Results:
Output should be to specification.

Stator output at full throttle (minimum) Voltage 30 VAC
Flywheel Stator Magnets Test

LEGEND:
A Magnet
Flywheel Stator Magnets
Reason:
To make sure flywheel magnet have enough force to induce current into stator.
Procedure:
[1] - Park machine on level surface.
[2] - Turn key switch to off position.
[3] - Move forward and reverse pedals to neutral position.
[4] - Engage park brake.
[5] - Raise hood.
[6] - Remove flywheel blower housing from engine.
[7] - Remove flywheel. See engine section.
[8] - Loosely hold screwdriver blade about 25 mm (1.0 in.) away from magnet (A).
Results:
Magnet should attract blade to it.

If blade is not attracted to magnet, flywheel must be replaced.
Flywheel Ignition Magnet Test

LEGEND:
A Magnet
Flywheel Ignition Magnet
Reason:
To make sure flywheel magnets have enough force to induce current into ignition coil.
Procedure:
[1] - Park machine on level surface.
[2] - Turn key switch to off position.
[3] - Move forward and reverse pedals to neutral position.
[4] - Engage park brake.
[5] - Remove flywheel blower housing from engine.
[6] - Loosely hold screwdriver blade about 25 mm (1.0 in.) away from magnet (A).
Results:
Magnet should attract blade to it.

If blade is not attracted to magnet, flywheel must be replaced.
Diode Test
Diode
Reason :
To determine if diode has failed.

Procedure:
[1] - Remove diode.
[2] - Set digital multi-meter to diode test.
[3] - Connect meter leads to each lead or end of diode. Check for continuity
[4] - Reverse test leads. Check for continuity
Results:
The diode must have a low resistance reading in one direction and a high resistance reading in the other direction. Replace the
diode if low resistance reading occurs in both directions or high resistance reading occurs in both directions.

PTO Switch Test
PTO Switch Test

LEGEND:
1 Terminal
2 Terminal
3 Terminal
4 Terminal
5 Terminal
6 No terminal
7 Terminal
8 Terminal
9 Terminal
Reason:
To determine proper operation of PTO switch.
Test Connections:
Set ohmmeter for 1X scale
→NOTE:
On analog (swing needle) ohmmeters, set zero point before each test.
Procedure:
[1] - Remove connector from PTO switch.
[2] - Use ohmmeter to check continuity across switch terminals.
PTO Switch Test
Switch Continuity
Off 1—7 and 2—8 and 3—9
On 1—4 and 2—5
Results:
All other possible combinations have infinite resistance. If any continuity is NOT correct, replace switch

Electric PTO Clutch Test
PTO Clutch
LEGEND:
A Terminals
Reason:
To check condition of PTO clutch coil.
Procedure:
→NOTE:
PTO clutch should make an audible click when engaged.
[1] - Park machine on level surface and turn key switch off.
[2] - Raise seat.
[3] - Disconnect PTO clutch connector.
[4] - Set ohmmeter for 1x ohms scale.

Ohmmeter
Not Applicable
To measure resistance.
[5] - Measure resistance across PTO clutch terminals (A).
[6] - Resistance should measure within specification. If resistance is not within specification, replace PTO clutch.
PTO Clutch Resistance 3.0 ohm ± 10%
[7] - Measure resistance from each terminal to ground to check for short circuits. Replace clutch as necessary.
Key Switch Test

LEGEND:
A Terminal
B Terminal
C Terminal
D Terminal
E Terminal
F Terminal
Key Switch
[1] - Disconnect switch.
a. If continuity is not present between terminals listed for each switch position, replace switch
b. If continuity exists between terminals not listed for each switch position, replace switch.
Switch Continuity
Switch Continuity
Off A—B
Run C—D
Start C — D and E — F

Start Relay Test
Start Relay Test

LEGEND:
A Negative Battery Terminal
B Solenoid Terminal
C Solenoid Terminal
D Terminal
Reason:
To determine if starting solenoid is defective.
Procedure:
[2] - Disconnect and ground spark plug leads.
[3] - Connect VOM to negative (-) battery terminal (A) and terminal (B) of starting motor solenoid. Check for battery voltage.
No battery voltage - Check battery positive (+) terminal and starting motor solenoid terminal (B) for loose connections.
Clean any corrosion.
Battery voltage - go to next step.
[4] - Connect VOM to negative (—) battery terminal (A) and terminal (C) of starting motor solenoid.
[5] - Momentarily turn ignition key to start position and check for battery voltage.
Battery voltage - starting motor solenoid is not defective.

No battery voltage - go to next step.
[6] - Connect VOM to negative (—) battery terminal (A) and terminal (D) (Pur wire) of starting motor solenoid.
[7] - Momentarily turn ignition key to start position and check for battery voltage.
No battery voltage - Check Pur wire and connections.

Battery voltage - Check Blk wire and connections between starting motor solenoid and frame ground. If OK, starting
motor solenoid is defective, replace solenoid.
Relay Test
LEGEND:
85 Coil
86 Coil
30 COM
87a NC
87 NO
Relay
[1] - Remove relay from load center.
[2] - Use ohmmeter to check continuity between relay terminals 87A and 30.
[3] - Check for no continuity between terminals 30 and 87.
[4] - Measure resistance between 85 and 86.
[5] - Connect a jumper wire from battery positive (+) post to relay terminal 85. Connect a jumper wire from relay terminal 86
to ground (—). Continuity should now exist between terminals 30 and 87 ; no continuity between 30 and 87A .
Results:
If continuity is not correct, replace relay.

If resistance is approximately 680 ohms the relay coil is open, replace relay.
If resistance between terminals 85 and 86 does not meet specification, replace relay.
Relay Coil Resistance 80 ohms ±10%
Fuel Shutoff Solenoid Test, B&S

Reason:
To determine if the fuel shutoff plunger retracts when the solenoid is energized.
Procedure:

Fuel Shutoff Solenoids
[2] -
CAUTION:
Keep gasoline away from sparks, flame, or hot engine parts or personal injury can result.
Pinch off, or disconnect and plug fuel line feeding carburetor.
[3] - Unplug harness connector from fuel shutoff solenoid.
[4] - Remove fuel shutoff solenoid from float bowl.
[5] - Use an ohmmeter to measure solenoid coil resistance across terminals (A).
[6] - Connect a 12 VDC power source to terminals. Plunger should retract.
[7] - Remove 12 VDC power source. Plunger should extend.
Results:
If plunger does not retract, replace solenoid.

If resistance does not meet specification or if the plunger does not move, replace solenoid.

Solenoid Type “L” Resistance 37 ohms ±15%
Solenoid Type “S” Resistance 28 ohms ±15%
Seat Switch Test

Seat Switch
Reason :
To determine if seat switch functions properly.
Tools
Ohmmeter or Continuity Tester
Procedure:
[2] - Remove connector from witch.
Switch Continuity
Switch Continuity
Released A—B
Pressed None
Results:
If continuity is not correct, replace switch.
Headlight Switch (S.N. -130000)

Headlight Switch
Reason :
Procedure:

not applicable
Check continuity
Switch Continuity
Switch Continuity
On Position Continuity
Off Position No Continuity
Results:
Headlight Switch (S.N. 130001- )

Headlight Switch
Reason :
Procedure:

not applicable
Check continuity
Switch Continuity
Switch Continuity
On Position Continuity (1—2)
Off Position No Continuity
On Position Continuity (2—3)
Results:
Park Brake and Neutral Switch Test

Section 240 - ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 40: Wiring Schematics
LEGEND:
A Common
B Common
C Normally Closed
D Normally Open
Park Brake Switch
[2] - Access the switch on the left side of the machine.
[3] - Disconnect switch from wiring harness.

not applicable
Check continuity
Switch Continuity
Switch Continuity
Released A—C
Pressed B—D

Group 40 - Wiring Schematics

Schematic Legend
Main Electrical Schematic (S.N. -120000)
Main Electrical Schematic (S.N. 120001-130000)
Main Electrical Schematic (S.N. 170001- )
Schematic Legend
Components:
DEFINITIONS:
D1, D1 Diode
D3 Diode (S.N. 120001- )
E1 Spark Plug
F1 Fuse 20A
F2 Fuse 20A
F3 Fuse 7.5A
F4 Fuse 7.5A (option)
G1 Battery
G2 Stator
K1 Start Relay
K2 Interlock Relay
L1 Left Headlight (option)
L2 Right Headlight (option)
L6 Low Fuel Indicator Light (SN 170001-)
M1 Starting Motor
P1 Hourmeter
R1 Thermistor (SN 170001-)
SW1 Key Switch
SW2 Left Handle Neutral Lock Switch
SW3 Right Handle Neutral Lock Switch
SW5 Seat Switch
SW6 PTO Switch
SW7 Headlight Switch (option) (S.N. 130001- )
SW99 Headlight Switch (option) (S.N. -130000)
T1 Ignition Coil
W2 Engine Ground
Y2 PTO Clutch
Connectors:
DEFINITIONS:
C1 Power Connector (SN 130001-)
C3F W1 Main Wiring Harness to W3 Lighting Kit Wiring Harness (S.N. 130001- )
C3M W3 Lighting Kit Wiring Harness to W1 Main Wiring Harness (S.N. 130001- )
C4E W2 Engine Wiring Harness to W1 Main Wiring Harness
C4M W1 Main Wiring Harness to W2 Engine Wiring Harness
SWA Thermistor Connector (SN 170001-)
SWB Thermistor Connector (SN 170001-)
Wiring Harnesses:
DEFINITIONS:
W1 Main Wiring Harness
W3 Lighting Kit Wiring Harness (option)

Main Electrical Schematic (S.N. -120000)
Main Schematic (1 of 2)

Main Schematic (S.N. -120000)


Main Schematic (S.N. 120001-130000)


Main Schematic (S.N. 130001-170000)


Section 240 - ELECTRICAL DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 50: Connector Information
Main Schematic (S.N. 170001- )

Group 50 - Connector Information

Load Center (S.N. -120000)
Load Center (S.N. 120001-130000)
Load Center (S.N. 130001- )
Hour Meter Connector
Key Switch Connector
Left Handle Neutral Switch Connector
Right Handle Neutral Switch Connector
Park Brake Switch Connector
Seat Switch Connector
PTO Switch Connector
Light Switch Connector
Headlight Harness Connector, C3F (W1 Main Harness) (S.N. 130001- )
Headlight Harness Connector, C3M (W3 Light Kit Harness) (S.N. 130001- )
Headlight Connector
Power Connector (S.N. 130001- )
Engine Connector
PTO Clutch Connector
Start Relay Connectors
Regulator/Rectifier Connectors

Layout
Schematic: Main Electrical Schematic (S.N. -120000)
Wiring Harness: W1 Main Wiring Harness (S.N. -120000)
Terminal Circuit Number
A1 220A Red
A2 202D Red
A3 202C Red
A4 201 Red
A5 475A Yel
A6 400B Yel
A7 605 Wht (K2 pin 85)
A8 100R Blk (K2 pin 87a)
B3 400E Yel
B4 900 Yel (optional)
B7 602B Pnk (K2 pin 30)
B9 400C Yel (K2 pin 86)

Load Center (S.N. 120001-130000)
Load Center (S.N. 120001-130000)
Layout
Load Center (S.N. 120001-130000)
Schematic: Main Electrical Schematic (S.N. 120001-130000)
Wiring Harness: W1 Main Wiring Harness (S.N. 120001-130000)
A1 220A Red
A2 202D Red
A3 202C Red
A4 201 Red
A5 475A Yel
A6 400B Yel
A7 100E Blk (K2 pin 85)
A8 601B Wht (K2 pin 87a)
A9 704 Wht (K2 pin 87)
B1 420B Yel, 420C Yel (D3)
B2 702A Grn (D3)
B3 400E Yel
B4 900 Yel (optional)
B7 100R Blk (K2 pin 30)
B9 420A, 420C Yel (K2 pin 86)

Layout
Schematic: Main Electrical Schematic (S.N. 130001-170000) , or Main Electrical Schematic (S.N. 170001- )
Wiring Harness: W1 Main Wiring Harness (S.N. 130001-170000) , or W1 Main Wiring Harness (S.N. 170001- )
A1 220A Red
A2 202D Red
A3 202C Red
A4 201 Red
A5 475A Yel
A6 400B Yel
A7 100E Blk (K2 pin 85)
A8 601B Wht (K2 pin 87a)
A9 704 Wht (K2 pin 87)
B1 420B Yel, 420C Yel (D3)
B2 702A Grn (D3)
B3 400E Yel
B4 900A Yel
B7 100R Blk (K2 pin 30)
B9 420A, 420C Yel (K2 pin 86)

Hour Meter Layout
Hour Meter Connector (S.N. -120000)
1 475B
2 100H
3 601G
4 420
Hourmeter Layout
Hour Meter Connector (S.N. 120001-)
Schematic: Main Electrical Schematic (S.N. 120001-130000) , Main Electrical Schematic (S.N. 130001-170000) , or Main Electrical Schematic (S.N. 170001- )
Wiring Harness: W1 Main Wiring Harness (S.N. 120001-130000) , W1 Main Wiring Harness (S.N. 130001-170000) , or W1 Main Wiring Harness (S.N. 170001- )
1 475B
2 100H
3 601G
4 419A

Key Switch Connector Layout
Key Switch Connector (S.N. -120000)
Wiring Harnesses: W1 Main Wiring Harness (S.N. -120000)
A 400A
B 220A, 220B
G 100G
M 601F
S1 703
S2 220B
Key Switch Connector Layout
Key Switch Connector (S.N. 120001-)
Main Electrical Schematic (S.N. 120001-130000) , Main Electrical Schematic (S.N. 130001-170000) , or Main Electrical Schematic (S.N. 170001-
Schematic:
)
Wiring Harnesses: W1 Main Wiring Harness (S.N. 120001-130000) , W1 Main Wiring Harness (S.N. 130001-170000) , or W1 Main Wiring Harness (S.N. 170001- )

A 400A
B 220A
G 100G, 100H
M 601F
S1 703
S2 702B

Left Handle Neutral Layout
Left Handle Neutral Switch Connector (S.N. -120000)
A 603A, 603B
B 702
C 601C
D 701
Left Handle Neutral Layout
Left Handle Neutral Switch Connector (S.N. 120001-)
Main Electrical Schematic (S.N. 120001-130000) , Main Electrical Schematic (S.N. 130001-170000) , or Main Electrical Schematic (S.N. 170001-
Schematic:
)
Wiring Harnesses: W1 Main Wiring Harness (S.N. 120001-130000) , W1 Main Wiring Harness (S.N. 130001-170000) , or W1 Main Wiring Harness (S.N. 170001- )
A —
B 419A, 419B
C —
D 701

Right Handle Neutral Layout (S.N. -120000)
Right Handle Neutral Switch Connector (S.N. -120000)
A 603A
B 701
C 601B
D 700
Right Handle Neutral Layout (S.N. 120001-130000)
Right Handle Neutral Switch Connector (S.N. 120001-130000)
Schematic: Main Electrical Schematic (S.N. 120001-130000)
Wiring Harnesses: W1 Main Wiring Harness (S.N. 120001-130000)
A —
B 701
C —
D 608C
Right Handle Neutral Layout (S.N. 130001- )
Right Handle Neutral Switch Connector (S.N. 130001- )
Wiring Harnesses: W1 Main Wiring Harness (S.N. 130001-170000) , or W1 Main Wiring Harness (S.N. 170001- )
A —
B 701
C —
D 608C, 608A

Park Brake Switch Layout (S.N. -120000)
Park Brake Switch Connector (S.N. -120000)
Schematics: Main Electrical Schematic (S.N. -120000)
A 601D
B 100F
C 602A, 602B
D 603B, 603C
Park Brake Switch Layout (S.N. 120001-130000)
Park Brake Switch Connector (S.N. 120001-130000)
Schematics: Main Electrical Schematic (S.N. 120001-130000)
Wiring Harnesses: W1 Main Wiring Harness (S.N. 120001-130000)
A 419B
B 608B, 608C
C 608A, 608B
D 605
Park Brake Switch Layout (S.N. 130001- )
Park Brake Switch Connector (S.N. 130001- )
Schematics: Main Electrical Schematic (S.N. 130001-170000) , or Main Electrical Schematic (S.N. 170001- )
A 608B
B 608B, 608C
C 605
D 419B

Seat Switch Connector Layout (S.N. -120000)
Seat Switch Connector (S.N. -120000)
A 100E
B 605
Seat Switch Connector Layout (S.N. 120001- )
Seat Switch Connector (S.N. 120001- )
A 608A
B 420B

PTO Switch Connector Layout (S.N. -120000)
PTO Switch Connector (S.N. -120000)
1 601E
2 475A, 475B
3 703
4 602A
5 604
7 —
8 —
9 702
PTO Switch Connector Layout (S.N. 120001- )
PTO Switch Connector (S.N. 120001- )
1 —
2 475A, 475B
3 605
4 —
5 604
7 —
8 —
9 702A, 702B

Light Switch Connector Layout (S.N. -130000)
Light Switch Connector (S.N. -130000)

Schematics:
Wiring Harness: W3 Lighting Kit Wiring Harness (S.N. -130000)
1 900
2 901B, 901C
3 —
4 —
5 —
Light Switch Connector Layout (S.N. 130001- )
Light Switch Connector (S.N. 130001- )
Wiring Harness: W3 Lighting Kit Wiring Harness (S.N. 130001- )
1 800
2 900A
3 901B
4 —
5 —
Headlight Harness Connector, C3F (W1 Main Harness) (S.N. 130001- )
Headlight Harness Connector, C3F (S.N. 130001- )

Headlight Harness Connector Layout, C3F (S.N. 130001- )
Headlight Harness Connector, C3F (S.N. 130001- )
A 901B
B 100P
Headlight Harness Connector, C3M (W3 Light Kit Harness) (S.N. 130001-
)
Headlight Harness Connector, C3M (S.N. 130001- )
Headlight Harness Connector Layout, C3M (S.N. 130001- )
Headlight Harness Connector, C3M (S.N. 130001- )
Wiring Harnesses: W3 Lighting Kit Wiring Harness (S.N. 130001- )
A 901C, 901D
B 100K, 100L

Headlight Connector
Headlight Connector (S.N. -130000) Shown
Headlight Connector Layout (S.N. -130000)
Headlight Connector (S.N. -130000)
Schematics: Main Electrical Schematic (S.N. -120000) or Main Electrical Schematic (S.N. 120001-130000)
Wiring Harness: W3 Lighting Kit Wiring Harness (S.N. -130000)
A 901B (left), 901C (right)
B 100K (left), 100L (right)
Headlight Connector Layout (S.N. 130001- )
Headlight Connector (S.N. 130001- )
Wiring Harness: W3 Lighting Kit Wiring Harness (S.N. 130001- )
A 901C (left), 901D (right)
B 100K (left), 100L (right)
Power Connector Layout (S.N. 130001- )

A 100N
B 800

Engine Connector
Engine Connector
Engine Connector Layout (S.N. -120000)
Engine Connector (S.N. -120000)
1 201
2 601A
3 420
4 —
5 —
6 —
Engine Connector Layout (S.N. 120001- )
Engine Connector (S.N. 120001- )
1 201
2 601A
3 420A
4 —
5 —
6 —

PTO Clutch Connector Layout
Main Electrical Schematic (S.N. -120000) or Main Electrical Schematic (S.N. 120001-130000) , Main Electrical Schematic (S.N. 130001-170000)
Schematics:
, or Main Electrical Schematic (S.N. 170001- )
W1 Main Wiring Harness (S.N. -120000) or W1 Main Wiring Harness (S.N. 120001-130000) , W1 Main Wiring Harness (S.N. 130001-170000) , or
Wiring Harnesses:
A 604
B 100C

Start Relay Connectors Layout
Main Electrical Schematic (S.N. -120000) , Main Electrical Schematic (S.N. 120001-130000) , Main Electrical Schematic (S.N. 130001-170000) ,
Schematics:
or Main Electrical Schematic (S.N. 170001- )
W1 Main Wiring Harness (S.N. -120000) , W1 Main Wiring Harness (S.N. 120001-130000) , W1 Main Wiring Harness (S.N. 130001-170000) , or
Wiring Harnesses:
A 202A, 202B
B 705
C 700 (S.N. -120000), 703 (S.N. 120001- )
D 603C (S.N. -120000), 704 (S.N. 120001- )

POWER TRAIN DIAGNOSIS, TESTS, AND ADJUSTMENTS (g) by Belgreen v2.0
Regulator/Rectifier Connectors Layout
Main Electrical Schematic (S.N. -120000) , Main Electrical Schematic (S.N. 120001-130000) , Main Electrical Schematic (S.N. 130001-170000) , or
Schematics:
Wiring Harness: W2 Engine Wiring Harness
A Stator
B Engine Harness

Section 250 - POWER TRAIN DIAGNOSIS, TESTS, AND ADJUSTMENTS

Table of contents
Group 20 - Theory of Operation ............................................................................................................. 1
Drive Operation (S.N. -130000) ............................................................................................................ 2
Drive Operation (S.N. 130001- ) ........................................................................................................... 3
Transaxle Operation ............................................................................................................................. 4
Group 30 - Diagnosis ............................................................................................................................... 6
Transaxle Check ................................................................................................................................... 6
Machine Does Not Achieve Full Speed .................................................................................................. 8
Machine Will Not Move ......................................................................................................................... 8
Noisy Operation .................................................................................................................................... 9
Wheel Will Not Rotate ........................................................................................................................... 9
Wheel Rotates One Direction Only ....................................................................................................... 9
Group 40 - Tests and Adjustments ...................................................................................................... 10
Specifications ..................................................................................................................................... 10
Adjust Tracking ................................................................................................................................... 10
Adjust Neutral Creep (S.N. -130000) .................................................................................................. 12
Adjust Neutral Creep (S.N. 130001- ) ................................................................................................. 13
Adjust Return To Neutral (RTN) .......................................................................................................... 15
Adjust Motion Control Levers .............................................................................................................. 16
Adjust Park Brake (S.N. -130000) ....................................................................................................... 17
Adjust Park Brake (S.N. 130001- ) ...................................................................................................... 18
Purge Transaxle Hydraulic System ..................................................................................................... 18

Section 250 - POWER TRAIN DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 20: Theory of Operation

Drive Operation (S.N. -130000)
Drive Operation (S.N. 130001- )
Transaxle Operation

Drive Operation (S.N. -130000)
Drive Operation
LEGEND:
A Engine Drive Sheave
B Idler Sheave
C Control Lever
D Return to Neutral (RTN)
Drive Train System:
The drive train consists of two separate transaxles. Each transaxle drives a rear wheel independent of the other transaxle and
wheel. The transaxles are mirror images of each other. The transaxles provide infinitely variable speed control and the
capability of forward or reverse directional travel of each wheel.
Drive Belt Operation:
The traction drive belt is driven by the engine drive sheave (A). The traction belt transmits engine power to the input sheaves
of the hydrostatic transaxles.
The traction drive belt is tensioned by an idler sheave (B), which is mounted on a spring loaded bracket.
Transaxle Control Operation:
The operator control lever (C) controls the pumps variable swash plate and direction of wheel rotation. (See Transaxle
Operation .) Pushing the control lever forward will cause forward rotation of the drive wheel on that side of the machine. Pulling
the control lever back will cause reverse rotation of the drive wheel.
The return to neutral (RTN) mechanism (D) applies spring tension to the control arm to force it back to neutral from the reverse
travel position.

Drive Operation (S.N. 130001- )
Drive Operation
LEGEND:
A Engine Drive Sheave
B Idler Sheave
C Control Lever
D Return to Neutral (RTN)
Drive Train System:
The drive train consists of two separate transaxles. Each transaxle drives a rear wheel independent of the other transaxle and
wheel. The transaxles are mirror images of each other. The transaxles provide infinitely variable speed control and the
capability of forward or reverse directional travel of each wheel.
Drive Belt Operation:
The traction drive belt is driven by the engine drive sheave (A). The traction belt transmits engine power to the input sheaves
of the hydrostatic transaxles.
The traction drive belt is tensioned by an idler sheave (B), which is mounted on a spring loaded bracket.
Transaxle Control Operation:
The operator control lever (C) controls the pumps variable swash plate and direction of wheel rotation. (See Transaxle
Operation .) Pushing the control lever forward will cause forward rotation of the drive wheel on that side of the machine. Pulling
the control lever back will cause reverse rotation of the drive wheel.
The return to neutral (RTN) mechanism (D) applies spring tension to the control arm to force it back to neutral from the reverse
travel position.

Transaxle Operation
Transaxle Operation
LEGEND:
A Pump Input Shaft
B Pump Rotating Group
C Swash Plate
D Motor Rotating Group
E Angled Bearing Housing
F Motor Output Shaft
G Bypass Lever
H Double Gear Set
I Axle Bull Gear
J Wheel Axle
Hydraulic Oil Circuit Operation:
The input pulley is rotated by the traction drive belt in a single direction. It rotates the pump input shaft (A). The pump input
shaft is splined to the pump rotating group (B) and the charge pump. The pump rotating group is composed of an axial piston
pump and a swash plate (C) which provides variable pump displacement. The pump draws pressure-free oil from the reservoir
through a filter and check valve, and supplies oil to the pump rotating group. The pump rotating group provides oil under
pressure to the motor rotating group (D) through one of two passages. Output to one or the other passage is controlled by the
direction and amount that the variable swash plate is angled.
The motor rotating group is composed of an axial piston motor and an angled bearing housing (E) which provides fixed motor
displacement. Since the motor has a fixed displacement angle it is forced to turn with the flow of oil. The motor converts
hydraulic energy into rotary motion, which is output through the motor output shaft (F). This rotary motion of the motor output
shaft is the beginning of the gear power flow.
As the angle of the pump swash plate is increased the amount of oil being pumped will increase and cause a higher rotation
speed of the motor. Reversing the angle of the swash plate will reverse the direction of oil flow and motor rotation.
Freewheel Operation:
The freewheel system allows the machine to be pushed forward or reverse with the engine off and the brake released.
Section 250 - POWER TRAIN DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 30: Diagnosis
When the bypass release rod is pulled rearward, the rod rotates the bypass lever (G). The bypass lever lifts the motor block off
of the center section running surface. This allows oil (and oil pressure) from the cylinder blocks to be released allowing the
operator to push the machine in forward or reverse with the engine off and the brake released.
Gear Operation:
The motor output shaft (F) is splined to a small gear. This gear drives a double gear set (H) which drive the axle bull gear (I).
The wheel axle (J) is splined to the bull gear. The set of drive gears provides a reduction ratio 19.2:1.

Transaxle Checks
81
Transaxle Checks
Test Conditions
Test Conditions:
• Machine parked safely on level surface

• Engine OFF
• Front wheels blocked
• Rear wheels raised off surface with frame on jack stands
Transaxle Check
( 1 ) Fan
Action:
Is the fan in good condition and tight?
Result:

NO:Replace defective or worn components.
( 2 ) Drive Belt
Action:
Is the drive belt in good condition and not glazed, split, unraveled, or stretched?
Result:

NO:Replace drive belt. (See Remove Traction Belt (S.N. -130000) or Remove Traction Belt (S.N. 130001- ) and Install Traction
Belt (S.N. -130000) or Install Traction Belt (S.N. 130001- ) .)
( 3 ) Idler Tensioning Spring
Action:
Is the tensioning spring installed and not damaged?
Result:

NO:Install or replace spring.
( 4 ) Sheaves and Idlers, Belt Traction Drive System
Action:
Are drive sheaves and idlers in good condition?
Result:

NO:Repair or replace.
( 5 ) (continued)
Action:
Is the belt slipping, squealing, or vibrating excessively?

Result:

NO:Check belt condition. Check condition of idlers and guides. Adjust, repair or replace components as needed..
( 6 ) Transaxle Housing Exterior
Action:
Do the cooling fins have accumulated debris?
Result:
YES:Clean the cooling fins.

NO:Go to next step.
( 7 ) (continued)
Action:
Does the housing exterior have cracks, leaks, or loose hardware?
Result:
YES:Tighten hardware.
YES:Replace damaged components or transaxle.
NO:Go to next step.
( 8 ) Park Brakes
Action:
Are park brakes fully released with the brake control in the released position?
Result:
YES:Go on to next step.

NO:S.N. -130000: Adjust released park brake pad to rotor clearance. (See Adjust Park Brake (S.N. -130000) .)
NO:S.N. 130001- : Park brake is not adjustable. Check park brake function and replace damaged components. (See Repair
Park Brake (S.N. 130001- ) .)
NO:Replace damaged components.
( 9 ) Axles
Action:
Are the axles straight?
Result:

NO:Replace transaxle.
( 10 ) Tires, Wheels, and Axles
Action:
Are the tire pressures equal?
Result:

NO:Adjust air pressure.

( 11 ) (continued)
Action:
Do the driving tires each have the same radius?
Result:

NO:Match tires for same circumference.
( 12 ) (continued)
Action:
Are wheels bent or out of round?
Result:
YES:Replace wheels.
NO:Go to next step.
( 13 ) Engine Performance
Action:
Is the engine running smoothly throughout throttle range, and is it being operated at high idle?
Result:

NO:Adjust, or repair engine.
( 14 ) Stroking Control Arm: (Lack of Forward or Reverse Speed)
Action:
Is there lost motion between the control arm and input shaft?
Result:
YES:Check control arm and linkage. Replace components as necessary

NO:Check complete.
Machine Does Not Achieve Full Speed
81
Machine Does Not Achieve Full Speed
Does Not
Traction belt worn, frayed, glazed or Replace traction belt. (See Remove Traction Belt (S.N. -130000) or Remove Traction Belt (S.N. 130001- )
Achieve Full
stretched. and Install Traction Belt (S.N. -130000) or Install Traction Belt (S.N. 130001- ) .)
Speed
Traction belt not properly tensioned. Check belt tensioning spring and arm. Replace worn, damaged, or missing parts.
Tracking bolts improperly adjusted. Adjust tracking. (See Adjust Tracking .)
Park brake not fully released with brake S.N. -130000: Adjust released park brake pad to rotor clearance. (See Adjust Park Brake (S.N. -130000)
control in off position. .)
S.N. 130001- : Park brake is not adjustable. Check park brake function and replace damaged
components. (See Repair Park Brake (S.N. 130001- ) .)
Machine Will Not Move

81
Machine Will Not Move

Section 250 - POWER TRAIN DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 40: Tests and Adjustments
Engine Stops When Control

Handles are Moved From Neutral Park brake applied. Release park brake.
Position With Operator on Seat
Machine Will Not Move Forward or Freewheeling bypass release rods are
Disengage freewheeling levers.
Reverse disengaged.
Replace traction belt. (See Remove Traction Belt (S.N. -130000) or Remove
Traction belt worn, frayed, glazed or stretched. Traction Belt (S.N. 130001- ) and Install Traction Belt (S.N. -130000) or Install
Traction Belt (S.N. 130001- ) .)
Check belt tensioning spring and arm. Replace worn, damaged, or missing
Traction belt not properly tensioned.
parts.
Engine drive sheave or key damaged Replace sheave or key. (See correct engine repair section.)
Noisy Operation
81
Noisy Operation
Replace traction belt. (See Remove Traction Belt (S.N. -130000) or Remove Traction Belt (S.N.
Noisy Operation Traction belt worn, frayed, glazed or stretched.
130001- ) and Install Traction Belt (S.N. -130000) or Install Traction Belt (S.N. 130001- ) .)
Hydrostatic oil low, not at operating

Purge air from system. (See Purge Transaxle Hydraulic System .)
temperature, or foamy.
Drain transaxle and fill to correct level with specified oil.
Wheel Will Not Rotate

81
Wheel Will Not Rotate
One Wheel Will Not Rotate Forward or
Hydrostatic transaxle oil low. Fill to correct level with specified oil.
Reverse
Freewheeling bypass release rod disengaged. Disengage freewheeling lever.
Freewheel linkage components do not move freely. Eliminate binding and/or replace damaged components.
Transaxle drive sheave damaged. Replace sheave.
Control arm linkage damaged or missing. Replace control arm linkage.
Shock absorber binding or damaged. Replace shock absorber.
Air trapped in the hydraulic system. Purge hydraulic system. (See Purge Transaxle Hydraulic System .)
Transaxle has internal damage. Replace transaxle.
Wheel Rotates One Direction Only

81
Wheel Rotates One Direction Only
Wheel Rotates In
Forward/reverse linkage not adjusted. Adjust linkage. (See Adjust Neutral Creep (S.N. -130000) or Adjust Neutral Creep (S.N. 130001- ) .)
One Direction Only
Eliminate binding, replace faulty or damaged components. Adjust control levers. (See Adjust Motion
Forward/reverse linkage binding.
Control Levers .)
Shock absorber binding or damaged. Replace shock absorber.
Control arm linkage damaged or missing. Replace faulty or damaged components. Adjust control levers. (See Adjust Motion Control Levers .)
Air trapped in the hydraulic system. Purge hydraulic system. (See Purge Transaxle Hydraulic System .)
Transaxle has internal damage. Replace transaxle.


Adjust Tracking
Adjust Neutral Creep (S.N. -130000)
Adjust Neutral Creep (S.N. 130001- )
Adjust Return To Neutral (RTN)
Adjust Motion Control Levers
Adjust Park Brake (S.N. -130000)
Adjust Park Brake (S.N. 130001- )
Purge Transaxle Hydraulic System
Specifications
RTN Adjustment Screw Torque 23—27 N·m
(200—240 lb.-in.)
(0.02—0.04 in.)
(75 lb.-ft.)
Adjust Tracking
LEGEND:
A Adjustment Lever
B Adjusting Tool
C Control Quadrant
D Tracking Bolt
E Tracking Bolt
Z225 and Z245 (S.N. -130000)
Z235 and Z255 (S.N. 130001- )
[1] -

CAUTION:
Do not attempt any servicing or adjustments with the engine running. Use caution while inspecting the
drive belt assembly and all machine linkage!
[2] - Fully raise and lock mowing deck height adjustment lever (A) in transport position.
[3] - Rotate and remove tracking bolt adjusting tool (B) from deck height control quadrant (C).
[4] -
→NOTE:
Tracking bolts limit top forward speed. If both levers contact tracking bolts, turn both bolts
counterclockwise equal amounts until only one bolt contacts the lever. This will achieve maximum
forward speed.
Adjust tracking bolts (D) or (E) to correct tracking.
If machine tracks left, turn right tracking bolt (D) in.

If machine tracks right, turn left tracking bolt (E) in.
Check tracking and readjust if necessary.
[5] - Return tracking bolt adjusting tool to original position in mowing deck height adjustment quadrant.
[6] - Readjust motion control lever height or angle as desired for best fit.

Adjust Neutral Creep (S.N. -130000)

Purpose:
To set control linkage to prevent forward or reverse creep of machine with the control arms in neutral position.
Procedure:
LEGEND:
A Locking Pin
B Mounting Pin
C Drive Link
Left side shown, right side similar.
[1] -
CAUTION:
Avoid Injury! Rotating parts. Use caution while servicing or making adjustments with the engine running!
Park machine safely. See “Park Machine Safely” in the Safety section.
[3] - Unlock the park brake and remove the rear wheels.
[4] - Position the drive handles in the locked neutral position.
[5] - Lock the park brake and simulate an operator in the seat and start and run the engine at idle.
[6] - Disconnect locking pin (A), and removing rod end from mounting pin (B).
[7] - Position the drive link (C) either forward or reverse so that the axle does not turn and hold in this position.
[8] - Turn the rod end on the drive link until the rod end hole aligns with the mounting pin.
[9] - Install rod end back onto mounting pin and secure with locking pin.
[10] - Repeat procedure, as necessary, on opposite side.
[11] - Stop the engine.
[12] - Install the rear wheels.
[13] - Raise the machine and remove the jack stands.
[14] - Check that the RTN is set properly. (See Adjust Return To Neutral (RTN) .)
Results:
If the machine still creeps or the control arms can not be moved to the outward neutral slot position from a “neutral” position,
perform Neutral Creep adjustment again.

Adjust Neutral Creep (S.N. 130001- )

LEGEND:
A Bolts
B Steering Arm
C Connector
D Pins
E Panel
Seat and Style panel
Purpose:
To set control linkage to prevent forward or reverse creep of machine with the control arms in neutral position.
Test Conditions:
Engine running
Motion control levers in the start/shutdown position
Park brake off
Machine on level ground
[1] -
CAUTION:
Avoid Injury! Rotating parts. Use caution while servicing or when adjustments are made with the engine
running!
Park machine safely. See “Park Machine Safely” in the Safety section.
[2] - Remove style panel for better access to adjustment components (if desired):
a. Remove two bolts (A) and steering arm (B).

b. Raise seat and disconnect wiring harness connector (C) from seat switch.
c. Remove two L-pins (D) to remove seat.
d. Remove seven push retainers from style panel (E) and remove style panel.
[3] -
LEGEND:
G Rod End
H Pin
I Rod

Right side shown, left side similar.

On linkage side needing adjustment, remove spring locking pin (F) and rod end (G) from pivot pin (H). Turn rod end (G) on rod
(I) in (clockwise) to decrease forward creep and out (counterclockwise) to decrease reverse creep.
[4] - Repeat procedure, as necessary, on opposite side.
[5] - Install rod ends back onto arms and secure with spring locking pins.
[6] - Install style panel and push retainers, seat, seat switch, and steering arm if previously removed.
[7] - Check that the RTN is set properly. (See Adjust Return To Neutral (RTN) .)
Results:
If the machine still creeps or the control arms cannot be moved to the outward neutral slot position from a “neutral” position,
perform Neutral Creep adjustment again.

Adjust Return To Neutral (RTN)

Purpose:
To set the transaxle return to neutral control arm assembly so the direction control arm returns to a neutral position from
reverse when the operator releases the control arms.
Test Procedure:
[1] -
CAUTION:
Do not attempt any servicing or adjustments with the engine running. Use caution while inspecting park
brake assemblies and all machine linkage!
[3] - Start the engine and run it at high idle until it is at operating temperature.
[4] - One wheel at a time, place the control arm in reverse until the selected wheel is rotating and then release the control
arm.
If the control arm returns to neutral and the wheel stops rotating, pull the control arm to a fast reverse position and
release it.
If the control arm returns to neutral and the wheel stops rotating, repeat the procedure on the other drive wheel.
If both control arms return to neutral and the wheels stop rotating, the return to neutral (RTN) is properly adjusted.
If either wheel fails, continue with adjustment procedure for the side that failed.
[5] - Stop engine.
Adjustment Procedure:
[1] -
CAUTION:
Rotating parts. Use caution while servicing or making adjustments with the engine running!
Verify the machine does not creep in neutral. (See Adjust Neutral Creep (S.N. -130000) or Adjust Neutral Creep (S.N. 130001- )
.)
[2] - Position the drive handles in the locked neutral position.
[3] -
LEGEND:
A Screw
B Plate Assembly
C Tab
D Control Arm

Z225, Z245 shown; Z235, Z255 is similar.

Loosen the return to neutral (RTN) adjustment screw (A) until the return plate assembly (B) can be rotated.
[4] - Rotate the return plate assembly until the tab (C) makes firm contact with the control arm (D). Hold in position and
tighten the adjustment screw to specification.
RTN Adjustment Screw Torque 23—27 N·m
(200—240 lb.-in.)
[5] - Start the engine and repeat test steps to check for axle rotation. Repeat procedure until both axles do not rotate.
[6] - Stop engine.
Adjust Motion Control Levers

LEGEND:
A Upper Hole
B Middle Hole
C Lower Hole
Lever shown in lowest position.
[2] -
→NOTE:
Z225, Z245 is shown; Z235, Z255 is similar.
To adjust motion control lever height, remove two bolts and nuts and raise or lower each control lever to your comfort level.
For highest lever position, use upper holes (A).

For medium lever position, use middle holes (B).
For lowest lever position, use lower holes (C).
[3] - You can also adjust motion control levers slightly forward or rearward (D) within slotted holes. This can be done for
operator comfort or for aligning the levers after performing other adjustments.

Adjust Park Brake (S.N. -130000)

Purpose:
Ensure park brake effectiveness when applied while reducing drag when released.
Procedure:
[1] -
CAUTION:
Do not attempt any servicing or adjustments with the engine running. Use caution while inspecting park
brake assemblies and all machine linkage!
[4] - Remove rear wheels.
[5] - Pull hydrostatic bypass release rods rearward and secure in release position.
[6] -
LEGEND:
A Control Cable
B Release Spring
C Linkage
Park Brake Cables, Springs and Linkage

Apply and release park brake control lever several times, while checking for:
Damage to control cables (A), release springs (B), or linkages (C).

Free movement of control cables and actuating levers.
Positive retention of park brake control in applied position.
Retraction of actuating pins and brake pads on release of park brake control.
Minimal drag in released position.
[7] -

LEGEND:
D Park Brake Rotor
E Transaxle Housing
F Feeler Gauge
G Brake Rotor
H Outboard Brake Pad
I Castle Nut
J Cotter Pin
Park Brake Rotor

Using light finger pressure, press park brake rotor (D) inboard toward transaxle housing (E) with park brake control released.
[8] - Check clearance with feeler gauge (F) between brake rotor (G) and outboard brake pad (H) for both left and right side
brake.
[9] - If clearance is not within specification, make required adjustment at castle nut (I).
(0.02—0.04 in.)
If park brake clearance is greater than specification, turn castle nut clockwise.
If park brake clearance is less than specification, turn castle nut counterclockwise.
[10] - Remove cotter pin (J).
[11] - Turn castle nut in or out as required to bring brake clearance within specification.
[12] - Turn castle nut out to closest position allowing alignment of cotter pin.
[13] - Install and secure cotter pin.

(75 lb.-ft.)
[18] - Engage park brake. Control lever should have some initial free movement, with a force of approximately 44 N (10 lb.)
then required to apply and lock park brakes.
Adjust Park Brake (S.N. 130001- )

It should not be necessary to adjust the transaxle parking brake over the life of the machine.
Purge Transaxle Hydraulic System

Purpose:
Reduce noise and transaxle inefficiency caused by compression and expansion of air in the oil.
P rocedure:

ATTACHMENTS DIAGNOSIS, TESTS, AND ADJUSTMENTS (g) by Belgreen v2.0
[3] - Open the transaxle bypass valve and start the engine.
[4] - Slowly move the directional control lever in both forward and reverse directions (5 to 6 times).
[5] - Close the bypass valve and slowly move the directional control lever in both forward and reverse directions (5 to 6 times).
[6] - Repeat steps until air is purged from the system. Repeat procedure for other transaxle.
[7] - Stop the engine and lower the machine to the ground.
[8] - Repeat the procedure with the control valve closed with the machine in normal operating conditions.

Section 260 - ATTACHMENTS DIAGNOSIS, TESTS, AND ADJUSTMENTS

Table of contents
Group 20 - Diagnosis ............................................................................................................................... 1
Procedure ............................................................................................................................................. 1
Procedure ............................................................................................................................................. 1
Procedure ............................................................................................................................................. 2
Procedure ............................................................................................................................................. 3
Specifications ....................................................................................................................................... 4
Adjust Mower Wheels (S.N. -130000) ................................................................................................... 5
Adjust Mower Wheels (S.N. 130001- ) .................................................................................................. 7
Adjust Mower Level .............................................................................................................................. 8

Section 260 - ATTACHMENTS DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 20: Diagnosis
Mower Blade Does Not Rotate
108
Mower Blade Does Not Rotate
Procedure
( 1 ) Checks
Action:
Is the PTO clutch engaged?
Result:

NO:Engage PTO. If the PTO will not engage, refer to PTO clutch diagnostics in the Electrical section.
( 2 ) (continued)
Action:
Is the drive belt broken, worn, frayed, glazed, or stretched?
Result:
YES:Replace belt. (See Replace Mower Drive Belt (42C) (S.N. -130000) or Replace Mower Drive Belt (42C) (S.N. 130001- ) or
Replace Mower Drive Belt (48TD) .)
NO:Go to next step.
( 3 ) (continued)
Action:
Is the drive belt tensioning spring weak or unhooked.
Result:
YES:Replace or reattach spring.

Mower Deck Vibrates
108
Mower Deck Vibrates
Procedure
( 1 ) Checks
Action:
Are blades out of balance?
Result:
YES:Balance blades. (See Sharpen and Balance Blades .)

NO:Go to next step.
( 2 ) (continued)
Action:
Are blades bent?
Result:
YES:Replace blades. (See Remove and Install Mower Blade .)

Section 260 - ATTACHMENTS DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 20: Diagnosis
NO:Go to next step.

( 3 ) (continued)
Action:
Are drive sheaves damaged?
Result:
YES:Replace drive sheave(s).

Mower Deck Cuts Unevenly or with Striping
108
Mower Deck Cuts Unevenly or with Striping
Procedure
( 1 ) Checks
Action:
Are blades dull?
Result:
YES:Sharpen blades. (See Sharpen and Balance Blades .)

NO:Go to next step.
( 2 ) (continued)
Action:
Is the deck level side-to-side and front-to-back?
Result:

NO:Level mower deck side-to-side and/or front-to-back. (See Adjust Mower Level .)
( 3 ) (continued)
Action:
Are gage wheels adjusted properly?
Result:
YES:Go to next step. (See Adjust Mower Wheels (S.N. -130000) or Adjust Mower Wheels (S.N. 130001- ) .)
NO:Adjust gage wheels.
( 4 ) (continued)
Action:
Are blades bent?
Result:
YES:Replace blades. (See Remove and Install Mower Blade .)

NO:Go to next step.
( 5 ) (continued)
Action:

Section 260 - ATTACHMENTS DIAGNOSIS, TESTS, AND ADJUSTMENTS Group 30: Tests and Adjustments
Result:

Mower Belt Slips or Jumps Off Sheaves
108
Mower Belt Slips or Jumps Off Sheaves
Procedure
( 1 ) Checks
Action:
Is the drive belt broken, worn, frayed, glazed, or stretched?
Result:
YES:Replace belt. (See Replace Mower Drive Belt (42C) (S.N. -130000) or Replace Mower Drive Belt (42C) (S.N. 130001- ) or
Replace Mower Drive Belt (48TD) .)
NO:Go to next step.
( 2 ) (continued)
Action:
Is the drive belt tensioning spring weak or unhooked?
Result:
YES:Replace or reattach spring.

NO:Go to next step.
( 3 ) (continued)
Action:
Result:


Adjust Mower Wheels (S.N. -130000)
Adjust Mower Wheels (S.N. 130001- )
Adjust Mower Level
Specifications
Mower Wheel Bolt and Nut Torque 34 N·m
(25 lb.-ft.)
Tire Pressure
(10 psi)
(30 psi)
(10 psi)

Adjust Mower Wheels (S.N. -130000)

LEGEND:
A Position 1
B Position 2
C Position 3
D Position 4
E Bolt
F Nut
G Wheel
42 Inch Mower Wheel
[1] -
CAUTION:
accidently.
IMPORTANT:
The mower deck can be damaged if mower wheels are adjusted wrong:
Wheels must not ride on ground supporting mower weight.

Check wheel adjustment each time cutting height is changed.
Park machine safely on a level surface.
[2] - Inflate tires to correct pressure.
[3] - Raise mower deck lift lever, and lock in transport position.
[4] - Adjust mower wheels to correct height:
42 Inch Mower
42 Inch Mower
Position 1 (A) 25—38 mm (1—1-1/2 in.) Height of Cut
Position 2 (B) 44—50 mm (1-3/4—2 in.) Height of Cut
Position 3 (C) 57—69 mm (2-1/4—2-3/4 in.) Height of Cut
Position 4 (D) 76—101 mm (3—4 in.) Height of Cut
Remove shoulder bolt (E) and nut (F). Move wheel (G) to proper hole position. Secure with shoulder bolt and nut. Tighten nut to
specification.
(25 lb.-ft.)
48 Inch Mower

LEGEND:
H Position 1
I Position 2
J Position 3
K Position 4
L Bolt
M Nut
N Wheel
48 Inch Mower Wheel
42 Inch Mower
Position 1 (H) Disables anti-scalp feature (should not be used)
Position 2 (I) 25—50 mm (1—2 in.) Height of Cut
Position 3 (J) 57—76 mm (2-1/4—3 in.) Height of Cut
Position 4 (K) 82—101 mm (3-1/4—4 in.) Height of Cut
Remove shoulder bolt (L) and nut (M). Move wheel (N) to proper hole position. Secure with shoulder bolt and nut. Tighten nut to
specification.
(25 lb.-ft.)

Adjust Mower Wheels (S.N. 130001- )

LEGEND:
A Position 1
B Position 2
C Position 3
D Position 4
E Bolt
F Nut
G Wheel
42 Inch Mower shown.
[1] -
CAUTION:
accidently.
IMPORTANT:
The mower deck can be damaged if mower wheels are adjusted wrong:
Wheels must not ride on ground supporting mower weight.

Check wheel adjustment each time cutting height is changed.
[2] - Inflate tires to correct pressure.
[3] - Raise mower deck lift lever, and lock in transport position.
[4] - Adjust mower wheels to correct height:
42 and 48 Inch Mower
42 Inch Mower
Position 1 (A) 25—38 mm (1—1-1/2 in.) Height of Cut
Position 2 (B) 44—50 mm (1-3/4—2 in.) Height of Cut
Position 3 (C) 57—69 mm (2-1/4—2-3/4 in.) Height of Cut
Position 4 (D) 76—101 mm (3—4 in.) Height of Cut
Remove shoulder bolt (E) and nut (F). Move wheel (G) to proper hole position. Secure with shoulder bolt and nut. Tighten nut to
specification.
(25 lb.-ft.)

Adjust Mower Level

LEGEND:
A Leveling Gauge
B Blade Tip
C Left Blade
D Right Blade
A convenient leveling gauge (A) (AM130907) is available

from your dealer.
Blades
[1] -
CAUTION:
accidently.
→NOTE:
Mower wheels should not contact the ground when leveling the deck.
[2] - Inflate tires to the correct pressure.

Tire Pressure
(10 psi)
(30 psi)

(10 psi)
[3] - Set mower to preferred cutting height, and lower deck into the mowing position.
[4] - Measure mower level (side-to-side).
a. Position mower blades as follows and measure from each outside blade tip (B) to the level surface.
b. Turn left blade (C) as shown. Hold drive belt and turn right blade (D) as shown. Take measurement for both blades.
The difference between blade measurements must not be more than 3 mm (1/8 in.) .
LEGEND:
F Nut
c.
Mower Rear Nuts
Adjust mower level, if necessary, by turning rear nuts (F) clockwise to raise the side of the mower deck, or
counterclockwise to lower the mower deck.
[5] -
LEGEND:
E Right Blade
Mower Level Front-to-Rear

Measure mower level (front-to-rear).
a. Turn right blade (E) so blade tip points straight forward.

b. Measure from blade tip to the surface. Take measurement for both blades. The front blade tip must be 3 - 6 mm (1/8 -
1/4 in.) lower than rear blade tip.

SERVICE TOOLS AND KITS (g) by Belgreen v2.0
LEGEND:
H Rear Nuts
I Front Nuts
J Bracket Sides
c.
Front Lift Rod
Adjust mower level, if necessary, by loosening rear nuts (H) on front lift rod. Turn front nuts (I) clockwise to raise front of
mower or counterclockwise to lower it. Make sure front lift rod contacts mower deck bracket on both sides (J) to maximize
stability of deck. Tighten rear nut after adjustment is complete.

Section 299 - SERVICE TOOLS AND KITS

Table of contents
Group 10 - Service Tools ......................................................................................................................... 1

Section 299 - SERVICE TOOLS AND KITS Group 10: Service Tools
Group 10 - Service Tools

→NOTE:
Order tools according to information given in the ServiceGard ™ Catalog. Some tools may be available

19203
Use to remove flywheel.
C-Ring Removal Tool
JDG1087
JDG1086
Pulse Tachometer
JT07270
Use to measure engine speed.
Digital Photo Tachometer
JT05719
Use to measure engine speed.
Thickness Gauge
0.15 mm (0.006 in.)
Use to measure piston ring side gap.
Plug
8741-F66
Use to perform vacuum test.
Barbed Fitting
JTO5703
Hose
JTO5699
Vacuum Gauge
JTO3503
JTO3502
Use to check for engine air leaks.
Breaker Bar Socket
32 mm Socket
Use to hold flywheel in place.
Spark Tester
D053515T

Section 299 - SERVICE TOOLS AND KITS Group 10: Service Tools
Use to check spark.

Pulse Tachometer
JTO7270
JTO7262
Use to measure oil pressure.
Connector
JTO5487
Hose Assembly
JTO3017
Coupler
JTO3262
Gauge
JTO7034
Battery Tester
Use to load test battery.
Current Clamp
JT02153
Use to measure current.
Multimeter
JT05791A
Use to perform electrical tests.

TM 112919

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<- Go to Global Table of contents TM112919-TECHNICAL MANUAL

<- Go to Section TOC Section 10 page 1 TM112919-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

<- Go to Global Table of contents TM112919-TECHNICAL MANUAL

Understand Signal Words

Follow Safety Instructions

<- Go to Section TOC Section 10 page 1 TM112919-TECHNICAL MANUAL

<- Go to Section TOC Section 10 page 2 TM112919-TECHNICAL MANUAL

Practice Safe Maintenance

Keep Area Clean

Use Proper Tools

<- Go to Section TOC Section 10 page 3 TM112919-TECHNICAL MANUAL

Handle Fluids Safely—Avoid Fires

Drain Gasoline When Storing Machine

<- Go to Section TOC Section 10 page 4 TM112919-TECHNICAL MANUAL

Gasoline stored in fuel tank can explode.

<- Go to Section TOC Section 10 page 5 TM112919-TECHNICAL MANUAL

Prevent Acid Burns

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

Prevent Battery Explosions

<- Go to Section TOC Section 10 page 6 TM112919-TECHNICAL MANUAL

Handling Batteries Safely

<- Go to Section TOC Section 10 page 7 TM112919-TECHNICAL MANUAL

Filling batteries in a well-ventilated area

If acid is spilled on skin or in eyes:

1. Flush skin with water.

1. Do not induce vomiting.

<- Go to Section TOC Section 10 page 8 TM112919-TECHNICAL MANUAL

Prepare for Emergencies

First Aid Kit

Be prepared if a ﬁre starts.

Park Machine Safely

Remove the Key

Before working on the machine:

Lower all equipment to the ground.

Support Machine Properly

<- Go to Section TOC Section 10 page 9 TM112919-TECHNICAL MANUAL

<- Go to Section TOC Section 10 page 10 TM112919-TECHNICAL MANUAL

Wear Protective Clothing

Work in Clean Area

Clean Work Area

Before starting a job:

Clean work area and machine.

<- Go to Section TOC Section 10 page 11 TM112919-TECHNICAL MANUAL

Read all instructions thoroughly; do not attempt shortcuts.

Service Machines Safely

Work In Ventilated Area

Engine exhaust fumes

Illuminate Work Area Safely

<- Go to Section TOC Section 10 page 12 TM112919-TECHNICAL MANUAL

Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Proper Lifting Equipment

<- Go to Section TOC Section 10 page 13 TM112919-TECHNICAL MANUAL

Follow Tire Recommendations

Keep your machine in proper working order.