1200A

Bunker and Field Vehicle

TECHNICAL
MANUAL

John Deere
Lawn & Grounds Care Division
TM1587 (17FEB95)

Litho in U.S.A
M83102
 INTRODUCTION

This technical manual is written for an experieced

technician and contains sections that are specifically for
this product. It is a part of a total product support Safety
program.

Specifications and
Information

The manual is organized so that all the information on a

particular system is kept together. The order of grouping Engine
is as follows:
• Table of Contents
• Specifications
• Theory of Operation
• Troubleshooting Diagram
• Diagnostics
• Tests & Adjustments Electrical
• Repair

Note: Depending on the particular section or system

being covered, not all of the above groups may be Power Train
used.

Each section will be identified with a symbol rather than a

number. The groups and pages within a section will be Steering
consecutively numbered.

Brakes

All information, illustrations and specifications in this

manual are based on the latest information available at
the time of publication. The right is reserved to make
Hydraulics
changes at any time without notice.

Attachments

We appreciate your input on this manual. To help, there

are postage paid post cards included at the back. If you
find any errors or want to comment on the layout of the
manual please fill out one of the cards and mail it back to
us.
Miscellaneous

COPYRIGHT© 1995
JOHN DEERE HORICON WORKS
Horicon, Wisconsin
All rights reserved

2/17/95 i
INTRODUCTION

ii 2/17/95
 SAFETY

RECOGNIZE SAFETY HANDLE FLUIDS SAFELY-AVOID

INFORMATION FIRES
Be Prepared For Emergencies

T81389

TS291

This is the safety-alert symbol. When you see this

symbol on your machine or in this manual, be alert to
the potential for personal injury.

Follow recommended precautions and safe servicing

practices.

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—
is used with the safety-alert symbol. DANGER
identifies the most serious hazards. TS227

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.
REPLACE SAFETY SIGNS
When you work around fuel, do not smoke or work
near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and
debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.

TS201

Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign
placement.

2/17/95 1- 1
SAFETY

USE CARE IN HANDLING AND USE SAFE SERVICE PROCEDURES

SERVICING BATTERIES Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.

Prolonged exposure to loud noise can cause

impairment or loss of hearing. Wear a suitable hearing
protective device such as earmuffs or earplugs to
protect against objectionable or uncomfortable loud
noises.

Operating equipment safely requires the full attention

of the operator. Do not wear radio or music
TS204 TS203 headphones while operating machine.

Prevent Battery Explosions

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

Prevent Acid Burns TS206

• Sulfuric acid in battery electrolyte is poisonous. It

is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
• Avoid acid burns by:
1. Filling batteries in a well-ventilated area.
Service Machine Safely
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.

2. Wearing eye protection and rubber gloves. Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
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. TS228

3. Flush your eyes with water for 15-30 minutes.

4. 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 1.9 L (2 quarts).
3. Get medical attention immediately.
Use Proper Tools
Use tools appropriate to the work. Makeshift tools 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.
Use only service parts meeting John Deere
specifications.

1-2 2/17/95

Park Machine Safely
TS230
• Before working on the machine:
1. Lower all equipment to the ground.
2. Stop the machine and remove the key.
3. Disconnect the battery ground strap.
4. Hang a “DO NOT OPERATE” tag in operator
station.
Support Machine Properly and Use
Proper Lifting Equipment
TS229
If you must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous
load. Do not work under a machine that is supported
solely by a jack. Follow recommended procedures in
this manual.
Lifting heavy components incorrectly can cause
severe injury or machine damage. Follow
recommended procedure for removal and installation
of components in the manual.
Work In A Clean Area
• Before starting a job:
1. Clean work area and machine.
2. Make sure you have all necessary tools to do your
job.
2/17/95
SAFETY
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Work In A Ventilated Area
TS220
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.
Remove Paint Before Welding Or
Heating
Avoid potentially toxic fumes and dust. Hazardous
fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work
outside or in a well ventilated area. Dispose of paint
and solvent properly. Remove paint before welding or
heating: If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator. If you use solvent
or paint stripper, remove stripper with soap and water
before welding. Remove solvent or paint stripper
containers and other flammable material from area.
Allow fumes to disperse at least 15 minutes before
welding or heating.
1- 3
SAFETY
SERVICE TIRES SAFELY
TS952
Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not
inflate the tires above the recommended pressure.
Never weld or heat a wheel and tire assembly. The
heat can cause an increase in tire pressure resulting in
a tire explosion. Welding can structurally weaken or
deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
1-4
USE CARE AROUND HIGH-
PRESSURE FLUID LINES
Avoid High-Pressure Fluids
X9811
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is
available from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
HANDLE CHEMICAL PRODUCTS
SAFELY
TS1132 TS1133
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with John Deere equipment include such items as
lubricants, coolants, paints, and adhesives.
2/17/95
 SAFETY

A Material Safety Data Sheet (MSDS) provides LIVE WITH SAFETY

specific details on chemical products: physical and
health hazards, safety procedures, and emergency
response techniques. Check the MSDS before you
start any job using a hazardous chemical. That way
you will know exactly what the risks are and how to do
the job safely. Then follow procedures and
recommended equipment.

Dispose of Waste Properly

Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with John Deere equipment include such items
as oil, fuel, coolant, brake fluid, filters, and batteries. TS231
Use leakproof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them. Do not pour waste Before returning machine to customer, make sure
onto the ground, down a drain, or into any water machine is functioning properly, especially the safety
source. Inquire on the proper way to recycle or systems. Install all guards and shields.
dispose of waste from your local environmental or
recycling center, or from your John Deere dealer.

2/17/95 1- 5
SAFETY

This page intentionally left blank.

1-6 2/17/95
CONTENTS SPECIFICATIONS & INFORMATION

CONTENTS
Page

SPECIFICATIONS & INFORMATION

GENERAL VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
REPAIR INFORMATION
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES . . . . . . . . . . . . . . . 2-5
METRIC BOLT AND CAP SCREW TORQUE VALUES . . . . . . . . . . . . . . . . . . . . 2-6
FUEL AND LUBRICANTS
GASOLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
OILSCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
TRANSAXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
OPTIONAL HYDRAULIC PUMP OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
OIL FILTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SERIAL NUMBER LOCATIONS
MACHINE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
TRANSAXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
OPTIONAL HYDRAULIC PUMP SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . 2-9

1/4/95 2-1
SPECIFICATIONS & INFORMATION VEHICLE SPECIFICATIONS

VEHICLE SPECIFICATIONS

ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere "K" Series
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FE290D-AS11
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural
Horsepower (SAEJ1349). . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 kW (7.1 HP) at 2700 rpm
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 mL (17.5 cu. in.)
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 mm (3.070 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.360 in.)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4:1
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1175 ± 75 rpm
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3100 ± 75 rpm
Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Filter
Engine Oil Capacity (with filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 L (2.75 pt.)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy duty with replaceable filter element
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal discharge below frame

FUEL SYSTEM
Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Behind driver, left-hand side
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.25 L (3.5 gal)
Fuel (min. octane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded gasoline, 87 octane
Fuel Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On right-hand side of engine
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Draft Carburetor
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable in-line

ELECTRICAL
Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic CDI
Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Alternator
Charging Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 amp at 3,000 rpm, Regulated
Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI Group, U1
Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Battery Reserve Capacity at 25 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC 38
Battery Cold Cranking amps at -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . .295 amps
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Halogen
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter, Hourmeter
Ignition Interlock Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Start

2-2 1/4/95
VEHICLE SPECIFICATIONS SPECIFICATIONS & INFORMATION

POWER TRAIN
Clutch
Type. . . . . . . . . . . . . . . . . . . . . . . . Continuously Variable, Belt-Driven Torque Converter

Transaxle
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully enclosed, oil bath
Transaxle Lubricant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L (2.5 qt)
Lubricant Type. . . . . . . . . . . . . . . . . . . . . . . . . . John Deere 85W140 API GL-5 Gear Oil
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forward, Neutral, Reverse
Reduction Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.03:1
Differential Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Operated
Travel Speeds at Governed Fast Idle
Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.50 km/h (11.5 mph)
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.50 km/h (11.5 mph)

STEERING
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, Roller-chain and Sprocket
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4:1

BRAKES
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transaxle
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Disk, Single Pedal
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pedal Locking Lever

WEIGHTS AND DIMENSIONS

Empty Weight (less attachments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 kg (542 lb)
Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.054 m (41.5 in.)
Overall Width (less attachments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.473 m (58 in.)
Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.676 m (66 in.)
Overall Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.041 m (41 in.)
Turning Radius (inside rear wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 mm (12 in.)
Ground Clearance at Rake Attachment . . . . . . . . . . . . . . . . . . . . . . . . 241 mm (9.5 in.)

WHEELS AND TIRES

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One 22.5 x 10.00-8 2PR High Flotation
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two 25 x 12.00-9 2PR High Flotation
Tire Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.6—41.4 kpa (4—6 psi)

ATTACHMENTS AND KITS

Front-mount Attachments
Lift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual with Up-Lock Position
Lift Assist Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Spring
Lift Lever Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right-hand Side of Platform
Front Blade (Optional)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016 mm (40 in.)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 mm (6 in.)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 kg (56 lb)

1/4/95 2-3
SPECIFICATIONS & INFORMATION VEHICLE SPECIFICATIONS

Front-mount Attachments, continued

60-Inch Aluminum Blade (Optional)
(Mounts to optional front blade.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1626 mm (60 in.)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 mm (6 in.)
Weight (Blade Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 kg (8 lb)
Weight (60-inch Blade with 40-inch Front Blade) . . . . . . . . . . . . . . . . . . . 29 kg (64 lb)
Core Removal Blade (Optional)
(Mounts to optional front blade.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1231 mm (48 in.)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 mm (9.25 in.)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 kg (24 lb)

Mid-mounted Attachments
Lift System . . . . . . . . . . . . . . Manual (Hand Control) with 5-Position Depth Adjustment
Lift Assist Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Spring
Lift Lever Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right-hand Side of Seat
Cultivator (Optional)
(Mounts to optional mid-mount base.)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Blades
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1626 mm (64 in.)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 kg (44 lb)
64.5-Inch Scraper Blade
(Mounts to optional mid-mount base with either
wide or narrow scarifier tines also attached.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1654 mm (64.5 in.)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 mm (5.625 in.)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 kg (21 lb)
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two bolts attach it to Cultivator Toolbar
Wide- and Narrow-Interval Scarificer Tines Attachment
(Mounts to optional mid-mount base.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wide—1622 mm (63.25 in.)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Narrow—1590 mm (62 in.)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wide—10 kg (22 lb)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Narrow—11.3 kg (25 lb)
Tines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wide—20 Tines, 90 mm (3.50 in.) Long
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Narrow—35 Tines, 90 mm (3.50 in.) Long

Rear-mounted Attachments
Lift System . . . . . . . . . . . . . . . . . . . . . . . . . . Electro-Mechanical (Hydraulic—Optional)
Lift Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right-hand Side of Dash Panel
Bunker/Field Rake (Optional)
(Mounts to optional rear frame.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1981 mm (78 in.)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 kg (44 lb)
Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Section, Bunker or Field
Prong Rake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three Section, 24 Prongs
25—76 mm (1—3 in.) Adjustment
Field Finisher (Optional)
(Mounts to optional rear frame.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1538 mm (60 in.)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 kg (40 lb)

a
Specifications and design subject to change without notice.

2-4 1/4/95
UNIFIED INCH TORQUE VALUES SPECIFICATIONS & INFORMATIO N

UNIFIED INCH TORQUE VALUE S

1 or 2b 5 5.1 5.2 8 8.2
SAE
Grade
and Head No Marks
Markings

2 5 8
SAE
Grade No Marks
and Nut
Markings
TS1162

Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya

SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft

1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5

5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26

3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46

7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75

1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115

9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160

5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225

3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400

7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650

1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975

1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350

1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950

1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550

1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

DO NOT use these values if a different torque value or
tightening procedure is given for a specific application.
Torque values listed are for general use only. Check
tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original. Make
sure fasteners threads are clean and that you properly
start thread engagement. This will prevent them from
failing when tightening.Tighten plastic insert or crimped
steel-type lock nuts to approximately 50 percent of the
dry torque shown in the chart, applied to the nut, not to
the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a
“Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without any
lubricationb
b Grade 2 applies for hex cap screws (not hex bolts) up
to 152 mm (6-in.) long. Grade 1 applies for hex cap
screws over 152 mm (6-in.) long, and for all other types
of bolts and screws of any length.

2/9/95 2- 5
SPECIFICATIONS & INFORMATION METRIC TORQUE VALUES

METRIC TORQUE VALUE S

4.8 8.8 9.8 10.9 12.9
Property
Class
and 4.8 8.8 9.8 10.9 12.9
Head
Markings 4.8 8.8 9.8 10.9 12.9 12.9

Property 5 10 10 12
Class
and

10

10

12
5

Nut 5 10 10 12
Markings
Ts1163

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya

SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft

M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35

M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70

M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109

M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300

M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410

M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580

M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800

M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000

M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500

M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000

M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750

M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500

DO NOT use these values if a different torque value or
tightening procedure is given for a specific application.
Torque values listed are for general use only. Check
tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original. Make
sure fasteners threads are clean and that you properly
start thread engagement. This will prevent them from
failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to
approximately 50 percent of the dry torque shown in
the chart, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a
“Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without any
lubrication.
b
Grade 2 applies for hex cap screws (not hex bolts) up
to 152 mm (6-in.) long. Grade 1 applies for hex cap
screws over 152 mm (6-in.) long, and for all other types
of bolts and screws of any length.

2-6 2/9/95
FUEL AND LUBRICANTS SPECIFICATIONS & INFORMATIO N

FUEL AND LUBRICANT S FUEL STORAGE

Keep fuel in a clean container in a protected area.
Water and sediment must bromated before fuel gets to
GASOLINE SPECIFICATIONS the engine. Do not use deicers to remove water from
fuel. Do not depend on fuel filters to remove water.

c CAUTION: If possible, install a water separator at the storage tank

outlet.

IMPORTANT: Keep all dirt, scale, water or other

Handle fuel with care, it is highly flammable. DO foreign material out of fuel.
NOT refuel machine:
• Indoors. Always fill fuel tank outdoors . If transporter is either stored or used during the winter,
• While you smoke. add TY6295 John Deere Gasoline Storage Stabilizer or
• When machine is near and open flame or an equivalent to the fuel. Follow directions on can.
sparks.
• When engine is running. STOP engine .
LUBRICANT SPECIFICATIONS
• When engine is hot. Allow it to cool .

Help prevent fires: ENGINE OIL

• Fill fuel tank only to bottom of filler neck .
• Clean oil, grease and dirt from machine .
• Clean up spilled fuel immediately .
• Do not store machine with fule in tank in a
building where fumes may reach an open
flame or spark.
Use oil viscosity based on the expected air
temperature range during the period between oil
changes.
The following oil is preferred:
• John Deere PLUS-4®

To prevent fire and explosion caused by static

electric discharge while you fill tank :
• Use approved, non-metal fuel container .
• When using a funnel, MAKE SURE it is
PLASTIC.
• Avoid using a funnel which has a metal screen
or filter.

IMPORTANT: To avoid engine damage :

• DO NOT mix oil with gasoline

• Use only clean oil and fuel
• Use clean approved containers and funnels.
• Store oil and fuel in an area protected from dust,
moisture and other contamination.
Unleaded fuel is recommended because it burns
cleaner and leaves less unburned deposits in engine
combustion chamber. Regular leaded gasoline with an
anti-knock index of 87 or higher may be used.Use of
gasohol is acceptable as long as the ethyl alcohol TS1411
blend does not exceed 11 percent. Unleaded gasohol
is preferred over leaded gasohol. Other oils may be used if they meet one of the
following:
Fill fuel tank at end of each day's operation. Fill only to
bottom of filler neck. Fuel Tank Capacity is 13.25 L (3.5 • API Service Classification SG
U.S. gal). • API Service Classification SF
• CCMC Specification G4
Oils meeting Military Specification MIL-L-46167B may
be used as arctic oils.

2/9/95 2- 7
SPECIFICATIONS & INFORMATION
OILSCAN®
OILSCAN is a John Deere sampling program to help
you monitor machine performance and identify
potential problems before they cause serious damage.
Oil samples should be taken from each system prior to
its recommended change interval.
Check with your John Deere dealer for the availability
of an OILSCAN kit.
T6828AB
GREASE
Use grease based on the expected air temperature
range during the service interval.
The following greases are preferred:
• John Deere MOLY HIGH TEMPERATURE EP
GREASE
• John Deere HIGH TEMPERATURE EP GREASE
• John Deere GREASE-GARDTM
TS1417
Other greases may be used if they meet one of the
following:
• SAE Multipurpose EP Grease with a maximum of 5%
molybdenum disulfide.
2-8
FUEL AND LUBRICANTS
• SAE Multipurpose EP Grease
Greases meeting Military Specification MIL-G-10924F
may be used as arctic grease.
TRANSAXLE OIL
John Deere 85W140 API GL-5 gear oil is
recommended. If other oils are used, they must be oils
meeting the following requirements:
API Service Classification GL-5
Military Specification MIL-L-2105B
Military Specification MIL-L-2105C
At temperatures below 35°C (31°F), use arctic oils
such as those meeting Military Specifications MIL-G-
10324A.
OPTIONAL HYDRAULIC PUMP OI L
NOTE: This hydraulic pump is filled with John Deere
Low Viscosity HY-GARD (J20D) transmission/
hydraulic oil at the factory. DO NOT mix oils.
This machine may be equipped with an optional
hydraulic pump. To ensure optimum performance, use
only Low Viscosity HY-GARD (J20D) transmission/
hydraulic oil. It is specifically formulated to provide
maximum protection against mechanical wear,
corrosion and foaming.
ALTERNATIVE LUBRICANT S
Conditions in certain geographical areas outside the
United States and Canada may require different
lubricant recommendations than these printed in this
manual or the operator's manual. Consult with your
John Deere Dealer, or Sales Branch to obtain the
alternative lubricant recommendations.
SYNTHETIC LUBRICANT S
Synthetic lubricants may be used in John Deere
equipment if they meet the applicable performance
requirements (industry classification and/or military
specification).
The recommended temperature limits and service or oil
change intervals should be maintained as shown in the
operator's manual.
Avoid mixing different brands, grades 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.
OIL FILTERS
Filtration of oils is critical to proper lubrication. Always
change filter regularly.
Use filters meeting John Deere performance
specifications.
LUBRICANT STORAG E
This machine can operate at top efficiency only if clean
lubricants are used.
Use clean containers to handle all lubricants. Store
them in an area protected from dust, moisture and
other contamination. Store drum on their sides.
2/9/95
SERIAL NUMBER LOCATION SPECIFICATIONS & INFORMATIO N

SERIAL NUMBER LOCATIO N CARBURETOR SERIAL NUMBE R

SERIAL NUMBER LOCATIO N

When ordering parts or submitting a warranty claim, it
is IMPORTANT that the machine product identification
number and component serial numbers are included.
The location of the machine identification number and
component serial numbers are shown.

MACHINE IDENTIFICATION
NUMBER M83186

TRANSAXLE SERIAL NUMBER

M83160

ENGINE SERIAL NUMBER M83159

OPTIONAL HYDRAULIC PUM P

SERIAL NUMBER

M83161

M80702

2/9/95 2- 9
SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATION

This page intentionally left blank.

2 - 10 2/9/95
CONTENTS

CONTENT S
Page

ENGINE (FE290D )
SPECIFICATION S
ENGINE DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
TROUBLESHOOTIN G
ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART. . . . . . . . . . . . . . 3-9
ENGINE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
CHECKS, TESTS AND ADJUSTMENT S
ACCELERATOR CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
CHOKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
GOVERNOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
FAST IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
SLOW IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CYLINDER COMPRESSION PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . 3-19
VALVE CLEARANCE, CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 3-19
AUTOMATIC COMPRESSION RELEASE (ACR) CHECK. . . . . . . . . . . . . . . . . 3-20
CRANKCASE VACUUM TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
CRANKSHAFT END PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
SPARK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
SPARK PLUG GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
REPAIR
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
ACCELERATOR CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
MUFFLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
AIR CLEANER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
ENGINE—REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
BREATHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
BLOWER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
ROCKER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
ANALYZE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
RECONDITION VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
LAP VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
CHECK PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

1/27/95 3- 1
 CONTENTS CONTINUED

Page

REPAIR, continue d
ANALYZE PISTON RING WEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
ANALYZE PISTON WEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR. . . . . . . . . . . . . . . 3-44
CAMSHAFT AND TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
ACR RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
RECIPROCATING BALANCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
CRANKSHAFT OIL SEAL—FLYWHEEL END . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
CRANKSHAFT OIL SEAL—PTO END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR. . . . . . . . . . . . . . . 3-50
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
OIL FILTER MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
GOVERNOR SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
ARMATURE WITH COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
IGNITION MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

3-2 1/27/95
SPECIFICATIONS ENGINE

SPECIFICATIONS

ENGINE DESIGNATION

FE 290 D
Four Cycle D- Direct Drive
R- Gear Box Drive
Model Designation/ G- Gear Drive off Camshaft
Variation A, B, C, D, etc. Displacement
V- Vertical

TEST AND ADJUSTMENT SPECIFICATIONS

Choke Knob-to-Cable Mount Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3 mm (0.08—0.12 in.)
Carburetor SLOW Idle Mixture Screw Initial Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3/8 turns
Throttle Control Arm SLOW Idle Stop Screw Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1175 (±75) rpm
Carburetor SLOW Idle Stop Screw Setting . . . . . . . . . . . . . . . . . . . . . . . . . 50 rpm less than throttle control
arm SLOW idle stop screw setting
Throttle Control Arm FAST Idle Stop Screw Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3100 (±75) rpm
Minimum Cylinder Compression Pressure at Operating Temperature . . . . . . . . . . . . . . . . 393 kPa (57 psi)
Valve Clearance (Cold)
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.125 ±0.025 mm (0.005 ±0.001 in.)
Exhaust Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.125 ±0.025 mm (0.005 ±0.001 in.)
Intake and Exhaust Valve Adjustment Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hrs.
Valve Adjustment Screw Jam Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Valve Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Minimum Exhaust Valve ACR Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 mm (0.020 in.)
Maximum Exhaust Valve ACR Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 mm (0.065 in.)
ACR Release RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 900 rpm
Minimum Crankcase Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mm (1.2 in.) water movement at fast idle
Minimum Engine Oil Pressure at 3800 RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 kPa (45 psi)
Fuel Pump Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.120 kPa (0.90 psi)
Fuel Pump Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 ml/15 seconds (2.7 oz/15 seconds)
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09—0.22 mm (0.004—0.009 in.)
Starter No-Load Amperage (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 amps
Starter No-Load RPM(Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 rpm
Armature With Coil:
Resistance Between Primary Lead and Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.67—1.10 ohms
Resistance Between Spark Plug Cap and Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6—10 ohms
Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)

1/27/95 3-3
ENGINE SPECIFICATIONS

REPAIR SPECIFICATIONS
Muffler Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 N•m (124 lb-in.)
Engine Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)
Breather Air Gap (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 N•m (63 lb-ft)
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.125 ±0.025 mm (0.005 ±0.001 in.)
Rocker Arm
Shaft O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.)
Bearing I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.)
Push Rod
Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)
Valves and Springs
Valve Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.75 mm (1.289 in.)
Valve Guide I.D. (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.065 mm (0.2781 in.)
Finished Valve Guide I.D. (Reamed) . . . . . . . . . . . . . . . . . . 7.00—7.015 mm (0.2756—0.2762 in.)
Valve Stem Bend (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.0012 in.)
Intake Valve Stem O.D. (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.930 mm (0.2728 in.)
Exhaust Valve Stem O.D. (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.915 mm (0.2722 in.)
Valve Seat
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50—1.10 mm (0.020—0.043 in.)
Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve Face Margin (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.020 in.)
Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Cylinder Head
Cylinder Head Flatness (Maximum Distortion) . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Cap Screw Torque in Sequence (Lubricated)
Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (159 lb-in.)
Second Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Crankcase
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 L (2.7 pt)
Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (230 lb-in.)
Oil Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Maximum Crankcase Main Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.08 mm (1.184 in.)
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09—0.22 mm (0.004—0.009 in.)
Crankshaft Oil Seal Depth (PTO End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 mm (0.158 in.)
Governor Mounting Shaft Height (Top of Shaft-to-Cover) . . . . . . . .32.2—32.8 mm (1.267—1.291)
Governor Shaft Oil Seal Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 mm (0.056 in.)

3-4 1/27/95
SPECIFICATIONS ENGINE

REPAIR SPECIFICATIONS, continued

Camshaft
Minimum PTO and Flywheel Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.93 mm (0.903 in.)
Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.70 mm (1.287 in.)
Maximum Cylinder Block and Cover Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . 23.06 mm (0.908 in.)
Reciprocating Balancer
Link Rod
Small End I.D. (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.60 mm (0.475 in.)
Large End I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.12 mm (1.855 in.)
Bushing Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.040 in.)
Balancer Weight
Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.027 in.)
Bushing Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)
Support Shaft
Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.93 mm (1.021 in.)
Balancer Bushing Assembly Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 N•m (65 lb-in.)
Piston
Maximum Ring Groove Clearance
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.)
Oil Control Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not measured
Minimum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Maximum Ring End Gap
Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.047 in.)
Oil Control Ring Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not measured
Piston Pin O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.98 mm (0.865 in.)
Piston Pin Bore O.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.03 mm (0.749 in.)
Piston O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.85—77.87 mm (3.0649—3.0657 in.)
0.50 mm (0.020 in.) Oversize . . . . . . . . . . . . . . . . 78.35—78.37 mm (3.0849—3.0857 in.)
Piston-to-Cylinder Bore Clearance. . . . . . . . . . . . . . . . . . . 0.110—0.151 mm (0.0043—0.0059 in.)
Connecting Rod
Crankshaft Bearing I.D. (Wear Limit)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.07 mm (1.617 in.)
Undersized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.07 mm (1.380 in.)
Piston Pin Bearing I.D. (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.06 mm (0.750 in.)
End Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)

1/27/95 3-5
ENGINE SPECIFICATIONS

REPAIR SPECIFICATIONS, continued

Crankshaft
Link Rod Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.86 mm (1.845 in.)
Main Bearing Journal O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.92 mm (1.178 in.)
Connecting Rod Journal O.D. (Wear limit)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.93 mm (1.611 in.)
Undersized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.93 mm (1.375 in.)
Maximum Crankcase Cover Plain Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 38.06 mm (1.498 in.)
Maximum TIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09—0.22 mm (0.004—0.009 in.)
PTO Side Oil Seal Depth . . . . . . . . . . . . . . . . . . . . . . . . . . 4 mm (0.158 in.) below crankcase cover flange
Cylinder Bore I.D.
Standard Size Bore:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.98—78.00 mm (3.070—3.071 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.08 mm (3.074 in.)
Oversize Bore:
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.46—78.48 mm (3.089—3.090 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.55 mm (3.093 in.)
Out-of-Round (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.056 mm (0.0022 in.)
Oil Pump
Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.63 mm (0.497 in.)
Maximum Rotor Shaft Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.77 mm (0.503 in.)
Outer Rotor
Minimum Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.92 mm (0.391 in.)
Minimum O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.596 in.)
Outer Rotor Bearing
Minimum Depth (Cylinder Block). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 mm (0.421 in.)
Maximum I.D. (Cylinder Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.77 mm (1.605 in.)
Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.00 mm (0.748 in.)
Ignition Air Coil Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
Start Brush Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.)

3-6 1/27/95
SPECIFICATIONS ENGINE

SPECIAL OR ESSENTIAL TOOLS

NOTE: Order tools according to information given in the U.S. SERVICE-GARD Catalog or in the
European Microfiche Tool Catalog (MTC).

JDM-71 Vibration Tachometer

Used to check/adjust engine slow and fast idle rpm.
JDM-59 Compression Gauge
Used to check engine compression.
AHT8741-F66 Plug
Used to connect U-tube manometer to engine for Crankcase Vacuum Test.
JT05703 Barb Fitting
Used to connect U-tube manometer to engine for Crankcase Vacuum Test.
JT05699 Clear Fuel Line
Used to connect U-tube manometer to engine for Crankcase Vacuum Test.
JT05698 U-Tube Manometer
Used to check engine crankcase vacuum.
JT03349 Connector—1/8" BSP Thread
Used to connect pressure gauge to engine when performing Engine Oil Pressure Test.
JT03017 Hose Assembly
Used to connect pressure gauge to engine when performing Engine Oil Pressure Test.
JT07034 Pressure Gauge Assembly
Used to read engine oil pressure when performing Engine Oil Pressure Test.
JDG356 Pressure Gauge
Used to check fuel pump performance.
D-05351ST Spark Tester
Used to check overall condition of ignition system.
JDG504 Valve Guide Driver Tool
Used to replace valve guide bushings.
JDM70 Valve Spring Compressor
Used to remove and install valve springs.

1/27/95 3-7
ENGINE SPECIFICATIONS

OTHER MATERIALS
Number Name Use
SCOTCH-BRITE Abrasive Sheets/Pads Clean cylinder head.
Valve Guide Cleaner Clean valve guides.
Stanisol (or Kerosene) Finish ream valve guides.
Prussian Blue Compound Check valve seat contact.
Lithium Base Grease Pack oil seals.
Zinc Oxide/Wood Alcohol Check block for cracks.
Mineral Spirits Clean armature.
M79292 MPG-2 Polymer Multipurpose Grease Apply to engine crankshaft.
LOCTITE PRODUCTS
U.S./
Canadian/
LOCTITE No.
Number Name Use
TY9375/ Pipe Sealant with TEFLON Apply to threads of oil
TY9480/592 pressure plug.

SERVICE PARTS KITS

The following are available through your parts catalog:
• Carburetor Repair Kit
• Main Jet and Pilot Jet Kit
• Shim Set
• Short Block
• Short Block Kit
• Engine Gasket Kit
• Intake Valve Kit
• Exhaust Valve Kit
• Screw and Nut Kit
• Rocker Arm Kit
• Camshaft Complete
• Camshaft and Tappet Kit
• Governor Kit
• Starter Brush Kit
• Clutch Kit

TEFLON is a trademark of the DuPont Co.

LOCTITE is a registered trademark of the Loctite Corp.

3-8 1/27/95
TROUBLESHOOTING ENGINE

TROUBLESHOOTING

ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART

Engine surges, or has uneven

Exhaust smoke black or uses

Engine will not stay running,

Engine has low oil pressure.

excessive oil consumption.
Exhaust smoke blue or has
Problem Or

Excessive engine noise or

Engine cranks but will not

Lack of fuel in carburetor.

runs rough, or irregularly.
Engine stalls frequently.
Symptom

Engine has low power.

Engine will not crank.

Engine has no spark.
or uncontrolled rpm.
start or starts hard.

Engine overheats.
Engine backfires.

Engine misses.

Engine floods.

too much fuel.

Check

Fuel in oil.

vibration.
Or
Solution

Spark plug fouled, defective,

or gap not correct. Incorrect
spark plug.
Defective ignition
components.
Starter worn. Cranking rpm
too slow.
Fuel filter or line restricted.
Fuel pump weak, restricted,
or leaking. Fuel stale,
contains water, or wrong
type.
Fuel pump not operating.

Air filter element(s) plugged,

oil soaked, or restricted.
Choke, throttle, or governor
linkage misadjusted.
Carburetor misadjusted.
Carburetor worn,
contaminated with debris or
varnish. Passages plugged.
Wrong jets.
Carburetor, intake manifold,
or cylinder head gaskets
leaking or damaged.
Low compression from worn
piston, rings, cylinder, valves
or warped head.
Valve clearance incorrect.
Burned or warped valves and
seats. Defective springs.

Continued on next page.

5/11/95 3-9
ENGINE TROUBLESHOOTING

ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART, continued

Engine surges, or has uneven

Exhaust smoke black or uses

Engine will not stay running,

Engine has low oil pressure.

excessive oil consumption.
Exhaust smoke blue or has
Problem Or

Excessive engine noise or

Engine cranks but will not

runs rough, or irregularly.

Lack of fuel in carburetor.

Engine stalls frequently.
Symptom

Engine has low power.

Engine will not crank.

Engine has no spark.
or uncontrolled rpm.
start or starts hard.

Engine overheats.
Engine backfires.

Engine misses.

Engine floods.

too much fuel.

Check

Fuel in oil.

vibration.
Or
Solution

Engine oil viscosity or level

incorrect. Engine oil filter
restricted.
Engine gaskets or seals
leaking.
Crankcase breather
restricted, reed valve
damaged, clearance
incorrect, or drain hole
plugged.
Valve guides or seals worn
or leaking. Valve stems worn.
Worn, stuck, or broken piston
rings. Cylinder bore worn.
Check compression and
vacuum.
Connecting rod or crankshaft
bearings worn. Internal wear
limits out of specification.
Battery cables corroded, or
battery weak.

3 - 10 5/11/95
TROUBLESHOOTING ENGINE

ENGINE TROUBLESHOOTING GUIDE

Engine Hard to Start

Remove spark plug and NO Are sparks produced when spark plug YES • Faulty spark plug.
check spark by cranking is replaced? Replace
engine while having the NO
plug grounded against YES
engine block. Install
YES
spare plug to plug hole Are sparks produced between high • Faulty contact of plug
to avoid fuel spitting from Correct
tension lead and engine block with cap terminal to lead.
the hole. plug cap removed? NO

• Faulty control unit. Replace

c CAUTION: YES
To avoid electric shock,
do not hold plug. Are sparks produced between high • Faulty ignition coil. Replace
Make sure to hold plug tension lead and engine block when
• Faulty high tension Replace
cap. control unit is replaced? NO
cord.
• Incorrect ignition coil Correct
air gap.
• Demagnetized Replace
flywheel.

Is compression YES Crank engine several times, then NO • No fuel in the tank. Add
sufficient? remove spark plug and observe • Clogged fuel filter. Clean
electrodes.
NO Are they wet? • Plugged air hole in Clean
tank cap.
YES • Plugged fuel line. Clean

• Excessive use of Open choke

choke.
• Clogged air cleaner. Clean
• Fuel level too high in Adjust
float bowl.

• Worn piston/piston Replace

rings.
• Stuck piston rings. Clean or replace
• Worn cylinder bore. Bore or replace
• Insufficient cylinder Retighten
head tightening.
• Faulty contact of valve Lap
seat.
• Plunged-up valve. Adjust
• Warped cylinder Repair or replace
Check carburetor. • Check for plugged fuel passage. head.
• Check for plugged air passage. • Broken valve spring. Replace
• Check float level. • Stuck valve. Clean or grind
• Check carburetor setting. • Burned head gasket. Replace

5/11/95 3 - 11
ENGINE TROUBLESHOOTING

Engine Malfunctions at Low Speed

Remove spark plug and • Faulty plug insulation. Replace
check spark by cranking WEAK • Fouled electrodes. Clean
engine while having the
plug grounded against • Faulty high tension Replace
engine block. Install cord.
spare plug to plug hole STRONG • Incorrect ignition coil Correct
to avoid fuel spitting from air gap.
the hole.

cCAUTION:
To avoid electric
shock, do not hold
plug. Make sure to
hold plug cap.

Is unusual smoke emitted out of YES • Overrich fuel in Adjust

muffler? NO carburetor slow
system.

Gradually open throttle valve by YES • Passages in Clean

hand. Does engine speed drop or carburetor plugged.
does engine stall at a certain NO
position?

Is air drawn through carburetor YES • Loose flange nuts. Tighten

flange? NO • Damaged gasket. Replace

Is valve clearance normal? NO • Compression Adjust

leak through
YES
valve.

Is alignment of timing gear marks NO • Largely deviated valve Correct

correct? timing.

3 - 12 5/11/95
TROUBLESHOOTING ENGINE

Engine Runs Erratically

Problem in fuel system (lack of fuel). • Dust or water in fuel pipe or fuel filter. Clean
• Air or vapor lock in fuel line. Remove
• Plugged air vent in fuel tank cap. Clean
• Plugged air/fuel passages in carburetor. Clean
• Too little opening of carburetor pilot air-screw. Correct

Problem in governor system. • Incorrect governor linkage adjustment. Correct

• Faulty governor spring. Replace
• Governor gear assembly malfunction. Check

Engine knocks. • Stale fuel. Change

• Excessive carbon deposit in engine. Clean
• Excessive engine load. Adjust
• Engine overheating. See Has
Low Power

Oil Consumption Is Excessive

Is compression sufficient? YES • Plugged oil ring groove. Clean
• High oil level. Adjust
NO
• Worn valve stems and valve guides. Replace
• Oil leakage along governor shaft. Replace
• Oil seals leaking. Replace
• Head gasket leaking. Replace
• Drain plug leaking. Retighten or
replace
• Breather valve clogged. Clean
• Drain-back hole in tappet chamber plugged. Clean
• Incorrect oil viscosity. Change

• Same as Hard To Start.

5/11/95 3 - 13
ENGINE TROUBLESHOOTING

Engine Has Low Power

Is engine overheated? YES • Excessive engine load. Adjust load
NO • Carburetor not properly adjusted. Adjust
• Dirty or clogged air intake screens, shroud and Clean
engine fins.
• Carbon deposit in combustion chamber. Clean
• Wrong spark plug. Replace

Is lubricating condition normal? NO • Too much or too little oil in crankcase. Correct
YES • Excessively contaminated lubricating oil. Change

YES • Air cleaner clogged. Clean

Is unusual smoke emitted out of
muffler? • Carbon deposit in exhaust hole and muffler. Clean
NO
• Carburetor not properly adjusted. Adjust
• Too much oil in crankcase. Correct

Is compression sufficient? NO
• Same as Hard To Start.

Fuel Consumption Is Excessive

Is compression sufficient? YES • Carburetor not properly adjusted. Adjust
• Air cleaner clogged. Clean
NO
• High idling RPM Adjust
• Choke valve not fully open. Open

• Same as Hard To Start.

3 - 14 5/11/95
TROUBLESHOOTING ENGINE

STARTER MOTOR
TROUBLESHOOTING GUIDE c CAUTION
1. Disconnect spark plug cap, and ground the cap
terminal. Engine may be cranked in this test. Do not touch
any rotating parts of engine and equipment
2. Turn engine switch to “START” position and check
during test.
condition.
IMPORTANT: If starter does not stop by engine
switch “OFF”, disconnect negative (-)
lead from battery as soon as possible.
Starter Does Not Rotate
Is click sound from solenoid (switch)? NO • Faulty battery. Charge or replace
• Faulty leads or connection. Repair or replace
YES
• Melted fuse. Replace
• Faulty engine switch. Repair or replace
• Faulty solenoid (switch). Replace

• Weak battery. Charge or replace

• Faulty leads or connection. Repair or replace
(Solenoid to motor)
• Faulty solenoid (switch). Replace
(Main terminal in solenoid)
• Faulty starter motor. Repair or replace

Starter Rotates Slow

Is battery normal and charged? NO • Weak battery. Charge or replace

YES
• Faulty leads or connection. Repair or replace
(Solenoid to motor)
• Faulty solenoid (switch). Replace
(Main terminal in solenoid)
• Faulty starter motor. Repair or replace
• Faulty engine. Repair or replace

Starter Rotates but Can Not Crank Engine

Does pinion mesh with ring gear? NO • Worn pinion or ring gear. Replace
YES • Incorrect starter alignment. Correct

• Faulty clutch. Replace

Starter Does Not Stop in Engine Switch “OFF”

Can stop starter by engine switch NO • Faulty engine switch. Repair or replace
“OFF”? • Faulty solenoid (switch). Replace
YES

• Faulty pinion or ring gear Repair or replace

• Incorrect starter alignment. Correct
• Faulty pinion return mechanism. Repair or replace

5/11/95 3 - 15
ENGINE CHECKS, TESTS AND ADJUSTMENTS

CHECKS, TESTS AND CHOKE ADJUSTMENT

ADJUSTMENTS
Reason:
ACCELERATOR CABLE To make sure the choke valve opens and closes
completely when knob is pushed and pulled.
ADJUSTMENT
Procedure:
Reason:
1. Park machine on level surface.
To make sure the throttle control lever of carburetor is
2. Turn key switch OFF.
adjusted correctly in relation to the accelerator pedal.
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake.
Procedure: 4. Lower front blade (if equipped).
1. Park machine on level surface. 5. Raise rear body cowling.
2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake. Cable Lock Nuts
4. Lower front blade (if equipped).
5. Raise rear body cowling.
Stop

Block (Rear)
Cover Cap Screws

M83196

Spacer

Cable Mount
Cap Screw M83194

6. Remove cap screws, spacer and cover.

Slow Idle
Stop Screw Governor
Control Lever Choke Knob M83463

6. Loosen cable lock nuts.

7. Adjust cable position so:
Fast Idle - There is 2—3 mm (0.08—0.12 in.) clearance
Cable Lock Nuts
Stop Screw between choke knob and cable mount when
choke open stop contacts block on rear of air
M83464
intake duct.
- Choke stop contacts block on front side of air
7. Loosen cable lock nuts.
intake duct when choke knob is pulled out.
8. Adjust cable length so governor control lever:
8. Tighten cable lock nuts.
- Contacts slow idle stop screw when accelerator
pedal is NOT pressed.
- Contacts fast idle stop screw when accelerator
pedal is fully pressed.
9. Tighten cable lock nuts.
10. Move accelerator pedal through full range to be
sure linkage is not binding.

3 - 16 2/9/95
CHECKS, TESTS AND ADJUSTMENTS ENGINE

GOVERNOR ADJUSTMENT 4. Lower front blade (if equipped).

5. Raise rear body cowling.

Reason:
To make sure the governor shaft contacts the fly-weight
plunger when the engine is stopped. Cover Cap Screws

NOTE: Adjust accelerator cable before adjusting

governor linkage.

Procedure: Spacer

1. Park machine on level surface.

2. Turn key switch OFF. Cap Screw M83194
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake. 6. Remove cap screws, spacer and cover.
4. Lower front blade (if equipped). 7. Start and run engine at MEDIUM idle for ten
5. Raise rear body cowling. minutes.
6. Move accelerator lever to FAST idle position.

c CAUTION
Shaft Engine will be HOT. Be careful around hot
components.

8. Move accelerator lever to FAST idle position.

9. Check engine speed using a JDM-71 Vibration
Nut Tachometer.
10. Set tachometer to 3100 rpm and put on a flat
M83198 surface of engine or on frame close to engine.

7. Loosen nut.
8. Hold governor arm in the full right position. Turn
governor shaft clockwise until governor shaft
stops. Hold governor shaft and tighten nut.
9. Move accelerator lever through full range to be sure
linkage is not binding.

FAST IDLE SPEED ADJUSTMENT

Fast Idle
Reason: Stop Screw M83474

To set engine fast idle speed setting.

11. Adjust fast idle stop screw until 3100 rpm (±75 rpm)
is achieved.
Test Equipment:
• JDM-71 Vibration Tachometer

Procedure:
1. Park machine on level surface.
2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake.

2/9/95 3 - 17
ENGINE CHECKS, TESTS AND ADJUSTMENTS

SLOW IDLE SPEED ADJUSTMENT NOTE: When accelerator pedal is released, it takes
approximately 30 seconds for engine idle
speed to stabilize.
Reason:
To ensure correct fuel/air mixture and that engine is
running at proper SLOW idle rpm.

Test Equipment: c CAUTION

• JDM-71 Vibration Tachometer
Procedure:
1. Park machine on level surface.
2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake.
4. Lower front blade (if equipped).
5. Raise rear body cowling.
Engine components are HOT. Be careful not to
touch, especially the exhaust pipe or muffler
while making adjustments. Wear protective eye
glasses and clothing.
10. Turn slow idle stop screw counterclockwise until
screw does not touch throttle arm stop tab.

Lock Nuts
Cover Cap Screws

Spacer M83461

Cap Screw M83194

NOTE: It may be necessary to loosen accelerator
6. Remove cap screws, spacer and cover. cable lock nuts and move cable slightly to
obtain proper slow idle speed setting.

11. Turn slow idle mixture screw on carburetor

Stop Tab clockwise until engine speed begins to drop off;
Slow Idle
Stop Screw note position. Turn it counterclockwise until engine
speed increases and begins to drop off; note
position.
12. Adjust screw half-way between positions. Turn
screw counterclockwise an additional 1/4 turn.
13. Check engine speed using a JDM-71 Vibration
Tachometer.
Slow Idle 14. Set tachometer to 1175 rpm and put on a flat
M83465
Mixture Screw surface of engine or on frame close to engine.
15. Adjust throttle control arm slow idle stop screw to
1175 rpm (±75 rpm).
IMPORTANT: DO NOT overtighten idle mixture 16. Turn slow idle stop screw clockwise until it touches
screw, the needle and seat will be damaged. stop tab.
17. Hold tab against stop screw; adjust screw until
7. Turn SLOW idle mixture screw clockwise until engine speed is 50 rpm less than throttle control
lightly seated, then turn counterclockwise 1-3/8 arm slow idle.
turns. 18. Depress and slowly release accelerator pedal.
8. Start and run engine at MEDIUM idle for 5 minutes Allow idle speed to stabilize. Recheck throttle slow
to bring engine to operating temperature. idle speed.
9. Release accelerator pedal.

3 - 18 2/9/95
CHECKS, TESTS AND ADJUSTMENTS ENGINE

19. Hold throttle arm against carburetor slow idle stop
screw. Engine speed should be 50 rpm less than
the throttle control arm slow idle. Readjust if
necessary.
It may be necessary to readjust accelerator cable. (See
ACCELERATOR CABLE ADJUSTMENT.)
9. Remove spark plug and install JDM-59
Compression Gauge.
10. Move the accelerator lever to FAST idle position.
11. Crank engine for 5 seconds and record
compression reading. Minimum compression is
393 kPa (57 psi).

CYLINDER COMPRESSION Results:

PRESSURE TEST • If compression is below specifications, squirt clean
engine oil into cylinder and repeat test.
• If compression pressure DOES NOT increase after
Reason: retest, check for leaking intake or exhaust valves,
To determine the condition of piston, rings, cylinder valve seal, or cylinder head gasket. Repair engine
wall, and valves. as necessary.
• If compression pressure INCREASES after retest,
check rings, piston and cylinder bore for broken
Test Equipment: rings, scoring, wear, or damage. Repair engine as
• JDM-59 Compression Gauge necessary.
• Procedure:
1. Park machine on level surface. VALVE CLEARANCE, CHECK AND
2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position.
ADJUSTMENT
Engage parking brake.
4. Lower front blade (if equipped). Reason:
5. Raise rear body cowling.
To obtain the proper valve clearance that is critical for
6. Start and run engine for 5 minutes to bring engine the valves to seat properly and for the automatic
to operating temperature. compression release to operate correctly.
7. Turn key switch OFF.

Test Equipment:

c
• Feeler Gauge (blade type)
CAUTION
Procedure:
Engine will be HOT. Be careful around hot
components.
IMPORTANT: Perform valve clearance
measurement or adjustment when engine is
IMPORTANT: Spark plug wire must be grounded or cold. Proper valve clearance is essential for the
electronic ignition could be damaged. compression release system to operate
correctly.

1. Park machine on level surface.

2. Turn key switch OFF. Allow engine to cool.
Compression 3. Move gearshift pedals to NEUTRAL position.
Gauge Engage parking brake.
4. Lower front blade (if equipped).
5. Raise rear body cowling.
High Tension 6. Remove and ground spark plug lead. Remove
Lead spark plug.
7. Remove valve cover.

M83466

8. Disconnect and ground spark plug high tension

lead.

2/9/95 3 - 19
ENGINE CHECKS, TESTS AND ADJUSTMENTS

High Tension
Lock Nut Lead
20 N•m (177 lb-in.)
Exhaust Valve

Adjustment
Screw

Exhaust
Intake
Rocker Arm
Rocker Arm M83467 M83468

8. Turn crankshaft until piston ia at TDC (top dead
center) of the compression stroke (both intake and
exhaust valves will be closed).
9. Use a feeler gauge to measure valve clearance.
Valve clearance should be 0.125 mm (± 0.025
mm), (0.005 in. ± 0.001 in.)
10. If clearance does meet specifications, loosen lock
nut and turn adjustment screw as necessary.
11. Tighten lock nut.
NOTE: Before installing rocker cover and spark plug,
perform Compression Release Check.
2. The exhaust valve must open (depress) briefly just
after the intake valve closes.
3. Use a dial indicator to measure exhaust valve ACR
movement. Minimum exhaust valve ACR
movement should be 0.6 mm (0.020 in.).
Results:
• If the exhaust valve does not open or depress
properly, the automatic compression release tab is
faulty. Disassemble engine and repair as
necessary.

CRANKCASE VACUUM TEST

Specifications:
Intake and Exhaust Valve
Clearance (cold) . . . . . . . . 0.125 mm (± 0.025 mm) Reason:
(0.005 ± 0.001 in.) To determine operation of breather, condition of seals,
Jam Nut Torque . . . . . . . . . . . . 20 N•m (180 lb-in.) gaskets, rings, piston and cylinder wall.
Valve Cover Cap
Screw Torque . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.) Test Equipment:
Spark Plug Torque . . . . . . . . . . 20 N•m (177 lb-in.) • AHT8741-F66 Plug
• JT05703 Barb Fitting
• JT05699 Clear Fuel Line
AUTOMATIC COMPRESSION
• JT05698 U-Tube Manometer
RELEASE (ACR) CHECK
Procedure:
Reason:
1. Park machine on level surface.
To determine if the automatic compression release is 2. Turn key switch OFF.
opening the exhaust valve.
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake.
Test Equipment: 4. Lower front blade (if equipped).
• Dial Indicator 5. Raise rear body cowling.
6. Remove dipstick.

Procedure:
1. Immediately after adjusting the valves, while valve
cover and spark plug are removed, rotate
crankshaft slowly to observe valve operation.

3 - 20 2/9/95
CHECKS, TESTS AND ADJUSTMENTS
Clear Line
Manometer
Barbed
Fitting
Plug
Dipstick Tube
M83469
7. Install JT05703 Barbed Fitting in AHT8741-F66
Plug. Push plug and fitting into dipstick tube.
IMPORTANT: DO NOT make connection between
U-Tube Manometer and Line BEFORE engine is
running or fluid in Manometer could be sucked
into crankcase. DO NOT turn engine OFF until
Line has been disconnected from Manometer.
8. Start and run engine at fast idle.
9. Connect JT05699 Line on barbed fitting and
JT05698 Manometer.
10. Open Manometer vent and record crankcase
vacuum reading. Manometer should show a
minimum vacuum of 30 mm (1.2 in.) of water at
fast idle.
11. Run engine at slow idle. DO NOT TURN ENGINE
OFF!
12. Disconnect Line from Manometer.
13. Stop the engine.
14. Remove Barbed Fitting and Plug from dipstick tube
and install dipstick.
Results:
• If crankcase vacuum is BELOW specifications,
check the following:
- Breather reed valve clearance and condition.
- Seals and gaskets for leakage.
- Fuel pump vacuum hose leakage.
- Rings, piston, and cylinder bore for wear or
damage.
2/9/95
ENGINE
ENGINE OIL PRESSURE TEST
Reason:
To verify if the engine has enough oil pressure to
lubricate the internal components.
Test Equipment:
• JT03349 Connector—1/8" BSP Thread
• JT03017 Hose Assembly
• JT07034 Pressure Gauge Assembly
Procedure:
1. Park machine on level surface.
2. Turn key switch OFF. Allow engine to cool.
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake.
4. Lower front blade (if equipped).
5. Raise rear body cowling.
c CAUTION
Engine components are HOT. Be careful not to
touch, especially the exhaust pipe or muffler
while making adjustments. Wear protective eye
glasses and clothing.
6. Check engine oil level, bring to full mark, if
necessary.
Filter Housing
M83489
7. Remove plug from filter housing
8. Install JT03349 Connector, JT03017 Hose, and
JT05577 Pressure Gauge Assembly.
9. Monitor oil pressure while cranking engine. If no oil
pressure is present, discontinue cranking engine.
Determine and correct the cause before running
engine.
IMPORTANT: If pressure reading is below 69 kPa
(10 psi), STOP THE ENGINE IMMEDIATELY and
determine cause.
3 - 21
ENGINE CHECKS, TESTS AND ADJUSTMENTS

10. Start and run engine at MEDIUM idle for 5 minutes
to heat engine oil to normal operating temperature.
11. Run engine at fast idle. Gauge should read a
minimum oil pressure of 314 kPa (45 psi).
12. Remove hose, gauge and connector. Install plug,
use John Deere Pipe Sealant with TEFLON
(medium strength), or equivalent, on plug threads.
Results:
• If oil pressure is BELOW specifications, inspect or
replace the following:
- Oil pressure relief valve for damage.
- Oil pump worn or damaged.
- Oil pump suction screen or oil passages
plugged.
- Oil filter plugged.
- Excessive wear of connecting rod and main
bearings.
8. Disconnect fuel pump outlet hose. Install plug in
hose.
9. Connect JDG356 Pressure Gauge to fuel pump
outlet.
10. Start and run engine at fast idle for 15 seconds.
Record pressure reading. Gauge should read a
minimum pressure reading of 6.12 kPa (0.90 psi).
11. Stop engine.
12. Remove pressure gauge and connect fuel pump
outlet hose.
13. Start and run engine at slow idle for 1 minute to fill
carburetor with fuel.
14. Stop the engine.
Pump Outlet

FUEL PUMP TEST

Reason:
To check condition of fuel pump and determine fuel M83471
pressure.
15. Disconnect fuel pump outlet hose from carburetor
and put it in a graduated container.
Test Equipment: 16. Start and run engine at fast idle for 15 seconds,
• JDG356 Pressure Gauge then stop the engine and record container
measurement. Minimum flow is 80 mL/15
• Graduated Container
seconds (2.7 oz/15 seconds).

Procedure:
Results:
1. Park machine on level surface.
• If fuel pump pressure or flow does not meet the
2. Turn key switch OFF. specifications, check the following:
3. Move gearshift pedals to NEUTRAL position. - Fuel lines, filter, shut-off valve, and fuel tank cap
Engage parking brake. for restrictions.
4. Lower front blade (if equipped). - Check crankcase vacuum. (See CRANKCASE
5. Raise rear body cowling. VACUUM TEST.)
6. Start and run engine at slow idle for 1 minute to fill • If pressure or flow is still below specifications,
carburetor with fuel. replace fuel pump.
7. Stop the engine.

CRANKSHAFT END PLAY CHECK

Gauge Hose Test Equipment:
• Dial indicator

Procedure:
1. Park machine on level surface.
2. Turn key switch OFF.
Fuel Pump
Outlet Hose 3. Move gearshift pedals to NEUTRAL position.
Engage parking brake.
M83470
4. Remove drive clutch. (See procedure in POWER
TRAIN section.)

3 - 22 2/9/95
CHECKS, TESTS AND ADJUSTMENTS ENGINE

8. Connect high tension lead to Spark Tester.

IMPORTANT: Do not adjust spark tester gap

Dial Indicator beyond 5.0 mm (0.200 in.) (5 turns), as damage
to ignition components could occur.

9. Adjust spark tester gap to 4.2 mm (0.166 in.)( 4

M83485
5. Measure end play using dial indicator. Move
crankshaft in and out. Crankshaft end play
specification is 0.09—0.22 mm (0.004—0.009 in.).
Results:
• Remove crankcase cover and adjust end play if not
within specifications. (See CRANKSHAFT AND
MAIN BEARINGS.)
turns) with screw.
10. Move key switch to RUN position.
11. Spin engine with starter and watch spark at spark
tester. If engine will start, watch spark with engine
running. A steady, strong, blue spark should be
observed.
Results:
• If spark is weak, or no spark is present, install a
new spark plug and repeat test.
• If spark is still weak, or no spark is present, run
tests on individual components to find the cause of
the malfunction.

SPARK TEST SPARK PLUG GAP ADJUSTMENT

Reason: Equipment:

Check overall condition of ignition system. • Feeler Gauge

Test Equipment: Procedure:

• D-05351ST Spark Tester 1. Park machine on level surface.

2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position.
Procedure: Engage parking brake.
1. Park machine on level surface. 4. Lower front blade (if equipped).
2. Turn key switch OFF. 5. Raise rear cowling.
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake.

c
4. Lower front blade (if equipped).
5. Raise rear body cowling. CAUTION
Engine components are HOT. Be careful not to
Spark Tester touch, especially the exhaust pipe or muffler
while making adjustments. Wear protective eye
glasses and clothing.

Spark 6. Remove spark plug.

Adjuster Screw
IMPORTANT: Do not clean spark plug with sand
paper or abrasives. Engine scoring can result.
High Tension Lead
M83484
7. Scrap or wire brush deposits from spark plug.
6. Remove high tension lead from spark plug.
7. Connect D-05351ST Spark Tester to spark plug.

2/9/95 3 - 23
ENGINE CHECKS, TESTS AND ADJUSTMENTS

8. Inspect spark plug for:

• Cracked porcelain
• Pitted or damaged electrodes

M48365

9. Check spark plug gap using a feeler gauge. Set gap

to 0.64 mm (0.025 in.).
10. Install and tighten spark plug to 25 N•m (18 lb-ft).

3 - 24 2/9/95
REPAIR ENGINE

REPAIR ACCELERATOR CABLE

FUEL TANK
Replacement
Removal/Installation 1. Lower front blade (if equipped).
2. Raise rear body cowling.

c3 CAUTION
Cover Cap Screws
Gasoline vapor is explosive. Do not expose to
spark or flame. Serious personal injury can
result.

1. Lower front blade (if equipped).

2. Raise rear body cowling. Spacer

Cap Screw M83194

Cap Fuel Line
Screw 3. Remove cap screws, spacer and cover.
(3 used)

Fuel Tank

Spacer
Lock Nuts
Washer

M83461

4. Loosen lock nuts and remove cable from bracket.

5. Disconnect accelerator cable from throttle control
lever.

Lock Nut Cotter Pin

(3 used)
M83127AE

3. Disconnect fuel line.

Washer
NOTE: Plastic spacer is located between fuel tank and
frame on front mounting bracket only.

Lock Nut
4. Remove three cap screws, washers and nuts.
5. Remove spacer (front mounting bracket only).
6. Remove fuel tank.
7. Inspect fuel tank for wear or damage. Replace if
necessary.

M83460
Installation is done in the reverse order of removal.

2/9/95 3 - 25
ENGINE REPAIR

6. Remove cotter pin and washer. MUFFLER

7. Loosen lock nut. Remove cable.
8. Cut tie straps as necessary. Removal/Installation
Installation is done in the reverse order of removal.
• Route new cable through loop under platform.
• Install tie straps as necessary.
c CAUTION
• Adjust accelerator cable. (See Checks, Tests and
Muffler may be hot. Allow muffler to cool before
Adjustments.)
removing.

CHOKE CABLE 1. Remove:

- Rake assembly. (See procedure in
ATTACHMENTS section.)
Removal/Installation - Drive belt. (See procedure in POWER TRAIN
section.)
1. Lower front blade (if equipped).
- Fuel tank. (See FUEL TANK.)
2. Raise rear body cowling.
3. Remove dash panel. (See procedure in
MISCELLANEOUS section.)

Nuts
14 N•m (124 lb-in.)

Retaining
Nut
Choke Knob

M83109
M83107

4. Remove choke knob and retaining nut.

2. Remove nuts and lock washers.
5. Cut tie straps as necessary to free cable.

Nut Cap Screw

Choke Arm and Washer
Bracket

Slot Cap Screw,

Washer
M83139
M83108 and Nut

3. Remove cap screw and washer.

6. Loosen nut.
4. Remove cap screw, washer and nut and bracket.
7. Rotate choke arm and remove cable through slot.
5. Remove muffler.
6. Inspect muffler for wear or damage. Replace if
Installation is done in the reverse order of removal. necessary.
• Install tie straps as needed.
• Adjust choke. (See Checks, Tests And Installation is done in the reverse order of removal.
Adjustments.)
• Install new gasket.

3 - 26 2/9/95
REPAIR ENGINE

AIR CLEANER ASSEMBLY Inspection

Removal/Installation Cover
1. Lower front blade (if equipped).
2. Raise rear cowling.

Cap Screws Spring

and Nuts
Filter Element

Housing

M83180AE

Hose Clamp IMPORTANT: Carefully remove air cleaner cover

and filter element. Inspect inside paper element
and intake passage for signs of dust. If present,
replace elements and test engine compression
or inspect for damage.

M83128 Any time the air cleaner is removed, check for

free choke operation during reassembly.
3. Loosen hose clamp.
4. Remove cap screws, nuts and spring.
5. Remove air cleaner. NOTE: Replace filter element yearly or every 300
hours.

Installation is done in the reverse order of removal.

1. Remove and disassemble air cleaner.

IMPORTANT: Do not clean paper filter element with

solvent or compressed air.

2. Inspect filter element.

• Element is still usable if you can see light through it
and filter element appears clean.
• Replace if oily, dirty, or damaged in any way.
3. Inspect all parts for damage. Replace parts as
necessary.
4. Assemble and install air cleaner.

2/9/95 3 - 27
ENGINE REPAIR

FUEL PUMP 2. Remove battery cover and disconnect negative (-)

cable at battery.

Replacement NOTE: Engine oil capacity is 1.3 L (2.7 U.S. pt)

3. Drain engine oil.

c CAUTION
Gasoline is extremely flammable. Do not smoke. Nut
Always work in a ventilated area away from open Choke Arm
flame or spark producing equipment; this
includes equipment that utilizes pilot lights.

Cap Slot
Screws Outlet Fuel Hose
M83108
Inlet
Fuel 4. Loosen nut.
Hose 5. Rotate choke arm and remove cable through slot.

Vacuum
Hose
Fuel Inlet Hose

M83110

1. Disconnect vacuum hose

2. Disconnect inlet and outlet fuel hoses.
3. Remove cap screws and nuts.
M83479
4. Remove fuel pump.

Installation is done in the reverse order of removal.

ENGINE
c CAUTION
Gasoline vapor is explosive. Do not expose to
spark or flame. Serious personal injury can
Removal/Installation result.
1. Remove:
- Mid-mount implement (if equipped). (See 6. Disconnect fuel inlet hose.
procedure in ATTACHMENTS section.)
- Gearshift linkage. (See procedure in POWER
TRAIN section.)
- Rear cowling. (See procedure in
MISCELLANEOUS section.)
- Muffler. (See MUFFLER.)
- Air Cleaner. (See AIR CLEANER.)
- Drive clutch. (See procedure in POWER TRAIN
section.)
- Differential lock pedal. (See procedure in POWER
TRAIN section.)

3 - 28 2/9/95
REPAIR ENGINE

CARBURETOR
Fuel Pump
Vacuum Hose
Removal/Installation

Engine Ground
Connection
c CAUTION
Gasoline is extremely flammable. Do not smoke.
Always work in a ventilated area away from open
Wiring Starter flame or spark producing equipment; this
Connectors Battery includes equipment that utilizes pilot lights.
Terminal
M83476
1. Drain fuel from carburetor.
7. Disconnect fuel pump vacuum hose.
8. Disconnect engine ground connections.
9. Disconnect leads from starter battery terminal.
Nut
10. Disconnect wiring connectors. Choke Arm

Slot

Cap Screws M83108

23 N•m (204 lb-in.)
2. Loosen nut.
3. Rotate choke arm and remove cable through slot.
M83480
4. Remove air cleaner assembly and hose.

11. Remove engine mounting cap screws.

NOTE: Remove engine from left-hand side of Vent Tube

machine.

12. Remove engine.

Breather Hose

Installation is done in the reverse order of removal.

• Apply MPG-2 Polymer Multipurpose Grease to
engine crankshaft.
• Fill engine to proper level with oil of correct Fuel Supply Hose
specifications. (See SPECIFICATIONS AND
M83191
GENERAL INFORMATION section.)
• Adjust accelerator cable. (See Checks, Tests and 5. Disconnect fuel supply and breather hose.
Adjustments.) 6. Disconnect vent tube.
• Adjust choke. (See Checks, Tests and
Adjustments.)
• Adjust gearshift linkage. (See procedure in
POWER TRAIN section.)

2/9/95 3 - 29
ENGINE REPAIR

Studs

Governor
Linkage

Carburetor

Gasket

Gasket
Gasket Heat
Shield

Cable
Bracket
Air
Intake Duct
Nuts M83192AE

7. Remove nuts.
8. Remove air intake duct, cable bracket and gaskets.

Hole

c CAUTION
When removing carburetor, be careful not to
bend governor linkage.

9. Separate carburetor from heat shield. Remove

carburetor.
10. Disconnect governor linkage.
11. Remove heat shield and gaskets.
Installation is done in the reverse order of removal.
• Install heat shield-to-carburetor gasket with tab
pointing up on fuel inlet side of carburetor.
M83193
• Install carburetor-to-cable bracket and cable
bracket-to-air intake duct gaskets with hole
pointing away from fuel inlet side of carburetor.
• Adjust choke linkage. (See Checks, Tests and
Adjustments.)

3 - 30 2/9/95
REPAIR ENGINE

Disassembly/Assembly Clean/Inspect/Rebuild Carburetor

c
IMPORTANT: To remove float, use a long nosed
CAUTION pliers on end of pin. Do not strike opposite end
of pin. Damage to pin holder may result.
Gasoline is extremely flammable. Do not smoke.
Do not clean holes or passages with small drill
Always work in a ventilated area away from open bits or wire.
flame or spark producing equipment; this
includes equipment that utilizes pilot lights.
NOTE: If all rubber and plastic parts cannot be
removed for cleaning, use a cleaning solvent
Throttle with a high flash point that will not damage
Choke Shaft these parts when cleaning.
Shaft Choke Throttle
Valve Valve 1. Remove rubber and plastic parts from carburetor.
Soak all carburetor metal parts in carburetor
Seal cleaning solvent for 1/2 hour maximum.
E-Clip 2. Spray all passages with a carburetor cleaning spray
Screw to verify that all internal passages are open.
Spring
Lock Washer
Plate Seal
Bushing

c
Pilot
Lever
Screw
Pilot Jet CAUTION
Spring
Bushing Reduce compressed air to less than 210 kPa (30
psi) when using for cleaning purposes. Clear
Vent Idle area of bystanders, guard against flying chips,
Tube Screw O-Ring and wear personal protection equipment
Spring (2) including eye protection.

IMPORTANT: Rinse carburetor body in warm water

to neutralize corrosive action of cleaner on
aluminum.

Pilot Air Jet Carburetor

Main Air Jet Body 3. Rinse carburetor with warm water and dry with
compressed air. Do not use rags or paper to dry
Float Pin Main Nozzle parts; lint may plug holes or passages.
Needle Valve • Inspect all parts for wear or damage; replace as
necessary.
Bleed Pipe
Main Jet
NOTE: Float is plastic. The float cannot be adjusted.
Float Replace if necessary.

Main jet high altitude kits are available.

Washer Gasket

Plug

Spring
Float Chamber

Drain Screw
M80402

2/9/95 3 - 31
ENGINE REPAIR

BREATHER BLOWER HOUSING

Inspection/Replacement Removal/Installation
1. Remove rocker arm cover and gasket.
Cover 3 Spark Plug Breather Hose
Lead
Reed Valve
Plate
Air Gap

Cover 1

Valve Seat Support Cover 2 M82401

M51757
2. Measure air gap between reed valve and valve seat
at valve tip. Air gap specification is 1—2 mm
(0.20—0.008 in.). Replace reed valve if gap
exceeds specification.
1. Disconnect spark plug lead.
2. Disconnect breather hose.
3. Remove support and covers 1, 2 and 3. Remove
covers in order listed.

Bracket Cover
Breather
Valve
Assembly

Blower
M82402
M80403
Housing

4. Remove bracket cover and blower housing.

3. Remove breather valve assembly.
4. Inspect breather for sticking, binding, cracks or Installation is done in the reverse order of removal.
distortion. Replace breather if worn or damaged.
5. Inspect valve seating surface. Surface must be free
of nicks or burrs. FLYWHEEL
Removal/Installation
Installation is done in the reverse order of removal.
1. Remove blower housing.

Flywheel

Nut and Washer

85 N•m (63 lb-ft)

M83189

3 - 32 2/9/95
REPAIR ENGINE

2. Remove armature with coil. Inspection

3. Hold flywheel and remove nut and washer.
4. Remove flywheel using a flywheel puller.
5. Remove shaft key.

Installation is done in the reverse order of removal.

• Install washer with concave side toward flywheel.
• Adjust armature air gap. (See Checks, Tests and
Adjustments.)

ROCKER ARM ASSEMBLY

M80406

Removal/Installation • Measure outside diameter of rocker shaft. Replace

shaft if O.D. is less than 11.95 mm (0.470 in.).
1. Remove rocker arm cover and gasket.
2. Turn crankshaft until piston is at highest position in
compression stroke.

E-Clip Washer

M80407

• Measure inside diameter of rocker arm bearing.

Rocker Arms M80405
Replace rocker arm if bearing I.D. is greater than
12.07 mm (0.475 in.).
3. Remove E-clip.
4. Remove rocker shaft, washer and rocker arms.

IMPORTANT: Push rods must be installed in the

same locations from which they were removed.

5. Mark each push rod and cylinder head bore to aid in

installation.
6. Remove push rods.
7. Inspect all parts for wear or damage. (See
Inspection procedure.)
M50044

Installation is done in the reverse order of removal.
IMPORTANT: Align rocker arms over push rods
during assembly.
• Inspect push rod for bend using V-blocks and a dial
indicator. Turn rod slowly and read variation on
indicator. Replace if variation is greater than 0.30
mm (0.012 in.).

• Check valve clearance. (See Checks, Tests and

Adjustments.)

2/9/95 3 - 33
ENGINE REPAIR

CYLINDER HEAD AND VALVES

Collet Halves
Removal/Installation
1. Remove blower housing, carburetor, and rocker Retainer
arm assembly.
2. Remove spark plug.
Spring

Mounting Cap Stem Seal

5
Screws (5 used)
M8x45
4 1

Seat

Intake Valve
3
2

6 Exhaust Valve
Cylinder Head M53065

3. Remove cylinder head assembly.

4. Disassemble and inspect cylinder head and valves. M82404A
(See Inspection procedure.)
1. Compress intake valve spring with JDM70 Valve
Installation is done in the reverse order of removal. Spring Compressor and remove collet halves.

IMPORTANT: Torque should be applied in the

sequence shown, in three stages of gradually- IMPORTANT: Spring seat for intake valve can only
increasing torque. be removed with valve stem seal. Removal of
seat or seal damages stem seal. If seal is not
• Install caps screws until finger-tight, then tighten to
damaged, do not remove it.
specifications.

2. Inspect springs, valves, guides, and seals. (See

Torque Specifications:
Inspection procedure.)
Initial Torque. . . . . . . . . . . . . . . . . 18 N•m (159 lb-in.)
Second Torque . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Installation is done in the reverse order of removal.
Final Torque . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.)
Spark Plug Torque . . . . . . . . . . . . 20 N•m (177 lb-in.) • Apply clean engine oil to intake and exhaust valve
stems during assembly.
• Check valve clearance. (See procedure in Checks,
Tests and Adjustments.) • Install springs with smaller pitch end toward
cylinder head.
• After each valve has been installed, tap top of valve
Disassembly/Assembly stem with a plastic hammer to seat retainers.

Valve Spring Inspection

Compressor

Cylinder Head:
• Before inspection, remove carbon deposits from
combustion chamber and gasket surface using
SCOTCH-BRITE abrasive pads or an equivalent.
Collet
Halves

M53066

3 - 34 2/9/95
REPAIR ENGINE

Valve Guides:
• Clean inside of valve guides with valve guide

c
cleaner.
CAUTION
Reduce compressed air to less than 210 kPa (30
psi) when using for cleaning purposes. Clear
area of bystanders, guard against flying chips,
and wear personal protection equipment
including eye protection.

• Clean head with a suitable solvent and dry with

compressed air.
• Inspect for cracks or broken cooling fins.
• Inspect gasket surface for burrs and nicks.
• Inspect head gasket for burns and traces of gas
leakage. Replace if necessary.
• Check that oil drainback passages are not plugged.
M80410
• Measure inside diameter of valve guides or
bushings. Replace bushing if I.D. is greater than
7.065 mm (0.2781 in.). (See Replacement
procedure.)

Valve Seats:
• If valve seats are loose, warped or distorted beyond
reconditioning, replace cylinder head. Pitted or
worn seats can be re-faced using a seat cutter.

Valve
Seat
M80409
Width

• Put cylinder head on a surface plate. Check for

distortion at several points around the head using
a feeler gauge. Replace head if distortion is more
than 0.05 mm (0.002 in.).

Intake Valve Stem Seal:

Intake Valve
Stem Seal M82405A

• Measure valve seat width. If valve seat width is not

within 0.50—1.10 mm (0.020—0.043 in.),
recondition valve seat. (See Recondition Valve
Seats procedure.)
• Lap valves after reconditioning with lapping
compound and recheck valve seating surface for
proper width and evenness of seating pattern.
M80408 (See LAP VALVES.)

• Inspect intake valve stem seal for wear or damage.

• If necessary to replace stem seal, remove it with a
screwdriver.

2/9/95 3 - 35
ENGINE REPAIR

Valve Springs: • Check valve stem for bend using V-blocks and a
dial indicator. Turn valve slowly and read variation
• Inspect springs for pitting, rust, and burrs. Replace
on indicator. Replace if variation is greater than
if necessary.
0.03 mm (0.001 in.).

M82034A
M82406A

• Measure spring free length. Replace spring if

measurement is less than 32.75 mm (1.289 in.). • Measure valve stem diameter in two directions at
right angles, at four different positions. Replace if
Intake and Exhaust Valves: measurement is less than specifications.

• Analyze valves. (See ANALYZE VALVES.)

Remove carbon from valve head, face, and stem with a Valve Stem O.D. (Wear Limit):
power-operated wire brush. Be sure carbon is Intake Valve. . . . . . . . . . . . . . . 6.930 mm (0.2728 in.)
removed, not merely burnished.
Exhaust Valve . . . . . . . . . . . . . 6.915 mm (0.2722 in.)

Valve
Face Valve Guide Bushing Replacement
Margin
Valve Guide
Driver
Valve Valve Guide
Stem Bushing
End
Valve
Chamber
M38087

• Measure face margin. If margin is less than 0.60

mm (0.024 in.), replace valve.
• Inspect valve head, face, and stems for defects.
Replace if necessary.
Replace warped valves. Valve stem ends should be
ground square before checking valve to tappet
clearance.
M50038
1. Drive valve guide bushing into valve chamber using
JDG504 Valve Guide Driver.
2. Clean carbon deposits from valve guide port.

Valve Valve Guide

Snap
Guide Chamber
Ring
Bushing

M51753 M50039

3 - 36 2/9/95
REPAIR
3. Install new snap ring on bushing. Install new
bushing with Valve Guide Driver. Drive in from
valve chamber side until snap ring seats on head.
4. Ream inside diameter of valve guide bushings with
Stanisol or kerosene lubricant and 7 mm valve
guide reamer. Turn reamer clockwise. Finished
valve guide inside diameter should be 7.00—7.015
mm (0.2756—0.2762 in.).
ANALYZE VALVES
Lead deposits on the intake valve are caused by
exhaust gas leaking past the valve. This indicates the
valve is not seating properly. Grind intake valve and re-
face seat to correct this condition.
NOTE: Do not grind the exhaust valve or the valve life
will be shortened
Be sure to reset valve-to-tappet clearance after
grinding valves.
Lead Deposits
M29934
Valve stem corrosion is caused by moisture in the
engine. Moisture in the fuel/air mixture can condense
inside the engine when engine is stopped and cools
down.
Valve corrosion can also occur during storage. Fogging
or pouring oil in the combustion chamber before storing
helps prevent valve corrosion.
Corroded or pitted valves collect deposits and may
cause sticking valves. Replace badly corroded or pitted
valves.
Valve Stem
Corrosion
M5563
2/9/95
ENGINE
Exhaust valves are designed to function in
temperatures exceeding 2760°C (5000°F). However,
when operating at high temperatures for long periods
of time, valve burning may occur. Valves running too
hot will show a dark discoloration of the valve stem into
the area protected by the valve guide. Another
indication is discoloration of the valve margin and valve
face. Valve inserts may also begin to burn away.
Valve Face
Valve Margin
M30024
IMPORTANT: Do not run engine with blower
housing removed.
Poor engine cooling due to dirt or obstructions is a
common cause for overheating an engine and the
valves. Remove blower housing and clean the engine
cooling fins.
Other causes for valves running hot are worn valve
guides or valve springs, incorrect valve clearance, lean
fuel/air mixture, and incorrect or overheated spark
plug.
Using old or stale gasoline is a common cause for
sticky valves.
This gummy deposit can be seen on the valve. When
this condition exists, the carburetor may also contain
gum deposits and will require cleaning.
Always use fresh gasoline and drain fuel tank, lines
and carburetor before storing tractor.
Gummy (Sticky)
Deposit
M29936
3 - 37
ENGINE REPAIR

RECONDITION VALVE SEATS LAP VALVES

1. Inspect valve seats for damage. If valve seats are
loose, warped or distorted beyond reconditioning,
replace cylinder head. Pitted or worn seats can be
re-faced using a seat cutter.
If valve seat does not make proper contact, lap the
valve into the seat.
1. Apply a small amount of fine lapping compound to
face of valve.

Valve Seating
Surface Width
Valve Margin

Valve Seat Valve Face

Angle Angle

Valve Narrowing
Angle

M9552
M50041

To recondition valve seat, cut at 45° angle to clean up

seat. Cut narrowing angle at 30°. Finish cut at 45° to
establish seating surface width.
Cut valve seating surface as close as possible to
specifications.
Specifications:
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve Seating
Surface . . . . . . . . . 1.10—1.46 mm (0.043—0.057 in.)
Valve Margin . . . . . . . . . . . . . . . . 0.60 mm (0.020 in.)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . 30°
2. Grip top of valve with a vacuum cup tool and turn
valve to lap valve to seat.
3. Lift valve from seat every 8 to 10 strokes. Lap until
a uniform ring appears around the surface of the
valve face.
4. Wash all parts in solvent to remove lapping
compound. Dry all parts.
5. Check position of lap mark on valve face. Lap mark
must be on or near center of valve face.
CRANKCASE COVER
Removal/Installation

NOTE: Approximate crankcase oil capacity is 1.3 L

(2.7 pt) with filter.

Valve Face Valve Seat Mounting

Stud 3 5
26 N•m
Correct (230 lb-in.)
7
8

1 2

6 4
Incorrect Incorrect
M18615 Oil Drain Plug
Mounting Cap Screw (7 used) 21 N•m (186 lb-in.)
2. Lap valves to seats after re-facing. (See LAP M8 x 45
VALVES.) 26 N•m (230 lb-in.) M53069
3. Center valve seat on the valve face, note correct
1. Remove drain plug and drain crankcase.
and incorrect positions.
2. Remove crankcase cover and gasket.
4. Check seat for good contact using Prussian Blue
Compound. 3. Clean crankcase and crankcase cover gasket
surfaces.

3 - 38 2/9/95
REPAIR ENGINE

Installation is done in the reverse order of removal. 2. Stagger piston ring end gaps 180° apart, but do not
align with oil ring side rail end gaps.
NOTE: Do not force cover. Gears must mesh for 3. Apply a light film of clean engine oil to piston and
proper positioning. rings. Compress rings with a ring compressor.
4. Apply a light film of oil to cylinder bore, connecting
• Install new gasket. rod bearing surface and cap screws.
• Install short end of mounting stud into block. 5. Install piston assembly in cylinder bore with
• Tighten cap screws to specifications using the engraved match mark/arrow on piston head facing
sequence shown. flywheel side of engine.
6. Install connecting rod cap and cap screws.
7. Rotate governor shaft 180° and tighten nut.
PISTON AND CONNECTING ROD 8. Install crankcase cover and cylinder head.
Removal
1. Remove cylinder head.
Disassembly
2. Remove crankcase cover. 1. Analyze piston and piston ring wear. (See
ANALYZE PISTON RINGS AND PISTON WEAR.)
2. Analyze connecting rod wear. (See ANALYZE
CRANKSHAFT AND CONNECTING ROD
Cap screws Governor Shaft WEAR.)
20 N•m (177 lb-in.) 3. Remove piston rings with a piston ring expander.

Piston

Connecting
Rod Piston Pin

M80425
Circlip
3. Loosen governor arm nut and rotate governor shaft
180°.
4. Check cylinder bore for ridges These ridges can
cause piston damage if not removed. M50063

5. If necessary, remove ridge from top of cylinder bore

with a ridge reamer.
6. Remove cap screws and connecting rod cap.
7. Push piston and connecting rod from cylinder bore.
8. Disassemble and inspect all parts for wear or
damage. (See Disassembly and Inspection
procedures.)
Installation
1. If new piston rings are installed, deglaze cylinder
bore. (See Deglaze Cylinder Bore procedure.)
4. Remove circlip, piston pin and connecting rod.
5. Inspect all parts for wear or damage. Replace as
necessary. (See Inspection procedures.)
Assembly
• Apply a light film of clean engine oil to piston pin
and connecting rod bearing during assembly.
Arrow Match Mark

First Compression "MADE IN JAPAN"

Ring
Second
Compression
Ring

M80426
Side Rails
1. Assemble piston to rod with arrow match mark on
piston opposite "MADE IN JAPAN" on connecting
Spacer M80429 rod.

2/9/95 3 - 39
ENGINE REPAIR

2. Install piston pin and circlips. 2. Clean carbon from piston ring grooves with a ring
3. Before installing rings on piston, check ring end gap groove cleaner. If cleaning tool is not available,
in cylinder bore. (See CHECK PISTON RING END break an old ring and use it to carefully clean
GAP.) groove.
3. Check that oil return passages in grooves are open.
First Compression 4. Inspect piston for scoring or fractures. Replace
Ring piston if damaged.
Second
Compression NOTE: Inspect clearance visually. Replace piston if
Ring clearance appears excessive.

Side Rails

Feeler Gauge
Spacer M80429

4. Install oil control and compression rings:

• Oil ring: Install spacer, then side rails. Align side rail
end gaps 180° apart.

NOTE: Install compression rings with "R" or "NPR"

mark facing up.
M38102

• Install second compression ring in middle groove.
Ring should turn freely in groove. Turn ring until
gap is 180° away from oil ring gap.
• Install first compression ring in top groove. Ring
should turn freely in groove. Turn ring until gap is
180° away from second ring gap.
Inspection
Piston:
5. Measure ring groove clearance at several points
around piston. Replace piston if clearance is
greater than specifications.
Ring Side Clearance Specifications:
1st Compression
Ring (Top) . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
2nd Compression
Ring (Middle) . . . . . . . . . . . . . . . 0.14 mm (0.005 in.)
Oil Control Ring . . . . . . . . . . . . . . . . . .Not Measured

IMPORTANT: Do not use a caustic cleaning

solution or a wire brush to clean piston.

1. Remove all deposits from the piston.

Ring Groove Cleaner

M29946

3 - 40 2/9/95
REPAIR ENGINE

M80428

8. Measure piston O.D. perpendicular to piston pin

bore.

NOTE: If the engine has had a previous major

overhaul, an oversize piston and rings may
Measuring Positions
have been installed. Pistons and rings are
available in 0.50 mm (0.020 in.) oversize.

Piston O.D Specifications:

M82050A
6. Measure piston pin diameter at six places. Replace
pin if measurement is less than 18.98 mm (0.747
in.).
Standard Piston . . . . . . . . . . . . . . . 77.85—77.87 mm
(3.0649—3.0657 in.)
0.50 mm (0.020 in.)
Oversize Piston . . . . . . . . . . . . . . . 78.35—78.37 mm
(3.0849—3.0857 in.)
• If piston diameter is less than specifications, install
a new piston.
9. Measure cylinder bore. (See CYLINDER BLOCK.)
10. Subtract piston O.D. measurement from cylinder
bore measurement to determine piston-to-cylinder
bore clearance.
11. Replace piston and/or rebore cylinder block if not
within 0.051—0.089 mm (0.002—0.0035 in.).

Connecting Rod:
1. Analyze connecting rod wear. (See ANALYZE
CRANKSHAFT AND CONNECTING ROD
WEAR.)
M80427
2. Clean and inspect rod. Replace if scored.
7. Measure piston pin bore. Replace piston if 3. Install connecting rod cap. Tighten to 20 N•m (177
measurement is greater than 19.03 mm (0.749 lb-in.).
in.).

2/9/95 3 - 41
ENGINE
Piston Pin Bearing
Crankshaft Bearing
M50066
4. Measure connecting rod crankshaft bearing
diameter and piston pin bearing diameter. Replace
connecting rod if either measurement is greater
than specifications.
NOTE: If the engine has had a previous overhaul, an
undersized connecting rod may have been
installed. A 0.50 mm (0.020 in.) undersized rod
is available.
Connecting Rod Bearing ID. (Wear Limit):
Crankshaft Bearing
Standard . . . . . . . . . . . . . . . . 35.57 mm (1.400 in.)
Undersized . . . . . . . . . . . . . . 35.07 mm (1.380 in.)
Piston Pin Bearing . . . . . . . . 19.06 mm (0.750 in.)
CHECK PISTON RING END GAP
Before installing rings on piston, check end gap in
cylinder bore.
Install each ring squarely in bore approximately 25.4
mm (1.0 in.) down from top of cylinder.
End Cap
M80430
Measure piston ring end gap. Replace if end gap is
greater than specifications.
3 - 42
REPAIR
End Gap Specifications:
Minimum End Gap . . . . . . . . . . . 0.18 mm (0.007 in.)
Maximum End Gap
Compression Rings
(Wear Limit) . . . . . . . . . . . . . . . . 1.20 mm (0.047 in.)
Oil Control Ring Assembly . . . . . . . . .Not Measured
ANALYZE PISTON RING WEAR
Rings of the wrong size or rings having improper end
gap will not conform to the shape of the cylinder. This
results in high oil consumption and excessive blow-by.
Ring end gaps should be staggered on the piston
during installation. End gaps in alignment can also
cause oil consumption and blow-by.
Light scuffing or scoring of both rings and piston occurs
when unusually high friction and combustion
temperatures approach the melting point of the piston
material.
M29943
When this condition exists, it is due to one or more of
the following probable causes:
• Dirty cooling shroud and cylinder head.
• Lack of cylinder lubrication.
• Improper combustion.
• Wrong bearing or piston clearance.
• Too much oil in crankcase causing fluid friction.
The engine operating at abnormally high temperatures
may cause varnish, lacquer or carbon deposits to form
in the piston grooves making the rings stick. When this
happens, excessive oil consumption and blow-by will
occur.
2/9/95
REPAIR ENGINE

Increased oil consumption may be caused by:

Varnish, Lacquer or Carbon Deposits

• Worn side rails with low tension.
• Worn or distorted inner spacer.

M29944

Spacer Side Rails

Engine overheating and ring sticking is usually caused
by one or more of the following:
M38101
• Overloading.
• Incorrect ignition timing.
• Lean fuel mixture.
• Dirty cooling fins.
ANALYZE PISTON WEAR
• Incorrect oil. Detonation, is abnormal combustion causing excessive
• Low oil supply. temperature and pressure in the combustion chamber.
Commonly called carbon knock, spark knock or timing
• Stale fuel.
knock, detonation occurs as the compressed fuel-air
Vertical scratches across the piston rings are due to an mixture ignites spontaneously to interrupt the normal
abrasive in the engine. Abrasives may be airborne, ignition.
may have been left in the engine during overhaul or
may be loose lead and carbon deposits.

Vertical Scratches

M29947

M29945
When this condition exists, check for one or more of
the following:
• Damaged, collapsed or improperly installed air
filter.
• Loose connection or damaged gasket between air
cleaner and carburetor.
• Air leak around carburetor-to-cylinder block gasket.
• Air leakage around accelerator shaft.
• Failure to properly clean cylinder bore after
reconditioning engine.
Abrasive particles in engine oil cause scratches on side
rails of oil control ring. Inner spacer wear or distortion
may case:
• High oil consumption.
• Increased deposits in combustion chamber.
• Sticking compression rings.
The following is a list of possible causes for detonation:
• Lean fuel mixture.
• Low octane fuel.
• Advanced ignition timing.
• Engine lugging.
• Build-up of carbon deposits on piston or cylinder
head, causing excessive compression.
• Wrong cylinder head or milling of head increasing
compression ratio.
Pre-ignition is the igniting of the fuel-air mixture prior to
regular ignition spark. Pre-ignition causes internal
shock, resulting in pings, vibration, detonation and
power loss. Severe damage to piston , rings and valves
results from pre-ignition.

2/9/95 3 - 43
ENGINE REPAIR

Retaining rings loosen or break due to:

Damaged • Rod misalignment.
Area • Excessive crankshaft end play.
• Crankshaft journal taper.
• Weak retaining rings.
• Incorrectly installed retaining rings.
Inertia can cause a broken retaining ring to beat out the
piston and cylinder, causing extensive damage.

ANALYZE CRANKSHAFT AND

M30039
Check the following for causes of pre-ignition:
• Internal carbon deposits.
• Incorrect spark plug (high heat range).
• Broken ceramic in spark plug.
• Sharp edges on valves.
Check rod and piston alignment when piston shows a
diagonal wear pattern extending across the skirt of the
piston. Contact with the cylinder wall shows on bottom
of skirt at left and ring lands on the right.
CONNECTING ROD WEAR
Check connecting rod and cap for damage or unusual
wear patterns.
Lack of lubrication or improper lubrication can cause
the connecting rod and cap to seize the crankshaft.
When the rod and cap seize to the crankshaft, the
connecting rod and piston may both break causing
other internal damage. Inspect block carefully before
rebuilding engine.
Crankshaft and connecting rod damage can result
from:
• Engine run low on oil or without oil.
• Oil not changed regularly.
• Bearing cap installed incorrectly.

CAMSHAFT AND TAPPETS

Diagonal Wear
Pattern
Removal/Installation
1. Remove crankcase cover.
M29948

A cylinder bored at an angle to the crankshaft can also Camshaft

cause improper ring contact with the cylinder. Timing Marks
This condition causes:
• Rapid piston wear.
Crankshaft
• Uneven piston wear.
Shim(s)
• Excessive oil consumption.
A broken retaining ring caused the damage shown.

M80412

2. Remove crankshaft shim(s).

IMPORTANT: Align timing marks to prevent

damage to tappets when removing camshaft.

Damaged
Area 3. Rotate crankshaft until timing marks align.
4. Remove and inspect camshaft. (See Inspection
M29949 procedures.)

3 - 44 2/9/95
REPAIR ENGINE

ACR Weights

Tab

Tappets

M80417

ACR Spring M80416

IMPORTANT: Tappets must be installed in their
same bores from which they were removed.
5. Mark each tappet and bore to aid in assembly.
6. Remove and inspect tappets for wear or damage.
Replace if necessary.
Installation is done in the reverse order of removal.
• Apply a light coat of clean engine oil to tappets and
bores.
7. Apply a light coat of clean engine oil to camshaft
lobes and journals.
8. Align timing marks and install camshaft.
3. Inspect Automatic Compression Release (ACR) for
damage.
4. Inspect spring. Replace if worn or damaged.
5. Move weights by hand to check for proper
operation. Check that tab sits slightly above cam
lobe when weights are released. Tab should drop
below cam when weights are operated. Replace
camshaft if automatic compression release does
not operate properly.
Inspect camshaft bearings:

Inspection
1. Inspect camshaft for worn or broken teeth.
NOTE: Camshaft and tappets are a matched set.
Replace both camshaft and tappets if
necessary.

PTO Side Journal

Cam Lobes M80414
Flywheel Side
Cylinder Block Bearing
Journal

M80413

2. Measure PTO side journal, flywheel side journal

and cam lobes. Replace camshaft and tappets if
any measurement is less than specifications.

Camshaft Specifications (Minimum):
PTO Side Journal . . . . . . . . . . . 22.93 mm (0.903 in.)
Flywheel Side Journal . . . . . . . 22.93 mm (0.903 in.)
Cam Lobe Height . . . . . . . . . . . 32.70 mm (1.287 in.)
M80415
Crankcase Cover Bearing
• Measure camshaft bearings in cylinder block and
crankcase cover. Replace block or cover if either
diameter is greater than 23.06 mm (0.908 in.).

2/9/95 3 - 45
ENGINE REPAIR

RECIPROCATING BALANCER

Removal/Installation
1. Remove flywheel, camshaft, and piston.

Balancer Assembly

Support
Shaft

O-Ring

Balancer Weight M80418

2. Remove four nuts, washers, support shaft, and O-

ring.
3. Remove crankshaft with balancer assembly and
weight from crankcase.
4. Inspect balancer assembly and make repairs as
necessary. (See Disassembly/Assembly
procedures.)
5. Inspect oil seals.

Installation is done in the reverse order of removal.

• Cover keyway on flywheel end of crankshaft with
tape to prevent damage to oil seal when installing
assembly.
• Apply a light film of clean engine oil to crankshaft
bearing surfaces.
• Check and adjust crankshaft end play. (See
CRANKSHAFT AND BEARINGS—END PLAY
ADJUSTMENT.)

3 - 46 2/9/95
REPAIR ENGINE

Disassembly/Assembly

Collar

Woodruff Key
Crankshaft

Link Rod (2 used)

Link Rod (2 used)

Crank Gear

Balancer Weight

Governor Drive Gear

Shim(s) (as required)
M80419

1. Remove collar, crank gear, governor drive gear and Inspection

woodruff key.
2. Remove link rods and crankshaft. 1. Clean and inspect all parts for wear or damage.
Replace parts, if necessary.
3. Inspect crankshaft. (See CRANKSHAFT AND MAIN
BEARINGS.)
4. Inspect balancer assembly. (See Inspection Link Rod Journal
procedure.)

Assembly is done in the reverse order of

disassembly.
• Apply a light film of clean engine oil to bearing
surfaces.
• Install collar with flat face toward link rod.
• Install governor drive gear with chamfered face
toward link rod. M80420
• Install crank gear with flat face toward governor
drive gear. 2. Measure link rod journal diameters on crankshaft. If
diameter is less than 46.86 mm (1.845 in.),
replace crankshaft.

2/9/95 3 - 47
ENGINE REPAIR

Bushing Replacement
Large
NOTE: Replace bushings using a driver set and a
Bushing
press.

Link Rod

Small Bushing
Seam

M80421

3. Measure inside diameter of link rod bushings. If link

rod small end I.D. is more than 12.06 mm (0.475
in.), replace link rod. If link rod large end I.D. is
more than 47.12 mm (1.855 in.) replace link rod Link Rod Bushing
bushing.
Centerline M80424

1. Install link rod bushings with seam at a 90° angle to

Balancer Weight centerline.
2. Install bushing 1.00 mm (0.040 in.) below link rod
surface.

Wrist Pins
CRANKSHAFT AND MAIN
BEARINGS

M80422
Removal/Installation
4. Measure support shaft bearing diameter in balancer 1. Remove reciprocating balancer.
weight. If bearing is more than 26.10 mm (1.027 2. Remove balancer from crankshaft.
in.), replace balancer weight. 3. Inspect crankshaft for wear or damage. (See
5. Inspect wrist pins for any damage. Inspection procedure.)

Support Shaft Installation is done in the reverse order of removal.

• Cover keyway on flywheel end of crankshaft with
tape to prevent seal damage when installing
crankshaft.
• Apply a light coat of clean engine oil on crankshaft
bearing surfaces before installation.
• Pack grease in oil seals.

Inspection
M80423
1. Analyze crankshaft and connecting rod wear. (See
ANALYZE CRANKSHAFT AND CONNECTING
6. Measure support shaft diameter. If shaft O.D. is ROD WEAR procedures.)
less than 25.93 mm (1.021 in.), replace shaft.

IMPORTANT: A bent crankshaft must be replaced;

it cannot be straightened.

2. Clean and inspect crankshaft. Replace if scratched

or damaged.

3 - 48 2/9/95
REPAIR
Connecting Rod Journal O.D. (Wear Limit):
Standard . . . . . . . . . . . . . . . . . . 35.43 mm (1.395 in.)
Undersized . . . . . . . . . . . . . . . . 34.93 mm (1.375 in.)
Results:
M80432
3. Place crankshaft into an alignment jig and rotate
crankshaft slowly. Use dial indicators (A) to
measure maximum total indicated runout (TIR). If
runout exceeds 0.05 mm (0.002 in.), replace
crankshaft.
M54495
4. Measure main bearing journal diameters. If either
journal O.D. is less than 29.92 mm (1.178 in.),
replace crankshaft.
Connecting Rod Journal O.D.
Journal Radii
M38036
NOTE: If the engine has had a previous overhaul,
connecting rod journals may have been
resized for undersized rod. 0.50 mm (0.020 in.)
undersized rod is available.
5. Measure connecting rod journal diameter.
2/9/95
ENGINE
• If standard journal diameter is less than
specifications, have journal ground undersize by a
qualified machine shop. Before sending for
grinding, inspect journal radii for cracks.
• If undersized journal diameters is less than
specifications, replace crankshaft.
M80431
6. Measure crankshaft main bearing diameter in
crankcase. Replace crankcase if diameter is
greater than 30.08 mm (1.184 in.).
7. Inspect crankshaft ball bearing:
• Remove crankcase cover oil seal.
• Remove crankshaft bearing using a driver set.
• Thoroughly clean bearing in solvent. Dip bearing in
light weight oil.
Axial
Free
Play
Radial
Free
Play
M38073
• Spin the bearing by hand and check for axial and
radial free play. Replace the bearing if it is noisy or
has too much play.
• Install bearing flush to inside of crankcase using a
driver set.
3 - 49
ENGINE REPAIR

End Play Adjustment • Remove worn or damaged seals using a

screwdriver. Install seal with lip toward inside of
engine using a driver set. Press in seal until flush
with hub.
Crankcase Cover
Crankshaft Mounting Face • Pack lithium based grease inside lips of seal.
Gear
Gasket PTO Bearing End

"A" "B"
CRANKSHAFT OIL SEAL—PTO END

Replacement
Remove crankshaft cover.
M51545

1. With gasket installed on crankcase, measure from

gasket surface to crankshaft gear surface. Record
measurement "A".
2. Measure from crankcase cover mounting face to
PTO bearing end. Record measurement "B".

M80436
MEASUREMENT “B”

• Remove worn or damaged seals using a

screwdriver. Install seal with lip toward inside of
cover using a driver set. Press in seal to a depth of
4 mm (0.158 in.) below crankcase cover flange
surface.
• Pack lithium based grease inside lips of seal.

MEASUREMENT “A”

M80434 ANALYZE CRANKSHAFT AND

3. Locate measurements on table. Follow lines to CONNECTING ROD WEAR
where recorded measurements intersect. Choose Check connecting rod and cap for damage or unusual
the next smaller shim from the table. wear patterns.
4. Install shims on end of crankshaft.
Lack of lubrication or improper lubrication can cause
the connecting rod and cap to seize the crankshaft.
CRANKSHAFT OIL SEAL—
When the rod and cap seize to the crankshaft, the
FLYWHEEL END connecting rod and piston may both break causing
other internal damage. Inspect block carefully before
Replacement rebuilding engine.
Remove crankshaft.
Crankshaft and connecting rod damage can result
from:
• Engine run low on oil or without oil.
• Oil not changed regularly.
• Bearing cap installed incorrectly.

M80435

3 - 50 2/9/95
REPAIR
CYLINDER BLOCK
Inspection
Clean and check block for cracks.
NOTE: Cracks not visible to the eye may be detected
by coating the suspected area with a mixture of
25 percent kerosene and 75 percent light
engine oil. Wipe area dry and immediately
apply coating of zinc oxide dissolved in wood
alcohol. If crack is present, coating becomes
discolored at the defective area. Replace block
if any cracks are found.
A bare block is available for service.
Top Position
Middle Position
Bottom Position
Direction of
Crankshaft
Rotation
Direction of
Crankshaft Centerline
M82411A
Measure cylinder bore diameter at three positions: top,
middle and bottom. At these three positions, measure,
in both directions: along crankshaft centerline and
direction of crankshaft rotation.
NOTE: If the engine has had a previous major
overhaul, an oversize piston and rings may
have been installed. Piston and rings are
available in 0.50 mm (0.020 in.) oversize.
2/9/95
ENGINE
Cylinder Bore I.D.:
Standard Size Bore:
Standard . . . . 77.98—78.00 mm (3.070—3.071 in.)
Wear Limit . . . . . . . . . . . . . . . 78.07 mm (3.074 in.).
Out-of-Round (Maximum) . . . 0.056 mm (0.0022 in.)
0.50 mm (0.020 in.) Oversize Bore:
Standard . . . . 78.46—78.48 mm (3.089—3.090 in.)
Wear Limit . . . . . . . . . . . . . . . 78.55 mm (3.093 in.)
If cylinder bore exceeds wear limit, rebore cylinder or
replace cylinder block. (See Rebore Cylinder Bore
procedure.)
NOTE: If cylinder is rebored, oversize piston and rings
must be installed.
Deglaze Cylinder Bore
IMPORTANT: If cylinder bore is to be deglazed with
crankshaft installed in engine, place clean shop
towels over crankshaft to protect journal and
bearing surfaces from any abrasives.
1. Deglaze cylinder bore using a rigid hone with a 220
to 300 grit stone.
2. Use hone as instructed by manufacturer to obtain
45° crosshatch pattern.
IMPORTANT: Do not use gasoline, kerosene, or
commercial solvent to clean cylinder bores.
Solvents will not remove all abrasives from
cylinder walls.
3. Remove excess abrasive residue from cylinder
walls using a clean dry rag. Clean cylinder walls
using clean white rags and warm soapy water.
Continue to clean cylinder until white rags show no
discoloration.
Rebore Cylinder Bore
IMPORTANT: Check stone for wear or damage. Use
correct stone for the job.
The cylinder block can be rebored to use a 0.50 (0.020)
oversize piston and rings. Have a reliable repair shop
rebore the block, or use the drill press and honing tool.
Rebore cylinder with a honing tool to initial and final
bore specifications.
1. Align center of bore to drill press center.
3 - 51
ENGINE REPAIR

2. Lower and raise hone until ends extend 20—25 mm OIL PUMP
(0.75—1.0 in.) past ends of cylinder.
3. Adjust hone so lower end is even with end of
cylinder bore. Disassembly/Assembly
4. Adjust rigid hone stones until they contact
narrowest point of cylinder. 1. Remove stator.
5. Coat inside of cylinder with honing oil. Turn hone by
hand. Adjust if too tight. Pump Cover Oil Screen

Gasket

40-60°

Rotor Cover
Outer Rotor

Relief Valve
Check Ball
Spring Rotor Shaft M80438

2. Remove pump cover, gasket, rotor cover, outer

rotor, rotor shaft, relief valve check ball and spring.

NOTE: To inspect or clean oil screen, remove

M82412A crankcase cover. (See CRANKCASE
COVER.)
6. Run drill press between 200—250 RPM. Move
hone up and down in cylinder approximately 20
3. Inspect all parts for wear or damage. (See
times per minute.
Inspection procedure.)

NOTE: Measure bore when cylinder is cool.

Assembly is done in the reverse order of
disassembly.
7. Stop press and check cylinder diameter. • Apply clean engine oil to all internal parts.

NOTE: Finish should not be smooth, but have a 40— Inspection

60° cross-hatch pattern.
Inspect all parts for wear or damage.

8. Check bore for size, taper, and out-of-round.

9. Hone the cylinder an additional 0.028—0.030 mm
(0.0011—0.0012 in.) for final bore specifications.
This allows for 0.020 mm (0.0008 in.) shrinkage
when cylinder cools.

IMPORTANT: DO NOT use gasoline or commercial

solvents to clean cylinder bores. Solvents will
not remove metal particles produced during
honing.

M80439
10. Clean the cylinder thoroughly using soap, warm
water and clean rags. Continue to clean cylinder • Measure rotor shaft diameter. If shaft O.D. is less
until white rags show no discoloration. than 12.63 mm (0.497 in.), replace both shaft and
11. Dry the cylinder. Apply engine oil to cylinder wall. outer rotor.

3 - 52 2/9/95
REPAIR ENGINE

M80440 M80442

• Measure rotor shaft bearing. If bearing I.D. is • Measure inside diameter of rotor bearing. If bearing
greater than 12.77 mm (0.503 in.) replace cylinder I.D. is greater than 40.77 mm (1.605 in.), replace
block. cylinder block.

M80015 M80017

• Measure thickness of outer rotor. If thickness is less • Measure outside diameter of rotor. If rotor O.D. is
than 9.92 mm (0.391 in.), replace both outer rotor less than 40.47 mm (1.596 in.), replace both rotor
and shaft. and shaft.

Bearing Depth

M80441 M50083

• Measure outer rotor bearing depth. If depth is • Measure relief valve spring free length. If free
greater than 10.17 mm (0.421 in.), replace length is less than 19.00 mm (0.748 in.), replace
cylinder block. spring.

2/9/95 3 - 53
ENGINE REPAIR

OIL FILTER MANIFOLD GOVERNOR SHAFT

Removal/Installation Inspection/Replacement

NOTE: It is not necessary to remove governor shaft

Gasket unless seal is leaking or shaft is damaged.

Oil Filter Manifold

Plug
1. Remove crankcase cover.
Oil Filter

Governor Lever

Retaining Pin
Mounting Cap Nut
Screw (2 used)
M6 x 40 Washers

M80443

Governor Shaft
GOVERNOR
M80444
Inspection/Replacement
1. Remove crankcase cover. 2. Inspect shaft for wear or damage. Replace if
necessary.
IMPORTANT: Do not remove governor assembly To replace governor shaft:
unless damaged. Removal damages the
assembly. - Scribe a mark across shaft and lever to aid in
installation.
- Loosen nut on governor lever.
Sleeve
- Remove retaining pin, governor shaft and washers.
- Install washers, shaft and retaining pin.
- Align marks made during removal and tighten nut.

Governor
Gear STATOR
Removal/Installation
Washer 1. Remove flywheel.
Shaft

M51762 Stator Leads

2. Inspect governor for wear or damage. Replace if Clamp

necessary. Rubber Grommet
To replace governor:
- Use two screwdrivers to pry governor assembly
from shaft. Do Not damage crankcase sealing
surfaces.
Stator M80445
- If shaft is removed, press shaft back into cover until
it protrudes 32.2—32.8 mm (1.267—1.291 in.).
2. Disconnect stator leads.
- Install sleeve onto governor gear.
3. Remove clamp, rubber grommet, screws and stator.
- Install washer and governor assembly onto shaft.
Push down on assembly until it snaps into place.
Check assembly for freedom of movement. Installation is done in the reverse order of removal.

3 - 54 2/9/95
REPAIR ENGINE

ARMATURE WITH COIL Air Gap Adjustment

1. Turn flywheel magnet away from armature.
Removal/Installation
1. Remove blower housing. Feeler Gauge Blade

Mounting
Cap Screws

Wiring Lead

Mounting M80447
Cap Screws
Armature
2. Insert a 0.30 mm (0.012 in.) feeler gauge between
with Coil flywheel and armature.
M82413
3. Push armature against flywheel and tighten
2. Disconnect wiring lead. mounting cap screws.
3. Remove cap screws and armature with coil. 4. Turn flywheel to remove feeler gauge.
4. Test armature with coil. (See Test procedure.)

IGNITION MODULE
Installation is done in the reverse order of removal.
• Adjust armature air gap. Tighten cap screws.
Replacement
Test

Ignition Module
Primary Lead

Wiring Lead

Core

M80448
Spark Plug Cap
1. Disconnect wiring lead.
2. Remove mounting screw and replace ignition
module.
M82802

1. Measure resistance between primary lead and

core. If resistance is not within 0.67—1.10 ohms,
replace the ignition coil.
2. Measure resistance between spark plug cap and
core. If resistance is not within 6—10 ohms,
replace the ignition coil.

2/9/95 3 - 55
ENGINE REPAIR

STARTER NOTE: Check that battery is fully charged and of

proper size to ensure accuracy of test.

Analyze Condition
The starter overheats because of: Soleniod
• Long cranking. Battery
“Start” Terminal
• Armature binding. Terminal
The starter operates poorly because of:
• Armature binding.
• Dirty or damaged starter drive.
• Badly worn brushes or weak brush springs.
• Excessive voltage drop in cranking system.
• Battery or wiring defective.
Current Gun
• Shorts, opens, or grounds in armature. M45867

1. Connect jumper cables to battery.

NOTE: Starter repair is limited to brushes, end caps,
and starter drive. Fields in starter are
permanent magnets and are not serviceable. If
housing or armature is damaged, replace
starter.
No-Load Amperage Test
2. Connect negative (-) cable to starter body. Connect
positive (+) cable to terminal (A).
3. Connect ammeter in series with jumper wire, or
place current gun over positive (+) jumper cable.
4. Use jumper wire to briefly connect solenoid battery
terminal and “Start” terminal. Measure starter
amperage. Maximum starter amperage is 50
amps.

Reason:
Results:
To determine if starter is binding or has excessive
amperage draw under no-load. • If amperage is out of specification, check for
binding or seizing bearings, sticking brushes, dirty
or worn commutator. Repair or replace starter.
Test Equipment

Procedure:

IMPORTANT: Complete this test in 20 seconds or

less to prevent starter damage. Allow at least
two minutes for cooling and battery recovery
before operating again. Overheating caused by
excessive operation will seriously damage
starting motor.

3 - 56 2/9/95
REPAIR ENGINE

Disassembly/Assembly

Flange Nut

Solenoid

Solenoid Mounting Nuts (2 used)

Armature
Front Cover
Pinion
Stopper Half
Retaining Clip
Stopper Half

Washer

Shift Lever

Long Cap Screw (2 used)

Field Coil Housing End Cover

Insulator

Brush (4 used)

Brush Holder
Spring (4 used) M82414A

1. Mark body and covers for correct alignment during Inspection/Test

reassembly.
2. Remove two long cap screws and end cover. 1. Measure field coil brush lengths. If any one brush
length is less than 6 mm (0.240 in.), replace all
3. Remove insulator, springs and brush holder.
four brushes.
4. Remove flange nut.
2. Inspect brush springs for wear or damage. Replace
5. Remove field coil housing from armature assembly. if necessary.
6. Remove two solenoid mounting nuts.
7. Remove solenoid, shift lever and armature Switch Arm
assembly. Solenoid Body
8. Remove washer and separate stopper halves to
remove retaining clip.
9. Remove pinion from armature. Terminal “A”
10. Inspect and test solenoid, starter armature and
brushes. (See Inspection/Test procedures.)
Assembly is done in the reverse order of
disassembly.
Apply a thin coat of multipurpose grease to:
• Sliding surfaces of armature and solenoid shift
lever. Tang
• Armature shaft spline. Terminal “B” M51705

• Front and rear cover bearings.

2/9/95 3 - 57
ENGINE REPAIR

1. Test solenoid:
• Test solenoid terminals "A" and "B" for continuity.
There should be no continuity.
• Depress switch arm. There should be continuity
when arm is fully depressed.
• Test for open circuits between terminal "B" and
tang. There should be continuity.
• Test for open circuits between tang and solenoid
body. There should be continuity.
If solenoid fails any test, it is defective and must be
replaced.

M50116
Field Coil Brushes
3. Test for open field coil:
Touch one probe of tester to each field coil brush. If
there is no continuity, the field coil is open and the field
coil housing assembly must be replaced.

IMPORTANT: Do not clean armature with solvent.

Solvent can damage insulation on windings.
Use only mineral spirits and a brush.

Field Coil 4. Inspect armature. Look for signs of dragging

Housing against pole shoes.
M50115

2. Test for grounded field winding:

Touch one probe of tester to field coil brush and the
other probe to the field coil housing. Be sure the brush
lead is not touching the field coil housing. If there is
continuity, the coil is grounded and the field coil
housing must be replaced.

M24861

5. Locate short circuits by rotating armature on a

growler while holding a hacksaw blade or steel
strip on armature. The hacksaw blade will vibrate
in area of short circuit.

3 - 58 2/9/95
REPAIR ENGINE

NOTE: Shorts between bars are sometimes caused by Touch probes on each commutator bar. Armature
dirt or copper between bars. Inspect for this windings are connected in parallel, so each
condition. commutator bar needs to be checked.
If test shows continuity, a winding is grounded and the
6. If test indicates short circuited windings, inspect armature must be replaced.
commutator. Look for roughness, burned bars, or
any material which might cause short circuits
between bars. If necessary, clean and touch up
with 400 sandpaper. NEVER use emery cloth.
Clean all dust from armature when finished.
7. Check armature again. If test still indicates short
circuit, replace armature.

M50113

9. Test for open circuited windings using an ohmmeter

or test light.
Touch probes on two different commutator bars. If test
shows no continuity, there is an open circuit and
armature must be replaced.
M50112

8. Test for grounded windings using an ohmmeter or

test light.

2/9/95 3 - 59
ENGINE REPAIR

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3 - 60 2/9/95
CONTENTS ELECTRICAL

CONTENT S
Page

ELECTRICA L
SPECIFICATION S
TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
THEORY AND DIAGNOSTIC INFORMATIO N
THEORY OF OPERATION INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
READING ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
WIRE COLOR ABBREVIATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
ELECTRICAL SCHEMATI C
ELECTRICAL SCHEMATIC—STANDARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
ELECTRICAL SCHEMATIC—OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . 4-8
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
ELECTRICAL WIRING HARNESSE S
W1 STANDARD WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
W2 LIGHTING WIRING HARNESS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 4-11
W3 HYDRAULIC PUMP WIRING HARNESS (OPTIONAL). . . . . . . . . . . . . . . . 4-12
TROUBLESHOOTIN G
ELECTRICAL SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . 4-13
LIFT SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
CIRCUIT OPERATION AND DIAGNOSI S
POWER CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
POWER CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
CRANKING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
IGNITION CIRCUIT OPERATION—ENGINE RUNNING. . . . . . . . . . . . . . . . . . 4-24
IGNITION CIRCUIT OPERATION—ENGINE SHUTTING OFF . . . . . . . . . . . . . 4-26
IGNITION CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
CHARGING CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
CHARGING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
LIFT SYSTEM CIRCUIT OPERATION—RAISE. . . . . . . . . . . . . . . . . . . . . . . . . 4-36
LIFT SYSTEM CIRCUIT OPERATION—LOWER. . . . . . . . . . . . . . . . . . . . . . . . 4-38
LIFT SYSTEM CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
OPTIONAL HYDRAULIC PUMP CIRCUIT OPERATION—RAISE. . . . . . . . . . . 4-44
OPTIONAL HYDRAULIC PUMP CIRCUIT OPERATION—LOWER . . . . . . . . . 4-46
OPTIONAL HYDRAULIC PUMP CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . 4-48

1/31/95 4- 1
ELECTRICAL CONTENTS CONTINUED

Page

TEST AND ADJUSTMENT S

COMMON CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52
GROUND CIRCUIT TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53
CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54
REGULATED AMPERAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
REGULATED VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
UNREGULATED VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
STARTER SOLENOID TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
STARTER LOADED AMPERAGE DRAW TEST. . . . . . . . . . . . . . . . . . . . . . . . . 4-57
LIFT MOTOR AMPERAGE DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
IGNITION MODULE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59
FLYWHEEL MAGNET TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
KEY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59
NEUTRAL START SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
LIFT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60
RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61
REPAIR
LIFT ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62
CONNECTOR BODY—BLADE TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
METRO-PACK CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

4-2 1/31/95
SPECIFICATIONS ELECTRICAL

SPECIFICATIONS

TEST AND ADJUSTMENT SPECIFICATIONS

Battery:
Specific Gravity (Minimum) . . . . 1.225 with less than 50 point variation between cells
Voltage (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 volts
Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 amps at -18°C (0°F)
13 amps at 13.5—15 volts
Starter:
Maximum Amperage (No-load) . . . . . . . . . . . . . . . . . . . . . . . . . 50 amps at 6000 rpm
Maximum Amperage (Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 amps at 750 rpm
Stator:
Voltage Output (Minimum—Unregulated at Fast Idle) . . . . . . . . . . . . . . . . 34 volts AC
Voltage Output (Regulated at Fast Idle) . . . . . . . . . . . . . . . . . . . 12.2—14.7 volts DC
Amperage (Minimum—Regulated at Fast Idle) . . . . . . . . . . . . . . . . . . . . . . . .13 amps
Lift Actuator:
Amperage Draw
Raise (No Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—6 amps
Lower (No Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3—4 amps
Raise (Maximum Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 amps

REPAIR SPECIFICATIONS
Lift Actuator
Retaining Plate-to-Lower Housing Cap Screw Torque . . . . . . . . . . . 8 N•m (70 lb-in.)
Lower Housing-to-Upper Housing Cap Screw Torque. . . . . . . . . . . 2.3 N•m (20 lb-in.)
Motor Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.)

5/11/95 4-3
ELECTRICAL SPECIFICATIONS

SPECIAL OR ESSENTIAL TOOLS

NOTE: Order tools according to information given in the U.S. SERVICE-GARD Catalog or in the
European Microfiche Tool Catalog (MTC).

JT05685 Battery Tester

Test battery performance.
JDG777 Terminal Removal Tool
Used to remove contacts from connector body.
JDG776 Crimper
Used to attach contacts and seals.
JDG145 Universal Electrical Pliers
Used to cut wires and strip insulation.

SERVICE PARTS KITS

The following kits are available through your parts catalog:
• Lift Actuator Clutch Kit
• Lift Actuator Seal Kit
• Lift Actuator Motor Kit
• Lift Actuator Boot Repair Kit

4-4 5/11/95
THEORY AND DIAGNOSTIC INFORMATION ELECTRICAL

THEORY AND DIAGNOSTIC READING ELECTRICAL

INFORMATION SCHEMATICS
The electrical schematic is made up of individual
circuits laid out in a sequence of related functions. It is
THEORY OF OPERATION formatted with all power wires (A) across the top and all
INFORMATION ground wires (B) across the bottom. Current flow is
generally from top to bottom through each circuit and
The theory of operation stories divide the electrical component. All components are shown in the OFF
system into individual circuits by function. Each circuit
position. The diagram does not list connector (C)
is isolated from the main schematic and only shows
information unless needed to avoid confusion. If the
components that are used in it. The story contains
connector is shown, the number next to it is the
information on function, operating conditions, and
terminal pin location (D) in the connector.
theory of operation. The circuit schematics are drawn
with the components in operating position, with power, Each component is shown by a symbol (E), its name
or battery positive into them across the top, and (F), and an identification code (G). The identification
ground, or battery negative across the bottom. code contains a device identifying letter (H) and
number (I).
The identifying letter is always the same for a specific
DIAGNOSTIC INFORMATION component, but the identifying numbers are numbered
The diagnostic procedures are used to test the consecutively from upper left to lower right. The
complete circuit regardless of the problem or terminal designation (J) is placed directly outside the
complaint. Select a symptom or system from the quick symbol next to the connecting wire path. Switch
check or troubleshooting chart and follow the test positions (K) are also placed directly outside the
procedures under that heading. symbol. The solid line (L) shows the position the switch
is currently in and dashed lines (M) represent other
The diagnostic procedure lists: switch positions.
• Test conditions Each circuit is identified at the bottom of the drawing by
• Test sequence a section number (N) and section name (O).
• Test location The circuit number (P) and wire color (Q) of the wires
• Normal reading are shown directly next to the wire path.
• Check or test to perform if reading obtained is not
The same component name and identification code are
correct
used consistently throughout all diagrams in this
When performing the test or check, be sure to set your section. Components can be easily cross-referenced.
mower up to the test conditions listed and follow the
sequence carefully. The middle "NORMAL" column
gives the reading or condition that should be obtained
when performing the test or check. If the results of the
test or check are not normal, perform the test, check or
adjustment listed in the third "IF NOT NORMAL"
column to repair the malfunction. The detailed test or
adjustments referred to in the "IF NOT NORMAL"
column are located at the end of that group. The
system diagram that accompanies each test procedure
is drawn to resemble mower components. The key
number on the art matches the number in the "TEST
LOCATION" column and the arrow points to the exact
point where the test is to be made.

1/31/95 4-5
ELECTRICAL
WIRE COLOR ABBREVIATION
CHART
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Black
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray
Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Rust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rust
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan
Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . .Black/White
Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
4-6
THEORY AND DIAGNOSTIC INFORMATION
M46311
Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
Dk Brn/Lt Grn . . . . . . . . . .Dark Brown/Light Green
Dk Brn/Red. . . . . . . . . . . . . . . . . . Dark Brown/Red
Dk Brn/Yel . . . . . . . . . . . . . . . . Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . .Dark Green
Lt Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . .Light Green
Grn/Wht . . . . . . . . . . . . . . . . . . . . . . . Green/White
Org/Wht . . . . . . . . . . . . . . . . . . . . . . Orange/White
Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . .Pink/Black
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . .Purple/White
Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . .Red/White
Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . .White/Red
Yel/Blk. . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White
1/31/95
ELECTRICAL SCHEMATICS ELECTRICAL

ELECTRICAL SCHEMATIC—STANDAR D

M83125AE

5/11/95 4-7
ELECTRICAL SCHEMATICS ELECTRICAL

ELECTRICAL SCHEMATIC—STANDAR D

M83125AE

5/11/95 4-7
ELECTRICAL SCHEMATICS ELECTRICAL

ELECTRICAL SCHEMATIC—STANDAR D

M83125AE

5/11/95 4-7
ELECTRICAL SCHEMATICS ELECTRICAL

ELECTRICAL SCHEMATIC—STANDAR D

M83125AE

5/11/95 4-7
 ELECTRICAL ELECTRICAL SCHEMATICS

ELECTRICAL SCHEMATIC—OPTIONA L

M83188AE

4-8 5/11/95
 ELECTRICAL ELECTRICAL SCHEMATICS

ELECTRICAL SCHEMATIC—OPTIONA L

M83188AE

4-8 5/11/95
 ELECTRICAL ELECTRICAL SCHEMATICS

ELECTRICAL SCHEMATIC—OPTIONA L

M83188AE

4-8 5/11/95
 ELECTRICAL ELECTRICAL SCHEMATICS

ELECTRICAL SCHEMATIC—OPTIONA L

M83188AE

4-8 5/11/95
COMPONENT LOCATION ELECTRICAL

COMPONENT LOCATION

Neutral Start Switch S1

K1 Lift Relay
Connector X13 K2 Lower Relay

X23 Connector
Circuit Breaker (Optional) F4
E3 Left Light
Rear Light E2 X21 Connector

Hydraulic Pump Motor (Optional) M3

M2 Lift Actuator Motor
Connector X22
A1 Ignition Module
Optional Light Kit Harness X21 X18 Engine Connector
Engine Wiring
Connector X21 Harness S4 Lift Switch
Grounds
Connector X24

P1 Hour Meter
Right Light E4

P2 Voltmeter

Battery G1
S2 Key Switch

Spark Plug E1

Magneto Ignition Coil T1

Stator G2

Starter Motor M1
20 Amp Fuse F1 N1 S3 Light Switch
20 Amp Fuse F2 Voltage Regulator/Rectifier M83101AE

5/11/95 4-9
COMPONENT LOCATION ELECTRICAL

COMPONENT LOCATION

Neutral Start Switch S1

K1 Lift Relay
Connector X13 K2 Lower Relay

X23 Connector
Circuit Breaker (Optional) F4
E3 Left Light
Rear Light E2 X21 Connector

Hydraulic Pump Motor (Optional) M3

M2 Lift Actuator Motor
Connector X22
A1 Ignition Module
Optional Light Kit Harness X21 X18 Engine Connector
Engine Wiring
Connector X21 Harness S4 Lift Switch
Grounds
Connector X24

P1 Hour Meter
Right Light E4

P2 Voltmeter

Battery G1
S2 Key Switch

Spark Plug E1

Magneto Ignition Coil T1

Stator G2

Starter Motor M1
20 Amp Fuse F1 N1 S3 Light Switch
20 Amp Fuse F2 Voltage Regulator/Rectifier M83101AE

5/11/95 4-9
COMPONENT LOCATION ELECTRICAL

COMPONENT LOCATION

Neutral Start Switch S1

K1 Lift Relay
Connector X13 K2 Lower Relay

X23 Connector
Circuit Breaker (Optional) F4
E3 Left Light
Rear Light E2 X21 Connector

Hydraulic Pump Motor (Optional) M3

M2 Lift Actuator Motor
Connector X22
A1 Ignition Module
Optional Light Kit Harness X21 X18 Engine Connector
Engine Wiring
Connector X21 Harness S4 Lift Switch
Grounds
Connector X24

P1 Hour Meter
Right Light E4

P2 Voltmeter

Battery G1
S2 Key Switch

Spark Plug E1

Magneto Ignition Coil T1

Stator G2

Starter Motor M1
20 Amp Fuse F1 N1 S3 Light Switch
20 Amp Fuse F2 Voltage Regulator/Rectifier M83101AE

5/11/95 4-9
 ELECTRICAL ELECTRICAL WIRING HARNESSES

ELECTRICAL WIRING HARNESSES

Circuit Number Wire Size Color Circuit Number Wire Size Color
W1 STANDARD WIRING HARNESS 100 3.0 Blk 450 2.0 Org/Blk
670 101, 102, 110, 850 2.0 Blk 500 1.0 Red/Wht
435
X7 103, 104, 115, 120, 125 0.8 Blk 590 1.0 Yel
Lift
Switch 200, 211, 212, 400 2.0 Red 595 1.0 Yel/Blk
209 (Fusible Link Wire) 1.0 Red 670 0.8 Yel/Wht
675 410 (A)
700 (S2) 415 210 3.0 Red 675 0.8 Yel/Blk
-
X6 401 0.8 Red/Blk 700 0.8 Pur
400 (M)
(S1) 401 401
+ 125 410 2.0 Blu 745 0.8 Pur/Wht
415, 420, 800 2.0 Org 940 0.8 Blk/Wht
X5 (G) 120
115
940 (M)
425, 430, 435 0.8 Org
430
Key 103
X8 105 450
Switch

X9 Headlight
Harness
Splice (Power) Connection
435
430
Hour Meter X4 415
425 425
420 830 800

Hour Meter 700

120 100 745
X3 210 X13 Lift Actuator
125 Neutral X10
Motor
Start Connection
745 Switch
209 X15
Ground X14
105 Starter
500 200 110 X16 Solenoid
Ground
410 X19
110 210
115 595 X17 211 212
Starter

450 420
590 100 102
Voltage 590
Regulator/Rectifier 940 Engine
X18
Harness 101
X2
X1 Spare 595 X13 104
400 Fuses 500
X12
Headlight 670
Switch 675
850
Fuse Block 200 Lift 800 Lower
Relay Relay
101 211
103
102 212
104 104
M83123AE

4 - 10 5/11/95
 ELECTRICAL ELECTRICAL WIRING HARNESSES

ELECTRICAL WIRING HARNESSES

Circuit Number Wire Size Color Circuit Number Wire Size Color
W1 STANDARD WIRING HARNESS 100 3.0 Blk 450 2.0 Org/Blk
670 101, 102, 110, 850 2.0 Blk 500 1.0 Red/Wht
435
X7 103, 104, 115, 120, 125 0.8 Blk 590 1.0 Yel
Lift
Switch 200, 211, 212, 400 2.0 Red 595 1.0 Yel/Blk
209 (Fusible Link Wire) 1.0 Red 670 0.8 Yel/Wht
675 410 (A)
700 (S2) 415 210 3.0 Red 675 0.8 Yel/Blk
-
X6 401 0.8 Red/Blk 700 0.8 Pur
400 (M)
(S1) 401 401
+ 125 410 2.0 Blu 745 0.8 Pur/Wht
415, 420, 800 2.0 Org 940 0.8 Blk/Wht
X5 (G) 120
115
940 (M)
425, 430, 435 0.8 Org
430
Key 103
X8 105 450
Switch

X9 Headlight
Harness
Splice (Power) Connection
435
430
Hour Meter X4 415
425 425
420 830 800

Hour Meter 700

120 100 745
X3 210 X13 Lift Actuator
125 Neutral X10
Motor
Start Connection
745 Switch
209 X15
Ground X14
105 Starter
500 200 110 X16 Solenoid
Ground
410 X19
110 210
115 595 X17 211 212
Starter

450 420
590 100 102
Voltage 590
Regulator/Rectifier 940 Engine
X18
Harness 101
X2
X1 Spare 595 X13 104
400 Fuses 500
X12
Headlight 670
Switch 675
850
Fuse Block 200 Lift 800 Lower
Relay Relay
101 211
103
102 212
104 104
M83123AE

4 - 10 5/11/95
 ELECTRICAL ELECTRICAL WIRING HARNESSES

ELECTRICAL WIRING HARNESSES

Circuit Number Wire Size Color Circuit Number Wire Size Color
W1 STANDARD WIRING HARNESS 100 3.0 Blk 450 2.0 Org/Blk
670 101, 102, 110, 850 2.0 Blk 500 1.0 Red/Wht
435
X7 103, 104, 115, 120, 125 0.8 Blk 590 1.0 Yel
Lift
Switch 200, 211, 212, 400 2.0 Red 595 1.0 Yel/Blk
209 (Fusible Link Wire) 1.0 Red 670 0.8 Yel/Wht
675 410 (A)
700 (S2) 415 210 3.0 Red 675 0.8 Yel/Blk
-
X6 401 0.8 Red/Blk 700 0.8 Pur
400 (M)
(S1) 401 401
+ 125 410 2.0 Blu 745 0.8 Pur/Wht
415, 420, 800 2.0 Org 940 0.8 Blk/Wht
X5 (G) 120
115
940 (M)
425, 430, 435 0.8 Org
430
Key 103
X8 105 450
Switch

X9 Headlight
Harness
Splice (Power) Connection
435
430
Hour Meter X4 415
425 425
420 830 800

Hour Meter 700

120 100 745
X3 210 X13 Lift Actuator
125 Neutral X10
Motor
Start Connection
745 Switch
209 X15
Ground X14
105 Starter
500 200 110 X16 Solenoid
Ground
410 X19
110 210
115 595 X17 211 212
Starter

450 420
590 100 102
Voltage 590
Regulator/Rectifier 940 Engine
X18
Harness 101
X2
X1 Spare 595 X13 104
400 Fuses 500
X12
Headlight 670
Switch 675
850
Fuse Block 200 Lift 800 Lower
Relay Relay
101 211
103
102 212
104 104
M83123AE

4 - 10 5/11/95
1/31/95
151
101 152
Circuit Number Wire Size Color
102
100, 101, 102 1.0 Blk
100 150
150, 151, 152 1.0 Blk/Wht
101 151
Left
Light
ELECTRICAL SCHEMATICS

X23

Rear
Light X22

150 Main
Harness
W2 LIGHTING WIRING HARNESS (OPTIONAL)

X21
100

Rear
Light

X24

102
152

M83124AE
ELECTRICAL

4 - 11
ELECTRICAL ELECTRICAL SCHEMATICS

W3 HYDRAULIC PUMP WIRING HARNESS (OPTIONAL)

400

300 400
100
300 305
305
X28
400 X25
Hydraulic Pump
Hydraulic Pump
X26 X27 Harness to
Main Harness
Circuit Breaker

X29
Ground
Circuit Number Wire Size Color
100
100 3.0 Blk

300 3.0 Red

400 3.0 Red/Blk

M83496AE

4 - 12 1/31/95
TROUBLESHOOTING ELECTRICAL

TROUBLESHOOTIN G
ELECTRICAL SYSTEM TROUBLESHOOTING CHAR T
Problem or

dead, discharges

does not operate

but will not start.

Lift system does

Symptom

Starter cranking

or overcharges.

hydraulic pump
Engine will not
Engine cranks

Battery goes

not operate
Check or

problems.

No spark.

properly.

properly.
Optional
shut off.
Solution

See Power Circuit Diagnosis.

See Cranking Circuit Diagnosis.
Check ground circuit.
Test battery and battery connections.
See Ignition Circuit Diagnosis.
See Charging Circuit Diagnosis.
Check for shorted circuit.
See Lift System Troubleshooting Chart and
Diagnosis.
See Optional Hydraulic Pump Diagnosis

LIFT SYSTEM TROUBLESHOOTING CHAR T

Problem or

Switch operates in
Lift actuator stops

not hold position.

Lift system does

operates slowly.
Symptom

wrong direction.
Lift actuator will

Lift actuator will

Lift actuator will

Fast thumping
in mid-stroke.
not operate.

implement.

implement.

Lift system
Check or
not lower
not raise

Solution

noise.
Lift not receiving power. Check connection
and fusible links at starter. See Lift Circuit
Diagnosis.
Thermal overload cut-out. Let cool.
Stripped nut or gears. Check for excessive
shock loads.
Excessive load. Reduce load.
Clutch worn. Replace clutch.
Brake worn, seized or broken. Replace
brake.
Fusible link burnt. Replace.
Low voltage. See Lift Circuit Diagnosis.
Faulty switch.
Actuator binding. Check lift pivot points for
binding and wear.
Cylinder at end of stroke or clutch slipping.
Wire location switched at control switch
outlet terminals or in motor connector.

2/9/95 4 - 13
ELECTRICAL
CIRCUIT OPERATION AND
DIAGNOSIS
POWER CIRCUIT OPERATIO N
Function:
Provides unswitched power to the primary circuit
whenever the battery is connected.
Operating Conditions, Unswitched Circuits :
Voltage must be present at the following components
with the key switch in the OFF position:
• Battery Positive (+) Terminal.
• Battery Terminal of Starter Solenoid Bolt.
• Fuse Block—Fuse (F1).
• Fuse Block—Fuse (F2).
• Battery Terminal of Key Switch.
• S1 Terminal of Key Switch.
• Battery Terminal of Voltage Regulator/Rectifier.
• Terminal 87 of Lift Relay.
• Terminal 87 of Lower Relay.
4 - 14
CIRCUIT OPERATION AND DIAGNOSI S
Theory of Operation:
The positive battery cable connects the battery (G1) to
the starter (M1). The starter bolt is used as a tie point
for the rest of the electrical system.
The battery cables and the starter tie point connections
must be in good condition for the electrical system to
function properly.
The ground cable connections are equally important as
the positive cable. Starter operation depends on these
cables and connections to carry the high current
necessary for its operation.
The connection between the starter and key switch is
protected by a 20 amp main power fuse (F1). The
connection between the starter and voltage regulator is
protected by a 20 amp fuse (F2). The connection
between the starter and lift (K1) and lower (K2) relays
are protected by a fusible link (F3). These devices are
designed to fail (open) if current draw is excessive or a
short circuit occurs, protecting the wiring harness from
damage.
Switched Circuits:
Voltage must be present at the following components
with the key switch in the RUN position:
• “A” Terminal of Key Switch.
• Voltage Regulator/Rectifier—Blue wire No. 410.
• Positive (+) Terminal of Hour Meter.
• Common Terminal of Lift Switch.
• Common Terminal of Headlight Switch.
• Positive Terminal of Voltmeter.
These circuits are controlled by the key switch and are
protected by a 20 amp main power fuse (F1).
1/31/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

POWER CIRCUIT OPERATION

5/11/95 4 - 15
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

POWER CIRCUIT OPERATION

5/11/95 4 - 15
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

POWER CIRCUIT OPERATION

5/11/95 4 - 15
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

POWER CIRCUIT DIAGNOSI S

Test Conditions:

• Key switch in OFF position. • Meter positive (+) lead on battery positive (+)
• Meter negative (-) lead on battery negative (-) terminal.
terminal. • Check connection(s) for corrosion and looseness
when checking/testing.

Test/Check Point Normal If Not Normal

1. Battery positive (+) terminal. 11.8—13.2 volts. Test battery.

2. Starter solenoid to motor Battery voltage. Check battery cables and clamps.
bolt—Battery terminal. Clean and tighten connections.

3. Fuse block—Fuse (F1). Battery voltage. Check red wire No. 200 and
connections.

4. Fuse block—Fuse (F1). Battery voltage. Replace fuse.

5. Key switch—Terminal B. Battery voltage. Check red wire No. 400 and
connections.

6. Key switch—Terminal S1. Battery voltage. Check red/black wire No. 401.

7. Fuse block—Fuse (F2). Battery voltage. Check red wire No. 200 and
connections.

8. Fuse block—Fuse (F2). Battery voltage. Replace fuse.

9. Voltage regulator/rectifier— Battery voltage. Check red/white wire No. 500 and
Battery terminal. connections.

10. Lift relay—Terminal 87. Battery voltage. Check red wires No. 209, 210, 211,
fusible link (F3) and connections.

11. Lower relay—Terminal 87. Battery voltage. Check red wires No. 209, 210, 212,
fusible link (F3) and connections.

Test Conditions:

• Key switch in RUN position. • Check connection(s) for corrosion and looseness
• Park brake engaged. when checking/testing.

Test/Check Point Normal If Not Normal

12. Key switch—Terminal A. Battery voltage. Test key switch. (See procedure in
Tests and Adjustments.)

13. Voltage regulator/rectifier. Battery voltage. Check blue wire No. 410 and
connections.

4 - 16 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

13

G1 Batter y M82886 N1 Voltage Regulator/Rectifie r M83144AE

10

M1 Starting Moto r M82887 M83147AE

K1 Lift Rela y

4
11

Spare Fuses
8
Fuse Bloc k M83142AE K2 Lower Rela y M83147AE

12

S2 Key Switc h M83143AE

1/31/95 4 - 17
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

POWER CIRCUIT DIAGNOSIS, continue d

Test Conditions:

• Key switch in RUN position. • Check connection(s) for corrosion and looseness
• Park brake engaged. when checking/testing.

Test/Check Point Normal If Not Normal

14. Hour Meter positive (+) Battery voltage. Check orange wires No. 415 and
terminal. 425 and connections.

15. Voltmeter positive (+) Battery voltage. Check orange wires No. 415 and
terminal. 430 and connections.

16. Headlight switch. Battery voltage. Check orange wires No. 415 and
420 and connections.

17. Lift switch. Battery voltage. Check orange wires No. 415 and
435 and connections.

4 - 18 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

14

16 (Orange Wire)
or
16 (Orange Wire)

P1 Hour Mete r M83146AE S3 headlight Switc h M83148AE

17

15

P2 Voltmete r M83145AE M83149AE

S4 Lift Switc h

1/31/95 4 - 19
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

CRANKING CIRCUIT OPERATIO N The neutral start switch is used in the neutral start
circuit to prevent the engine from cranking if the
transaxle is in gear. With the neutral start switch closed
Function: (transaxle in neutral), current flows to the starter
solenoid, engaging the solenoid. The solenoid is
The cranking system is used to energize the starting engaged by current flowing through both pull-in and
motor. hold-in windings, pulling the plunger inward. The
plunger closes the solenoid main contacts. When the
main contacts are closed, both ends of the pull-in
Operating Conditions:
windings have the same voltage so current through the
• Key switch in START position. pull-in windings stops. Current continues through the
• Gearshift pedals in NEUTRAL position (Neutral hold-in windings, keeping the solenoid engaged.
start switch CLOSED). With the solenoid main contacts closed, high current
from the battery flows across the main contacts to the
starter motor (M1) causing it to turn.
System Operation:
The starting motor is a solenoid shift design. The
power circuit provides current to the key switch (S2)
and protects the cranking circuit with a 20 amp fuse
(F1). Current flows from the battery (G1) positive (+)
terminal to the starter solenoid battery terminal, 20 amp
main power fuse, key switch battery terminal and key
switch S1 terminal. With the key switch in the START
position, current flows from key switch terminal S1 to
terminal S2 and the neutral start switch.

4 - 20 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

CRANKING CIRCUIT OPERATIO N

5/11/95 4 4- 21
-1
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

CRANKING CIRCUIT DIAGNOSI S

Test Conditions:

• Key switch in OFF position. • Meter negative (-) lead on battery negative (-)
terminal.

Test/Check Point Normal If Not Normal

1. Battery positive (+) terminal. 11.8—13.2 volts. Test battery.

2. Starter solenoid to motor Battery voltage. Check battery cables and clamps.
bolt—Battery terminal. Clean and tighten connections.

3. Fuse block—Fuse (F1). Battery voltage. Check red wire No. 200 and
connections.

4. Fuse block—Fuse (F1). Battery voltage. Replace fuse.

5. Key switch—Terminal B. Battery voltage. Check red wire No. 400 and
connections.

6. Key switch—Terminal S1. Battery voltage. Check red/black wire No. 401.

Test Conditions:

• Key switch in START position. • Neutral start switch in NEUTRAL position.

Test/Check Point Normal If Not Normal

7. Key switch—Terminal S2. Battery voltage. Test key switch. (See procedure in
Tests and Adjustments.)

8. Neutral start switch. Battery voltage. Check purple wire No. 700 and
connections.

9. Neutral start switch. Battery voltage. Test neutral start switch. (See
procedure in Tests and
Adjustments.)

10. Starter solenoid. Battery voltage. Check purple/white wire No. 745
and connections.

4 - 22 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

7 5

G1 Batter y M82886 S2 Key Switc h M83143AE

10

M1 Starting Moto r M82887 M83150AE

S1 Neutral Start Switc h

Fuse Bloc k M83142AE

1/31/95 4 - 23
ELECTRICAL
IGNITION CIRCUIT OPERATION—
ENGINE RUNNING
Function:
To create a spark that ignites the fuel/air mixture in the
engine.
Operating Conditions:
• Key switch in START or RUN position.
• Transmission in neutral. (Neutral start switch
CLOSED.)
System Operation:
The ignition system is a transistor-controlled magneto
design. Ignition timing is controlled by the ignition
module and is not adjustable. The engine is shut off by
grounding the ignition coil through the key switch (S2).
With the key switch in the START or RUN position the
path to ground is eliminated so a spark can be
produced. As the flywheel turns, a magnet in the
flywheel starts to align with the ignition coil (T1) and
produces current in the primary coil by electromagnetic
induction. In the initial stage low voltage current is
produced. The low voltage current flows to a transistor
(C), and resistors (A and B) in the ignition module (A1).
4 - 24
CIRCUIT OPERATION AND DIAGNOSI S
Resistor (B) has high resistance so current will flow
through resistor (A) to transistor (C). The transistor
base is energized which closes the transistor and
provides a path to ground for ignition coil current flow.
In the spark stage (spark produced), the flywheel
magnet is fully aligned with the ignition coil; a high
voltage (maximum) current is induced in the primary
coil. The high voltage current can now flow through
resistor (B) to transistor (C). The transistor base is
energized which closes the transistor and provides a
path to ground for current that was flowing to transistor
base. With current no longer applied to transistor base,
the transistor opens breaking the path to ground. The
sudden reduction of current flow, because the
transistor is open and all current must flow through the
transistor, induces high voltage current in the
secondary coil. The high voltage current flows through
the coil wire to the spark plug (E1). The voltage is now
high enough to jump the spark plug gap and a spark is
produced, igniting the fuel/air mixture in the cylinder.
1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

IGNITION CIRCUIT OPERATION—ENGINE RUNNIN G

5/11/95 4 4- 25
-2
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

IGNITION CIRCUIT OPERATION—

ENGINE SHUTTING OF F

Function:
To shut off the engine by grounding the ignition coil
through the key switch.

Operating Conditions:
• Key switch in OFF position.

System Operation:
When the key switch (S2) is turned to the OFF position,
a path to ground is provided for ignition coil current.
The low voltage current produced in the primary coil of
the magneto ignition coil (T1) flows to the ignition
module (A1) and key switch, grounding the ignition coil
current.

4 - 26 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

IGNITION CIRCUIT OPERATION—ENGINE SHUTTING OF F

5/11/95 4 4- 27
-3
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

IGNITION CIRCUIT DIAGNOSI S

When diagnosing an ignition problem, isolate the magneto circuit from the ground circuit by separating the engine
connector (X18). If the engine will not start check the magneto circuit first and then the ground circuit. If the engine
will not shut off, check the ground circuit first. Remember the engine is stopped by grounding the ignition coil
through the key switch.

Test Conditions:

• Key switch in START position. • Check connection(s) for corrosion and looseness
• Engine connector (X18) DISCONNECTED. when checking/testing.
• Meter negative (-) lead on battery negative (-)
terminal.

Test/Check Point Normal If Not Normal

1. Spark plug/Spark Tester. (See
procedure in ENGINE
section.)
Spark test indicates hot blue spark.
No spark present: Test ignition coil
and ignition module. Check ignition
coil air gap, and flywheel magnets.
Spark present: Check spark plug
gap and condition of spark plug. If
plug is good, continue testing
ground circuit.

Test Conditions:

• Key switch in OFF position. • Engine Connector (X18) CONNECTED.

Test/Check Point Normal If Not Normal

2. Ignition module.
Maximum 0.1 ohms resistance.
Check battery negative cable
shielded ground, black wires No.
110 and 115 and black/white wire
No. 940 and connections. Test key
switch. (See procedure in Tests and
Adjustments.)

4 - 28 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

1 2

E1 Spark Plu g M82882 A1 Ignition Modul e M83153

1/31/95 4 - 29
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

CHARGING CIRCUIT OPERATIO N The power/battery charging circuit provides current to

the key switch (S2) battery terminal and protects the
charging circuit with a 20 amp main power fuse (F1).
Function: With the key switch in the RUN position, current flows
from battery (G1) positive (+) terminal to fuse (F1), key
To maintain battery voltage between 11.6 and 14.5 switch (S2) and voltage regulator/rectifier (N1). The
volts DC. voltage sensing circuit allows the regulator/rectifier to
monitor battery voltage.
Operating Conditions: As the flywheel turns, a permanent magnet located in
the flywheel induces AC current in the stator (G2)
• Key switch in RUN position.
windings. The AC current flows to the regulator/
• Engine running. rectifier. The regulator/rectifier converts the AC current
to DC current needed to charge the battery.
System Operation: If the battery voltage is low, the voltage regulator/
rectifier allows DC current to flow to the battery to
The charging system is a permanent magnet and stator
charge it through the power/battery charging circuit.
design. Charging output is controlled by a regulator/
rectifier. A voltmeter allows the operator to monitor the When the battery is fully charged, the regulator stops
current flow to the battery.
stator output.
The ground circuit provides a path to ground for the
regulator/rectifier.

4 - 30 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

CHARGING CIRCUIT OPERATIO N

5/11/95 4 4- 31
-4
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

CHARGING CIRCUIT DIAGNOSI S

Test Conditions:

• Key switch in OFF position. • Meter negative (-) lead on battery negative (-)
terminal.

Test/Check Point Normal If Not Normal

1. Battery positive (+) terminal. 11.8—13.2 volts. Test battery.

2. Fuse block—Fuse (F1). Battery voltage. Check red wire No. 200 and
connections.

3. Fuse block—Fuse (F1). Battery voltage. Replace fuse.

4. Key switch—Terminal B. Battery voltage. Check red wires No. 400 and
connections.

5. Fuse block—Fuse (F2). Battery voltage. Check red wire No. 200 and
connections.

6. Fuse block—Fuse (F2). Battery voltage. Replace fuse.

7. Voltage regulator/rectifier— Battery voltage. Check red/white wire No. 500 and
Battery terminal. connections.

8. Voltage regulator/rectifier— Maximum 0.1 ohms resistance. Check battery negative cable,
Black wire No.110. shielded ground, black wire No.
110.

Test Conditions:

• Key switch in RUN position—Engine not running.

Test/Check Point Normal If Not Normal

9. Key switch—Terminal A. Battery voltage. Test key switch. (See procedure in

Tests and Adjustments.)

10. Voltage regulator/rectifier— Battery voltage. Check blue wire No. 410 and
Blue wire No. 410. connections.

4 - 32 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

G1 Batter y M82886 S2 Key Switc h M83143AE

8
2

10

5 7

Fuse Bloc k M83142AE M83144AE

N1 Voltage Regulator/Rectifie r

1/31/95 4 - 33
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

CHARGING CIRCUIT DIAGNOSIS, continue d

Test Conditions:

• Key switch in RUN position—Engine running.

Test/Check Point Normal If Not Normal

11. Stator connector. (Perform Voltage output to specifications. See Unregulated Voltage Output
Unregulated Voltage Output Test.
Test.)

12. Voltage regulator/rectifier— Regulated amperage to Check yellow/black wire No. 595,
Red/wht wire No. 500. specification. yellow wire No. 590 and black
(Perform Regulated wires. If OK, replace voltage
Amperage Test.) regulator/rectifier.

4 - 34 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

12
11

G2 Stato r M82883 N1 Voltage Regulator/Rectifie r M83144AE

1/31/95 4 - 35
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

LIFT SYSTEM CIRCUIT The power circuit provides current to the key switch
(S2) and protects the lift circuit with a 20 amp fuse (F1).
OPERATION—RAIS E Current flows from the battery (G1) positive (+) terminal
to the starter solenoid battery terminal, 20 amp main
power fuse, key switch battery terminal, lift relay
Function:
terminal 87 and lower relay terminal 87. With the key
To control the direction of current applied to the lift switch in the RUN position, current flows from key
actuator motor to raise the rake assembly. switch battery terminal to terminal A and lift switch (S4).
When the lift switch is moved to the RAISE position
Operating Conditions: battery voltage is applied to lift relay terminal 86,
energizing the relay. Battery voltage can then flow from
• Key switch in RUN position. lift relay terminal 87 to terminal 30 to the lift actuator
• Lift switch in RAISE position. motor (M2). The motor will continue to run until the
switch is released.

System Operation:
The heart of the lift system is an electromechanical,
screw type linear actuator. It consists of an electric
motor, gear train, drive screw and ram.
The ground circuit provides a path to ground for the lift
actuator motor through the normally-closed contact
(87A)of the lower relay.

4 - 36 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

LIFT SYSTEM CIRCUIT OPERATION—RAIS E

5/11/95 4 4- 37
-5
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

LIFT SYSTEM CIRCUIT The power circuit provides current to the key switch
(S2) and protects the lift circuit with a 20 amp fuse (F1).
OPERATION—LOWE R Current flows from the battery (G1) positive (+) terminal
to the starter solenoid battery terminal, 20 amp main
power fuse, key switch battery terminal, lift relay
Function:
terminal 87 and lower relay terminal 87. With the key
To control the direction of current applied to the lift switch in the RUN position, current flows from key
actuator motor to lower the rake assembly. switch battery terminal to terminal A and lift switch (S4).
When the lift switch is moved to the LOWER position
Operating Conditions: battery voltage is applied to lower relay terminal 86,
energizing the relay. Battery voltage can then flow from
• Key switch in RUN position. lift relay terminal 87 to terminal 30 to the lift actuator
• Lift switch in LOWER position. motor (M2). The motor will continue to run until the
switch is released.

System Operation:
The heart of the lift system is an electromechanical,
screw type linear actuator. It consists of an electric
motor, gear train, drive screw and ram.
The ground circuit provides a path to ground for the lift
actuator motor through the normally-closed contacts
(87A) of the lift relay.

4 - 38 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

LIFT SYSTEM CIRCUIT OPERATION—LOWE R

5/11/95 4 4- 39
-6
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

LIFT SYSTEM CIRCUIT DIAGNOSI S

Test Conditions:

• Key switch in OFF position. • Meter negative (-) lead on battery negative (-)
terminal.

Test/Check Point Normal If Not Normal

1. Battery Positive (+) terminal. 11.8—13.2 volts. Test battery.

2. Fuse block—Fuse (F1). Battery voltage. Check red wire No. 200 and
connections.

3. Fuse block—Fuse (F1). Battery voltage. Replace fuse.

4. Key switch—Terminal B. Battery voltage. Check red wire No. 400 and
connections.

5. Lift relay—Terminal 87. Battery voltage. Check red wires No. 209, 210, 211,
fusible link (F3) and connections.

6. Lower relay—Terminal 87. Battery voltage. Check red wires No. 209, 210, 212,
fusible link (F3) and connections.

7. Lift relay—Terminal 87A. Maximum 0.1 ohms resistance. Check battery negative cable,
shielded ground, black wires No.
100 and 101 and connections.

8. Lower relay—Terminal 85. Maximum 0.1 ohms resistance. Check battery negative cable,
shielded ground, black wires No.
103, 104 and 105.

9. Lower relay—Terminal 87A. Maximum 0.1 ohms resistance. Check battery negative cable,
shielded ground, black wires No.
100 and 102.

Test Conditions:

• Key switch in RUN position. Lift switch in RAISE position.

Test/Check Point Normal If Not Normal

10. Key Switch—Terminal A. Battery voltage. Test key switch. (See procedure in
Tests and Adjustments.)

11. Lift switch common terminal. Battery voltage. Check orange wires No. 415 and
435 and connections.

12. Lift switch. Battery voltage. Test lift switch. (See procedure in
Tests and Adjustments.)

13. Lift relay—Terminal 86. Battery voltage. Check yellow/white wire No. 670
and connections.

14. Lift relay—Terminal 30. Battery voltage. Test lift relay. (See procedure in
Tests and Adjustments.)

4 - 40 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

13

14

G1 Batter y M82886 K1 Lift Rela y M83147AE

9
8
Fuse Bloc k M83142AE M83147AE
K2 Lower Rela y

12

4 11
10

S2 Key Switc h M83143AE S4 Lift Switc h M83149AE

1/31/95 4 - 41
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

LIFT SYSTEM CIRCUIT DIAGNOSIS, continue d

Test Conditions:

• Key switch in RUN position. • Lift switch in RAISE position.

Test/Check Point Normal If Not Normal

15. Lift actuator motor. Battery voltage. Check black wire No. 850 and
connections.

16. Lift switch. Battery voltage. Test lift switch. (See procedure in
Tests and Adjustments.)

17. Lower relay—Terminal 86. Battery voltage. Check yellow/black wire No. 675
and connections.

18. Lower relay—Terminal 30. Battery voltage. Test lift relay. (See procedure in
Tests and Adjustments.)

19. Lift actuator motor. Battery voltage. Check orange wire No. 800 and
connections.

4 - 42 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

19

15

17

18

M2 Lift Actuator Moto r M83152AE K2 Lower Rela y M83147AE

16

S4 Lift Switc h M83149AE

1/31/95 4 - 43
ELECTRICAL
OPTIONAL HYDRAULIC PUMP
CIRCUIT OPERATION—RAIS E
Function:
To provide power to a hydraulic pump used for lifting
rear rake or pulled implement.
Operating Conditions:
• Key switch in RUN position.
• Lift switch in RAISE position.
Theory of Operation:
NOTE: When the hydraulic pump is used, the linear
actuator motor ground wire must be
disconnected at the grounding bolt on the
engine and isolated with tape when the
hydraulic pump motor harness ground is
attached to the ground bolt. Failure to
disconnect the linear actuator ground wire will
result in slow hydraulic pump operation, high
current draw and possible tripping of the circuit
breaker.
4 - 44
CIRCUIT OPERATION AND DIAGNOSI S
The power circuit provides current to the key switch
(S2) and protects the lift circuit with a 20 amp fuse (F1).
Current flows from the battery (G1) positive (+) terminal
to the starter solenoid battery terminal, 20 amp main
power fuse, key switch battery terminal, lift relay
terminal 87 and lower relay terminal 87. With the key
switch in the RUN position, current flows from key
switch battery terminal to terminal A and lift switch (S4).
When the lift switch is moved to the RAISE position
battery voltage is applied to lift relay terminal 86,
energizing the relay. Battery voltage can then flow from
lift relay terminal 87 to terminal 30 to the hydraulic
pump motor (M3). The motor will continue to run until
the switch is released.
A path to ground for the hydraulic pump motor is
provided by black wire No.100 in the hydraulic pump
harness (W3). This wire replaces black wire No. 100 in
the main harness when the hydraulic pump is
connected. Black wire No. 100 from the main harness
should be disconnected from ground and isolated with
tape whenever the hydraulic pump motor gound is
connected to the ground bolt. A separate path to
ground for the lift relay is provided through black wires
No. 103 and 105.
1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

OPTIONAL HYDRAULIC PUMP CIRCUIT OPERATION—RAIS E

5/11/95 4 4- 45
-7
ELECTRICAL
OPTIONAL HYDRAULIC PUMP
CIRCUIT OPERATION—LOWE R
Function:
To provide power to a hydraulic pump used for lifting
rear rake or pulled implement.
Operating Conditions:
• Key switch in RUN position.
• Lift switch in LOWER position.
Theory of Operation:
NOTE: When the hydraulic pump is used, the linear
actuator motor ground wire must be
disconnected at the grounding bolt on the
engine and isolated with tape when the
hydraulic pump motor harness ground is
attached to the ground bolt. Failure to
disconnect the linear actuator ground wire will
result in slow hydraulic pump operation, high
current draw and possible damage to wiring
harness.
4 - 46
CIRCUIT OPERATION AND DIAGNOSI S
The power circuit provides current to the key switch
(S2) and protects the lift circuit with a 20 amp fuse (F1).
Current flows from the battery (G1) positive (+) terminal
to the starter solenoid battery terminal, 20 amp main
power fuse, key switch battery terminal, lift relay
terminal 87 and lower relay terminal 87. With the key
switch in the RUN position, current flows from key
switch battery terminal to terminal A and lift switch (S4).
When the lift switch is moved to the LOWER position
battery voltage is applied to lower relay terminal 86,
energizing the relay. Battery voltage can then flow from
lift relay terminal 87 to terminal 30 to the hydraulic
pump motor (M2). The motor will continue to run until
the switch is released.
A path to ground for the hydraulic pump motor is
provided by black wire No.100 in the hydraulic pump
harness (W3). This wire replaces black wire No. 100 in
the main harness when the hydraulic pump is
connected. Black wire No. 100 from the main harness
should be disconnected from ground and isolated with
tape whenever the hydraulic pump motor gound is
connected to the ground bolt. A separate path to
ground for the lower relay is provided through black
wires No. 103, 104 and 105.
1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

OPTIONAL HYDRAULIC PUMP CIRCUIT OPERATION—LOWE R

5/11/95 4 4- 47
-8
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

OPTIONAL HYDRAULIC PUMP CIRCUIT DIAGNOSI S

Test Conditions:

• Key switch in OFF position. • Meter negative (-) lead on battery negative (-)
terminal.

Test/Check Point Normal If Not Normal

1. Battery positive (+) terminal. 11.8—13.2 volts. Test battery.

2. Fuse block—Fuse (F1). Battery voltage. Check red wire No. 200 and
connections.

3. Fuse block—Fuse (F1). Battery voltage. Replace fuse.

4. Key switch—Terminal B. Battery voltage. Check red wire No. 400 and
connections.

5. Lift relay—Terminal 87. Battery voltage. Check red wires No. 209, 210, 211,
fusible link (F3) and connections.

6. Lower relay—Terminal 87. Battery voltage. Check red wires No. 209, 210, 212,
fusible link (F3) and connections.

7. Lower relay—Terminal 85. Maximum 0.1 ohms resistance. Check battery negative cable,
shielded ground, black wires No.
103, 104 and 105 and connections.

8. Hydraulic pump motor. Maximum 0.1 ohms resistance. Check battery negative cable,
shielded ground, black wire No. 100
and connections.

9. Lift/Lower relay—Terminal Open circuit to battery negative (-) Disconnect black wire No. 100
87A. terminal. (main harness) from ground.

Test Conditions:

• Key switch in RUN position. • Lift switch in RAISE position.

Test/Check Point Normal If Not Normal

10. Key Switch—Terminal A. Battery voltage. Test key switch. (See procedure in
Tests and Adjustments.)

11. Lift switch common terminal. Battery voltage. Check orange wires No. 415 and
435 and connections.

12. Lift switch. Battery voltage. Test lift switch. (See procedure in
Tests and Adjustments.)

13. Lift relay—Terminal 86. Battery voltage. Check yellow/white wire No. 670
and connections.

14. Lift relay—Terminal 30. Battery voltage. Test lift relay. (See procedure in
Tests and Adjustments.)

4 - 48 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

9
7

G1 Batter y M82886 K2 Lower Rela y M83147AE

3
8

Fuse Bloc k M83142AE M3 Hydraulic Pump Moto r M83151AE

12

11
4
10

S2 Key Switc h M83143AE S4 Lift Switc h M83149AE

13

9
14

K1 Lift Rela y M83147AE

1/31/95 4 - 49
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSI S

OPTIONAL HYDRAULIC PUMP CIRCUIT DIAGNOSIS, continue d

Test Conditions:

• Key switch in RUN position. • Lift switch in RAISE position.

Test/Check Point Normal If Not Normal

15. Circuit breaker. Battery voltage. Check black wire No. 850, red wire
No. 305 and connections.

16. Circuit breaker. Battery voltage. Replace circuit beaker.

17. Hydraulic pump motor. Battery voltage. Check red wire No. 300 and
connections.

Test Conditions:

• Key switch in RUN position. • Lift switch in LOWER position.

Test/Check Point Normal If Not Normal

18. Lift switch. Battery voltage. Test lift switch. (See procedure in
Tests and Adjustments.)

19. Lower relay—Terminal 86. Battery voltage. Check yellow/black wire No. 675
and connections.

20. Lower relay—Terminal 30. Battery voltage. Test lift relay. (See procedure in
Tests and Adjustments.)

21. Hydraulic pump motor. Battery voltage. Check orange wire No. 800, red/
black wire No. 400 and
connections.

4 - 50 1/31/95
CIRCUIT OPERATION AND DIAGNOSI S ELECTRICAL

16
15

18

E4 Circuit Breake r M83187AE S4 Lift Switc h M83149AE

17 21

20 19

M3 Hydraulic Pump Moto r M83151AE K2 Lower Rela y M83147AE

1/31/95 4 - 51
ELECTRICAL
TESTS AND ADJUSTMENT S
COMMON CIRCUIT TES T
Shorted/Grounded Circuit:
A shorted circuit on the ground side of a component
(i.e., improper wire-to-wire or wire to ground contact)
may result in improper component operation.
A shorted circuit on the power side of a component or
contact of two power circuits (i.e., improper wire-to-wire
or wire to ground contact) may result in blown fusible
links and fuses.
To test for a shorted or improperly wired circuit:
1. Turn component switch ON.
2. Start at the controlling switch of the component that
should not be operating.
3. Follow the circuit and disconnect wires at
connectors until components stop operating.
4. Shorted or improper connections will be the last two
wires disconnected.
High Resistance or Open Circuit :
High resistance or open circuits usually result in slow,
dim, or no component operation (i.e., poor, corroded, or
severed connections). Voltage at the component will be
low when the component is in operation. To test for
high resistance and open circuits:
1. Check all terminals and ground connections of the
circuit for corrosion.
2. If terminals are not loose or corroded, the problem
is in the component or wiring.
GROUND CIRCUIT TES T
Reason:
To check for open circuits, loose terminal wire crimps,
poor connections, or corrosion in the ground circuit.
Equipment:
• Ohmmeter or Voltmeter
NOTE: The voltmeter method checks ground
connections under load.
Procedure—OHMMETER METHOD :
1. Park machine on level surface.
2. Turn key switch to OFF position.
3. Move gearshift pedals to NEUTRAL position.
4. Engage parking brake.
4 - 52
TESTS AND ADJUSTMENTS
5. Raise rear body cowl.
6. Connect ohmmeter to negative (black)lead to
negative terminal of battery. Connect meter
positive (red) lead to negative terminal of battery
and record reading.
Ground Terminal
M83181
7. Connect ohmmeter red lead to ground terminal of
circuit or component to be tested that is closest to
the battery negative terminal. Resistance reading
must be the same or very close to the battery
negative terminal reading. Work backward
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 ohm s. Check both
sides of the connectors closely, as disconnecting
and connecting may temporarily solve problem.
Procedure—VOLTMETER METHOD :
1. Park machine on level surface.
2. Move gearshift pedals to NEUTRAL position.
3. Engage parking brake.
4. Turn key switch to RUN position.
5. Raise hood.
6. Connect voltmeter negative (black) lead to negative
terminal of battery.
7. Connect voltmeter positive (red) lead to ground
terminal of circuit (A and/or B) or component to be
tested. Be sure that component circuit is activated
(key ON, switches CLOSED) so that voltage will
be present at the component. Record voltage.
Voltage must be greater than 0, but less than 1
volt. Some components will have a very small
voltage reading on the ground side and still be
operating correctly.
Results:
• If voltage is 0, the component is open.
• If voltage is greater than 1 volt, the ground circuit is
bad. Check for open wiring, loose terminal wire
crimps, poor connections, or corrosion in the
ground circuit.
1/31/95
TESTS AND ADJUSTMENTS ELECTRICAL

BATTERY TEST

c 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:
1. Filling batteries in a well-ventilated area .
2. Wearing eye protection and rubber gloves .
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoid spilling or dripping electrolyte .
5. Use proper jumpstart procedure .
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10—15
minutes. Get medical attention immediately .
If acid is swallowed:
1. Drink large amounts of water or milk .
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately .
Reason:
To check condition of battery and determine battery
voltage.
M49596
9. Use an hydrometer to check for a minimum
specific gravity of 1.225 with less than 50 point
variation in each cell.
Results:
• If all cells are less than 1.175, charge battery at 10
amp rate.
• If all cells are less than 1.225 with less than 50
point variation, charge battery at 10 amp.
• If all cells are more than 1.225 with less than 50
point variation, load test battery.
• If more than 50 point variation, replace battery.
10. Use a voltmeter or JT05685 Battery Tester to check
for a minimum battery voltage of 12.4 volt s.
Results:
• If battery voltage is less than 12.4 VDC, charge
battery (see CHARGE BATTERY).
• If battery voltage is more than 12.4 VDC, test
specific gravity (see Step 9).
11. Install battery.

Equipment:
CHARGE BATTERY
• Hydrometer
• Voltmeter or JT05685 Battery Tester
Reason:
To increase battery charge after the battery has been
Procedure:
discharged.
1. Park machine on level surface.
2. Turn key switch OFF.
Equipment:
3. Engage parking brake.
4. Clean cable ends, battery terminals and top of • Battery charger (variable rate)
battery.
5. Remove battery to workbench.
Procedure:
6. Inspect battery terminals and case for breakage or
cracks.
7. Check electrolyte level in each battery cell. Add NOTE: See BATTERY TEST procedure before
clean, soft water as needed. If water is added, charging battery.
charge battery for 20 minutes at 10 amps.
8. Remove surface charge by placing a small load on
1. Park machine on level surface.
the battery for 15 seconds.
2. Turn key switch OFF.

1/31/95 4 - 53
ELECTRICAL TESTS AND ADJUSTMENTS

3. Engage parking brake. Results:

4. Clean cable ends, battery terminals and top of • If MORE THAN 50 point variation between cells,
battery. replace battery;
5. Remove battery to workbench. • If LESS THAN 50 point variation between cells, go
to Steps 11 and 12.

NOTE: If battery was discharged at slow or unknown

rate, charge battery at 10—15 amps for 6—12
hours. (Maintenance-free battery: 4—8 hours).

11. Continue to charge battery until specific gravity is

1.230—1.265 points.
12. Perform BATTERY LOAD TEST.
13. Install battery.
M49598

6. Connect variable rate charger to battery. BATTERY LOAD TES T

NOTE: Maximum time at boost setting is 10 minutes. Reason:

Allow an additional 5 minutes for each degree To check condition of battery under load.
below 70°F.

Equipment:
7. Start charger at SLOW rate. Increase charge rate
ONE setting at a time. Check charger ammeter • JT05685 Battery Tester
after 1 minute at each setting. Maintain 10 amp
charge rate. Use boost setting as necessary.
Procedure:
8. Check if battery is accepting 10 amp charge rate
after 10 minutes at boost setting. 1. Park machine on level surface.
2. Turn key switch to OFF position.
3. Engage parking brake.
Results:
4. Clean cable ends, battery terminals and top of
• If battery WILL NOT accept 10 amp charge after 10 battery.
minutes at boost setting, replace battery; 5. Remove battery to workbench.
• If battery is accepting 10 amp charge after 10
minutes at boost setting, and battery did NOT
need water, go to Steps 11 and 12; Positive (+)
Negative (-) Terminal DC Volt
• If battery is accepting 10 amp charge after 10 Amperage
Terminal Scale
minutes at boost setting, but battery DID need Scale
water or all cells were BELOW 1.175, go to Steps
9 and 10.
9. Set charger at 15—25 amps.

IMPORTANT: Decrease charge rate if battery gases

or bubbles excessively or becomes too warm to Load Knob
touch.
M49597

10. Check specific gravity after 30 minutes (60 minutes
for maintenance-free battery).
6. Turn load knob counterclockwise to OFF position.
7. Connect tester positive (red) cable to battery
positive (+) terminal.
8. Connect tester negative (black) cable to battery
negative (-) terminal.

4 - 54 1/31/95
TESTS AND ADJUSTMENTS ELECTRICAL

9. Turn load knob of tester clockwise (in) until

amperage reading is equal to:
• cold cranking amperage rating of battery (use blue
scale).

-or- Red Wire

• three times ampere hour rating (use black scale).

10. Hold for 15 seconds and turn load knob of tester
counterclockwise (out) into OFF position.
11. Repeat Steps 8 and 9 above and read condition of
battery at DC Volts scale.
M83494

Results: 7. Connect ammeter in series with red wire (circuit No.

200), or place current gun over wire.
• If battery DOES NOT pass test and has NOT been
charged, charge battery and retest.
• If battery DOES NOT pass test and HAS BEEN DC Voltage Scale
charged, replace battery.

REGULATED AMPERAGE OUTPUT

TEST

Reason:
To determine the amperage output of the charging
system.

Load Knob
Test Equipment:
M83495
• JT05685 Battery Tester
• Current Gun or Ammeter 8. Turn knob of battery tester to OFF position (fully
counterclockwise).
9. Connect red clamp of JT05685 Battery Tester to
Procedure:
positive (+) terminal of battery and black clamp to
frame.
NOTE: The battery should be in good condition and
fully charged before performing test. (See
IMPORTANT: Perform this test as quickly as
BATTERY TEST.)
possible to prevent damage to electrical system
components. DO NOT apply a full load to the
1. Park machine on level surface. battery for more than 10 seconds .
2. Move gearshift pedals to NEUTRAL position.
3. Engage parking brake. 10. Start and run engine at fast idle.
4. Turn key switch to OFF position. 11. Turn load knob until voltage reads 11 VDC.
5. Lower front blade (if equipped). 12. Read and record amperage reading. Amperage
6. Raise rear body cowling. should read a minimum of 13 amps at fast idle.
13. Turn load knob OFF (fully counterclockwise).

Results:
• If the amperage output is below minimum
specification, perform UNREGULATED VOLTAGE
OUTPUT TEST.

1/31/95 4 - 55
ELECTRICAL TESTS AND ADJUSTMENTS

REGULATED VOLTAGE OUTPUT UNREGULATED VOLTAGE OUTPUT

TEST TEST

Reason: Reason:
To determine regulated voltage output of the regulator/ To measure stator voltage output to determine stator
rectifier. condition.

Test Equipment: Test Equipment:

• Voltmeter • Voltmeter

Procedure: Procedure:
1. Park machine on level surface. 1. Park machine on level surface.
2. Turn key switch OFF. 2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position. 3. Move gearshift pedals to NEUTRAL position.
4. Engage parking brake. 4. Engage parking brake.
5. Lower front blade (if equipped). 5. Lower front blade (if equipped).
6. Raise rear body cowling. 6. Raise rear body cowling.
7. Remove battery cover.
8. Remove surface charge from battery by placing a
small load on the battery for 15 seconds.
9. Set voltmeter for 25 or 50 DC volt scale.

Positive Terminal Negative Terminal

Stator Wire
Leads

M83182

7. Disconnect stator wire leads.

M83472
10. Connect meter red lead to battery positive (+)
terminal.
11. Connect meter black lead to battery negative (-)
terminal.
12. Start and run engine at fast idle.
13. Read meter several times during 5 minutes of
running time. Voltage should remain between
12.2—14.7 volts DC.
8. Set voltmeter to 50 volt AC scale.
9. Connect meter leads to engine side of stator wire
leads.
10. Start and run engine at fast idle.
11. Measure stator voltage. Voltage should read a
minimum of 34 volts AC.
Results:
• If voltage is less than specifications, test flywheel
magnet and then replace stator. (See FLYWHEEL
MAGNET TEST.)

Results:
• If the DC voltage remains below the minimum
specification, test unregulated voltage output. (See
UNREGULATED VOLTAGE OUTPUT TEST.)
• If the DC voltage goes above the maximum
specification, replace the regulator/rectifier.

4 - 56 1/31/95
TESTS AND ADJUSTMENTS ELECTRICAL

STARTER SOLENOID TES T STARTER LOADED AMPERAGE

DRAW TEST
Reason:
To determine if the starter solenoid or starter motor is Reason:
defective. To determine the amperage required to crank the
engine and check the starter motor operation under
load.
Test Equipment:
• Jumper Wire
Test Equipment:
• JT05685 Battery Tester
Procedure:
• JT05719 Photo Tachometer
1. Park machine on level surface.
2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position. Procedure:
4. Engage parking brake. 1. Park machine on level surface.
5. Lower front blade (if equipped). 2. Turn key switch OFF.
6. Raise rear body cowling. 3. Move gearshift pedals to NEUTRAL position.
7. Remove spark plug high tension lead and ground to 4. Engage parking brake.
engine. 5. Test system ground connections. (See GROUND
CIRCUIT TEST procedure.)
Battery Terminal 6. Test battery. (See BATTERY TEST procedure.)

Starter Terminal

Solenoid Terminal
DC Amperage Scale
Purple/White Wire
M83170 DC Voltage Scale

8. Disconnect purple/white wire No. 745 from starter

solenoid terminal.
9. Connect jumper wire to positive battery terminal Load Knob
and briefly jump to starter terminal.
Reflective Tape

Results:
• Starter runs: solenoid is good, check circuit wiring.
(See CRANKING CIRCUIT DIAGNOSIS.)
• Starter does not run: go to Step 9.
10. Remove black rubber boot from battery terminal.
11. Connect jumper wire between starter solenoid
terminal and battery terminal.
Results:
• Starter runs: Replace solenoid.
• Starter does not run: Check battery cables, then
replace starter.
M83473
7. Turn knob of battery tester to OFF position (fully
counterclockwise).
8. Connect red clamp of JT05685 Battery Tester to
positive (+) terminal of battery and black clamp to
negative (-) terminal of battery.
9. Remove flywheel screen and install tachometer
reflective tape on flywheel screen.
10. Remove spark plug high tension lead and ground
to engine.
11. Crank engine and read voltage on DC voltage scale
of Battery Tester and check engine rpm using
JT05719 Photo Tachometer.
12. Turn key switch to OFF position.

1/31/95 4 - 57
ELECTRICAL TESTS AND ADJUSTMENTS

IMPORTANT: Perform the following procedure

within 15 seconds to prevent electrical damage
to components.

13. Turn knob on Battery Tester clockwise until the DC

voltage is the same as when cranking.
14. Read DC amperage on Battery Tester. Maximum Red Wire
starter amperage draw should be 51 amps at 750
rpm.

Results:
• If amperage is above specification, or cranking rpm
is low, test starter no-load rpm and amperage.
(See procedure in ENGINE section.)
M83494

9. Turn key switch to RUN position.

LIFT MOTOR AMPERAGE DRAW
10. Raise rear implement and record amperage
TEST reading.
11. Lower rear implement and record amperage
reading.
Reason:
To determine the condition of the lift motor and actuator
assembly. Specifications:

Test Equipment: Amperage Draw

• Current Gun or Ammeter Raise (No Load) . . . . . . . . . . . . . . . . . . . . 3—6 amps
Lower (No Load) . . . . . . . . . . . . . . . . . . . . 3—4 amps
Raise (Maximum Load) . . . . . . . . . . . . . . . . 28 amps
Procedure:

Results:
NOTE: The battery should be in good condition and
fully charged before performing test. (See
BATTERY TEST.)
1. Park machine on level surface.
2. Move gearshift pedals to NEUTRAL position.
3. Engage parking brake.
4. Lower rear implement to the ground.
5. Turn key switch to OFF position.
6. Lower front blade (if equipped).
7. Raise rear body cowling.
8. Connect ammeter in series with lift circuit power
lead (Red wire with in-line fusible link), or place
current gun over lead.
• If amperage is below specifications and unit does
not lift, check for stripped gears or worn clutch.
• If amperage is zero, check control circuit or fusible
link. If control circuit and fusible link are OK, and
motor will not run, thermal protector or motor may
be defective. Replace motor.
• If amperage is above specification, check lift
actuator gears, worm gears or bearings for
binding, causing excessive load.
• Repair or replace lift actuator.

4 - 58 1/31/95
TESTS AND ADJUSTMENTS ELECTRICAL

IGNITION MODULE TES T 4. Engage parking brake.

5. Remove blower housing. (See procedure in
ENGINE section.)
Reason: 6. Rotate flywheel so magnet is away from coil.
To determine if the ignition module is defective.

Procedure:
1. Park machine on level surface.
2. Move gearshift pedals to NEUTRAL position.
3. Engage parking brake.
4. Turn key switch to OFF position.
5. Lower front blade (if equipped).
6. Raise rear body cowling.

M45476

Ignition Module 7. Hold a steel tool about 25 mm (1.0 in.) from

flywheel magnet. The tool should be attracted by
the magnet.

Results:
• Replace the flywheel if tool is not attracted to
magnet.

M83183
KEY SWITCH TES T
7. The ignition module is very sensitive to the type of
meter used to check resistance. Due to variations
in meters, the best way to determine if the ignition Reason:
module is good is to replace the questionable To verify proper operation of key switch.
ignition module with a known good module.

Test Equipment:
Results:
• Ohmmeter or Continuity Tester
• If the new ignition module does not solve the
problem, check other ignition components.
Procedure:
1. Park machine on level surface.
FLYWHEEL MAGNET TES T
2. Turn key switch to OFF position.
3. Move gearshift pedals to NEUTRAL position.
Reason: 4. Engage parking brake.
To make sure the flywheel magnet has enough force to 5. Remove dash panel. (See procedure in
induce current in the ignition coil. MISCELLANEOUS section.)
6. Disconnect wiring connector from switch.

Procedure:

NOTE: This is a rough test and should only be used to

determine flywheel magnet strength only if no
other cause for weak or no spark is found.

1. Park machine on level surface.

2. Turn key switch to OFF position.
3. Move gearshift pedals to NEUTRAL position.

1/31/95 4 - 59
ELECTRICAL TESTS AND ADJUSTMENTS

A
C

Terminals

F D
E M83171 M83172

7. Use an ohmmeter or continuity tester to test switch 8. Check continuity across terminals. There should be
continuity in OFF, RUN and START positions. continuity.
9. Depress and hold forward or reverse pedal to
engage transaxle.
NOTE: DO NOT refer to markings stamped on
10. Check continuity across terminals. There should be
terminals. Identify by art keys ONLY. Terminal
no continuity.
combinations other than those listed should
not have continuity.
Results:
Key Switch Continuity: • If continuity is not correct, replace switch and
repeat test.
• If after replacing switch, there is still no continuity
Switch Position Terminal Continuity when the transaxle is in the NEUTRAL position,
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C and D inspect transaxle linkage.
RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E and F
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E and F
A and B
LIFT SWITCH TES T

Results: Reason:
To verify that the lift switch is operating properly.
• If any continuity is NOT correct, replace the switch.

Test Equipment:
NEUTRAL START SWITCH TES T
• Ohmmeter or Continuity Tester

Reason:
Procedure:
To verify that the neutral start switch has continuity
when the transaxle is in neutral. 1. Park machine on level surface.
2. Turn key switch to OFF position.
3. Move gearshift pedals to NEUTRAL position.
Test Equipment: 4. Engage parking brake.
• Ohmmeter or Continuity Tester 5. Remove dash panel. (See procedure in
MISCELLANEOUS section.)
6. Disconnect lift switch connector.
Procedure:
1. Park machine on level surface.
2. Turn key switch to OFF position.
3. Move gearshift pedals to NEUTRAL position.
4. Engage parking brake.
5. Lower front blade (if equipped).
6. Raise rear body cowling.
7. Disconnect transaxle neutral start switch connector.

4 - 60 1/31/95
TESTS AND ADJUSTMENTS ELECTRICAL

Terminal 30
Terminal 86

A
Terminal 87
B

Terminal 87A
C
M83177 M56817
Terminal 85
7. With switch in LIFT position, use an ohmmeter or 5. Check terminal continuity using an ohmmeter or
continuity tester to check for the following: continuity tester.
• Continuity exists between terminals (B and C).
• NO continuity exists between terminals (A and B).
Results:
8. With switch in LOWER position, use an ohmmeter
or continuity tester to check for the following: • There should be continuity between terminals 87A
and 30, and between terminals 85 and 86.
• Continuity exists between terminals (A and B).
• There should NOT be continuity between terminals
• NO continuity exists between terminals (B and C).
87 and 30.
6. Connect a jumper wire from battery positive (+)
Results: terminal to relay terminal 85. Connect a jumper
wire from relay terminal 86 and ground (-).
• If switch fails any part of Steps 7 and 8, replace
switch.
Results:
RELAY TEST • There should be continuity between terminals 87
and 30.
• If continuity is NOT correct, replace relay.
Reason:
To check relay terminal continuity in the energized and
de-energized condition.

Equipment:
• Ohmmeter or Continuity Tester

Procedure:
1. Park machine on level surface.
2. Turn key switch to OFF position.
3. Engage parking brake.
4. Disconnect relay connector from harness.

1/31/95 4 - 61
ELECTRICAL REPAIR

REPAIR 3. Disconnect wiring connector.

LIFT ACTUATOR

Removal/Installatio n

NOTE: Lift actuator mounting position and orientation

Nut
may vary depending on the implement being
used. (See ATTACHMENTS section.)

1. Remove rear implement. (See ATTACHMENTS

section.)
2. Raise lift bar to full UP position.

Wiring Connector
Nut M83112AE

4. Remove nuts.
5. Remove lift actuator.

Installation is done in the reverse order of removal .

M83111

4 - 62 2/9/95
REPAIR ELECTRICAL

Disassembly/Assembl y

Flange Nut
Cap
Screw

Motor

Actuator
Screw
Assembly
Cap Screw (4 used)
8 N•m (70 lb-in.)

Retaining Plate

Upper
Pin
Gear
Gasket
Housing

Nut (2 used)
Seal 8 N•m (70 lb-in.)

Thrust Washer

Clutch Intermediate Gear

Cover Tube
Thrust Washer Gasket

Lower Gear Housing

Screw
2.3 N•m (20 lb-in.)
O-Ring

Flange Nut
Cap Screw
M83131AE

NOTE: Remove seal only if replacement is necessary. IMPORTANT: When replacing motor, note direction
(See Cover Tube Seal Replacement that the motor is installed. Intermediate gear
procedure.) should ride close to the center of motor gear .

• Inspect all parts for wear or damage. Replace parts • Install new gaskets.
as necessary.

Assembly is done in the reverse order of

disassembly.

2/9/95 4 - 63
ELECTRICAL REPAIR

Cover Tube Seal Replacemen t CONNECTOR BODY—BLADE

TERMINALS
Cap Screw (4 used) Replacement
8 N•m (70 lb-in.)

Retaining Flange
Plate Nut

Gasket
Cap Screw
Seal Locking Tang

Cover
Tube Original Position RW4218

Use a small screwdriver to depress locking tang

terminal. Slide connector body off.
Be sure to bend locking tang back to its original
position before installing connector body.

O-Ring

M83134AE

1. Remove cover tube.

2. Remove seal from tube cover using a disk and
driver set.
3. Install seal and O-ring until flush with end of tube.
4. Install cover tube using new gasket.

4 - 64 2/9/95
REPAIR ELECTRICAL

METRO-PACK CONNECTORS

Removal

Mounting Post (Optional)

Sleeve Body Wire Retainer

Wire Retainer

Pin Body

Pin
SHURE-SEAL
SHURE-SEAL Sleeve
M56685

IMPORTANT: Identify wire number/color locations

with connector terminal letters.

M56684

2. Remove retainer on wire end of connector with a

screwdriver.
M56682

1. Open connector body.

2/9/95 4 - 65
ELECTRICAL REPAIR

Replacement
Locking Tang 1. Remove wire from connector.

Insert
Tool
Here

Sleeve Contact M83501

TSO132

Locking Tang 2. Use JDG145 Universal Electrical Pliers to cut wire

as close as possible to connector.

IMPORTANT: METRO-PACK connectors are

"keyed" (A, B, C, etc.) for proper contact mating.
Be sure contacts and wire color numbers match
and are in proper alignment.
Insert
Tool Here Pin Contact M83502

IMPORTANT: Insertion of the tool in the correct

location is critical when removing contact from
connector body. Incorrect insertion can damage
connector.

NOTE: To remove sleeve contact from sleeve body

(short connector half) insert tool in slot
between terminal contact and connector body.
To remove pin contact from body (long TSO136
connector half) insert tool in center of contact.

3. Use JDG777 Terminal Removal Tool to depress NOTE: Cables seals are available for three sizes of
locking tang. Remove contact from connector wire:
body.

• Large - 1.0 mm (16 gauge) wire

• Medium - 0.8 mm (18 gauge) wire
• Small - 0.5 mm (20 gauge) wire
3. Remove enough insulation to expose 6 mm (0.25
in.) of wire. Align cable seal with edge of
insulation.

M56689

4. Hold the removal tool fully seated and pull wire from
connector body.

4 - 66 2/9/95
REPAIR ELECTRICAL

M56686 M56689

4. Place proper size contact on wire and use JDG776 6. Push contact into new connector body until fully
Crimper to crimp contact in place with a "W" type seated.
crimp. 7. Pull on wire slightly to be certain terminal is locked
in place.
8. Install wire retainer.

M56687

5. Use JDG776 Crimper to secure cable seal to M56683

contact as shown.
9. Transfer remaining wires to correct terminal in new
connector.
10. Place retainer on wire end of connector and snap in
place.
Barb 11. Close connector body.

Pin

Sleeve
Barb
(Inside)
M56688

IMPORTANT: Proper barb location and orientation

for installation of "sleeve" and "pin" is shown .

NOTE: Connector bodies are "keyed" for proper

contact mating. Be sure contacts are in proper
alignment.

2/9/95 4 - 67
ELECTRICAL REPAIR

This page intentionally left blank.

4 - 68 2/9/95
CONTENTS GEAR POWER TRAIN

CONTENTS
Page

GEAR POWER TRAIN

SPECIFICATIONS
TEST AND ADJUSTMENT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . 5-2
REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
COMPONENT LOCATION AND OPERATION
CLUTCH SYSTEM COMPONENT
LOCATION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
TRANSAXLE COMPONENT LOCATION
AND OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
DIAGNOSIS
LACK OF DRIVE—ONE DIRECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
LACK OF DRIVE—BOTH DIRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
VEHICLE CREEPS—IN GEAR AT IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
JERKY OR AGGRESSIVE ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
SLOW ERRATIC ACCELERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
PREMATURE BELT WEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
DIFFERENTIAL LOCK WILL NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . 5-15
CHECKS, TESTS AND ADJUSTMENTS
DRIVE BELT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
GEARSHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
DRIVE TRAIN PERFORMANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
DRIVEN CLUTCH SPRING TORSION CHECK . . . . . . . . . . . . . . . . . . . . . . 5-18
REPAIR
DIFFERENTIAL LOCK PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . 5-19
GEARSHIFT PEDALS AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
DRIVEN PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

2/2/95 5-1
GEAR POWER TRAIN SPECIFICATIONS

SPECIFICATIONS

TEST AND ADJUSTMENT SPECIFICATIONS

Drive Belt Width (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 mm (1.0625 in.)
Drive (Primary) Clutch Engagement Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550 rpm
Vehicle Driving Check:
Standing Start Through 15.2 m (50 ft.) Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Seconds
Standing Start Through 30.5 m (100 ft.) Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 Seconds
Travel Time Through 30.5 m (100 ft.) (at full throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Seconds
Driven (Secondary) Clutch Spring Torsion Standard Wrap. . . . . . . . . . . . . . . . . . . . . . . 22—40 N (5—9 lb)

REPAIR SPECIFICATIONS

Drive (Primary) Clutch

Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Spider Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 N•m (100 lb-ft)

Driven (Secondary) Clutch

Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft)

Transaxle
Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L (2.5 qt.)
Axle Shaft Bearing Carriage Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (216 lb-in.)
Transaxle-to-Frame Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Transaxle Case Cap Screw Torque
Same Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (228 lb-in.)
New Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 N•m (21 lb-ft)
Neutral Start Switch Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
Breather Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (90 lb-in.)
Shift Shaft
Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (228 lb-in.)
Shift Shaft O.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.96—17.00 mm (0.668—0.669 in.)
Shift Shaft Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.02—17.04 mm (0.670—0.671 in.)
Shift Shaft-to-Bore Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.01 in.)
Shift Block Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7—13.9 mm (0.54—0.55 in.)
Shift Block-to-Collar Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in.)

5-2 5/11/95
SPECIFICATIONS GEAR POWER TRAIN

REPAIR SPECIFICATIONS, continued

Input Shaft Assembly
Drive Gear Washer Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45—1.55 mm (0.057—0.061 in.)
Reverse Sprocket Washer Thickness. . . . . . . . . . . . . . . . . . . . . 1.55—1.65 mm (0.061—0.064 in.)
Drive Gear I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.01—24.02 mm (0.945—0.946 in.)
Input Shaft O.D. (Reverse Gear) . . . . . . . . . . . . . . . . . . . 19.987—20.00 mm (0.7868—0.7874 in.)
Input Shaft O.D. (Driver Gear) . . . . . . . . . . . . . . . . . . . . . . . . 19.99—20.01 mm (0.787—0.788 in.)
Reverse Sprocket I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.01—24.02 mm (0.945—0.946 in.)
Shift Collar Groove Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1—14.3 mm (0.55—0.56 in.)
Detent Spring
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.2 mm (0.95 in.)
Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0 mm (0.79 in.)
Working Load Length . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8 mm at 53 N (0.62 in. at 12 lb)
Differential Assembly
Differential Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (19 lb-ft)
Differential Lock Collar Groove Width . . . . . . . . . . . . . . . . . . . . . . . . 7.1—7.3 mm (0.28—0.29 in.)
Washer Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.74—0.86 mm (0.28—0.29 in.)
Bevel Pinion Washer Thickness . . . . . . . . . . . . . . . . . . . . . . . . . 0.96—1.04 mm (0.038—0.041 in.)
Bevel Pinion I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.03—16.05 mm (0.631—0.632 in.)
Pinion Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95—15.97 mm (0.628—0.629 in.)
Pinion Shaft-to-Bevel Pinion Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.01 in.)
Differential Lock Shaft
Lock Fork Finger Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7—6.9 mm (0.26—0.27 in.)
Lock Fork-to-Shift Lock Collar Groove Clearance (Maximum) . . . . . . . . . . . . . . . . 2.0 mm (0.08 in.)
Lock Fork I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.05—20.10 mm (0.789—0.791 in.)
Differential Lock Shaft O.D. (at fork seating area) . . . . . . . . . 19.95—20.00 mm (0.785—0.787 in.)
Lock Fork I.D.-to-Lock Shaft O.D. Clearance (Maximum). . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.)
Differential Lock Spring
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.6 mm (3.06 in.)
Working Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 mm at 511 N•m (2.07 in. at 115 lb.)

SPECIAL OR ESSENTIAL TOOLS

JDG813-1 Clutch Removal Tool
Used to remove primary clutch.
JDG813-2 Spanner Wrench
Used to disassemble primary clutch.
JDG813-3 Tapered Holding Tool
Used to hold primary clutch while performing service.

5/11/95 5-3
GEAR POWER TRAIN SPECIFICATIONS

OTHER MATERIALS
Number Name Use
M79292 MPG-2 Polymer Multipurpose Grease Prevents parts from seizing.
Apply to transaxle axles shafts.
TY22034 John Deere SuperLube Apply to rollers and cam weight
pivots of drive clutch.

LOCTITE PRODUCTS
U.S./
Canadian/
LOCTITE No.
Number Name Use
T43512/ Thread Lock and Sealer Apply to various fasteners.
TY9473/242 (Medium Strength)
TY6305/ Clean and Cure Primer Clean transmission case mating
TY9485/ surfaces.
764
TY6304/ Flexible Sealant Seal transmission case.
TY94854/
518

SERVICE PARTS KITS

The following kits are available through your parts catalog:
• Clutch Button and Roller Kit
• Clutch Pivot Bolt Kit
• Clutch Cam Arm Kit

 MPG-2 is a registered trademark of DuBois USA.

 LOCTITE is a registered trademark of the Loctite Corp.

5-4 5/11/95
COMPONENT LOCATION AND OPERATION GEAR POWER TRAIN

COMPONENT LOCATION AND OPERATION

CLUTCH SYSTEM COMPONENT LOCATION AND OPERATION

Up-Shifting Back-Shifting
Minimum Load Increasing Load

Spring

Wear Buttons

Driven
(Secondary) Ramp
Clutch

Moveable Sheave
Engagement RPM
Low Output Speed

High Rpm

Drive
(Primary)
Flyweights
Clutch
M56089

Function: High Engine RPM, Light Load, High

To transmit engine power to the transaxle.
Theory of Operation:
The variable clutch system is speed and load sensitive.
The primary and secondary clutches work together,
automatically up-shift and back-shift. This shifting
changes the ratio between the clutches, allowing the
engine to operate at optimum efficiently, at the peak of
its power curve.
The primary drive clutch is mounted on the engine
crankshaft and operates on the principle of centrifugal
force, and is sensitive to engine speed. The secondary
clutch, mounted on the transaxle input shaft is load
sensitive.
Engagement RPM, Minimum Load,
Low Output Speed
Primary clutch sheaves are moving closer together, just
starting to move the drive belt. Belt is running at the top
of the secondary clutch. A high ratio between the
clutches exists, similar to a low gear as long as there is
a minimum load.
Output Speed
As engine speed increases, centrifugal force acting on
the flyweights force the primary clutch to upshift,
moving the belt to the outer pulley diameter,
overcoming secondary clutch spring. The belt is then
pulled deep into the secondary clutch resulting in a low
ratio, similar to a high gear.
High Engine RPM, Increasing Load,
Lower Output Speed
Back-shifting occurs as a load such as a hill or soft
terrain is encountered. The stationary side of the
secondary clutch resists forward movement of the
wheels, at the same time, torque from the belt moves
the movable sheave up the ramp. The ramp and spring
forces the belt to the outside diameter of the secondary
clutch and overcomes centrifugal forces of the primary
clutch causing back-shifting.

2/2/95 5-5
GEAR POWER TRAIN
TRANSAXLE COMPONENT
LOCATION AND OPERATION
Function:
The transaxle provides:
• A means for shifting into forward, neutral and
reverse.
• Differential action between axles for turning.
• Differential lock, allowing axles to be locked
together for better traction.
Theory of Operation:
Neutral:
In neutral the shift levers centers the shift collar
between the forward and reverse gears so that neither
are engaged. The input shaft rotates freely and no
power is transferred to the intermediate shaft.
In this position, the shift fork engages the neutral start
switch. The switch will allow the engine to be started
only when the transaxle is in neutral.
Forward Power Flow:
Power to the transaxle is supplied by the clutch
system. The driven clutch is splined to the transaxle
input shaft. Splined to the input shaft is the shift collar.
5-6
COMPONENT LOCATION AND OPERATION
When the transaxle is shifted to the forward position,
the shift collar engages the forward gear. Power is
transmitted from the input shaft through the shift collar,
forward drive gear, forward driven gear to the
intermediate shaft. A gear on the intermediate shaft is
in constant mesh with the differential gear. The
differential gear and housing rotate together
transmitting power through the bevel and pinion gears
to the axles.
Reverse Power Flow
When shifted into reverse, the shift collar engages the
reverse sprocket and transmits power through the
reverse chain and driven sprocket to the intermediate
shaft. The chain drives the intermediate shaft in the
opposite direction from forward gear, rotating the
differential gear in the reverse direction. Power is
transmitted through the differential to the axle.
Differential Lock
The differential lock is engaged by depressing the
pedal at the operators station. As the pedal is
depressed, the differential lock shaft turns. As the shaft
turns, the shaft pins ride against the locking fork cam
and push the locking collar and pins inward.
The locking pins slide into the bevel gear. This locks
the differential gears to the housing resulting in both
axles turning the same speed. As the pedal is
released, the pedal return spring disengages the
locking collar by pushing the fork outward.
2/2/95
COMPONENT LOCATION AND OPERATION GEAR POWER TRAIN

Neutral
Start Switch

Shift Fork
Reverse
Drive Chain
Shift Collar
Reverse
Drive Sprocket
Reverse
Driven Sprocket

Transaxle
Forward Input Shaft
Driven Gear
Shaft Pin

Differential
Lock Shaft
Intermediate Shaft

Locking Collar
Bevel Gears

Differential
Drive Gear
Differential Locking
Housing Collar Pins Output Shaft
M83135A

2/2/95 5-7
GEAR POWER TRAIN TROUBLESHOOTING CHART

TROUBLESHOOTING CHART
Problem or

Jerky or aggressive

Differential lock will

Symptom

Vehicle creeps in
Noisy operation.
both directions.
Lack of drive —

Lack of drive —

Premature belt
one direction.

engagement.

acceleration.
Check or

not operate.
Slow erratic
gear at idle.
Solution

wear.
Gearshift linkage not adjusted
● ●
properly.

Transaxle internal components

● ● ● ●
worn or damaged.

Gearshift linkage damaged. ● ●

Control arm spring pin damaged

●
or missing.

Drive belt worn or broken. ● ● ● ● ●

Drive clutch components worn or

● ● ● ● ● ●
damaged.

Axle bearings worn or not

● ●
properly lubricated.

Engine slow idle speed too high. ●

Driven clutch components worn or

● ● ●
damaged.

Vehicle overloaded. ● ●

Differential control linkage loose. ●

5-8 5/11/95
DIAGNOSIS GEAR POWER TRAIN

DIAGNOSIS

LACK OF DRIVE—ONE DIRECTION

Test Conditions:

• Engine OFF. • Parking brake ENGAGED.

• Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

1. Gearshift linkage. Linkage shifts transaxle into Perform GEARSHIFT LINKAGE

Forward, Neutral and Reverse when ADJUSTMENT.
pedals are depressed.
Linkage not damaged. Repair or replace damaged
components.

Test Conditions:

• Gearshift linkage disconnected at transaxle control

lever.

Test/Check Point Normal If Not Normal

2. Transaxle. Internal components not worn or Repair or replace worn or damaged

damaged. components.

LACK OF DRIVE—BOTH DIRECTIONS

Test Conditions:

• Engine operating at slow idle. • Rear wheels supported securely off floor.
• Gearshift pedals in FORWARD or REVERSE
position.

Test/Check Point Normal If Not Normal

1. Drive clutch. Engages at proper engine rpm. Repair or replace drive clutch.
(Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.

Continued on next page.

5/11/95 5-9
GEAR POWER TRAIN DIAGNOSIS

LACK OF DRIVE—BOTH DIRECTIONS, continued

Test Conditions:

• Engine OFF. • Parking brake ENGAGED.

• Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

2. Drive belt. Belt in good condition. Minimum Replace drive belt.

width 27 mm (1.0625 in.)

3. Gearshift linkage. Linkage not damaged. Repair or replace damaged

components.

4. Control Arm. Spring pin not damaged or missing. Replace spring pin in control arm.

5. Transaxle. Transaxle oil filled to check hole Fill to correct level with John Deere
level. 85W140 API GL-5 gear oil.
Internal components not worn or Repair or replace worn or damaged
damaged. components.

NOISY OPERATION

Test Conditions:

• Engine operating at slow idle. • Rear wheels supported securely off floor.
• Gearshift pedals in FORWARD or REVERSE
position.

Test/Check Point Normal If Not Normal

1. Drive clutch. Engages at proper engine rpm. Repair or replace drive clutch.
(Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.

2. Driven clutch.
Completely up-shifts and back-shift Repair or replace driven clutch.
as engine is accelerated and
decelerated. (Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.

Continued on next page.

5 - 10 5/11/95
DIAGNOSIS GEAR POWER TRAIN

NOISY OPERATION, continued

Test Conditions:

• Engine OFF. • Parking brake ENGAGED.

• Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

3. Drive belt. Belt in good condition. Minimum Replace belt.

width 27 mm (1.0625 in.)

Test Conditions:

• Rear wheels supported securely off floor. • Parking brake RELEASED.

Test/Check Point Normal If Not Normal

4. Axle bearings. Rotates smoothly with little or no end Lubricate bearings.

play.
Bearings not worn or damaged. Replace if worn or damaged.

VEHICLE CREEPS—IN GEAR AT IDLE

Test Conditions:

• Engine operating at slow idle. • Rear wheels supported securely off floor.
• Gearshift pedals in FORWARD or REVERSE
position.

Test/Check Point Normal If Not Normal

1. Engine. Engine slow idle speed adjusted to Perform SLOW IDLE SPEED
specifications. ADJUSTMENT. (See procedure in
ENGINE section.)

2. Drive clutch. Engages at proper engine rpm. Repair or replace drive clutch.
(Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.

Continued on next page.

5/11/95 5 - 11
GEAR POWER TRAIN DIAGNOSIS

VEHICLE CREEPS—IN GEAR AT IDLE, continued

Test Conditions:

• Engine OFF. • Parking brake ENGAGED.

• Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

3. Drive belt. Belt in good condition and within New belt can cause slight creeping.
specifications.

4. Gearshift linkage. Linkage properly adjusted. Perform GEARSHIFT LINKAGE

ADJUSTMENT.

JERKY OR AGGRESSIVE ENGAGEMENT

Test Conditions:

• Engine operating at slow idle. • Rear wheels supported securely off floor.
• Gearshift pedals in FORWARD or REVERSE
position.

Test/Check Point Normal If Not Normal

1. Drive clutch. Engages at proper engine rpm. Repair or replace drive clutch.
(Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.

Test Conditions:

• Engine OFF. • Parking brake ENGAGED.

• Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

2. Drive belt. Belt in good condition. Minimum Replace drive belt.

width 27 mm (1.0625 in.)

5 - 12 5/11/95
DIAGNOSIS
SLOW ERRATIC ACCELERATION
Test Conditions:
• Vehicle on level surface.
• Engine running.
Test/Check Point
1. Vehicle performance.
Test Conditions:
• Engine operating at slow idle.
• Gearshift pedals in FORWARD or REVERSE
position.
Test/Check Point
2. Drive clutch.
3. Driven clutch.
Continued on next page.
5/11/95
GEAR POWER TRAIN
• Gearshift pedals in FORWARD or REVERSE
position.
• Attachments RAISED.
Normal If Not Normal
Vehicle upshifts smoothly with Vehicle pulling/pushing power
operator and pulling load added to exceeded. Reduce load to vehicle.
vehicle.
• Rear wheels supported securely off floor.
Normal If Not Normal
Engages at proper engine rpm. Repair or replace drive clutch.
(Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.
Completely up-shifts and back- Repair or replace driven clutch.
shifts as engine is accelerated and
decelerated. (Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.
5 - 13
GEAR POWER TRAIN DIAGNOSIS

SLOW ERRATIC ACCELERATION, continued

Test Conditions:

• Engine OFF. • Parking brake ENGAGED.

• Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

4. Drive belt. Belt in good condition and within Replace drive belt.
specifications.

5. Transaxle. Transaxle oil filled to check hole Fill to correct level with John Deere
level. 85W140 API GL-5 gear oil.
Internal components not worn or Repair or replace worn or damaged
damaged. components.

6. Axle bearings. Rotates smoothly with little or no end Lubricate bearings.

play. Replace if worn or damaged.
Bearings not worn or damaged.

PREMATURE BELT WEAR

Test Conditions:

• Vehicle on level surface. • Gearshift pedals in FORWARD or REVERSE

• Engine running. position.
• Attachments RAISED.

Test/Check Point Normal If Not Normal

1. Vehicle performance. Vehicle upshifts smoothly with Vehicle pulling/pushing power

operator and pulling load added to exceeded. Reduce load to vehicle.
vehicle.

Continued on next page.

5 - 14 5/11/95
DIAGNOSIS GEAR POWER TRAIN

PREMATURE BELT WEAR, continued

Test Conditions:

• Engine operating at slow idle. • Rear wheels supported securely off floor.
• Gearshift pedals in FORWARD or REVERSE
position.

Test/Check Point Normal If Not Normal

2. Drive clutch. Engages at proper engine rpm. Repair or replace drive clutch.
(Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.

3. Driven clutch. Completely up-shifts and back- Repair or replace driven clutch.
shifts as engine is accelerated and
decelerated. (Perform DRIVE TRAIN
PERFORMANCE TESTS.)
Not worn or damaged.

DIFFERENTIAL LOCK WILL NOT OPERATE

Test Conditions:

• Engine OFF. • Parking brake ENGAGED.

• Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

1. Differential control linkage. Linkage installed correctly and Repair or replace linkage as
hardware secure. necessary.
Linkage not damaged.

2. Transaxle. Internal components not worn or Repair or replace worn or damaged

damaged. components.

5/11/95 5 - 15
GEAR POWER TRAIN CHECKS, TESTS AND ADJUSTMENTS

CHECKS, TESTS AND Procedure:

ADJUSTMENTS 1. Park machine on level surface.
2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position.
DRIVE BELT CHECK Engage parking brake.

Reason:
To check belt wear and condition of belt.

Tie Rod End

Procedure:
1. Park machine on level surface.
2. Turn key switch OFF. Jam Nut
3. Move gearshift pedals to NEUTRAL position.
Engage parking brake.
4. Lower front blade (if equipped). Cap Screw and Nut M83492
5. Raise rear body cowling.
4. Remove cap screw and nut to disconnect shift rod
at pedal assembly.
5. Lower front blade (if equipped).
6. Raise rear body cowling.
Ruler 7. Verify that the transaxle is in NEUTRAL position.

Forward Pedal

Guide
M83320

6. Measure belt width. Belt must not be less than 27

mm (1.0625 in.).
7. Check drive belt condition. Belt must not be glazed
or cracked.
M83359

Results: 8. Align forward pedal even with guide.

• If belt is less than specification, replace. 9. Loosen jam nut.
• If belt is within specifications, and there is a 10. Rotate tie rod end until it aligns with hole in pedal
performance complaint, check clutches and assembly.
perform POWER TRAIN PERFORMANCE 11. Install and tighten cap screw and nut.
TESTS. 12. Tighten jam nut.

GEARSHIFT LINKAGE DRIVE TRAIN PERFORMANCE

ADJUSTMENT TESTS

Reason: Engagement and Full Up-Shift

To insure gearshift pedals are at the proper height Check
when transaxle is in neutral.
To insure both forward and reverse gears will be
completely engaged. Reason:
To determine if the engine and drive train are operating
at peak performance.

5 - 16 2/9/95
CHECKS, TESTS AND ADJUSTMENTS
Procedure:
NOTE: Engine slow and fast idle speed must be set to
specifications before performing tests. (See
procedure in ENGINE section.)
1. Park machine on level surface.
2. Move gearshift pedals to NEUTRAL position.
Engage parking brake.
3. Inspect drive belt. Belt should be in good condition
and within specification.
4. Lower front blade (if equipped).
5. Raise rear body cowling.
6. Start and run engine at MEDIUM idle for 5 minutes
to heat engine oil to normal operating temperature.
Gap Closed
M83493
7. Start engine. Slowly increase engine rpm. Observe
engine rpm when clutch starts to grab and move
belt (Engagement).
8. Accelerate from idle to wide-open throttle and back
to idle several times. Watch belt for smooth
transition from bottom to of primary clutch. Watch
closely for any hesitation or engine surging.
Observe gap between drive (primary) clutch
movable sheave and stationary sheave. Gap
should close completely.
9. When approaching idle, watch for a positive
disengagement from belt.
NOTE: On clutches with some hours of use, system
may not disengage as smoothly due to drive
clutch spring taking a set and other wear in the
drive components.
10. Shut engine off.
Results:
• Clutch should slowly start to engage and move
primary belt at 1550 rpm. Belt should be riding high
in the primary clutch and low in secondary clutch.
• Clutch has harsh engagement, erratic transition or
hesitation or clutch noise (chirping), perform
primary clutch lubrication. Check primary clutch
2/9/95
GEAR POWER TRAIN
for; flyweights binding, pivot pins worn, flat spots
on roller or rollers sticking. No groove in sheave.
Repair or replace primary clutch as necessary.
• Engine surging, check engine and governor
performance.
• Smooth engagement and transition (upshift). Drive
clutch is good. Perform Driven (Secondary) Clutch
Back-Shifting Check.
Driven (Secondary) Clutch Back-
Shifting Check
Reason:
To determine condition of driven clutch and back-
shifting performance.
Test Equipment:
• JT05719 Hand-Held Digital Tachometer
Procedure:
c CAUTION
Rear wheels will rotate during test. Keep clear.
1. Park machine on level surface.
2. Turn key switch OFF.
3. Move gearshift pedals to NEUTRAL position.
4. Lift machine high enough to raise rear wheels of the
floor. Support with jackstands.
5. Lower front blade (if equipped).
6. Raise rear body cowling.
7. Engage differential lock.
8. Start and run engine at full throttle.
9. Read engine rpm using a JT05719 Hand-Held
Digital Tachometer.
Results:
• Engine and wheel speed should remain at constant
speed. Belt should be riding high in the drive
(primary) clutch and low in the driven (secondary)
clutch.
10. Momentarily load power train by slowly applying
brake until down shift is made.
11. Quickly observe engine speed and release the
brake.
5 - 17
GEAR POWER TRAIN CHECKS, TESTS AND ADJUSTMENTS

Results: DRIVEN CLUTCH SPRING TORSION

• Clutches should back-shift as load is increased. CHECK
• Drive belt should not squeal or slip.
• If engine speed drops below 3000 rpm or if clutches
do not back-shift, perform DRIVEN CLUTCH Reason:
SPRING TORSION CHECK. To verify condition and spring adjustment of driven
clutch.

Driving Check
Test Equipment:
• Spring scale.
Reason:
To determine operating performance of vehicle.
Procedure:
1. Park machine on level surface.
Procedure:
2. Turn key switch to OFF position.
3. Move gearshift pedals to FORWARD position.
Engage parking brake.

c CAUTION
When operating vehicle to observe any clutch
problems, find and operate vehicle in an area flat
and free of obstacles so that you can
concentrate on observing performance safely.
1. Park machine on level surface.
2. Move gearshift pedals to NEUTRAL position.
Engage parking brake.
3. Start and run engine at MEDIUM idle for 5 minutes
to heat engine oil to normal operating temperature.
4. Move gearshift pedals to FORWARD position.
Release parking brake.
5. From a standing start, accelerate through 15.2 m
(50 ft.). This should take approximately 7.0
seconds.
6. Stop Vehicle.
7. From a standing start, accelerate through 30.5 m
(100 ft.). This should take approximately 10.0
seconds.
8. Once at maximum speed, travel time through 30.5
m (100 ft.) should be approximately 6.0 seconds.
Results:
• If performance is not to specifications, check
engine performance: engine rpm, governor,
compression and valve clearance. (See ENGINE
section.)
• Check driven clutch for correct spring tension and
that all ramp shoes are in place and against ramp.
Repair driven clutch.
4. Lower front blade (if equipped).
5. Raise rear body cowling.
6. Remove belt.
Spring Scale
Locking Pilers
M83322
IMPORTANT: Do not damage sheave when
clamping pliers. Use protective strips of brass
or aluminum.
7. Clamp locking-type pliers to movable sheave.
8. Use a spring scale to measure force at the point
sheave is returning and almost contact ramp.
Standard wrap should be 22—40 N (5—9 lb.).
Results:
• Spring force within specification, secondary or
driven clutch is OK. Check engine rpm and
performance.
• Spring force is less than specification, up-shift will
be faster and engine load greater, reducing engine
rpm and response time. Check spring position or
replace.
• Spring force higher than specification, up-shift or
acceleration will be slower, reducing engine load,
increasing engine rpm and response time. Check
spring position or replace spring. Spring position is
hole 2.

5 - 18 2/9/95
REPAIR GEAR POWER TRAI N

REPAIR

DIFFERENTIAL LOCK PEDAL AND LINKAG E

Link Rod Spring Locking Spring Pin

Pin (2 used)

Lever

Differential
Lock Pedal

Rod

M80771

• Inspect all parts for wear or damage.

Replace parts as necessary.

2/9/95 5 - 19
GEAR POWER TRAIN REPAIR

GEARSHIFT PEDALS AND LINKAG E

Control
Arm Cap
Screw
Spring Pin

Tie
Rod
End
Cap
Screw Jam Lock
Nut Nut
Gearshift Pedal
Assembly
Forward Bracket
Pedal Pad

Reverse Shift Rod

Pedal Pad

Spring Pin
(2 used)
Cap
Screw

Tie Rod
End
Pivot Rod
Jam
Lock Nut
Nut M83129AE

• Inspect all parts for wear or damage. Replace parts

as necessary.
• Adjust linkage. (See procedure in CHECKS,
TESTS AND ADJUSTMENTS.)

5 - 20 2/9/95
REPAIR GEAR POWER TRAI N

DRIVE BELT

Removal/Installatio n
1. Lower front blade (if equipped).
2. Raise rear cowling.

Arrows JDG813-1 Clutch Removal Tool

M56704

IMPORTANT: Lightly grease end of puller to

prevent puller wear. To prevent clutch thread
damage, DO NOT thread bolt in any farther than
necessary to remove clutch.

M83462
Fuel tank removed for photo.
3. Loop slack in belt over driven pulley.
4. Rotate driven pulley to remove drive belt.
Installation is done in the reverse order of removal .
• Install belt with arrows pointing forward.
NOTE: An air impact wrench works well to remove the
drive clutch.
4. Remove cap and install JDG813-1 Clutch Removal
Tool. Thread puller into clutch and against
crankshaft until clutch loosens. Leave puller in
clutch to remove cover.
Installation is done in the reverse order of removal .

DRIVE (PRIMARY) CLUTC H Disassembly/Inspection/Assembl y

5. Remove clutch cover bolts. Rap end of puller bolt
Removal/Installatio n sharply, cover should pop off. Do not pry on cover.

1. Remove drive belt. (See DRIVE BELT.)

JDG813-2
2. Remove drive (primary) clutch center cover.
Spanner Wrench

Cap Screw
50 N•m (37 lb-ft)
Spider JDG813-3
135 N•m (100 lb-ft) Tapered
Holding
Tool

M83486 M83487

3. Remove cap screw. 6. Install JDG813-3 Tapered Holding Tool and retain it
with M10 x 1.5 x 150 mm hex-head bolt.

2/9/95 5 - 21
GEAR POWER TRAIN REPAIR

IMPORTANT: Always use a spider wrench to DRIVEN PULLEY

remove spider. Unequal pressure on clutch
towers could cause stress fractures or break
them off. A medium strength thread locking Removal/Installatio n
compound is used on spider threads .
1. Remove
- Drive belt. (See DRIVE BELT.)
7. Use JDG813-2 Spanner Wrench to remove spider.
- Fuel tank. (See procedure in ENGINE section.)

Stationary
Sheave
Driven Clutch
Spring

Washer

Spider

O-Ring Button Mounting Cap Screw

24 N•m (18 lb-ft) M83323

O-Ring
Button
NOTE: Mounting cap screw has left-hand threads.
O-Ring Roller
(One each Clutch
side of roller)
Sheave 2. Hold clutch with a strap wrench and remove cap
screw.
Flyweights
3. Tap on inside of clutch with a rubber mallet.
4. Remove driven clutch.
Nut
Pivot Bolt Installation is done in the reverse order of removal .
M83488
• Apply MPG-2 Polymer Multipurpose Grease, or
8. Inspect all parts for wear or damage. Replace parts equivalent to splines of transaxle input shaft.
as necessary.

IMPORTANT: Do not tighten cap screw beyond 24

Assembly is done in the reverse order of N•m (18 lb-ft). Damage to transaxle will result if
disassembly. over-tightened.
• Lubricate cam weight pivot area using
SUPERLUBE Spray or equivalent. Slide bolts to
side to allow lubricant to penetrate pivot area. Bolt • Install new mounting cap screw or apply Thread
may need to be removed to lubricate properly. Lock and Sealant to original cap screw. New cap
Replace bolt if worn through plating. Check screw will have Thread Lock and sealant applied.
flyweight for binding.
• Apply Thread Lock and Sealant (Medium Strength)
to spider threads.

5 - 22 2/9/95
REPAIR GEAR POWER TRAI N

Disassembly Ramp Shoe Replacemen t

Set Screw
Bushing Ramp Shoes
Hole Ramp

Cam
Spring

Alignment
Marks M83481 M83482

1. Release tension on spring using a punch in hole of 1. Inspect ramp shoes for wear or cracks.
cam. 2. Apply heat to moveable sheave ramp and pull off
2. Remove set screw. shoes. If shoe mounting tabs break off inside
3. Put alignment marks on cam and movable sheave sheave ramp, remove tabs using a drill bit.
half to aid in assembly. 3. Install ramp shoe tabs into ramp holes.
- If shoes are too difficult to install, sand tabs as
necessary.

c
- If tabs are loose, apply Thread Lock and Sealant
CAUTION (Medium Strength) on tabs.
4. Inspect bushing for wear or damage. Replace
moveable sheave if necessary.
Hold cam securely to prevent sudden spring
release.
Assembly
4. Cam is press-fit on shaft. Use a three-jaw puller and
1. Install spacer and moveable sheave on fixed
an impact wrench at low speed to remove.
sheave.
5. Remove spring, movable sheave half and spacer.

Hole Set Screw

NOTE: Ramp shoes are interference fit. Remove
shoes only if replacement is necessary.
String

6. Inspect ramp shoes for wear or cracks. Replace if

necessary. (See Ramp Shoe Replacement
procedure.)
Alignment
Marks

M83483

2. Install spring. Insert spring tab in hole marked "2" in

moveable sheave half. Place cam on spring.
3. Align set screw bores and alignment marks. Press
cam on shaft until it stops.
4. Apply Thread Lock and Sealant (Medium Strength)
to threads of set screw and install until flush with
surface.
5. Pry spring away from cam and loop a piece of string
around top spring tab. Pull on string until tab seats
in hole in cam.

2/9/95 5 - 23
GEAR POWER TRAIN REPAIR

Replace Ramp Shoes (Clutch TRANSAXLE

Mounted on Machine )
1. Remove drive belt. (See DRIVE BELT.) Removal/Installatio n
1. Remove:
- Rear body cowling. (See procedure in
MISCELLANEOUS section.)
- Rear wheels. (See procedure in
MISCELLANEOUS section.)
Allen Wrench - Driven pulley. (See DRIVEN PULLEY.)
- Brake disk. (See procedure in BRAKES section.)

Carriage Bolts and Nuts

Small Block of Wood 25 N•m (216 lb-in.)

Locking Pliers
M83324

2. Install locking pliers on outer edge of fixed sheave

half. Move pliers against frame.
3. Turn moveable sheave half until shoes are away
from ramps. Install a small block of wood between M83325
other ramps and shoes to hold sheave half in
position.

c CAUTION
Prevent burns. Hold allen wrench with locking
pliers.

4. Heat short end of a 2 mm (0.078 in.) allen wrench

until red. Insert wrench into center of ramp shoe as
plastic melts. Hold wrench in place until plastic M83326
hardens.
5. Twist and pull on allen wrench to remove ramp 2. Remove four carriage bolts and nuts from axle
shoe. bearing flanges.
6. Install ramp shoe tabs into ramp holes. 3. Pull axle shaft out of coupler, both sides.
- If shoes are too difficult to install, sand tabs as
necessary.
NOTE: Transaxle oil capacity is approximately 2.3 L
- If tabs are loose, apply Thread Lock and Sealant (2.5 qt.).
(Medium Strength) on tabs.

4. Drain transaxle.

5 - 24 2/9/95
REPAIR GEAR POWER TRAI N

• Fill transaxle to proper level with clean John Deere

85W140 API GL-5 gear oil. (See SPECIFICATIONS
AND GENERAL INFORMATION section.)
Locking Pins
• Apply MR-2 Multipurpose Polymer grease to axle
shafts.

Rod Disassembly/Inspectio n
1. Thoroughly clean the outside of the transaxle.

M83327 Spring Pin

5. Remove both locking pins. Remove rod.

Shift Arm

Cap screw
Wire Connector M83330

2. Drive spring pin from shift arm. Remove shift arm.

M83328

6. Disconnect neutral start switch wire connector.

7. Remove shift rod and cap screw.

Differential Arm
Spring Pin

M83331

3. Remove spring pin and differential arm.

IMPORTANT: Grease shafts to avoid tearing seals

and O-rings when separating case .
Cap Screws
50 N•m (37 lb-ft)
4. Remove cap screws from housings and separate
using a screwdriver and rubber hammer.

M83329

8. Remove cap screws, washers and nuts. Remove

transaxle.

Installation is done in the reverse order of removal .

2/9/95 5 - 25
GEAR POWER TRAIN REPAIR

Intermediate Shaft
Input Shaft O-Ring

Shifter Shaft
Differential

Shifter Block

M83335

10. Clean and inspect shift shaft and O-ring for wear or
damage.
11. Measure O.D. of shift shaft. Replace if
measurement is less than specifications.
12. Measure I.D. of shift shaft bore in case. Replace if
measurement is greater than specifications.
M83332
Differential Lock Shaft 13. Subtract shift shaft O.D. from I.D. of shaft bore in
case to find clearance. Replace shift shaft and
5. Tap on end of input shaft and pry on gear of case if clearance is greater than specifications.
intermediate shaft to remove as one unit.
6. Remove differential and differential lock assembly
together. Specifications:
Shift Shaft O.D. . . . . . . . . . . . . . . 16.96—17.00 mm
Shift Shaft: (0.668—0.669 in.)
Shift Shaft Bore I.D. . . . . . . . . . . 17.02—17.04 mm
(0.670—0.671 in.)
Shift Shaft-to-Bore
Clearance (Maximum) . . . . . . . . . 0.2 mm (0.01 in.)
Retainer

Cap Screw

Shifter Shaft
Snap Ring Block Width

M83347
Neutral Start Switch
14. Measure shift block width. Replace if measurement
is less than specifications.
M83337
15. Subtract block width from shift collar groove width
to fin clearance. Replace shift block and collar if
7. Remove cap screw, snap ring and retainer. clearance is greater than specifications.
8. Remove shifter shaft.
9. Remove neutral start switch (if necessary).
Specifications:
Shift Block Width . . . . . . . . . . . . . . 13.7—13.9 mm
(0.54—0.55 in.)
Shift Block-to-Collar
Clearance (Maximum) . . . . . . . . . 2.0 mm (0.08 in.)

5 - 26 2/9/95
REPAIR GEAR POWER TRAI N

Needle Drive Gear

Bearing Washer Ball
Reverse Drive Bearing
Chain Drive Gear

Diameter "A"

Input Shaft
Diameter "B"
M83334

Needle
16. Remove reverse drive chain. Step
Bearing
17. Inspect chain for worn or loose links. Washer Snap
Ring

Reverse
Input Shaft: Sprocket
Wear Reverse
Sleeve Sprocket M83497AE
Bearing Washer
Washer 22. Inspect bearings for scoring or pitting. Replace if
Sleeve
Needle necessary.
Bearing 23. Inspect drive gear washer for scoring. Replace if
Drive Gear necessary.
24. Measure drive gear washer thickness. Replace if
measurement is less than specifications.
Bearing
25. Inspect needle bearings for wear or pitting. Replace
if necessary.
26. Measure reverse sprocket washer thickness.
Bearing RW11886 Replace if measurement is less than
specifications.
18. Remove sleeve and bearings using a knife-edge 27. Inspect drive gear teeth and chamfer of splines for
puller. wear or damage.
19. Remove washer, needle bearing and drive gear. 28. Measure I.D. of drive gear. Replace if
measurement is greater than specifications.
Shift Collar 29. Measure diameter "B" of input shaft. Replace if
measurement is less than specifications.
Input Shaft
30. Measure diameter "A" of input shaft. Replace if
Reverse Detent
measurement is less than specifications.
Sprocket Spring 31. Inspect reverse sprocket teeth and chamfer of
Step
Washer splines for wear or damage.
Detent 32. Measure I.D. of reverse gear. Replace if
Snap Balls
Ring measurement is greater than specifications.
33. Inspect input shaft for wear or scoring. Replace if
necessary.
Needle
Bearing M83498AE
Washer
Specifications:
20. Remove sprocket retaining snap ring, washer,
needle bearing and reverse chain sprocket. Drive Gear Washer
Thickness . . . . . . . . . . . . . . . . . . . . 1.45—1.55 mm
(0.057—0.061 in.)
NOTE: Detent spring and balls will fly out from holes in Reverse Sprocket
shaft when shift collar is removed. when Washer Thickness . . . . . . . . . . . . . 0.65—0.75 mm
removing. (0.026—0.029 in.)
Drive Gear I.D. . . . . . . . . . . . . . . 24.01—24.02 mm
21. Remove shift collar carefully to avoid losing detent (0.945—0.946 in.)
balls and spring.

2/9/95 5 - 27
GEAR POWER TRAIN REPAIR

Input Shaft O.D. 40. Inspect all parts for wear or pitting. Replace parts if
(Diameter "B") . . . . . . . . . . . . 19.987—20.000 mm necessary.
(0.7868—0.7874 in.)
Input Shaft O.D.
(Diameter "A") . . . . . . . . . . . . . . 19.99—20.01 mm
(0.787—0.788 in.)
Reverse Sprocket I.D. . . . . . . . . 24.01—24.02 mm
(0.945—0.946 in.)

Shift Groove
Shift Collar

Bolt
Nut

M83339
Detent Spring
Detent Balls NOTE: New nuts and bolts will be used when
RW12127 assembling differential.
41. Remove nuts and bolts from differential housing.
34. Inspect chamfered spline of shift collar for wear. Discard nuts and bolts.
35. Measure width of shift groove. Replace if 42. Separate housings. Note position of bevel pinion
measurement is greater than specifications. for reassembly.
36. Inspect detent spring and balls for nick or cracks.
37. Measure detent spring length. Replace if Differential
measurement is not within specifications. Lock Collar
Washer
Specifications:
Shift Groove Width. . . . . . . . . . . . . 14.1—14.3 mm
(0.55—0.56 in.)
Detent Spring
Snap Ring
Free Length . . . . . . . . . . . . 24.2 mm (0.95 in.) Output Shaft
Gear
Free Length (Minimum) . . . 20.0 mm (0.79 in.)
Bearing
Working Load Length . . . . . 15.8 mm at 53 N M83340
(0.62 in. at 12 lb)
43. Remove output shaft from both carriers.
Intermediate Shaft: 44. Remove washer, snap ring and gear from output
shaft.
45. Press bearings from both carrier housings and
Snap
Bearing remove differential lock collar from left carrier.
Ring
Washer

Reduction
Gear Splines
Bearing
Intermediate M83336
Drive Gear
38. Remove bearings from intermediate shaft using a
knife-edge puller.
39. Remove washer, intermediate drive gear and snap
ring.

5 - 28 2/9/95
REPAIR GEAR POWER TRAI N

Bearing
Right
Right Differential Axle
Housing Shaft

Bevel Pinion Washe r (2 used) Washer

Bevel Pinion Gear (2 used)

Pinion
Left Shaft Right Bevel Gear
Bevel
Gear Snap Ring
(2 used)
Washer

Differential
Gear

Left Differential
Housing

Differential
Lock Collar
Left Axle Bearing
Shaft

M83197

46. Clean differential parts and inspect for wear or Specifications:

scoring.
Differential Lock Collar
47. Measure differential lock collar groove width. Groove Width . . . . . . 7.1—7.3 mm (0.28—0.29 in.)
Replace if measurement is not within
specifications. Washer
48. Measure washer thickness. Replace if Thickness . . . . . . . 0.74—0.86 mm (0.28—0.29 in.)
measurement is not within specifications. Bevel Pinion
49. Measure bevel pinion washer thickness. Replace if Washer Thickness . . . . . . . . . . . . . 0.96—1.04 mm
measurement is not within specifications. (0.038—0.041 in.)
50. Measure bevel pinion I.D. Replace if measurement Bevel Pinion I.D. . . . . . . . . . . . . . 16.03—16.05 mm
is not within specifications. (0.631—0.632 in.)
51. Measure pinion shaft O.D. Replace if measurement Pinion Shaft O.D. . . . . . . . . . . . . 15.95—15.97 mm
is not within specifications. (0.628—0.629 in.)
52. Subtract pinion shaft O.D. from bevel pinion I.D. to
find clearance. Replace bevel pinion and pinion Pinion Shaft-to-Bevel
shaft if clearance is greater than specifications. Pinion Clearance (Maximum) . . . 0.2 mm (0.01 in.)

2/9/95 5 - 29
GEAR POWER TRAIN REPAIR

Differential Lock Shaft:

O-Ring

RW12141
O-Ring
Spring Pins M83348
Washer 61. Measure I.D. of lock fork. Replace if measurement
is greater than 20.05—20.10 mm (0.789—0.791
53. Remove O-rings and washers.
in.).
54. Drive out outer spring pins.

Spring Pins

Lock Fork

RW12142
M83346

62. Inspect lock shaft for scoring or wear. Replace if

55. Mount lock shaft in vice to compress spring.
56. Drive out inner spring pin.
57. Release pressure. Remove lock fork.
necessary.
63. Measure O.D. of shaft at fork seating area. Replace
if measurement is less than 19.95—20.00 mm
(0.785—0.787 in.).
64. Subtract shaft O.D. from lock fork I.D. to find
clearance. Replace shaft and lock fork if clearance
is greater than 0.5 mm (0.02 in.).

M83344

58. Inspect lock fork fingers for scoring or wear.

59. Measure thickness of lock fork fingers. Replace if
measurement is not within 6.7—6.9 mm (0.26—
0.27 in.).
60. Subtract lock fork finger thickness from lock collar
groove width to find clearance. Replace lock fork
and lock collar if clearance is greater than 2.0 mm
(0.08 in.).
RW12140
65. Measure free length of lock spring. Replace if
measurement is less than 77.6 mm (3.06 in.).
66. Measure working length of lock spring. Replace if
measurement is less than 52 mm at 511 N•m
(2.07 in. at 115 lb).

5 - 30 2/9/95
REPAIR GEAR POWER TRAI N

Input Shaft Seal Intermediate Shaft Seal Seal

Seal
Spacer

M83338
Output Shaft Seals
67. Clean sealant from case mounting surfaces. Seal
Output
Shaft

c CAUTION Seal
Spacers

M80781
Reduce compressed air to less than 210 kPa (2
bar) (30 psi) when using for cleaning purposes. 1. Apply multipurpose grease to inside lips of seals.
Clear area of bystanders, guard against flying
chips, and wear personal protection equipment
IMPORTANT: Install output shaft spacers as
including eye protection.
shown.

68. Clean all metal parts with solvent and blow dry with
compressed air. 2. Apply multipurpose grease to spacers to hold in
69. Inspect input shaft seal, output shaft seals and placed. Install spacers.
intermediate shaft seal. Replace if necessary.
Inspect case halves for wear or damage. Replace as
Shift Shaft:
necessary.

Assembly O-Ring

Retainer
IMPORTANT: Always use new seals and O-rings.
Damaged or used parts will leak. Cap Screw
25 N•m
(228 lb-in.)
NOTE: Lubricate all seals and O-rings with petroleum
jelly during assembly.

Apply clean John Deere 85W140 API GL-5

gear oil to all internal parts during assembly. Shifter Shaft
Snap Ring

Neutral Start Switch

39 N•m (29 lb-ft)

M83337
M83337

2/9/95 5 - 31
GEAR POWER TRAIN REPAIR

NOTE: Coat shift shaft and bore in case half with

multipurpose grease before assembly.
Shift Splines
Snap Ring
3. Install shift shaft in bore in case.
4. Install O-ring. Washer
5. Install retaining plate, snap ring and cap screw.
6. Install neutral start switch.

Input Shaft:

Shift Collar RW12100

Needle Bearing
11. Install sprocket to keyed end of input shaft with shift
Shift Collar splines facing shift collar.
12. Install needle bearing washer and snap ring.

Step Washer
Detent Spring
Bearing
Detent Balls
RW12127
Wear
Sleeve

NOTE: Apply a light coat of multipurpose grease to

detent balls to hold in place.

Snap Ring M83499AE

7. Position detent spring and balls through input shaft.
8. Install shift collar to neutral position with shoulder 13. Press bearing onto shaft against snap ring.
toward short end of input shaft. 14. Apply a light coat of multipurpose grease to shaft
and wear sleeve.
15. Press wear sleeve onto shaft against bearing.
Shift
Collar
Shift
Splines Needle Intermediate Shaft:
Bearing Washer

Washer Gear
Bearing

Shoulder
RW12099

9. Install drive gear onto short end of input shaft with

shift splines facing shift collar.
Bearing Snap
10. Install needle bearing and washer. Press bearing
Ring
tight against shoulder of input shaft. M83341

16. Install snap ring and gear with gear shoulder facing
snap ring.
17. Press bearings onto intermediate shaft.

5 - 32 2/9/95
REPAIR GEAR POWER TRAI N

Differential Assembly:

Differential Bearing
Locking Collar

Bolt
M83342 Nut
27 N•m
18. Assemble differential lock collar onto left differential (19 lb-ft) M83339
housing half.
19. Press carrier bearings onto both differential 23. Assemble two differential halves to differential gear.
housing halves.
NOTE: Use new bolts and nuts to secure differential
Differential halves.
Lock Collar
Washer
24. Apply Thread Lock and Sealer (Medium Strength)
to bolts. Tighten nuts.

Differential Lock Shaft:

Snap Ring
Output Shaft
Gear

M83340
Fork
20. Install long input shaft and notched differential gear
with snap ring and washer into left housing half Spring
with lock collar. Snap Ring
21. Install short output shaft, gear and snap ring
assembly in right housing half.

Gears M83345
Washer
Washers
25. Install snap ring, washer and spring.
26. Install fork on shaft.

Split
Spring Pins
Pinion Shaft

M83343

Lock Fork
NOTE: Be sure bevel pinion is seated into correct
housing notch.

M83346
22. Install pinion shaft with gears and washers into
right differential carrier half. 27. Compress spring in vice.

2/9/95 5 - 33
GEAR POWER TRAIN REPAIR

28. Install double spring pin with split facing away from
lock fork.

Differential Gear

Single
Spring Split O-Ring
Pin

O-Ring
Washer Double Spring Pin M83348

29. Install double spring pins with split facing spring.

30. Install single spring pin with slit facing toward fork.
31. Install washer onto shaft until seated against spring
pin. Shifter Block M83350
32. Install O-rings.

NOTE: Apply multipurpose grease to input and output

Reverse Drive Intermediate shafts and seals before assembly.
Chain Shaft

35. Install differential and differential lock shaft into left

case half.
36. Start input shaft through case while working
sprocket and chain behind differential gear.
37. Align shift block with shift collar.
Input
Shaft 38. Align intermediate shaft with case bore.
M83334 39. Tap intermediate and input shafts with a rubber
mallet to seat bearings.
33. Assemble input shaft and intermediate shaft with 40. Clean case mating surfaces using Clean and Cure
reverse drive chain. Primer. Apply a coat of Flexible Sealant or
equivalent to mating surfaces of case halves.

Fork

Collar
M83349

34. Assemble differential lock shaft fork into collar.

M83351

5 - 34 2/9/95
REPAIR GEAR POWER TRAI N

41. Assemble right case half to left case half carefully

to avoid tearing seals and o-rings.
42. Install cap screws. Tighten to specifications.

Specifications:

Cap Screw Torque

Same Case. . . . . . . . . . . . 25 N•m (228 lb-in.)
New Case. . . . . . . . . . . . . . . 29 N•m (21 lb-ft)

Breather
10 N•m
(90 lb-in.)

Check
Plug

RW12150

43. If breather has been removed, apply Thread Lock

and Sealant (Medium Strength) to threads.
44. Install drain plug.
45. Install check plug and oil fill cap.

2/9/95 5 - 35
GEAR POWER TRAIN REPAIR

This page intentionally left blank.

5 - 36 2/9/95
STEERING CONTENTS

CONTENTS
Page

STEERING
SPECIFICATIONS
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
COMPONENT LOCATION AND OPERATION . . . . . . . . . . . . . . . . . . . . 6-3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
DIAGNOSIS
STEERING WANDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
LOST MOTION AT STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
VIBRATION AT STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
STEERING WHEEL TURNS HARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
ADJUSTMENTS
STEERING CHAIN TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
REPAIR
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
STEERING SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
STEERING FORK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

2/2/95 6-1
STEERING SPECIFICATIONS

SPECIFICATIONS

REPAIR SPECIFICATION S
Locking Collar Set Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (64 lb-in.)
Steering Disk Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 N•m (24 lb-ft)
Steering Wheel-to-Shaft Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 N•m (24 lb-ft)

OTHER MATERIAL S

Number Name Use

M79292 MPG-2 Multipurpose Apply to steering shaft and steering fork shaft.
Polymer Grease
MPG-2 is a registered trademark of DuBois USA.

6-2 1/31/95
COMPONENT LOCATION AND OPERATION STEERING

COMPONENT LOCATION AND OPERATION

STEERING SYSTEM COMPONENTS AND OPERATION

Steering Wheel

Steering Shaft
and Sprocket Steering Disk and Chain

Bushing

Bearing

Locking Collar Steering Fork

Wheel Bearing

M83178AE

Function: Steering effort is quite low due to the 8 to 1 reduction

between the steering shaft and the fork shaft. There
To direct movement of the machine in forward or
are two mechanical stops between the fork and frame
reverse.
which limits the steering angle of the front wheel.

Theory of Operation:
When the steering wheel is turned, the steering shaft
and sprocket rotate. The sprocket is connected to the
steering disk by a chain. The steering disk is splined to
the steering fork. As the sprocket turns, the chain
causes the steering disk/steering fork to rotate, turning
the front wheel.

2/2/95 6-3
STEERING TROUBLESHOOTING CHART

TROUBLESHOOTING CHART
Problem or

Steering wheel turns

Lash (lost motion) at

Vibration at steering
Symptom

Steering wander.

steering wheel.
Check or
Solution

wheel.

hard.
Steering wheel loose on column.

Steering chain loose or worn.

Sprocket teeth worn or damaged.

Wheel bearings worn.

Fork shaft bearings worn.

Steering shaft bushings worn.

Steering shaft bushings tight or

not lubricated.

Rim bent.

Tire incorrectly mounted on rim.

6-4 1/31/95
DIAGNOSIS STEERING

DIAGNOSIS

STEERING WANDER

NOTE: Before checking for a steering problem, make sure that tire inflation is correctly adjusted to 4—6 psi.

Test Conditions:

• Parking brake engaged • Key switch in OFF position.

• Front wheel raised off ground.

Test/Check Point Normal If Not Normal

1. Steering chain. Chain tightened to specification. Perform STEERING CHAIN

TENSION ADJUSTMENT.

2. Steering shaft. Bushings and tube clean and Clean and lubricate bushings and
lubricated. tube.
Sprocket not worn or damaged. Replace shaft.
Locking collar tight. Tighten locking collar.

3. Wheel bearings. Wheel rotates freely without feeling Replace wheel bearings.
rough spots, no side play.

4. Tire. Tire mounted correctly on rim. Remount tire correctly on rim.

Runout less than 3 mm (0.125 in.). Replace tire.

5. Wheel Rim. Not bent. Replace rim.

Runout less than 3 mm (0.125 in.).

2/2/95 6-5
STEERING DIAGNOSIS

LOST MOTION AT STEERING WHEEL

NOTE: Before checking for a steering problem, make sure that tire inflation is correctly adjusted to 4—6 psi.

Test Conditions:

• Parking brake engaged • Key switch in OFF position.

• Front wheel raised off ground.

Test/Check Point Normal If Not Normal

1. Steering wheel. Wheel securely mounted to shaft. Tighten nut to specifications.

2. Chain. Chain properly tensioned. Perform STEERING CHAIN

Not worn or damaged. TENSION ADJUSTMENT.
Replace chain.

3. Steering shaft sprocket. Teeth not worn or damaged. Replace steering shaft.

VIBRATION AT STEERING WHEEL

NOTE: Before checking for a steering problem, make sure that tire inflation is correctly adjusted to 4—6 psi.

Test Conditions:

• Parking brake engaged • Key switch in OFF position.

• Front wheel raised off ground.

Test/Check Point Normal If Not Normal

1. Wheel bearings. Wheel rotates freely without feeling Replace wheel bearings.
rough spots, no side play.

2. Tire. Tire mounted correctly on rim. Remount tire correctly on rim.

Runout less than 3 mm (0.125 in.). Replace tire.

3. Wheel Rim. Not bent. Replace rim.

Runout less than 3 mm (0.125 in.).

4. Fork shaft bearings. Fork shaft rotates freely without Replace bearings.
feeling rough spots, no side play.

5. Steering shaft. Sprocket not worn or damaged. Replace shaft.

Locking collar tight. Tighten locking collar.

6-6 2/2/95
DIAGNOSIS STEERING

STEERING WHEEL TURNS HARD

NOTE: Before checking for a steering problem, make sure that tire inflation is correctly adjusted to 4—6 psi.

Test Conditions:

• Parking brake engaged • Key switch in OFF position.

• Front wheel raised off ground.

Test/Check Point Normal If Not Normal

1. Fork shaft bearings Fork shaft rotates freely without Replace bearings.
feeling rough spots, no side play.

2. Steering shaft. Bushings and tube clean and Clean and lubricate bushings and
lubricated. tube.
Sprocket not worn or damaged. Replace shaft.
Locking collar tight. Tighten locking collar.

2/2/95 6-7
STEERING ADJUSTMENTS

ADJUSTMENTS

STEERING CHAIN TENSION

ADJUSTMENT

Procedure:
1. Park machine on level surface.
2. Move Forward/Reverse pedals to NEUTRAL
position.
3. Turn key switch to OFF position.
4. Remove hood. (See procedure in
MISCELLANEOUS section.)

Spring

Lock Nut
M83168

5. Tighten lock nut until spring is fully compressed.

6. Loosen locknut 1/2 turn.

6-8 5/11/95
REPAIR STEERING

REPAIR
Chain

Spring
STEERING WHEEL
Lock Nut
Removal/Installation

Cap

Lock Nut
Steering 33 N•m (24 lb-ft)
Wheel

M83121

2. Remove lock nut, spring and disconnect chain.

Steering Shaft

Bushing

M83119AE

1. Remove cap.
2. Remove nut.
3. Remove steering wheel.

Installation is done in the reverse order of removal. Bushing

STEERING SHAFT Set Screw

Washer 8 N•m (64 lb-in.)
Locking Collar
Removal/Inspection/Installation
1. Remove front hood. (See procedure in Cap M83136AE
MISCELLANEOUS section.)
3. Remove cap.
4. Loosen set screw and remove locking collar.
5. Remove shaft and washer.
6. Inspect all parts for wear or damage, Replace parts
if necessary.

NOTE: Remove bushings only if replacement is

necessary.

7. Inspect bushings for wear or damage. Replace if

necessary.
Remove bushings using a blind hole puller set.

1/31/95 6-9
STEERING REPAIR

Installation is done in the reverse order of removal.

• Apply MPG-2 Polymer Multipurpose Grease to Cap Screw
lower half of steering shaft. 33 N•m (24 lb-ft)
• Install bushings using a driver set. Lock Washer Lock Nut
• Install locking collar with recessed side facing Washer Spring
down. Do not install locking collar tight against
frame.
Stud

Steering
Disk Thrust
Washer

Bearing
Chain

Spring

Lock Nut
M83168 Thrust
Washer Bearing
• Tighten lock nut until spring is fully compressed.
Loosen lock nut 1/2 turn.

STEERING FORK ASSEMBLY

Removal/Inspection Steering Fork

1. Remove front hood (See procedure in
MISCELLANEOUS section.)
2. Remove front wheel. (See procedure in
MISCELLANEOUS section.)

M83169AE

3. Remove lock nut, spring and disconnect stud and

chain.
4. Support steering fork.
5. Remove cap screw, lock washer, washer, steering
disk and thrust washer.
6. Remove steering fork.
7. Inspect all parts for wear or damage. Replace parts
as necessary.

NOTE: Bearings are press-fit. Remove only if

replacement is necessary.

8. Inspect bearings for wear or damage. Replace if

necessary.
9. Replace bearings.

6 - 10 1/31/95
REPAIR STEERING

Installation

Thrust Washer

Spring

Thrust
Washer Lock Nut
M83168

• Tighten lock nut until spring is fully compressed.

Loosen lock nut 1/2 turn.
Steering Fork

M83190AE

10. Apply MPG-2 Polymer Multipurpose Grease to

steering fork shaft.
11. Install thrust washer on steering fork shaft and
install steering fork.
12. Support steering fork.
13. Install thrust washer.
14. Rotate steering fork until parallel to frame.

Disk

Cap Screw
33 N•m
(24 lb-ft)

Chain End

M83167

15. Position disk with chain end in 4 o'clock position as

shown.
16. Align disk ID splines with steering fork shaft and
install.
17. Install flat washer, lock washer and cap screw.

1/31/95 6 - 11
STEERING REPAIR

This page intentionally left blank.

6 - 12 1/31/95
CONTENTS BRAKES

CONTENTS
Page

BRAKES
SPECIFICATIONS
ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
COMPONENT LOCATION AND OPERATION
BRAKE SYSTEM COMPONENTS AND OPERATION . . . . . . . . . . . . . . . . . . . 7-3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
DIAGNOSIS
MACHINE WILL NOT MOVE IN FORWARD OR REVERSE . . . . . . . . . . . . . . 7-5
BRAKES DO NOT ENGAGE WHEN PEDAL DEPRESSED. . . . . . . . . . . . . . . 7-5
BRAKES DO NOT HOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
BRAKES DRAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
EXCESSIVE BRAKE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
ADJUSTMENTS
BRAKE LINING CONTACT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
BRAKE LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
REPAIR
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
BRAKE DISK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
BRAKE PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

2/2/95 7-1
BRAKES SPECIFICATIONS

SPECIFICATIONS

ADJUSTMENT SPECIFICATIONS
Brake Pad Contact Adjustment Screw . . . . . . . . . . . . Tighten, then turn counterclockwise 1/2 turn.
Brake Pedal Lock Tab-to-Lock Lever Notch Gap . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 mm (0.125 in.)

REPAIR SPECIFICATIONS
Brake Caliper-to-Frame Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 N•m (24 lb-ft)
Axle Shaft Bearing Carriage Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (216 lb-in.)

OTHER MATERIALS
Number Name Use
M79292 MPG-2 Polymer Prevents parts from seizing.
Multipurpose Grease Apply to transaxle axles shaft splines and
brake actuator pin.
AR31790 Adhesive Attaches brake lining to caliper housing.

MPG-2 is a registered trademark of DuBois USA.

7-2 1/31/95
COMPONENT LOCATION AND OPERATION BRAKES

COMPONENT LOCATION AND OPERATION

BRAKE SYSTEM COMPONENTS AND OPERATION

Parking Brake Lock Lever

Brake Disk
Pedal Assembly
Brake Linings

Return Spring
Caliper Assembly

Brake Actuator Arm

Brake Rod

M83179AE

Function: As the brake lever is released, the return spring pulls

the pedal assembly back releasing pressure on the
To provide a means of stopping the machine and also
brake linings, allowing the transaxle gears to rotate
prevent movement when machine is not in use.
freely.
The brake can be locked for parking by depressing the
Theory of Operation: pedal and engaging the parking brake locking lever.
The brakes are a mechanical disk type mounted on the
intermediate shaft of the transaxle.
When the brake pedal is pressed, the brake rod moves
to the rear pushing the brake actuator arm to the rear.
As the actuator arm moves, it forces a pin within the
caliper assembly against the brake linings, pushing the
linings against the brake disk slowing vehicle motion.

2/2/95 7-3
BRAKES TROUBLESHOOTING CHART

TROUBLESHOOTING CHART

Problem or

engage when pedal

Brakes do not hold

move in forward or
Symptom

Excessive brake
Machine will not

Brakes do not
Check or

Brakes drag
depressed
Solution

reverse

wear
Linkage loose or not adjusted
correctly.

Brake linings worn.

Linkage adjustment incorrect.

Return spring damaged or

broken.

Brake disk warped, grooved or

worn.

Parking brake locked.

Linkage binding.

Brake rod damaged.

Actuator pin binding.

7-4 1/31/95
DIAGNOSIS BRAKES

DIAGNOSIS

MACHINE WILL NOT MOVE IN FORWARD OR REVERSE

Test Conditions:

• Machine parked on level surface. • Parking brake DISENGAGED.

• Key switch in OFF position. • Transmission in NEUTRAL.

Test/Check Point Normal If Not Normal

1. Parking Brake. Brake not depressed and locked. Release parking brake.

2. Brake linkage. Brake rod not damaged or binding. Eliminate binding, replace damaged
components.
Brake linkage properly adjusted. Perform Brake Linkage Adjustment.

3. Pedal assembly return spring. Spring returns pedal assembly to Replace stretched or broken spring.
rest position when brake pedal is
released.

BRAKES DO NOT ENGAGE WHEN PEDAL DEPRESSED

Test Conditions:

• Machine parked on level surface. • Parking brake DISENGAGED.

• Key switch in OFF position. • Transmission in NEUTRAL.
• Rear wheels raised off ground.

Test/Check Point Normal If Not Normal

1. Brake linkage. Brake rod not damaged or binding. Eliminate binding, replace damaged
components.
Brake linkage properly adjusted. Perform Brake Linkage Adjustment.

2. Brake actuator arm. Engages brakes when brakes Replace if damaged or worn.
applied.

3. Brake linings. Linings not worn. Replace linings if worn.

4. Brake disk. Not warped, grooved, worn or Replace brake disk.

damaged.

2/9/95 7-5
BRAKES DIAGNOSIS

BRAKES DO NOT HOLD

Test Conditions:

• Machine parked on level surface. • Parking brake DISENGAGED.

• Key switch in OFF position. • Transmission in NEUTRAL.
• Rear wheels raised off ground.
• Brake pedal engaged.

Test/Check Point Normal If Not Normal

1. Brake linkage. Brake rod not damaged or binding. Eliminate binding, replace damaged
components.
Brake linkage properly adjusted. Perform Brake Linkage Adjustment.

2. Brake linings. Linings not worn. Replace linings if worn.

3. Brake disk. Not warped, grooved, worn or Replace brake disk.

damaged.

BRAKES DRAG

Test Conditions:

• Machine parked on level surface. • Parking brake DISENGAGED.

• Key switch in OFF position. • Transmission in NEUTRAL.
• Rear wheels raised off ground.

Test/Check Point Normal If Not Normal

1. Brake linkage. Brake rod not damaged or binding. Eliminate binding, replace damaged
components.
Brake linkage properly adjusted. Perform Brake Linkage Adjustment.

2. Pedal assembly return spring. Spring returns pedal assembly to Replace stretched or broken spring.
rest position when brake pedal is
released.

3. Actuator pin. Not binding, properly lubricated. Eliminate binding, lubricate actuator
pin.

7-6 2/9/95
DIAGNOSIS BRAKES

EXCESSIVE BRAKE WEAR

.

Test Conditions:

• Machine parked on level surface. • Parking brake DISENGAGED.

• Key switch in OFF position. • Transmission in NEUTRAL.
• Rear wheels raised off ground.

Test/Check Point Normal If Not Normal

1. Brake linkage. Brake rod not damaged or binding. Eliminate binding, replace damaged
components.
Brake linkage properly adjusted. Perform Brake Linkage Adjustment.

2. Pedal assembly return spring. Spring returns pedal assembly to Replace stretched or broken spring.
rest position when brake pedal is
released.

3. Brake disk. Not warped, grooved, worn or Replace brake disk.

damaged.

4. Actuator pin. Not binding, properly lubricated. Eliminate binding, lubricate actuator
pin.

2/9/95 7-7
BRAKES ADJUSTMENTS

ADJUSTMENTS

BRAKE LINING CONTACT Tie Rod End

Jam Nut
ADJUSTMENT

Procedure:
1. Park machine on level surface.
2. Move gearshift pedals to NEUTRAL position.
3. Turn key switch to OFF position. Cap Screw and Nut
4. Lower front blade (if equipped). M83491
5. Raise rear body cowling.
4. Remove cap screw and nut to disconnect brake rod
at pedal assembly.

Gap
3.2 mm (0.125 in.)

Jam Nut

Screw
M83154

6. Loosen jam nut. M83490

7. Turn screw clockwise until tight.

5. Rotate park brake lock lever against brake pedal.
8. Turn screw counterclockwise 1/2 turn.
6. Depress brake pedal until there is a 3.2 mm (0.125
9. Tighten jam nut. in.) gap between the bottom of the brake lock tab
10. Adjust brake linkage. and the first notch on the park brake lock lever.
7. Loosen jam nut.
8. Hold brake rod in the fully actuated position.
BRAKE LINKAGE ADJUSTMENT 9. Rotate tie rod end until it aligns with hole in pedal
assembly.
Procedure: 10. Install and tighten cap screw and nut.
11. Tighten jam nut.

NOTE: Perform Brake Lining Contact Adjustment

before adjusting brake linkage.

1. Park machine on level surface.

2. Move gearshift pedals to NEUTRAL position.
3. Turn key switch to OFF position.

7-8 2/9/95
REPAIR BRAKES

REPAIR
BRAKE CALIPER
Removal/Installation
1. Lower front blade (if equipped).
2. Raise rear body cowling.

Nut
33 N•m (24 lb -ft)

Cap Screw
33 N•m (24 lb-ft)

Brake Rod

Cap Screw, Washer and Nut

M83154

3. Remove cap screw, washer, and nut.

4. Remove brake rod.
5. Remove cap screws and nuts and brake caliper.

Installation is done in the reverse order of removal.

• Adjust brake pad contact. (See Adjustments.)

2/9/95 7-9
BRAKES REPAIR

Disassembly/Inspection/Assembly

Adjustment Jam Nut Spring

Screw

Housing Half

Actuator Pin

Wear Plate
Cap Screw Lining
(2 used)
Lining
Pin (Glued to housing half)

Housing Half
Lever

Washer
(2 used)
Nut (2 used)
33 N•m (24 lb-ft) M83156AE

• Apply AR31790 Adhesive, or an equivalent to

lining.
PAT No. Characters
• Apply MPG-2Polymer Multipurpose Grease to
spherical end of actuator pin.

NOTE: Install lever with thin part away from PATENT

Lever No. characters.

• Do not tighten adjustment screw. Adjust brake pad

Thin Area contact. (See Adjustments.)
M83165

NOTE: Lining is glued to housing half. Replace only if

necessary.

Remove pin using a hammer and punch.

• Disassemble parts.
• Inspect all parts for wear or damage. Replace parts
if necessary.
• Inspect linings for excessive wear. Replace if
necessary.

Installation is done in the reverse order of removal.

7 - 10 2/9/95
REPAIR BRAKES

BRAKE DISK

Removal/Inspection/Installation
1. Remove: Snap Ring
- Battery.
- Rake attachment. (See ATTACHMENTS section.)
- Brake caliper. (See BRAKE CALIPER.)
- Right-hand side rear wheel. (See Disk
MISCELLANEOUS section.)
M83163

4. Remove snap ring.

5. Remove disk and key.

Installation is done in the reverse order of removal.

• Inspect all parts for wear or damage. Replace parts
as necessary.
Carriage Bolts • Apply MPG-2 Multi-Purpose Polymer Grease or
25 N•m (216 lb-in.) an equivalent to transaxle shaft and axle splines.
M83164

Axle Shaft

M83166

2. Remove four carriage bolts and lock nuts.

3. Pull axle shaft out of coupler. Remove coupler.

2/9/95 7 - 11
BRAKES REPAIR

BRAKE PEDAL AND LINKAGE

Return Spring
Pedal Pad Clamp
Brake Pedal
Pin Screw

Nut

Brake Rod
Tie Rod End
(2 used)

Park Brake Spring Pin (2 used)

Locking Lever

Cap Nut
Screw
Cap
Screw
Pivot Rod
Washer
Washer
(2 used)

Nut
M83155AE

NOTE: Spring pins may be replaced with cotter pins.

• Inspect all parts for wear or damage. Replace parts

as necessary.

Installation is done in the reverse order of removal.

• Apply multipurpose grease to pivot rod.
• Adjust brake linkage. (See Adjustments.)

7 - 12 2/9/95
CONTENTS HYDRAULICS

CONTENTS
Page

HYDRAULICS
SPECIFICATIONS
TEST SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
JIC HYDRAULIC CIRCUIT SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
COMPONENT OPERATION
OPTIONAL HYDRAULIC PUMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
RELIEF VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
TROUBLESHOOTING
DIAGNOSIS
IMPLEMENT WILL NOT RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
IMPLEMENT WILL NOT LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
CHECKS, TESTS AND ADJUSTMENTS
RAISE RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
LOWER RELIEF VALVE PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
REPAIR
OPTIONAL HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

2/2/95 8-1
HYDRAULICS SPECIFICATIONS

SPECIFICATIONS

TEST SPECIFICATIONS
Raise Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . 4826—5516 kPa (700—800 psi)
Lower Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . 2413—3103 kPa (350—450 psi)

REPAIR SPECIFICATIONS
Hydraulic Pump:
Reservoir Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 mL (12.4 oz)
Reservoir Breather/Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (45 lb-in.)
Gear Pump Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.)
Hex Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 N•m (44 lb-ft)
Lower Relief Valve Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (20 lb-in.)
Raise Relief Valve Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (20 lb-in.)
Thermal Relief Valve Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (60 lb-in.)

SPECIAL OR ESSENTIAL TOOLS

NOTE: Order tools according to information given in the U.S. SERVICE-GARD Catalog or in the
European Microfiche Tool Catalog (MTC).

JT05471 0—6900 kPa (0—1000 psi) Gauge

Used to check hydraulic relief valve pressures.

8-2 2/1/95
JIC HYDRAULIC CIRCUIT SYMBOL S HYDRAULICS

JIC HYDRAULIC CIRCUIT SYMBOL S

M82612AE

5/11/95 8- 3
HYDRAULICS JIC HYDRAULIC CIRCUIT SYMBOL S

M82613AE

8-4 5/11/95
HYDRAULIC SCHEMATIC HYDRAULICS

HYDRAULIC SCHEMATI C

Lift Cylinder
(Customer Supplied)

Quick
Disconnect Lift Cylinder Hoses
Couplers (Customer Supplied) Thermal
Thermal
Relief Relief
Valve Valve

2500—3000 PSI 2500—3000 PSI

Shuttle

Raise Check Lower Check

Raise Relief Added Flow Lower Relief

Valve Lower Check Valve

Motor

750 ± 50 PSI 400 ± 50 PSI

Gear
Pump Inlet Check

Suction Screen

Reservoir

M83358AE

2/2/95 8- 5
HYDRAULICS
COMPONENT OPERATIO N
Optional Hydraulic Pump Operatio n
Function:
The hydraulic pump supplies hydraulic pressure to
raise or lower the implement. The hydraulic pump is a
dealer installed option.
Theory of Operation:
Raise
When the lift switch is in the RAISE position and the
motor is operating, the gear pump draws oil from the
reservoir through the suction screen. The inlet check
valve opens, allowing oil to flow to the inlet side of the
gear pump.
The gear pump produces high pressure on the outlet
side of the gear pump. This high pressure oil closes
inlet check so oil can not flow back to the reservoir.
High pressure acts against the shuttle, moving the
shuttle toward the down port check valve opening the
down port check valve.
As pressure increases, the UP check valve opens by
overcoming the spring force. This allows high pressure
oil to flow to the lift cylinder (customer supplied) to
extend the cylinder. The raise relief valve prevents the
pressure from exceeding 5271 ± 345 kPa (750 ± 50
psi).
Oil from the head of the cylinder flows back to the
pump, through the open DOWN port check valve and
to the suction side of the pump.
Neutral
NOTE: The following operation describes lift-to-neutral
operation. Lower-to-neutral operation is similar
with oil flow reversed.
When the lift switch is release, the motor and gear
pump stop operating. The oil pressure The oil pressure
at the outlet side of the gear pump decreases. As oil
pressure decreases, spring tension closes the UP
check valve. Oil returning from the cylinder overcomes
the DOWN check valve spring pressure, closing the
down check valve. As the DOWN check valve closes, it
pushes the shuttle to the NEUTRAL position.
Oil in the lift cylinder is now trapped, maintaining the
implement in its desired position. Oil remaining in the
shuttle and gear pump overcome inlet check valve
spring pressure, closing the inlet check valves.
8-6
COMPONENT OPERATION
Lower
When the lift switch is moved to the lower position, the
motor and gear pump rotate in the opposite direction
as the raise operation. The gear pump draws oil from
the reservoir through the suction screen and inlet
check valve.
The gear pump produces high pressure oil on the
outlet side of the gear pump. The high pressure oil
closes the inlet check valve, preventing oil flow back to
the reservoir. High pressure oil acts on the shuttle,
moving the shuttle toward the UP port check valve. The
shuttle contacts the UP port check valve, opening the
check valve.
As oil pressure increases, the DOWN check valve
spring pressure is overcome, opening the check valve.
This allows high pressure oil to flow to the rod end of
the lift cylinder. The lower relief valve prevents the
lower pressure from exceeding 2758 ± 345 kPa (400
±50 psi).
Oil from the lift cylinder flows through the UP port
check valve, past the shuttle, and to the inlet side of the
gear pump. More oil is present in the head end of the
cylinder than the rod end, so to allow the greater
volume of oil to return to the pump, the return oil
unseats the added flow check valve allowing a portion
of the oil to return directly to the reservoir.
Relief Valve Operatio n
If the load being raised is too heavy or an oil passage
becomes blocked, oil pressure will increase at the
outlet side of the gear pump. When oil pressure
overcomes the raise relief valve spring the relief valve
opens allowing high pressure oil to relieve directly to
the reservoir. This protects the gear pump from
damage. the raise relief valve is set at approximately
5171 kPa (750 psi). The raise relief valve is adjustable
by turning the relief valve body.
When the lift cylinder is lowered and the implement
contact the ground, cylinder bottoms or an oil passage
becomes blocked, oil pressure will increase on the
Down side of the gear pump. When oil pressure
overcomes the lower relief valve spring the relief valve
opens, allowing high pressure oil to relieve directly to
the reservoir. The lower relief valve is set at
approximately 2758 kPa (400 psi). The lower relief
valve is also adjustable.
With the lift system in the neutral position, the check
valves are closed. If the cylinder encounters a shock
load, oil pressure in the cylinder will increase because
it is blocked by the lift check. When oil pressure
overcomes the thermal relief valve spring, the relief
valve opens allowing high pressure oil to relieve to the
reservoir. This protect the lift cylinder from damage.
The thermal valve is set at approximately 17237—
20684 kPa (2500—3000 psi). The thermal relief valve
is not adjustable.
1/26/95
TROUBLESHOOTING CHART HYDRAULICS

TROUBLESHOOTING CHART
Problem or

Implement will not

Implement will not

Symptom

Noisy operation.
Check or
Solution

lower.
raise.
Maximum load exceeded. ●

Oil level low. ● ● ●

Wrong oil viscosity. ● ● ●

Suction screen damaged or

● ●
binding.

Gear pump worn or damaged. ● ●

Shuttle valve binding or o-ring

● ●
damaged.

Thermal relief valve binding or

● ●
damaged.

Raise relief valve binding or

●
damaged.

Raise relief valve not properly

●
adjusted, binding or damaged.

Lower relief valve not properly

●
adjusted, binding or damaged.

2/2/95 8-7
HYDRAULICS DIAGNOSIS

DIAGNOSIS

IMPLEMENT WILL NOT RAISE

Test Conditions:

• Machine parked on level surface. • Parking brake ENGAGED.

• Key switch in RUN position. • Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

1. Implement. Load does not exceed 225 kg Remove some of the load.
(500 lb).

2. Hydraulic pump UP port. Raise relief valve pressure within Adjust relief valve setting.
specifications. (Perform Raise
Relief Valve Pressure Test.)

Test Conditions:

• Key switch in OFF position.

Test/Check Point Normal If Not Normal

3. Pump reservoir.
Minimum oil level above suction
screens.
Correct oil viscosity.
Oil clean and not contaminated.
Fill to correct level with John Deere
Low Viscosity HY-GARD (J20D)
transmission/hydraulic oil.
Drain oil and fill to correct level with
John Deere Low Viscosity HY-
GARD (J20D) transmission/
hydraulic oil.

4. Suction screen. Screen clean, not damaged. Clean or replace screen.

5. Inlet checks. Ball and seat free from debris, not Replace pump.
damaged.

6. Gear pump. Gear pump not worn or damaged. Replace pump.

7. Shuttle. Shuttle must move freely in bore, not Replace valve and manifold.
damaged.
Shuttle valve O-ring free of nicks or Replace O-ring.
cuts.

8. Thermal relief valve. Spring not broken or cracked. Ball Replace thermal relief valve.
and seat free of debris, not
damaged.

8-8 5/11/95
DIAGNOSIS HYDRAULICS

IMPLEMENT WILL NOT LOWER

Test Conditions:

• Machine parked on level surface. • Parking brake ENGAGED.

• Key switch in RUN position. • Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

1. Hydraulic pump UP port. Lower relief valve pressure within Adjust relief valve setting.
specifications. (Perform Lower Relief
Valve Pressure Test.)

Test Conditions:

• Key switch in OFF position.

Test/Check Point Normal If Not Normal

1. Pump reservoir.
Minimum oil level above suction
screens.
Correct oil viscosity.
Oil clean and not contaminated.
Fill to correct level with John Deere
Low Viscosity HY-GARD (J20D)
transmission/hydraulic oil.
Drain oil and fill to correct level with
John Deere Low Viscosity HY-
GARD (J20D) transmission/
hydraulic oil.

2. Suction screen. Screen clean, not damaged. Clean or replace screen.

3. Inlet checks. Ball and seat free from debris, not Replace pump.
damaged.

4. Shuttle. Shuttle must move freely in bore, not Replace valve and manifold.
damaged.
Shuttle valve O-ring free of nicks or Replace O-ring.
cuts.

5. Check valves. Spring not broken or cracked. Replace spring.

Check valve tip not worn or Replace check valve.
damaged.

5/11/95 8-9
HYDRAULICS DIAGNOSIS

NOISY OPERATION

Test Conditions:

• Machine parked on level surface. • Parking brake ENGAGED.

• Key switch in OFF position. • Gearshift pedals in NEUTRAL position.

Test/Check Point Normal If Not Normal

1. Pump reservoir.
Minimum oil level above suction
screens.
Correct oil viscosity.
Oil clean and not contaminated.
Fill to correct level with John Deere
Low Viscosity HY-GARD (J20D)
transmission/hydraulic oil.
Drain oil and fill to correct level with
John Deere Low Viscosity HY-
GARD (J20D) transmission/
hydraulic oil.

2. Gear pump. Gear pump not worn or damaged. Replace pump.

8 - 10 5/11/95
CHECKS, TESTS AND ADJUSTMENTS HYDRAULICS

CHECKS, TESTS AND Adjust Raise Relief Valve Pressure:

ADJUSTMENTS Drain and remove reservoir.

Raise Relief Valve Pressure Test

Reason:
To check raise relief valve pressure setting.
Nut

Test Equipment:
• JT05471 0—6900 kPa (0—1000 psi) Gauge

M80635
Procedure:
Loosen nut. Turn relief valve body:
NOTE: Hydraulic oil should be at room temperature - Clockwise to increase pressure.
when performing test. - Counterclockwise to decrease pressure.
Hold relief body and tighten nut.
1. Park machine on level surface. Install reservoir and fill with John Deere Low Viscosity
2. Turn key switch to OFF position. HY-GARD (J20D) transmission/hydraulic oil
3. Move gearshift pedals to NEUTRAL position.
4. Engage parking brake.
5. Lower rear implement.
Lower Relief Valve Pressure Test

Reason:
Quick Coupler
—UP Port To check lower relief valve pressure setting.

JT05471 Test Equipment:

Pressure Gauge
• JT05471 0—6900 kPa (0—1000 psi) Gauge

Procedure:

M80634 NOTE: Hydraulic oil should be at room temperature

when performing test.
6. Connect JT05471 Pressure Gauge to quick
coupler—UP port.
7. Turn Key switch to RUN position. 1. Park machine on level surface.
8. Move lift switch to LIFT position. Record raise relief 2. Turn key switch to OFF position.
valve pressure. Release switch. 3. Move gearshift pedals to NEUTRAL position.
4. Engage parking brake.
5. Lower rear implement.
Results:
• If pressure is not within 4826—5516 kPa (700—
800 psi), adjust raise relief valve.

5/11/95 8 - 11
HYDRAULICS CHECKS, TESTS AND ADJUSTMENTS

JT05471
Pressure Gauge

Quick Coupler
—DOWN Port
M80636

6. Connect JT05471 Pressure Gauge to quick

coupler—DOWN port.
7. Turn Key switch to RUN position.
8. Move lift switch to LOWER position. Record raise
relief valve pressure. Release switch.
Results:
• If pressure is not within 2413—3103 kPa (350—
450 psi), adjust lower relief valve.

Adjust Lower Relief Valve Pressure:

Drain and remove reservoir.

Nut

M80637

Loosen nut. Turn relief valve body:

- Clockwise to increase pressure.
- Counterclockwise to decrease pressure.
Hold relief body and tighten nut.
Install reservoir and fill with John Deere Low Viscosity
HY-GARD (J20D) transmission/hydraulic oil.

8 - 12 5/11/95
REPAIR HYDRAULICS

REPAIR 1. Lower rear implement.

2. Lower front blade (if equipped).
3. Raise rear body cowling.
HYDRAULIC PUM P (OPTIONAL)
Hoses
Removal/Installatio n
Wiring
Connector

c CAUTION
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard by Cap Screws
relieving pressure before disconnecting M80702
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with 4. Disconnect wiring connector.
a piece of cardboard. Protect hands and body 5. Disconnect hoses.
from high pressure fluids. 6. Remove two cap screws and washers and remove
pump.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be removed
within a few hours or gangrene may result. Installation is done in the reverse order of removal .
Doctors unfamiliar with this type of injury may
call Deere & Company Medical Department in
Moline, Illinois, or other knowledgeable medical
source.

Always lower all attachments to the ground

before you work on the machine. If must work on
a lifted machine or attachment, securely support
the machine or attachment. Failure to do so may
result in serious injury.

5/11/95 8 - 13
HYDRAULICS REPAIR

Disassembly/Inspection/Assembl y A-Hex Plu g

B-Sprin g
C-Lift Check Assembl y
D-Lift Check Bod y
E-Shuttle Valv e
F-Adapte r
G-Ball
H-Eyele t
I-Sprin g
J-Set Scre w
Coupler K-Steel Ball (2 used )
L-Eyelet (3 used )
M-Spring (3 used )
N-Nut (2 used )
Pump motor O-Lower Relief Valv e
O-Ring M80699 P-Raise Relief Valv e
Q-Fitting (2 used )
R-Seal
1. Remove two cap screws. S-Reservoi r
2. Remove pump motor, O-ring and coupler. T-Breather/Plu g
U-O-Rin g
V-Scre w
W-Suction Screen (2 used )
X-Scre w
Y-Gear Pum p
Z-O-Ring (2 used )
AA-Thermal Relief Valve (2 used )
F
AB-Plastic Ball (2 used )
G
H
E
D I NOTE: Reservoir oil capacity is 367 mL (12.4 oz).
C J
B
A 3. Remove breather/plug (T) and drain reservoir.
4. Remove parts (R—V).
K
Z
L
NOTE: Gear pump (Y), relief valves (O, P and AA) and
Y
AB M adapter assembly (F) are serviced as
N assemblies.
X
AA P O
IMPORTANT: Mark the position of the relief valves
before removal. Failure to install the relief
valves in their original position will change the
Q
W relief pressures, which may damage
components.
R

5. Mark relief valves (O, P and AA), nuts (N) and

adaptor (F) for each relief valve assembly prior to
S removal to aid in assembly. Also measure the
length of each relief valve from the adapter to the
end of the relief in case the relief valve must be
T replaced.
6. Inspect relief valve springs (M), balls (K and AB),
and seat for debris, cracks, wear or damage.
Replace parts as necessary.
U 7. Inspect gear pump (Y) teeth for nicks or burrs.
Inspect pump housing for wear or damage.
Replace parts as necessary.
V 8. Check shuttle valve (E) for free movement in bore
and O-ring for damage. Replace parts as
necessary.
M80705 9. Inspect passages for plugged conditions.

8 - 14 5/11/95
REPAIR HYDRAULICS

IMPORTANT: Absolute cleanliness is essential

when working on pump. Contamination can
result in serious damage or inadequate
operation.

DO NOT use shop towels or rags to dry clean

parts. Lint will clog passages in hydrostatic
system and cause damage.

c CAUTION
Reduce compressed air to less than 210 kPa (2
bar) (30 psi) when using for cleaning purposes.
Clear area of bystanders, guard against flying
chips, and wear personal protection equipment
including eye protection.

10. Clean components in solvent and dry with

compressed air. Be sure all passages are clear.

Assembly is done in the reverse order of

disassembly.

IMPORTANT: Always use new O-rings. Damaged or

used parts will leak.

• Lubricate O-rings with petroleum jelly during

assembly.
• Apply a light coating of clean hydraulic oil to all
internal parts before assembly.

NOTE: Install fittings (Q) and screens (W) pointing

180° to set screw (J).

Install reservoir (S) with breather/plug (T) in

alignment with set screw (J).

• Tighten components to specifications.

• Fill reservoir with John Deere Low Viscosity HY-
GARD (J20D) transmission/hydraulic oil.

Torque Specifications
Reservoir Breather/Plug (T) . . . . . . 5 N•m (45 lb-in.)
Gear Pump Screw (X) . . . . . . . . . . . 8 N•m (70 lb-in.)
Hex Plug (A) . . . . . . . . . . . . . . . . . . . 59 N•m (44 lb-ft)
Lower Relief Valve Nut (D). . . . . . . . 2 N•m (20 lb-in.)
Raise Relief Valve Nut (O) . . . . . . . . 2 N•m (20 lb-in.)
Thermal Relief Valve (AA) . . . . . . . . 7 N•m (60 lb-in.)

5/11/95 8 - 15
HYDRAULICS REPAIR

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8 - 16 5/11/95
CONTENTS ATTACHMENTS

CONTENTS
Page

ATTACHMENTS
SPECIFICATIONS
REPAIR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
REPAIR
OPTIONAL 40-INCH FRONT BLADE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 9-3
OPTIONAL 60-INCH FRONT ALUMINUM BLADE. . . . . . . . . . . . . . . . . . . . . . 9-5
OPTIONAL FRONT CORE REMOVAL BLADE . . . . . . . . . . . . . . . . . . . . . . . . 9-6
MID-MOUNT LIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
OPTIONAL CULTIVATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
OPTIONAL SCRAPER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
REAR IMPLEMENT LIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
OPTIONAL RAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
OPTIONAL FIELD FINISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

2/9/95 9-1
ATTACHMENTS SPECIFICATIONS

SPECIFICATIONS

REPAIR SPECIFICATIONS
Mid-Mount Lift Handle Return Spring Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 mm (3.50 in.)

9-2 5/11/95
REPAIR ATTACHMENTS

REPAIR 2. Support front blade.

3. Disconnect springs from blade frame.

OPTIONAL 40-INCH FRONT BLADE

ASSEMBLY

Removal/Installation
Pin

Turnbuckle

Pin M83174

4. Disconnect turnbuckle from frame.

5. Remove pins.
Cap Screw
6. Raise handle above platform.
Storage Hole
7. Remove front blade and framework from under
machine.
M83162

Installation is done in the reverse order of removal.

NOTE: Storage hole is used to store spring lock pin • Connect springs to blade frame last.
during blade operation.

1. Remove cap screws, washers and lock nut.

Springs M83173

c CAUTION
Front blade will drop when springs are removed.
Support blade before removing springs.

2/9/95 9-3
ATTACHMENTS REPAIR

Disassembly/Inspection/Assembly

Strap
Spring Locking Pin Bracket

Lock Nut
Cap Screws
Cover

Lock Nut

Cap Screw
Washer Ball Joint
Flat Washer
Lock Nut
Cap Screw

Washer

Nut
Knob
Stud
Nut
Spring
Bumper Ball Joint

Spring

Bumper Pin Spring

Locking Pin

Front Blade
Lock Nut

M83199

• Inspect all parts for wear or damage. Replace parts

as necessary.
• Do not overtighten lock nuts. Parts must be free to
pivot.
• Adjust ball joints as necessary.

9-4 2/9/95
REPAIR ATTACHMENTS

OPTIONAL 60-INCH FRONT ALUMINUM BLADE

Disassembly/Inspection/Assembly

Lock Nut

Washer

40-Inch Blade

Cap Screw

Washer 60-Inch Blade

M83353AE

NOTE: 60-inch Front Aluminum Blade attaches to

optional 40-inch Front Blade Assembly.

• Inspect all parts for wear or damage. Replace parts

as necessary.

2/9/95 9-5
ATTACHMENTS REPAIR

OPTIONAL FRONT CORE REMOVAL BLADE

Disassembly/Inspection/Assembly

Lock Nut
40-inch Blade Washer Lock Lever

Washer
Cap Screw
3/8" x 2-3/4" Frame

Lock Nut Washer

Lock Nut
Lock Nut Washer
Cap Screw
Washer 3/8" x 2"

Cap Screw
3/8" x 1-1/4"

Cap Screw
1/4" x 2"

Core Removal Blade

Washer
Cap Screw Cap Screw
M83355AE
1/4" x 2" 3/8" x 2-1/2"

NOTE: Front Core Removal Blade attaches to optional

40-inch Front Blade Assembly.

Inspect all parts for wear or damage. Replace parts as

necessary.

9-6 2/9/95
REPAIR ATTACHMENTS

MID-MOUNT LIFT LINKAGE

Disassembly/Inspection/Assembly

Knob

Lift Handle Washer (2 used)

Lock Nut (2 used)

Lock Nut

Cap Screw
(2 used) Return Spring Lock Nut (2 used)

Washer
(2 used)

Stud

Lock Nut

Lift Spring Set Screw

Support

Cap Screw (2 used)

M83351AE

• Inspect all parts for wear or damage. Replace parts

as necessary.
• Install R.H. rear cap screw with head to inside of
frame.
• Adjust handle lock nut until length of return spring is
89 mm (3.50 in.).
• Do not overtighten handle lock nut. Handle must be
free to pivot.

2/9/95 9-7
ATTACHMENTS REPAIR

OPTIONAL CULTIVATOR ASSEMBLY

Removal/Installation
1. Lower cultivator to the ground.

Hook Bolt

Spring
Locking
Pin Strap Spring Locking Pin
Hook Bolt
M83176

2. Remove spring locking pin and disconnect hook

bolt from pivot strap. Repeat on opposite side.
3. Remove spring locking pin and drilled pin from
strap. Repeat on opposite side.
4. Remove cultivator from under machine.

Installation is done in the reverse order of removal.

Collar
M83175

NOTE: If hook bolt does not line up with pivot strap,

move left-hand collar to adjust pivot shaft.

9-8 2/9/95
REPAIR ATTACHMENTS

Disassembly/Inspection/Assembly

Spring Locking Pin

Hook Bolt

Spring

Washer
Hook Bolt
Spring Locking Pin

Washer
Spring

Spring Locking Quick Locking Pin

Pin (2 used) Lock Nut (10 Used)

Pin (2 used)
Angle

Quick Locking Pin

Scarifier Tines (5 used)

(wide or narrow)

Blade (5 used)

Washer (10 used)

Cap Screw (10 used)

M83333AE

• Inspect all parts for wear or damage. Replace parts

as necessary.

2/9/95 9-9
ATTACHMENTS REPAIR

OPTIONAL SCRAPER BLADE

Disassembly/Inspection/Assembly

Spring Locking Pin

Hook Bolt
Spring Spring
Locking
Pin
Washer
Angle

Hook Bolt

Spring
Locking Spring
Pin (2 used)
Washer

Pin (2 used) Lock Nut

Quick
(12 used)
Locking
Pin

Quick
Locking Pin

Scraper Blade Scarifier Tines

(Wide or Narrow)

Washer
(12 used) Lock Nut
(12 used)
Cap Screw
(12 used)
M83356AE

NOTE: Scraper blade is removed and installed in the

same manner as cultivator. (See
CULTIVATOR.)

• Inspect all parts for wear or damage. Replace parts

as necessary.

9 - 10 2/9/95
REPAIR ATTACHMENTS

REAR IMPLEMENT LIFT LINKAGE

Removal/Installation

Lift Actuator
When using Field Finisher attachment
lift actuator must be repositioned.
(See REPOSITION LIFT ACTUATOR.)

Field
Finisher
Hole Lock Nut
Rear
Rake
Hole
Cap Screw

Lift Bar

Spring Hole

Field Finisher Hole

Cap Screw
Spring Rear Rake Hole
Lock Nut M83185AE
Lock Nut

1. Remove rear implement.

2. Raise lift bar to UP position.
3. Remove lift actuator-to-lift bar lock nut.
4. Disconnect spring from lift bar.
5. Remove cap screws, lock nuts and lift bar.
• Inspect all parts for wear or damage. Replace parts
as necessary.

Installation is done in the reverse order of removal.

• Do not overtighten lock nuts. Handle must be free
to pivot.

2/9/95 9 - 11
ATTACHMENTS REPAIR

Reposition Lift Actuator

NOTE: Lift actuator is positioned at the factory for

bunker and field rake operation. In this
position, the actuator motor is located above
the cyinder. When using the field finisher the
actuator MUST be repositioned with the motor
below the cylinder to prevent interference with
electrical relay mounted on side frame.

1. Remove rear implement.

2. Raise lift bar to full UP position.
.
Nuts

M83500

6. Remove nut from bolt at each end of the cylinder.

Remove bolts and install from opposite side into
cylinder shaft holes. Install nuts on bolts.

Field
Wiring Connector Finisher
Hole
M83111

3. Disconnect wiring connector.

Nut

Nut
Field
Finisher
Hole

Nut M83477AE

7. Rotate actuator so that the motor is below the

cylinder.
8. Install bolts in field finisher holes in frame and lift
bar. Secure with nuts.
9. Connect wiring connector.

Nut M83112AE

4. Remove nuts.
5. Remove lift actuator.

9 - 12 2/9/95
REPAIR ATTACHMENTS

RAKE ASSEMBLY

Removal/Installation
1. Lower rake assembly to the ground.

Lift Hook
Lift Hook
Pin

M83157

2. Remove chains from lift hooks.

3. Remove pin. Remove rake hitch from frame.

Installation is done in the reverse order of removal.

Guide

Spring
M83158

• Raise rake. Guide must have spring compressed

and touching frame. Adjust chain length if
necessary.

2/9/95 9 - 13
ATTACHMENTS REPAIR

Disassembly/Inspection/Assembly

Rake Blade (5 used)

R.H. Angle
Center Angle

Chain link
Compression (10 used)
Guide
Spring
Chain
(2 used) L.H. Angle

Cap Screw
(2 used)

Pin

Cap Screw
Frame (2 used)

Lock Nut
(2 used)
Hitch Prong Rake Bolt
(24 used)

M83357AE

• Inspect all parts for wear or damage. Replace parts

as necessary.
• Do not overtighten hitch cap screws. Hitch must be
free to pivot.
• Do not overtighten right and left angle cap screws
and lock nuts. Angles must be free to pivot.

9 - 14 2/9/95
REPAIR ATTACHMENTS

OPTIONAL FIELD FINISHER

Disassembly/Inspection/Assembly

Compression Spring
Guide

Chain (2 used)

Field Finisher

Cap Screw
(2 used)

Pin

Washer (2 used)

Frame

Spring Locking Pin (2 used)

Hitch
M83354AE

IMPORTANT: Correct machine setup is critical for
optimum field finisher performance. (See FIELD
FINISHER SETUP.)
NOTE: Field finisher is removed and installed in the
same manner as rake assembly. (See RAKE.)
• Inspect all parts for wear or damage. Replace parts
as necessary.
• Do not overtighten hitch cap screws. Hitch must be
free to pivot.
Field Finisher Setup
For most field conditions:
• Lower field finisher to the ground and make sure
frame is in lowest position.
• Make sure field finisher is squared with vehicle.
• Pull chains tight without lifting the field finisher and
fasten chains to the frame hooks
• If chain has clack when conected to the frame, twist
chain one revolution and reattach to frame.
NOTE: To prevent dirt build-up on the finisher screen
in muddy soil or other conditions, shorten both
chains equally to raise the front of the screen
attachment slightly.

IMPORTANT: Correct air pressure is necessary to

ensure proper field finishing performance. Tire
pressure is 27.6-41.4 kPa (4-6 psi). Rear tire
pressure MUST be equal for finisher to provide
optimum performance.

2/9/95 9 - 15
ATTACHMENTS REPAIR

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9 - 16 2/9/95
MISCELLANEOUS CONTENTS

CONTENTS
Page

MISCELLANEOUS
SPECIFICATIONS
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
REPAIR
DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
FRONT HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
SPLASH GUARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
REAR BODY COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
FRONT WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
REAR WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

2/2/95 10- 1
MISCELLANEOUS SPECIFICATIONS

SPECIFICATIONS

REPAIR SPECIFICATIONS
Rear Wheel Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N•m (60 lb-ft)

SERVICE PARTS KITS

The following kits are available through your parts catalog:
• Front Wheel Repair Kit

10 - 2 1/27/95
REPAIR MISCELLANEOUS

REPAIR FRONT HOOD

DASH PANEL Removal/Installation

1. Lower front blade (if equipped).
Removal/Installation 2. Raise rear body cowling.
3. Remove dash panel. (See DASH PANEL.)
1. Remove steering wheel. (See procedure in
STEERING section.)

Cap Screws Retaining Nut

Choke Knob

M83109

M83103 4. Remove choke knob and retaining nut.

2. Remove cap screws from both sides of panel.

Wiring Connector

Lift Switch Connector Voltmeter Leads

Hourmeter Connector
Light Switch Connectors

M83104

3. Disconnect lift switch wiring connector. Screws

4. Disconnect voltmeter leads. M83105
5. Disconnect hourmeter wiring connectors.
6. Disconnect light switch connectors. 5. Disconnect wiring connector from key switch.
6. Remove screws, washers and nuts from both sides
of hood.
Installation is done in the reverse order of removal. 7. Remove front hood.

Installation is done in the reverse order of removal.

2/9/95 10 - 3
MISCELLANEOUS REPAIR

SPLASH GUARD 6. Remove rear body cowling.

Installation is done in the reverse order of removal.

Removal/Installation
1. Remove steering fork. (See procedure in
STEERING section.) FRONT WHEEL
Splash Guard
Removal/Installation
1. Lift machine high enough to remove weight from
wheel. Place jackstands under machine frame.

Lock Nut

Screws
M83137

2. Remove four screws and washers.

3. Remove splash guard.

M83138
Installation is done in the reverse order of removal.
2. Remove lock nut, cap screw and wheel.
REAR BODY COWLING 3. Inspect wheel bearings for wear or damage.
Replace if necessary. (See INSPECTION/
REPLACEMENT procedure.)
Removal/Installation
1. Lower front blade (if equipped). Installation is done in the reverse order of removal.
2. Raise rear body cowling. Attach a lifting strap to
support cowling.
Wheel Bearing Inspection/
Replacement
Cap Screws

NOTE: Remove bearings only if replacement is

necessary.

1. Inspect bearings for wear or damage. Replace if

necessary.

Support Cylinder NOTE: Bearings are pressed-fit in wheel and slip fit on
axle tube.

Lock Nut Lighting Harness

Connector
M83106

3. Disconnect lighting harness, if equipped.

4. Remove lock nut and disconnect support cylinder.
5. Remove cap screws and lock nuts.

10 - 4 2/9/95
REPAIR MISCELLANEOUS

REAR WHEELS
Axle Tube

Driver Set
Removal/Installation
1. Lift machine high enough to remove weight from
wheels. Place jackstands under machine frame.

Cap Screws
80 N•m
(60 lb-ft)

M80798

2. Remove wheel bearing from wheel by driving axle

tube from opposite side using a driver set. Turn
wheel over and repeat process for remaining
bearing.

M80861
Raised Side
2. Remove cap screws and rear wheels

Installation is done in the reverse order of removal.

Install wheels with valve stems

facing away from machine.
M80799

NOTE: Install bearings with raised side facing away

from wheel. Press on outer race only.

3. Install one bearing in wheel until seated using a

driver set. Turn wheel over and repeat process for
remaining bearing.
4. Install front wheel.

2/9/95 10 - 5

Numerics
40-Inch Front Blade Assembly
Disassembly/Inspection/Assembly . . . . . . . 9-4
Removal/Installation . . . . . . . . . . . . . . . . . . 9-3
60-Inch Front Aluminum Blade . . . . . . . . . . . . . . 9-5
A Removal/Installation . . . . . . . . . . . . . . . . . . 3-29
Accelerator Cable
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-25
Air Cleaner Assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Removal/Installation . . . . . . . . . . . . . . . . . 3-27
Armature with Coil . . . . . . . . . . . . . . . . . . . . . . . 3-55
Air Gap Adjustment . . . . . . . . . . . . . . . . . . 3-55
Removal/Installation . . . . . . . . . . . . . . . . . 3-55
Automatic Compression Release Check . . . . . . 3-20
B Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Balancer
Bushing Replacement . . . . . . . . . . . . . . . . 3-48
Disassembly/Assembly . . . . . . . . . . . . . . . 3-47
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Removal/Installation . . . . . . . . . . . . . . . . . 3-46
Battery
Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Blower Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Brake Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Brake Lining Contact Adjustment . . . . . . . . . . . . 7-8
Brake Linkage Adjustment . . . . . . . . . . . . . . . . . 7-8
Brake Pedal and Linkage . . . . . . . . . . . . . . . . . 7-12
Brakes
Adjustment Specifications . . . . . . . . . . . . . . 7-2
Components and Operation . . . . . . . . . . . . 7-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Repair Specifications . . . . . . . . . . . . . . . . . . 7-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . 7-4
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
5/11/95
Index
C
Camshaft and Tappets
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Removal/Installation . . . . . . . . . . . . . . . . . . 3-44
Carburetor
Clean/Inspect/Rebuild . . . . . . . . . . . . . . . . 3-31
Disassembly/Assembly . . . . . . . . . . . . . . . 3-31
Charging Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Choke Adjustment . . . . . . . . . . . . . . . . . . . . . . . 3-16
Choke Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Clutch System
Component Location and Operation . . . . . . 5-5
Common Circuit Test . . . . . . . . . . . . . . . . . . . . . 4-52
Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Crankcase Vacuum Test . . . . . . . . . . . . . . . . . . 3-20
Cranking Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Crankshaft and Connecting Rod,
Analyze Wear . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Crankshaft and Main Bearings
Crankshaft End Play Check . . . . . . . . . . . . 3-22
End Play Adjustment . . . . . . . . . . . . . . . . . 3-50
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Removal/Installation . . . . . . . . . . . . . . . . . . 3-48
Crankshaft Oil Seal
Flywheel End . . . . . . . . . . . . . . . . . . . . . . . 3-50
PTO End . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Cultivator Assembly
Disassembly/Inspection/Assembly . . . . . . . . 9-9
Removal/Installation . . . . . . . . . . . . . . . . . . . 9-8
Cylinder
Compression Pressure Test . . . . . . . . . . . . 3-19
Deglaze . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Rebore . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Cylinder Head and Valves
Disassembly/Assembly . . . . . . . . . . . . . . . 3-34
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Removal/Installation . . . . . . . . . . . . . . . . . . 3-34
Valve Guide Bushing Replacement . . . . . . 3-36
Index-1
Index
D Front Core Removal Blade . . . . . . . . . . . . . . . . . . 9-6
Dash Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Lock Pedal and Linkage . . . . . . . . .
Drive (Primary) Clutch
Disassembly/Inspection/Assembly . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . .
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt Check . . . . . . . . . . . . . . . . . . . . . . . .
Drive Train Performance Tests . . . . . . . . . . . . .
Driven Clutch Spring Torsion Check . . . . . . . . .
Driven Pulley
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . .
Ramp Shoe Replacement . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . .
Replace Ramp Shoes (Clutch Mounted on
Machine) . . . . . . . . . . . . . . . . . . . . . . . . . .
E
Electrical
Components . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Repair Specifications . . . . . . . . . . . . . . . . . . 4-3
Schematic - Optional Equipment . . . . . . . . . 4-8
Schematic - Standard . . . . . . . . . . . . . . . . . 4-7
Test and Adjustment Specifications . . . . . . . 4-3
Troubleshooting Chart . . . . . . . . . . . . . . . . 4-13
Wire Color Abbreviation Chart . . . . . . . . . . . 4-6
Wiring Harness - Hydraulic Pump . . . . . . . 4-12
Wiring Harness - Lighting . . . . . . . . . . . . . 4-11
Wiring Harness - Standard . . . . . . . . . . . . 4-10
Engine
Designation . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removal/Installation . . . . . . . . . . . . . . . . . 3-28
Repair Specifications . . . . . . . . . . . . . . . . . . 3-4
Test and Adjustment Specifications . . . . . . . 3-3
Troubleshooting Chart . . . . . . . . . . . . . . . . . 3-9
Troubleshooting Guide . . . . . . . . . . . . . . . 3-11
Engine Oil Pressure Test . . . . . . . . . . . . . . . . . . 3-21
F
Field Finisher
Disassembly/Inspection/Assembly . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Magnet Test . . . . . . . . . . . . . . . . . . . .
Index-2
Front Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10-3 Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
5-19 Fuel Pump
Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-28
5-21 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
5-21 Fuel System
5-21 Troubleshooting Chart . . . . . . . . . . . . . . . . . 3-9
5-16 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
5-16
5-18
5-23 G
5-23
Gearshift Linkage Adjustment . . . . . . . . . . . . . . 5-16
5-23
Gearshift Pedals and Linkage . . . . . . . . . . . . . . 5-20
5-22
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
5-24 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Governor Shaft . . . . . . . . . . . . . . . . . . . . . . 3-54
Ground Circuit Test . . . . . . . . . . . . . . . . . . . . . . 4-52
H
Hydraulic Pump
Adjust Lower Relief Valve Pressure . . . . . . 8-12
Adjust Raise Relief Valve Pressure . . . . . . 8-11
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Disassembly/Inspection/Assembly . . . . . . . 8-14
Lower Relief Valve Pressure Test . . . . . . . . 8-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Raise Relief Valve Pressure Test . . . . . . . . 8-11
Removal/Installation . . . . . . . . . . . . . . . . . . 8-13
Hydraulic Pump Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Hydraulic Pump Oil . . . . . . . . . . . . . . . . . . . . . . . 2-8
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . 8-5
Hydraulics
Repair Specifications . . . . . . . . . . . . . . . . . . 8-2
Test Specifications . . . . . . . . . . . . . . . . . . . . 8-2
I
9-15
9-15 Idle Speed Adjustment
3-32 Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
4-59 Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
5/11/95

Ignition Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Engine Running . . . . . . . . . . . . . . . . . . . . . 4-24
Engine Shutting Off . . . . . . . . . . . . . . . . . . 4-26
Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Ignition Module Test . . . . . . . . . . . . . . . . . . . . . 4-59
Inspection/Replacement . . . . . . . . . . . . . . . . . . 3-32
J Disassembly/Assembly . . . . . . . . . . . . . . . 3-52
JIC Hydraulic Circuit Symbols . . . . . . . . . . . . . . . 8-3
K
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
L Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Lift Actuator
Cover Tube Seal Replacement . . . . . . . . . 4-64
Disassembly/Assembly . . . . . . . . . . . . . . . 4-63
Motor Amperage Draw Test . . . . . . . . . . . . 4-58
Removal/Installation . . . . . . . . . . . . . . . . . 4-62
Service Parts Kits . . . . . . . . . . . . . . . . . . . . 4-4
Lift Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Lift System Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Lift System Troubleshooting Chart . . . . . . . . . . 4-13
Lubricants
Alternative . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
M R
Machine Identification Number . . . . . . . . . . . . . . 2-9
METRO-PACK Connectors . . . . . . . . . . . . . . . . 4-65
Mid-Mount Lift Linkage . . . . . . . . . . . . . . . . . . . . 9-7
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
5/11/95
Index
N
Neutral Start Switch Test . . . . . . . . . . . . . . . . . . 4-60
O
Oil Filter Manifold . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Oil Pump
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Oilscan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
P
Piston and Connecting Rod
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
End Gap Check . . . . . . . . . . . . . . . . . . . . . 3-42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Piston Ring
Analyze Wear . . . . . . . . . . . . . . . . . . . . . . . 3-42
Piston, Analyze Wear . . . . . . . . . . . . . . . . . . . . . 3-43
Power Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Power Train
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Repair Specifications . . . . . . . . . . . . . . . . . . 5-2
Service Parts Kits . . . . . . . . . . . . . . . . . . . . . 5-4
Special or Essential Tools . . . . . . . . . . . . . . 5-3
Test and Adjustment Specifications . . . . . . . 5-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . 5-8
Rake Assembly
Disassembly/Inspection/Assembly . . . . . . . 9-14
Removal/Installation . . . . . . . . . . . . . . . . . . 9-13
Rear Body Cowling . . . . . . . . . . . . . . . . . . . . . . 10-4
Index-3
Index

Rear Implement Lift Linkage Steering System

Removal/Installation . . . . . . . . . . . . . . . . . 9-11 Components and Operation . . . . . . . . . . . . . 6-3
Reposition Lift Actuator . . . . . . . . . . . . . . . 9-12 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Repair Specifications . . . . . . . . . . . . . . . . . . 6-2
Regulated Amerage Output Test . . . . . . . . . . . . 4-55 Troubleshooting Chart . . . . . . . . . . . . . . . . . 6-4
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Removal/Installation . . . . . . . . . . . . . . . . . . . . . 10-4
Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . 3-33
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 T
Transaxle
S Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Component Location and Operation . . . . . . 5-6
Scraper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Disassembly/Inspection . . . . . . . . . . . . . . . 5-25
Serial Number Removal/Installation . . . . . . . . . . . . . . . . . . 5-24
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Transaxle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . 8-7
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . 2-9
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Spark Plug Gap Adjustment . . . . . . . . . . . . . . . 3-23 V
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Valve Clearance, Check and Adjustment . . . . . . 3-19
Splash Guard . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Valve Seats
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Recondition . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Analyze Condition . . . . . . . . . . . . . . . . . . . 3-56
Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Disassembly/Assembly . . . . . . . . . . . . . . . 3-57
Valves
Inspection/Test . . . . . . . . . . . . . . . . . . . . . 3-57
Analyze . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Loaded Amperage Draw Test . . . . . . . . . . 4-57
Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
No-Load Amperage Test . . . . . . . . . . . . . . 3-56
Voltage Test
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . 4-57
Regulated Output . . . . . . . . . . . . . . . . . . . . 4-56
Starter Motor
Unregulated Output . . . . . . . . . . . . . . . . . . 4-56
Troubleshooting Guide . . . . . . . . . . . . . . . 3-15
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Steering Chain Tension Adjustment . . . . . . . . . . 6-8 W
Steering Fork Assembly . . . . . . . . . . . . . . . . . . 6-10
Steering Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Wheel Bearing Inspection/Replacement . . . . . . 10-4

Index-4 5/11/95