JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER

EQUIPMENT DIVISION

2023

Garden Tractors
June 2004

X465, X475, X485, X575 and X585

TM2023 JUNE 2004

TECHNICAL MANUAL

North American Version

Litho in U.S.A.
 INTRODUCTION
Manual Description
Introduction

This technical manual is written for an experienced Safety

technician and contains sections that are specifically for
this product. It is a part of a total product support program.
The manual is organized so that all the information on a Specifications and Information
particular system is kept together. The order of grouping is
as follows:
• Table of Contents Engine - Gas (Air-Cooled)
• Specifications and Information
• Identification Numbers
• Tools and Materials Engine - Gas (Liquid-Cooled)
• Component Location
• Schematics and Harnesses
Electrical
• Theory of Operation
• Operation and Diagnostics
• Diagnostics Power Train - Hydrostatic
• Tests and Adjustments
• Repair
• Other Hydraulics
NOTE: Depending on the particular section or system
being covered, not all of the above groups may be
used. Steering
The bleed tabs for the pages of each section will align with
the sections listed on this page. Page numbering is
consecutive from the beginning of the Safety section Brakes
through the last section.
We appreciate your input on this manual. If you find any
errors or want to comment on the layout of the manual Attachments
please contact us.

Miscellaneous

All information, illustrations and

specifications in this manual are based
on the latest information at the time of
publication. The right is reserved to
make changes at any time without
notice.
COPYRIGHT© 2004
Deere & Co.
John Deere Worldwide Commercial and
Consumer Equipment Division
All rights reserved
Previous Editions
COPYRIGHT© 2002; 2003

Introduction
 SAFETY
Handle Fluids Safely - Avoid Fires
Safety

Recognize Safety Information Be Prepared For Emergencies

MIF

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

on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe servicing
practices.

Understand Signal Words MIF

A signal word - DANGER, WARNING, or CAUTION - is • When you work around fuel, do not smoke or work near
used with the safety-alert symbol. DANGER identifies the heaters or other fire hazards.
most serious hazards.
• Store flammable fluids away from fire hazards. Do not
DANGER or WARNING safety signs are located near incinerate or puncture pressurized containers.
specific hazards. General precautions are listed on
• Make sure machine is clean of trash, grease, and
CAUTION safety signs. CAUTION also calls attention to
debris.
safety messages in this manual.
• Do not store oily rags; they can ignite and burn
spontaneously.
Replace Safety Signs
• 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.

Use Care In Handling And Servicing Batteries

MIF

Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign
placement. MIF

Safety -1
 SAFETY
Prevent Battery Explosions such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
• Keep sparks, lighted matches, and open flame away
from the top of battery. Battery gas can explode. Operating equipment safely requires the full attention of the
operator. Do not wear radio or music headphones while
• Never check battery charge by placing a metal object operating machine.
across the posts. Use a volt-meter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm Use Care Around High-pressure Fluid Lines
battery to 16°C (60°F).
Avoid High-Pressure Fluids
Prevent Acid Burns
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.

Avoid acid burns by:

1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added. MIF

4. Avoiding spilling or dripping electrolyte. Escaping fluid under pressure can penetrate the skin
causing serious injury.
5. Use proper jump start procedure.
Avoid injury from escaping fluid under pressure by stopping
If you spill acid on yourself: the engine and relieving pressure in the system before
disconnecting or connecting hydraulic or other lines.
1. Flush your skin with water.
Tighten all connections before applying pressure.
2. Apply baking soda or lime to help neutralize the acid.
Search for leaks with a piece of cardboard. Protect hands
3. Flush your eyes with water for 10 - 15 minutes. and body from high pressure fluids.
4. Get medical attention immediately. If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
If acid is swallowed: few hours or gangrene may result. Doctors unfamiliar with
1. Drink large amounts of water or milk. this type of injury should reference a knowledgeable
medical source. Such information is available from Deere &
2. Then drink milk of magnesia, beaten eggs, or vegetable Company Medical Department in Moline, Illinois, U.S.A.
oil.
3. Get medical attention immediately. Avoid Heating Near Pressurized Fluid Lines

Wear Protective Clothing

MIF
MIF
Flammable spray can be generated by heating near
Wear close fitting clothing and safety equipment pressurized fluid lines, resulting in severe burns to yourself
appropriate to the job. and bystanders. Do not heat by welding, soldering, or using
Prolonged exposure to loud noise can cause impairment or a torch near pressurized fluid lines or other flammable
loss of hearing. Wear a suitable hearing protective device materials. Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.

Safety -2
 SAFETY
Service Machines Safely Support Machine Properly and Use Proper
Lifting Equipment

MIF

Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get MIF
caught, severe injury could result. If you must work on a lifted machine or attachment,
Remove rings and other jewelry to prevent electrical shorts securely support the machine or attachment.
and entanglement in moving parts. Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
Use Proper Tools work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
Use tools appropriate to the work. Makeshift tools and
Lifting heavy components incorrectly can cause severe
procedures can create safety hazards. Use power tools
injury or machine damage. Follow recommended
only to loosen threaded parts and fasteners. For loosening
procedure for removal and installation of components in the
and tightening hardware, use the correct size tools. DO
manual.
NOT use U.S. measurement tools on metric fasteners.
Avoid bodily injury caused by slipping wrenches. Use only
service parts meeting John Deere specifications. Work In Clean Area
Before starting a job:
Park Machine Safely
1. Clean work area and machine.
2. Make sure you have all necessary tools to do your job.
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.

Using High Pressure Washers

Directing pressurized water at electronic/electrical
MIF
components or connectors, bearings, hydraulic seals, fuel
injection pumps or other sensitive parts and components
Before working on the machine:
may cause product malfunctions. Reduce pressure and
1. Lower all equipment to the ground. spray at a 45 to 90 degree angle.
2. Stop the engine and remove the key.
3. Disconnect the battery ground strap. Illuminate Work Area Safely
4. Hang a “DO NOT OPERATE” tag in operator station. Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.

Safety -3
 SAFETY
Work In Ventilated Area Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when
handling components containing asbestos fibers.
Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos
fibers are brake pads, brake band and lining assemblies,
clutch plates, and some gaskets. The asbestos used in
these components is usually found in a resin or sealed in
some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not
generated.
MIF
Avoid creating dust. Never use compressed air for cleaning.
Engine exhaust fumes can cause sickness or death. If it is
Avoid brushing or grinding material containing asbestos.
necessary to run an engine in an enclosed area, remove
When servicing, wear an approved respirator. A special
the exhaust fumes from the area with an exhaust pipe
vacuum cleaner is recommended to clean asbestos. If not
extension.
available, apply a mist of oil or water on the material
If you do not have an exhaust pipe extension, open the containing asbestos. Keep bystanders away from the area.
doors and get outside air into the area.
Service Tires Safely
Warning: California Proposition 65 Warning
Gasoline engine exhaust from this product contains
chemicals known to the State of California to cause cancer,
birth defects, or other reproductive harm.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes
can be generated when paint is heated by welding, MIF
soldering, or using a torch. Do all work outside or in a well Explosive separation of a tire and rim parts can cause
ventilated area. Dispose of paint and solvent properly. serious injury or death.
Remove paint before welding or heating: If you sand or
grind paint, avoid breathing the dust. Wear an approved Do not attempt to mount a tire unless you have the proper
respirator. If you use solvent or paint stripper, remove equipment and experience to perform the job.
stripper with soap and water before welding. Remove Always maintain the correct tire pressure. Do not inflate the
solvent or paint stripper containers and other flammable tires above the recommended pressure. Never weld or heat
material from area. Allow fumes to disperse at least 15 a wheel and tire assembly. The heat can cause an increase
minutes before welding or heating. in air pressure resulting in a tire explosion. Welding can
structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety cage
if available.
Check wheels for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.

Safety -4
 SAFETY
Avoid Injury From Rotating Blades, Augers Direct exposure to hazardous chemicals can cause serious
And PTO Shafts injury. Potentially hazardous chemicals used with John
Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.

Dispose of Waste Properly

MIF
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
Keep hands and feet away while machine is running. Shut with John Deere equipment include such items as oil, fuel,
off power to service, lubricate or remove mower blades, coolant, brake fluid, filters, and batteries. Use leakproof
augers or PTO shafts. containers when draining fluids. Do not use food or
beverage containers that may mislead someone into
Service Cooling System Safely drinking from them. Do not pour waste onto the ground,
down a drain, or into any water source. Inquire on the
proper way to recycle or dispose of waste from your local
environmental or recycling center, or from your John Deere
dealer.

Live With Safety

MIF

Explosive release of fluids from pressurized cooling system

can cause serious burns.
Shut off machine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop to
relieve pressure before removing completely.

Handle Chemical Products Safely

MIF

Before returning machine to customer, make sure machine

is functioning properly, especially the safety systems. Install
all guards and shields.

MIF

Safety -5
SAFETY

Safety -6
 SPECIFICATIONS & INFORMATION TABLE OF CONTENTS
Specifications & Information

Table of Contents

Fastener Torques..............................................9
Metric Fastener Torque Values ......................9
Inch Fastener Torque Values .......................10
O-Ring Seal Service Recommendations ......11
Face Seal Fittings With Inch Stud Ends
Torque ..........................................................11
Face Seal Fittings With Metric Stud Ends
Torque ..........................................................12
O-Ring Face Seal Fittings ............................13
O-Ring Boss Fittings ....................................13
Straight Fitting or Special Nut Torques ........14
Metric Fastener Torque Value - Grade 7
(Special) .......................................................14
General Information........................................14
Gasoline .......................................................14
Gasoline Storage..........................................15
4 - Cycle Gasoline Engine Oil ......................15
Break-In Engine Oil - 4-Cycle Gasoline........16
Hydrostatic Transmission and Hydraulic Oil.16
Gear Case Oil...............................................17
Gear Transmission Grease ..........................18
Alternative Lubricants...................................18
Synthetic Lubricants .....................................18
Lubricant Storage .........................................18
Mixing of Lubricants .....................................18
Oil Filters ......................................................18
Coolant Specifications ...................................19
Gasoline Engine Coolant..............................19
Gasoline Engine Coolant Drain Interval .......19
Serial Number Locations ...............................20
Product Serial Number .................................20
Gasoline Engine Serial Number Location ....20

Specifications & Information Table of Contents - 7

SPECIFICATIONS & INFORMATION TABLE OF CONTENTS

Specifications & Information Table of Contents - 8

 SPECIFICATIONS & INFORMATION FASTENER TORQUES
Fastener Torques

Metric Fastener Torque Values

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

MIF
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a
SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m 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 hand torque values if a different torque When bolt and nut combination fasteners are used, torque
value or tightening procedure is given for a specific values should be applied to the NUT instead of the bolt
application. Torque values listed are for general use only head.
and include a ±10% variance factor. Check tightness of Tighten toothed or serrated-type lock nuts to the full torque
fasteners periodically. DO NOT use air powered wrenches. value.
Shear bolts are designed to fail under predetermined loads.
a “Lubricated” means coated with a lubricant such as
Always replace shear bolts with identical grade.
engine oil, or fasteners with phosphate and oil coatings.
Fasteners should be replaced with the same grade. Make “Dry” means plain or zinc plated (yellow dichromate -
sure fastener threads are clean and that you properly start Specification JDS117) without any lubrication.
thread engagement. This will prevent them from failing Reference: JDS - G200.
when tightening.

Specifications & Information Fastener Torques - 9

 SPECIFICATIONS & INFORMATION FASTENER TORQUES
Inch Fastener Torque Values
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

MIF
Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a
SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m 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 hand torque values if a different torque head.

value or tightening procedure is given for a specific
Tighten toothed or serrated-type lock nuts to the full torque
application. Torque values listed are for general use only
value.
and include a ±10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches. a “Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil coatings.
Shear bolts are designed to fail under predetermined loads. “Dry” means plain or zinc plated (yellow dichromate -
Always replace shear bolts with identical grade. Specification JDS117) without any lubrication.
Fasteners should be replaced with the same grade. Make b “Grade 2” applies for hex cap screws (Not Hex Bolts) up
sure fastener threads are clean and that you properly start to 152 mm (6 in.) long. “Grade 1” applies for hex cap
thread engagement. This will prevent them from failing screws over 152 mm (6 in.) long, and for all other types of
when tightening. bolts and screws of any length.
When bolt and nut combination fasteners are used, torque
Reference: JDS - G200
values should be applied to the NUT instead of the bolt

Specifications & Information Fastener Torques - 10

 SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE
O-Ring Seal Service Recommendations

Face Seal Fittings With Inch Stud Ends Torque

Stud End Tube Nut

Stud Straight and Tube Nut Swivel Nut

Locknut
Tube Nut
Stud End
90 Swivel Elbow and Tube Nut
90 Adjustable Stud Elbow
Bulkhead Union and Bulkhead Locknut
MIF

Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends

Metric Inch Tube OD Thread Tube Nut/ Bulkhead Thread Size Straight Fitting or
Tube Size Swivel Nut Lock Nut Lock Nut Torque
OD Torque Torque

mm Dash in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
Size

5 -3 0.188 4.76 3/8-24 8 6

6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9

8 -5 0.312 7.94 1/2-20 16 12

10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18

12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34

16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46

19 -12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75

22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90

25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105

32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140

38 -24 1.50 38.10 2-12 217 160 217 160 1-7/8-12 217 160

NOTE: Torque tolerance is +15%, -20%

Specifications & Information O-Ring Seal Service Recommendations - 11

 SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE
Face Seal Fittings With Metric Stud Ends Torque

Stud End Tube Nut

Groove For Metric Identification

Swivel Nut
Stud Straight and Tube Nut Locknut
Tube Nut
Groove For Metric
Identification Stud End
90 Swivel Elbow and Tube Nut
90 Adjustable Stud Elbow
Bulkhead Union and Bulkhead Locknut
MIF

Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends, Straight Fitting or
Lock Nut

Metric Inch Tube OD Thread Hex Tube Nut/ Bulkhead Thread Hex Steel or Aluminum
Tube Size Size Swivel Lock Nut Size Size Gray Iron Torque
OD Nut Torque Torque
Torque

mm Dash in. mm in. mm N•m lb-ft N•m lb-ft mm mm N•m lb-ft N•m lb-ft
Size

6 -4 0.250 6.35 9/16-18 17 16 12 12 9 M12X1.5 17 21 15.5 9 6.6

8 -5 0.312 7.94

M14X1.5 19 33 24 15 11

10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16X1.5 22 41 30 18 13

12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18X1.5 24 50 37 21 15

16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1.5 27 69 51 28 21

-12 0.750 19.05 1-3/16-12 36 102 75 102 75 M27X2 32 102 75 46 34

22 -14 0.875 22.22 1-3/16-12 36 102 75 102 75 M30X2 36

25 -16 1.000 25.40 1-7/16-12 41 142 105 142 105 M33X2 41 158 116 71 52

28 M38X2 46 176 130 79 58

32 -20 1.25 31.75 1-11/16- 50 190 140 190 140 M42X2 50 190 140 85 63
12

38 -24 1.50 38.10 2-12 60 217 160 217 160 M48X2 55 217 160 98 72

NOTE: Torque tolerance is +15%, -20%

Specifications & Information O-Ring Seal Service Recommendations - 12

 SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE
O-Ring Face Seal Fittings O-Ring Boss Fittings
1. Inspect boss O-ring boss seat. It must be free of dirt and
defects. If repeated leaks occur, inspect for defects with a
A magnifying glass. Some raised defects can be removed
with a slip stone.

A
B

MIF

1. Inspect the fitting sealing surfaces (A). They must be MIF

free of dirt or defects. 2. Put hydraulic oil or petroleum jelly on the O-ring (B).
2. Inspect the O-ring (B). It must be free of damage or Place electrical tape over the threads to protect O-ring from
defects. nicks. Slide O-ring over the tape and into the groove (A) of
fitting. Remove tape.
3. Lubricate O-rings and install into groove using
petroleum jelly to hold in place during assembly.
4. Index angle fittings and tighten by hand pressing joint
together to insure O-ring remains in place.

IMPORTANT: Avoid damage! DO NOT allow

hoses to twist when tightening fittings. Use two D
wrenches to tighten hose connections; one to
hold the hose, and the other to tighten the swivel E
C
fitting.

5. Tighten fitting or nut to torque value shown on the chart

per dash size stamped on the fitting.

MIF

3. For angle fittings, loosen special nut (D) and push

special washer (C) against threads so O-ring can be
installed into the groove of fitting.
4. Turn fitting into the boss by hand until special washer or
washer face (straight fitting) contacts boss face and O-ring
is squeezed into its seat.
5. To position angle fittings (E), turn the fitting counter-
clockwise a maximum of one turn.
6. Tighten straight fittings to torque value shown on chart.
For angle fittings, tighten the special nut to value shown in
the chart while holding body of fitting with a wrench.

Specifications & Information O-Ring Seal Service Recommendations - 13

 SPECIFICATIONS & INFORMATION GENERAL INFORMATION
Straight Fitting or Special Nut Torques General Information

Thread Size Torquea Number of Flatsb Gasoline

N•m lb-ft 4 - Cycle Engines
3/8-24 UNF 8 6 2

7/16-20 UNF 12 9 2 c HIGHLY

CAUTION: Avoid Injury! Gasoline is
FLAMMABLE, handle it with care.
1/2-20 UNF 16 12 2 DO NOT refuel machine while: indoors,
9/16-18 UNF 24 18 2 always fill gas tank outdoors; machine is
near an open flame or sparks; engine is
3/4-16 UNF 46 34 2 running, STOP engine; engine is hot, allow
it to cool sufficiently first; smoking.
7/8-14 UNF 62 46 1-1/2 Help prevent fires: fill gas tank to bottom of
1-1/16-12 UN 102 75 1 filler neck only; be sure fill cap is tight after
fueling; clean up any gas spills
1-3/16-12 UN 122 90 1 IMMEDIATELY; keep machine clean and in
good repair - free of excess grease, oil,
1-5/16-12 UN 142 105 3/4 debris, and faulty or damaged parts; any
1-5/8-12 UN 190 140 3/4 storage of machines with gas left in tank
should be in an area that is well ventilated
1-7/8-12 UN 217 160 1/2 to prevent possible igniting of fumes by an
open flame or spark, this includes any
a
Torque tolerance is ± 10 percent. appliance with a pilot light. To prevent fire
bTo be used if a torque wrench cannot be used. After or explosion caused by STATIC ELECTRIC
tightening fitting by hand, put a mark on nut or boss; then DISCHARGE during fueling:•ONLY use a
tighten special nut or straight fitting the number of flats clean, approved POLYETHYLENE PLASTIC
shown. fuel container and funnel WITHOUT any
metal screen or filter.
Metric Fastener Torque Value - Grade 7
To avoid engine damage:
(Special)
• DO NOT mix oil with gasoline;
Size Steel or Gray Aluminum • ONLY use clean, fresh unleaded gasoline with an
Iron Torque Torque octane rating (anti-knock index) of 87 or higher;

N•m (lb-ft) N•m (lb-ft) • fill gas tank at the end of each day's operation to help
prevent condensation from forming inside a partially filled
M6 11 (8) 8 (6) tank;

M8 24 (18) 19 (14) • keep up with specified service intervals.

Use of alternative oxygenated, gasohol blended, unleaded
M10 52 (38) 41 (30)
gasoline is acceptable as long as:
M12 88 (65) 70 (52) • the ethyl or grain alcohol blends DO NOT exceed 10%
M14 138 (102) 111 (82) by volume or
• methyl tertiary butyl ether (MTBE) blends DO NOT
M16 224 (165) 179 (132) exceed 15% by volume
RFG (reformulated) gasoline is acceptable for all machines
designed for use of regular unleaded fuel. Older machines
(that were designed for leaded fuel) may see some
accelerated valve and seat wear.

Specifications & Information General Information - 14

 SPECIFICATIONS & INFORMATION GENERAL INFORMATION
4 - Cycle Gasoline Engine Oil
Use the appropriate oil viscosity based on the expected air
temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
MIF
• PLUS - 4® - SAE 10W-40;
IMPORTANT: Avoid damage! California
Proposition 65 Warning: Gasoline engine • TORQ - GARD SUPREME® - SAE 5W-30.
exhaust from this product contains chemicals The following John Deere oils are also recommended,
known to the State of California to cause cancer, based on their specified temperature range:
birth defects, or other reproductive harm.
• TURF - GARD® - SAE 10W-30;
• PLUS - 4® - SAE 10W-30;
Gasoline Storage
• TORQ - GARD SUPREME® - SAE 30.
IMPORTANT: Avoid damage! Keep all dirt, scale, Other oils may be used if above John Deere oils are not
water or other foreign material out of gasoline. available, provided they meet one of the following
specifications:
Keep gasoline stored in a safe, protected area. Storage of
gasoline in a clean, properly marked (“UNLEADED • SAE 10W-40 - API Service Classifications SG or higher;
GASOLINE”) POLYETHYLENE PLASTIC container • SAE 5W-30 - API Service Classification SG or higher;
WITHOUT any metal screen or filter is recommended. DO
• SAE 10W-30 - API Service Classifications SG or higher;
NOT use de-icers to attempt to remove water from gasoline
or depend on fuel filters to remove water from gasoline. • SAE 30 - API Service Classification SC or higher.
Use a water separator installed in the storage tank outlet.
BE SURE to properly discard unstable or contaminated
gasoline. When storing the machine or gasoline, it is
recommended that you add John Deere Gasoline
Conditioner and Stabilizer (TY15977) or an equivalent to
the gasoline. BE SURE to follow directions on container
and to properly discard empty container.

SAE 30
SAE 10W-40

SAE 10W-30
SAE 5W-30

PREFERRED

AIR TEMPERATURE
MIF

Specifications & Information General Information - 15

 SPECIFICATIONS & INFORMATION GENERAL INFORMATION
Break-In Engine Oil - 4-Cycle Gasoline

IMPORTANT: Avoid damage! ONLY use a quality

break-in oil in rebuilt or remanufactured engines
for the first 5 hours (maximum) of operation. DO
NOT use oils with heavier viscosity weights than
SAE 5W-30 or oils meeting specifications API SG
or SH, these oils will not allow rebuilt or
remanufactured engines to break-in properly.

BREAK-IN OIL

SAE 5W-30
The following John Deere oil is PREFERRED:
• BREAK - IN ENGINE OIL.
John Deere BREAK - IN ENGINE OIL is formulated with
special additives for aluminum and cast iron type engines
to allow the power cylinder components (pistons, rings, and
liners as well) to “wear-in” while protecting other engine
components, valve train and gears, from abnormal wear.
Engine rebuild instructions should be followed closely to
determine if special requirements are necessary.
John Deere BREAK - IN ENGINE OIL is also
recommended for non-John Deere engines, both aluminum PREFERRED
and cast iron types. AIR TEMPERATURE
The following John Deere oil is also recommended: MIF

• TORQ - GARD SUPREME® - SAE 5W-30.

If the above recommended John Deere oils are not
Hydrostatic Transmission and Hydraulic Oil
available, use a break-in engine oil meeting the following Use the appropriate oil viscosity based on these air
specification during the first 5 hours (maximum) of temperature ranges. Operating outside of these
operation: recommended oil air temperature ranges may cause
• SAE 5W-30 - API Service Classification SE or higher. premature hydrostatic transmission or hydraulic system
failures.
IMPORTANT: Avoid damage! After the break-in
period, use the John Deere oil that is IMPORTANT: Avoid damage! Mixing of LOW
recommended for this engine. VISCOSITY HY - GARD® and HY - GARD® oils is
permitted. DO NOT mix any other oils in this
transmission. DO NOT use engine oil or “Type F”
(Red) Automatic Transmission Fluid in this
transmission. DO NOT use BIO-HY-GARD® in
this transmission.

The following John Deere transmission and hydraulic oil is

PREFERRED:
• LOW VISCOSITY HY-GARD® - JDM J20D.
The following John Deere oil is also recommended if above
preferred oil is not available:
• HY-GARD® - JDM J20C.
Other oils may be used if above recommended John Deere
oils are not available, provided they meet one of the
following specifications:
• John Deere Standard JDM J20D;
• John Deere Standard JDM J20C.

Specifications & Information General Information - 16

SPECIFICATIONS & INFORMATION GENERAL INFORMATION
Gear Case Oil
Use the appropriate oil viscosity based on the air
temperature ranges. Operating outside of these
recommended oil air temperature ranges may cause
premature gear case failure.

JDM J20C
IMPORTANT: Avoid damage! ONLY use a quality
oil in this gear case. DO NOT mix any other oils
in this gear case. DO NOT use BIO-HY-GARD® in
this gear case.
JDM J20D

The following John Deere gear case oil is PREFERRED:

• GL-5 GEAR LUBRICANT® - SAE 80W-90.
The following John Deere gear case oil is also
recommended if above preferred oil is not available:
• GL-5 GEAR LUBRICANT® - SAE 85W-140.
Other gear case oils may be used if above recommended
John Deere gear case oils are not available, provided they
meet the following specification:
PREFERRED • API Service Classification GL - 5.
AIR TEMPERATURE
MIF

SAE 85W-140
SAE 80W-90

PREFERRED
AIR TEMPERATURE
MIF

Specifications & Information General Information - 17

 SPECIFICATIONS & INFORMATION GENERAL INFORMATION
Gear Transmission Grease Synthetic Lubricants
Use the following gear grease based on the air temperature Synthetic lubricants may be used in John Deere equipment
range. Operating outside of the recommended grease air if they meet the applicable performance requirements
temperature range may cause premature gear (industry classification and/or military specification) as
transmission failure. shown in this manual.
The recommended air temperature limits and service or
IMPORTANT: Avoid damage! ONLY use a quality lubricant change intervals should be maintained as shown
gear grease in this transmission. DO NOT mix in the operator’s manual, unless otherwise stated on
any other greases in this transmission. DO NOT lubricant label.
use any BIO - GREASE in this transmission.
Avoid mixing different brands, grades, or types of oil. Oil
The following John Deere gear grease is PREFERRED: manufacturers blend additives in their oils to meet certain
• NON-CLAY HIGH-TEMPERATURE EP GREASE® - specifications and performance requirements. Mixing
JDM J13E4, NLGI Grade 2. different oils can interfere with the proper functioning of
these additives and degrade lubricant performance.
Other greases may be used if above preferred John Deere
grease is not available, provided they meet the following
specification: Lubricant Storage
• John Deere Standard JDM J13E4, NLGI Grade 2. All machines operate at top efficiency only when clean
lubricants are used. Use clean storage containers to
handle all lubricants. Store them in an area protected from
dust, moisture, and other contamination. Store drums on
their sides. Make sure all containers are properly marked
as to their contents. Dispose of all old, used containers and
their contents properly.

Mixing of Lubricants
NLGI Grade 2
JDM J13E4

In general, avoid mixing different brands or types of

lubricants. Manufacturers blend additives in their lubricants
to meet certain specifications and performance
requirements. Mixing different lubricants can interfere with
the proper functioning of these additives and lubricant
properties which will downgrade their intended specified
performance.

Oil Filters

IMPORTANT: Avoid damage! Filtration of oils is

critical to proper lubrication performance.
Always change filters regularly.
AIR TEMPERATURE The following John Deere oil filters are PREFERRED:
MIF • AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL
FILTERS.
Alternative Lubricants Most John Deere filters contain pressure relief and anti-
drainback valves for better engine protection.
Use of alternative lubricants could cause reduced life of the
component. Other oil filters may be used if above recommended John
Deere oil filters are not available, provided they meet the
If alternative lubricants are to be used, it is recommended
following specification:
that the factory fill be thoroughly removed before switching
to any alternative lubricant. • ASTB Tested In Accordance With SAE J806.

Specifications & Information General Information - 18

 SPECIFICATIONS & INFORMATION COOLANT SPECIFICATIONS
Coolant Specifications
IMPORTANT: Avoid damage! To prevent engine
damage, DO NOT use pure anti-freeze or less
Gasoline Engine Coolant than a 50% anti-freeze mixture in the cooling
system. DO NOT mix or add any additives/
The engine cooling system when filled with a proper
conditioners to the cooling system in Lawn and
dilution mixture of anti-freeze and deionized or distilled
Grounds Care/Golf and Turf Division equipment.
water provides year-round protection against corrosion,
Water used to dilute engine coolant concentrate
cylinder or liner pitting, and winter freeze protection down
must be of high quality - clean, clear, potable
to -37°C (-34°F).
water (low in chloride and hardness - Table 1) is
The following John Deere coolant is PREFERRED: generally acceptable. DO NOT use salt water.
• COOL-GARD® PRE-DILUTED SUMMER COOLANT Deionized or distilled water is ideal to use.
(TY16036). Coolant that is not mixed to these specified
levels and water purity can cause excessive
This coolant satisfies specifications for “Automobile and scale, sludge deposits, and increased corrosion
Light Duty Engine Service” and is safe for use in John potential.
Deere Lawn and Grounds Care/Golf and Turf Division
equipment, including aluminum block gasoline engines and
Property Requirements
cooling systems.
The above preferred pre-diluted anti-freeze provides: Total Solids, Maximum 340 ppm (20 grns/gal)
• adequate heat transfer Total Hardness, Maximum 170 ppm (10 grns/gal)
• corrosion-resistant chemicals for the cooling system Chloride (as Cl), Maximum 40 ppm (2.5 grns/gal)
• compatibility with cooling system hose and seal material
Sulfate (as SO4), Maximum 100 ppm (5.8 grns/gal)
• protection during extreme cold and extreme hot weather
operations Mix 50 percent anti-freeze concentrate with 50 percent
distilled or deionized water. This mixture and the pre-diluted
• chemically pure water for better service life mixture (TY16036) will protect the cooling system down to -
• compliance with ASTM D4656 (JDM H24C2) 37°C (-34°F) and up to 108°C (226°F).
specifications Certain geographical areas may require lower air
If above preferred pre-diluted coolant is not available, the temperature protection. See the label on your anti-freeze
following John Deere concentrate is recommended: container or consult your John Deere dealer to obtain the
latest information and recommendations.
• COOL-GARD® CONCENTRATED SUMMER
COOLANT CONCENTRATE™ (TY16034).
If either of above recommended engine coolants are
Gasoline Engine Coolant Drain Interval
available use any Automobile and Light Duty Engine When using John Deere Pre-Diluted (TY16036) Automobile
Service ethylene glycol base coolant, meeting the following and Light Duty Engine Service coolants, drain and flush the
specification: cooling system and refill with fresh coolant mixture every
• ASTM D4985 (JDM H24A2). 36 months or 3,000 hours of operation, whichever comes
first.
Read container label completely before using and follow
instructions as stated. When using John Deere Concentrate (TY16034)
Automobile and Light Duty Engine Service coolants, drain
and flush the cooling system and refill with fresh coolant
mixture every 24 months or 2,000 hours of operation,
whichever comes first.
If above John Deere Automobile and Light Duty Engine
Service coolants are not being used; drain, flush, and refill
the cooling system according to instructions found on
product container or in equipment operator’s manual or
technical manual.

Specifications & Information Coolant Specifications - 19

 SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS
Serial Number Locations

Product Serial Number

M55444

The 13-digit product identification number (A) is located on

the right-hand side frame, just below engine compartment.

Gasoline Engine Serial Number Location

MX13637

Engine serial number (A) is located on the valve cover or

on the front of the engine crankcase.

Specifications & Information Serial Number Locations - 20

 ENGINE - GAS (AIR-COOLED) TABLE OF CONTENTS
Push Rod and Rocker Arm Removal and
Engine - Gas (Air-Cooled)

Table of Contents
Installation.................................................... 57
Valve Train Removal and Installation .......... 58
Piston Removal and Installation .................. 59
Specifications .................................................23 Inspect Piston and Cylinder ........................ 61
General Specifications .................................23 Cylinder Bore Honing................................... 64
Tests & Adjustments Specifications .............23 Cylinder Bore Resizing ................................ 64
Repair Specifications....................................24 Crankcase Cover Removal and Installation. 65
Torque Specifications (Alphabetical)............25 Crankcase Cover Inspection........................ 67
Special or Required Tools ............................26 Governor Assembly Removal/Replacement 67
Component Location......................................27 Governor Assembly Inspection.................... 69
Engine - 21 HP (FH641D) ............................27 Camshaft/Tappet Removal and Installation 69
Theory of Operation .......................................28 Camshaft Disassembly/Inspection .............. 70
Carburated Engine Fuel and Air System Oper- Crankshaft Removal/Replacement ............. 72
ation..............................................................28 Crankshaft Inspection .................................. 73
Governor Operation......................................28 Connecting Rod Inspection ......................... 74
Lubrication System Operation ......................29 Breather Valve Removal and Installation..... 75
Troubleshooting .............................................30 Breather Valve Inspection............................ 76
Engine Troubleshooting Guide.....................30 Oil Pump Removal and Installation.............. 76
Engine Runs Erratically/Loss Of Power .......31 Oil Pump Inspection..................................... 77
Starting Motor Troubleshooting Guide .........31 Oil Pickup Removal and Installation ............ 78
Diagnostics .....................................................33 Oil Screen Inspection/Cleaning ................... 78
Diagnostic Table...........................................33 Flywheel Removal and Installation .............. 79
Tests and Adjustments ..................................35 Stator Coil Inspection................................... 81
Throttle Cable Adjustment............................35 Ignition Coil Removal and Installation.......... 81
Choke Adjustment ........................................35 Starting Motor Removal and Installation...... 82
Governor Adjustment ...................................36 Starting Motor Solenoid Tests ..................... 82
Low Idle Speed Adjustment..........................36 Starting Motor Test ...................................... 83
High Idle Speed Adjustment.........................36 Starter Motor Disassembly/Assembly.......... 83
Compression Test ........................................37 Starting Motor Inspection............................. 86
Valve Clearance Adjustment ........................38
Crankcase Vacuum Test ..............................39
Fuel Flow Test..............................................40
Oil Pressure Test..........................................41
Spark Test ....................................................42
Engine Repair..................................................42
Fuel Pump Removal and Installation............42
Fuel Pump/Fuel Filter Inspection..................43
Air Cleaner - Removal/Inspection/
Installation ....................................................43
Carburetor Removal and Installation............44
Carburetor Disassembly/Assembly ..............45
Carburetor Clean/Inspect/Rebuild: ...............50
Intake Manifold Removal and Installation.....50
Muffler Removal and Installation ..................51
Engine Removal and Installation..................52
Cylinder Head Removal and Installation ......55

Engine - Gas (Air-Cooled) Table of Contents - 21

ENGINE - GAS (AIR-COOLED) TABLE OF CONTENTS

Engine - Gas (Air-Cooled) Table of Contents - 22

 ENGINE - GAS (AIR-COOLED) SPECIFICATIONS
Specifications

General Specifications
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH641D
Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7 kW (21 HP)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675 cc (41.2 cu-in.)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.2 mm (2.96 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm (2.99 in.)
Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8: 1
Compression Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic
Crankshaft Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal, Counterbalanced
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized, Positive Displacement Pump
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 – 310 kPa (35 – 45 psi)
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cartridge Type, Full Flow, Spin-On Filter
Crankcase Capacity (With Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 L (1.9 qt)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Element, Replaceable Paper
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horizontal, Discharge Below Frame
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 ± 25 rpm
Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 ± 25 rpm
Maximum Angle of Operation (Full Crankcase):
Continuous (All Directions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Intermittent (All Directions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35°
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable, In-Line Type
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Mounted Diaphragm-type Pulse Pump
Fuel Shut-Off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (Below Carburetor Float Bowl)
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float type, Fixed Main Jet, Two Barrel
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RCJ8Y
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V – 13 Amps with Regulator
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.5 kg (98.1 lbs)

Tests & Adjustments Specifications

Engine
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.)
Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 – 0.125 mm (0.003 – 0.005 in.)
Oil Pressure (Minimum at 1250 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 - 310 kPa (35 to 45 psi)
Cylinder Compression (Minimum, with Engine Warm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 kPa (57 psi)

Engine - Gas (Air-Cooled) Specifications - 23

 ENGINE - GAS (AIR-COOLED) SPECIFICATIONS
Fuel/Air System:
Slow Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 ± 25 rpm
Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 ± 25 rpm

Repair Specifications
Cylinder Head:
Cylinder Head Flatness (Maximum Warpage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.)

Valves and Valve Lifters:

Valve Clearance (Intake/Exhaust Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 – 0.125 mm (0.003 – 0.005 in.)
Valve Stem Runout (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.)
Intake Valve Stem OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.95 mm (0.234 in.)
Exhaust Valve Stem OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.93 mm (0.233 in.)
Valve Guide:
Intake and Exhaust ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.08 mm (0.239 in.)
Valve Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.0 mm (1.22 in.)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Push Rod Runout (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.)

Crankshaft:
Crankshaft Journal Bearing ID: Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.15 mm (1.581 in.)
Crankshaft Journal OD (Minimum):
PTO Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.896 mm (1.571 in.)
Flywheel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.896 mm (1.571 in.)
Crankshaft Runout (TIR) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Crankpin OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.94 mm (1.572 in.)
Crankpin Width (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.1 mm (1.697 in.)
Connecting Rod:
Twist (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm over 100 mm (0.006 over 3.94 in.)
Bend (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm over 100 mm (0.006 over 3.94 in.)
Connecting Rod Big End Width (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.45 mm (0.805 in.)

Camshaft:
Crankcase Bearing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14 mm (0.635 in.)
Crankcase Cover Bearing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14 mm (0.635 in.)
Camshaft Journal Diameter:
PTO Side (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.985 mm (0.6293 in.)
Flywheel Side (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.985 mm (0.6293 in.)
Cam Lobe Height (Minimum):
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.621 mm (1.166 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.621 mm (1.166 in.)

Oil Pump:
Inner And Outer Rotor Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
Outer rotor OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.593 in.)

Engine - Gas (Air-Cooled) Specifications - 24

 ENGINE - GAS (AIR-COOLED) SPECIFICATIONS
Outer Rotor Thickness (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.83 mm (0.387 in.)
Pump Housing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.801 mm (1.6063 in.)
Pump Housing Depth (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.230 mm (0.4028 in.)
Pump Shaft OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.923 mm (0.4300 in.)
Pump Shaft Bearing ID (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.4358 in.)
Relief Valve Spring Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.77 in.)

Cylinder Bore, Pistons and Rings

Cylinder Bore ID:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.18 – 75.20 mm (2.960 – 2.961 in.)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.28 mm (2.964 in.)
Cylinder Bore Out of Round (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.056 mm (0.0022 in.)
Piston Pin Bore ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.08 mm (0.633 in.)
Piston Pin OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.96 mm (0.628 in.)
Top Compression Ring-To-Groove Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Middle Compression Ring-To-Groove Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Piston Ring Thickness (Top, Second) (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055 in.)
Top Ring End Gap (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.65 mm (0.026 in.)
Second Ring End Gap (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.78 mm (0.031 in.)
Oil Ring End Gap (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 mm (0.041 in.)
Piston OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.99 mm (2.952 in.)

Torque Specifications (Alphabetical)

NOTE: Use a torque wrench that reads within the range given. Convert pound-inches to pound-feet as follows:
pound-inches/12 = pound-feet
Air Cleaner Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Camshaft Breather Chamber Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Carburetor-to-Manifold Mounting Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Choke Valve Screw (use non-permanent thread locker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 N•m (8.4 lb-in.)
Control Panel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Crankcase Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft.)
Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
Drain Screw (Carburetor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (18 lb-in.)
Engine Drain Plug (Plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.)
Engine Drain Plug (Metal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (15 lb-ft)
Engine Drain Plug Joint (Plastic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)
Engine Drain Plug Joint (Metal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
Engine Shroud Bolt (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.)
Engine Shroud Bolt (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Engine Oil Screen Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Fan Housing Bolt (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.)
Fan Housing Bolt (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Fan Housing Screen Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)

Engine - Gas (Air-Cooled) Specifications - 25

 ENGINE - GAS (AIR-COOLED) SPECIFICATIONS
Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft)
Fuel Shut Off Solenoid Valve (Carburetor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (14 lb-ft)
Float Chamber Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (35 lb-in.)
Governor Arm Clamp Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 N•m (69 lb-in.)
Governor Shaft Plate Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (17 lb-in.)
Ignition Coil Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Intake Manifold Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Muffler Flange Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (11 lb-in.)
Main Jet Plug Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (13 lb-ft)
Oil Pump Cover Plate Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 N•m (87 lb-in.)
Rocker Arm Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (21 lb-ft)
Rocker Cover Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.)
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Stator Coil Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.)
Starter Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (11 lb-in.)
Throttle Valve Screws (use non-permanent thread locker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 N•m (8.4 lb-in.)
Valve Clearance Lock Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.)
Regulator Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.)

Special or Required Tools

Special or Required Tools

Tool Name Tool No. Tool Use
6.4 mm (0.25 in.) Drill Bit Throttle and choke adjustment
Dial Indicator Automatic compression relief test, Valve inspection
Photo Tachometer JT05719 Slow idle adjustment
Cylinder Leakdown Tester JT03502 Cylinder leakdown test
Crankcase Vacuum Test Kit JT03503 Crankcase vacuum check
Oil Pressure Test Adapter w/ O-ring (required JT07262 Oil pressure test
ONLY on engines without test ports)
Connector JT05847
Hose Assembly JT03017
Coupler JT03262
Gauge, 0 – 700 kPa (0 – 100 psi) JT07034
Lapping Tool Valve lapping

Engine - Gas (Air-Cooled) Specifications - 26

 ENGINE - GAS (AIR-COOLED) COMPONENT LOCATION
Component Location

Engine - 21 HP (FH641D)

C E

B
F

K
M
L

MX14219 H - Exhaust Ports

A - Valve Cover I - Crankshaft
B - Oil Fill Cap J - Crankcase Cover
C - Air Cleaner Port K - Starter
D - Air Cleaner Cover L - Oil Drain Port
E - Dipstick M - Starter Solenoid
F - Throttle Control Plate N - Engine Cover
G - Governor Lever

Engine - Gas (Air-Cooled) Component Location - 27

 ENGINE - GAS (AIR-COOLED) THEORY OF OPERATION
Theory of Operation Governor Operation
System Operation:
Carburated Engine Fuel and Air System
Operation The governor controls engine speed. Governed engine
speed is a balance between governor spring tension, set by
Function: the throttle control, and actual engine speed, countered by
centrifugal force of the governor flyweights. As tension is
The fuel system supplies pressurized fuel to the carburetor applied to governor spring, governor linkage opens
for combustion. The air intake system filters air needed for carburetor throttle shaft and plate, increasing engine rpm.
combustion. As the engine speed increases, flyweight assembly (driven
by the crankshaft gear) pushes on governor arm, rotating
System Operation:
governor shaft and lever, moving throttle shaft, closing
An diaphragm pulse fuel pump mounted on the engine throttle plate slightly and reducing rpm to governed
supplies fuel to the carburetor. The fuel pump draws fuel operating speed. If a heavy load is encountered, engine
through the fuel filter and supplies it to the carburetor. The speed drops, as does the governor assembly speed.
fuel cap is vented to release pressure from the fuel tank. Flyweights retract and allow the shaft arm to move the
The ignition delay module is used with the fuel shut-off governor shaft and lever in the opposite direction, opening
solenoid to prevent backfire. The ignition delay module the throttle plate and allowing more air into the venturi,
allows the spark plugs to fire for one additional second after drawing in more fuel until engine peak operating speed is
the key switch is turned off to burn any fuel remaining in the recovered. Springs provide a smooth yet responsive
cylinder. When the key switch is turned off, the fuel shut-off transitional control.
solenoid is de-energized.
IMPORTANT: Avoid damage! Flyweight
Air enters the air filter though the side panel screen and air assembly shaft is pressed into crankcase cover
filter inlet hose. The primary and secondary elements filter and is not serviceable. If it is damaged or pulled
the air before entering the carburetor. The breather hose
loose, the crankcase cover MUST BE replaced.
vents crankcase fumes into the carburetor for burning to
decrease emissions.

Engine - Gas (Air-Cooled) Theory of Operation - 28

 ENGINE - GAS (AIR-COOLED) THEORY OF OPERATION
Lubrication System Operation

G
K
L H
F

MX14201 The filter contains a bypass valve, which opens if the

element becomes plugged to insure engine lubrication.
System Operation:
An oil pressure switch (M) mounted above the oil filter turns
A positive displacement gerotor pump (I) is used to on a warning light if oil pressure is below 98 kPa (14.2 psi).
pressurize the lubrication system. The lubrication system is Filtered pressure oil flows through a passage in the oil
protected by an oil pressure relief valve (K), low pressure sump to the crankshaft main bearing (H) (PTO side).
switch (M), and an oil filter (L) with bypass.
Drilled passages in the crankshaft (G) distribute oil from the
The oil pump (I) draws oil from the sump through a filter main bearing to the connecting rod (E) journals and
screen (J). Pressure oil from the pump flows to the oil crankshaft main bearing (F) (flywheel side). A drilled
pressure relief valve (K). Oil pressure should be 241 – 310 passage in the connecting rods allows oil from the
kPa (35 – 45 psi). If the oil pressure exceeds 310 kPa (45 connecting rod journal to lubricate the piston (D) and
psi), the relief valve opens allowing oil to return to the cylinder walls and camshaft (A), tappets (B), and rocker
sump. The relief valve is not adjustable. arms and valves (C).
Pressure oil from the relief valve flows to the oil filter (L).

Engine - Gas (Air-Cooled) Theory of Operation - 29

 ENGINE - GAS (AIR-COOLED) TROUBLESHOOTING
Troubleshooting
IMPORTANT: Avoid damage! Perform a visual
inspection first to determine if battery cables are
Engine Troubleshooting Guide tight and not corroded and if the battery is of
sufficient size to turn the engine over at minimum

c start
cranking speed of 350 rpm.
CAUTION: Avoid Injury! The engine may
to rotate at any time. Keep hands away Symptom: Engine Hard To Start
from moving parts when testing.
(1) Is there a strong blue spark?
NOTE: To test specific electrical components, see Yes - See “Spark Test” on page 324 in the Electrical
Electrical Section and refer to either Diagnostics or section. Go to step 3.
Tests & Adjustments for further guidance.
No - Replace spark plug. Recheck for spark and go
to next step.
Test Conditions:
(2) Is there a strong blue spark?
• Operator On Seat
Yes - Check engine starting.
• PTO Switch In OFF Position
No - Check if sparks are produced between high
• Brake On tension lead and ignition block. Check high tension
lead, ignition coil air gap, pulsar coil.
Symptom: Engine Doesn’t Crank
(3) Check compression. Is compression sufficient?
(1) Are battery cables loose or dirty?
Yes - See “Compression Test” on page 37. Make
Yes - Tighten or clean. starting attempts a number of times, remove spark
No - Go to next step. plug and observe electrodes. Go to next step.

(2) Is battery fully charged? No - Go to step 5.

No - Charge battery. See “Battery - Charge” on (4) After starting attempts, are spark plug
page 300 in the Electrical section. electrodes wet?

Yes - Go to next step. Yes - Check for excessive use of choke, plugged air
cleaner, float bowl level too high.
(3) Is key switch working correctly?
No - Check fuel tank and lines.
Yes - Go to next step.
(5) Compression is low?
No - Test switch. See “Cranking Circuit Operation -
All Models” on page 235 in the Electrical section. Yes - Check piston rings and cylinder for wear. See
Replace as needed. “Piston Removal and Installation” on page 59.
Inspect cylinder head.
(4) Has engine seized?
Yes - See Engine Repair Section. Symptom: Engine Runs Erratically
No - Go to next step. (1) Is fuel delivery correct?

(5) Is starting motor or solenoid defective? Yes - See “Fuel Flow Test” on page 40. Check for
plugged air/fuel passages in carburetor. See
Yes - Repair or replace. See “Starter Solenoid Test” “Carburetor Clean/Inspect/Rebuild:” on page 50.
on page 305 or “Starting Motor No-load Amperage
and RPM Test” on page 306 in the Electrical section. No - Check for contamination, or an air or vapor lock
in the fuel tank and lines.

c CAUTION: Avoid injury! Keep spark plug as

far away from the plug hole as possible.
Symptom: Engine Malfunctions At Low Speed
(1) Is unusual smoke emitted out of muffler?
Gasoline spray from the open cylinders
may be ignited by ignition spark and cause Yes - Check choke. See “Choke Adjustment” on
an explosion or fire. page 35.
No - Go to next step.

Engine - Gas (Air-Cooled) Troubleshooting - 30

 ENGINE - GAS (AIR-COOLED) TROUBLESHOOTING
Symptom: Engine Malfunctions At Low Speed Engine Runs Erratically/Loss Of Power
(2) Does engine rpm drop or engine stall at a
IMPORTANT: Avoid damage! Before proceeding,
certain point when throttle is gradually opened by
inspect the mower deck and belts for binding in the
hand?
spindle assemblies or belts that are too tight/loose.
Yes - Plug in carburetor interior, clean carburetor. A loose belt, like a loose blade can cause a backlash
See “Carburetor Clean/Inspect/Rebuild:” on page 50. effect that will counteract engine cranking effort.
Excessive drive belt tension may cause premature
No - Go to next step.
bearing wear or result in bearing seizure. Grass
(3) Is air sucked through carburetor or intake clippings that build up near the cutting blades can
manifold flanges? cause excessive resistance and heat build-up that
causes problems with the engine’s ability to turn the
Yes - Tighten manifold flange nuts or replace
blades at a constant speed. Low lubricant levels in
damaged gasket.
the spindles will build-up heat causing excessive
No - Go to next step. resistance for the engine to deal with.
(4) Are valve clearances set correctly? NOTE: To test specific electrical components, see
No - Adjust valves. See “Valve Clearance Electrical Section and refer to either Diagnostics or
Adjustment” on page 38. Tests & Adjustments for further guidance

Symptom: Oil Consumption Is Excessive Starting Motor Troubleshooting Guide

(1) Check compression. Is compression
sufficient?
Yes - See “Compression Test” on page 37. Check for
c start
CAUTION: Avoid Injury! The engine may
to rotate at any time. Keep hands away
oil leaks, high oil level, plugged oil ring groove, oil from moving parts when testing.
seals, incorrect oil viscosity.
No - Check for worn, stuck or broken piston rings, or IMPORTANT: Avoid damage! If starting motor
worn cylinder bore. does not by turning ignition switch to Off
(2) Is breather valve clean and is oil to correct position, disconnect negative (-) lead from
level? battery as soon as possible.

Yes - Check for clogged breather valve, plugged NOTE: To test specific electrical components, see
drain back hole in breather. See “Breather Valve Electrical Section and refer to either Diagnostics or
Inspection” on page 76. Tests & Adjustments for further guidance.
No - Check for worn, stuck or broken piston rings, or Symptom: Starter Does Not Rotate
worn cylinder bore.
(1) Is there a click sound from starter solenoid?
Yes - Repair starting motor. See “Starting Motor
Removal and Installation” on page 82, and “Starter
Motor Disassembly/Assembly” on page 83.
No - Check that all starting conditions are met. Go to
next step.
(2) Are battery cables loose or dirty?
Yes - Tighten or clean.
No - Go to next step.
(3) Is battery fully charged?
No - Charge battery. See “Battery - Charge” on
page 300 in the Electrical section.
Yes - Go to next step.

Engine - Gas (Air-Cooled) Troubleshooting - 31

 ENGINE - GAS (AIR-COOLED) TROUBLESHOOTING
Symptom: Starter Does Not Rotate
(4) Is key switch working correctly?
Yes - Go to next step.
No - Test switch. See “Cranking Circuit Operation -
All Models” on page 235 in the Electrical section.
Replace as needed.
(5) Has engine seized?
Yes - See Engine Repair Section.

Symptom: Starter Rotates Slowly

(1) Are battery cables loose or dirty?
Yes - Tighten or clean.
No - Go to next step.
(2) Is battery fully charged?
Yes - Go to next step.
No - Charge battery. See “Battery - Charge” on
page 300 in the Electrical section.
(3) Has engine seized?
Yes - See Engine Repair Section.
No - Go to next step.
(4) Is starting motor or solenoid defective?
Yes - Repair or replace. See “Starter Solenoid Test”
on page 305, or “Starting Motor No-load Amperage
and RPM Test” on page 306 in the Electrical section.

Engine - Gas (Air-Cooled) Troubleshooting - 32

 ENGINE - GAS (AIR-COOLED) DIAGNOSTICS
Diagnostics • Park brake engaged.
• PTO Switch OFF.
Diagnostic Table • Key switch OFF unless indicated otherwise.
Test Conditions: • Spark plug connected to D-05351ST Spark Tester
• Machine parked on level surface.
Test/Check Point Normal Condition If Not Normal

Engine dipstick and exterior engine Oil level between “L” and “H” marks. Change oil and inspect for
surface source of contamination.
Oil not burnt, or contaminated with metal
particles, fuel, or coolant. Check gaskets, seals, plugs,
cylinder head, block, and
No external leakage, filter clean.
intake manifold and
breather.
Change oil filter.

Fuel tank, pump, lines, filter Fuel level correct, not contaminated; or stale Drain and clean fuel tank.
smelling; no water fuel. Add fresh fuel.

Fuel pump filter and in-line filter free of Replace filters.

debris.

Fuel shutoff valve in ON position Move to ON position

Fuel hoses not cracked or leaking. Replace.

Fuel hose clamps tight. Replace or tighten.

Fuel tank does not have vacuum. Replace vented fuel cap.

Fuel shutoff solenoid (Key in “START” Fuel shutoff solenoid must pull in and stay in If solenoid will not pull in and
position when key is returned to ON position. Listen hold in, see Fuel Shutoff
for clicking as key is cycled. Solenoid Circuit Diagnosis in
Electrical section.

Hand throttle control lever linkage Full movement of governor control arm from Repair; replace or adjust
idle to full speed. linkage.

Air filter and air intake Air filter outlet hose not cracked; clamps Replace hose and/or tighten
tight. clamps.
Elements not plugged. Air filter housing Replace element or housing.
sealed; no dirt tracking inside filter element. Replace indicator.
Air filter restriction indicator not leaking

Spark plug (key switch in start Steady blue spark. If spark is weak (yellow) or
position) no spark, install new spark
Engine must crank.
plug and test again. If still
weak or no spark, see
“Ignition Circuit Diagnosis” in
Electrical section. See
“Cranking Circuit Diagnosis”
in the Electrical section.

Spark plug (key switch off) Plug dry. Check carburetor inlet
needle for debris, choke,
and mixture adjustment.

Engine - Gas (Air-Cooled) Diagnostics - 33

 ENGINE - GAS (AIR-COOLED) DIAGNOSTICS
Test/Check Point Normal Condition If Not Normal

Intake and exhaust valves Valve clearance within specification (engine Adjust valves. See “Valve
cold). Clearance Adjustment” on
page 38.
Valves not sticking.
Check valve guides and
stems.

Perform cylinder compression test Cylinder compression within specification. Rebuild engine.
Pressure difference between cylinders
within specification.

Flywheel and starting motor Minimum cranking rpm within specification. See “Starter Amp Draw Test”
in Electrical section.

Carburetor—fuel filter, fuel pump, and Fuel level increases in filter. See “Fuel pump and Fuel
carburetor bowl drain screw (key Shutoff Solenoid Circuit
Fuel pump operating—listen for humming
switch on). Diagnosis” in the Electrical
sound near fuel cap.
section.
Fuel present in float bowl when screw is
Test fuel pump pressure and
opened.
flow.
Check carburetor for debris.

Carburetor choke and governor Linkage not binding and adjusted correctly. Repair, replace or adjust
linkage linkage.

Carburetor (engine running) Low idle at 1550 rpm. See “Low Idle Speed
Adjustment” on page 36,
High idle at 3600 rpm.
and/or “High Idle Speed
Adjustment” on page 36.

Oil pressure switch port Minimum oil pressure within specifications. Test engine oil pressure.
See “Oil Pressure Test” on
page 41.

Muffler Not restricted. Replace muffler.

Engine - Gas (Air-Cooled) Diagnostics - 34

 ENGINE - GAS (AIR-COOLED) TESTS AND ADJUSTMENTS
Tests and Adjustments Choke Adjustment
Reason:
Throttle Cable Adjustment
To make sure the choke plate is fully closed when the
Reason: choke lever is in the full choke position. Correct adjustment
also makes sure choke is completely open in the fast idle
To make sure the throttle cable moves the throttle and
position.
choke control lever through its full range of movement.
Procedure:
Procedure:
1. Set the throttle lever in the slow idle position. Check that NOTE: Adjust throttle cable before adjusting choke.
the throttle control lever (A) contacts the idle speed 1. Remove air cleaner assembly.
adjustment screw (B) at the slowest throttle lever setting.

B C

MX11694

2. If the throttle control lever (A) is not touching the screw

(B) at the slowest setting, loosen the throttle cable clamp
MX11695
(C). Pull throttle cable to left. When the control lever
contacts the control plate idle adjustment screw, retighten 2. Move choke lever forward to full choke position. Check
the cable clamp. that the choke butterfly (B) in the carburetor is fully closed.
3. Set the throttle lever to the fastest idle position. Check 3. If adjustment is necessary, loosen the choke cable
that the throttle control lever is advancing to the full open clamp (A). Move the cable to obtain a fully closed position.
position. Retighten the cable clamp.
4. If the control lever is not advancing to the full open 4. Release the choke lever and make certain the return
position, loosen the cable clamp and readjust the cable. spring on the governor control plate is returning the choke
butterfly to the fully open position.
5. If the cable cannot be adjusted to obtain the full open
throttle lever position at fastest idle, while maintaining 5. Reinstall the air cleaner assembly and check the choke
contact with the adjustment screw at lowest idle position, it operation while starting the machine.
will be necessary to adjust the control plate idle speed
adjustment screw.
6. Turn the idle adjustment screw (B) clockwise until it
contacts the throttle control lever when set in the slow idle
position. After completing the idle screw adjustment, check
to make certain the motor is maintaining a 1550 RPM
governed low idle setting. Follow the Low Idle Speed
Adjustment sequence in this chapter if corrections are
necessary.

Engine - Gas (Air-Cooled) Tests and Adjustments - 35

 ENGINE - GAS (AIR-COOLED) TESTS AND ADJUSTMENTS
Governor Adjustment
Reason:
c careful
CAUTION: Avoid Injury! Engine will be HOT. Be
not to burn skin.
To make sure the governor shaft contacts the flyweight
plunger when the engine is stopped. 4. Move throttle lever to idle position. Hold the throttle lever
on the carburetor in the closed position (turn governor arm
NOTE: Adjust throttle cable before adjusting governor clockwise all the way).
linkage.
5. Adjust the low idle speed screw (A) until the engine idles
Procedure: at 1450 rpm (carburetor idle rpm). Use the photo
tachometer to check engine rpm at the blower housing
NOTE: It is not necessary to remove the throttle or screen.
choke cables from the governor plate assembly to
reach the governor arm. The governor plate can be
swung away with the cables installed when accessing
the governor arm components.
1. Remove governor plate assembly.

B B
MX11674

6. Release the throttle lever and adjust the low idle speed
set screw (B) on the control plate to obtain a 1550 rpm
C governed low idle speed.

High Idle Speed Adjustment

MX11696
Reason:
2. Loosen nut (A) holding the governor arm (B) to the
To set engine high idle mixture and rpm.
governor shaft.
3. Turn the governor arm full counterclockwise and hold. Equipment:
4. Turn the governor shaft (C) full counterclockwise and • JTO5719 Photo Tachometer
hold. • 6 mm bolt or 1/4” drill bit.
5. Tighten nut.
Procedure:
Low Idle Speed Adjustment
Reason:
c clear
CAUTION: Avoid Injury! Always keep hands
of moving parts.
To set engine slow idle mixture rpm.
1. Move throttle lever to the high idle position.
Equipment:
IMPORTANT: Avoid damage! Do not adjust high idle
• JTO5719 Photo Tachometer
speed with air cleaner removed.
Procedure: 2. Match the lever hole on the governor control plate with
1. Disconnect all external loads from engine. the panel hole (A) and insert the bolt or drill bit.
2. Put reflective tape on blower housing screen.
3. Start and run engine at medium idle for five minutes.

Engine - Gas (Air-Cooled) Tests and Adjustments - 36

 ENGINE - GAS (AIR-COOLED) TESTS AND ADJUSTMENTS
Compression Test

B Reason:
To determine the condition of pistons, rings, cylinder walls
A and valves.
B

A
MX11675 B
3. Loosen the two M6 control panel mounting bolts (B)
enough to allow the control panel to move.
4. Slide the control panel up or down in the slot at the right
side (C) to set the idle speed.
5. Use a photo tachometer to check engine rpm at the
blower housing screen.
MX11780
6. Set the high idle speed at 3600 RPM and tighten the M6
mounting bolts to 5.9 Nm (52 lb-in.). Procedure:
7. Remove the bolt or drill bit from the panel hole. 1. Adjust valve clearance to 0.075 – 0.125 mm (0.003 –
8. Recheck the idle speed and readjust if necessary. 0.005 in.) with engine at top dead center (TDC)
compression stroke. Engine must be “cold” (shop
Specifications: temperature, 60 – 86°F (16 – 30°C).
High idle setting . . . . . . . . . . . . . . . . . . . . . . . . 3600 rpm 2. Run engine until it reaches operating temperature.
Carburetor idle setting . . . . . . . . . . . . . . . . . . . 1450 rpm 3. Remove both spark plugs (B) and ground leads (A) to
Governed idle setting. . . . . . . . . . . . . . . . . . . . 1550 rpm block or use spark testers.
4. Put throttle lever in fast idle (wide open) position. Choke
NOTE: For high altitude operation above 4000 feet, use
must be properly adjusted and fully open. Air filter must be
high altitude carburetor kit, to prevent over rich fuel
clean.
mixture and black exhaust smoke.
IMPORTANT: Avoid damage! DO NOT overheat
starting motor during test. Starter duty is 5
seconds on, 10 seconds off.

5. Attach compression gauge to engine, and crank hot

engine until highest compression reading is obtained.
6. Record pressure readings for each cylinder.

Specifications:
Minimum Compression . . . . . . . . . . . . . 390 kPa (57 psi)

Results:
• If pressure readings are above specification, adjust
valves and check fuel and intake air systems. Check
exhaust for restriction.
• If pressure readings are below specification, squirt clean
engine oil into cylinders and repeat test.

Engine - Gas (Air-Cooled) Tests and Adjustments - 37

 ENGINE - GAS (AIR-COOLED) TESTS AND ADJUSTMENTS
• If pressure increases significantly, check piston rings flywheel clockwise and determine TDC as follows:
and cylinder walls for wear or damage. • On the No. 1 Cylinder the left projection (A) on the
• If pressure does NOT increase after retest, check for flywheel must be aligned with the right leg (B) of the #1
leaking valves, valve seats or cylinder head gaskets. ignition coil (C).
• Install spark plugs and reconnect ignition coils when • On the No. 2 Cylinder the left projection (D) on the
finished with testing procedure. flywheel must be aligned with the right leg (E) of the #2
ignition coil (F).
Valve Clearance Adjustment • Make sure the intake and exhaust valves are closed
completely on the cylinder you are checking. If they are
Reason: not, turn the flywheel one rotation clockwise (360o) and
To avoid engine damage and provide optimum operating realign the left projection with the right leg.
performance.

Equipment: H

• Feeler gauge set. J

Procedure:
1. Remove the rocker cover.

IMPORTANT: Avoid damage! Valve clearance must

be checked when the engine is cold (room
temperature). K

C MX17440
#1
3. Measure the valve clearance between the rocker arm
(G) and the valve stem end with a feeler gauge (H). Valve
clearance should be between 0.075 – 0.125 mm (0.003 –
0.005 in.) for both the intake and exhaust valves.
A B 4. If valve clearance is incorrect, loosen the lock screws (J)
and the valve clearance adjusting nuts (K).
5. Insert a 0.10 mm (0.004 in.) feeler gauge (H) between
the rocker arm and the valve stem. Tighten the adjusting
nut until the feeler gauge just begins to bind between the
rocker arm and the valve stem end when pulled. The gauge
E
should offer some resistance as it is drawn through, but
F
should not bind.

#2 6. Hold the adjusting nut (K) with a wrench and tighten the
lock screw to 6.9 N•m (61 lb-in.).
7. Recheck the clearance after tightening the lock screws.

MX11810/MX11811

2. Place the piston on the cylinder you will be adjusting at

top dead center (TDC) of the compression stroke. Turn the

Engine - Gas (Air-Cooled) Tests and Adjustments - 38

 ENGINE - GAS (AIR-COOLED) TESTS AND ADJUSTMENTS
Crankcase Vacuum Test
Reason: C
To measure the amount of crankcase vacuum, to ensure
the crankcase is not pressurized. A pressurized crankcase
will force oil past the seals.

Equipment:
• JTO5697 U-Tube Manometer Test Kit; or,
• JT03503 Crankcase Vacuum Test Kit

Procedure 1: M88762

7. Zero out the manometer by sliding the ruled scale up or

IMPORTANT: Avoid damage! Test must be run with down so “0” (C) is located where water level on both sides
the engine at normal operating temperature, if not, is even.
test will be inaccurate. DO NOT use more than 3 feet
8. Hold finger over rubber plug hole to keep oil from
of manometer tubing. If a longer hose is used the
spraying out. Start engine, move the throttle lever to fast
readings will be inaccurate.
idle (3400 rpm) and allow engine to reach operating
1. Park machine on level surface. temperature.
2. Raise engine hood and remove dipstick. Check dipstick/ 9. Quickly attach clear line from manometer to rubber plug
oil fill cap and O-ring for cracks or damage, replace as in dipstick opening.
necessary.
3. Install appropriate size rubber plug in dipstick tube.
D
4. Insert barbed fitting in rubber plug so that clear line to
fitting (A) can be connected at a later step.

IMPORTANT: Avoid damage! DO NOT make

connection between U-Tube Manometer clear line
and engine crankcase BEFORE engine is running or
fluid in manometer could be drawn into crankcase.

5. Attach manometer magnets to a solid metal surface.

A B

M88764

Example: 3 + 3 = 6 in. of vacuum

[Link] vacuum reading. Gauge should show a
minimum vacuum of 10.2 cm (4 in.) of water movement.
M88761 The reading is obtained by adding (D) and (E) water
6. Open top valves (A) and (B) one turn. movement from “0” position.

Engine - Gas (Air-Cooled) Tests and Adjustments - 39

 ENGINE - GAS (AIR-COOLED) TESTS AND ADJUSTMENTS
• Seals and gaskets for leakage
IMPORTANT: Avoid damage! Repeat test at least
three times for accuracy. To repeat test, remove the • Rocker arm cover O-ring for leakage
manometer tube from top of manometer at “A”. • Rings, piston, and cylinder bore for wear or damage
DO NOT remove manometer tube from engine.
Perform step #7 then reattach manometer tube to
side “A”. Continue with step #10.
Fuel Flow Test

[Link] line from manometer before stopping engine. Reason:

Then remove dipstick hose connection and install dipstick. To check the condition of fuel pump and determine fuel
pressure.
Procedure 2:
1. Park machine on level surface. Equipment:

2. Raise engine hood and remove dipstick. Check dipstick/ • Proper Fuel Container
oil fill cap and O-ring for cracks or damage, replace as • 2’ Fuel Line
necessary.
Procedure:
3. Install appropriate size rubber plug (A) in dipstick tube.
4. Insert barbed fitting (B) in rubber plug so that clear line
(C) to fitting can be connected at a later step.
A
IMPORTANT: Avoid damage! DO NOT make the
connection between the test gauge and rubber plug
BEFORE engine is running at FAST idle. Gauge B
damage may result.

After the test reading is made, DO disconnect the

test gauge WHILE the engine is running at FAST idle
to prevent damage to the gauge.

5. Hold finger over rubber plug hole to keep oil from

C
spraying out. Start engine, move the throttle lever to fast E
idle (3400 rpm) and allow engine to reach operating D
temperature.
6. Connect gauge (D), clear line, and barbed fitting to
rubber plug.
7. Record crankcase vacuum reading. Gauge should show
a minimum vacuum of 10.2 cm (4 in.) of water movement.
MX11739
8. Disconnect barbed fitting, clear line, and gauge from 1. Temporarily clamp fuel line (D) to prevent fuel flow.
rubber plug while engine is running at FAST idle. Hold
finger over rubber plug hole to keep oil from spraying out.
IMPORTANT: Avoid damage! Ensure that the fuel
9. Move throttle to SLOW idle and turn engine OFF. container is clean if fuel is to be returned to the tank
[Link] rubber plug and install dipstick. after test.

2. Disconnect fuel line (B) from fuel pump outlet (A) and
Specification:
replace with two foot hose section at fuel pump. Run the
Minimum crankcase lower end of hose into a clean container.
Vacuum at 3400 rpm. . . . . . . . . . . 10.2 cm (4 in. water)
3. Release clamp on fuel line (D).
Results: 4. Crank engine, fuel should flow freely into container.
If crankcase vacuum does not meet specification, check 5. Clamp line (D) again, and re-install carburetor fuel line
the following: (B) to the fuel pump outlet (A).
NOTE: A new engine may have low vacuum readings 6. Pour captured fuel into tank.
because the piston rings have not seated.

Engine - Gas (Air-Cooled) Tests and Adjustments - 40

 ENGINE - GAS (AIR-COOLED) TESTS AND ADJUSTMENTS
Results: Procedure - Preliminary Check:
If fuel flow is slow or non-existent, check the following:
• Replace fuel filter (E)

F
A

MX11743

MX11742

• Check fuel pump vent holes (C) on the face of the pump
B
and filter (F) on the back of the pump for plugging or
clogging, remove foreign matter.
• Check fuel lines, fuel tank outlet, and fuel tank cap for
restrictions.
• Check crankcase vacuum.
• Replace fuel pump if flow is still not correct.
NOTE: The fuel pump cannot be disassembled or
repaired. If any damage or malfunction is suspected
the fuel pump must be replaced.

Oil Pressure Test MX11744

1. Park machine on level surface.

Reason:
2. Turn key switch OFF. Allow engine to cool.
To verify that the engine has enough oil pressure to
lubricate the internal engine components. 3. Move forward/reverse pedals to NEUTRAL position.
4. Engage parking brake and raise hood.
Equipment:
5. Check engine oil level, bring oil level to full mark.
• JT03344 Pressure Gauge Assembly
6. Remove oil pressure switch (A).
• JT03349 Connector
7. Install JT03349 Connector.
• JT03017 Hose Assembly
8. Install JT03017 Hose Assembly and JT03344 pressure

c are
gauge assembly (B).
CAUTION: Avoid Injury! Engine components 9. Monitor oil pressure while cranking engine. If no oil
HOT. Be careful not to touch, especially the pressure is present discontinue cranking engine.
exhaust pipe or muffler while making Determine and correct cause before running engine.
adjustments. Wear protective eye glasses and
clothing. IMPORTANT: Avoid damage! If pressure reading is
below 69kPa (10 psi), STOP ENGINE IMMEDIATELY
and determine cause.

Engine - Gas (Air-Cooled) Tests and Adjustments - 41

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Procedure- Engine Running: 2. Turn key switch OFF.
1. Start and run engine at medium idle for five minutes to 3. Move forward/reverse pedals to NEUTRAL position.
heat engine to normal operating temperature.
4. Engage parking brake and raise hood.
2. Run engine at fast idle (3350 rpm) and check oil
5. Remove high tension lead (A) from spark plug.
pressure. Oil pressure should be 241 kPa (35 psi)
minimum. 6. Connect D-05351ST Spark Tester (B) to spark plug.
7. Connect high tension lead to Spark Tester.
Results:
8. Adjust spark tester gap to 4.2 mm (0.166 in.) (4 turns)
• If oil pressure reading is BELOW specifications, inspect
with screw (C).
or replace the following:
9. Crank engine and watch spark (D) at spark tester. If
– Oil pressure relief valve spring worn or broken
engine will start, watch spark with engine running. A
– Oil pressure relief valve stuck or broken steady, strong, blue spark should be observed.
– Oil pump worn or damaged
IMPORTANT: Avoid damage! Do not adjust spark
– Oil pump suction screen or oil passages plugged tester gap beyond 5.0 mm (0.20 in.) (5 turns).
– Connecting rod and main bearing journals excessively Damage to ignition components could occur.
worn
– Connecting rod and main bearing journals excessively Engine Repair
worn
– Oil filter plugged Fuel Pump Removal and Installation
Procedure:
Spark Test
1. Close fuel shut-off (if equipped), or pinch fuel line shut.
Reason:
Check overall condition of ignition system.

Equipment:
• D-05351ST Spark Tester B

c especially
CAUTION: Avoid Injury! Engine components,
the exhaust pipe or muffler, are HOT.
Be careful not to touch when making
adjustments. Wear protective eye glasses and C
clothing.

Procedure:

B
A
MX11685

2. Disconnect fuel lines (A).

3. Remove bolts (B) from fuel pump.
4. Install components in reverse order of removal.

C C

M49887

1. Park machine on level surface.

Engine - Gas (Air-Cooled) Engine Repair - 42

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Fuel Pump/Fuel Filter Inspection Air Cleaner - Removal/Inspection/Installation
Procedure:
A
NOTE: The fuel pump cannot be disassembled or
repaired. If any damage or malfunction is suspected
B
the fuel pump must be replaced.
1. Check the fuel pump for visual damage. Replace the
pump if it is damaged or worn.
C

MX11742
H
2. Remove the pump body vacuum inlet (D) from the
vacuum hose and lift pump up to inspect both the front and F
I
back of the pump body.
G J
3. Check the vent holes on the front and the filter (D) on
the back of the pump body for plugging or clogging. If either
K
the holes or filter are plugged remove the foreign matter.
4. Install components in reverse order of removal.
L

N P

Q
MX14445

A - Air Cleaner Cover Mounting Screw

B - Element Mounting Wing Nut
C - Air Cleaner Cover
D - Paper Element
E - Precleaner
F - Washer
G - Anti-backfire Shield
H - Mounting Screws (2)

Engine - Gas (Air-Cooled) Engine Repair - 43

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
I - Mounting Studs (2)
J - Mounting Locknuts (2)
K - Base Mounting Screws (2)
L - Air Cleaner Base
M - Base Gasket
N - Base Mounting Bracket
A
O - Base Mounting Bolts (2)
P - Breather Hose B C

Q - Breather Hose Clamp

1. Inspect precleaner and paper element for dirt and dust.
2. Clean precleaner if necessary:
• Rinse in clean water.
• Squeeze to remove water.
• Air dry.
MX11790
3. Apply 30 mL (1 oz) of clean engine oil to precleaner.
Squeeze to distribute oil evenly and to remove excess oil. 3. Remove the air cleaner base (A) and anti backfire plate
by removing four mounting bolts (B) and two carburetor
IMPORTANT: Avoid damage! DO NOT wash stud nuts (C).
paper element. Clean or replace paper element 4. Remove four phillips screws holding the carburetor
as necessary. access cover to the blower housing. Remove cover to
4. Tap paper element gently to remove dust. access carburetor and manifold mounting bolts.

5. Replace element if oily, dirty or damaged.

6. Apply Thread Lock and Sealer (Medium Strength) on
E F
mounting screws before installation.
7. Install breather hose. Make certain the breather hose
end is fully seated in the air cleaner base and the hose is
not kinked.

Carburetor Removal and Installation

Procedure:
1. Disconnect battery negative cable. D

2. Remove air cleaner cover and air filter element (See Air
Cleaner Removal and Installation. MX11788

5. Disconnect carburetor fuel line (D) at the fuel pump

outlet. Disconnect the wiring harness plug at the left side of
the engine and pull the wiring harness (E) up off the
carburetor. Remove the crankcase breather line (F) from
the engine cases.

Engine - Gas (Air-Cooled) Engine Repair - 44

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Carburetor Disassembly/Assembly
H
J Disassembly:

B
C

A
E
F G
G
H I

J
AA
K
Z L
M
N
Y O
MX11791 P
X
6. Unhook the throttle (G) and choke link (H) rods from the W
carburetor. Disconnect the throttle link spring (J) from
throttle shaft lever.
Q
7. Unbolt the intake manifold as detailed in Intake Manifold
R
Removal and Installation. It is necessary to pull the intake
V
manifold/carburetor assembly away from the engine to U
remove the carburetor from the studs. N
O
S

T
MX14441
K A - Choke Shaft
B - Screw
C - Choke Valve
D - Seal
E - Spring
F - Pilot Screw
L
G - Limiter
MX11789 H - Throttle Valve
8. Remove the carburetor mounting bolts (K) and nuts (L). I - Screw
Slide the carburetor back toward the governor plate to J - Float Valve
remove from the studs. K - Seal
9. Clean the carburetor and intake manifold mating L - Collar
surfaces. Fit a new intake manifold gasket on the carburetor M - Throttle Shaft
studs. Replace the insulator between the float bowl and N - Plug, Main Jet
carburetor if worn or damaged.
O - Gasket
[Link] the carburetor into position. Install the mounting P - Main Jet (L)
bolts and nuts. Tighten nuts to 5.9 N•m (52 lb-in).
Q - Solenoid Valve
[Link] intake manifold/carburetor assembly as detailed R - Gasket
in Intake Manifold Removal and Installation. S - Main Jet (R)

Engine - Gas (Air-Cooled) Engine Repair - 45

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
T - Screws
U - Spring G F
V - Drain Screw E
W - Pilot Jet
X - Pilot Jet
Y - Gasket
Z - Float
AA- Pin H

1. Remove carburetor from engine (See Carburetor

Removal and Installation).

C
G

M99826

4. Carefully pull the float chamber (E) straight away from

the carburetor body (F). Do not damage either the pickup
tubes (G) or the float assembly (H).

M99827

2. Remove the float chamber drain screw and spring (A),

fuel shutoff solenoid (B), and vent hose (C).
M99828
E Note: Float pivot pin end is serrated. Pin can be
removed from one side only without damaging pin
D and/or float hinge.
5. Using a small pin punch, carefully drive the float pivot
pin (I) out from the side opposite the throttle lever of the
float hinge.

M99829

3. Remove four screws (D) holding the float chamber (E) to

the carburetor body.

Engine - Gas (Air-Cooled) Engine Repair - 46

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
9. Slide the choke shaft (O) and shaft seal (P) out of the
carburetor body (F).
J
R

Q
F M99831

[Link] the throttle valve plates (R) so they can be

M99830 installed in the original position. Remove four screws (Q)
6. Lift the float (J) and float valve (K) off the carburetor securing the plates to the throttle shaft.
body (F).
7. Carefully remove the rubber gasket (L)

N U S

F
T

M M99833

M99832 [Link] the throttle shaft (S), shaft seal (T) and collar (U)
out of the carburetor body (F).
8. Mark the choke plate (N) so it can be installed in the
original position. Remove two screws (M) securing the [Link] throttle and choke shafts and bushings for wear.
choke plate to the choke shaft. Wear between shafts and carburetor bushings should not
exceed 0.25 mm (0.010 in.).
[Link] wear by placing carburetor on 6 mm (1/4 in.) thick
F
raised flat surface. Measure the up and down movement of
the shaft with a feeler gauge or dial indicator while moving
the shaft up and down.

O
P

M99834

Engine - Gas (Air-Cooled) Engine Repair - 47

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Assembly:
V
E D

B
M99835

Note: Idle mixture adjustment is factory set, and M99836

mixture screws are sealed. No adjustment should Note: Main jets change for altitude ranges: 0 to
be performed except by EPA/C.A.R.B. certified 1067m (0 to 3500 ft); 1067 to 2134m (3500 to 7000
technicians and repair facilities. ft); 2134m (7000 ft) and up. High altitude
[Link] two slow speed jets (V) from the float chamber performance can be improved by installing smaller
(E). diameter main jets and readjusting the idle mixture.
1. Install main jets with the #104 jet (A) in the port marked
IMPORTANT: Avoid damage! Carburetor is equipped “L” for the number one cylinder and the #106 jet installed in
with a different size fixed main jet for each cylinder. the port marked “R” (D) for the number two cylinder.
The carburetor is marked “L” for number 1 cylinder Tighten main jets to 0.7 N•m (6 lb-in.).
and is equipped with a #104 main jet. The number 2
2. Inspect the gasket (B) and gasket seat for any nicks.
cylinder is marked “R” and is equipped with a #106
Remove any imperfections, replace the gasket and install
main jet. The carburetor is marked in two areas; The
the main jet plug (C). Tighten plug to 19 N•m (165 lb-in.).
carburetor upper body near the choke valve and the
lower body near the main jet plugs (Z).
E

U S

F F

F
M99835
T
M99836 3. Install slow speed jets (F) into the float chamber (E).
Tighten to 0.7 N•m (6 lb-in.).
15..Remove the left main jet plug (W), gasket (X) and main
jet (Y) from the float chamber. Repeat the same procedure
for the right main jet.

Engine - Gas (Air-Cooled) Engine Repair - 48

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

N
J

K
O

K
H M99834
G
6. Slide the choke shaft seal (N) onto the choke shaft (O).
M99833 The lip of the shaft seal should face the inside of the
4. Slide the collar (G) and the throttle shaft seal (H) onto carburetor. Slide the choke shaft assembly into the
the throttle shaft (J). The lip of the shaft seal should face carburetor body (K).
the inside of the carburetor. Slide the throttle shaft
assembly into the carburetor body (K).
P

M99832
L 7. Install the choke plate in its original location. Place the
choke plate (P) into the carburetor throat over the flat
M99831
surface of the choke shaft. Install two screws (Q). Tighten
5. Install the throttle valve plates in their original locations. to 1 N•m (9 lb-in.).
Insert the throttle valve plates (M) into the carburetor bore
over the flats of the throttle shaft. Install four screws (L).
Tighten to 1 N•m (9 lb-in.).

Engine - Gas (Air-Cooled) Engine Repair - 49

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Carburetor Clean/Inspect/Rebuild:

U
IMPORTANT: Do not clean holes or passages in the
carburetor body with sharp objects such as wire or
R
small drill bits.

T
c and
CAUTION: Avoid Injury! When cleaning rubber
plastic carburetor parts, use a cleaning
solvent that will not damage the components.

1. Inspect moving parts such as shafts, choke and throttle

V
plates etc. for wear or damage. Replace if necessary.
2. Check the carburetor body and float chamber for cracks,
nicks or other damage. Replace components as necessary.

S 3. Remove all rubber and plastic parts from the carburetor.

Soak all metal carburetor parts in cleaning solvent for a
M99830 maximum of 1/2 hour.
8. Lightly coat the rubber gasket (R) with grease. Carefully 4. Spray all internal passages and jets in the carburetor
place it on the carburetor body (S) in the gasket groove. body with a spray carburetor cleaner to verify that
9. Hook the float valve (T) into the float (U). Place the float passages and jets are open.
and float valve onto the carburetor body (S) so the valve is
seated into the inlet jet and the float pin (V) is aligned. IMPORTANT: Avoid damage! Rinse carburetor body
in warm water immediately after using carburetor
[Link] press the float pin (V) into the float and cleaning solvent or spray to neutralize corrosive
carburetor body until flush. Insert the pin from the throttle action of cleaner on aluminum.
lever side with the serrated end toward the throttle lever.
5. Rinse carburetor with warm water and dry with
compressed air. Do not use rags or paper to dry parts as
X
Y W lint may plug holes or passages.
6. Inspect all parts for wear or damage, replace as
necessary.

Intake Manifold Removal and Installation

Z
Procedure:
1. Remove air cleaner assembly from carburetor (see
Carburetor Removal and Installation).
2. Remove blower housing.

Y C
B
M99826
B
[Link] set the float chamber (W) straight down onto
the carburetor body (X) to prevent damage to the pickup
tubes (Y) or the float assembly (Z).
[Link] four screws holding the float chamber to the A
carburetor body and tighten to 4 N•m (34 lb-in.).
13. Install carburetor to engine (See Carburetor Removal MX11801
and Installation). 3. Cut the ties (A) holding the wiring harness and ignition
coil leads to the intake manifold. Disconnect the fuel
solenoid lead.

Engine - Gas (Air-Cooled) Engine Repair - 50

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
4. Remove the manifold mounting bolts (B) and the intake Muffler Removal and Installation
manifold (C). Separate the carburetor from the manifold.
5. Inspect the intake manifold for signs of cracks or porous Procedure:
spots. Fuel stains on the surface of the manifold often
indicate a suspect area. Inspect the manifold gasket
mounting surfaces for burned areas or nicks and gouges.
c may
CAUTION: Avoid Injury! Muffler and shield
be hot. Allow muffler and shield to
Replace the intake manifold if it is cracked, or if the gasket
cool before removing.
surfaces are damaged to where they will not seal properly
when using new gaskets. 1. Disconnect headlight connector, and remove hood.
2. Disconnect battery leads and remove battery.

D
E

MX11795

6. Clean all old gasket residue off the mating surfaces of A

the intake manifold and the cylinder heads. Install new
gaskets (D) with the offset (E) to the inside.
7. Install the carburetor to the manifold as detailed in MX11751
Carburetor Removal and Installation. Install the manifold/
3. Remove hood support bracket bolts at (A) and (B) on
carburetor assembly. Tighten the intake manifold mounting
both sides of the machine.
bolts to 5.9 N•m (52 lb-in.).

MX11801

8. Reroute the wiring harness and ignition coil leads as C

E
shown. Fasten the harness to the manifold with three ties
(F) as shown. Cut excess material off the ends of the ties.
Reconnect fuel solenoid lead.
9. Install the air cleaner assembly and blower housing. MX11753

4. Remove cap screws (C and D) from the battery box.

5. Remove two bolts holding the battery box to the back
side of the frame cross member (E). Lift the battery box/
hood support assembly out and up to separate from the
muffler bracket.

Engine - Gas (Air-Cooled) Engine Repair - 51

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Engine Removal and Installation
Conditions:
L • Machine parked on level surface
• Park brake engaged
• PTO disengaged
• Mower deck removed

Procedure:
M
1. Drain engine oil.
MX11578 2. Remove muffler and exhaust manifold, see previous
6. Remove three 13 mm nuts (L) from exhaust manifold procedure.
studs. 3. Remove air cleaner cover and element.
7. Remove 12 mm nut (M) and lock washer from inside 4. Disconnect throttle and choke cables at the governor
stud on right exhaust manifold. control plate.

G
MX11579

8. Remove two bolts (N) holding muffler mount to engine MX11754

case. Slide exhaust system off exhaust manifold studs and 5. Disconnect engine ground strap (F) at left front engine
remove from machine. bolt. Remove the ground strap and the negative battery
9. Inspect parts for wear or damage. Replace as cable (G).
necessary.
[Link] parts in reverse order of removal, and tighten all
hardware.

Specifications:
Muffler Flange Nuts . . . . . . . . . . . . . . . 15 N•m (11 lb-ft) J

MX11755

6. Disconnect starter leads (H) and positive battery cable

(J) from starter lug. Disconnect lead from spade terminal
on starter.

Engine - Gas (Air-Cooled) Engine Repair - 52

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
7. Remove gas line at fuel pump outlet. Unbolt fuel pump
from bracket and swing out of way. See Fuel Pump
Removal and Installation.

R
K
MX11771

[Link] two drive shaft U-joint pinch bolts (R) at the

MX11757 hydrostatic input shaft.
8. Disconnect wiring harness coupler (K) at left side of [Link] the engine slightly with a hoist using the two lift
engine. brackets on the top of the engine.

P S

MX11767
MX11775
[Link] the motor/drive shaft/shroud unit forward to access
9. Remove five bolts and nuts (O) holding the drive shaft
the crankshaft output coupler bolts (T). Remove three bolts
shroud to the fire wall. Remove the vented side panels (P)
and separate the drive shaft coupler from the crankshaft
to access the heads of the two lower bolts.
output coupler.
NOTE: If the drive shaft and /or shroud will not be
serviced or replaced, it is not necessary to remove
rubber damper (S) from the drive shaft coupler. If it is
necessary to remove the shroud from the drive shaft
unit, pop the plastic push pins (U) out of the access
panel and slide the access panel down off the drive
shaft.
Q

MX11902

[Link] the hydrostatic line from the guide bolted to the

bottom of the engine. Remove four engine cradle mounting
bolts (Q).

Engine - Gas (Air-Cooled) Engine Repair - 53

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

MX11902
MX11766

[Link] engine up out of machine with hoist. Remove five 4. Position the engine on the frame rails, and install four
bolts (V) from the bottom of the engine and the two bolts on engine cradle mounting bolts. Tighten
the face (W) to remove the engine mount cradles. to 29 N•m (21 lb-ft). Note that the right front engine cradle
mounting bolt (B) is installed with the threads up, the left
Installation: front bolt has the ground strap and wiring harness ground
1. Install engine mount cradles with two face bolts, wire installed under the head.
tightening to 23 N•m (17 lb-ft), and four bottom mounting 5. Tighten the drive shaft U-joint pinch bolts to 40 N•m (30
bolts tightening to 63 N•m (47 lb-ft). Install the hydraulic lb-ft).
hose guide on the right side cradle with one bolt. Tighten to
12 N•m (8 lb-ft). 6. Install the drive shaft shroud to the fire wall of the
machine with five bolts and nuts. Reinstall the vented side
access panels to the machine.
A 7. Install the ground strap and negative battery cable to the
left front engine cradle mounting bolt. Position the ground
strap so some slack is left in the cable.
8. Connect and adjust throttle and choke cables.
9. Install fuel pump to bracket, making certain the vacuum
inlet is connected to the vacuum line. Connect fuel line to
fuel pump and adjust carburetor.
[Link] all electrical wiring connections, including starter
leads and spark plug leads.

MX11903

2. Lower engine assembly into position slightly above

frame rails in machine with a hoist. Slide the drive shaft /
shroud unit forward. Install the drive shaft coupler to the
crankshaft output coupler with three bolts (A). Tighten to 40
N•m (30 lb-ft).
3. With the help of an assistant, slide the engine/drive
C
shaft/shroud assembly back into position while the
assistant slides the splined drive shaft U-joint onto the
hydrostatic unit input shaft.

MX11904

[Link] hydraulic hose in hose guide (C) on bottom of

engine.

Engine - Gas (Air-Cooled) Engine Repair - 54

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

B
D

MX11780
MX11751
5. Remove cylinder shrouds. Remove right shroud by
[Link] exhaust system to engine and machine in reverse
removing the bolt on the front of the cylinder (B) and the
order of disassembly.
lower fuel pump bracket bolt (C). Remove spark plug lead
[Link] the hood support /battery box assembly to the at plug. Disconnect all electrical leads and connections to
machine in reverse order of disassembly. Tighten the hood the rectifier assembly (D) and remove the shroud complete
support bolts (B) to 40 N•m (30 lb-ft). with rectifier.
[Link] battery. Remove left cylinder shroud by removing upper cable guide
[Link] hood and reconnect headlight connector. bolt, front cylinder bolt, upper blower housing bolt and
spark plug lead.

Cylinder Head Removal and Installation

E
Procedure:
1. Remove air cleaner assembly (see carburetor removal).
2. Remove fan housing. #2 #1
3. Remove exhaust system assembly (see Engine
Removal & Replacement).

B
E

MX11782

6. Before removing the cylinder head, the piston should be

set to TDC on the intake stroke for the cylinder you are
C working on. This can be determined by the position of the
flywheel magnet (E) in relation to the coils.
NOTE: No. 1 cylinder is the left cylinder when sitting in
the drivers seat, No. 2 cylinder is the right.
A

MX11787

4. Remove intake manifold and carburetor (See Carburetor

removal). Remove carburetor valley (A) from between the
cylinders. Remove governor control panel (B) by removing
the two bolts (C) fastening it to the cylinder heads.

Engine - Gas (Air-Cooled) Engine Repair - 55

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
[Link] the cylinder you are working on to TDC of power
stroke (E).

IMPORTANT: Avoid damage! Cylinder head gaskets

are coated with sealing agents. Gasket leaks could
occur if the sealing compound is scratched or
F damaged.

[Link] new gaskets on the cylinders.

[Link] the cylinder into position, aligning the push rods with
the rocker arms (see push rod removal and installation).
G

4
1
MX11783

7. Unscrew the rocker cover mounting bolts (F) and

remove the cover (G) and gasket. 3

IMPORTANT: Avoid damage! Cylinder head can be

warped during removal if the correct head bolt 2
removal procedure is not followed. 5

2 MX17402
5
[Link] the cylinder head bolts and tighten in the
sequence shown above. Use a torque wrench. Tighten in
the following steps to prevent warping the head:
3
• 8 N•m (70 lb-in.)
• 16 N•m (141 lb-in.)
4 • 25 N•m (221 lb-in.)
1
[Link] valve clearance and adjust if necessary (see
valve clearance adjustment).
[Link] gasket and rocker cover, tightening rocker cover
MX17402 mounting bolts to 6.9 N•m (61 lb-in.).
8. Loosen the cylinder head bolts 1/4 turn at a time in the [Link] cylinder shrouds, flywheel cover, governor plate,
sequence shown. Repeat the sequence until all bolts are carburetor and manifold, fuel pump and fuel solenoid wires
removed and lift off the cylinder head assembly. in reverse order of disassembly.

NOTE: If removing push rods, mark each rod for

assembly in original location.
9. Clean the mating surfaces of the cylinder heads and
cylinder of all old gasket material and sealing compound.
[Link] push rods in their original positions if removed
(See push rod removal and installation).
[Link] the knock pins in the cylinder head assemblies (if
removed).

Engine - Gas (Air-Cooled) Engine Repair - 56

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Push Rod and Rocker Arm Removal and 7. Inspect the push rods for damage or excessive runout.
Installation Place each push rod in V blocks set as near to the ends of
the rod as possible. Set up a dial gauge at the center point
Procedure: of the push rod. Turn the rod to measure the runout. Check
the difference between the highest and lowest dial readings
1. Set the piston on the cylinder you are working on at TDC to determine runout. If this figure exceeds 0.5 mm (0.02 in.)
of the power stroke. the push rod must be replaced.
8. Set the piston at TDC on the cylinder you are working on
before beginning push rod installation.
C

A
A

MX17401

2. Remove rocker covers (see cylinder head removal).

3. Loosen the valve clearance adjusting nuts (A).
4. Move the rocker arms (B) to provide access to the push
rods (C). Pull out the push rods. Mark each rod so it can be F
installed in the original position during reassembly.
5. If rocker arms are to be removed, remove the valve
clearance adjusting nuts and lift off the rocker arms. G

MX11802

MX11797 9. Install each push rod (E) in its original position by

inserting the end of the rod so it is sliding along the inside
6. Clean the rocker arms. Inspect the push rod and valve wall of the crankcase (F). Position the push rod on the
stem contact points (D). If the contact surfaces are tappet (G).
excessively worn or show signs of galling or surface flaking,
replace the rocker arm. [Link] that both intake and exhaust push rods on the
cylinder you are assembling are at the lowest position on
the cam lobes (H). If not, turn the flywheel clockwise one
turn (360o) and reset the piston at TDC of the power stroke.
[Link] that the ends of both push rods are correctly
seated on the tappets and reinstall the rocker arms on the
push rods. Apply clean engine oil to the rocker arm pivot
seat area and the contact points on the arm when
reinstalling the rocker arms. Temporarily tighten the valve
clearance adjusting nuts. Adjustment the valves as detailed
in the Engine Tests and Adjustments section.
MX11799

Engine - Gas (Air-Cooled) Engine Repair - 57

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Valve Train Removal and Installation
Procedure:
1. Remove cylinder head (see Cylinder Head Removal and
Installation). E

NOTE: When removing valve train, mark all parts so

they can be reinstalled in their original position.

MX17417

5. Remove the stem seals (E). Replace the seals

whenever the cylinder head is dismantled.
B
NOTE: Valve guides are not replaceable. If a valve
guide is damaged or worn beyond specification, the
cylinder head must be replaced.
MX17419
6. Check to see if the valve seats properly in the valve
2. Remove valve adjusting nuts (A) and rocker arms (B). seat. If not, resurface the valve seat and/or replace the
valve.
7. Install new stem seals if necessary.
8. Apply engine oil to the valve stem to avoid damaging the
C valve stem seal. Install the valve and check for smooth
operation in the valve guide. Replace valve if it binds in the
guide, or if the guide to stem clearance is excessive.
9. Install valve spring, collets and spring retainer on the
valve.
[Link] clean engine oil to the rocker arm at the spherical
pivot seat, and the points where the arm contacts the push
rod and the valve stem end.
D [Link] the rocker arm on the stud and screw the pivot
and locknut on the stud temporarily. Perform a valve
adjustment as detailed in Valve Clearance Inspection and
MX17418 Adjustment in the Engine Tests and Adjustments Section.
3. Support the valves inside the combustion chamber.
Push down with your thumbs on the valve spring retainer
(D) as shown. Remove the collets (C) and retainer.
4. Remove the springs and valves from the cylinder head.

Engine - Gas (Air-Cooled) Engine Repair - 58

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Piston Removal and Installation
Procedure:
F

E
B

MX11819
A
6. Remove one of the piston snap rings (E) with a needle
MX17424 nose pliers (F).
1. Remove cylinder heads (See Cylinder Head Removal/ 7. Push the piston pin out the side where the snap ring
Replacement). was removed and remove the piston from the rod.
2. Remove the crankcase cover and the camshaft.(See 8. Remove the top and second rings with piston ring pliers.
Camshaft/Crankshaft Removal/Replacement).
3. Turn the crankshaft to expose the connecting rod cap
bolts (A). Remove the bolts. Remove and label the
connecting rod caps (B). G

IMPORTANT: Avoid damage! Note location of the

arrow mark (C) on the piston heads in relation to the
K mark (D) on the connecting rod. The arrow marks
on both piston heads face the flywheel. The K marks
on the connecting rods must be face-to-face. Keep
components together as a matched set.

C C MX11820

9. If piston ring pliers are not available, carefully spread the

ring opening with your thumbs and push up on the back
side of the ring (G) to remove it. Remove the 3-piece oil
ring using the same method.
D
[Link] and clean the piston and rings before installation
(See Piston Assembly Inspection).
MX17425
H
4. Label the piston and connecting rod assemblies for
correct reassembly.
5. Push the connecting rod end up into the cylinder, and
pull the piston and connecting rod assembly out the top of J
the cylinder.

MX11821

Engine - Gas (Air-Cooled) Engine Repair - 59

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
[Link] a new oil control ring on the piston in the following
sequence:
• Install the expander (H) in the oil ring groove with the S
ends (J) touching together, not overlapping.
• Install the upper and lower steel rails. Rails are
interchangeable and do not have an up or down
orientation. T
U

L R
Q

MX11825
K [Link] fresh engine oil to the piston pin and assemble
the piston for the #1 cylinder (Q) with the arrow mark (S)
facing away from the K mark (U) on the connecting rod.
[Link] fresh engine oil to the piston pin and assemble
the piston for the #2 cylinder (R) with the arrow mark (S)
facing the K mark (T) on the connecting rod.

MX11822

[Link] the scraper ring (K) in the second groove with the V
notch facing down.
[Link] the compression ring (L) in the first groove with W
the bevel facing down.

N
M
P

N O
M MX11826

[Link] new piston pin snap rings to both pistons. Align the
O snap ring gap (V) so it does not align with the piston pin
P
hole notch (W).

IMPORTANT: Avoid damage! Do Not reuse piston pin

MX11823 snap rings. Weakened and deformed snap rings
[Link] the ring gaps on the piston as shown: could fall out causing engine damage. Use only new
snap rings when reinstalling pistons.
• M - piston arrow mark
• N - top ring and upper steel rail end gaps [Link] fresh engine oil to the piston skirt and cylinder
bore.
• O - 30o - 45o
[Link] a ring compressor to compress the piston rings.
• P - second ring and lower steel rail end gaps

Engine - Gas (Air-Cooled) Engine Repair - 60

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Inspect Piston and Cylinder
Procedure:

MX17426

[Link] the piston and rod assembly in the cylinder bore MX11831
with the arrow mark on the piston (Z) facing the flywheel. 1. Remove the piston and piston rings (See Piston
Lightly tap the top of the piston with a plastic mallet to insert Removal/Replacement).
the piston assembly in the bore.
IMPORTANT: Avoid damage! Never attempt to clean
AB carbon deposits with the piston in the engine.
Carbon particles will fall between the piston and
cylinder and could damage crankshaft bearings and
AD
seals.

2. Scrape carbon deposits off the piston head (A) using a

AC scraper that will not gouge or scratch the piston.
AE AF

AD
c edges
CAUTION: Avoid Injury! The top and bottom
of the ring may be extremely sharp.
AF
AB
B

AC

MX11830

[Link] engine oil to the inner surface (AB) of the

connecting rod big end (AC) and caps (AD).

IMPORTANT: Avoid damage! The connecting rod

and rod big end cap are machined as a matched set. MX11832
They must be replaced as a set in their original 3. Clean the piston ring grooves (B) with a broken ring or a
position on the crankshaft. suitable tool.
[Link] the rods on the crankshaft, and install the big end
rod caps in their original position.
[Link] a small amount of engine oil (AE) to the thread
and seating surface of the rod cap bolts. Install bolts (AF)
and tighten to 9.8 N•m (87 lb-in.).

Engine - Gas (Air-Cooled) Engine Repair - 61

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

M86906

• Piston Ring End Gap - Use the piston to push each

MX11833 piston ring into the cylinder bore to a point
approximately 25 mm (1 in.) from top of the cylinder.
4. Check piston ring grooves for wear by inserting a new
Measure the gap (E) between the ends of the ring with a
ring in the piston and measuring the clearance between
feeler gauge.
piston and ring with a feeler gauge (C). Wear should not
exceed: Top Ring End Gap – 0.65 mm (0.026 in.) service limit
• Top Ring — 0.18 mm (0.007 in.) Second Ring End Gap – 0.78 mm (0.031 in.) service
limit.
• Second Ring — 0.16 mm (0.006 in.)
Oil Ring End Gap – 1.05 mm (0.041 in.) service limit
If piston ring groove clearance is greater than specified,
replace the piston. If any measurement is greater than the service limit,
replace the entire set of rings.
NOTE: The three piece oil ring is difficult to measure
for ring groove clearance. Check both ring and piston
groove visually for damage or wear and replace either
component as necessary.

MX11838
D 6. Measure the OD of the piston pin with a micrometer at
several points (F). If the OD is less than 15.96 mm (0.628
in.) the piston pin must be replaced.
MX11834

5. Worn rings normally show visual evidence of wear such

as surface scratches or an extremely shiny sealing surface.
Before reusing rings measure the following: G

• Ring Thickness - Use a micrometer to measure at

several points around the ring (D). The minimum service
limit for both the top and second ring is 1.40 mm (0.055
in.). If any measurement is less than the service limit,
replace the entire set of rings.

MX11839

Engine - Gas (Air-Cooled) Engine Repair - 62

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
7. Measure the ID of the piston pin with a dial bore gauge
at several points (G) on both sides of the piston. If the ID is
greater than 16.08 mm (0.633 in.) the piston must be
replaced.

MX11840 M86883

8. Measure the ID of the connecting rod small end with a [Link] the cylinder and inspect the bores for scoring,
dial bore gauge (H) at several points. If the ID is greater signs of seizure or ridges at the top or bottom of the
than 16.05 mm (0.632 in.) the piston must be replaced. cylinder.
[Link] the cylinder ID (L) using a dial bore gauge.
Measure the cylinder front to back and side to side at the
following points:
• 10 mm (0.394 in.) from top of cylinder
• 10 mm (0.394 in.) from bottom of cylinder
• 55 mm (2.165 in.) from top of cylinder
[Link] any of the cylinder bore measurements are greater
K than the following service limits, the cylinder must be bored
and honed (see Resizing Cylinder Bore and Cylinder Bore
Honing). If cylinder bores are within specifications and
J show no signs of damage, new piston rings may be fitted
provided the cylinder bores are honed. This will restore the
proper cross hatch angle in the cylinder bores ensuring
MX11841 proper lubrication and piston ring rotation.
9. Measure the OD of the piston (J) at a point (K), 12.5 mm • Standard Cylinder Bore ID: 75.18 – 75.20mm (2.959
(0.5 in.) up from the bottom of the piston and 90 degrees – 2.961 in.)
from the piston pin hole. If the OD is less than 74.99 mm • Standard Cylinder Bore Service Limit: 75.28 mm
(2.952 in.), the piston must be replaced. (2.964 in.)
• 0.5 mm Oversize Cylinder Bore ID: 75.68 – 75.70
mm (2.979 – 2.980 in.)
• 0.5 mm Oversize Cylinder Bore Service Limit: 75.78
mm (2.983 in.)
• Standard Cylinder Bore Out-of-Round: 0.01 mm
(0.0004 in.)
• Standard Cylinder Bore Out-of-Round Service Limit:
0.056 mm (0.0022 in.)

Engine - Gas (Air-Cooled) Engine Repair - 63

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Cylinder Bore Honing Cylinder Bore Resizing
Procedure: Procedure:
NOTE: To produce the proper cross hatch finish use a
drill speed of approximately 200 rpm and 40 – 60
strokes per minute. Lubricate hone liberally to prevent A
build up on finishing stones.

H
A
B

M86885
G C
1. The cylinder finish, (cross hatch) should be applied after
cylinder bore has been resized to within 0.03 mm (0.001
in.) of the desired size or when reconditioning a cylinder
bore. The finishing stones will produce the correct cross
hatch necessary for proper lubrication and piston ring E
rotation. The correct hatch angle is approximately 45° (A).
2. It is recommended that the cylinder bores be
reconditioned to restore the cross hatch when new piston F
rings are to be installed in a cylinder that is within D
specification. Be careful not to hone oversize or it will be
necessary to resize the cylinder. E

IMPORTANT: Avoid damage! Ensure that the entire

cylinder and crankcase are thoroughly cleaned after M88942
honing. First wash the cylinder and crankcase 1. If the cylinder bore is not within specifications, it will
carefully in a solvent such as kerosene or have to be resized using a boring bar or hone. Always
commercial solvent. Then thoroughly wash cylinder resize to exactly 0.50 mm (0.020 in.) over standard size.
and crankcase using a stiff brush with soap and hot
2. If this is done accurately, the service oversize rings and
water. Rinse thoroughly with hot running water.
pistons will fit perfectly and proper clearances will be
Repeat washing and rinsing until all traces of honing
maintained.
grit are gone. Honing grit is highly abrasive and will
cause rapid wear to all of the internal components of
the engine unless it is completely removed. IMPORTANT: Avoid damage! If a boring bar is used,
a hone must be used after the boring operation to
3. When cylinder and crankcase have been thoroughly produce the proper cylinder cross hatch. See
cleaned, use a white rag or napkin and wipe the cylinder ‘CYLINDER BORE HONING’.
bore. If honing grit is present, it will appear as a grey
residue on rag. If any honing grit is evident, re-wash and 3. If a hone is used to resize the cylinder bore, place hone
rinse entire cylinder and crankcase and check again. When (A) in middle of cylinder bore (C). Tighten adjusting knob
cleaning is complete, oil cylinder bore to prevent rusting. with finger until stones fit snugly against cylinder wall. DO
NOT FORCE.

Engine - Gas (Air-Cooled) Engine Repair - 64

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
4. Connect drive shaft to hone. Be sure that cylinder and
hone are centered and aligned with drive shaft and drill
spindle. Lubricate hone as recommended by hone
manufacturer. C

5. The recommended drill speed is 300 to 700 rpm

maximum and 40 – 60 strokes per minute.
6. Because cylinder bores normally wear (H) only in the
area of ring travel (B), the cylinder bore will be round above
and below ring travel (G). B
7. Start drill and, as hone spins, move it up and down at
the bottom of the cylinder bore (D).
8. Gradually increase the length of the strokes until hone
travels full length of cylinder bore (F). Do not travel more
than 19 mm (0.75 in.) to 25 mm (1 in.) above cylinder bore
(E).
9. Lubricate hone frequently to prevent build up on stones.
[Link] cutting tension decreases, stop hone and tighten
adjusting knob following hone manufacturer’s
recommendations.
[Link] cylinder bore size frequently.
[Link] cylinder bores at top and bottom for burrs.
Remove burrs. Cylinder head and crankcase cover D
surfaces must be free of burrs and gasket material. D

[Link] the cylinder bore has been sized to the proper

dimension, a cross hatch finish must be applied to the bore. MX17439

4. Remove 10 cover mounting bolts (B). Remove the

Crankcase Cover Removal and Installation crankcase cover (C) from the crankcase. There are two
knock points (D) on the cover where a plastic or wood
Procedure: mallet can be used to gently tap the cover loose.
1. Remove engine from machine. (See “Engine Removal 5. Remove the crankcase cover gasket and any gasket
and Installation” on page 52.) residue from both the cover and the crankcase mating
2. Drain engine oil. area.

c and
CAUTION: Avoid Injury! Clean the crankcase
cover in a well ventilated area where no
A sparks or flames, including appliance pilot
lights, are present. Never use gasoline or a low
flash-point solvent to clean parts. A fire or
explosion could result.

6. Clean the mating surfaces of the cover and the

crankcase. Blow out the oil passage in the cover using
compressed air.
7. Replace the governor shaft oil seal and the crankshaft
MX11696 PTO oil seal if necessary. Note the following while replacing
3. Remove Governor Control Panel and Governor Arm (A) these seals:
(See Governor Removal/Replacement).

Engine - Gas (Air-Cooled) Engine Repair - 65

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

H F

MX11848

• The oil seal (E) is installed in the cover (F) after the
governor shaft is inserted in the cover. The marks (G) on O
the seal must face out. The seal is pressed in to a depth
(H) of 0 – 2 mm (0 – 0.08 in.) from the top of the cover.

P
K
MX11851

8. Check that the dowels (O) are in place on the

J crankcase. Install a new gasket (P) to the crankcase.

IMPORTANT: Avoid damage! If one cover bolt at a

L
time is tightened completely, the cover could be
N M warped.

MX11847

• The crankshaft PTO oil seal is installed with the

marks (J) facing out. Press the new seal into the cover
until it is flush with the flange surface (K). Pack high
temperature grease (M) into the space between the seal
lip (L) and the dust lip (N).

Engine - Gas (Air-Cooled) Engine Repair - 66

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
2. Measure the ID (A) of the PTO shaft bearing at several
9 points. This bearing is not replaceable. If it is damaged, or
the ID is more than 40.15 mm (1.581 in.) the crankcase
cover must be replaced.
10 8 3. Install crankcase cover (See Crankcase Cover Removal/
Replacement).
4. Replace engine oil.

Governor Assembly Removal/Replacement

1
7 Special or Required Tools:
• Snap Ring Pliers

Procedure:
1. Remove the crankcase cover.
2. Remove governor control plate and governor control
3 arm (see Crankcase Cover Removal and Installation).
2
3. Remove the push rods (see Cylinder Head Removal/
Replacement).
4. Turn the engine upside down so tappets fall away from
cam lobes, and remove the camshaft (A) from the cases.

4 J
6 G
5 C

MX17439

9. Install the crankcase cover. Tighten the bolts 1/2 turn at

a time in the sequence shown. Tighten to 25 N•m (221 lb-
in.) after all bolts are snug.
B D F
Crankcase Cover Inspection E
J H
Procedure: MX11855

5. Remove governor assembly from end of camshaft. Slide

washer (B) off end of camshaft and remove snap ring (C).
6. Slide the sleeve (D) and governor plate (E) off the
camshaft for access to the second snap ring (F).
A
7. Remove the second snap ring (F). Slide ball guide (G)
and ball plate (H) off as a unit to prevent steel balls (J) from
falling out.

MX17449

1. Remove the crankcase cover (see Crankcase Cover

Removal /Replacement.

Engine - Gas (Air-Cooled) Engine Repair - 67

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
13. Install the crankcase cover with a new gasket. (See
“Crankcase Cover Removal and Installation” on page 65.)

S
L
W

T
MX17469

8. Remove the governor shaft plate from the crankshaft

cover by removing the two governor shaft plate screws (L).
V
9. Pull the governor shaft (K) from the crankcase cover.
NOTE: It is only necessary to remove the governor
R
shaft if damage to the shaft is suspected, or the shaft
oil seal is being replaced. Q

[Link] the governor assembly on the camshaft in

reverse order of removal. During reassembly make certain
the steel balls remain in their grooves in the ball guides.
Check that both snap rings seat firmly in their grooves on X P
the camshaft. Q
11. Reinstall the governor shaft if removed. If the governor
shaft seal is leaking or damaged, replace it at this time. The
MX11861
seal must be replaced after the shaft is installed (see
Crankcase Cover Removal and Installation). Apply engine 14. Insert a 2mm steel pin (P) through the jig pin hole of the
oil to the governor shaft and insert it to the crankcase governor shaft (Q).
cover. 15. Install the governor arm (R) on the governor shaft
temporarily and hook throttle link rod (S) to arm.
16. Check to make certain the link spring (T) is in place and
O pulling the governor arm toward the throttle lever (U).
17. Loosen the clamp nut (V) on the throttle arm enough to
allow the governor shaft to rotate without moving the arm.
18. Turn the governor arm counterclockwise until the
throttle valve in the carburetor (W) is fully open, hold it in
this position. Use the steel pin to rotate the governor shaft
fully counterclockwise until it is at the end of its travel. Hold
the shaft in this position and tighten the governor arm
N
clamp nut to 7.8 N•m (69 lb-in.).
19. Check that the governor arm shaft extension above the
governor arm is approximately 6.5 mm (0.26 in.) as shown
MX11862
(X).
12. Align the governor shaft (N) with the threaded holes
20. Install the governor control panel, connecting the
facing up, and install the shaft plate (O). Tighten the shaft
governor spring to the governor arm.
plate screws to 2 N•m (17 lb-in.).

Engine - Gas (Air-Cooled) Engine Repair - 68

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Governor Assembly Inspection
Procedure:

A
C

MX17401
A
6. Push down at point (A) on the spring side of the rocker
arm. Move the rocker to the side (arrow) to clear the push
MX11862 rod. Remove the push rods from both cylinders. Mark them
for reinstallation in original position.
1. Remove governor assembly (see Governor Removal/
Replacement).
2. Check governor arm and shaft (A) for smooth operation.
If the shaft is a loose fit in the crankshaft cover or shows
signs of galling or wear at the pivot points, replace the
crankcase cover.
3. Check the shaft plate (B) for wear or damage. If the
engagement ears (C) are bent, excessively worn or show
signs of surface galling replace the shaft plate. F
4. Disassemble the governor assembly (See Governor
Removal/Replacement). Check the condition of the ball
guide, the ball plate and the steel balls. If the balls are
dimpled or worn or the guide or plate show tracking or
grooving they must be replaced. Remove any oil sludge or
varnish from inside the ball guide.

Camshaft/Tappet Removal and Installation

Procedure:
1. Remove engine and drain oil. (See “Engine Removal
and Installation” on page 52.)
2. Remove governor control panel and carburetor with
intake manifold. (See “Carburetor Removal and Installation”
on page 44.)
3. Remove crankcase cover. (See “Crankcase Cover MX17486
Removal and Installation” on page 65.) 7. Turn the crankcase upside down so that tappets fall
4. Remove rocker covers. (See “Cylinder Head Removal away from cam lobes. Pull the camshaft (D) out of the
and Installation” on page 55.) crankcase.

5. Place the piston at TDC for the cylinder being worked

on.

Engine - Gas (Air-Cooled) Engine Repair - 69

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
[Link] push rods and check valve clearances before
reinstalling rocker covers (See Valve Clearance
E Adjustment).
[Link] remaining components in the order they were
removed. Fill engine with fresh oil.

Camshaft Disassembly/Inspection
Procedure:
1. Remove the governor assembly. (See “Governor
Assembly Removal/Replacement” on page 67.)

MX17483

Note: Crankshaft removed for clarity.

8. Remove the tappets (E) and mark them for
reinstallation.
9. Before reinstalling tappets and camshaft apply fresh A
engine oil to:
• Tappet Journals
C
• Camshaft Journals B

• Cam Lobe Surface

MX17448
• Camshaft Gear
2. Remove the spring (A) from the Automatic Compression
[Link] the crankcase turned upside down, install the Release (ACR) assembly. DO NOT attempt to remove the
tappets in their original positions. ACR weight. If the ACR weight (B) is damaged, or does not
swing freely when shaking the cam, replace the camshaft.

C D

D C

E
E
MX17463 MX17462
[Link] the camshaft into position in the crankcase 3. Inspect camshaft gear (C) for pitting, fatigue cracks,
aligning the timing marks on the crankshaft gear and burrs or uneven wear due to improper tooth contact.
camshaft gear (F). Replace camshaft if necessary.
[Link] washer (G) on the camshaft.
[Link] crankcase cover with a new gasket.

Engine - Gas (Air-Cooled) Engine Repair - 70

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

IMPORTANT: Avoid damage! Damaged or worn cam

lobes usually indicate damaged tappets. Check
tappets when replacing camshaft.

4. Check the top of the cam lobes (D) for signs of uneven
wear, grooving, pitting or flaking of hardened wear area.
Replace camshaft if any of these conditions exist.
5. Measure the height of the cam lobes. Replace the cam if
the cam lobe height is less than the service limit.
6. Measure the camshaft journals (E) at several points G
around the journal circumference. If either journal is worn
under the service limit, replace the camshaft.

MX17449

8. Measure the ID (G) of the camshaft bearing bore in

crankcase cover at several points. Replace the crankcase
cover if the ID is greater than the service limit.
9. Install a new spring on the ACR unit. Install the governor
assembly on the camshaft (See Governor Removal/
F Replacement).
[Link] the camshaft in the crankcase. (See “Camshaft/
Tappet Removal and Installation” on page 69.)

Cam Lobe Height Service Limit:

Intake and Exhaust Valve . . . . . . . 29.62 mm (1.166 in.)

Camshaft Journal Diameters:

PTO Side . . . . . . . . . . . . . . . . . . . 15.985 mm (0.6293 in.)
MX17450 Flywheel Side . . . . . . . . . . . . . . . 15.983 mm (0.6293 in.)
7. Measure ID of the crankcase camshaft bearing bore (F)
at several points. The bearing is not serviceable. Replace Camshaft Bearing Bores:
the crankcase if the ID exceeds the service limit. Service Limit. . . . . . . . . . . . . . . . 16.136 mm (0.6352 in.)

Engine - Gas (Air-Cooled) Engine Repair - 71

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Crankshaft Removal/Replacement
Procedure:
1. Drain engine oil.

A
MX17470

6. Pull the crankshaft (B) out of the crankcase. It may be

necessary to tap on the crankshaft with a wood or plastic
mallet to loosen the crankshaft.
7. Before installing the crankshaft, clean the crankshaft
journals and the crankcase bearing surfaces thoroughly.
8. Pack high temperature grease into the crankcase oil
seal.
MX11886 9. Apply engine oil to the crankshaft journals and bearing
2. Remove drive shaft coupler from flywheel by removing surfaces. Carefully insert crankshaft (B) into the main
four bolts (A). bearing and crankcase oil seal.

3. Remove flywheel. (See “Flywheel Removal and [Link] pistons and rods on crankshaft (see Piston
Installation” on page 79.) Removal/Replacement).
[Link] tappets and camshaft. (See “Camshaft/Tappet

c mated
CAUTION: Avoid Injury! Used tappets are
to their camshaft lobes. Mark them for
Removal and Installation” on page 69.)
[Link] a new crankshaft oil seal to the crankcase cover.
installation in the same bore they were Install the crankcase cover. (See “Crankcase Cover
removed from. Removal and Installation” on page 65.)
[Link] the drive shaft coupler. Tighten mounting bolts to
4. Remove camshaft and tappets. (See “Camshaft/Tappet 40 N•m (30 ft-lb).
Removal and Installation” on page 69.)
5. Remove pistons and connecting rods. (See “Piston
Removal and Installation” on page 59.)

Engine - Gas (Air-Cooled) Engine Repair - 72

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Crankshaft Inspection
AA
Procedure:
1. Remove crankshaft. (See “Crankshaft Removal/
Replacement” on page 72.)
2. Clean the crankshaft and connecting rods with a high
flash point solvent and dry with compressed air. DD

3. Inspect the teeth of the crankshaft gear for fatigue

BB BB
cracks, pitting, spalling or signs of uneven tooth contact.
Replace crank gear if necessary. CC

4. Inspect the crankshaft and connecting rod bearing

surfaces for wear, uneven contact, gouging and scratching.
Replace a component with any of these conditions.
MX11891

8. Crankpin surfaces should be concentric and parallel to

each other within 0.006 mm (0.0002 in.). Final finishing of
C the crankpin surface should be accomplished with a super
finishing stone. Final finishing dimensions for a resized
crank are as follows:

A Crankpin Finishing Dimension Specifications

D
AA 39.457 – 39.470 mm 1.5534 – 1.5539 in.

BB R 2.3 – 2.7 mm 0.91 – 0.106 in.

B CC 43.0 mm Max 1.693 in. Max
MX17471 DD 37.95 – 38.05 mm 1.494 – 1.498 in.
5. Measure the crankpin OD (A) at several points around
the circumference. If the crankpin diameter is less than the
service limit at any point, replace the crankshaft or have the E
crankpin resized by a reliable machine shop to accept a
39.5mm (1.555 in.) undersize connecting rod. Replace the
crankshaft if any cracks are found.
6. Measure the crankpin width (B) at several points with a
dial caliper. If crankpin width exceeds the service limit at
any point, replace the crankshaft.
7. Measure the flywheel side (C) and PTO side (D) main
journals at several points. If either journal is less than the
MX11892
service limit, the crankshaft must be replaced.
9. Measure the crankshaft runout. Set the crankshaft in a
flywheel alignment jig or on V blocks. Set up dial gauges
(E) at both bearing journals. Turn the crankshaft slowly by
hand and measure the runout. The difference between the
highest and lowest dial gauge reading is the amount of
runout. If the measurement at either journal exceeds the
service limit, the crankshaft must be replaced.

Engine - Gas (Air-Cooled) Engine Repair - 73

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Connecting Rod Inspection
Procedure:
1. Remove pistons and connecting rods (See Piston
Removal/Replacement).

F
A

MX17482
F
2. Measure the connecting rod big end width (A). If the
measurement is less than the service limit, the rod must be
replaced.
Apply a light film of oil to the threads of the cap bolts. Install
the rod cap and the cap bolts and tighten the bolts to 9.8
N•m (87 lb-in.). Measure the ID (B) of the big end at several
MX17450
points. If the ID is greater than the service limit, the rod and
[Link] the ID (F) of the crankshaft journal bearing in cap must be replaced.
the crankcase at several points. The bearing is not
replaceable. Replace the crankcase if the ID exceeds the
service limit.
C
Specifications:
Crankpin OD
Service Limit . . . . . . . . . . . . . . . . . 39.94 mm (1.5724 in.)
D
Crankpin Width E
Service Limit . . . . . . . . . . . . . . . . . . 43.10 mm (1.697 in.)

Crank Main Journal PTO Side

Service Limit . . . . . . . . . . . . . . . . . . 43.10 mm (1.697 in.)
Crank Main Journal Flywheel Side
MX11898
Service Limit . . . . . . . . . . . . . . . . . 39.896 mm (1.571 in.)
Crankshaft Runout 3. Measure connecting rod bend. Insert an arbor (D) the
Service Limit . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) same size as the big end through the connecting rod big
Crankcase Journal ID end. Insert an arbor 100 mm (3.94 in.) (E) or longer the
Service Limit . . . . . . . . . . . . . . . . . 40.15 mm (0.002 in.) same diameter as the small end through the connecting rod
small end. Place V blocks on a surface plate, and support
the big end arbor in the V blocks as shown.
4. Hold the small end of the rod straight up vertically.
Measure from the surface plate to the small end arbor on
both sides of the connecting rod. Measurement must be
taken at a point that is exactly 100 mm (3.94 in.) apart. The
difference between the two measurements determines the
rod bend (C). If the connecting rod bend exceeds the
service limit the rod and rod cap must be replaced.

Engine - Gas (Air-Cooled) Engine Repair - 74

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Breather Valve Removal and Installation
Procedure:
1. Remove engine from machine. (See “Engine Removal
and Installation” on page 52.)
2. Remove carburetor and intake manifold. (See
“Carburetor Removal and Installation” on page 44.)
3. Remove blower shroud and flywheel. (See “Flywheel
Removal and Installation” on page 79.)

F
4. Remove four bolts holding the breather cover (B) to the
G crankcase.
MX11901

5. Measure connecting rod twist. With the big end mounted A

in V blocks, hold the connecting rod horizontally and
measure the amount that the small end arbor varies (F)
from being parallel with the surface plate over a 100 mm
length (G). If twist exceeds the service limit the rod and cap
must be replaced.
6. Install the connecting rods and pistons (See Piston
Removal/Replacement.

Specifications:
Connecting Rod Big End Width
Service Limit . . . . . . . . . . . . . . . . . . 20.45 mm (0.805 in.)
MX11906
Connecting Rod Big End ID
5. Remove the vented baffle plate (A) from the breather
Service Limit . . . . . . . . . . . . . . . . 40.044 mm (1.5765 in.)
chamber.
Connecting Rod Bend
Service Limit . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

Connecting Rod Twist

Service Limit . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
B

MX11907

6. Remove the crankcase cover. (See “Crankcase Cover

Removal and Installation” on page 65.)
7. From the crankcase cover side of the engine, remove
the two screws (B) holding the breather valve (C) in place.
8. Install breather valve in reverse order of removal. Install
a new cover gasket and tighten breather valve mounting
screws to 2.0 N•m (18 lb-in.) and breather cover mounting
bolts to 5.9 N•m (52 lb-in.).

Engine - Gas (Air-Cooled) Engine Repair - 75

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Breather Valve Inspection Oil Pump Removal and Installation
Procedure: Procedure:

C
B
A

MX11908

1. Remove breather valve assembly from engine. (See

“Breather Valve Removal and Installation” on page 75.) D

2. Inspect the reed valve (A) for hairline cracks, distortion

B
or signs of metal fatigue at the base. Replace valve if any
signs of wear or damage are present.
C
3. Inspect the back plate (B) for damage or a rough contact
surface.
4. Inspect the valve seating surface (C) for nicks, burrs,
scratches or fretting. If damage or wear is evident, remove
the reed valve and backing plate and clean the surface with
fine emery paper. If damage cannot be removed from
MX17488
surface, replace the complete breather valve assembly.
1. Remove crankcase cover. (See “Crankcase Cover
Removal and Installation” on page 65.)
2. Remove five bolts (A, D) holding the oil pump assembly
(B) and pickup (C) to the crankcase cover. Remove the oil
pump assembly.

Engine - Gas (Air-Cooled) Engine Repair - 76

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Oil Pump Inspection
G
Procedure:

L
A

H
K

J
H
MX17501

1. Install inner and outer rotor to crankcase cavity. Check

clearance between the rotors with a feeler gauge. Take this
measurement where the high point of the inner rotor meets
the high point of the outer rotor (A). If the clearance
exceeds the service limit, replace the rotors as a set.

E D 2. Remove the oil pump rotors from the crankcase cover.

(see “Oil Pump Removal and Installation” on page 76.)
MX11912
Visually inspect the pump gear, inner and outer rotors and
3. Remove the relief valve ball (D) and spring (E) from the cover plate for wear or damage. Replace components as
crankcase cover. necessary.
4. Remove the drive pin (J). Separate the pump gear/shaft
assembly (H) from the cover plate (G).
5. Remove the inner (K) and outer rotor (L) from the pump
B C
cavity.
6. Assemble the pump in reverse order of disassembly.
7. Fill the rotor housing in the pump cavity with fresh oil.
8. Install the pressure relief valve ball and spring, and the MX11916
inner and outer pump rotors to the crankcase cover.
3. Measure the thickness (B) of the outer rotor at several
9. Install the pump gear/shaft through the oil pump cover. points.
Install drive pin to the pump gear/shaft.
4. Measure the OD (C) of the outside rotor at several
NOTE: Use grease to keep the oil pump drive pin in the points with a micrometer. If any rotor dimension is beyond
drive gear/shaft when installing the oil pump cover. the service limit, replace the rotors as a set.
[Link] certain to align the 6 mm diameter hole in the
cover plate (G) with center of the relief valve. Put the oil
pickup in position. Install five mounting bolts. Tighten to 5.9
N•m (52 lb-in.). E
E
[Link] the crankcase cover with a new gasket. (See D
“Crankcase Cover Removal and Installation” on page 65.)
D

MX17502

Engine - Gas (Air-Cooled) Engine Repair - 77

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
5. Measure the ID of the pump housing (D) at several removed. Do not lose the spacers.
points.
3. Remove the spacers. Remove the pickup assembly from
6. Measure the depth of the pump housing (E) at several the oil pump.
points.
4. Remove the screen from the pickup tube.
7. Measure the ID of the pump shaft bearing (F) in the
crankcase cover at several points. If any dimension of the
pump housing exceeds the service limit at any point E
replace the crankcase cover.

c ventilated
CAUTION: Avoid Injury! Clean parts in a well
area using a high flash point solvent.
Make certain no spark or flame such as pilot
light is near the work area.

8. Remove the relief valve spring and steel ball from the
crankcase cover. Clean the valve seat and valve
components with a high flash point solvent, and blow any F
foreign particles out of the seat with compressed air.
Inspect the steel ball for wear or dimpling. Replace the MX11922
steel ball and spring if any wear or damage is evident. 5. Install a new or cleaned screen (E) to the pickup
9. Install oil pump assembly to crankcase cover. (See “Oil assembly (F) by applying pressure on both edges of the
Pump Removal and Installation” on page 76.) screen to allow it to snap into place in the slots.
6. Install the pipe to the oil pump assembly with the
Oil Pump Specifications:
mounting bolts and spacers. Tighten the mounting bolts to
Inner-to-Outer Rotor Clearance 5.9 N•m (52 lb-in.).
Service Limit . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
7. Install crankcase cover. (See “Crankcase Cover
Removal and Installation” on page 65.)
Outer Rotor OD
Service Limit . . . . . . . . . . . . . . . . . 40.47 mm (1.593 in.)
Oil Screen Inspection/Cleaning
Outer Rotor Thickness
Service Limit . . . . . . . . . . . . . . . . . . . 9.83 mm (0.387 in.) Procedure:
Pump Housing ID 1. Remove oil screen. (See “Oil Pickup Removal and
Service Limit . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.) Installation” on page 78.)
Pump Housing Depth
2. Check the oil screen for metal particles that could
Service Limit . . . . . . . . . . . . . . . . . 10.230 mm (0.403 in.)
indicate an engine problem.
Pump Shaft OD
Service Limit . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.)

Pump Shaft Bearing ID

c ventilated
CAUTION: Avoid Injury! Clean parts in a well
area using a high flash point solvent.
Service Limit . . . . . . . . . . . . . . . . 11.072 mm (0.4359 in.)
Make certain no spark or flame such as pilot
light is near the work area.
Oil Pickup Removal and Installation
3. Clean the oil screen with a high flash-point solvent and
Procedure: remove any particles stuck to it.
1. Remove the crankcase cover. (See “Crankcase Cover 4. Inspect the screen carefully for holes or torn wires. If
Removal and Installation” on page 65.) damage is present or it is impossible to clean all debris
from the screen, replace it.
2. Remove two mounting bolts (D, photo MX17488, Oil
Pump Removal Procedure) holding the pickup to the oil 5. Install oil screen. (See “Oil Pickup Removal and
pump assembly. Installation” on page 78.)

NOTE: There are spacers on bolts (D) which may

remain on the bolts or in the pickup when the bolts are

Engine - Gas (Air-Cooled) Engine Repair - 78

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Flywheel Removal and Installation
D
Procedure:
1. Remove engine from machine. (See “Engine Removal
and Installation” on page 52.)

C
A

MX11956

5. Hold the flywheel with a suitable tool and remove the

flywheel bolt (C) and washer (D).

E
B F

MX11927 G

2. Loosen eight bolts (A), four from each side of the engine MX11946
(left side shown). Remove the fan housing (B). 6. Remove two bolts (E) the fan plate (F) and fan (G).
3. Remove ignition coils. (See Ignition Coil Removal and
Installation.) IMPORTANT: Avoid damage! Do not attempt to
remove the flywheel without the correct puller.
Damage to the flywheel or crankshaft could occur.
A

H
A

MX11952
MX11928 7. Remove the flywheel (J) with a suitable puller (H).
4. Remove four bolts (A). Remove the output coupler (B).

Engine - Gas (Air-Cooled) Engine Repair - 79

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

K
L P
K

LM

L
R
M
L

MX17487 MX17503

8. Remove the woodruff key (K), screws (L) and stator coil [Link] the fan (P) with the position bosses (Q) located to
(M). fit around the ignition magnets (R).

N S

P
MX17503
MX17490, MX17491
[Link] the flywheel plate (S) so that the fan bosses (T) fit
9. Inspect the crankshaft taper (N) for scoring or in the holes on the plate. Secure the fan to the flywheel with
imperfections. Check the key slot (M) for elongation or two bolts.
damage. Slight imperfections or scratches on the taper can
be removed with emery cloth. Extensive damage to the
Y
taper or key slot requires crankshaft replacement. Inspect
V
the key slot (O) and the flywheel taper (P). Clean oil or dirt
off the crankshaft taper and the flywheel taper with contact
cleaner and a clean cloth.
[Link] the stator coil. Tighten the screws (L in photo
MX17487) to 3.4 N•m (30 lb-in.). X

[Link] a new woodruff key securely in the slot on the

crankshaft. Install the flywheel on the crankshaft taper.
Make certain the woodruff key is not dislodged from the W
crankshaft slot and fits in the keyway slot on the flywheel.

MX11957

Engine - Gas (Air-Cooled) Engine Repair - 80

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
[Link] the Belleville washer (V) and flywheel bolt (W) Ignition Coil Removal and Installation
onto the crankshaft (X) to secure the flywheel (Y). Make
certain the washer is installed with the convex portion to the Procedure:
outside. Tighten the bolt to 56 N•m (41 lb-ft).
1. Remove fan housing (See Flywheel Removal and
[Link] ignition coils, output coupler and flywheel housing Installation).
in reverse order of removal (See Ignition Coil Removal and
Installation).
A
Stator Coil Inspection
Procedure: B
1. Check battery condition and alternator output before
running stator tests. Battery must be fully charged to
accurately make charging system tests (See electrical
section of this manual). Warm engine to bring components
to normal operating temperature.
D
C

MX17536

2. Remove spark plug cap (A) from spark plug and stop
B switch lead (B) from coil. Remove two bolts (C) and remove
coil (D).

E 2 E
1 2

MX17404 #2 #1
2. Disconnect connector (A). Connect an ohmmeter
between the stator pins (B). If stator coil resistance is F F
outside specification, replace the coil (See Stator Removal
and Installation).
3. Check for continuity between each pin and ground. The
meter should register infinite ohms (no continuity). If
reading is incorrect replace the stator coil. MX11960

4. Connect an AC voltmeter to the stator pins (B) to check 3. Install ignition coil on crankcase with the stop switch
for unregulated stator output. Start the engine and run at lead (E) facing out toward flywheel. Install mounting bolts
3,000 rpm. If voltage reading is less than the minimum but do not tighten.
specification replace the stator coil. 4. Ignition coil mounting bolts must be tightened in the (1) -
(2) sequence while adjusting the ignition coil air gap (F).
Specifications:

Stator Coil Resistance (Electric Start Model):

Resistance Range. . . . . . . . . . . . . . . . . . 0.01 to 0.1 Ohm
Unregulated Stator Output:
Minimum Volts at 3,000 rpm . . . . . . . . . . . . . . . . 26 VAC

Engine - Gas (Air-Cooled) Engine Repair - 81

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
5. Remove two mounting bolts (D). Pull the starter as far
forward in the machine as possible. Angle the starter up
A over the engine mount and out of the machine.
H 6. Clean the starter motor and engine mounting flanges to
ensure good electrical contact when installing starter. If
corrosion is evident on either machined mounting surface,
clean the area with emery cloth or sandpaper.
7. Install the starter by angling the motor down over the
front engine mount and sliding toward the front of machine.
G
Slide starter back and align the mounting feet with the
engine mounting points. Install mounting bolts (B) and
tighten to 20 N•m (15 lb-ft).
8. Install rectifier, front engine mount bolt and all electrical
leads in reverse order of removal. Install negative battery
MX17403 terminal (–).
5. Use a feeler gauge (G) to obtain the specified air gap
between the three legs of the ignition coil and the two pole Starting Motor Solenoid Tests
plates. When the specified air gap is obtained at all three
points, torque the mounting bolts (H) in the 1-2 sequence NOTE: Before beginning starter tests, make certain
shown previously. that the battery is in good condition and is fully
charged (12.4 V or greater).
6. Install fan housing (See Flywheel Removal and
Installation).

Ignition Coil Specifications:

A
Coil Air Gap. . . . . . . . . . 0.2 – 0.4 mm (0.008 – 0.016 in.)
Coil Mounting Bolt Torque . . . . . . . . 5.9 N•m (52 lb-in.)

Starting Motor Removal and Installation

1. Disconnect battery negative terminal (–).

A
C

D MX17538

1. Disconnect the starter motor lead (A) from the solenoid

terminal. Bend the lead back to prevent it from contacting
the terminal during the tests.
B

MX11962

2. Disconnect battery terminal and leads (A) from starting

motor.
3. Remove right front engine cradle mounting bolt (B) to
allow clearance for removing starter.
4. Remove electrical leads (C) at the spade terminals on
the rectifier unit. Remove the screw holding the rectifier unit
to the engine shroud and remove rectifier to allow
clearance for starter removal.

Engine - Gas (Air-Cooled) Engine Repair - 82

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Starting Motor Test
B
D IMPORTANT: Avoid damage! Be careful not to
deform the starter motor body when clamping it in a
vice.

1. Remove the starter motor from the machine (See

Starting Motor Removal and Installation).

MX17543 A
2. Set a hand tester to the Rx1 ohm position. Connect the
tester leads to the solenoid terminals (B). Turn the ignition
switch key to the start position and read the tester. The
solenoid should click and the tester should read 0 ohms. If
not, the solenoid is faulty and should be replaced.
3. If the solenoid makes a single clicking sound, the tester
reads 0 ohms and the pinion gear moves outward, the
solenoid and starter circuit are OK. If the solenoid clicks but
the tester doesn’t read 0 ohms, the solenoid is faulty and
must be replaced. MX11969
4. If the solenoid does not click when the key is activated, 2. Carefully clamp the motor in a vice and connect a
disconnect the lead (C). jumper cable from the battery (+) terminal to the starter
5. Set the hand tester to the R x 1 ohm position and motor terminal (A) on the solenoid.
connect one lead to terminal (C). Ground the other lead to 3. Connect a second jumper cable to the (-) terminal of the
the case (D). If the tester reads close to 0 ohm, the battery. Touch the bare end of the cable to the starter body
solenoid may be OK. Check the starter switch as detailed in intermittently for one second intervals. The pinion should
step 6. If the tester does not read close to 0 ohm, the rotate freely when contact is made, if it does not replace the
solenoid must be replaced. starter motor.
6. Set the hand tester to the 25 VDC position and connect
the tester lead to the ignition lead for terminal (C) and the Starter Motor Disassembly/Assembly
other test lead to ground (D). Turn the ignition switch to the
start position and read the tester. If battery voltage (12.4 V) 1. Remove the starter motor from the machine (See
is indicated, starter switch and circuit are OK and the Starting Motor Removal and Installation).
starter solenoid is bad. If the tester reads no voltage or very
low voltage either the wiring or ignition switch are bad.
Check the wiring for breaks or other damage and replace
the ignition switch as necessary.

MX11970

2. Pull back the rubber boot and remove the lead (A) from
the starter motor to the solenoid.

Engine - Gas (Air-Cooled) Engine Repair - 83

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

L
M

C
B

MX11971 MX11974

3. Unscrew the mounting nuts (B) and remove the solenoid 6. Separate the front stopper (J) from the rear stopper (K)
assembly (C). and remove the front stopper from the armature shaft. Push
the rear stopper down the shaft and remove the snap ring
(L). Pull the rear stopper and pinion gear (M) from the
D
armature shaft.
F

E
N

G O

MX11972

4. Pull the rubber insert (D) from the starter motor and
remove the pinion gear cover (E). Slip the actuating arm (F)
MX11975
from the pinion gear. Remove the motor through bolts (G).
7. Pull the end cover (N) from the yoke and remove the
I insulator (O).
H

S P

MX11973

5. Pull the armature (H) from the yoke (I).

MX11976

8. Remove the brush springs (P) from the brush holder

(Q). Separate the brushes (R) from the holder and remove
the holder from the yoke (S).

Engine - Gas (Air-Cooled) Engine Repair - 84

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

T
T

L
X

MX11974
MX11981
9. Before beginning assembly apply a small amount of
dielectric grease to the indicated areas (T) of the armature 12. Grease the pinion gear fork fingers, and set the pinion
shaft. Obtain a new snap ring (L). Assemble the pinion gear gear fork so that the fingers fit into the groove in the gear.
on the armature shaft with the new snap ring and install the Fit the notch (Y) in the yoke onto the projection (X) on the
pinion assembly and actuating arm. Slide the yoke over the pinion gear fork. Install the through bolts through the rear
armature. cover and thread into the pinion gear cover.

U
Z

MX11979
MX11979
10. Inspect the solenoid rubber boot (U) for visible damage
(hole, rips, dry rot etc.); replace if necessary. 13. Engage the hook (Z) on the starter solenoid with the
pinion gear fork. Install the solenoid mounting nuts.
14. Install the solenoid to starter motor lead. Install the
V starter assembly in the machine (See Starting Motor
W Removal and Installation).

MX11975

11. Install the brush assembly and insulator on the yoke. Fit
the notch (V) in the (-) lead grommet onto the projection
(W) on the end cover (N). Install the end cover.

Engine - Gas (Air-Cooled) Engine Repair - 85

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
Starting Motor Inspection 4. Measure the depth of the grooves between the
commutator segments (D). If groove depth is less than 0.2
1. Disassemble starter (See Starter Motor Disassembly/ mm (0.008 in.) undercut the insulating mica (E) to the
Reassembly). standard depth (F) of 0.5 to 0.8 mm (0.012 to 0.031 in.)
using a thin file. If grooves are only dirty, clean them
carefully and measure depth before cutting the mica.

MX11984

2. Measure length of brush (A). If any brush is shorter than

6 mm (0.24 in.), replace all brushes. Inspect the brush MX11988
springs for any distortion or damage. Replace if necessary.
5. Measure the commutator OD at several points. If the
diameter is less than 27 mm (1.06 in.) replace the armature
with a new one.

MX11980
MX11989
3. Inspect the surface of the commutator. If the surface is
scratched or dirty, polish it with very fine emery cloth (B) 6. Support the armature in an alignment jig at each end of
and then clean out the grooves (C). the shaft as shown. Position a dial indicator perpendicular
to the commutator. Rotate the armature slowly and read the
commutator runout. If runout is more than 0.4 mm (0.016
D
in.) replace the armature.

MX11987

Engine - Gas (Air-Cooled) Engine Repair - 86

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR
9. Place the armature on a growler (G) and hold a thin
metal strip (e.g. a hack saw blade) on top of the armature.
Turn on the growler and rotate the armature one complete
turn. If the metal strip vibrates, the windings are internally
shorted to each other and the starter must be replaced.

MX11990

7. Set a multimeter to the R x 1 ohm position and check the –

resistance between each segment and all others. If the
armature winding resistance registers either infinite or
much greater than 0 ohms the starter motor should be
replaced. MX11998

[Link] the multimeter in the 1k ohm position, measure the

resistance between the positive brushes and starter motor
yoke. If resistance is less than infinite on any brush, the
brush is shorted and the yoke assembly must be replaced.

– –

MX11991

8. With the multimeter in the R x 1 ohm position measure

the resistance between the armature shaft and the
commutator. If the resistance is less than infinite, the
armature is shorted and must be replaced. MX12000

[Link] the multimeter in the 1 ohm position, measure the

resistance between the negative brushes and starter motor
yoke. If resistance is less than infinite on any brush, the
brush is shorted and the yoke assembly must be replaced.

MX11992

Engine - Gas (Air-Cooled) Engine Repair - 87

 ENGINE - GAS (AIR-COOLED) ENGINE REPAIR

MX14440

[Link] the pinion clutch and turn it by hand. The clutch

should turn freely counterclockwise, and lock up and not
turn in a clockwise direction. If the clutch does not operate
correctly or is noisy when freewheeling, replace it.

Engine - Gas (Air-Cooled) Engine Repair - 88

 ENGINE - GAS (LIQUID-COOLED) TABLE OF CONTENTS
Thermostat Test......................................... 118
Engine - Gas (Liquid-Cooled)

Table of Contents
Cooling System Test.................................. 120
Repair............................................................ 120
Thermostat Removal and Installation ........ 120
Specifications .................................................91 Fan Belt Removal and Installation ............. 121
General Specifications .................................91 Cooling Fan and Bracket Removal and
Tests and Adjustments Specifications..........92 Installation.................................................. 122
Repair Specifications....................................92 Coolant Pump Removal and Installation.... 122
Torque Specifications (Alphabetical)............93 Radiator Removal and Installation............. 124
Special or Required Tools ............................94 Muffler Removal and Installation ............... 127
Component Location......................................95 Air Cleaner Removal and Installation ........ 128
Engine - 23 HP (FD671D) ............................95 Carburetor Removal and Installation -
Engine - 25 HP (FD711D) ............................96 23 HP (FD671D) ........................................ 129
Theory of Operation .......................................97 Throttle Body Removal and Installation -
Cooling System Operation ...........................97 25 HP (FD711D) ........................................ 131
Fuel and Air System Operation ....................98 Fuel Injector Removal and Installation -
Fuel Injection Air System Components and 25 HP (FD711D) ........................................ 132
Operation 25 HP - (FD711D)........................98 Fuel Pressure Regulator Removal and
Fuel Pressure Regulator Operation - Installation - 25 HP (FD711D).................... 133
FD711D ........................................................99 Cylinder Head Removal and Installation.... 134
Governor Operation......................................99 Intake Manifold Removal and Installation -
Lubrication System Operation ....................100 23 HP (FD671D) ........................................ 135
Throttle Body Operation - 25 HP Intake Manifold Removal and Installation -
(FD711D)....................................................101 25 HP (FD711D) ........................................ 136
Diagnostics ...................................................102 Starting Motor Removal and Installation.... 138
Engine Diagnosis .......................................102 Starter Motor Disassembly and Assembly. 138
Engine Tests ..............................................106 Starting Motor Inspection........................... 140
Tests and Adjustments ................................108 Engine Removal and Installation ............... 143
Throttle Lever Adjustment ..........................108 Flywheel Removal and Installation ............ 146
Throttle Cable Adjustment..........................109 Push Rod/Rocker Arm Removal and
Choke Adjustment - 23 HP (FD671D) ........109 Installation.................................................. 147
Governor Adjustment .................................109 Valve Train Removal and Installation ........ 149
Low Idle Speed Adjustment........................110 Crankcase Cover Removal and
High Idle Speed Adjustment.......................111 Installation.................................................. 150
Compression Test ......................................111 Crankcase Cover Inspection...................... 151
Valve Clearance Adjustment ......................112 Governor Assembly Removal and
Crankcase Vacuum Test ............................113 Installation.................................................. 152
Engine Oil Pressure Test ...........................114 Piston Removal and Installation ................ 154
Fuel Pump Flow Test for Carburetor - Inspect Piston and Cylinder ...................... 157
23 HP (FD671D).........................................115 Cylinder Bore Honing................................. 160
Fuel Pump Pressure Test for Carburetor - Cylinder Bore Resizing .............................. 160
23 HP (FD671D).........................................115 Camshaft/Tappet Removal and
Fuel Pump Pressure Test For Fuel Injection - Installation ................................................. 161
25 HP (FD711D).........................................116 Camshaft Disassembly and Inspection ..... 162
Bleed Fuel System - 25 HP (FD711D) ......117 Crankshaft Removal and Replacement .... 163
Fan Belt Tension Adjustment .....................117 Crankshaft Inspection ................................ 163
Radiator Bubble Test..................................118 Connecting Rod Inspection ....................... 165
Radiator Cap Pressure Test.......................118 Breather Valve Removal and Installation... 166

Engine - Gas (Liquid-Cooled) Table of Contents - 89

 ENGINE - GAS (LIQUID-COOLED) TABLE OF CONTENTS
Oil Pump Removal and Installation ............166
Oil Pump Inspection ...................................167
Oil Screen Removal and Installation ..........169

Engine - Gas (Liquid-Cooled) Table of Contents - 90

 ENGINE - GAS (LIQUID-COOLED) SPECIFICATIONS
Specifications

General Specifications
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki
Model Number (23 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD671D
Model Number (25 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD711D
Power (23 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2 kW (23 HP)
Power (25 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6 kW (25 HP)
Displacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745 cm3 (45.5 cu-in.)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves
Bore: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 mm (3.07 in.)
Stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 mm (3.07 in.)
Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 : 1
Compression Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic
Crankshaft Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal (Counterbalanced)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressurized by Positive Displacement Pump
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 kPa (40 psi minimum)
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge Type, Full Flow, Spin-On Filter
Crankcase Capacity (With Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 L (1.9 qt)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled
Cooling System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 L (4.2 qt)
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Element replaceable paper
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horizontal; discharge frame side
Maximum Angle of Operation (With Full Crankcase):
Continuous (All Directions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20°
Intermittent (All Directions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35°
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable (In-Line Type)
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Pump (In-Tank Type)
Fuel Shut-Off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replaceable (Below Carburetor Float Bowl)
Carburetor (23 HP, FD671D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float type, fixed main jet, two barrel
Fuel Injection (25 HP, FD711D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simultaneous port fuel injection
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(M138938) NGK BPR4ES
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V - 20 amps with regulator
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 kg (128 lbs)

Engine - Gas (Liquid-Cooled) Specifications - 91

 ENGINE - GAS (LIQUID-COOLED) SPECIFICATIONS
Tests and Adjustments Specifications
Engine:
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.)
Fan Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19 mm (0.48 - 0.75 in.)
Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Oil Pressure (Minimum at 1250 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 kPa (40 psi)
Cylinder Compression (Minimum, with Engine Warm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620 kPa (90 psi)

Fuel/Air System:
Slow Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 ± 25 rpm
Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 ± 25 rpm

Repair Specifications
Cylinder Head:
Cylinder Head Flatness (Maximum Warp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.)

Valves and Valve Lifters:

Valve Clearance (Intake/Exhaust Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Valve Stem Runout (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.)
Valve Stem OD (Exhaust and Intake, Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 mm (0.273 in.)
Valve Guide ID (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.)
Valve Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.0 mm (1.22 in.)
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45°
Push Rod Runout (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.)

Crank shaft:
Crankshaft Journal Bearing ID: Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.14 mm (1.659 in.)
Crankshaft Journal OD (Minimum)
PTO Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.935 mm (1.651 in.)
Flywheel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.935 mm (1.651 in.)
Crankshaft Runout (TIR) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Crankpin OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.95 mm (1.573 in.)
Crankpin Width (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.5 mm (1.83 in.)
Connecting Rod:
Twist (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm over 100 mm (0.006 over 3.94 in.)
Bend (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm over 100 mm (0.006 over 3.94 in.)
Connecting Rod Big End Width (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.35 mm (0.88 in.)

Camshaft:
Bearing ID Maximum (Crankcase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.081 mm (0.791 in.)
Bearing ID Maximum (Crankcase Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.081 mm (0.791 in.)
Camshaft Journal Diameter:
PTO Side (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.927 mm (0.785 in.)
Flywheel Side (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.927 mm (0.785 in.)
Cam Lobe Height (Minimum):
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.594 mm (1.323 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.594 mm (1.323 in.)

Engine - Gas (Liquid-Cooled) Specifications - 92

 ENGINE - GAS (LIQUID-COOLED) SPECIFICATIONS
Oil Pump:
Inner and outer rotor clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)
Outer rotor OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.593 in.)
Outer rotor thickness (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.830 mm (0.781 in.)
Pump Housing inside diameter (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.801 mm (1.606 in.)
Pump Housing depth (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.230 mm (0.797 in.)
Pump Shaft outside diameter (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.923 mm (0.4300 in.)
Pump Shaft bearing inside diameter (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.072 mm (0.436 in.)
Relief Valve Spring length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.77 in.)

Cylinder Bore, Pistons and Rings

Cylinder Bore ID:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.00 mm (3.071 in.)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.08 mm (3.074 in)
Cylinder Bore Out of Round (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.056 mm (0.0022 in.)
Piston Pin Bore ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.080 mm (0.751 in.)
Piston Pin OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.960 mm (0.747 in.)
Top and Middle Compression Ring-To-Groove Side Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Piston Ring Thickness (Top, Second) (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055 in.)
Top and Second Ring End Gap (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.04 in.)
Oil Ring End Gap (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 mm (0.05 in.)
Piston OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70 mm (3.059 in.)

Torque Specifications (Alphabetical)

NOTE: Use appropriate torque wrench which will read within the inch pound range given, or convert inch pounds
to foot pounds as follows: Inch-pounds/12 = Foot-pounds
Air Cleaner Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 N•m (87 lb-in.)
Camshaft Breather Chamber Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Carburetor to Manifold Mounting Bolts and Nuts, 23 HP (FD671D). . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)
Throttle Body and Intake Pipe Mounting Bolts, 25 HP (FD711D) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)
Choke Valve Screw, 23 HP (FD671D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 N•m (8.4 lb-in.)
Throttle Valve Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90 N•m (8.0 lb-in.)
Water Temperature Sensor, 25 HP (FD711D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Vacuum Sensor, 25 HP (FD711D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 N•m (87 lb-in.)
Control Panel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 N•m (52 lb-in.)
Crankcase Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Cylinder Head Bolts (Silicone Sealant Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Float Chamber Mounting Screw (Carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (18 lb-in.)
Oil Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
Engine Flywheel Cover Bolt (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.)
Cooling Fan Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft)
Fuel Shut Off Solenoid Valve, 23 HP (FD671D) Carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N•m (61 lb-in.)
Float Chamber Mounting Screw, 23 HP (FD671D) Carburetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (17 lb-in.)
Governor Arm Clamp Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (69 lb-in.)
Ignition Coil Bolts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.)
Intake Manifold Mounting Bolts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)

Engine - Gas (Liquid-Cooled) Specifications - 93

 ENGINE - GAS (LIQUID-COOLED) SPECIFICATIONS
Muffler Flange Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Main Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 N•m (6 lb-in.)
Oil Pump Cover Plate Mounting Bolts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (52 lb-in.)
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (132 lb-in.)
Rocker Arm (Valve Clearance) Adjusting Locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Rocker Arm Bracket Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Rocker Cover Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N•m (61 lb-in.)
Connecting Rod Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.)
Starter Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Voltage Regulator Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.)

Special or Required Tools

Special or Required Tools

Tool Name Tool No. Tool Use
Photo Tachometer JT05719 Slow and fast idle adjustment
Cylinder Leakdown Tester JT03502 Cylinder leakdown test
Crankcase Vacuum Test Kit JT03503 Crankcase vacuum check
Connector JT03349 Oil pressure test
Hose Assembly JT03017
Pressure Gauge Assembly JT03344
Compression Gauge JDM59 Cylinder compression test
Fuel Pump Pressure Test Kit JDG356 Fuel pump pressure test - FD671D engines
Fitting JDG41 Fuel pump pressure test - FD711D engines
Pressure Gauge 0-400 kPa (0-60 psi) JTO7032
Fuel Hose
Tension Gauge JDST28 Fan belt tension check
Cooling System Pressure Pump D05104ST Radiator cap and cooling system pressure tests
Radiator Test Kit JDG692
Lapping Tool Valve lapping

Engine - Gas (Liquid-Cooled) Specifications - 94

 ENGINE - GAS (LIQUID-COOLED) COMPONENT LOCATION
Component Location

Engine - 23 HP (FD671D)

C D
B

MX14278 F - Ignition Coil

A - Throttle Cable G - Starting Motor
B - Governor Arm H - Engine Frame Ground
C - Coolant Temperature Sensor I - Spark Plug
D - Coolant Hose NOTE: Number 1 cylinder is on same side of engine as
E - Fuel Shutoff Solenoid oil filter.

Engine - Gas (Liquid-Cooled) Component Location - 95

 ENGINE - GAS (LIQUID-COOLED) COMPONENT LOCATION
Engine - 25 HP (FD711D)
E
D
R G
C H

J
P

O K

L
M

MX14312 I - Y2 Fuel Shutoff Solenoid

A - B4 Engine Coolant Temperature Sensor - 485 J - T1 Ignition Module
and 585 K - T2 Ignition Module
B - Y4 #2 Cylinder Fuel Injector - 485 and 585 L - X2 Wiring Harness Connector
C - B5 Air Temperature Sensor - 485 and 585 M - X25 Wiring Harness Connector
D - B6 Vacuum Pressure Sensor - 485 and 585 N - Y1 Starting Motor Solenoid
E - Fuel Pressure Relief Screw O - W1 Frame Ground
F - Y5 #1 Cylinder Fuel Injector - 485 and 585 P - E2 Spark Plug
G - B3 Engine Coolant Temperature Sensor
NOTE: Number 1 cylinder is on same side of engine as
H - B1 Engine Oil Pressure Switch (RH Side) oil filter.

Engine - Gas (Liquid-Cooled) Component Location - 96

 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION
Theory of Operation

Cooling System Operation

D F
C

G
B

K H

MX14217 temperature sensor and thermostat.

A - Radiator When the engine temperature is below approximately 82°C
B - Cooling Fan (180°F), the thermostat is closed and coolant is directed
C - Radiator Cap, maintains radiator pressure at 78 back to the water pump through bypass hose to be
- 98 kPa (11.3 - 14.2 psi) recirculated. This allows the engine to warm up to
D - Thermo Switch, detects at 111°C (232°F) operating temperature quickly.
E - Bypass Tube When the engine temperature is approximately 82°C
F - Engine Body (180°F), the thermostat begins to open and is fully open at
95°C (203°F). Coolant from the water jackets and cylinder
G - Water Pump (Impeller)
heads now flow through the thermostat to the radiator,
H - Jiggle Valve which is cooled by the radiator fan. The fan is driven by a
I - Drain Plug belt off the crankshaft pulley. If the engine coolant
J - Valve, One Way temperature raises to 111°C (232°F), a thermo switch
K - Thermostat, fully open at 95°C (203°F) detects this, and turns on a warning light on the dash,
warning you of a potentially dangerous overheating
Function: situation.
The coolant pump circulates coolant through the cooling The radiator cap maintains a pressure of 78 - 98 kPa (11.3
system, drawing hot coolant from the engine block, and - 14.2 psi) inside the radiator, which actually raises the
circulating it through the radiator for cooling. boiling point of the coolant. The radiator cap contains a
pressure valve and a vacuum valve. When the coolant is
System Operation: hot and pressure is above 98 kPa (14.2 psi), the pressure
The impeller-type coolant pump draws coolant from the valve opens, allowing some coolant to flow to the recovery
bottom of the radiator when the thermostat is open, or from tank. After the engine is stopped, the coolant cools and the
the bypass when the thermostat is closed. Coolant from the pressure inside the radiator decreases. The pressure
water pump flows to the water jackets in block, up through difference between the radiator and recovery tank forces
cylinder heads, intake manifold, past the coolant the vacuum valve open and some coolant from the
recovery tank flows back to the radiator.

Engine - Gas (Liquid-Cooled) Theory of Operation - 97

 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION
Fuel and Air System Operation Fuel Injection Air System Components and
Operation 25 HP - (FD711D)
Function:
The fuel system supplies fuel to the engine for combustion. B
A
The air intake system filters air needed for combustion. C

A
A B

C
F E
MX14223

A - Fuel Injectors
B - Fuel Pressure Regulator
C - Air Temperature Sensor
MX14324
D - Water Temperature Sensor
The fuel tank holds the fuel pick-up and fuel sensor E - Vacuum Pressure Sensor
assembly. The carburated engine has a fuel pump mounted F - Thermo Switch
to the side of the engine The fuel pick-up (A) consists of a
fuel pick-up tube and a float type fuel sensor. The fuel Function:
pump draws fuel through the fuel pump screen. Low
pressure fuel from the fuel pump flows through the fuel The fuel injection system supplies pressurized fuel to the
shut-off valve and in-line fuel filter to the carburetor. Fuel fuel injectors for combustion. The air intake system filters
pressure is maintained at the carburetor inlet needle until air needed for combustion.
the float allows more fuel in the bowl.
System Operation:
The fuel injected engine has pressurized fuel supplied to
An electric fuel pump mounted inside the fuel tank provides
the engine. The fuel pick-up (B) consists of a fuel pick-up
pressurized fuel to the fuel injectors (A). The fuel pump
tube with an in-line electric fuel pump (C).
uses the fuel for lubrication and cooling. The fuel pump and
System Operation - Fuel Injection: fuel injectors are controlled by the fuel injection module
computer. The controller monitors engine operating and
An electric fuel pump (C) mounted inside the fuel tank environmental conditions to calculate the amount of fuel to
provides pressurized fuel to the carburetor. The fuel pump inject. The fuel pump draws fuel through the fuel pump
uses the fuel for lubrication and cooling. The fuel shutoff screen. High pressure fuel from the fuel pump flows
solenoid shuts off fuel to the main jet, preventing gas fumes through the in-line fuel filter to the fuel pressure regulator
from escaping into the air for emission control, while the (B) and fuel injector. The fuel injector is a solenoid operated
fuel cap is vented for releasing any increased pressure type valve with single point injection. Fuel is injected into
within the fuel tank. the throttle body when the solenoid is energized by the
The ignition delay module is used with the fuel shut-off controller. Fuel pressure is controlled by the fuel pressure
solenoid to prevent backfire. The ignition delay module regulator. The regulator is an overflow type regulator that
allows the spark plugs to fire for one additional second after maintains fuel pressure at the fuel injector at a constant
the key switch is turned off to burn any remaining fuel in the 175 kPa (25 psi). Excess fuel flows through the regulator
cylinder. When the key switch is turned off, the fuel shut-off valve and fuel return hose to the fuel tank. The fuel shutoff
solenoid is de-energized. solenoid shuts off fuel to the main jet, preventing gas fumes
from escaping into the air for emission control, while the
Air enters the air filter though the side panel screen and air fuel cap is vented for releasing any increased pressure
filter inlet hose. The breather hose vents crankcase fumes within the fuel tank
into the carburetor for burning to decrease emissions.

Engine - Gas (Liquid-Cooled) Theory of Operation - 98

 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION
The throttle control lever, which is connected to the throttle E - Inlet from Injector
lever and the governor lever, controls engine rpm. The F - Return to Tank
governor lever is connected to the throttle valve inside the G - Fuel Chamber
throttle body. Slow idle is adjusted by turning the slow idle
H - Valve
stop screw and fast idle is adjusted by moving the throttle
control plate. I - Diaphragm

Air enters the air filter through the side panel screen and air System Operation:
filter inlet hose. The primary and secondary elements filter
The pressure regulator is an overflow type of regulator. The
the air before entering the throttle body. The breather hose
spring chamber is connected to the throttle body to insure
vents crankcase fumes into the throttle body for burning to
that they are operating at the same air pressure. High
decrease emissions. A small amount is always present due
pressure fuel from the injector flows to the pressure
to some restriction of air movement through the filter
regulator inlet and fills the fuel chamber. A hose from the
elements. The vacuum increases as the filter elements
vacuum inlet is connected to the intake manifold. This
become plugged.
allows the air pressure in the spring chamber and intake
manifold to be equal.
Fuel Pressure Regulator Operation - FD711D
When intake manifold vacuum increases, the spring
Function: chamber vacuum also increase and overcomes spring
tension, allowing the diaphragm to move upward. With the
Maintains a constant differential in pressure between fuel valve connected to the diaphragm, the valve moves upward
pressure at the injector and air pressure in the throttle body. and allows more fuel to flow out of the outlet and return to
Therefore, the amount of fuel injected is determined by the the fuel tank. This lowers the fuel pressure. As intake
opening time of the injector. manifold vacuum decreases, the spring chamber vacuum
decreases and the spring returns the diaphragm to the
original position. The valve restricts fuel flow to return and
fuel pressure increases.
B
C
Governor Operation
A
System Operation:
The governor controls engine speed. Governed engine
I D speed is a balance between governor spring tension, set by
the throttle control, and actual engine speed, countered by
H
centrifugal force of the governor flyweights. As tension is
applied to governor spring, governor linkage opens
carburetor/fuel injection throttle shaft and plate, increasing
engine rpm. As the engine speed increases, flyweight
E assembly (driven by the crankshaft gear) pushes on
G governor arm, rotating governor shaft and lever, moving
throttle shaft, closing throttle plate slightly and reducing
rpm to governed operating speed. If a heavy load is
encountered, engine speed drops, as does the governor
assembly speed. Flyweights retract and allow shaft arm to
move governor shaft and lever in opposite direction to open
F
throttle plate and allow more air into venturi to draw in more
fuel until engine peak operating speed is recovered.
Springs provide a smooth yet responsive transitional
control.
M45334
IMPORTANT: Avoid damage! Flyweight
A - To Throttle Body assembly shaft is pressed into crankcase cover
B - Spring and is not serviceable. Therefore, if it is
C - Spring Chamber damaged or pulled loose, the crankcase cover
D - Valve Support MUST BE replaced.

Engine - Gas (Liquid-Cooled) Theory of Operation - 99

 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION
Lubrication System Operation

D
E

C
A
B

I
H
J

L
M

MX14218 Pressure oil from the relief valve flows to the oil filter (N).
The filter contains a bypass valve, which opens if the
System Operation: element becomes plugged to insure engine lubrication.
A positive displacement gerotor pump (L) is used to An oil pressure switch (O) mounted above the oil filter turns
pressurize the lubrication system. The lubrication system is on a warning light if oil pressure is below 98 kPa (14.2 psi).
protected by an oil pressure relief valve (M), low pressure Filtered pressure oil flows through a passage in the oil
switch (O), and an oil filter (N) with bypass. sump to the crankshaft main bearing (J) (PTO side).
The oil pump (L) draws oil from the sump through a filter Drilled passages in the crankshaft (I) distribute oil from the
screen (K). Pressure oil from the pump flows to the oil main bearing to the connecting rod (G) journals and
pressure relief valve (M). Oil pressure reading should be crankshaft main bearing (H) (flywheel side). A drilled
276 kPa (40 psi) minimum. If oil pressure exceeds 310 passage in the connecting rods allows oil from the
kPa (45 psi), the relief valve (M) opens allowing oil to connoting rod journal to lubricate the piston (F) and
return to sump. The relief valve is not adjustable. cylinder walls and camshaft (B), tappets (C), governor gear
(A), water pump gear (D) and rocker arms and valves (E).

Engine - Gas (Liquid-Cooled) Theory of Operation - 100

 ENGINE - GAS (LIQUID-COOLED) THEORY OF OPERATION
Throttle Body Operation - 25 HP (FD711D)

E
D
C
B

I
J

MX14223 Excess fuel not used by the injector flows through the
A - Fuel Injectors pressure regulator (C) back to the fuel tank.
B - Fuel Inlet The FD711D has an extra passage (fuel pressure relief
C - Fuel Pressure Regulator screw (F)) in the throttle body that allows for a means to
D - Vacuum Hose relieve the fuel pressure in the fuel lines before any work is
done on the system.
E - Fuel Return Hose
F - Fuel Pressure Relief Screw
G - Air Temperature Sensor
H - Water Temperature Sensor
I - Vacuum Pressure Sensor
J - Thermo Switch

Function:
Injects and atomizes the fuel into the intake air for the
proper combustion.

System Operation:
An electric fuel pump, controlled by the computer, supplies
fuel to the inlet (B) of the throttle body to the injector. The
fuel pressure regulator holds the fuel under pressure in the
injectors (A). The computer receives signals from the
throttle sensor and other sensors then controls the time the
injector is open. The injector injects the atomized fuel into
the throat of the throttle body.

Engine - Gas (Liquid-Cooled) Theory of Operation - 101

 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS
Diagnostics Symptom: Engine Starting Problems
Yes - Clogged fuel line or filter.
Engine Diagnosis
Yes - Fuel tank vent line clogged.

c fluid
CAUTION: Avoid Injury! Engine radiator
is extremely hot during operation. The
Yes - Air filter restricted.
Yes - Defective head gasket.
engine may start to rotate at any time. Keep Yes - Cylinder head loose.
hands away from all moving parts when
testing. Yes - Broken valve spring.
Yes - Warped cylinder head.
Symptom: Engine Starting Problems
Yes - Poor compression. Worn piston/piston rings
(1) Engine will not crank? stuck or not seated. Worn cylinder bore.
Yes - Battery weak or discharged. Yes - Worn or burned valves, or improper clearance.
Yes - Fusible link defective (3) Engine will not start; plug wet?
Yes - Check key switch or wiring. No - Go to next step.
Yes - Starter solenoid defective. Yes - Mixture too rich.
Yes - Starter motor defective. Yes - Clean under engine shrouding.
No - Go to next step. Yes - Check spark plug gap and spark (see Electrical
(2) Engine cranks but will not start? section).

No - Go to next step. Yes - Inlet needle and seat sticking. (23 HP

(FD671D) engine).
Yes - Battery weak or discharged.
Yes - Clean carburetor (23 HP (FD671D) engine).
Yes - Fuel shut-off valve closed (in-line valve).
(4) Engine is hard to start when cold?
Yes - Fuel shut-off solenoid not allowing fuel into
main jet (23 HP (FD671D) engine). No - For additional tests, see “Engine Tests” on
page 106.
Yes - Fuel shut-off solenoid not allowing fuel into fuel
injector (25 HP (FD711D engine). Yes - Mixture too rich.

Yes - Improper use of choke (23 HP (FD671D) Yes - Mixture too lean.
engine). Yes - Clean under engine shrouding.
Yes - Float level too high (23 HP (FD671D) engine). Yes - Choke is not completely shut. Adjust. (23 HP
Yes - Check spark (See Electrical section). (FD671D) engine.)

Yes - Weak or faulty spark plug. Yes - Inlet needle and seat sticking. (23 HP
(FD671D) engine).
Yes - Faulty high tension leads.
Yes - Clean carburetor (23 HP (FD671D) engine).
Yes - Faulty ignition module (23 HP (FD671D)
engine). Symptom: Engine Performance Problems
Yes - Faulty fuel injection module (25 HP (FD711D (1) Loss of power?
engine).
No - Go to next step.
Yes - Faulty ignition coil.
Yes - Low oil level.
Yes - Faulty pulsar coil.
Yes - Too much oil in crankcase.
Yes - Contaminated fuel or faulty fuel supply system.
Yes - Carburetor out of adjustment (23 HP (FD671D)
Yes - Defective fuel pump. engine).
Yes - Air being drawn in through a hole in fuel line(s). Yes - Air/Fuel passages plugged.

Engine - Gas (Liquid-Cooled) Diagnostics - 102

 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS
Symptom: Engine Performance Problems Symptom: Engine Performance Problems
Yes - Carbon deposits in exhaust pipe/muffler. Yes - Faulty governor spring.
Yes - Carbon deposits in combustion chamber. Yes - Governor gear assembly binding or broken.
Yes - Weak or faulty spark plug. Yes - Check spark (See Electrical section).
Yes - Faulty high tension leads. Yes - Carburetor flange loose or leaking at gasket (23
HP (FD671D) engine).
Yes - Faulty ignition module (23 HP (FD671D)
engine). Yes - Throttle body flange loose or leaking at gasket
(25 HP (FD711D) engine).
Yes - Faulty fuel injection module (25 HP (FD711D
engine). Yes - Carburetor body and throttle shaft worn (23 HP
(FD671D) engine).
Yes - Faulty ignition coil.
Yes - Throttle body and throttle shaft worn (25 HP
Yes - Faulty pulsar coil.
(FD711D) engine).
Yes - Contaminated fuel or faulty fuel supply system.
Yes - Weak or faulty spark plug.
Yes - Defective fuel pump.
Yes - Faulty high tension leads.
Yes - Air being drawn in through a hole in fuel line(s).
Yes - Faulty ignition module (23 HP (FD671D)
Yes - Clogged fuel line or filter. engine).
Yes - Fuel tank vent line clogged. Yes - Faulty fuel injection module (25 HP (FD711D
engine).
Yes - Vapor lock.
Yes - Faulty ignition coil.
Yes - Air filter restricted.
Yes - Faulty pulsar coil.
Yes - Defective breather valve.
Yes - Contaminated fuel or faulty fuel supply system.
Yes - Cylinder head loose.
Yes - Defective fuel pump.
Yes - Mixture too lean.
Yes - Air being drawn in through a hole in fuel line(s).
Yes - Check and clean air cleaner.
Yes - Clogged fuel line or filter.
Yes - Adjust idle mixture and check engine
performance. (23 HP (FD671D) engine.) Yes - Fuel tank vent line clogged.
Yes - Choke is not completely open. Adjust. (23 HP Yes - Vapor lock.
(FD671D) engine.)
Yes - Oil leakage around governor shaft.
Yes - Clean carburetor (23 HP (FD671D) engine).
Yes - Defective oil seal.
Yes - Worn or burned valves, or improper clearance.
(3) Engine misses at high rpm?
Yes - Broken valve spring.
No - Go to next step.
Yes - Warped cylinder head.
Yes - Check spark (See Electrical section).
Yes - Defective head gasket.
Yes - Weak or faulty spark plug.
Yes - Poor compression. Worn piston/piston rings
Yes - Faulty high tension leads.
stuck or not seated. Worn cylinder bore.
Yes - Faulty ignition module (23 HP (FD671D)
(2) Engine runs erratically?
engine).
No - Go to next step.
Yes - Faulty fuel injection module (25 HP (FD711D
Yes - Carburetor out of adjustment (23 HP (FD671D) engine).
engine).
Yes - Faulty ignition coil.
Yes - Lack of coolant.
Yes - Faulty pulsar coil.
Yes - Governor linkage out of adjustment.

Engine - Gas (Liquid-Cooled) Diagnostics - 103

 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS
Symptom: Engine Performance Problems Symptom: Engine Performance Problems
Yes - Carburetor out of adjustment (23 HP (FD671D) No - Go to next step.
engine).
Yes - Mixture too rich.
Yes - Clogged fuel line or filter.
Yes - Check and clean air cleaner.
Yes - Fuel tank vent line clogged.
Yes - Adjust idle mixture and check engine
Yes - Defective fuel pump. performance. (23 HP (FD671D) engine).
Yes - Warped cylinder head. Yes - Choke is not completely open. Adjust. (23 HP
(FD671D) engine.)
(4) Engine misses at low rpm?
Yes - Clean carburetor (23 HP (FD671D) engine).
No - Go to next step.
(8) Black, smoky exhaust?
Yes - Carburetor out of adjustment (23 HP (FD671D)
engine). No - Go to next step.
Yes - Air/Fuel passages plugged. Yes - Check spark plug gap and spark (see Electrical
section).
Yes - Air being drawn through carburetor or intake
manifold flanges (23 HP (FD671D) engine). Yes - Mixture too rich.
Yes - Air being drawn through throttle body or intake Yes - Check and clean air cleaner.
manifold flanges (25 HP (FD711D) engine).
Yes - Choke is not completely open. Adjust. (23 HP
Yes - Incorrect timing gear alignment. (FD671D) engine.)
Yes - Check spark (See Electrical section). (9) Spark plug fouled black?
Yes - Weak or faulty spark plug. No - Go to next step.
Yes - Faulty high tension leads. Yes - Check spark plug gap and spark (see Electrical
section).
Yes - Faulty ignition module (23 HP (FD671D)
engine). Yes - Mixture too rich.
Yes - Faulty fuel injection module (25 HP (FD711D Yes - Check and clean air cleaner.
engine).
Yes - Adjust idle mixture and check engine
Yes - Faulty ignition coil. performance. (23 HP (FD671D) engine).
Yes - Faulty pulsar coil. Yes - Choke is not completely open. Adjust. (23 HP
(FD671D) engine.)
Yes - Worn or burned valves, or improper clearance.
Yes - Inlet needle and seat sticking. (23 HP
Yes - Warped cylinder head.
(FD671D) engine).
(5) Engine rpm low or engine stalls?
(10) Spark plug burned white?
No - Go to next step.
No - Go to next step.
Yes - Battery weak or discharged.
Yes - Check spark plug gap and spark (see Electrical
(6) Engine speed unstable (surging)? section).
No - Go to next step. Yes - Mixture too lean.
Yes - Mixture too lean. Yes - Clean under engine shrouding.
Yes - Clean under engine shrouding. Yes - Clean carburetor (23 HP (FD671D) engine).
Yes - Adjust idle mixture and check engine (11) Runs better without air cleaner?
performance. (23 HP (FD671D) engine).
No - Go to next step.
Yes - Clean carburetor (23 HP (FD671D) engine).
Yes - Mixture too rich.
(7) Engine is sluggish?
Yes - Check and clean air cleaner.

Engine - Gas (Liquid-Cooled) Diagnostics - 104

 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS
Symptom: Engine Performance Problems Symptom: Engine Performance Problems
(12) Runs worse when warm? Yes - Lack of coolant.
No - Go to next step. Yes - Excessive engine load.
Yes - Mixture too rich. Yes - Fan belt slippage.
Yes - Check and clean air cleaner. Yes - Defective radiator hose or clamp.
Yes - Adjust idle mixture and check engine Yes - Improper or defective radiator cap.
performance. (23 HP (FD671D) engine).
Yes - Broken or missing fan shroud.
Yes - Choke is not completely open. Adjust. (23 HP
Yes - Defective radiator.
(FD671D) engine.)
Yes - Loose stud bolts and cap screw.
Yes - Inlet needle and seat sticking. (23 HP
(FD671D) engine). Yes - Cracked or porous casting.
(13) Engine overheats? Yes - Damaged water pump seals.
No - Go to next step. Yes - Improperly installed gasket.
Yes - Mixture too lean. Yes - Warped cylinder head.
Yes - Clean under engine shrouding. Yes - Broken valve spring.
Yes - Water pump nylon impeller defective. Yes - Defective head gasket.
(14) Engine backfires? Yes - Worn or burned valves, or improper clearance.
No - Go to next step.
Symptom: Engine fuel/oil/coolant problems
Yes - Carburetor out of adjustment (23 HP (FD671D)
(1) Excessive fuel consumption?
engine).
No - Go to next step.
Yes - Check spark (See Electrical section).
Yes - Check spark (See Electrical section).
Yes - Faulty pulsar coil.
Yes - Weak or faulty spark plug.
Yes - Air being drawn in through a hole in fuel line(s).
Yes - Faulty high tension leads.
Yes - Cylinder head loose.
Yes - Faulty ignition module (23 HP (FD671D)
Yes - Warped cylinder head.
engine).
Yes - Defective head gasket.
Yes - Faulty fuel injection module (25 HP (FD711D
Yes - Intake valve burned or sticking. engine).
(15) Engine knocks? Yes - Faulty ignition coil.
No - Go to next step. Yes - Faulty pulsar coil.
Yes - Excessive engine load. Yes - Improper use of choke (23 HP (FD671D)
engine).
Yes - Faulty ignition module (23 HP (FD671D)
engine). Yes - Air filter restricted.
Yes - Faulty fuel injection module (25 HP (FD711D Yes - Carburetor out of adjustment (23 HP (FD671D)
engine). engine).
Yes - Contaminated fuel or faulty fuel supply system. Yes - Float level too high (23 HP (FD671D) engine).
Yes - Defective head gasket. Yes - Cylinder head loose.
(16) Engine overheats? Yes - Broken valve spring.
No - For additional tests, see “Engine Tests” on Yes - Worn or burned valves, or improper clearance.
page 106.

Engine - Gas (Liquid-Cooled) Diagnostics - 105

 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS
Symptom: Engine fuel/oil/coolant problems Engine Tests
Yes - Poor compression. Worn piston/piston rings
stuck or not seated. Worn cylinder bore. Test Conditions:

(2) Excessive oil consumption? • Machine parked on level surface.

No - Go to next step. • PTO Switch off

Yes - Too much oil in crankcase. • Key switch off unless indicated otherwise.

Yes - Incorrect oil viscosity. • Spark plug connected to D-05351ST Spark Tester

Yes - Drain-back in breather chamber plugged. System: Engine

Yes - Defective breather valve. (1) When checking dipstick, oil at proper level and
Yes - Worn valve stems(s) or valve guide(s). viscosity? No leakage? Clean oil and filter?

Yes - Plugged oil ring groove. Yes - Go to next step.

Yes - Poor compression. Worn piston/piston rings No - Change oil and inspect for source of
stuck or not seated. Worn cylinder bore. contamination.

(3) Coolant leakage? No - Change oil filter.

No - For additional tests, see “Engine Tests” on No - Check gaskets, seals, plugs, cylinder head,
page 106. block, and intake manifold and breather.

Yes - Lack of coolant. (2) Air filter outlet hose not cracked; clamps tight?

Yes - Improper or defective radiator cap. Yes - Go to next step.

Yes - Defective radiator hose or clamp. No - Replace hose and/or tighten clamps.

Yes - Defective radiator. (3) Air filter elements not plugged? Air filter
housing sealed; no dirt tracking inside filter
Yes - Cracked or porous casting. element?
Yes - Loose stud bolts and cap screw. Yes - Go to next step.
Yes - Engine overheating. No - Replace element or housing.
Yes - Damaged water pump seals. (4) Air filter restriction indicator not leaking?
Yes - Improperly installed gasket. Yes - Go to next step.
Yes - Cylinder head loose. No - Replace indicator.
(5) Does fuel shutoff solenoid pull in and stay in
when key is returned to “ON”? (Listen for clicking
as key is cycled.)
Yes - Go to next step.
No - If solenoid will not pull in and hold in, see Fuel
Shutoff Solenoid Circuit Diagnosis in Electrical
section.
(6) Check hand throttle control lever linkage. Full
movement of governor control arm from idle to full
speed?
Yes - Go to next step.
No - Repair; replace or adjust linkage.

Engine - Gas (Liquid-Cooled) Diagnostics - 106

 ENGINE - GAS (LIQUID-COOLED) DIAGNOSTICS
System: Engine System: Engine
(7) Check intake and exhaust valves. Valve (13) Carburetor/Throttle body (engine running).
clearance within specification (engine cold)? Low idle at 1550 rpm? High idle at 3600 rpm?
Valves not sticking?
Yes - Go to next step.
Yes - Go to next step.
No - See “Low Idle Speed Adjustment” on page 110
No - Adjust valves. (See “Tests and Adjustments” in and “High Idle Speed Adjustment” on page 111 in this
this section.) section.
No - Check valve guides and stems. (14) Engine runs smoothly through out rpm range
with low smoke and good power?
(8) Is fuel is reaching injectors (25 HP, FD711D
engine)? (Crack fuel injection lines at injectors. Yes - Go to next step.
Crank engine. Be sure fuel shutoff solenoid has
No - Adjust governor.
pulled in. Fuel leaks out.)
(15) Test oil pressure switch port. Minimum oil
Yes - Go to next step.
pressure within specifications?
No - No fuel present: Check fuel shutoff valve is
Yes - Go to next step.
open, fuel level in tank, inspect filter/separator
element. Test fuel pump. No - Test engine oil pressure. (See “Engine Oil
Pressure Test” on page 114 in this section.)
(9) Check flywheel and starting motor: Minimum
cranking rpm within specification? (16) Thermostat opening temperature within
specifications?
Yes - Go to next step.
Yes - Go to next step.
No - See “Starter Amp Draw Test” in Electrical
section. No - Perform thermostat opening test. (See “Tests
and Adjustments” in this section.)
(10) Carburetor choke and governor linkage, 23 HP
(FD671D). Linkage not binding and adjusted (17) Muffler not restricted?
correctly?
Yes - Go to next step.
Yes - Go to next step.
No - Replace muffler.
No - Repair, replace or adjust linkage.
(18) When performing cylinder compression test:
(11) Carburetor - fuel filter, fuel pump, and Cylinder compression within specification?
carburetor bowl drain screw (key switch on), 23 HP Pressure difference between cylinders within
(FD671D). Fuel level increases in filter? Fuel pump specification?
operating - listen for humming sound near fuel
Yes - Engine tests completed.
cap? Fuel present in float bowl when screw is
opened? No - Rebuild engine.
Yes - Go to next step.
System: Coolant tank and radiator
No - See “Shutoff Circuit Diagnosis” in the Electrical
(1) Coolant level between marks on tank when
section.
engine is warm? Coolant in radiator full to top?
No - Test fuel pump pressure and flow.
Yes - Go to next step.
No - Check carburetor for debris.
No - Add proper coolant mix.
(12) Fuel injection pump static timing test, 25 HP
(2) Coolant not contaminated with oil, fuel or
(FD711D engine). Timing should be correct?
discolored brown?
(Remove pump as the LAST possible solution.)
Yes - Go to next step
Yes - Go to next step.
No - Drain and flush system. Check for source of
No - Have injection pump static timing adjustment
contamination.
performed by a qualified service repair shop. (See
“Tests and Adjustments” in this section.) (3) Radiator screen free of debris?

Engine - Gas (Liquid-Cooled) Diagnostics - 107

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
System: Coolant tank and radiator Tests and Adjustments
Yes - Go to next step.
Throttle Lever Adjustment
No - Clean or replace.
Reason:
(4) Hoses not cracked or leaking; clamps and
radiator cap tight? To achieve smooth throttle lever movement with enough
tension to maintain throttle setting.
Yes - Go to next step.
No - Pressure test radiator and cap. Test Equipment:

(5) Water pump/alternator belt tight; not glazed or • Spring Scale

cracked?
Procedure:
Yes - Go to next step.
1. Connect a scale near the end of the throttle lever.
No - Replace and adjust belt tension. 2. Move throttle lever to slow idle position.
(6) Fan blades not damaged or warped?
Yes - Coolant tests completed.
No - Replace fan.

System: Fuel tank, pump, lines and filter

(1) Fuel level correct; not contaminated or stale
smelling; no water in fuel?
Yes - Go to next step.
A
No - Drain and clean fuel tank. Add fresh fuel.
(2) Fuel pump filter and in-line filter free of debris?
Yes - Go to next step.
No - Replace filters.
(3) Fuel hoses not cracked or leaking? MX14234A

Yes - Go to next step. 3. Adjust friction disks by tightening or loosening lock nut
(A) until throttle lever movement in forward direction is 18 -
No - Replace. 35 N (4 - 8 lb force).
(4) Fuel hose clamps tight? NOTE: Make sure throttle cable is not binding or stuck.
Yes - Go to next step.
No - Replace or tighten.
(5) Fuel tank does not have vacuum?
Yes - Fuel tank, pump, lines and filter tests
completed.
No - Replace vented fuel cap.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 108

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
Throttle Cable Adjustment Choke Adjustment - 23 HP (FD671D)
Reason: Reason:
To insure that the throttle lever cable moves the governor To make sure the choke plate is fully closed when the
linkage from slow to fast idle position. choke lever is in the full choke position. Correct adjustment
also makes sure choke is completely open in the fast idle
Procedure: position.

Procedure:
A
NOTE: Adjust throttle cable before adjusting choke.
1. Remove air cleaner assembly.
2. Move choke lever forward to full choke position and
check that choke butterfly in carburetor is fully closed.

B A
B
E D C

MX14227

Picture Note: 23 HP (FD671D) engine shown;

25 HP (FD711D) engine does not have choke
assembly parts (A).
1. Set the throttle lever in the slow idle position. Check that
the throttle control lever (D) contacts the idle speed C
adjustment screw (E) at the slowest throttle lever setting.
MX14227
2. If the throttle control lever (D) is not touching the screw
3. If adjustment is necessary, loosen the choke cable
(E) at the slowest setting, loosen the throttle cable clamp
clamp (A) and move the cable (B) to obtain a fully closed
(C). Pull throttle cable (B) to left. When the control lever
position. Retighten the cable clamp.
contacts the control plate idle adjustment screw, retighten
the cable clamp. 4. Release the choke lever and make certain the return
spring (C) on the governor control plate is returning the
3. Set the throttle lever to the fastest idle position and
choke butterfly to the fully open position.
check that the throttle control lever is advancing to the full
open position. 5. Reinstall air cleaner assembly and check choke
operation while starting machine.
4. If the control lever is not advancing to the fully open
position, loosen the cable clamp and readjust cable.
Governor Adjustment
5. If the cable cannot be adjusted to obtain a fully open
throttle lever position at fastest idle while maintaining Reason:
contact with the adjustment screw at lowest idle position, it
will be necessary to adjust the control plate idle speed To make sure the governor shaft contacts the flyweight
adjustment screw. plunger when the engine is stopped.

6. Turn the idle adjustment screw (E) clockwise until it NOTE: Adjust throttle cable before adjusting governor
contacts the throttle control lever when set in the slow idle linkage.
position. After completing the idle screw adjustment, check
to make certain the motor is maintaining a 1550 RPM Procedure:
governed low idle setting. Follow the Low Idle Speed NOTE: It is not necessary to remove the throttle or
Adjustment sequence in this chapter if corrections are choke cables from the governor plate assembly to
necessary. reach the governor arm. The governor plate can be
swung away with the cables installed when accessing
the governor arm components.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 109

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
Low Idle Speed Adjustment
B Reason:
C

D To set engine slow idle mixture rpm.

Equipment:
• JTO5719 Photo Tachometer

Procedure:
1. Disconnect all external loads from engine.
A
2. Put reflective tape on blower housing screen.
3. Start and run engine at MEDIUM idle for five minutes.
MX14227

23 HP (FD671D) engine shown;

25 HP (FD711D) engine does not have choke c careful
CAUTION: Avoid Injury! Engine will be HOT. Be
not to burn skin.
assembly parts (D).
1. Loosen bolt (A), and fully turn the bracket (B)
counterclockwise and hold it there.
2. Turn the top end of the governor arm (C) A
counterclockwise to fully open the carburetor/EFI throttle
valve and tighten the bolt (A).

C
E

D
MX14226

23 HP (FD671D) engine shown;

25 HP (FD711D) engine does not have choke
assembly parts (E).
4. Move throttle lever on dash to idle position. Hold the
throttle lever (A) on the carburetor in the closed position
(turn governor arm (C) clockwise all the way).
5. Adjust the low idle speed screw (B) until the engine idles
at 1450 rpm (carburetor idle rpm). Use the photo
tachometer to check engine rpm at the blower housing
screen.
6. Release the throttle lever and adjust the low idle speed
set screw (D) on the control plate to obtain a 1550 rpm
governed low idle speed.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 110

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
High Idle Speed Adjustment Specifications:
High idle setting . . . . . . . . . . . . . . . . . . . . . . . . . 3550 rpm
Reason:
Carburetor idle setting. . . . . . . . . . . . . . . . . . . . 1450 rpm
To set engine high idle mixture and rpm. Governed idle setting . . . . . . . . . . . . . . . . . . . . 1600 rpm
Equipment: NOTE: For high altitude operation above 4000 feet, use
• JTO5719 Photo Tachometer high altitude carburetor kit, to prevent over rich fuel
mixture and black exhaust smoke.
Procedure:
NOTE: High idle speed adjustment should be made Compression Test
after the low idle speed adjustment is performed.
Reason:

c clear
CAUTION: Avoid Injury! Always keep hands
of moving parts.
To determine the condition of pistons, rings, cylinder walls
and valves.

Test Equipment:
1. Start and run engine at MEDIUM idle for five minutes.
• JDM59 Compression Gauge
IMPORTANT: Avoid damage! Do Not adjust high idle
Procedure:
speed with air cleaner removed.
1. Adjust valve clearance to 0.15 mm (0.006 in.) with
engine at top dead center (TDC) compression stroke.
Engine must be “cold” (shop temperature, about 60 - 85°F
(16 - 30°C). (See “Valve Clearance Adjustment” on
D page 112 for procedure.)
NOTE: Be sure the battery is fully charged before
performing procedure.
2. Run engine until it reaches operating temperature
(thermostat opens, and both radiator hoses hot).

A B C

MX14227

23 HP (FD671D) engine shown; A

25 HP (FD711D) engine does not have choke
assembly parts (D).
2. Loosen the lock nut (C), and unscrew the high idle set
screw (B) a few turns.
3. Use a photo tachometer to check engine rpm at the
blower housing screen. B

4. Move the throttle lever on dash to obtain the a 3600

RPM high idle speed and leave it there.
MX14235
5. Turn the high idle set screw (B) so that the end of it just
3. Stop the engine, remove both spark plugs, and ground
touches the speed control lever (A), and tighten the lock nut
leads to block or use a spark tester (B).
(C).
4. Attach the compression gauge assembly (A) firmly into
6. Recheck the idle speed and readjust if necessary.
one plug hole.
5. Put throttle lever in fast idle (wide open) position. On 23
HP (FD671D) engines, choke must be properly adjusted
and fully open. Air filter must be clean.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 111

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS

IMPORTANT: Avoid damage! DO NOT overheat

B C
starting motor during test. Starter duty is 5
A
seconds one, 10 seconds off. Additionally, if
throttle lever is left in slow idle position (air flow
into carburetor restricted), compression could #2 #1
read up to 483 kPa (70 psi) below specification.

6. Crank hot engine until highest compression reading is

obtained.
7. Record pressure readings for each cylinder.

Specifications:
MX14236
Minimum Compression . . . . . . . . . . . . . 620 kPa (90 psi)
4. Align the flywheel magnet (B) with #1 ignition coil (C)
Results: and #2 ignition coil (A).
• If pressure readings are above specification, adjust 5. Both intake and exhaust valves will be closed and the
valves and check fuel and intake air systems. Check rocker arms will be loose. If one rocker arm is tight, the
exhaust for restriction. piston is on the exhaust stroke and the crankshaft must be
• If pressure readings are below specification, squirt clean turned another revolution (360 degrees).
engine oil into cylinders and repeat test.
• If pressure increases significantly, check piston rings
and cylinder walls for wear or damage.
• If pressure does NOT increase after retest, check for D
leaking valves, valve seats or cylinder head gaskets.
• Install spark plugs and reconnect ignition coils when E
finished with testing procedure.

Valve Clearance Adjustment

Reason:
Check and adjust valve clearance for proper engine
operation. F

IMPORTANT: Avoid damage! Perform valve MX14237

clearance measurement or adjustment when the
6. Loosen the lock nut (D) and valve clearance adjustment
engine is at room temperature, 16 - 27°C (60 -
bolt (E).
80°F). Proper valve clearance is essential for the
engine to operate properly. Check valve 7. Insert a 0.15 mm (.006 in.) feeler gauge (F) between
clearance for each cylinder separately. rocker arm and valve stem, and turn the adjusting bolt (E)
until the thickness gauge begins to bind between the rocker
Procedure: arm and valve stem end.

1. Remove spark plugs. 8. Holding the adjusting bolt, tighten the locknut to 11 N•m
(96 lb-in.). (Repeat for either exhaust or intake valve.)
2. Remove valve covers.
9. Repeat procedure for other cylinder.
3. Turn the crankshaft clockwise until piston, visible in the
spark plug hole, is at TDC (top dead center) of the Specifications:
compression stroke.
Valve Clearance
(at 16 - 27°C (60 - 80°F) . . . . . . . . . . 0.15 mm (0.006 in.)
Nut Torque . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 112

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
Crankcase Vacuum Test
Reason: C
To measure the amount of crankcase vacuum, to ensure
the crankcase is not pressurized. A pressurized crankcase
will force oil to leak past the seals.

Equipment:
• JTO5697 U-Tube Manometer Test Kit; or,
• JT03503 Crankcase Vacuum Test Kit

Procedure 1: M88762

7. Zero out the manometer by sliding the ruled scale up or

IMPORTANT: Avoid damage! Test must be run with down so “0” (C) is located where water level on both sides
the engine at normal operating temperature, if not, is even.
test will be inaccurate. DO NOT use more than 3 feet
8. Hold finger over rubber plug hole to keep oil from
of manometer tubing. If a longer hose is used the
spraying out. Start engine, move the throttle lever to fast
readings will be inaccurate.
idle (3400 rpm) and allow engine to reach operating
1. Park machine on level surface. temperature.
2. Raise engine hood and remove dipstick. Check dipstick/ 9. Quickly attach clear line from manometer to rubber plug
oil fill cap and O-ring for cracks or damage, replace as in dipstick opening.
necessary.
3. Install appropriate size rubber plug in dipstick tube.
D
4. Insert barbed fitting in rubber plug so that clear line to
fitting (A) can be connected at a later step.

IMPORTANT: Avoid damage! DO NOT make

connection between U-Tube Manometer clear line
and engine crankcase BEFORE engine is running or
fluid in manometer could be drawn into crankcase.

5. Attach manometer magnets to a solid metal surface.

A B

M88764

Example: 3 + 3 = 6 in. of vacuum

[Link] vacuum reading. Gauge should show a
minimum vacuum of 10.2 cm (4 in.) of water movement.
M88761 The reading is obtained by adding (D) and (E) water
6. Open top valves (A) and (B) one turn. movement from “0” position.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 113

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
Results:
IMPORTANT: Avoid damage! Repeat test at least
three times for accuracy. To repeat test, remove the If crankcase vacuum does not meet specification, check
manometer tube from top of manometer at “A”. the following:
DO NOT remove manometer tube from engine. NOTE: A new engine may have low vacuum readings
Perform step #7 then reattach manometer tube to due to the fact that the rings are not seated.
side “A”. Continue with step #10.
• Seals and gaskets for leakage
[Link] line from manometer before stopping engine.
Then remove dipstick hose connection and install dipstick. • Rocker arm cover O-ring for leakage
• Rings, piston, and cylinder bore for wear or damage
Procedure 2:
1. Park machine on level surface. Engine Oil Pressure Test
2. Raise engine hood and remove dipstick. Check dipstick/
oil fill cap and O-ring for cracks or damage, replace as Reason:
necessary. To determine condition of lubrication system.
3. Install appropriate size rubber plug in dipstick tube.
Equipment:
4. Insert barbed fitting in rubber plug so that clear line) to
• JT03344 Pressure Gauge Assembly
fitting can be connected at a later step.
• JT03349 Connector
IMPORTANT: Avoid damage! DO NOT make • JT03017 Hose Assembly
connection between test gauge and rubber plug
BEFORE engine is running at FAST idle or gauge
damage may result. c are
CAUTION: Avoid Injury! Engine components
HOT. Be careful not to touch, especially the
After test reading is made, DO disconnect test exhaust pipe or muffler while making
gauge WHILE engine is running at FAST idle to adjustments. Wear protective eye glasses and
prevent damage to gauge. clothing.
5. Hold finger over rubber plug hole to keep oil from
spraying out. Start engine, move the throttle lever to fast Procedure - Preliminary Check:
idle and allow engine to reach operating temperature. 1. Park machine on level surface.
6. Connect gauge, clear line, and barbed fitting to rubber 2. Turn key switch OFF. Allow engine to cool.
plug.
3. Move forward/reverse pedals to NEUTRAL position.
7. Record crankcase vacuum reading. Gauge should show
4. Engage parking brake and raise hood.
a minimum vacuum of 10.2 cm (4 in.) of water movement.
5. Check engine oil level, bring oil level to full mark.
8. Disconnect barbed fitting, clear line, and gauge from
rubber plug while engine is running at FAST idle. Hold
finger over rubber plug hole to keep oil from spraying out.
9. Move throttle to SLOW idle and turn engine OFF.
[Link] rubber plug and install dipstick.
B
Specification:
Minimum Crankcase Vacuum at 3400 rpm. . 10.2 cm (4 A
in. water)

MX14241

6. Disconnect oil pressure switch wiring lead (B).

7. Remove oil pressure switch (A).

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 114

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
E
Fuel Pump Flow Test for Carburetor - 23 HP
(FD671D)
Reason:
To determine proper fuel flow from transfer pump.

Test Equipment:
C
• Graduated container
D
Procedure:

B
MX14242
A
8. Install JT03349 Connector (C).
9. Install JT03017 Hose Assembly (D) and JT03344
pressure gauge assembly (E).
[Link] oil pressure while cranking engine. If no oil
pressure is present discontinue cranking engine.
Determine and correct cause before running engine.
MX15403
IMPORTANT: Avoid damage! If pressure reading is
1. Disconnect fuel supply hose (A) from carburetor (B) and
below 69 kPa (10 psi), STOP ENGINE IMMEDIATELY
put end in a graduated cylinder.
and determine cause.
2. Turn key switch on for 10 seconds. DO NOT start
Procedure- Engine Running: engine.
1. Start and Run engine at medium idle for five minutes to Results:
heat engine oil to normal operating temperature.
• If fuel flow is below 300 mL (10 oz)/10 seconds, check
2. Run engine at fast idle (3350 rpm) and check oil fuel pump filter, in-line filter, hoses, and fuel shutoff valve
pressure. Gauge should read a minimum oil pressure of for debris or restrictions. Replace filters; then test again.
276 kPa (40 psi).
• If fuel flow is still below 300 mL (10 oz)/10 seconds,
Results: replace fuel pump.
• If oil pressure reading is BELOW specifications, inspect
or replace the following: Fuel Pump Pressure Test for Carburetor - 23
- Oil pressure relief valve spring worn or broken
HP (FD671D)
- Oil pressure relief valve stuck or broken. Reason:
- Oil pump worn or damaged To check condition of fuel pump and determine fuel
pressure.
- Oil pump suction screen or oil passages plugged
- Connecting rod and main bearing journals excessively Test Equipment:
worn. • JDG356 Fuel Pump Pressure Test Kit
- Connecting rod and main bearing journals excessively
worn. Procedure:
- Oil filter plugged. 1. Engage parking brake.

Specifications:
Minimum Oil Pressure . . . . . . . . . . . . . . 276 kPa (40 psi)
Oil Pressure Switch Torque. . . . . . . 15 N•m (132 lb-in.)

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 115

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS

A
A

MX15403 MX15401/MX15402
2. Loosen clamp (A), and disconnect fuel supply hose (C) Left side of engine shown.
from fuel filter (B).
2. Loosen the fuel pressure relief screw (A) to relieve the
3. Connect fuel pump pressure test kit to end of supply high pressure in the return fuel hose; Do Not close it at this
hose (C). time, leave open.
4. Turn key switch on. DO NOT start engine. Observe
pressure reading.
c spilling
CAUTION: Avoid Injury! Be prepared for
fuel. Wipe up any fuel immediately.
Results:
DO NOT try to start engine with the fuel
• If fuel pressure is below 10 kPa (1.5 psi), check fuel hoses disconnected.
pump filter, in-line filter, hoses, and fuel shutoff valve for
debris or restrictions. Replace filters; then test again.
B
• If pressure is still below 10 kPa (1.5 psi), replace fuel
pump.
D
Fuel Pump Pressure Test For Fuel Injection -
25 HP (FD711D)
C
Reason:
To check condition of fuel pump and fuel pressure regulator
which determines fuel pressure.
A
Test Equipment:
• JT07032 400 kPa (60 psi) Pressure Gauge
• JDG41 1/4 M NPT X 1/8 ID Barbed Fitting
MX31772
• Fuel Hose and Hose Clamps
A - Fuel Line from Pump/Filter
Procedure: B - From Relief Screw on Throttle Body
C - Excess Pressure Return from Pressure
1. Engage park brake. Put PTO in OFF position.
Regulator
NOTE: Be sure the battery is fully charged. D - Main Return Line to Fuel Tank
3. Disconnect the fuel line (B) from the tee fitting.
4. Cap the tee fitting open port with a short piece of fuel
line and fuel line cap.
5. Install the pressure gauge into the fuel relief line (B).
6. Tighten the hose clamp in the correct position.
NOTE: The fuel pump will run for two seconds and
then shut off.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 116

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
7. Turn the key to the RUN position and read fuel pressure. 3. After the system has been “refueled”, tighten the relief
screw (A).
8. Fuel pressure should be 172 - 186 kPa (25 - 27 psi).
• If fuel pressure is higher than specified, check fuel
return hose for sharp bends, kinking or clogging or;
Fan Belt Tension Adjustment
vacuum hose for air leaks.
Reason:
• If fuel pressure is much lower than specified, inspect
To keep proper tension on belt to drive cooling fan.
for fuel line leakage or clogs in fuel filter or fuel pump.
If the inspection turns out good, replace entire pressure Test Equipment:
regulator or fuel pump. (See “Fuel Pressure Regulator • JDST28 Belt Tension Gauge
Removal and Installation - 25 HP (FD711D)” on
page 133 in this section, or “Fuel Pump/Fuel Gauge Procedure:
Sensor Removal and Installation” on page 554 in the

c clothing
Miscellaneous section.)
CAUTION: Avoid Injury! Fingers or loose
9. Remove pressure gauge.
can get caught in rotating parts.
[Link] the fuel relief hose to the tee fitting and clamp Park safely, stop engine, wait for all moving
it. parts to stop, and allow engine to cool
[Link] the fuel pressure relief screw (A). before servicing.

Bleed Fuel System - 25 HP (FD711D)

B
Reason:
When the engine is run out of fuel, injection components
fail, or fuel system opened, this procedure purges air from
fuel system.

Procedure: A

NOTE: This procedure should not be necessary, but

may be used when the engine does not start after ten
seconds of trying.

A MX14230

1. Use JDST28 Belt Tension Gauge (B) to check belt (A)

tension midway between fan and drive sheaves. Belt
tension should be between 25 kg (55 lb) and 40 kg (88 lb).
If belt tension is below 18 kg (40 lb), adjust or replace the
belt. See full specifications below.

D
C

MX15401/MX15402

Left side of engine shown.

1. Loosen the pressure release screw (A). F

NOTE: Cycling the key switch is necessary because

power is supplied to the fuel pump for only a few E
seconds.
2. With screw loosened, cycle the key switch back and MIF
forth (on-off, on-off). Do not turn the engine over.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 117

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
2. If the tension gauge is not available, apply moderate Radiator Cap Pressure Test
pressure (F) to belt between driveshaft sheave (D) and fan
pulley (E). Belt should deflect inward (C) as follows: Reason:
To test radiator cap for operating in correct pressure range.
Specifications:
Test Equipment:
Belt Tension Measurement Slacks
• D05104ST Cooling System Pressure Pump
25 kg (55 lb) force and 12 mm (0.47 in.) deflection
• JDG692 Radiator Pressure Test Kit (Adapters)
40 kg (88 lb) force and 9 mm (0.35 in.) deflection
Procedure:
18 kg (40 lb) force and 17 mm (0.67 in.) deflection
(adjust or replace belt)

Results:
• If deflection is not within specifications, disconnect drive
shaft and remove outer sheave half of fan drive pulley.
Remove shim(s) to increase belt tension or add shim(s) to
decrease tension. If proper belt tension cannot obtained,
replace belt. (See “Fan Belt Removal and Installation” on
page 121 for procedure and component explode for
adjustment.) T6333AX

1. Install radiator cap on appropriate adapter

Radiator Bubble Test
2. Attach adapter to D05104ST pressure pump.
Reason: 3. Apply pressure. Pressure valve in cap should open
To determine if compression pressure is leaking past head according to specifications.
gaskets and into cooling system.
Radiator Cap Test Specification:
Procedure: Relief Valve Opening
1. With coolant at proper level and radiator cap tight, start Pressure . . . . . . . . . . . . . . . . 78 - 98 kPa (11.3 - 14.2 psi)
and run engine to bring it to operating temperature.
Results:
2. Disconnect overflow hose from coolant recovery tank.
• If cap leaks, relieve pressure and retighten cap. Test
again. Replace cap if pressure is not within specification.

Thermostat Test
Reason:
To determine opening temperature of thermostat.

Equipment:
• Thermometer
• Glass Container
• Heating Unit
M55592a

3. Put end of hose in a container of water.

4. Check for bubbles coming from hose.
c thermostat
CAUTION: Avoid Injury! DO NOT allow
or thermometer to rest against
the side or bottom of glass container when
Results: heating water. Either may rupture if
• If bubbles are present, replace head gaskets. overheated.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 118

 ENGINE - GAS (LIQUID-COOLED) TESTS AND ADJUSTMENTS
Procedure:
1. Remove thermostat. (See “Thermostat Removal and
Installation” on page 120.)

M82122a

2. Suspend thermostat and a thermometer in a container

of water.
3. Heat and stir the water. Observe opening action of
thermostat and compare temperatures with specifications.
4. Remove thermostat and observe its closing action as it
cools.

Specifications:
Begin Opening . . . . . . . . . . . 80.5 - 83.5° C (177- 182° F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . 95° C (203° F)
Minimum Lift Height
Above 95° C (203° F) . . . . . . . . . . . . . . . 8 mm (0.31 in.)

Results:
• If thermostat does not open according to specifications,
replace.
• If closing action is not smooth and slow, replace
thermostat.

Engine - Gas (Liquid-Cooled) Tests and Adjustments - 119

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Cooling System Test Repair
Reason:
Thermostat Removal and Installation
To inspect cooling system for leaks.
1. Park machine with park brake ON, transmission in
Equipment: NEUTRAL, and engine OFF.
• D05104ST Cooling System Pressure Pump
• JDG692 Radiator Pressure Test Kit (Adapters) c above
CAUTION: Avoid Injury! Coolant may be
boiling temperature and under
Procedure: pressure in ---cooling system. DO NOT
remove pressure cap when system is hot.

c above
CAUTION: Avoid Injury! Coolant may be
boiling temperature and under
Escaping steam will burn unprotected skin.
Always wear protective clothing and
goggles when servicing cooling system
pressure in ---cooling system. DO NOT
remove pressure cap when system is hot. 2. Allow engine to cool before servicing cooling system.
Escaping steam will burn unprotected skin. Squeeze top radiator hose to verify the system pressure
Always wear protective clothing and has dropped before opening radiator cap.
goggles when servicing cooling system 3. Place container under cooling system drain and open
valve. Open radiator cap to speed up draining. Drain only
enough coolant to lower coolant level below thermostat
housing.

B D
A C

M87350

1. Check cooling system is cool and squeeze top radiator

hose to check system pressure has dropped.
A E A
2. Remove cap. Top off coolant if low. Wet the cap sealing F
surfaces with water or coolant to prevent pressure leaks.
MX15403
Attach D05104ST pressure pump to radiator filler neck.
4. Loosen the hose clamps (A), and remove the three

c procedure,
CAUTION: Avoid Injury! During testing
do not exceed the pressure for
coolant hoses.
5. Unscrew the mounting bolts (C), and remove the
thermostat body, enough to remove final clamp and hose
which the system was designed. The
(D). Remove thermostat body from engine.
maximum pressure is 102.7 kPa (14.9 psi).

3. Pressurize system with tester to 60 kPa (8.7 psi).

4. Check for leaks throughout cooling system.

Results:
• Pressure should hold to specifications. If pressure
decreases, check for leaks. Repair leaks or replace parts
as necessary.
• If leakage continues after all external leaks have been
stopped, a defective head gasket, cracked block, or
cylinder head may be the cause.

Engine - Gas (Liquid-Cooled) Repair - 120

 ENGINE - GAS (LIQUID-COOLED) REPAIR
7. Remove thermostat (G) from upper body (B). Test or
B replace thermostat. (See “Thermostat Test” on page 118.)
8. When installing thermostat, replace gasket (G) with a
new one.
9. Tighten bolts (E) to 10 N•m (87 lb-in.).

Fan Belt Removal and Installation

NOTE: Disconnect and remove spark plugs to allow for
G easy flywheel rotation during outer sheave half
installation.
E H
F
1. Remove spark plugs.
MX14243 NOTE: Rotate outer sheave half as nuts are tightened
6. Remove the bolts (E), and separate the thermostat to allow belt to center in sheave halves.
upper body (B) from the lower body (F).

A
B

C
D

M81225a and shim (D) to inner sheave half attached to flywheel.

A - Mounting Cap Screws 4. Remove fan belt (C). Remove shim (D) if belt is to be
B - Outer Sheave Half tightened. Leave shim in if installing a new belt.
C - Fan Belt 5. Install fan belt.
D - Shim
NOTE: Rotate sheave assembly as nuts are tightened
E - Mounting Nuts
to allow belt to center in sheave halves and not be
F - Drive Shaft pinched in an off-center position.
2. Remove three (3) cap screws (A) holding drive shaft (F)
6. Loosely install belt between sheave halves and start
onto outer sheave half (B).
installing the three outer sheave-retaining nuts (E).
3. Remove three (3) nuts (E) holding outer sheave half (B)

Engine - Gas (Liquid-Cooled) Repair - 121

 ENGINE - GAS (LIQUID-COOLED) REPAIR
7. Install and tighten mounting nuts (E) to 15 N•m (130 lb- D - Bearing (2 used)
in.). E - Mounting Flange
8. Install driveshaft, and tighten mounting cap screws (A) F - Pulley
to 20 N•m (15 lb-ft). G - Cap Screw
9. Check and adjust fan belt tension. (See “Fan Belt H - Flanged Nut
Tension Adjustment” on page 117.) I - Fan
[Link] and tighten spark plugs to 25 N•m (18 lb-ft). J - Stud
K - Pulley (outer half)
Specifications: L - Shim(s)
Sheave Mounting Nuts (E) . . . . . . . . 15 N•m (130 lb-in.) M - Fan Belt
Driveshaft Mounting Bolts (A) . . . . . . . 20 N•m (15 lb-ft) N - Cap Screw
Spark Plug Torque . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) O - Spacer
P - Nut
Cooling Fan and Bracket Removal and 1. Heat mounting bracket (C) with bearings (D) in hot oil to
Installation remove bearings. Tap bearings from mounting bracket.
2. Install bearings using a bushing, bearing and seal driver
IMPORTANT: Avoid damage! Bearings are a set and press.
press fit. Remove only if being replaced. To
3. Assemble fan (I), and belt sheave (F) to mounting flange
avoid pinching fan belt between flywheel and
(E) and install fan assembly to engine. Tighten hardware to
outer sheave half, rotate flywheel while
standard torque specifications.
tightening outer sheave half mounting cap
screws. 4. Install fan belt, shim(s) (L), and outer sheave half (K) to
flywheel. Tighten flange nuts (H) to 15 N•m (130 lb-in.).

c over
CAUTION: Avoid Injury! DO NOT heat oil
182°C (360°F). Oil fumes or oil can
5. Adjust belt tension. (See “Fan Belt Tension Adjustment”
on page 117.)

ignite above 193°C (380°F). Use a

thermometer. DO NOT allow a flame or Coolant Pump Removal and Installation
heating element to come in direct contact
Removing:
with the oil. Heat the oil in a well-ventilated
area. 1. Remove muffler. (See “Muffler Removal and
Installation.”)

F G

B A
E
D
C
A
B H C

A
I

D
O N
J
D
P M K MX14253
L

MX14252 A - Bolt, M8, 80 mm (3.15 in.)

B - Bolt, M8, 45 mm (1.77 in.)
A - Washer
C - Bolt, M8, 60 mm (2.36 in.)
B - Snap Ring
D - Bolt, M8, 30 mm (1.18 in.)
C - Bracket

Engine - Gas (Liquid-Cooled) Repair - 122

 ENGINE - GAS (LIQUID-COOLED) REPAIR
• Note the position of different lengths of bolts so they I - Cup Gasket
can be installed in their original positions. J - Pump Shaft
K - O-Ring
L - Dowel Pin
M - Impeller
E N - Pump Housing
5 10

4 1 C
N
D
G
2 B
9 3
8 G L
6 7
M A
O
F

MX14253 E
J
2. Loosen the hose clamp (F) and disconnect the water
hose (G) at the coolant inlet port of the water pump (E).
K
3. Unscrew the water pump bolts in the order shown, and
remove the water pump assembly. MX14255

Disassembly: 1. Remove pump gear (A).

2. Remove dowel pin (B), washer (C), claw washer (D).
NOTE: Do not attempt to remove the mechanical seal
(F), oil seal (D), and O-Ring (J), unless they are to be NOTE: Mechanical seal (G) is sealed into place and will
replaced. be difficult to remove. If mechanical seal parts are
damaged, replace the seal as a set.
A
3. Drive mechanical seal assembly (G) and remove oil seal
B (K) from the housing (N).

C • If the mechanical seal (G) is damaged, the coolant

leaks through the seal, and drains through the drainage
outlet passage (F).
N
D
• If the oil seal (E) is damaged, the engine oil drains
E through the drainage oil passage (F).

F
IMPORTANT: Avoid damage! Check impeller for
material break- down or deterioration. Replace
the complete coolant pump if impeller is
G
damaged. Flush cooling system to remove
H debris and add new coolant.
M L I 4. Remove dowel pin (L) from the pump shaft (J), and
K J
remove impeller (M).
MX14256
5. Measure outside diameter of shaft (J). If less than
A - Pump Gear
specifications or if it shows any signs of corrosion, replace
B - Dowel Pin it.
C - Washer
6. Measure pump shaft bore in housing (N). Replace
D - Claw Washer housing if greater than specifications.
E - Oil Seal
F - Drainage Outlet Passage Pump Specifications:
G - Mechanical Seal Cartridge Shaft OD (Minimum). . . . . . . . . . . . . 9.94 mm (0.391 in.)
H - Mating Ring Housing Shaft Bore/ID (Maximum) 10.09 mm (0.397 in.)

Engine - Gas (Liquid-Cooled) Repair - 123

 ENGINE - GAS (LIQUID-COOLED) REPAIR
7. Inspect all parts for wear or damage. Replace as Radiator Removal and Installation
necessary.
NOTE: When installing impeller assembly to housing,
coat mating surfaces with clean water. c above
CAUTION: Avoid Injury! Coolant may be
boiling temperature and under
Installing: pressure in ---cooling system. DO NOT
remove pressure cap when system is hot.
Escaping steam will burn unprotected skin.
B
Always wear protective clothing and
goggles when servicing cooling system.

NOTE: Cooling system capacity is approximately 2.8 L

(3.0 qt).
A
1. Drain coolant.

B
A

MX14255

1. Remove the old gasket from pump cover and pump

housing. C

IMPORTANT: Avoid damage! Do not get the

sealant into the water line hole on the crankcase D
or the crankcase cover.

2. Apply sealant bead to the mating surfaces of the pump E

cover and pump housing.
F
NOTE: Recall position of different lengths of bolts (in MX14397
removal procedure above).
25 HP (FD711D) EFI engine shown
2. Remove hoses (B and F).
3. Remove side panel (A) and side panel on opposite side
A of machine.
5 10
4. Remove recovery tank (C).

6
5. 25 HP (FD711D) engine: Remove screw holding bracket
9
for fuel filter (E) and fuel line (D). Move fuel filter and fuel
D
8 lines toward engine to be able to move radiator shroud
1 7 forward.
4 3 2

MX14253

3. Install the mounting bolts, and tighten them in the order

shown to 20 N•m (15 lb-ft).
4. Install hose (D) and hose clamp (C) to the coolant inlet
port of the water pump cover (A).

Engine - Gas (Liquid-Cooled) Repair - 124

 ENGINE - GAS (LIQUID-COOLED) REPAIR
H
G

J
K

MX14398

6. Loosen clamp (G), and remove air cleaner hose (H)

from air cleaner housing.
7. Loosen throttle cable clamp at throttle linkage and move
throttle cable (K) from top of radiator shroud (L).
NOTE: There is also a choke control cable equipped on
23 HP (FD671D) engines that will need to be moved in
order to move radiator shroud.
8. Remove bolts and nuts (J) on both sides of machine.
Move radiator shroud (L) towards front of machine, over
engine fan.
9. Remove four screws (I) holding radiator to pedestal, and
remove radiator from machine.

c compressed
CAUTION: Avoid Injury! Reduce
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.

[Link] radiator for debris lodged in fins. Clean radiator

using compressed air or pressure washer.
[Link] radiator for bent fins, cracks and damaged
seams. Repair as necessary.

Engine - Gas (Liquid-Cooled) Repair - 125

 ENGINE - GAS (LIQUID-COOLED) REPAIR

C
B
D
A

G P
E F

A H

N I

M
K

MIF O - Radiator Hose (Supply)

A - Hose Clamp) P - Support Bracket
B - Radiator Hose (Return)
Installation is done in the reverse order of removal.
C - Screw (3 used
D - Radiator Shroud • Close drain valve and fill radiator with proper coolant to
top of filler neck.
E - Filler Cap
F - Radiator • Start engine and allow it to reach proper operating
temperature. Check radiator, hoses and connections for
G - Overflow Hose
leaks. Adjust coolant level in recovery tank.
H - Bracket
I - Clip, Oil Radiator Mount
J - Foam Pad
K - Clip (Models before 2003)
L - Screen
M - Flange Nut
N - Screw

Engine - Gas (Liquid-Cooled) Repair - 126

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Muffler Removal and Installation
F
1. Disconnect headlight connector and remove hood.
2. Disconnect and remove battery.

MX16206

8. Unscrew the four (4) flange nuts (G), and remove the
A
spring washers and engine hook (F) on No. 1 cylinder side.
B

I
MX14370

Battery shield, right side view. H

3. Remove two cap screws (A) securing side brackets of

battery shield to frame and two nuts (B) securing hood
brackets to frame.

D
I
E

MX16207

9. Remove the four (4) bolts (I) on the muffler bracket and
C take off the muffler assembly (H).
[Link] the gaskets.
[Link] the exhaust pipe or muffler for dents, cracks,
rust or holes. check for breaks in seems and loose internal
MX14374
components. Replace muffler if any considerable damage
is found.
4. Remove cap screw (C) that secures battery shield to top
of frame. [Link] the exhaust pipe flanges to the exhaust port
gasket surfaces, and install new gaskets each time the
5. Compress positive battery cable retainer clip (D) and muffler is installed.
separate cable from battery shield.
NOTE: To prevent mis-threading, finger tight the flange
6. Loosen two cap screws that secure slotted mounting
nuts first. Next tighten the bolts on the muffler bracket.
holes in battery shield to back of frame at locations marked
(E). [Link] the muffler, engine hook, spring washers, and
7. Lift and remove battery shield. nuts. Tighten nuts (G) to 20 N•m (180 lb-in.).

Engine - Gas (Liquid-Cooled) Repair - 127

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Air Cleaner Removal and Installation G - Case
H - Cap Screw
I - Case
B
J - Gasket
K - Grommet
A C
L - Air Temperature Sensor, 25 HP (FD711D) only
M - Clamp
N - Hose
D O - Cap Screw
P - Vacuum Sensor, 25 HP (FD711D) only
Q - Bracket
E R - Cap Screw
S - Seal
T - Stud
1. Inspect precleaner and paper element for dirt and dust.
F
2. Clean precleaner if necessary:
3. Wash in warm, soapy water.
4. Rinse in clean water.
5. Squeeze to remove water.
G 6. Let air dry.
7. Apply 30 mL (1 oz) of clean engine oil to precleaner.
Squeeze to distribute oil evenly and to remove excess oil.

IMPORTANT: Avoid damage! DO NOT wash

T
paper element. Clean or replace paper element
H
S as necessary.
R
8. Tap paper element gently to remove dust.
9. Replace element if oily, dirty or damaged.
I
Q [Link] Thread Lock and Sealer (Medium Strength) on
mounting screws before installation.
[Link] installing breather hose, Make certain hose end is
fully seated in the air cleaner base and the hose is not
P
kinked.
J

O K
M

L
N M

MX14261

25 HP (FD711D) air cleaner assembly shown

A - Nut
B - Washer
C - Cover
D - Wing Nut
E - Foam Filter
F - Paper Filter

Engine - Gas (Liquid-Cooled) Repair - 128

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Carburetor Removal and Installation - 23 HP Disassembly and Assembly:
(FD671D)
D

c extremely
CAUTION: Avoid Injury! Gasoline is
flammable and can be explosive
C

B
under certain conditions. Turn the ignition
switch OFF. Do not smoke, and make sure
the area is well ventilated and free from any E
A
source of flame or sparks.

Removing:
1. Remove air cleaner and related parts. (See “Air Cleaner
Removal and Installation” on page 128.)
F
L
2. Remove radiator. (See “Radiator Removal and
Installation” on page 124.)
3. Remove cooling fan and fan belt. (See “Cooling Fan and
Bracket Removal and Installation” on page 122.)
K

C A J I G
D

MX16197

A - Spring
B
B - Pilot Screw
C - Limiter
D - Cover Assembly
MX16196
E - Pilot Jet
4. Turn the fuel shut off valve to the off position. F - Choke Valve Assembly
5. Drain the carburetor. G - Throttle Valve Assembly
6. Disconnect the fuel tube at the fuel inlet joint (A) of the H - Float Chamber Assembly
carburetor. I - Main Jet (L)
7. Disconnect the solenoid valve lead terminal. J - Main Jet (R)
K - Float Assembly
8. Unscrew the intake pipe and carburetor mounting bolts
(B). L - Screw

9. Unhook the throttle (C) and choke link rod (D) at the 1. Refer to the illustration shown for disassembly and
ends of their arms while pulling off the carburetor. assembly.

IMPORTANT: Avoid damage! Do Not clean holes

or passages in the carburetor body with sharp
objects such as wire or small drill bits.

• There are several passage plugs (ball plugs) in the

carburetor body. Do not remove them.
• Before disassembly, mark the outside of the choke
valve and throttle valves for assembling them.

Engine - Gas (Liquid-Cooled) Repair - 129

 ENGINE - GAS (LIQUID-COOLED) REPAIR
• If the float position is not correct, bend the tab as
c and
CAUTION: Avoid Injury! When cleaning rubber
plastic carburetor parts, use a cleaning
required for correct adjustment.

solvent with a high flash point that will not

damage the components.

2. Inspect moving parts such as shafts, choke and throttle

plates etc. for wear or damage. Replace if necessary.
3. Check the carburetor body and float chamber for cracks,
nicks or other damage. Replace components as necessary.
4. Remove all rubber and plastic parts from the carburetor.
Soak all metal carburetor parts in cleaning solvent for a
maximum of 1/2 hour.
5. Spray all internal passages and jets in the carburetor S T
body with a spray carburetor cleaner to verify that
passages and jets are open. MX16199

IMPORTANT: Avoid damage! Rinse carburetor body 9. Inspect the float valve for excessive wear or damage.
in warm water immediately after using carburetor • The tip should be smooth, without any grooves,
cleaning solvent or spray to neutralize corrosive scratches, or tears (S). The rod at the opposite end of
action of cleaner on aluminum. the needle should move smoothly when pushed in and
released.
6. Rinse carburetor with warm water and dry with
compressed air. Do Not use rags or paper to dry parts as • If either the valve or the valve seat is worn or
lint may plug holes or passages. damaged (T), replace the float assembly and carburetor
as a set.
7. Inspect all parts for wear or damage, replace as
necessary. [Link] the pilot screw in accordance with the following
procedure, if necessary:
8. Clean and check the float level as follows:
• Carefully mark the position of the pilot screw limiter

c onCAUTION:
on the carburetor body so that it can be installed and set
Avoid Injury! Do not push down to its original position later.
the float (K) during float level checking. • Remove the limiter, being careful not to turn the pilot
screw at this time.
K N
• Turn the pilot screw clockwise and count the number
O
M of turns until screw is gently seated in the pilot passage.
Record the number of turns needed to close the screw.
• Turn out the pilot screw to replace it with a new one.
Q
P
U
R V

MX16198

• With the float (K) assembly installed onto the

carburetor body (R), hold the carburetor upside down at
an eye level. Gently support the float with a finger and
bring it down slowly so that the float arm tab (P) just MX16200
touched the float valve (O). The float arm surface (N) [Link] the tapered portion (V) of the pilot screw (U) for
should be parallel (M) with the carburetor body mating wear or damage.
surfaces (Q).

Engine - Gas (Liquid-Cooled) Repair - 130

 ENGINE - GAS (LIQUID-COOLED) REPAIR
• If the pilot screw is worn or damaged on the taper 4. Adjust idle speed.
portion of it, replace it. 5. Install remaining components reverse of removal.
• Check the spring for a weakened condition; replace
it, if necessary. Throttle Body Removal and Installation - 25
[Link] the new pilot screw until the screw is gently HP (FD711D)
seated. Then open the screw the same number of turns as
recorded prior to removal. Removing:
• Align the limiter with the mark on the carburetor body
to install, taking care not to turn the pilot screw.
c extremely
CAUTION: Avoid Injury! Gasoline is
flammable and can be explosive
Installing:
under certain conditions. Turn the ignition
C
switch OFF. Do not smoke, and make sure
A the area is well ventilated and free from any
D
source of flame or sparks.

1. Remove air cleaner and related parts. (See “Air Cleaner

Removal and Installation” on page 128.)
2. Remove radiator. (See “Radiator Removal and
Installation” on page 124.)
3. Remove cooling fan and fan belt. (See “Cooling Fan and
B Bracket Removal and Installation” on page 122.)
4. Remove fan mounting holder.
5. Turn the fuel shut off valve to the OFF position.
MX16196

c from
1. Clean the mating surfaces of the carburetor, insulator
and intake pipe, and fit new gaskets. CAUTION: Avoid Injury! Release of fluids
pressurized fuel system can cause
IMPORTANT: Avoid damage! Take care not to serious injuries. Relieve fuel system
bend the throttle (C) and choke (D) link rods pressure before servicing.
during installation.
B C E
2. Install the gaskets, insulator, carburetor and intake pipe D
with mounting bolts (B), and tighten them to 12 N•m (106
lb-in.).
3. Install fuel tube at the fuel inlet joint (A).

E
F
A

F I
H

MX16210

6. Loosen the fuel pressure relief screw (B) to relieve the

high pressure in the return fuel hose (C), and then tighten
MX16201 it.
• Be sure the fuel tube clip ends (F) face toward the 7. Disconnect the fuel return hose (C).
intake manifold (E) as shown.

Engine - Gas (Liquid-Cooled) Repair - 131

 ENGINE - GAS (LIQUID-COOLED) REPAIR
8. Disconnect the inlet fuel hose (D) coming from the fuel Tighten screws to 0.9 N•m (8 lb-in.).
pump, and the fuel return hose (E), and drain all the fuel in
the hoses into a suitable container. Installing:
9. Disconnect the breather hose (H). 1. Clean the mating surfaces of the throttle body assembly
and intake pipe, and install new gaskets.
NOTE: Recall position of longer and shorter cap
screws when removing throttle body assembly. NOTE: Take care not to bend the throttle link rod
during installation.
[Link] the intake pipe and throttle body assembly
long mounting bolts (F), short mounting bolts (I), and nuts 2. Install the gaskets, throttle body assembly, and intake
(G). pipe with mounting bolts and tighten them to 12 N•m (106
lb-in.).
[Link] the throttle link rod (A) at both ends before
pulling off the throttle body assembly and fuel pressure 3. Install remaining fuel hoses and be sure they are
regulator. clamped securely in place.
4. Adjust idle speed. (See “Low Idle Speed Adjustment” on
Disassembly and Assembly: page 110.)
NOTE: Do not attempt to remove the throttle valve and
shaft unless they appear to be damaged. Fuel Injector Removal and Installation - 25 HP
(FD711D)

c extremely
CAUTION: Avoid Injury! Gasoline is
flammable and can be explosive
under certain conditions. Turn the ignition
K
switch OFF. Do not smoke, and make sure
the area is well ventilated and free from any
J
source of flame or sparks.

L Procedure:

c from
CAUTION: Avoid Injury! Release of fluids
pressurized fuel system can cause
M
serious injuries. Relieve fuel system
pressure before servicing.
MX16211
1. Turn the fuel shut off valve to the OFF position.
1. Remove the screws (M), and remove the throttle valves
2. Relieve fuel line pressure:
(K).
2. Remove the circlip (L), and pull out the throttle shaft (J).
3. Before assembling, thoroughly clean the throttle body of
dirt by applying compressed air.
A
NOTE: Replace the dust seal of the throttle shaft with a
new one.
4. Apply engine oil to the new dust seal and insert the
throttle shaft (J).
5. Install the throttle shaft into the throttle body.
NOTE: After tightening screws (M), be sure that the
throttle valves are positioned properly, and the throttle MX15401, MX15402
shaft moves freely without any irregularities.
a. Loosen fuel pressure relief screw (A) on left side of
6. Install the throttle valves (K). Applying a non-permanent machine to relieve pressure.
locking agent to the screws (M), secure valves with screws.

Engine - Gas (Liquid-Cooled) Repair - 132

 ENGINE - GAS (LIQUID-COOLED) REPAIR
b. Tighten relief screw.
3. Remove air cleaner and related parts. (See “Air Cleaner
Removal and Installation” on page 128.) E F
4. Remove radiator. (See “Radiator Removal and
Installation” on page 124.)
5. Remove cooling fan and fan belt. (See “Cooling Fan and
Bracket Removal and Installation” on page 122.)
6. Remove fan mounting holder.
7. Remove throttle body assembly. (See “Throttle Body
Removal and Installation - 25 HP (FD711D)” on page 131.)
MX16217

[Link] the injector into the intake manifold.

B C [Link] place the projections (E) of the injector cap

into the holes (F) of the intake.
[Link] the injector connector and injector cap.
[Link] the throttle body, control panel assembly, radiator,
and air cleaner assemblies reverse of removal.

D Fuel Pressure Regulator Removal and

Installation - 25 HP (FD711D)
1. Remove air cleaner assembly. (See “Air Cleaner
MX16215 Removal and Installation” on page 128.)

c from
8. Remove the injector cap (B).
9. Disconnect the injector connector (C). CAUTION: Avoid Injury! Release of fluids
pressurized fuel system can cause
IMPORTANT: Avoid damage! Never drop the serious injuries. Relieve fuel system
injector, especially on a hard surface. This can pressure before servicing.
permanently damage the injector.
C
[Link] out the fuel injector (D) from the intake manifold.
NOTE: Take care not to damage the injector inserts A
when they are pulled from the throttle body.
[Link] injector for damage and test injector. (See “Fuel B D
Injector Test - X485 and X585” on page 320 in the
Electrical section.)
[Link] assembly, replace any seals and O-Rings with
new ones. Apply engine oil to the seal(s) and O-Ring(s).

MX14288

2. Loosen the fuel pressure relief screw (A) to relieve the

high pressure in the return fuel hose, and then tighten it.
3. Remove vacuum hose (B) and fuel return hose (C).
4. Remove two bolts (D) and remove the regulator.

Engine - Gas (Liquid-Cooled) Repair - 133

 ENGINE - GAS (LIQUID-COOLED) REPAIR
5. Check the vacuum tube hose (B), fuel return hose (C)
and O-Ring for brittleness, cracks, or damage, and replace F G
if necessary. E

6. Apply engine oil to the O-Ring.

#2 #1
7. Install fuel pressure regulator, vacuum hose (B) and
clamp, and fuel return hose (C) and clamp.
8. Tighten the two bolts (D).

Cylinder Head Removal and Installation

Removing:
MX14236
1. Remove radiator and it’s bracket.
7. Before removing the cylinder head, the piston should be
2. Remove air cleaner and carburetor assemblies (see set to TDC (Top Dead Center) on the intake stroke for the
carburetor removal). cylinder you are working on. This can be determined by the
3. Remove muffler. (See “Muffler Removal and Installation” position of the flywheel magnet (F) in relation to the coils.
on page 70.) • When setting the flywheel a TDC of the #1 cylinder,
4. Remove intake manifold. (See “Intake Manifold Removal align the flywheel magnet (F) with the #1 ignition coil
and Installation - 23 HP (FD671D)” on page 135 or “Intake (G). If it is not at TDC, turn the flywheel clockwise one
Manifold Removal and Installation - 25 HP (FD711D)” on turn (360°).
page 136.) • When setting the flywheel a TDC of the #2 cylinder,
turn the flywheel magnet (F) clockwise from position at
B TDC. of #1 cylinder to the #2 ignition coil (E). If it is not
at TDC, turn the flywheel clockwise one turn (360°).
A

IMPORTANT: Avoid damage! Cylinder head can be

A
warped during removal if the correct head bolt
removal procedure is not followed.
C
3 1
D

MX16112

5. Remove spark plug(s) (D). 6

5
6. Unscrew the eight (8) rocker cover mounting bolts (A),
and remove the left (B) and right (C) covers and gaskets.
NOTE: No. 1 cylinder is the left cylinder when sitting in
2 4
the drivers seat, No. 2 cylinder is the right.

MX11613

8. Loosen the cylinder head bolts 1/4 turn in the sequence

shown. Repeat the sequence until all bolts are removed
and lift off the cylinder head assembly.
NOTE: If removing push rods, Mark each rod for
assembly in original location.
9. Clean the mating surfaces of the cylinder heads and
cylinder of all old gasket material and sealing compound.

Engine - Gas (Liquid-Cooled) Repair - 134

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Installing: 4 6
1. Install push rods in their original positions if removed
(See push rod removal and installation).

F G
E
1
2
#2 #1

5 3

MX11613

MX14236 6. Install the cylinder head bolts, noting the position of

different length bolts. Tighten in the sequence shown
2. Set the cylinder you are working on to TDC of intake
above. Use a torque wrench and tighten in the following
power stroke.
steps to prevent warping the head:
• When setting the flywheel a TDC of the #1 cylinder,
• 3 N•m (27 lb-in.)
align the flywheel magnet (F) with the #1 ignition coil
(G). If it is not at TDC, turn the flywheel clockwise one • 15 N•m (11 lb-ft)
turn (360°). • 27 N•m (20 lb-ft)
• When setting the flywheel a TDC of the #2 cylinder, 7. Check valve clearance and adjust if necessary (see
turn the flywheel magnet (F) clockwise from position at valve clearance adjustment).
TDC of #1 cylinder to the #2 ignition coil (E). If it is not at
TDC, turn the flywheel clockwise one turn (360°). 8. Install gasket and rocker cover, tightening rocker cover
mounting bolts to 6.9 N•m (61 lb-in.).
H 9. Install spark plugs, intake manifold, muffler, carburetor,
air cleaner, and radiator in reverse order of disassembly.

Intake Manifold Removal and Installation - 23

I HP (FD671D)
Removing:
1. Remove air cleaner assembly. (See “Air Cleaner
Removal and Installation” on page 128.)
I
A

MX16114

3. Install the two alignment pins (I) in the cylinder head

assemblies (if removed).

IMPORTANT: Avoid damage! Cylinder head gaskets

(H) are coated with sealing agents. Gasket leaks
could occur if the sealing compound is scratched or
damaged.

4. Position new gaskets (H) on the cylinders. D C

B
5. Lower the cylinder head, with push rods aligned under MX16110
the rocker arms.
2. Remove muffler and two cap screws (C) securing
control panel.

Engine - Gas (Liquid-Cooled) Repair - 135

 ENGINE - GAS (LIQUID-COOLED) REPAIR
3. Remove the control panel assembly (B), while Installing:
unhooking the governor spring (D) end loop at the panel
bracket. 8
6
4. Clear the choke link rod end (A) form the choke lever.
5. Remove carburetor. (See “Carburetor Removal and E
Installation - 23 HP (FD671D)” on page 129.) 2

6. Drain the coolant in the engine. 4

3

8
6 1

5
E
2 7
F
4
3
MX16111

1. If removed, install the cylinder heads on each cylinder

1
and tighten the head bolts. (See “Cylinder Head Removal
5
and Installation” on page 134.)

7 2. Place new gaskets (F) on each mating surface, and

F install the manifold (E).
MX16111 3. Tighten the manifold mounting bolts in sequence above,
3.0 N•m (27 lb-in.) at a time, until the torque on each bolt is
7. Unscrew the manifold mounting nuts in numerical
20 N•m (15 lb-ft).
sequence, 1/4 turn at a time, until all bolts are loose.
4. Fill engine coolant.
8. Remove the manifold (E) and gaskets (F).
5. Install the carburetor, control panel assembly, and air
9. Inspect the intake manifold for signs of cracks or porous
cleaner assembly reverse of removal.
spots. Fuel stains on the surface of the manifold often
indicate a suspect area. Inspect the manifold gasket
mounting surfaces for burned areas or nicks and gouges. Intake Manifold Removal and Installation - 25
Replace the intake manifold if it is cracked, or the gasket HP (FD711D)
mounting surfaces are damaged to the point they will not
seal properly with new gaskets. Visually inspect the coolant Removing:
passage in the manifold for deposits or corrosion in layer
inside the passage; clean the passage if necessary.
[Link] all old gasket residue off the mating surfaces of
c from
CAUTION: Avoid Injury! Release of fluids
pressurized fuel system can cause
the intake manifold and the cylinder heads. Install new
serious injuries. Relieve fuel system
gaskets.
pressure before servicing.

1. Remove air cleaner assembly. (See “Air Cleaner

Removal and Installation” on page 128.)
2. Drain the coolant in the engine, and remove radiator.
(See “Radiator Removal and Installation” on page 124.)

Engine - Gas (Liquid-Cooled) Repair - 136

 ENGINE - GAS (LIQUID-COOLED) REPAIR

5 3
B 2 8

A C

D
E
F 4 6
7 1

MX16214
MX16216
3. Remove two cap screws (B) and bracket (A).
9. Unscrew the manifold mounting nuts in numerical
4. Remove two cap screws (E) securing control panel.
sequence, 1/4 turn at a time, until all bolts are loose.
5. Clear the throttle link rod end (C) from the choke lever.
[Link] the manifold (L) and gaskets.
6. Remove the control panel assembly (D), while
[Link] the intake manifold for signs of cracks or porous
unhooking the governor spring (F) end loop at the panel
spots. Fuel stains on the surface of the manifold often
bracket.
indicate a suspect area. Inspect the manifold gasket
7. Remove throttle body assembly. (See “Throttle Body mounting surfaces for burned areas or nicks and gouges.
Removal and Installation - 25 HP (FD711D)” on page 131.) Replace the intake manifold if it is cracked, or the gasket
mounting surfaces are damaged to the point they will not
I seal properly with new gaskets. Visually inspect the coolant
H
passage in the manifold for deposits or corrosion in layer
inside the passage; clean the passage if necessary.
G
[Link] all old gasket residue off the mating surfaces of
the intake manifold and the cylinder heads. Install new
gaskets.

Installing:
J

K 5 3
2 8

L
MX16215

8. Disconnect fuel injector leads (J), water temperature

lead (G), vacuum sensor lead (H), and thermo switch lead
(I).

4 6
7 1

MX16216

1. If removed, install the cylinder heads on each cylinder

and tighten the head bolts. (See “Cylinder Head Removal
and Installation” on page 134.)
2. Place new gaskets on each mating surface, and install
the manifold (L).

Engine - Gas (Liquid-Cooled) Repair - 137

 ENGINE - GAS (LIQUID-COOLED) REPAIR
3. Tighten the manifold mounting bolts in sequence above, 6. Install the starter, and two mounting bolts (C). Tighten
3.0 N•m (27 lb-in.) at a time, until the torque on each bolt is mounting bolts to 20 N•m (180 lb-in.).
20 N•m (15 lb-ft). 7. Install all electrical leads in reverse order of removal.
Install negative battery terminal (-).
I
H

Starter Motor Disassembly and Assembly

G
1. Remove the starter motor from the engine. (See
“Starting Motor Removal and Installation” on page 138.)

MX16215

4. Connect fuel injector leads (J), water temperature lead

(G), vacuum sensor lead (H), and thermo switch lead (I).
5. Fill engine coolant. A

6. Install the throttle body, control panel assembly, radiator,

and air cleaner assembly reverse of removal. MX11970

2. Pull back the rubber boot and remove the lead (A) from
Starting Motor Removal and Installation the starter motor to the solenoid.
1. Disconnect battery negative terminal (-).

A C
C
B B

MX11971

3. Unscrew the mounting nuts (B) and remove the solenoid

assembly (C).
MX14279

2. Disconnect battery terminal and leads from starting

motor solenoid terminal (B).
3. Disconnect switch lead (A) from starting motor.
4. Remove the two (2) mounting bolts (C) and pull the
starter motor from the engine.
5. Clean the starter motor and engine mounting flanges to
ensure good electrical contact when installing starter. If
corrosion is evident on either machined mounting surface,
clean the area with emery cloth or sandpaper.

Engine - Gas (Liquid-Cooled) Repair - 138

 ENGINE - GAS (LIQUID-COOLED) REPAIR

D
F
N
G

MX11972 MX11975

4. Pull the rubber insert (D) from the starter motor and 7. Pull the end cover (N) from the yoke and remove the
remove the pinion gear cover (E). Slip the actuating arm (F) insulator (O).
from the pinion gear. Remove the motor through bolts (G).

I P
H S
Q

MX11976
MX11973
8. Remove the brush springs (P) from the brush holder
5. Pull the armature (H) from the yoke (I). (Q). Separate the brushes (R) from the holder and remove
the holder from the yoke (S).

T
T
L
M L

MX11974 MX11974
6. Separate the front stopper (J) from the rear stopper (K) 9. Before beginning assembly apply a small amount of
and remove the front stopper from the armature shaft. Push electric grease to the indicated areas (T) of the armature
the rear stopper down the shaft and remove the snap ring shaft. Obtain a new snap ring (L). Assemble the pinion gear
(L). Pull the rear stopper and pinion gear (M) from the on the armature shaft with the new snap ring and install the
armature shaft. pinion assembly and actuating arm. Slide the yoke over the
armature.

Engine - Gas (Liquid-Cooled) Repair - 139

 ENGINE - GAS (LIQUID-COOLED) REPAIR

U
Z

MX11979
MX11979
10. Inspect the solenoid rubber boot (U) for visible damage
(hole, rips, dry rot etc.); replace if necessary. 13. Engage the hook (Z) on the starter solenoid with the
pinion gear fork. Install the solenoid mounting nuts.
14. Install the solenoid to starter motor lead. Install the
V
starter assembly onto the engine. (See “Starting Motor
W Removal and Installation” on page 138.)

Starting Motor Inspection

N 1. Disassemble starter. (See “Starter Motor Disassembly
and Assembly” on page 138.)

MX11975

11. Install the brush assembly and insulator on the yoke. Fit
A
the notch (V) in the (-) lead grommet onto the projection
(W) on the end cover (N). Install the end cover.

MX11984
X
2. Measure length of brush (A). If any brush is shorter than
6 mm (0.24 in.), replace all brushes. Inspect the brush
springs for any distortion or damage. Replace if necessary.

MX11981

12. Grease the pinion gear fork fingers, and set the pinion
gear fork so that the fingers fit into the groove in the gear.
Fit the notch (Y) in the yoke onto the projection (X) on the
pinion gear fork. Install the through bolts through the rear
cover and thread into the pinion gear cover.

Engine - Gas (Liquid-Cooled) Repair - 140

 ENGINE - GAS (LIQUID-COOLED) REPAIR
5. Measure the commutator outside diameter at several
points. If the diameter is less than 27 mm (1.06 in.) replace
the armature with a new one.

MX11980
MX11989
3. Inspect the surface of the commutator. If the surface is
scratched or dirty, polish it with very fine emery cloth (B) 6. Support the armature in an alignment jig at each end of
and then clean out the grooves (C). the shaft as shown. Position a dial indicator perpendicular
to the commutator. Rotate the armature slowly and read the
commutator runout. If runout is more than 0.4 mm (0.016
D
in.) replace the armature.

F
MX11987

4. Measure the depth of the grooves between the

MX11990
commutator segments (D). If groove depth is less than 0.2
mm (0.008 in.) undercut the insulating mica (E) to the 7. Set a multimeter to the R x 1 ohm position and check the
standard depth (F) of 0.5 to 0.8 mm (0.012 to 0.031 in.) resistance between each segment and all others. If the
using a thin file. If grooves are only dirty, clean them armature winding resistance registers either infinite or
carefully and measure depth before cutting the mica. much greater than 0 ohms the starter motor should be
replaced.

MX11988 MX11991

Engine - Gas (Liquid-Cooled) Repair - 141

 ENGINE - GAS (LIQUID-COOLED) REPAIR
8. With the multimeter in the R x 1 ohm position measure
the resistance between the armature shaft and the
commutator. If the resistance is less than infinite, the
armature is shorted and must be replaced.

- -

MX12000
G
[Link] the multimeter in the Rx 1 ohm position, measure
the resistance between the negative brushes and starter
motor yoke. If resistance is less than infinite on any brush,
MX11992 the brush is shorted and the complete yoke assembly must
be replaced.
9. Place the armature on a growler (G) and hold a thin
metal strip (e.g. a hack saw blade) on top of the armature.
Turn on the growler and rotate the armature one complete
turn. If the metal strip vibrates, the windings are internally
shorted to each other and the starter must be replaced.

- MX14440

[Link] the pinion clutch and turn it by hand. The clutch

should turn freely counterclockwise, and lock up and not
turn in a clockwise direction. If the clutch does not operate
MX11998 correctly or is noisy when freewheeling, replace it.
[Link] the multimeter in the Rx 1k ohm position, measure
the resistance between the positive brushes and starter
motor yoke. If resistance is less than infinite on any brush,
the brush is shorted and the complete yoke assembly must
be replaced.

Engine - Gas (Liquid-Cooled) Repair - 142

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Engine Removal and Installation 7. Remove cap screw (C) that secures battery shield to top
of frame.
Prepare Machine: 8. Compress positive battery cable retainer clip (D) and
• Park machine safely. See “Park Machine Safely” in the separate cable from battery shield.
SAFETY section.
9. Loosen two cap screws that secure slotted mounting
• Allow engine to cool. holes in battery shield to back of frame at locations marked
(E).
• Open hood.
[Link] and remove battery shield.
Removing:
[Link] right side lift bracket and muffler. (See “Muffler
1. Disconnect headlight connector and remove hood. Removal and Installation” on page 127.)
2. Remove radiator cap and drain coolant into a clean
container.
3. Disconnect and remove upper and lower radiator hoses.
4. Loosen clamp and remove air cleaner intake hose.
5. Disconnect and remove battery.
F

MX14375

[Link] lift bracket (F) back onto right side muffler flange
studs. Use two muffler flange nuts as spacers, then
A bracket, then two remaining nuts to secure bracket to studs.
This will prevent damage to valve cover from lifting hook
B during removal and installation.

L H
MX14370

Battery shield, right side view. K

G
6. Remove two cap screws (A) securing side brackets of
battery shield to frame and two nuts (B) securing hood
brackets to frame. I
P M O

D
R
E N

J
C

MX14376

Fuel injected engine, left side.

[Link] the wiring harness plug-in connectors (G, H,
MX14374 I, J) and bullet connector (K). Note: The carburated engine

Engine - Gas (Liquid-Cooled) Repair - 143

 ENGINE - GAS (LIQUID-COOLED) REPAIR
will have fewer connectors than the fuel injected engine
shown.
[Link] the retaining bolt at the rear of the left cylinder
head, remove wire harness J-clip and disconnect ground X
wire (L). X

[Link] positive battery cable (M) and power lead

bundle (N) at the starting motor terminal and unplug
X
solenoid wire (O).
[Link] the engine ground strap (P) and the main
wiring harness ground wire bundle (Q) by removing the left
front engine mount bolt (R), washer and nut.

T
MX13614
U
[Link] the three cap screws (X) at the rear of the drive
coupler and disconnect drive shaft from engine sheave.
NOTE: Fuel lines may be pressurized on the fuel
injected engine. Relieve pressure prior to servicing
fuel lines or components.

MX14378

Throttle cable and shield, fuel injected engine.

[Link] two cap screws retaining throttle linkage shield Y
(S) and remove shield.
[Link] throttle cable clamp (T) and disconnect cable
(U).

W
MX15401, MX14502

Fuel pressure relief screw, fuel injected engine.

[Link] fuel pressure by loosening pressure relief
screw (Y), then tighten screw.

MX15403

Carburated engine fuel lines.

[Link] and plug the fuel supply line (V) and fuel
return line (W) on carburated engine.

Engine - Gas (Liquid-Cooled) Repair - 144

 ENGINE - GAS (LIQUID-COOLED) REPAIR

Z AD

AA

AB

AC AC

MX16001 MX16004

Fuel injected engine, right side. [Link] engine hoist to lift hooks on engine using
spreader bar (AD) with lift chains to avoid damage to air
[Link] and plug the fuel return line (Z), and cleaner during removal.
disconnect the supply line quick-coupler (AA) at the top of
the fuel filter (AB), on the fuel injected engine. [Link] engine slightly and pull away from radiator to clear
shroud and fuel filter, then remove engine from machine.
[Link] the two right side engine mount bolts (AC),
washers and nuts, and the left rear motor mount bolt, Installing:
washer and nut.
1. Lower the engine so that it rests slightly on the engine
[Link] any hydraulic lines that may be supported by J- mounts.
clips or other hardware connected to the bottom of the
engine. 2. Align the engine and mounts, then install the two right
side and the left rear engine mount bolts, washers and nuts
NOTE: If no spreader bar is available, remove air finger tight.
cleaner assembly and cover fuel injection air intake
3. Lower engine fully, disconnect hoist from engine lifting
hole with a clean shop rag to prevent entry of foreign
brackets and remove hoist.
objects.
4. Route ground wire bundle from main wiring harness to
original position by left front engine mount.
5. Install engine ground strap and ground wire bundle from
main wiring harness with left front engine mount hardware,
tighten hardware finger tight.
6. Tighten all engine mount bolts to 50 N•m (37 lb-ft).
7. Align drive coupler with engine sheave, install drive
coupler mounting bolts and tighten to 40 N•m (30 lb-ft).
8. Unplug and connect fuel return hose and connect fuel
supply hose quick-coupler to fuel filter.
9. Secure any hydraulic hoses, if removed in an earlier
step, to appropriate hardware attached to the bottom of the
engine.

Engine - Gas (Liquid-Cooled) Repair - 145

 ENGINE - GAS (LIQUID-COOLED) REPAIR
[Link] wire harness J-clip and ground wire to back of
left cylinder head with retaining bolt and tighten.
[Link] main wire harness plug-in connectors and
bullet connector to the corresponding engine connectors.
[Link] the main wiring harness power lead bundle A
and positive battery cable to the starter terminal, and
connect the solenoid plug.
[Link] and adjust throttle cable. (See “Throttle Cable
B
Adjustment” on page 109.)
[Link] throttle cable shield.
[Link] the right side lift bracket and four flange nuts
from the muffler flange studs.
MX16077
[Link] new muffler gaskets. 4. Hold flywheel with strap and remove flywheel bolt (A).
[Link] the muffler and the right side lifting bracket in their 5. Thread a flywheel puller into the pulling holes (B) and
original locations and tighten mounting hardware. (See remove the flywheel.
“Muffler Removal and Installation” on page 127.)
6. To remove stator coil, see “Stator Replacement” on
[Link] battery shield and attach positive battery cable page 326 in the Electrical section.
retainer clip.
7. To remove ignition coil, see “Ignition Coil Replacement”
19. Install battery and connect positive battery cable. on page 325 in the Electrical section.
[Link] and tighten upper and lower radiator hoses. 8. Align the flywheel keyway with the key on the crankshaft
[Link] radiator coolant. and install flywheel.
[Link] hood and connect headlight plug.
[Link] negative battery cable.

C
Flywheel Removal and Installation
Procedure:
1. Park machine safely. See Parking Machine Safely in
Safety section.
2. Remove engine from machine. (See “Engine Removal
and Installation” on page 143.)
3. Remove plastic cover surrounding lower half of flywheel,
and outer sheave attached to flywheel.
MX16079

9. Install spring washer (C) as shown.

[Link] and tighten the flywheel bolt.
[Link] engine into machine.

Specification:
Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft)

Engine - Gas (Liquid-Cooled) Repair - 146

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Push Rod/Rocker Arm Removal and Inspection:
Installation
Removing:
1. Set the piston on the cylinder you are working on at top
dead center (TDC) of the power stroke.
2. Remove rocker covers (see cylinder head removal). H

A
C
B B

C
I

A MX16116
E D • Clean the rocker arms and inspect the push rod and
D valve stem contact points (I). If the contact surfaces are
excessively worn or show signs of galling or surface flaking,
replace the rocker arm.
• Measure the inside diameter of the rocker arm bearing
(B) at several points using a dial bore gauge or inside
MX11613
micrometer. If the inside diameter is more than the service
3. Remove the valve clearance adjusting nuts (A), limit, replace the rocker arm.
washers, and bolts (C).
Rocker Arm Bearing Inside Diameter:
4. Remove the rocker arms (E), along with collars (D), to
provide access to the push rods (B). Pull out the push rods Service Limit. . . . . . . . . . . . . . . . . . 11.05 mm (0.435 in.)
and mark each rod so it can be installed in the original
position during reassembly.

MX11799

MX16115 • Inspect the push rods for damage or excessive runout.

Place each push rod in V blocks set as near to the ends of
5. Remove two bolts (F) and rocker arm bracket (G).
the rod as possible. Set up a dial gauge at the center point
of the push rod. Turn the rod to measure the runout. Check
the difference between the highest and lowest dial readings
to determine runout. If this figure exceeds 0.5 mm (0.02
in.) the push rod must be replaced.

Engine - Gas (Liquid-Cooled) Repair - 147

 ENGINE - GAS (LIQUID-COOLED) REPAIR

MX16117
L
• Measure the inside diameter (J) of the rocker arm collar
(D) with a micrometer at several points of the bearing of the
rocker arm. If the outside diameter is less than the service
M
limit, replace the rocker arm collar.

Rocker Arm Collar Outside Diameter:

Service Limit . . . . . . . . . . . . . . . . . . . 10.91 mm (0.43 in.)

Installing:
1. Set the piston at TDC on the cylinder you are working on N
before beginning push rod installation.
MX11802

G 3. Install each push rod (K) in its original position by

inserting the end of the rod so it is sliding along the inside
wall of the crankcase (L). Position the push rod on the
tappet (M).
4. Check that both intake and exhaust push rods on the
F cylinder you are assembling are at the lowest position on
the cam lobes (N). If not, turn the flywheel clockwise one
F
turn (360o) and reset the piston at TDC of the power stroke.

MX16115

2. If removed, install bracket (G) and two bolts (F). Tighten

bolts to 22 N•m (16 lb-ft).
P
A

C
D
E
Q
MX16117

5. Insert the collar (D) into the rocker arm hole so that the
groove (P) of the collar faces upward, then set them on the
bracket (O), positioning the push rod ends onto the rocker
arm detents.

Engine - Gas (Liquid-Cooled) Repair - 148

 ENGINE - GAS (LIQUID-COOLED) REPAIR
6. Insert the washer (Q) onto the bolt (C), and insert the 4. Support the valve heads inside the combustion chamber
bolt into the hole at the right side of the bracket and through with a suitable block such as a piece of wood.
the collar installed with the rocker arm.
5. Remove the spring retainer (E) by pushing down with
7. Install the nut (A) onto the bolt and tighten the nut your thumbs and removing the collets (G).
temporarily.
6. Remove the spring (H) and valve (F).
8. Apply clean engine oil to the rocker arm pivot seat area
NOTE: Bottom spring retainer (J) can only be removed
and the contact points on the arm when reinstalling the
with stem seal.
rocker arms. Perform a valve clearance adjustment as
detailed in the Engine Tests and Adjustments section of this
manual. I

9. Install rocker covers.

Valve Train Removal and Installation

J
Procedure:
1. Remove cylinder head. (See “Cylinder Head Removal
and Installation” on page 134.)
NOTE: When removing valve train, mark all parts so
they can be reinstalled in their original position.
K

C MX16120
A 7. Remove the stem seals (I). Stem seal replacement is
B
not mandatory on a low hour engine, but is recommended,
B particularly if a new valve has been installed.
NOTE: Valve guides (K) are not replaceable. If a valve
guide is damaged or worn beyond maximum
A specifications, the head casting must be replaced.
D
8. Check to see if the valve seats properly in the valve
seat. If not, resurface the valve seat and/or replace the
valve.
9. Install new stem seals if necessary.

MX11613 [Link] engine oil to the valve stem to avoid damaging the
valve stem seal. Install the valve and check for smooth
2. Remove valve clearance adjusting nuts (A), bolts (B) operation in the valve guide. Replace valve if valve binds in
and associated hardware to remove rocker arms (D). guide, or guide to stem clearance is excessive.
3. Remove rocker arm bracket (C). [Link] valve spring, collets and spring retainer on the
valve.
F [Link] rocker arm bracket (C).

E G [Link] clean engine oil to the rocker arm at the spherical

pivot seat, and the points where the arm contacts the push
rod and the valve stem end.
[Link] the rocker arm (and associated hardware) on the
rocker arm bracket, and tighten the bolt and nut temporarily.
H Perform a valve adjustment as detailed in Valve Clearance
Inspection and Adjustment in the Engine Tests and
Adjustments section.

MX16119

Engine - Gas (Liquid-Cooled) Repair - 149

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Crankcase Cover Removal and Installation
Procedure:
c and
CAUTION: Avoid Injury! Clean the crankcase
cover in a well ventilated area where no
1. Remove engine from machine. (See “Engine Removal sparks or flames are present including
and Installation” on page 143.) appliance pilot lights. Never use gasoline or a
2. Drain engine oil. low flash-point solvent to clean parts. A fire or
explosion could result.

7. Clean the mating surfaces of the cover and the

crankcase using a high flash point solvent. Blow out the oil
passage in the cover using compressed air.
8. Replace the crankshaft PTO oil seal if necessary. Note
the following while replacing this seal:

A
E
B

MX16110

3. Remove governor control panel (B) and governor arm I G

H
(A). (See “Governor Assembly Removal and Installation” on
page 152.)
4. Remove rocker covers. (See “Cylinder Head Removal
and Installation” on page 134.)

3 MX11847
C
6 • The crankshaft PTO oil seal is installed with the
marks (E) facing out. Press the new seal into the cover
7 until it is flush with the flange surface (F). Pack high
10 temperature grease (H) into the space between the seal
lip (G) and the dust lip (I).
9
8

5
4
D 1 2
D

MX16129

5. Remove the ten (10) cover mounting bolts and remove

the crankcase cover (C) from the crankcase. There are two
knock points (D) on the cover where a plastic or wood
mallet can be used to gently tap the cover loose.
6. Remove the crankcase cover gasket and any gasket
residue from both the cover and the crankcase mating
area.

Engine - Gas (Liquid-Cooled) Repair - 150

 ENGINE - GAS (LIQUID-COOLED) REPAIR
8
K C
5

4
1

J J
2
3

6
7
J 10 9

MX16129
L M 12. Install the crankcase cover (C). Noting the different
length of bolts, tighten the bolts 1/2 turn at a time in the
sequence shown, and to a final torque of 22 N•m (16.0 lb-
ft) when all bolts are tight.
N
[Link] rocker covers. (See “Cylinder Head Removal and
Installation” on page 134.)
[Link] governor control panel and governor arm. (See
“Governor Assembly Removal and Installation” on
MX16130
page 152.)

9. Check to see that the O-Rings (L) are in place on the [Link] engine with approximately 1.8 L (1.9 qt) of oil.
crankcase as shown above. [Link] engine onto machine. (See “Engine Removal and
[Link] silicone sealant bead (J), 1 - 2 mm (0.04 - 0.08 Installation” on page 143.)
in.) wide, to mating surface (K) of the crankcase (in areas
shown above). Crankcase Cover Inspection

c sealant
Procedure:
CAUTION: Avoid Injury! Do not get the
into the oil line hole (M) on the
crankcase or crankcase cover.

[Link] that the crankshaft dowels (N) are in place on the

crankcase and install a new gasket on the crankcase.
A
IMPORTANT: Avoid damage! If one cover bolt at a
time is tightened completely, the cover could be
warped.

MX16135

1. Drain engine oil and remove the crankcase cover. (See

“Crankcase Cover Removal and Installation” on page 150.)
2. Measure the inside diameter (A) of the PTO shaft
bearing at several points. This bearing is not replaceable. If
it is damaged, or the inside diameter is more than 42.09
mm (1.66 in.) the crankcase cover must be replaced.
3. Install crankcase cover. (See “Crankcase Cover
Removal and Installation” on page 150.)
4. Replace engine oil.

Engine - Gas (Liquid-Cooled) Repair - 151

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Governor Assembly Removal and Installation 5. Insert the bracket (G) onto the governor shaft (H) to the
bottom of the woodruff are of the shaft, and tighten the
Governor Arm Removal and Installation: clamp nut (D) to 8 N•m (69 lb-in.).
6. Install the control panel assembly, and connect the
B
bracket with the governor spring (M).
7. Install the end of throttle link rod (B) with the link spring
(J) around it into the governor arm hole (I) and the other
A end into the carburetor throttle lever (K) hole.
8. Install the governor arm (A) on the bracket (G) with the
bolt (F) and washer by turning the bolt counterclockwise so
the projection of the bracket fits into the governor arm hole
(E).
9. Loosen the bolt (F), and fully turn the bracket (G)
counterclockwise and hold it there.
C
D [Link] the top end of the governor arm (A)
MX16110 counterclockwise to fully open the carburetor throttle valve
23 HP (FD671D) engine shown; 25 HP (FD711D) and tighten the bolt (F).
engine does not have choke assembly.
Governor Removal and Installation:
1. To remove the governor arm, remove governor control

c governor
panel (C).
2. Loosen the clamp nut (D) and take off the governor arm CAUTION: Avoid Injury! Do not remove the
(A). assembly unless it is necessary.
Once it has been removed, it must be
3. Clear the throttle link rod (B) from the governor arm and replaced.
choke lever.
1. Remove crankcase cover. (See “Crankcase Cover
4. Disassemble remaining parts, and visually inspect for
Removal and Installation” on page 150.)
wear or damage; replace, as necessary.
NOTE: To avoid damage to the surface of crankcase
cover, use suitable soft mats (C) as shown below.

C
B

J
G A
H B
F
I
E D L

MX16191

2. Remove the governor assembly (A) with the sleeve (B)

by prying the gear with two proper size screw drivers.
M A 3. Remove the thrust washer.
MX14226

23 HP (FD671D) engine shown;

25 HP (FD711D) engine does not have choke
assembly parts (L).

Engine - Gas (Liquid-Cooled) Repair - 152

 ENGINE - GAS (LIQUID-COOLED) REPAIR
B E

F
C

F D
A
D
E

MX16192 MX16194
4. Install thrust washer (C). 4. The oil seal (E) must be assembled with the seal lip
5. Fit the sleeve (B) into the governor assembly (A), and towards inside of the engine.
install them as a set. 5. Press in the oil seal approximately 1.0 mm (0.04 in.) (D)
flush or below the crankcase surface (F).
NOTE: The sleeve (B) and the governor assembly (A)
cannot be installed separately. Push the set onto the
shaft (E) until inner flange (F) snaps into the groove (D)
securely.
6. Spin the governor assembly by hand and check that the
flyweights operate freely and the center sleeve moves C
outward.

Governor Shaft Removal and Installation: B

1. Remove camshaft. (See “Camshaft/Tappet Removal
and Installation” on page 161.)
A
2. Unscrew the governor arm clamp nut, and remove the
governor arm. (See “Governor Arm Removal and
Installation:” on page 152.)
MX16193

6. Apply engine oil to the governor shaft (C).

7. Insert the governor shaft into the crankcase and washer
(A).
8. Fit the circlip (B) securely into the groove of the
C
governor shaft (C), as shown above.
9. Check that the governor shaft moves freely in its
B operating range.

MX16193

3. Remove the circlip (B) on the governor shaft (C), and

remove the governor shaft and washer (A).
NOTE: Replace the oil seal only if the lip shows signs
of leakage or it has been damaged. If the oil seal is
removed, install it after the shaft (C) is installed.

Engine - Gas (Liquid-Cooled) Repair - 153

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Piston Removal and Installation
Removing:
F
1. Remove cylinder heads (See Cylinder Head Removal/
Replacement).
E
2. Remove the crankcase cover and the camshaft. (See
“Camshaft/Tappet Removal and Installation” on page 161.)

MX11819

MX16122

3. Turn the crankshaft to expose the connecting rod cap

bolts (A). Remove the bolts and take off the connecting rod
caps (B).

IMPORTANT: Avoid damage! Note location of the

arrow mark (F) on the piston head in relation to the MX16124
“Made in Japan” mark on the connecting rod. The
5. Remove one of the piston snap rings (I) with a needle
“Made in Japan” mark (D) on the No. 1 cylinder (C)
nose pliers (H).
connecting rod must be face to face with the “Made
in Japan” mark (E) on the No. 2 cylinder (G) 6. Push the piston pin out the side where the snap ring
connecting rod. Keep components together as a was removed and remove the piston from the rod.
matched set. 7. Remove the top and second rings with piston ring pliers.

J
F

D E

C G
MX11820

8. If piston ring pliers are not available, carefully spread the

MX16123
ring opening with your thumbs and push up on the back
4. Push the connecting rod end up into the cylinder, and side of the ring (J) to remove it.
pull the piston and connecting rod assembly out the top of
the cylinder. 9. Remove the 3-piece oil ring using the thumb method.

Engine - Gas (Liquid-Cooled) Repair - 154

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Installing:
1. Inspect and clean the piston and rings before installation
(See Piston Assembly Inspection).
P
O
R
L
P Q
K O

Q
R

MX11823

5. Orient the ring gaps on the piston as shown:

• O - piston arrow mark
MX11821 • P - top ring and upper steel rail end gaps
2. Install a new oil control ring on the piston in the following • Q - 30o - 45o
sequence:
• R - second ring and lower steel rail end gaps
• Install the expander (K) in the oil ring groove with the
ends (L) touching together, not overlapping.
• Install the upper and lower steel rails. Rails are
interchangeable and do not have an up or down
F
orientation.

D E
M

N C G

MX16123

6. Apply fresh engine oil to the piston pin and assemble

the piston for the #1 cylinder (C) with the arrow mark (F)
facing away from the “Made in Japan” mark (D) on the
MX11822
connecting rod.

3. Install the scraper ring (N) in the second groove with the 7. Apply fresh engine oil to the piston pin and assemble
notch facing down. the piston for the #2 cylinder (G) with the arrow mark (F)
facing the “Made in Japan” mark (E) on the connecting rod.
4. Install the compression ring (M) in the first groove with
the bevel facing down.

Engine - Gas (Liquid-Cooled) Repair - 155

 ENGINE - GAS (LIQUID-COOLED) REPAIR

T W

MX16125 MX16127

8. Fit new piston pin snap rings to both pistons. Align the 11..Insert the piston and rod assembly in the cylinder bore
snap ring gap (S) so it does not align with the piston pin with the arrow mark on the piston (W) facing the flywheel
hole notch (T). (X). Lightly tap the top of the piston with a plastic mallet (V)
to insert the piston assembly in the bore.
IMPORTANT: Avoid damage! Do Not reuse piston pin
snap rings. Weakened and deformed snap rings Y
could fall out causing engine damage. Use only new
snap rings when reinstalling pistons.
AA
9. Apply fresh engine oil to the piston skirt and cylinder
bore.
Z
U AB AC

U AA

AC
Y

V MX11830

MX16126 [Link] engine oil to the inner surface (Y) of the

10..Use a piston ring compression tool (U) to compress the connecting rod big end (Z) and caps (AA).
piston rings.
IMPORTANT: Avoid damage! The connecting rod
and rod big end cap are machined as a matched set.
They must be replaced as a set in their original
position on the crankshaft.

[Link] the rods on the crankshaft, and install the big end
rod caps in their original position.
[Link] a small amount of engine oil to the thread (AB)
and seating surface of the rod cap bolts. Install bolts (AC)
and tighten to 21 N•m (186 lb-in.).
[Link] the camshaft and the crankcase cover. (See
“Camshaft/Tappet Removal and Installation” on page 161.)

Engine - Gas (Liquid-Cooled) Repair - 156

 ENGINE - GAS (LIQUID-COOLED) REPAIR
[Link] cylinder heads. (See “Cylinder Head Removal
and Installation” on page 134.)
C

Inspect Piston and Cylinder

Procedure:

MX11833

4. Check piston ring grooves for wear by inserting a new

ring in the piston and measuring the clearance between
piston and ring with a feeler gauge (C). Wear should not
exceed:
• Top and Second Ring - 0.15 mm (0.006 in.)
MX11831
If piston ring groove clearance is greater than specified,
1. Remove the piston and piston rings. (See “Piston replace the piston.
Removal and Installation” on page 154.)
NOTE: The three piece oil ring is difficult to measure
IMPORTANT: Avoid damage! Never attempt to clean for ring groove clearance. Check both ring and piston
carbon deposits with the piston in the engine. groove visually for damage or wear and replace either
Carbon particles will fall between the piston and component as necessary.
cylinder and could damage crankshaft bearings and
seals.

2. Scrape carbon deposits off the piston head (A) using an

appropriate scraper that will not gouge or scratch the
piston.

c edges
CAUTION: Avoid Injury! The top and bottom
of the ring may be extremely sharp.
D

MX11834

5. Worn rings normally show visual evidence of wear such

as surface scratches or an extremely shiny sealing surface.
If you are considering reusing rings measure the following:
• Ring Thickness - Use a micrometer to measure at
several points around the ring (D). The minimum service
limit for both the top and second ring is 1.40 mm (0.055
in.). If any measurement is less than the service limit,
replace the entire set of rings.
MX11832

3. Clean the piston ring grooves (B) with a broken ring or a

suitable tool.

Engine - Gas (Liquid-Cooled) Repair - 157

 ENGINE - GAS (LIQUID-COOLED) REPAIR
cracked or porous casting, and through the push rod
compartment (H). If coolant leakage appears in the
push rod compartment, replace the crankcase.
E
• Check the cylinder head gasket. If coolant is leaking
through gasket surfaces, check the gasket surfaces (I)
for traces of the leakage, and check to make sure the
cylinder head and block surfaces are smooth, clean and
F
level.

MX16128

• Piston Ring End Gap - Use the piston to push each

piston ring (E) into the cylinder bore to a point close to
the bottom of the cylinder bore. Measure the gap (F)
between the ends of the ring with a feeler gauge.
J
Top and Second Ring End Gap - 1.00 mm (0.04 in.)
service limit
MX11838
Oil Ring End Gap - 1.2 mm (0.05 in.) service limit
7. Measure the outside diameter of the piston pin with a
If any measurement is greater than the service limit, micrometer at several points (J). If the outside diameter is
replace the entire set of rings. less than 18.96 mm (0.747 in.) the piston pin must be
replaced.
H

G K

MX16149 MX11839

6. Inspect the crankcase for an accumulation of dust, 8. Measure the inside diameter of the piston pin with a dial
scale, and lime in the water jacket (G). If this accumulation bore gauge at several points (K) on both sides of the piston.
is observed, flush the cooling system. If the inside diameter is greater than 19.08 mm (0.751 in.)
the piston must be replaced.
NOTE: A cracked or porous casting is not visible to the
eye. If evidence of leakage of coolant from any
suspected area is found, replace the crankcase.
• Inspect the crankcase for coolant leakage outside the
water jacket. Small leaks may appear only as rust,
corrosion or stains, due to evaporation. If this is
observed, tighten bolts and/or replace the cylinder head
gasket.
• Inspect the crankcase for coolant leakage into the
engine. Leakage occurs through a loose cylinder head,

Engine - Gas (Liquid-Cooled) Repair - 158

 ENGINE - GAS (LIQUID-COOLED) REPAIR

MX11840

9. Measure the inside diameter of the connecting rod small

end with a dial bore gauge (L) at several points. If the inside
O
diameter is greater than 19.06 mm (0.75 in.) the piston
must be replaced. M86883

[Link] the cylinder and inspect the bores for scoring,

signs of seizure or ridges at the top or bottom of the
cylinder.
[Link] the cylinder inside diameter (O) using a dial
bore gauge. Measure the cylinder front to back and side to
side at the following points:
• 10 mm (0.394 in.) from top of cylinder
• 10 mm (0.394 in.) from bottom of cylinder
N
• 55 mm (2.165 in.) from top of cylinder
[Link] any of the cylinder bore measurements are greater
M than the following service limits, the cylinder must be bored
and honed (see Resizing Cylinder Bore and Cylinder Bore
Honing). If cylinder bores are within specifications and
MX11841 show no signs of damage, new piston rings may be fitted
[Link] the outside diameter of the piston (M) at a provided the cylinder bores are honed. This will restore the
point (N), 11 mm (0.43 in.) up from the bottom of the piston proper cross hatch angle in the cylinder bores ensuring
and 90 degrees from the piston pin hole. If the outside proper lubrication and piston ring rotation.
diameter is less than 77.7 mm (3.06 in.), the piston must • Standard Cylinder Bore Inside Diameter: 78.00 mm
be replaced. (3.071 in.)
• Standard Cylinder Bore Service Limit: 78.08 mm
(3.074 in.)
• 0.5 mm Oversize Cylinder Bore Inside Diameter:
78.50 mm (3.091 in.)
• 0.5 mm Oversize Cylinder Bore Service Limit: 78.58
mm (3.094 in.)
• Standard Cylinder Bore Out-of-Round Service Limit:
0.056 mm (0.022 in.)

Engine - Gas (Liquid-Cooled) Repair - 159

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Cylinder Bore Honing Cylinder Bore Resizing
Procedure: Procedure:
NOTE: To produce the proper cross hatch finish use a
drill speed of approximately 200 rpm and 40 - 60
A
strokes per minute. Lubricate hone liberally to prevent
build up on finishing stones.

B
A

G C

M86885

1. The cylinder finish, (Cross Hatch) should be applied

after cylinder bore has been resized to within 0.007 - 0.009
mm (0.0003 - 0.0004 in.) of the desired size or when E
reconditioning a cylinder bore. The finishing stones will
produce the correct cross hatch necessary for proper
lubrication and piston ring rotation. The correct hatch angle F
is approximately 45° (A). D
2. It is recommended that the cylinder bores be
reconditioned to restore the cross hatch when new piston E
rings are to be installed in a cylinder that is within M88942
specification. Be careful not to hone oversize or it will be
necessary to resize the cylinder. 1. If the cylinder bore is not within specifications, it will
have to be resized using a boring bar or hone. Always
resize to exactly 0.50 mm (0.020 in.) over standard size.
IMPORTANT: Avoid damage! Ensure that the entire
cylinder and crankcase are thoroughly cleaned after 2. If this is done accurately, the service oversize rings and
honing. First wash the cylinder and crankcase pistons will fit perfectly and proper clearances will be
carefully in a solvent such as kerosene or maintained.
commercial solvent. Then thoroughly wash cylinder
and crankcase using a stiff brush with soap and hot IMPORTANT: Avoid damage! If a boring bar is used,
water. Rinse thoroughly with hot running water. a hone must be used after the boring operation to
Repeat washing and rinsing until all traces of honing produce the proper cylinder cross hatch. See
grit are gone. Honing grit is highly abrasive and will ‘CYLINDER BORE HONING’.
cause rapid wear to all of the internal components of
the engine unless it is completely removed. 3. If a hone is used to resize the cylinder bore, place hone
(A) in middle of cylinder bore (C). Tighten adjusting knob
3. When cylinder and crankcase have been thoroughly with finger until stones fit snugly against cylinder wall. DO
cleaned, use a white rag or napkin and wipe the cylinder NOT FORCE.
bore. If honing grit is present, it will appear as a grey
4. Connect drive shaft to hone. Be sure that cylinder and
residue on rag. If any honing grit is evident, re-wash and
hone are centered and aligned with drive shaft and drill
rinse entire cylinder and crankcase and check again. When
spindle. Lubricate hone as recommended by hone
cleaning is complete, oil cylinder bore to prevent rusting.
manufacturer.

Engine - Gas (Liquid-Cooled) Repair - 160

 ENGINE - GAS (LIQUID-COOLED) REPAIR
5. The recommended drill speed is 300 to 700 rpm 6. Turn the crankcase up side down so that tappets fall
maximum and 40 - 60 strokes per minute. away from cam lobes. Pull the camshaft out of the
crankcase.
6. Because cylinder bores normally wear (H) only in the
area of ring travel (B), the cylinder bore will be round above
and below ring travel (G).
C
7. Start drill and, as hone spins, move it up and down at
the bottom of the cylinder bore (D).
8. Gradually increase the length of the strokes until hone
travels full length of cylinder bore (F). Do not travel more
than 19.05 mm (0.750 in.) to 25.4 mm (1.0 in.) above
cylinder bore (E).
9. Lubricate hone frequently to prevent build up on stones.
[Link] cutting tension decreases, stop hone and tighten
adjusting knob following hone manufacturer’s
recommendations. MX16139
[Link] cylinder bore size frequently. 7. Remove the tappets (C) and mark them for
[Link] cylinder bores at top and bottom for burrs. reinstallation.
Remove burrs. Cylinder head and crankcase cover 8. Before reinstalling tappets and camshaft apply fresh
surfaces must be free of burrs and gasket material. engine oil to:
[Link] cylinder bore has been brought to proper resizing • Tappet Journals
dimension, a cross hatch must be applied to bore.
• Camshaft Journals
Camshaft/Tappet Removal and Installation • Cam Lobe Surface
• Camshaft Gear
Procedure:
9. With the crankcases turned upside down, install the
1. Remove engine and drain oil. (See “Engine Removal tappets in their original positions.
and Installation” on page 143.)
2. Remove crankcase cover. (See “Crankcase Cover
Removal and Installation” on page 150.)
3. Remove rocker covers. (See “Cylinder Head Removal D
and Installation” on page 134.)
4. Place the piston at Top Dead Center (TDC) for the
cylinder you are working on.

MX16141

[Link] the camshaft into position in the crankcase,

B aligning the punch marks on the crankshaft gear (D) and
camshaft gear (E).
[Link] crankcase cover with a new gasket.
[Link] pushrods and check valve clearances before
MX16113 reinstalling rocker covers. (See “Valve Clearance
Adjustment” on page 112.)
5. Remove rocker arms (B) and push rods (A). (See “Push
Rod/Rocker Arm Removal and Installation” on page 147.) [Link] remaining components in the order they were
removed. Fill engine with new oil.

Engine - Gas (Liquid-Cooled) Repair - 161

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Camshaft Disassembly and Inspection
Procedure:
E

MX16144

B 5. Measure both camshaft journals (E) at several points

around the journal circumference. If any journal is worn
MX16142 less than the service limit, replace the camshaft.
1. Inspect camshaft gear (A) for pitting, fatigue cracks,
burrs or uneven wear due to improper tooth contact.
Replace camshaft if necessary. F

IMPORTANT: Avoid damage! Damaged or worn cam

lobes usually indicate damaged tappets. Check
tappets when replacing camshaft.

2. Check the top of the cam lobes (B) for signs of uneven
wear, grooving, pitting or flaking of hardened wear area.
Replace camshaft if any of these conditions exist.

C
MX16145

B 6. Measure inside diameter (F) of the camshaft bearing

bore in crankcase at several points. This bearing is not
serviceable, so it will be necessary to replace the
D crankcase if the inside diameter is greater than the service
limit.

E
G
MX16143

3. Remove the spring (C) from the ACR (Automatic

Compression Release) assembly. DO NOT attempt to
remove the ACR weight. If the ACR weight (D) is damaged,
or does not swing freely when shaking the cam, the
camshaft must be replaced.
4. Measure the height of each cam lobe (B), if less than
service limit replace camshaft.
MX16146

Engine - Gas (Liquid-Cooled) Repair - 162

 ENGINE - GAS (LIQUID-COOLED) REPAIR
7. Measure inside diameter (G) of the camshaft bearing
bore in crankcase cover at several points. This bearing is
not serviceable, so it will be necessary to replace the A
crankcase cover if the inside diameter is greater than the
service limit.
8. Install a new spring on the ACR assembly.
9. Install the camshaft in the crankcase. (See “Camshaft/
Tappet Removal and Installation” on page 161.)

Cam Lobe Height:

Service Limit . . . . . . . . . . . . . . . IN 33.594 mm (1.323 in.)
. . . . . . . . . . . . . . . . . . . . . . . . . EX 33.594 mm (1.323 in.)
MX16147
Camshaft Journal Diameters:
PTO Side . . . . . . . . . . . . . . . . . . . . 19.927 mm (0.785 in.) 5. Pull the crankshaft (A) out of the crankcase. It may be
necessary to tap on the crankshaft with a wood or plastic
Flywheel Side . . . . . . . . . . . . . . . . 19.927 mm (0.785 in.)
mallet to loosen the crankshaft.
Camshaft Bearing Bores: 6. Before installing the crankshaft, clean the crankshaft
Crankcase Camshaft Bore . . . . . . 20.081 mm (0.791 in.) journals and the crankcase bearing surfaces thoroughly.
Crankshaft Cover Camshaft Bore 20.081 mm (0.791 in.) 7. Pack high temperature grease into the crankcase oil
seal.
Crankshaft Removal and Replacement 8. Apply engine oil to the crank journals and bearing
surfaces and carefully insert crank (A) into the main
Procedure: bearing and oil seal in the crankcase.
1. Remove engine and drain oil. (See “Engine Removal 9. Install pistons and rods on crankshaft (see Piston
and Installation” on page 143.) Removal/Replacement).
2. Remove flywheel. (See “Flywheel Removal and [Link] camshaft and tappets. (See “Camshaft/Tappet
Installation” on page 146.) Removal and Installation” on page 161.)
[Link] a new crank oil seal if necessary in the crankcase
c mated
CAUTION: Avoid Injury! Used tappets are
to their camshaft lobes. Mark them for
cover. Install the crankcase cover. (See “Crankcase Cover
Removal and Installation” on page 150.)
installation in the same bore they were
removed from. Crankshaft Inspection
3. Remove camshaft and tappets. (See “Camshaft/Tappet Procedure:
Removal and Installation” on page 161.)
1. Remove crankshaft. (See “Crankshaft Removal and
4. Remove connecting rod and piston assemblies. (See Replacement” on page 163.)
“Piston Removal and Installation” on page 154.)
2. Clean the crankshaft and connecting rods with a high
flash point solvent and dry with compressed air.
3. Inspect the teeth of the crankshaft gear for fatigue
cracks, pitting or signs of uneven tooth contact. Replace
crank gear if necessary.
4. Inspect the crankshaft and connecting rod bearing
surfaces for excessive wear, uneven contact or gouging
and scratching. Components should be replaced if any of
these conditions exist.

Engine - Gas (Liquid-Cooled) Repair - 163

 ENGINE - GAS (LIQUID-COOLED) REPAIR
8. Measure the crankshaft runout. Set the crankshaft in a
flywheel alignment jig or on V blocks. Set up dial gauges
A (E) at both bearing journals. Turn the crankshaft slowly by
hand and measure the runout. The difference between the
highest and lowest dial gauge reading is the amount of
runout. If the measurement at either journal exceeds the
service limit, the crankshaft must be replaced.

MX16148
F
5. Measure the crankpin outside diameter (A) at several
points around the circumference. If the crankpin diameter is
less than the service limit at any point, replace the
crankshaft.

C
MX16150
B
9. Measure the inside diameter (F) of the crankshaft
journal bearing on the crankcase at several points. Replace
the journal bearing if the inside diameter is more than the
service limit.
D

I
G
MX16148

6. Measure the crankpin width (C) at several points with a

dial caliper. If crankpin width exceeds the service limit at
any point, replace the crankshaft.
7. Measure the flywheel side (B) and PTO side (D) main J
journals at several points. If either journal is less than the
service limit, the crankshaft must be replaced.

E
MX16151

[Link] journal bearing (G) is press fit into the crankcase

(I).
• Remove the oil seal on the crankcase. (Note: The oil
seal should be replaced once removed.)
• Place the crankcase on a support block (J), with the
oil seal side up.
• Using a bushing tool (H), drive out the bearing as
shown.
MX11892

Engine - Gas (Liquid-Cooled) Repair - 164

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Specifications:
Crankpin Outside Diameter
(Service Limit). . . . . . . . . . . . . . . . 39.950 mm (1.573 in.)
C
Crankpin Width (Service Limit) . . . . 46.50 mm (1.83 in.)
Crank Main Journal PTO Side
(Service Limit). . . . . . . . . . . . . . . . 41.935 mm (1.651 in.)
Crank Main Journal Flywheel Side
D
(Service Limit). . . . . . . . . . . . . . . . 41.935 mm (1.651 in.)
Crank shaft Runout E
(Service Limit). . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Crankcase Journal Bearing Inside Diameter
(Service Limit). . . . . . . . . . . . . . . . . 42.14 mm (1.659 in.)

Connecting Rod Inspection MX11898

4. Measure connecting rod bend. Insert an arbor the same

Procedure: size as the big end through the connecting rod big end.
1. Remove pistons and connecting rods. (See “Piston Insert an arbor (D) 100 mm (3.397 in.) (E) or longer the
Removal and Installation” on page 154.) same diameter as the small end through the connecting rod
small end. Place V blocks on a surface plate, and support
the big end arbor in the V blocks.
5. Hold the small end of the rod straight up vertically and
measure from the surface plate to the small end arbor on
both sides of the connecting rod. Measurement must be
taken at a point that is exactly 100 mm (3.397 in.) apart.
B The difference between the two measurements determines
the rod bend (C). If the connecting rod bend exceeds the
service limit the rod and rod cap must be replaced.

MX16152

2. Measure the connecting rod big end width (A) with a

micrometer or dial caliper. If the measurement is less than
the service limit, the rod must be replaced.
3. Apply a light film of oil to the threads of the cap bolts.
Install the rod cap and the cap bolts and tighten the bolts to
21 N•m (180 lb-in.). Measure the inside diameter (B) of the F
big end at several points with a telescoping gauge or inside G
micrometer. If the inside diameter is greater than the
service limit, the rod and cap must be replaced.
MX11901

6. Measure connecting rod twist. With the big end mounted

in V blocks, hold the connecting rod horizontally and
measure the amount that the small end arbor varies (F)
from being parallel with the surface plate over a 100 mm
length (G). If twist exceeds the service limit the rod and cap
must be replaced.
7. Install the connecting rods and pistons (See Piston
Removal/Replacement.

Engine - Gas (Liquid-Cooled) Repair - 165

 ENGINE - GAS (LIQUID-COOLED) REPAIR
Specifications: • Inspect the back plate (D) for damage or a rough
contact surface. Replace if necessary.
Connecting Rod Big End Width Service Limit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.35 mm (0.88 in.) • Inspect the valve seating surface for nicks, burrs,
Connecting Rod Big End Inside Diameter Service Limit scratches or fretting. If damage or wear is evident,
40.055 mm (1.577 in.) remove the reed valve and backing plate and clean the
Connecting Rod Bend Service Limit surface with fine emery paper.
. . . . . . . . . . 0.15. mm (0.006 in.) over 100 mm (3.94 in.) NOTE: The mounting screw (C) is self-tapping. Be
Connecting Rod Twist Service Limit aware that mis-threading or overtightening the screw
. . . . . . . . . . . 0.15 mm (0.006 in.) over 100 mm (3.94 in.) will strip the female threads and ruin the hole.
5. To install assembly, align the center of the valve seat
Breather Valve Removal and Installation with the center of the reed valve (E) and back plate (D),
then tighten the mounting screw (C).
Procedure:
6. Before installing cover, be sure the drain hole (F) does
1. Remove engine from machine. (See “Engine Removal not accumulate any debris.
and Installation” on page 143.)
7. Install a new cover gasket (A) and install cover (B).
Tighten four breather valve cover mounting bolts to 20 N•m
(180 lb-in.).
A

Oil Pump Removal and Installation

Procedure:
1. Remove crankcase cover. (See “Crankcase Cover
B Removal and Installation” on page 150.)

MX16153

2. Remove the four (4) bolts holding the breather cover (B)
to the crankcase.
3. Inspect gasket (A) for damage, and replace if necessary.

C
B

D
MX16156

2. Remove two cap screws (B) holding oil screen filter (A)
onto crankcase cover.
E

MX16154

4. Unscrew the mounting screw (C), and remove the back

plate (D) and reed valve (E).
• Inspect the reed valve (E) for breakage, hair cracks
or distortion. Replace valve if any signs of wear or
damage are present.

Engine - Gas (Liquid-Cooled) Repair - 166

 ENGINE - GAS (LIQUID-COOLED) REPAIR
NOTE: When installing the pump parts assembly, align
the 6 mm diameter hole (L) on the cover plate with the
center of the relief valve.

MX16155
L
3. Remove the remaining three (3) bolts (C) holding the oil
D
pump assembly (D) to the crankcase cover and remove
pump assembly. MX16155

9. Install the relief valve and ball in the crankcase cover,

then install the pump parts assembly into the cover.
[Link] the pump assembly into the crankcase cavity
C
making certain to align the 6 mm diameter hole (L) in the
F
cover plate with center of the relief valve. Put the oil screen
filter in position, and install the five (5) mounting bolts
tightening to 6 N•m (52 lb-in.).
E [Link] the crankcase cover with a new gasket. (See
G
“Crankcase Cover Removal and Installation” on page 150.)

Oil Pump Inspection

Procedure:
M
H

K J I

MX11912

4. Remove the relief valve ball (I) and spring (J) from the
crankcase cover.
A
5. The pump can be disassembled by removing the pin (M)
and separating the pump gear (E) from the pump shaft (H) MX16157
and the cover plate (K).
1. Remove the oil pump assembly from the crankcase
6. Remove the inner (G) and outer rotor (F) from the pump cover. (See “Oil Pump Removal and Installation” on
cavity. page 166.) Visually inspect the pump gear, inner and outer
7. Assemble the pump in reverse order of disassembly. rotor and cover plate for wear or damage. Replace
components as necessary.
8. Fill the rotor housing in the crankcase cover with fresh
oil for initial lubrication.

Engine - Gas (Liquid-Cooled) Repair - 167

 ENGINE - GAS (LIQUID-COOLED) REPAIR
2. Install inner and outer rotor in crankcase cavity and
check clearance between inner and outer rotor with a feeler
gauge. Take this measurement at the point where the high
point of the inner rotor meets the high point of the outer
rotor (A). If the clearance exceeds the service limit replace
the inner and outer rotors as a set.

C
B
G

MX16160

8. Measure the outside diameter (G) of the pump shaft

with a micrometer at several points. If the diameter is less
than the service limit, replace the pump shaft.
MX16158

3. Measure the thickness (B) of the outer rotor with a

micrometer at several points. If the thickness is less than c ventilated
CAUTION: Avoid Injury! Clean parts in a well
area using a high flash point solvent.
the service limit at any point, replace the inner and outer
rotors. Make certain no spark or flame such as pilot
light is near the work area.
4. Measure the outside diameter (C) of the outside rotor at
several points with a micrometer. If the rotor diameter is
less than the service limit, replace the inner and outer rotor
as a set. H

E
MX16161

9. Remove the relief valve spring and steel ball from the
crankcase cover. Clean the valve seat and valve
F components with a high flash point solvent, and blow any
foreign particles out of the seat with compressed air.
MX16159
Inspect the steel ball for wear or dimpling. Replace the
5. Measure the inside diameter (E) of the pump housing steel ball and spring if any wear or damage is evident.
with an inside micrometer at several points. If the inside
[Link] the free length (H) of the spring with a vernier
diameter of the cover is greater than the service limit the
caliper. If the free length of the spring is less than the
crankcase cover must be replaced.
service limit, replace the spring.
6. Measure the depth (D) of the pump housing with a depth
[Link] oil pump assembly in crankcase cover. (See “Oil
micrometer at several points. If any measurement is greater
Pump Removal and Installation” on page 166.)
than the service limit the crankcase cover must be
replaced. Oil Pump Specifications:
7. Measure the inside diameter (F) of the pump shaft Inner to Outer Rotor Clearance (Service Limit) (A)
bearing in the crankcase cover at several points with an . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)
inside micrometer. If the inside diameter exceeds the
Outer Rotor Outside Diameter (Service Limit) (C)
service limit at any point it will be necessary to replace the
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.593 in.)
crankcase cover.
Outer Rotor Thickness (Service Limit) (B)

Engine - Gas (Liquid-Cooled) Repair - 168

 ENGINE - GAS (LIQUID-COOLED) REPAIR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.830 mm (0.781 in.) 3. Clean the oil screen (C) with a high flash-point solvent
Pump Housing Inside Diameter (Service Limit) (E) and remove any particles stuck to it. Check the screen
. . . . . . . . . . . . . . . . . . . . . . . . . . . 40.801 mm (1.606 in.) carefully for any damage, or metal particles that might
Pump Housing Depth (Service Limit) (D) indicate internal engine damage. If the screen is damaged,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.230 mm (0.797 in.) replace entire oil screen filter (A).
Pump Shaft Outside Diameter (Service Limit) (G) 4. Install the pipe on the oil pump assembly with the two
. . . . . . . . . . . . . . . . . . . . . . . . . . 10.923 mm (0.4300 in.) cap screws. Tighten the cap screws to 6 N•m (52 lb-in.).
Pump Shaft Bearing Inside Diameter 5. Install crankcase cover. (See “Crankcase Cover
(Service Limit) (F) . . . . . . . . . . . . . 11.072 mm (0.436 in.) Removal and Installation” on page 150.)
Spring Free Length (H). . . . . . . . . . . 19.50 mm (0.77 in.)

Oil Screen Removal and Installation

Procedure:
1. Remove the crankcase cover. (See “Crankcase Cover
Removal and Installation” on page 150.)

MX16156

2. Remove two cap screws (B) holding oil screen filter (A)
onto crankcase cover.

c ventilated
CAUTION: Avoid Injury! Clean parts in a well
area using a high flash point solvent.
Make certain no spark or flame such as pilot
light is near the work area.

MX16163

Engine - Gas (Liquid-Cooled) Repair - 169

ENGINE - GAS (LIQUID-COOLED) REPAIR

Engine - Gas (Liquid-Cooled) Repair - 170

 ELECTRICAL TABLE OF CONTENTS
W2, W6 and W7 Engine Wiring Harnesses -
Electrical

Table of Contents
X465 .......................................................... 203
W1 Main Wiring Harness - X475 and X575
(1 of 2) ....................................................... 204
General Information......................................175
W1 Main Wiring Harness - X475 and X575
Reading Electrical Schematics...................175
(2 of 2) ....................................................... 205
Theory of Operation Information ................176
W2 Engine Wiring Harness - X475 and
Diagnostic Information................................176
X575 .......................................................... 206
Wire Color Abbreviation Chart....................176
W1 Main Wiring Harness - X485 and X585
Common Circuit Tests................................177
(1 of 2) ....................................................... 207
Conductors For 12 Volt Circuits .................177
W1 Main Wiring Harness - X485 and X585
Specifications ...............................................178
(2 of 2) ....................................................... 208
General Specifications ...............................178
W2 Engine Wiring Harness - X485 and
Test and Adjustment Specifications ...........178
X585 .......................................................... 209
Repair Specifications..................................179
W2 Engine Wiring Harness Circuit
Special or Essential Tools ..........................180
Schematic - X485 and X585 ...................... 210
Other Materials...........................................180
W3 Headlight Wiring Harness.................... 211
Component Location....................................181
W4 Rear Wiring Harness ........................... 211
Right Side...................................................181
W5 PTO Option Wiring Harness................ 211
Left Side .....................................................182
W1 Main Wiring Harness Color Codes -
Engine Components (FH641D) ..................183
X465 .......................................................... 212
Engine Components (FD671D) ..................184
W1 Main Wiring Harness Color Codes -
Engine Components (FD711D EFI) ...........185
X475 and X575 .......................................... 213
Instrument Panel ........................................186
W1 Main Wiring Harness Color Codes -
Schematics and Harnesses .........................187
X485 and X585 .......................................... 214
Schematic and Wiring Harness Legend -
W2 Engine Wiring Harness Color Codes -
X465, X475 and X575 ................................187
X475 and X575 .......................................... 215
Schematic And Wiring Harness Legend -
W2 Engine Wiring Harness Color Codes -
X485 and X585...........................................188
X485 and X585 .......................................... 216
Electrical Schematic - X465 (1 of 3) ...........191
W3 Headlight Wiring Harness Color
Electrical Schematic - X465 (2 of 3) ...........192
Codes ........................................................ 216
Electrical Schematic - X465 (3 of 3) ...........193
W4 Rear Wiring Harness Color Codes ...... 216
Electrical Schematic - X475 and X575
W5 PTO Option Wiring Harness Color
(1 of 3) ........................................................194
Codes ........................................................ 216
Electrical Schematic - X475 and X575
Operation and Diagnostics ......................... 217
(2 of 3) ........................................................195
Power Circuit Operation - X465 ................. 217
Electrical Schematic - X475 and X575
Power Circuit Wiring Schematic - X465..... 218
(3 of 3) ........................................................196
Power Circuit Operation - X475 and X575. 220
Electrical Schematic - X485 and X585
Power Circuit Electrical Schematic - X475
(1 of 4) ........................................................197
and X575 ................................................... 221
Electrical Schematic - X485 and X585
Power Circuit Diagnosis - X465, X475 and
(2 of 4) ........................................................198
X575 .......................................................... 223
Electrical Schematic - X485 and X585
Power Circuit Operation - X485 and X585. 226
(3 of 4) ........................................................199
Power Circuit Electrical Schematic - X485
Electrical Schematic - X485 and X585
and X585 ................................................... 228
(4 of 4) ........................................................200
Power Circuit Diagnosis - X485 and X585. 231
W1 Main Wiring Harness - X465 (1 of 2)....201
Cranking Circuit Operation - All Models..... 235
W1 Main Wiring Harness - X465 (2 of 2)....202

Electrical Table of Contents - 171

 ELECTRICAL TABLE OF CONTENTS
Cranking Circuit Electrical Schematic - Electrical Schematic - X485 and X585 ...... 291
All Models...................................................236 Fuel Injection Sensor and Diagnostic Circuit
Cranking Circuit Diagnosis - All Models .....237 Diagnosis - X485 and X585 ....................... 294
Charging Circuit Operation - All Models .....239 Tests and Adjustments ............................... 298
Charging Circuit Electrical Schematic - Common Circuit Tests ............................... 298
All Models...................................................240 Ground Circuit Tests.................................. 298
Charging Circuit Diagnosis - All Models .....241 Battery Voltage and Specific Gravity Test . 299
Ignition Circuit Operation - X465, X475 and Battery - Charge ........................................ 300
X575 ...........................................................243 Battery - Load Test .................................... 300
Ignition Circuit Electrical Schematic - X465, Regulated Amperage and Voltage Test..... 301
X475 and X575...........................................244 Regulated Voltage Test ............................. 302
Ignition Circuit Diagnosis - X465, X475 and Voltage Regulator/Rectifier Test - X465 .... 302
X575 ...........................................................246 Unregulated Voltage Test - X465 .............. 303
Ignition Circuit Operation - X485 and X585 249 Unregulated Voltage Test - X475, X575,
Ignition Circuit Electrical Schematic - X485 X485, and X585 ......................................... 303
and X585 ....................................................250 Stator Resistance Test .............................. 304
Ignition Circuit Diagnosis - X485 and X585 253 Starting Motor Condition ............................ 304
PTO/RIP Circuit Operation - All Models .....259 Starter Solenoid Test ................................. 305
PTO Circuit Electrical Schematic - All Starting Motor Amp Draw Test .................. 305
Models........................................................261 Starting Motor No-load Amperage and
PTO Circuit Diagnosis - All Models ............263 RPM Test................................................... 306
Instrument Panel Circuit Operation - All Field Windings Test ................................... 306
Models........................................................266 Starter Armature Test ................................ 307
Instrument Panel Circuit Electrical Schematic - Ignition Interlock Test................................. 308
All Models (SN -30000) ..............................268 Engine Coolant Temperature Sensor Test -
Instrument Panel Circuit Schematic - All X475, X575, X485, and X585 .................... 310
Models (SN 30001-) ...................................269 Engine Oil Pressure Switch Test ............... 311
Instrument Panel Circuit Diagnosis - All Lights Switch Test...................................... 311
Models........................................................270 PTO/RIP Switch Test................................. 312
Lights Circuit Operation - All Models ..........272 Relay Test.................................................. 312
Lights Circuit Electrical Schematic - All Seat Switch Test........................................ 313
Models........................................................273 Brake Switch Test and Adjustment............ 313
Lights Circuit Diagnosis - All Models ..........274 RIO Switch Test......................................... 314
Fuel Pump and Fuel Shutoff Circuit Operation - RIO Switch Adjustment.............................. 314
X465, X475 and X575 ................................276 Service Timer Reset Switch (SN -30000) .. 315
Fuel Pump and Fuel Shutoff Circuit Electrical Fuse Test................................................... 315
Schematic - X465, X475 and X575 ............277 Instrument Panel Light Test....................... 316
Fuel Pump and Fuel Shutoff Circuit Diagnosis - PTO Solenoid Test .................................... 317
X465, X475 and X575 ................................279 PTO Switch Test (optional)........................ 317
Fuel Pump and Fuel Injector Circuit Operation Fuel Shutoff Solenoid Test - X465, X475
- X485 and X585 ........................................282 and X575 ................................................... 318
Fuel Pump and Fuel Injector Circuit Electrical Diode Test ................................................. 319
Schematic - X485 and X585.......................283 Fuel Tank Sensor Test .............................. 319
Fuel Pump and Fuel Injector Circuit Diagnosis Fuel Injector Test - X485 and X585 ........... 320
- X485 and X585 ........................................286 Fuel Injection Module Test - X485 and
Fuel Injection Sensor and Diagnostic Circuit X585 .......................................................... 320
Operation - X485 and X585........................290 Vacuum Pressure Sensor Test - X485 and
Fuel Injection Sensor and Diagnostic Circuit X585 .......................................................... 321

Electrical Table of Contents - 172

 ELECTRICAL TABLE OF CONTENTS
Air Temperature Sensor Test - X485 and
X585 ...........................................................322
Coolant Temperature Sensor Test - X485 and
X585 ...........................................................322
Spark Plug Gap Test ..................................323
Spark Plug Gap Adjustment .......................323
Ignition Coil Test ........................................324
Spark Test ..................................................324
Repair.............................................................325
Ignition Coil Replacement ..........................325
Stator Replacement....................................326

Electrical Table of Contents - 173

ELECTRICAL TABLE OF CONTENTS

Electrical Table of Contents - 174

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

Each component is shown by a symbol (E), its name (F), The same component name and identification code are
and an identification code (G). The identification code used consistently on all diagrams in this section.
contains a device identifying letter (H) and number (I). Components can be easily cross-referenced.

S1 Key On Off
Switch F2 414 Seat Seat
Wht 15 Amp Yel/ S2
Wht
B Fuse Blk Seat A
Red Red
Switch
X1 800
S1 X2 X3 Pink D
M
X3 D
6
Start C K2
Ignition
210 Run Relay
Red
Off 30 87
L K J
F3 85
15 Amp 86
Fuse
F1 K1
Fusible Start
Relay
Link X3
710
Pur

H
1
215
Org X2
721
Pur/
Wht
Red 805 Pnk/Blk
F
W3
Engine X3
Wiring X4
B S E Yel/
G T1 Harness Wht T2
I Ignition Ignition
X3 X5
G1 M1 H Coil Yel/Wht Yel/Wht Coil
Battery Starting P
M Motor
Blk B E1 Yel/ E2 Q
Spark Wht Spark
Plug Plug
W1 Wht Blk/Yel
Shielded F
E O C N
Ground 105 Blk

SE1-Power and Starting Circuit SE2-Ignition and Interlock Circuit SE3-PTO and Interlock

MIF

Electrical General Information - 175

 ELECTRICAL GENERAL INFORMATION
Theory of Operation Information Wire Color Abbreviation Chart
The theory of operation stories divide the electrical system Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
into individual circuits by function. Each circuit is isolated Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
from the main wiring schematic and only shows the Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
components that are used in it. The story contains
Grn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
information on function, operating conditions, and theory of
operation. The circuit schematics are drawn with the Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray
components in the operating position, with the power, or Org. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
battery positive, into them across the top and the ground, or Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
battery negative, across the bottom. Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Diagnostic Information Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan
The diagnostic procedures is used to test the complete Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
circuit regardless of the problem or complaint. Select a Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
symptom or system from the quick check or Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
troubleshooting chart and follow the test procedures under Blu/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
that heading. Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/White
The diagnostic procedure lists: Brn/Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow
• Test conditions Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green
• Test sequence
Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red
• Test location
Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow
• Normal reading Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
• Check or test to perform if reading is not normal Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
When performing the test or check, be sure to set your Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
machine up to the TEST POINT/PROCEDURES listed in Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White
the first column and follow the sequence carefully. The Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
middle RESULTS column gives the reading or condition Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/White
that should be obtained in BOLD print. If the results of the Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
test or check are not normal, perform the test, check, or
Red/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
adjustment listed below the BOLD print. The system
diagram that accompanies each test procedure is drawn to Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
resemble machine components. The leader line points to Wht/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
the exact point the test is to be made. Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow/White

Electrical General Information - 176

 ELECTRICAL GENERAL INFORMATION
Common Circuit Tests High Resistance or Open Circuit:

Shorted Circuit:

M85601 MIF

High resistance or open circuits usually result in slow, dim

or no component operation (i.e. poor, corroded, or
disconnected connections). Voltage at the component will
be low when the component is in operation. To test for high
resistance and open circuits:
M85600 MIF 1. Check all terminals and grounds of the circuit for
A shorted circuit may result in the wrong component corrosion.
operating (i.e. improper wire-to-wire contact). To test for a 2. If terminals are not corroded or loose, the problem is in
shorted or improperly wired circuit: the component or wiring.
1. Turn component switch ON.
Grounded Circuit:
2. Start at the controlling switch of the component that
should not be operating.
3. Follow the circuit and disconnect wires at connectors
until component stops operating.
4. Shorted or improper connections will be the last two
wires disconnected.

M85602 MIF

Grounded circuits usually result in no component operation

or a blown fuse.

Conductors For 12 Volt Circuits

Stranded Conductors For 12 Volt Circuits

SAE Wire Size (Gauge) 20 18 16 14 12 10

Metric Wire Size (MM) 0.5 0.8 1.0 2.0 3.0 5.0

Typical Stranding 7 X 28 16 X 30 19 X 29 19 X 27 19 X 25 19 X 23

Minimum Conductor Area In Circular Mils 1072 1537 2336 3702 5833 9343

Electrical General Information - 177

 ELECTRICAL SPECIFICATIONS
Specifications

General Specifications
Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic
Starter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solenoid Shift
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-amp Stator

Battery:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI Group U1
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Reserve Capacity @25A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Minutes
Cold Cranking Amps @0° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342

Headlights:
Incandescent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard
Halogen Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 watt (optional)
Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 watt Bayonet Base
Turn Signal/Hazard Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cd/m2, Single Element, Type 1156
Instrument Panel Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7 watt Bayonet Base

Test and Adjustment Specifications

X465, X475, X485, X575, and X585

Stator:
Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 amps (minimum) at high idle
Regulated Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 volts (maximum)
Unregulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 VAC (minimum)

Starter:
Amp Draw/RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 amps (maximum) at 500 RPM
No-Load Amps/RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 amps (maximum) at 6000 RPM

Ignition Coil:
Primary Winding Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 - 3.6 ohms
Secondary Winding Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 21 k-ohms

Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.)

Engine Coolant Temperature Sensor - X475/X575/X485/X585:

Variable Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 700 ohms

PTO Clutch Solenoid:

Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 ohms

Spark Plug Gap - X475/X575/X485/X585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.)

Spark Plug Gap - X465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.00 mm (0.040 in.)

Fuel Gauge Sender:

Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 6 - 103 ohms

Electrical Specifications - 178

 ELECTRICAL SPECIFICATIONS
Vacuum Pressure Sensor - X485/X585:
Left and Center Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2986 - 3034 ohms
Left and Right Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773 - 787 ohms
Center and Right Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3774 - 3798 ohms
Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .about 5 volts
Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 - 4.9 volts depending on Air Pressure

Air and Coolant Temperature Sensors - X485/X585:

At 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 - 2.69 k-ohms
At 0 - 30°C (32 - 86°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.88 - 1.65 k-ohms

Fuel Injector:
Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 ohms

RIO Switch:
Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.47 in.)

Repair Specifications
Starter - X465, X475, X485, X575, and X585
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 mm (0.24 in.)

EFI Module Fault Code Chart

The long flash “ - ” = 1.0 second
The short flash “•” = 0.5 second
OFF period = 3 to 4 seconds.
The flash code begins after the off period.
Let the code cycle several times while reading the code to be sure you are at the beginning of the code.

FAULT FLASH TEST POINT FAULT CAUSE

CODE SEQUENCE

12 - •• Intake air temperature B5 air temperature sensor circuit malfunctioning. Circuit either
sensor open or shorted.

13 - ••• Coolant temperature sensor B4 coolant temperature sensor circuit malfunctioning. Circuit
either open or shorted.

21 - - • Vacuum pressure sensor B6 vacuum pressure sensor circuit malfunctioning. Circuit

either open or shorted.

22 - - •• N/A EFI module air/fuel pressure calculation error. To reset: Stop

engine, wait for fault indicator light to go off and fuel pump to
stop (approximately 0.5 to 1 second). Start engine.

Electrical Specifications - 179

 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).

Special or Required Tools

Tool Name Tool No. Tool Use
Spark Tester D-05351ST Test ignition system and spark plugs.
Current Gun JTO5712 Starting motor tests.
Photo Tachometer JTO5719
Battery Tester JTO5685 Starting motor amp draw test and battery tests.
Current Gun JTO5712 Regulated amp and voltage tests.
Battery Tester JTO5685

Other Materials
Other Material
Part No. Part Name Part Use
TY9374/TY9375 Pipe sealant with Teflon® Seal threads on temperature sensor and oil pressure switches.

NOTE: Teflon is a registered trademark of the Du Pont

Company.

Electrical Specifications - 180

 ELECTRICAL COMPONENT LOCATION
Component Location

Right Side

C
E
B
A
F
G
H
I

R Q
P
O M
N

MX16063 J - E4 Left Headlight

A - X20 12VDC Accessory Plug K - G1 Battery
B - S10 Accessory Switch L - E3 Right Headlight
C - S3 Seat Switch M - K11 EFI Module Ground Relay - X485 and X585
D - S1 Key Switch N - S4 RIO Switch
E - S9 Light Switch O - K13 Fuel Pump Relay - X485 and X585
F - A3 PTO Interlock Module (option) P - K12 EFI Module Power Relay - X485 and X585
G - F1 Fuse 20 Amp Q - A1 Ignition Interlock Module
H - N1 Voltage Rectifier/Regulator R - S5 PTO/RIP Switch
I - A4 Electric Fuel Injection Module - X485 and
X585

Electrical Component Location - 181

 ELECTRICAL COMPONENT LOCATION
Left Side

C
D
A

G
E
F

I
T

S
R J

Q K

O L
P
M

MX16062 K - Y3 PTO Clutch Solenoid

A - G1 Battery L - V1 Diode
B - Instrument Panel Connector M - S8 Mid PTO Switch (optional)
C - S9 Light Switch N - S7 Rear PTO Switch (optional)
D - S5 PTO/RIP Switch O - E8 Left Backup Light
E - N1 Voltage Rectifier/Regulator P - E7 Left Tail Light
F - S3 Seat Switch Q - S6 Brake Switch
G - S10 Accessory Switch R - A4 Electric Fuel Injection Module - X485 and
H - E5 Right Tail Light X585
I - E6 Right Backup Light S - A3 PTO Interlock Module (optional)
J - M2 Fuel Pump (not on X465)/B2 Fuel Gauge T - S2 Service Timer Reset Switch (SN -30000)
Sensor U - F1 Fuse 20 Amp

Electrical Component Location - 182

 ELECTRICAL COMPONENT LOCATION
Engine Components (FH641D)

A B

H
C

E
D

MIF J - T1 Ignition Coil

A - E9 Spark Plug
B - Y2 Fuel Shutoff Solenoid
C - B1 Engine Oil Pressure Switch
D - M1 Starting Motr
E - Y1 Starting Motor Solenoid
F - G2 Alternator
G - T2 Ignition Coil
H - Flywheel
I - E10 Spark Plug

Electrical Component Location - 183

 ELECTRICAL COMPONENT LOCATION
Engine Components (FD671D)

A B

D
H

G E

MX14278

A - B3 Engine Coolant Temperature Sensor

B - B1 Engine Oil Pressure Switch (RH Side)
C - Y2 Fuel Shutoff Solenoid
D - T2 Ignition Module
E - T1 Ignition Module
F - Y1 Starting Motor Solenoid
G - W1 Frame Ground
H - E1 Spark Plug

Electrical Component Location - 184

 ELECTRICAL COMPONENT LOCATION
Engine Components (FD711D EFI)

D
E F
C G

I
O

N J

K
L

MX14312 H - Y2 Fuel Shutoff Solenoid

A - B4 Engine Coolant Temperature Sensor I - T2 Ignition Module
B - Y4 #1 Cylinder Fuel Injector J - T1 Ignition Module
C - B5 Air Temperature Sensor K - X2 Wiring Harness Connector
D - B6 Vacuum Pressure Sensor L - X25 Wiring Harness Connector
E - Y5 #2 Cylinder Fuel Injector M - Y1 Starting Motor Solenoid
F - B3 Engine Coolant Temperature Sensor N - W1 Frame Ground
G - B1 Engine Oil Pressure Switch (RH Side) O - E1 Spark Plug

Electrical Component Location - 185

 ELECTRICAL COMPONENT LOCATION
Instrument Panel

A B

J
I H F E
G D C

MX13564

A - Fuel Gauge
B - Coolant Temperature Gauge (not on X465)
C - Reverse Implement Option (RIO) Indicator Light
D - Battery Discharge Indicator Light
E - Rear PTO Indicator Light
F - Oil Pressure Indicator Light
G - Front and Mid PTO Indicator Light
H - Park Brake Indicator Light (S/N 30001-)
Service Indicator Light (S/N -30000)
I - EFI Diagnostic Light (X485 and X585)
J - Hour Meter

Electrical Component Location - 186

 ELECTRICAL SCHEMATICS AND HARNESSES
Schematics and Harnesses

Schematic and Wiring Harness Legend - K5 - Ignition Relay (SE3, W1)

X465, X475 and X575 K6 - PTO Relay (SE3, W1)
A1 - Ignition Interlock Module (SE3, W1) K7 - Brake Lock Relay (SE3, W1)
A2 - Service Light Timer Module (SE3, W1) - (SN -30000) K8 - Off Seat Relay (SE3, W1)
A3 - PTO Interlock Module (SE3, W1) K9 - Mid PTO Relay (SE3, W1)
B1 - Engine Oil Pressure Switch (SE2, W1) K10 - Rear PTO Relay (SE3, W1)
B2 - Fuel Gauge Sensor (SE3, W1) M1 - Starting Motor (SE1, W1)
B3 - Engine Coolant Temperature Sensor (SE3, W1) - M2 - Fuel Pump (SE3, W1) - X475 and X575 only
X475 and X575 only N1 - Voltage Regulator/Rectifier (SE2, W1)
E1 - Seat LED (SE3, W1) P1 - Hourmeter (SE3, W1)
E2 - PTO LED (SE3, W1) P2 - Fuel Gauge (SE3, W1)
E3 - RH Headlight (SE5, W3) P3 - Engine Coolant Temperature Gauge (SE3, W1) - X475
E4 - LH Headlight (SE5, W3) and 575 only
E5 - RH Tail Light (SE5, W4) S1 - Key Switch (SE2, W1)
E6 - RH Backup Light (SE5, W4) S2 - Service Timer Reset Switch (SE3, W1) (SN -30000)
E7 - LH Tail Light (SE5, W4) S3 - Seat Switch (SE3, W1)
E8 - LH Backup Light (SE5, W4) S4 - RIO Switch (SE3, W1)
E9 - Spark Plug (SE4, W2) S5 - PTO/RIP Switch (SE3, W1)
E10 - Spark Plug (SE4, W2) S6 - Brake Switch (SE3, W1)
F1 - Fuse 20A (SE1, W1) S7 - Rear PTO Switch (SE3, W5)
F2 - Fusible Link (SE1, W1) S8 - Mid PTO Switch (SE4, W5)
F3 - Fusible Link (SE1, W1) S9 - Light Switch (SE4, W1)
F4 - Fuse 15A (SE3, W1) S10 - Accessory Switch (SE5, W4)
F5 - Fuse 15A (SE3, W1) T1 - Ignition Coil (SE4, W2)
G1 - Battery (SE1, W1) T2 - Ignition Coil (SE4, W2)
G2 - Alternator (SE1, W1) V1 - Diode (SE3, W1)
H1 - Discharge Light (SE2, W1) V2 - Diode (SE3, W1)
H2 - Engine Oil Pressure Light (SE3, W1) V3 - Diode (SE3, W1)
H3 - Service Indicator Light (SE3, W1) - (SN -30000) V4 - Diode (SE3, W1)
H4 - RIO Defeat Light (SE3, W1) V5 - Diode (SE4, W1)
H5 - Rear PTO Light (SE3, W1) W1 - Frame Ground (SE1, W1)
H6 - Mid PTO Light (SE3, W1) Y1 - Starting Motor Solenoid (SE1, W1)
H7 - Dash Light (SE4, W1) Y2 - Fuel Shutoff Solenoid (SE3, W2)
H8 - Brake Light (SE3, W1) (SN 30001-) Y3 - PTO Clutch Solenoid (SE4, W1)
K1 - Start Relay (SE3, W1)
K2 - Magneto Start Relay (SE3, W1)
K3 - RIO Latch Relay (SE3, W1)
K4 - RIO Unlatch Relay (SE3, W1)

Electrical Schematics and Harnesses - 187

 ELECTRICAL SCHEMATICS AND HARNESSES
Connectors: Wiring Harnesses:
X1 - W1 Main Wiring Harness to A1 Ignition Interlock W1 - Main Wiring Harness
Module (SE1, W1)
W2 - Engine Wiring Harness
X2 - W1 Main Wiring Harness to W2 Engine Wiring W3 - Headlight Wiring Harness
Harness (SE2, W1; SE3, W1; SE4, W1)
W4 - Rear Wiring Harness
X3 - W1 Main Wiring Harness to Instrument Panel
(SE2, W1; SE3, W1; SE4, W1) W5 - PTO Solenoid Wiring Harness
X4 - W1 Main Wiring Harness to A1 Ignition Interlock W6 - Engine Wiring Harness (Ignition Coils)
Module (SE3, W1) W7 - Engine Wiring Harness (Fuel Shutoff Solenoid)
X5 - W1 Main Wiring Harness to A1 Ignition Interlock
Module (SE3, W1) Schematic And Wiring Harness Legend - X485
X6 - W1 Main Wiring Harness to W5 PTO Solenoid Wiring and X585
Harness (SE3, W1; SE4, W1)
A1 - Ignition Interlock Module (SE3, W1)
X7 - W1 Main Wiring Harness to A3 PTO Interlock Module
(SE3, W1) A2 - Service Light Timer Module (SE3, W1)
A3 - PTO Interlock Module (SE3, W1)
X8 - W1 Main Wiring Harness to A3 PTO Interlock Module
(SE3, W1) A4 - Electric Fuel Injection Module (SE6, W2)
X9 - W1 Main Wiring Harness to A3 PTO Interlock Module B1 - Engine Oil Pressure Switch (SE2, W1)
(SE3, W1)
B2 - Fuel Gauge Sensor (SE3, W1)
X10 - W1 Main Wiring Harness to B2 Fuel Gauge Sensor/
B3 - Engine Coolant Temperature Sensor (SE3, W1)
M2 Fuel Pump (M2 Fuel Pump not on X465) (SE3, W1)
B4 - Engine Coolant Temperature Sensor (SE6, W2)
X11 - W1 Main Wiring Harness to Y3 PTO Clutch Solenoid
(SE4, W1) B5 - Air Temperature Sensor (SE6, W2)
X12 - W1 Main Wiring Harness to W4 Rear Wiring Harness B6 - Vacuum Pressure Sensor (SE6, W2)
(SE5, W1) E1 - Seat LED (SE3, W1)
X13 - W1 Main Wiring Harness to W3 Headlight Wiring E2 - PTO LED (SE3, W1)
Harness (SE5, W1)
E3 - RH Headlight (SE5, W3)
X14 - W3 Headlight Wiring Harness to E3 RH Headlight
(SE5, W3) E4 - LH Headlight (SE5, W3)

X15 - W3 Headlight Wiring Harness to E4 LH Headlight E5 - RH Tail Light (SE5, W4)

(SE5, W3) E6 - RH Backup Light (SE5, W4)
X16 - W4 Rear Wiring Harness to E5 RH Tail Light E7 - LH Tail Light (SE5, W4)
(SE5, W4)
E8 - LH Backup Light (SE5, W4)
X17 - W4 Rear Wiring Harness to E6 RH Backup Light
E9 - Spark Plug (SE6, W2)
(SE5, W4)
E10 - Spark Plug (SE6, W2)
X18 - W4 Rear Wiring Harness to E7 LH Tail Light
(SE5, W4) F1 - Fuse 20A (SE1, W1)
X19 - W4 Rear Wiring Harness to E8 LH Backup Light F2 - Fusible Link (SE1, W1)
(SE5, W4) F3 - Fusible Link (SE1, W1)
X20 - W4 Rear Wiring Harness to 12 VDC Power Plug F4 - Fuse 15A (SE3, W1)
(SE5, W4)
F5 - Fuse 15A (SE3, W1)
X21 - W1 Main Wiring Harness to W1 Main Wiring Harness
(SE4, W1) F6 - Fusible Link (SE3, W1)
F7 - Fuse 10A (SE3, W1)
G1 - Battery (SE1, W1)
G2 - Alternator (SE1, W1)

Electrical Schematics and Harnesses - 188

 ELECTRICAL SCHEMATICS AND HARNESSES
H1 - Discharge Light (SE2, W1) V1 - Diode (SE3, W1)
H2 - Engine Oil Pressure Light (SE3, W1) V2 - Diode (SE3, W1)
H3 - Service Indicator Light (SE3, W1) (SN -30000) V3 - Diode (SE3, W1)
H4 - RIO Defeat Light (SE3, W1) V4 - Diode (SE3, W1)
H5 - Rear PTO Light (SE3, W1) V5 - Diode (SE4, W1)
H6 - Mid PTO Light (SE3, W1) W1 - Frame Ground (SE1, W1)
H7 - Dash Light (SE4, W1) W2 - Frame Ground (SE6, W2)
H8 - Circuit Integrity Light (SE3, W1) Y1 - Starting Motor Solenoid (SE1, W1)
H9 - Brake Light (SE3, W1) (SN 30001-) Y3 - PTO Clutch Solenoid (SE4, W1)
K1 - Start Relay (SE3, W1) Y4 - #1 Cylinder Fuel Injection Solenoid (SE6, W2)
K2 - Magneto Start Relay (SE3, W1) Y5 - #2 Cylinder Fuel Injection Solenoid (SE6, W2)
K3 - RIO Latch Relay (SE3, W1) Connectors:
K4 - RIO Unlatch Relay (SE3, W1) X1 - W1 Main Wiring Harness to A1 Ignition Interlock
K5 - Ignition Relay (SE3, W1) Module (SE1, W1)
K6 - PTO Relay (SE3, W1) X2 - W1 Main Wiring Harness to W2 Engine Wiring
Harness (SE2, W1; SE3, W1)
K7 - Brake Lock Relay (SE3, W1)
X3 - W1 Main Wiring Harness to Instrument Panel
K8 - Off Seat Relay (SE3, W1)
(SE2, W1; SE3, W1; SE4, W1)
K9 - Mid PTO Relay (SE3, W1)
X4 - W1 Main Wiring Harness to A1 Ignition Interlock
K10 - Rear PTO Relay (SE3, W1) Module (SE3, W1)
K11 - Injector Module Ground Relay (SE3, W1) X5 - W1 Main Wiring Harness to A1 Ignition Interlock
K12 - Injector Module Power Relay (SE4, W1) Module (SE3, W1)

K13 - Fuel Pump Relay (SE4, W1) X6 - W1 Main Wiring Harness to W5 PTO Solenoid Wiring
Harness (SE3, W1; SE4, W1)
M1 - Starting Motor (SE1, W1)
X7 - W1 Main Wiring Harness to A3 PTO Interlock Module
M2 - Fuel Pump (SE3, W1) (SE3, W1)
N1 - Voltage Regulator/Rectifier (SE2, W1) X8 - W1 Main Wiring Harness to A3 PTO Interlock Module
P1 - Hourmeter (SE3, W1) (SE3, W1)
P2 - Fuel Gauge (SE3, W1) X9 - W1 Main Wiring Harness to A3 PTO Interlock Module
(SE3, W1)
P3 - Engine Coolant Temperature Gauge (SE3, W1)
X10 - W1 Main Wiring Harness to B2 Fuel Gauge Sensor/
S1 - Key Switch (SE2, W1)
M2 Fuel Pump (SE3, W1)
S2 - Service Timer Reset Switch (SE3, W1) (SN -30000)
X11 - W1 Main Wiring Harness to Y3 PTO Clutch Solenoid
S3 - Seat Switch (SE3, W1) (SE4, W1)
S4 - RIO Switch (SE3, W1) X12 - W1 Main Wiring Harness to W4 Rear Wiring Harness
S5 - PTO/RIP Switch (SE3, W1) (SE5, W1)

S6 - Brake Switch (SE3, W1) X13 - W1 Main Wiring Harness to W3 Headlight Wiring
Harness (SE5, W1)
S7 - Rear PTO Switch (SE3, W5)
X14 - W3 Headlight Wiring Harness to E3 RH Headlight
S8 - Mid PTO Switch (SE4, W5) (SE5, W3)
S9 - Light Switch (SE4, W1) X15 - W3 Headlight Wiring Harness to E4 LH Headlight
S10 - Accessory Switch (SE5, W4) (SE5, W3)
T1 - Ignition Coil (SE6, W2) X16 - W4 Rear Wiring Harness to E5 RH Tail Light
(SE5, W4)
T2 - Ignition Coil (SE6, W2)

Electrical Schematics and Harnesses - 189

 ELECTRICAL SCHEMATICS AND HARNESSES
X17 - W4 Rear Wiring Harness to E6 RH Backup Light
(SE5, W4)
X18 - W4 Rear Wiring Harness to E7 LH Tail Light
(SE5, W4)
X19 - W4 Rear Wiring Harness to E8 LH Backup Light
(SE5, W4)
X20 - W4 Rear Wiring Harness to 12 VDC Power Plug
(SE5, W4)
X21 - W1 Main Wiring Harness to W1 Main Wiring Harness
(SE4, W1)
X22 - W1 Main Wiring Harness to W2 Engine Wiring
Harness (SE4, W1; SE5, W1)
X23 - W1 Main Wiring Harness to W2 Engine Wiring
Harness (SE5, W1)
X24 - W2 Engine Wiring Harness to W2 Engine Wiring
Harness (SE6, W1)
X25 - W1 Main Wiring Harness to W2 Engine Wiring
Harness (SE6, W1)
X26 - W1 Main Wiring Harness to A4 Electric Fuel Injection
(EFI) Module (SE6, W1)

Wiring Harnesses:
W1 - Main Wiring Harness
W2 - Engine Wiring Harness
W3 - Headlight Wiring Harness
W4 - Rear Wiring Harness
W5 - PTO Solenoid Wiring Harness

Electrical Schematics and Harnesses - 190

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X465 (1 of 3)

592 Blu
Wht
940 Wht
S2
Wht
592 S1 X5 H-B A1 Ignition Interlock Module
Blu S2
S1
S1 S2 X4
X1
Red A F4 Fuse -15 A F-2
B A
A X4
20A F1
Fuse Wht
M
F5 Fuse -15 A F-6
G M X4
M
F-3
200
Start X5
Red
202 Run H-F
Red
S1 Key Off X4
Switch F-5

E1 Grn K5
K2 Magneto LED Ignition
K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X5

H-C
201 X5
F3 Red G2
Fusible Stator H-D
G X5
Link
720 Pur X4
H-A

600
F-1 K3 RIO
E2 Red
X4
721 Latch Relay
Brn K4 RIO LED
F2 Pur Unlatch Relay PTO
F-4
Fusible X2 X5
Link
H-G
203 205 X5 H-E X5 H-H
Blk Lt Blu
720 Pur 130 605 Tan
Blk
503 Yel
Red
X3 V1 Diode V2 Diode
721 Pur
B S X3 503 Yel 11
14
H1 17
H2 Engine
Discharge Oil H3 P1
M Light Pressure Service Hourmeter
M1 Light Indicator
+ _ H4 RIO
Starting Defeat
Motor Y1
Starting
Motor X2 X3
620 Tan
Solenoid A2 Service
15
X3 850 Pnk Light Timer
7
Module
3 P
G1 136
S2 Service Timer
Battery
Blk X3
Reset Switch (SN -30000)
B1 Engine Oil 20 135
(SN -30000)
Reset

Off

151
Blk Pressure Blk
Blk
100 Blk Switch (NC) 100 Blk
110 Blk 110 Blk

W1
Frame Ground Unswitched Power Switched Power Secondary Power
Unswitched Ground Control Panel Wiring Harness

SE1 - Starting SE2 - Charging SE3 - Instrumentation and Interlocks

MIF

Electrical Schematics and Harnesses - 191

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X465 (2 of 3)

592 Blu 400 Yel/Blu

940 Wht 940 Wht
505 Yel

Yel/
400 Yel/Blu
Wht
RIP* X2 Y2 Fuel
On S5 PTO/RIP 650 Shutoff
500 Yel
Off Switch Pnk Solenoid
731 Pur
/Blk
6 730 Grn
754 Blu 3 830 Gry
705 Pnk/Blk 754 Blu
756 Blu
5 755 Blu 755 Blu
750 Blu 2
8 650 Pnk/Blk
786 Blu
652 Blu 4 652 Blu
705 Pnk/Blk 1 S6 Brake
765 Pur
7 Switch
789 Pur
Off
750 Blu On
751 Blu 751 Blu 787 Pur
501 770
S3 Seat 500 Yel Yel 765 Pur
501 Yel Pur
Switch
(Off)
786 Blu
(On)
502 767
503 520
800 Pnk 502 Yel Yel Pur
Yel Yel 605 Tan

820 Pnk 820 Pnk

735 Org
770 Pur
772 Blu
S4 RIO** Neutral/
S7 Rear
Forward
Switch PTO Switch
Reverse
730 Grn
505 Yel 830 Gry Off 789 Pur
735 Org On
772 Blu 756 Blu
605 Tan X6 740 Blu
503 Yel
731 X6
X3 Pur
757 Yel
1
520 Yel
P2 Fuel
Gauge 790
X3 Tan
900 Blk/Wht 900 Blk/Wht
Q
8

767 Pur X3 5
X3
4
6 H5 Rear H6 Mid
PTO Light PTO Light

H8
Brake V3
Light *RIP = Reverse Implement Position V4
**RIO = Reverse Implement Option Diode Diode
(SN 30001-) 135
Blk
100 Blk 100 Blk
110 Blk 110 Blk

SE3 - Instrumentation and Interlocks

MIF

Electrical Schematics and Harnesses - 192

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X465 (3 of 3)

592 E3 RH Headlight
400 Yel/Blu
S9 Light Blu X14
940 Wht On
Switch 171 172
505 Yel On
Blk X14 Blk
Off
810 Pnk
E4 LH Headlight
400 Yel/Blu
450 Yel/Wht
455 X13 170 Blk X15 173 Blk
Yel/Wht
451 X15
Yel/Wht 459
Yel/ X13
830 Gry Wht
830 Gry
755 Blu 755 Blu 110

X11 Y3 PTO X12 E5 RH Blk

Clutch Tail Light

758 Solenoid 420 Yel X16 130 Blk
Blu
A3 PTO Interlock Module X16
X7 V5 E6 RH
J5-C Diode Backup Light
116
K7 Brake Blk X11 451 820 Pur X17 150 Blk
Lock Relay Yel/
X7 115 Wht X17
X8 140 Blk Blk E7 LH
J5-A
J4-D Tail Light
X7 X18
400 Yel 100 Blk
K8 Off
J5-B
Seat X3 X18
Relay 19 E8 LH
X8 742
X8
J4-A Blu/Wht Backup Light
J4-B 800 Pur X19 110 Blk
K9 S8
Mid Mid H7 X19
PTO X6 S10 Accessory 120
Relay
PTO Dash Switch Blk
X8 Switch
Off
Light 140 Blk
J4-C On
X9 592 Pnk
593 Pnk X12
J6-A K10 Rear 122
X20 12 VDC
On
Off

PTO Relay Blk

X9 X6 Power Plug
520 115 Blk
J6-B Yel
520 Yel X3 135 Blk
X2
20
Wht
900 Blk/Wht

B2 Fuel
Gauge X10
Wht Wht
Sensor Blk Blk

Q E9 E10
Spark Spark
Plug Plug

T1 Ignition T2 Ignition
X10 Coil
Coil
120
Blk
100 Blk
110 Blk 110 Blk

SE3 - Instrumentation and Interlocks SE4 - Ignition SE5 - Lights

MIF

Electrical Schematics and Harnesses - 193

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X475 and X575 (1 of 3)

592 Blu
Wht
940 Wht
S2
Wht
592 S1 X5 H-B A1 Ignition Interlock Module
Blu S2
S1
S1 S2 X4
X1
Red A F4 Fuse -15 A F-2
B A
A X4
20A F1
Fuse Wht
M
F5 Fuse -15 A F-6
G M X4
M
F-3
200
Start X5
Red
202 Run H-F
Red
S1 Key Off X4
Switch F-5
G2
Alternator E1 Grn K5
X2 Ignition
G Blk K1 K2 Magneto
Start Relay
LED
Seat Relay K6
X5
Start Relay PTO Relay
3
U Blk
H-C
590 595
201
Brn/ Brn/ X5
F3 Red
Yel Wht
H-D
Fusible
Link + X5
N1
Rectifier/ U 720 Pur X4
H-A
Regulator - F-1 K3 RIO X4
Latch Relay E2 Red
125 600 504 721 K4 RIO LED
F2 Blk Brn Yel Pur Unlatch Relay PTO
F-4
Fusible X5
Link
H-G
203 205 X5 H-E X5 H-H
Blk Lt Blu
720 Pur 130 605 Tan
Blk 504 Yel
Red
X3 V1 Diode V2 Diode
721 Pur
B S X3 503 Yel 11
14
H1 17
H2 Engine
Discharge Oil H3 P1
M Light Pressure Service Hourmeter
M1 Light Indicator
+ _ H4 RIO
Starting Defeat
Motor Y1
Starting
Motor X2 620 Tan
X3
Solenoid A2 Service
15
X3 850 Pnk Light Timer
7
Module
3 P
G1 136
S2 Service Timer
Battery
Blk X3
Reset Switch (SN -30000)
B1 Engine Oil (SN -30000)
20 135
Reset

Off

151
Blk Pressure Blk
Blk
100 Blk Switch (NC) 100 Blk
110 Blk 110 Blk

W1
Frame Ground Unswitched Power Switched Power Secondary Power
Unswitched Ground Control Panel Wiring Harness

SE1 - Starting SE2 - Charging SE3 - Instrumentation and Interlocks

MIF

Electrical Schematics and Harnesses - 194

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X475 and X575 (2 of 3)

592 Blu 400 Yel/Blu

940 Wht 940 Wht

400 Yel/Blu S5 PTO/RIP Yel/

Switch Wht
RIP* X2 Y2 Fuel
500 Yel On 650 Shutoff
Off
731 Pur
Pnk Solenoid
/Blk
6 730 Grn
705 Pnk/Blk 754 Blu 3 830 Gry
756 Blu 754 Blu
5 755 Blu 755 Blu
750 Blu 2
8 650 Pnk/Blk
652 Blu 786 Blu
4 652 Blu 655
705 Pnk/Blk 1 S6 Brake Pnk
765 Pur
7 Switch
750 Blu 789 Pur
Off
751 Blu
On
751 Blu 787 Pur

770
S3 Seat 765 Pur
501 Yel Pur
Switch
(Off) 767 Pur
786 Blu
(On)
800 Pnk 502 Yel
605 Tan

820 Pnk 820 Pnk

735 Org
770 Pur
772 Blu
S4 RIO** Neutral/
S7 Rear
Forward
Switch PTO Switch
Reverse
730 Grn
505 Yel 830 Gry Off 789 Pur
735 Org On
772 Blu 756 Blu
605 Tan X6 740 Blu
504 Yel
X6
X3 731 Pur 790 757 Yel
1 Tan
504 Yel
P3 Engine Coolant P2 Fuel
Temperature Gauge Gauge 767 655 Pnk
Pur
X3
900 Blk/Wht 900 Blk/Wht
t0 Q
8
X3 6
2 310 X3 X3
4 5
Org/ H5 Rear H6 Mid H8
Wht PTO Light PTO Light Brake
Light (SN 30001-)
X2 *RIP = Reverse Implement Position
**RIO = Reverse Implement Option
t0 V3
B3 Engine Coolant V4
Diode
Temperature Diode
100 Blk
Sensor 100 Blk
110 Blk 110 Blk

SE3 - Instrumentation and Interlocks

MIF

Electrical Schematics and Harnesses - 195

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X475 and X575 (3 of 3)

E3 RH Headlight
400 Yel/Blu
S9 Light 592 X14
940 Wht On
Switch Blu 171 172
On
Blk X14 Blk
Off
810 Pnk
E4 LH Headlight
400 Yel/Blu
450 Yel/Wht
455 X13 170 Blk X15 173 Blk
Yel/Wht
451 X15
Yel/Wht 459
Yel/ X13
830 Gry Wht
830 Gry
755 Blu 755 Blu 110

X11 Y3 PTO X12 E5 RH Blk

Clutch Tail Light

758 Solenoid 420 Yel X16 130 Blk
Blu
A3 PTO Interlock Module X16
X7 V5 E6 RH
J5-C Diode Backup Light
116
K7 Brake Blk X11 820 Pur X17 150 Blk
Lock Relay
X7 115 X17
X8 140 Blk Blk E7 LH
J5-A 451
J4-D Yel/ Tail Light
X7 Wht X18
400 Yel 100 Blk
K8 Off
J5-B
Seat X3 X18
Relay 19 E8 LH
X8 742
X8
J4-A Blu/Wht Backup Light
J4-B 800 Pur X19 110 Blk
K9 S8
Mid Mid H7 X19
PTO X6 S10 Accessory 120
Relay
PTO Dash Switch Blk
X8 Switch
Off
Light 140 Blk
J4-C On
X9 592 Pnk
593 Pnk X12
J6-A K10 Rear 122
X20 12 VDC
On
Off

PTO Relay Blk

X9 X6 Power Plug
520 115 Blk
J6-B Yel
504 Yel X3 135 Blk
X2
655 Pnk 20

900 Blk/Wht 651 Pnk/Blk X21 Wht

B2 Fuel
Gauge X10 X10
Wht Wht
Sensor Blk Blk
M
Q E9 E10
Spark Spark
M2 Fuel Plug Plug
Pump
T1 Ignition T2 Ignition
X10 Coil
Coil
120
100 Blk Blk
110 Blk 110 Blk

SE3 - Instrumentation and Interlocks SE4 - Ignition SE5 - Lights

MIF

Electrical Schematics and Harnesses - 196

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X485 and X585 (1 of 4)

592 Blu
Wht
940 Wht
S2
Wht
592 S1 X5 H-B A1 Ignition Interlock Module
Blu S2
S1
S1 S2 X4
X1
Red A F4 Fuse -15 A F-2
B A
A X4
M
F1 Wht F5 Fuse -15 A F-6
20A
Fuse
G M X4
M
F-3
200
Start X5
Red
202 Run H-F
Red
S1 Key Off X4
Switch F-5
G2
Alternator E1 Grn K5
X2 LED Ignition
K2 Magneto
G Blk K1
Start Relay Seat Relay K6
X5
Start Relay PTO Relay
Blk
H-C
590 595
201
Brn/ Brn/ X5
Red
Yel Wht
F3 H-D
Fusible + X5
Link
U 720 Pur X4
H-A
N1 - F-1 K3 RIO X4
Rectifier/ Latch Relay E2 Red
125 600 504 721 K4 RIO LED
F2 Regulator Blk Brn Yel Pur Unlatch Relay PTO
F-4
Fusible X5
Link
H-G
203 205 X5 H-E X5 H-H
Blk Lt Blu
720 Pur 130 605 Tan
Blk 504 Yel
215 Gry 215 Gry
Red
X3 V1 Diode V2 Diode
721 Pur
B S X3 503 Yel 11
14
H1 17
H2 Engine
Discharge Oil H3 P1
M Light Pressure Service Hourmeter
M1 Light Indicator
+ _ H4 RIO
Starting Defeat
Motor Y1
Starting
Motor X2 X3
Blu/ 620 Tan
Solenoid Red
A2 Service
15
X3 850 Pnk Light Timer
7
Module
3 P
G1 136
S2 Service Timer
Battery
Blk X3
Reset Switch (SN -30000)
B1 Engine Oil 20 135
(SN -30000)
Reset

Off

151
Blk Pressure Blk
Blk
100 Blk Switch (NC) 100 Blk
110 Blk 110 Blk

W1
Frame Ground Unswitched Power Switched Power Secondary Power
Unswitched Ground Control Panel Wiring Harness

SE1 - Starting SE2 - Charging SE3 - Instrumentation and Interlocks

MIF

Electrical Schematics and Harnesses - 197

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X485 and X585 (2 of 4)
592 Blu 400 Yel/Blu
940 Wht 940 Wht 650 Pnk/Blk

S5 PTO/RIP
400 Yel/Blu Switch X2
RIP*
Blk
On
500 Yel
Off To
731 Pur
6 730 Grn SE6
754 Blu 3 830 Gry
705 Pnk/Blk 754 Blu
756 Blu
5 755 Blu 755 Blu
750 Blu 2
8 650 Pnk/Blk
786 Blu
652 Blu 4 652 Blu S6 Brake
705 Pnk/Blk 1
7 765 Pur Switch
789 Pur
Off
750 Blu On
751 Blu 751 Blu 787 Pur

770
S3 Seat 765 Pur
501 Yel Pur
Switch
(Off) 767 Pur
786 Blu
(On)
800 Pnk 502 Yel
605 Tan

820 Pnk 820 Pnk

735 Org
770 Pur
772 Blu
S4 RIO** Neutral/
S7 Rear
Forward
Switch 767 PTO Switch
Reverse Pur
730 Grn
505 Yel 830 Gry Off 789 Pur
735 Org
772 Blu 731 On 756 Blu
605 Tan
Pur X6 740 Blu
504 Yel
215 Gry X6
X3
790 757 Yel
1 Tan
504 Yel
P3 Engine Coolant P2 Fuel 6
F6 Fusible Link F7 Fuse 785 Grn
Temperature Gauge Gauge 220 Red 221 Red
X3
Q 900 Blk/Wht 900 Blk/Wht
t0
8
X3 H9 785
2 310 Brake X3 X3 Grn
4 5
Org/ Light H5 Rear H6 Mid X3
Wht (SN 30001-) PTO Light PTO Light 16

X2
*RIP = Reverse Implement Position
Yel
**RIO = Reverse Implement Option H8 EFI
V3 V4 Diagnostic
B3 Engine Coolant Diode Diode
t0
Light
Temperature
Sensor
100 Blk 100 Blk
110 Blk 110 Blk

SE3 - Instrumentation and Interlocks

MIF

Electrical Schematics and Harnesses - 198

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X485 and X585 (3 of 4)
592 E3 RH Headlight
400 Yel/Blu
S9 Light Blu X14
On
650 Pnk/Blk Switch 171 172
670 Pur On
Blk X14 Blk
670 Off
810 Pnk
E4 LH Headlight
86 87 87a K11 EFI Pur
400 Yel/Blu
Module X22 450 Yel/Wht
455 X13 170 Blk X15 173 Blk
Yel/Wht
85 30 Ground Org 451 X15
Relay 459
138
139 To Yel/Wht
Blk Yel/ X13
830 Gry
Blk SE6 830 Gry
Wht

755 Blu 110

755
X12 E5 RH Blk
Blu
Tail Light
420 Yel X16 130 Blk
A3 PTO Interlock Module X11
X16
X7 758 Y3 PTO
Blu E6 RH
J5-C V5 Clutch Backup Light
Diode Solenoid X17
K7 Brake 820 Pur 150 Blk
Lock Relay
X7 X17
X8 140 Blk E7 LH
J5-A 451
J4-D Yel/ Tail Light
X7 116 Wht X18
K8 Off Blk X11 400 Yel 100 Blk
J5-B
Seat 115 X3 X18
Relay 19 E8 LH
X8 742
Blk
X8
J4-A Blu/Wht Backup Light
J4-B 800 Pur X19 110 Blk
K9 S8
Mid Mid H7 X19
PTO X6 S10 Accessory 120
Relay
PTO Dash Switch Blk
X8 Switch
Off
Light 140 Blk
J4-C On
X9 592 Pnk
593 Pnk X12
J6-A K10 Rear 122
X20 12 VDC
On
Off

PTO Relay Blk

X9 X6 Power Plug
520 X3 135 Blk
J6-B 504 Yel Yel
785 Grn
20
785 Grn X22 Red
221 Red

900 Blk/Wht 651 Pnk/Blk

560
221 Red
230 Red 233 Red/Blu X23 Wht
X10 X10 Red /Yel
K12 EFI 87a 87 86 231
Module Red 232
Red
M Power
Q 30 85 87a 87 86
Relay K13 Fuel
230
Pump Relay
B2 Fuel M2 Fuel
Red
30 85
Gauge Pump 910 Wht X22 Brn
655
Sensor X21
X10 Pnk

120 150 115 140

Blk Blk Blk Blk
100 Blk 100 Blk
110 Blk 110 Blk

SE3 - Instrumentation and Interlocks SE4 - Ignition SE5 - Lights

MIF

Electrical Schematics and Harnesses - 199

 ELECTRICAL SCHEMATICS AND HARNESSES
Electrical Schematic - X485 and X585 (4 of 4)

To Blk
SE3
Blk
Blk Blk
Blk Blk

E9 E10
Spark Spark
Plug Plug
X24
T1 Ignition T2 Ignition
To Org Coil Coil
SE4 X26
W2 Ground
A
B
C
Y4 #1 Cylinder X25
Fuel Injector D
Yel/Blu Yel/Blu A 160 Blk
Solenoid E
Blk/Wht B 330 Org
F
Brn C 460 Yel A4
G
Blk/Yel D 510 Blu Electric
H
Yel/Red E 610 Tan Fuel
I Injection
Y5 #2 Cylinder Wht Blk/Wht F 710 Pur
Fuel Injector Yel/Red G
J Module
K
Solenoid Org H 860 Pnk
L
Red I 950 Wht
M
Blk J 170 Brn
N
Red/Blu K 340 Grn
O
Wht Wht L 240 Red
P
Tan M 470 Yel
N
Grn O 515 Blu
Blu P 615 Tan

Grn

B5 Air
to Temperature
Red Sensor
Blu
Blk/Yel
B4 Engine
Coolant
Wht to Temperature
Sensor
Blk/Yel

Blk/Yel
B6 Vacuum
Red/Blu
Brn m Pressure
Sensor
Tan

SE6 - Ignition and Carburetion - X485 and X585

MIF

Electrical Schematics and Harnesses - 200

 ELECTRICAL SCHEMATICS AND HARNESSES
W1 Main Wiring Harness - X465 (1 of 2)

AA
730
652 130
605
X5 to A1
Interlock
Module
735
940 800
720
721 400
X4 to A1
Interlock BB
Module
X1 to 705
Key Switch 770 750 500
772 751
200
140
X8 to A3 742
M1 PTO Interlock
Starting Module 820
789
Motor
605
X7 to A3
Fusible CC
PTO Interlock
Links 205 203
Module 787
786
W1
Frame
Ground 740 757
756
201
100
200 202
110 X9 Connector

DD

Y1 Start
Solenoid

720

S6 Brake
Switch
X2 to W2
501 751
110 Engine Wiring
Harness
455 650 770
765
600 201 767 787
X13 to W3
(SN -30001)
Headlight
Wiring Harness
620
940

MIF

Electrical Schematics and Harnesses - 201

 ELECTRICAL SCHEMATICS AND HARNESSES
W1 Main Wiring Harness - X465 (2 of 2)
755
S5 PTO/RIP 750 754 650
Switch 786 652
X3 to
765 Instrument Panel
754 705
AA 789
10 20
9 19 1 = 731 11 = 721
730 754 8 18 3 = 136 14 = 600
731 756 7 17 4 = 790 15 = 620
6 16 5 = 757
5 15 6 = 767**
4 14
17 = 503
7 = 850* 19 = 451
3 13
S9 Light 2 12 8 = 900 20 = 135
Switch 1 11
450 (* SN -30000)
(** SN 30001-)
BB
400
810 505

151 S2 Service Timer

Reset Switch (SN -30000)
850

CC
F1 Fuse

S4 RIO
202
Switch
592 735
772 830

450 451 505

455 459
100
120
130
135 500 B

136 115 501 A

140 120 503 502 900
122 520
151 X10 to B2
DD Fuel Gauge Sensor

122 459
(SN -30000) V5
Diode
758 592 810
116 830
X11 to Y3 X12 to W4
PTO Clutch
S3 Seat Rear Wiring
Switch 115 Harness
790 520 116
502 755
740 742 758
800 X6 to W5
820 PTO Solenoid
Wiring Harness

MIF

Electrical Schematics and Harnesses - 202

 ELECTRICAL SCHEMATICS AND HARNESSES
W2, W6 and W7 Engine Wiring Harnesses - X465

To B1 Engine Oil X5 To W3 Engine

Pressure Switch Wiring Harness

X7 To W5 Engine
Wiring Harness
Blk
X4 To W1 Main
Wiring Harness Brn
Grn
620 Tan 940 Wht W2 Engine
Wiring Harness
Red

Grn
600 Brn 650 Pnk/ 201 Red
Blk
Yel

To N1 Voltage
Regulator/Rectifier

W6 Engine T1 Magneto
Wiring Harness Ignition Coil
X5 To W2 Engine Blk
Wiring Harness
Blk

Splice
Blk T2 Magneto
Ignition Coil

W7 Engine
Wiring Harness
X7 To W2 Engine
Wiring Harness Y2 Fuel
Grn Shutoff
Solenoid

MIF

Electrical Schematics and Harnesses - 203

 ELECTRICAL SCHEMATICS AND HARNESSES
W1 Main Wiring Harness - X475 and X575 (1 of 2)

AA
730
652 130
605
X5 to A1
Interlock
Module
735
940 800
720
721 400
X4 to A1
Interlock BB
Module
X1 to 705
Key Switch 770 750 500
772 751
200
140
X8 to A3 742
M1 PTO Interlock
Starting Module 820
W1 789
Motor
Frame 605
Ground X7 to A3
Fusible CC
PTO Interlock
Links 205 203
100 Module 787
786
110
740 757
756
201

200 202
X9 Connector

DD

Y1 Start
Solenoid 651

X21
720 Connector

655 S6 Brake
Switch
X2 to W2
501 751
Engine Wiring
110
Harness
940 770
455 765
595 590 767 787
X13 to W3 (SN -30001)
Headlight
Wiring Harness 620 310
650
655

MIF

Electrical Schematics and Harnesses - 204

 ELECTRICAL SCHEMATICS AND HARNESSES
W1 Main Wiring Harness - X475 and X575 (2 of 2)

755
S5 PTO/RIP 750
754 650
Switch 786 652
X3 to
765 Instrument Panel
754 705
AA 789
10 20
9 19 1 = 731 8 = 900
730 754 8 18 2 = 310 11 = 721
731 756 7 17 3 = 136 14 = 600
6 16 4 = 790 15 = 620
5 15
5 = 757 17 = 503
4 14
3 13 6 = 767** 19 = 451
S9 Light 2 12 7 = 850* 20 = 135
Switch 1 11
450 (* SN -30000)
BB (** SN 30001-)

400
810 505

151 S2 Service Timer

Reset Switch
850 (SN -30000)
125
504
201 N1
CC Voltage
F1 Fuse Rectifier/Regulator
595
600
590 S4 RIO
Switch
202 592 735
772 830

450 451 505

455 459 100
120
125 651
130
135 500
136 115 501
140 120 503 502
X10 to 900
151 122 504 520
M2 Fuel Pump and
DD B2 Fuel Gauge Sensor

(SN -30000) 122 459

V5
Diode
758 592 810
116 830
X11 to Y3
PTO Clutch X12 to W4
S3 Seat Rear Wiring
Switch 115 Harness
790 520 116
502 755
740 742 758
800 X6 to W5
820 PTO Solenoid
Wiring Harness
MIF

Electrical Schematics and Harnesses - 205

 ELECTRICAL SCHEMATICS AND HARNESSES
W2 Engine Wiring Harness - X475 and X575

Yel/Wht

Y2 Fuel
Shutoff
Solenoid
Wht
X2 to W1 Main
T1 Wiring Harness Wht
Ignition
Coil Blk Blk

T2 Blu/Red Yel
Ignition
Coil Yel/Wht
Blk
Wht
Blk

B1 Engine Oil
Pressure
Switch (NC)
Blu/Red
G2
Alternator
Yel
B3 Engine Coolant
Temperature Sensor
MIF

Electrical Schematics and Harnesses - 206

 ELECTRICAL SCHEMATICS AND HARNESSES
W1 Main Wiring Harness - X485 and X585 (1 of 2)

X21 Connector
K13 Fuel
655 651
231 Pump Relay
232
232
AA
232 730
655 910
652 130
605
221 F7 Fuse
X5 to A1
220 Interlock
K12 EFI Module
Module
221 Power Relay 735
940 800
560 720
721 400
230 150 X4 to A1
K11 EFI Module Interlock BB
Ground Relay Module
670 X1 to 705
Key Switch 770 750 500
138 772 751
138
200
138 650 140
139 X8 to A3 742
M1 PTO Interlock
Starting Module 820
X25 to W2 789
W1 Motor Engine
Frame 605
Wiring Harness X7 to A3
Ground
Fusible CC
215 ABCD PTO Interlock
Links 205 203
100 E FGH Module 787
I J KL 786
MNOP
110
A = 160 I = 950
B = 330 J = 170 740 757
C = 460 K = 340 756
201
D = 510 L = 240
220
200 202 E = 610 M = 470
F = 710 O = 515 X9 Connector
H = 860 P = 615

DD
X23 to W2
Engine
Y1 Start Wiring Harness
Solenoid
233
720 X22 to W2
Engine Wiring 910
Harness 785 S6 Brake
Switch
X2 to W2
670 501 751
Engine Wiring
110
Harness
940 770
455 765
595 590 767 (SN -30001) 787
X13 to W3
Headlight
Wiring Harness 620 310

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Electrical Schematics and Harnesses - 207

 ELECTRICAL SCHEMATICS AND HARNESSES
W1 Main Wiring Harness - X485 and X585 (2 of 2)

755
S5 PTO/RIP 750 754 650 1 = 731 11 = 721
Switch 786 652 2 = 310 14 = 600
3 = 136 15 = 620
765 4 = 790 16 = 785
754 705
AA 789 X3 to 5 = 757 17 = 503
Instrument Panel 6 = 767** 19 = 451
730 754 7 = 850* 20 = 135
10 20
731 756 9 19 8 = 900
8 18
7 17 * (SN -30000) X26 to A4
6 16 ** (SN 30001-) Electric Fuel
5 15 Injection Module
4 14
3 13 160
2 12 330 610
S9 Light 1 11
BB Switch 460 710
450
510
860
400 470
505 950
810
170 515
151 S2 Service Timer 340
Reset Switch 615
240
850 (SN -30000)
125
504
201 N1
CC Voltage
F1 Fuse Rectifier/Regulator
595
600
590 S4 RIO
202
592 Switch
231 230 735
233 772 830
100
450 451 125 505
455 459 130
120
135 651
136 500
139 501
140 115 503 502
150 120 504 520
X10 to 900
151 122 560
M2 Fuel Pump and
DD B2 Fuel Gauge Sensor

122 459
(SN -30000) V5
Diode
758 592 810
116 830
X11 to Y3 X12 to W4
PTO Clutch
S3 Seat Rear Wiring
Switch 115 Harness
790 520 116
502 755
740 742 758
800 X6 to W5
820 PTO Solenoid
Wiring Harness
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Electrical Schematics and Harnesses - 208

 ELECTRICAL SCHEMATICS AND HARNESSES
W2 Engine Wiring Harness - X485 and X585

Dk Blk
X2 to W1 Main
T1 Wiring Harness Dk Blk
Ignition Lt Blk Lt Blk
Coil

T2 Blu/Red Yel
Ignition
Coil
Dk Blk Lt Blk Lt Blk

B1 Engine Oil
Pressure
Switch (NC)
Blu/Red
Wht Yel/Blu
G2
Alternator
Y4 #1 Cylinder
B5 Air Fuel Injector
Solenoid Yel Dk Blk
Temperature
Sensor B3 Engine Coolant
Grn AB
Temperature Sensor
AB

X24
Connector
Blk/Yel

B4 Engine Coolant Blk/Wht Blk

Temperature Sensor X22 to W1 Main Brn
W2 Ground
Blu Wiring Harness Red
AB

Org
Blk/Yel
B6 Vacuum
Pressure Sensor
Blk/Yel X23 to W1 Main
Wiring Harness

Tan Wht
AB
Red/Blu
Y5 #2 Cylinder
A = Yel/Blu I = Red
Fuel Injector
B = Blk/Wht J = Blk
Solenoid
C = Brn K = Red/Blu
D = Blk/Yel L = Wht
MNOP
E =Yel/Red M = Tan I J KL
Wht Yel/Red F = Blk/Wht O = Grn E FGH
ABCD
H = Org P = Blu
X25 to W1 Main
Wiring Harness

Electrical Schematics and Harnesses - 209

 ELECTRICAL SCHEMATICS AND HARNESSES
W2 Engine Wiring Harness Circuit Schematic - X485 and X585

X2 to Main W1 Main
Wiring Harness
Dk Blk Dk Blk
T1 Ignition Coil

T2 Ignition Coil
Dk Blk B3 Engine Yel
Coolant
Temperature
Sensor

X24
Dk Blk X22 to W1
Main Wiring
Blk Harness
Blu/
Red
Red Org Brn
B1 Engine
Oil Pressure
Switch

B5 Air Blk/Yel
Temperature Grn
Sensor X25 to W1 Main
Wiring Harness
A
B
C
Blk/Yel
B4 Engine D
Coolant Blu E
Temperature F
Sensor G
H
Blk/Yel
B6 Vacuum I Lt Blk Lt Blk
Pressure Tan J
Sensor Red/Blu
K
L
M
Y4 #1 Yel/Blu N
Cylinder Wht
O
Fuel Injector P
Solenoid
G2 Alternator

Y5 #2 Yel/Red
Cylinder
Wht
Fuel Injector
Solenoid

Blk/ Blk/
Wht Wht

Wht
X23 to W1
Main Wiring
Harness
W2 Ground

Electrical Schematics and Harnesses - 210

 ELECTRICAL SCHEMATICS AND HARNESSES
W3 Headlight Wiring Harness

E3 RH
Headlight

Blk Blk X13 To W1 Main

Wiring Harness
Blk
E4 LH
Blk
Headlight

MIF

W4 Rear Wiring Harness

E8 Left E7 Left E5 Right E6 Right

Backup Tail Tail Backup
Light Light Light Light

110 100 130 150

800 420 820

400
150
110 130
100 120

592
593

S10 Accessory
Switch X12 to Main
Wiring Harness
593 592 800
820
D B

X20 12 VDC C A
Power Plug 120 400
140 140 420
MIF

W5 PTO Option Wiring Harness

790 S7 Rear
PTO Switch

740 520 790

X6 to Main
Wiring Harness

742 742 740

S8 Mid
520 PTO Switch
MIF

Electrical Schematics and Harnesses - 211

 ELECTRICAL SCHEMATICS AND HARNESSES
W1 Main Wiring Harness Color Codes - X465 Size/No./Color Wire Connection Points

Size/No./Color Wire Connection Points 0.8 650 Pnk/Blk S5, X2

2.0 100 Blk W1, Splice 0.8 652 Blu X5, S5

1.0 110 Blk W1, X13 0.5 705 Pnk/Blk X4, S5

0.8 115 Blk Splice, X11 1.0 720 Pur Y1, X4

0.8 116 Blk V5, X11 0.8 721 Pur X4, X3

0.8 120 Blk Splice, X10 0.8 730 Grn S5, X5

3.0 122 Blk Splice, X12 0.8 731 Pur S5, X3

0.5 130 Blk Splice, X5 0.8 735 Org X5, S4

0.5 135 Blk Splice, X3 0.5 740 Blu X6, X9

0.5 136 Blk Splice, X3 0.5 742 Blu/Wht X6, X8

0.5 140 Blk Splice, X8 0.8 750 Blu S5, X4

0.8 151 Blk Splice, S2 (SN -30000) 0.8 751 Blu X4, S6

3.0 200 Red F3, X1 0.8 754 Blu S5, S5

2.0 201 Red F3, N1 0.8 755 Blu S5, X11

3.0 202 Red F2, F1 0.8 756 Blu X9, S5

1.0 203 Blk Fusible Link F2, M1 0.5 757 Yel X9, X3

0.8 205 Lt Blu Fusible Link F3, M1 0.8 758 Blu X11, V5

1.0 400 Yel/Blu X4, S9 0.8 765 Pur S5, S6

1.0 450 Yel/Wht S9, Splice 0.8 767 Pur S6, H8

0.5 451 Yel/Wht Splice, X3 0.8 770 Pur S6, X4

1.0 455 Yel/Wht Splice, X13 0.8 772 Blu X4, S4

0.8 459 Yel/Wht Splice, X12 0.5 786 Blu S5, X7

1.0 500 Yel X4, Splice 0.5 787 Pur X7, S6

0.5 501 Yel Splice, S6 0.5 789 Pur S5, X8

0.5 502 Yel Splice, S3 0.5 790 Tan X6, X3

0.5 503 Yel Splice, X3 0.8 800 Pnk X5, S3

0.8 505 Yel S9, S4 0.8 810 Pnk X12, S9

0.5 520 Yel Splice, X6 0.5 820 Pnk S3, X8

3.0 592 Blu X12, F1 0.8 830 Gry X12, S4

0.5 600 Brn N1, X3 0.8 850 Pnk S2, X3 (SN -30000)

0.5 605 Tan X5, X7 0.5 900 Blk/Wht X10, X3

0.5 620 Tan X2, X3 0.8 940 Wht X2, X5

Electrical Schematics and Harnesses - 212

 ELECTRICAL SCHEMATICS AND HARNESSES
W1 Main Wiring Harness Color Codes - X475 Size/No./Color Wire Connection Points
and X575
2.0 590 Brn/Yel N1, X2
Size/No./Color Wire Connection Points 3.0 592 Blu X12, F1
3.0 100 Blk W1, Splice 2.0 595 Brn/Wht N1, X2
1.0 110 Blk W1, X13 0.5 600 Brn N1, X3
0.8 115 Blk Splice, X11 0.5 605 Tan X5, X7
0.8 116 Blk V5, X11 0.5 620 Tan X2, X3
0.8 120 Blk Splice, X10 0.8 650 Pnk/Blk S5, X2
3.0 122 Blk Splice, X12 0.8 651 Pnk/Blk X10, X21
2.0 125 Blk Splice, N1 0.8 652 Blu X5, S5
0.5 130 Blk Splice, X5 0.8 655 Pnk X2, X21
0.5 135 Blk Splice, X3 0.5 705 Pnk/Blk X4, S5
0.5 136 Blk Splice, X3 1.0 720 Pur Y1, X4
0.5 140 Blk Splice, X8 0.8 721 Pur X4, X3
0.8 151 Blk Splice, S2 (SN -30000) 0.8 730 Grn S5, X5
2.0 200 Red F3, X1 0.8 731 Pur S5, X3
2.0 201 Red F3, N1 0.8 735 Org X5, S4
3.0 202 Red F2, F1 0.5 740 Blu X6, X9
1.0 203 Blk Fusible Link F2, M1 0.5 742 Blu/Wht X6, X8
0.8 205 Lt Blu Fusible Link F3, M1 0.8 750 Blu S5, X4
0.8 310 Org X2, X3 0.8 751 Blu X4, S6
1.0 400 Yel/Blu X4, S9 0.8 754 Blu S5, S5
1.0 450 Yel/Wht S9, Splice 0.8 755 Blu S5, X11
0.5 451 Yel/Wht Splice, X3 0.8 756 Blu X9, S5
1.0 455 Yel/Wht Splice, X13 0.5 757 Yel X9, X3
0.8 459 Yel/Wht Splice, X12 0.8 758 Blu X11, V5
1.0 500 Yel X4, Splice 0.8 765 Pur S5, S6
0.5 501 Yel Splice, S6 0.8 767 Pur S6, X3 (Pin 6 - instrument panel)
(SN 30001-)
0.5 502 Yel Splice, S3
0.8 770 Pur S6, X4
0.5 503 Yel Splice, X3
0.8 772 Blu X4, S4
0.5 504 Yel Splice, N1
0.5 786 Blu S5, X7
0.8 505 Yel S9, S4
0.5 787 Pur X7, S6
0.5 520 Yel Splice, X6
0.5 789 Pur S5, X8

Electrical Schematics and Harnesses - 213

 ELECTRICAL SCHEMATICS AND HARNESSES
Size/No./Color Wire Connection Points Size/No./Color Wire Connection Points

0.5 790 Tan X6, X3 0.8 205 Lt Blu Fusible Link F3, M1

0.8 800 Pnk X5, S3 0.5 215 Gry Fusible Link F4, M1

0.8 810 Pnk X12, S9 1.0 220 Red F6, F7

0.5 820 Pnk S3, X8 1.0 221 Red F7, K12

0.8 830 Gry X12, S4 0.8 230 Red K12, Splice

0.8 850 Pnk S2, X3 (SN -30000) 0.8 231 Red Splice, K13

0.5 900 Blk/Wht X10, X3 0.8 232 Red K13, K13

0.8 940 Wht X2, X5 0.5 233 Red/Blu Splice, X23

0.8 240 Red X25, X26

W1 Main Wiring Harness Color Codes - X485
and X585 0.8 310 Org X2, X3

0.8 330 Org X25, X26

Size/No./Color Wire Connection Points
0.8 340 Grn X25, X26
3.0 100 Blk W1, Splice
1.0 400 Yel/Blu X4, S9
1.0 110 Blk W1, X13
1.0 450 Yel/Wht S9, Splice
0.8 115 Blk Splice, X11
0.5 451 Yel/Wht Splice, X3
0.8 116 Blk V5, X11
1.0 455 Yel/Wht Splice, X13
0.8 120 Blk Splice, X10
0.8 459 Yel/Wht Splice, X12
3.0 122 Blk Splice, X12
0.8 460 Yel X25, X26
2.0 125 Blk Splice, N1
0.8 470 Yel X25, X26
0.5 130 Blk Splice, X5
1.0 500 Yel X4, Splice
0.5 135 Blk Splice, X3
0.5 501 Yel Splice, S6
0.5 136 Blk Splice, X3
0.5 502 Yel Splice, S3
1.0 138 Blk K11, K11
0.5 503 Yel Splice, X3
1.0 139 Blk Splice, K11
0.5 504 Yel Splice, N1
0.5 140 Blk Splice, X8
0.8 505 Yel Splice, S4
0.8 150 Blk Splice, K12
0.8 510 Blu X25, X26
0.8 151 Blk Splice, S2 (SN -30000)
0.8 515 Blu X25, X26
0.8 160 Blk X25, X26
0.5 520 Yel Splice, X6
0.8 170 Brn X25, X26
0.8 560 Red/Yel Splice, K12
2.0 200 Red F3, X1
2.0 590 Brn/Yel N1, X2
2.0 201 Red F3, N1
3.0 592 Blu X12, F1
3.0 202 Red F2, F1
2.0 595 Brn/Wht N1, X2
1.0 203 Blk Fusible Link F2, M1

Electrical Schematics and Harnesses - 214

 ELECTRICAL SCHEMATICS AND HARNESSES
Size/No./Color Wire Connection Points Size/No./Color Wire Connection Points

0.5 600 Brn N1, X3 0.5 787 Pur X7, S6

0.5 605 Tan X5, X7 0.5 789 Pur S5, X8

0.8 610 Tan X25, X26 0.5 790 Tan X6, X3

0.8 615 Tan X25, X26 0.8 800 Pnk X5, S3

0.5 620 Tan X2, X3 0.8 810 Pnk X12, S9

0.8 650 Pnk/Blk S5, K11 0.5 820 Pnk S3, X8

0.8 651 Pnk/Blk X10, X21 0.8 830 Gry X12, S4

0.8 652 Blu X5, S5 0.8 850 Pnk S2, X3 (SN -30000)

0.8 655 Pnk K13, X21 0.8 860 Pnk X25, X26

1.0 670 Pur K11, X22 0.5 900 Blk/Wht X10, X3

0.5 705 Pnk/Blk X4, S5 0.5 910 Wht X22, K13

0.8 710 Pur X25, X26 0.8 940 Wht X2, X5

1.0 720 Pur Y1, X4 0.8 950 Wht X25, X26

0.8 721 Pur X4, X3

W2 Engine Wiring Harness Color Codes -
0.8 730 Grn S5, X5 X475 and X575
0.8 731 Pur S5, X3
Size/No./Color Wire Connection Points
0.8 735 Org X5, S4
0.5 Blk X2, G2
0.5 740 Blu X6, X9
0.5 Blk X2, G2
0.5 742 Blu/Wht X6, X8
0.5 Wht X2, T1
0.8 750 Blu S5, X4
0.5 Wht X2, T2
0.8 751 Blu X4, S6
0.5 Yel/Wht X2, Y2
0.8 754 Blu S5, S5
0.5 Blu/Red X2, B1
0.8 755 Blu S5, X11
0.5 Yel X2, B3
0.8 756 Blu X9, S5

0.5 757 Yel X9, X3

0.8 758 Blu X11, V5

0.8 765 Pur S5, S6

0.8 767 Pur S6, X3 (SN 30001-)

0.8 770 Pur S6, X4

0.8 772 Blu X4, S4

0.5 785 Grn X22, X3

0.5 786 Blu S5, X7

Electrical Schematics and Harnesses - 215

 ELECTRICAL SCHEMATICS AND HARNESSES
W2 Engine Wiring Harness Color Codes - W3 Headlight Wiring Harness Color Codes
X485 and X585
Size/Color Wire Connection Points
Size/No./Color Wire Connection Points
0.8 Blk X14, E4
0.5 Lt Blk X2, G2
0.8 Blk X14, E4
0.5 Lt Blk X2, G2
0.8 Blk E3, E4
0.5 Dk Blk X2, T1
0.8 Blk E3, E4
0.5 Dk Blk X2, T2

0.5 Dk Blk X2, X24 W4 Rear Wiring Harness Color Codes

0.5 Blu/Red X2, B1 Size/No./Color Wire Connection Points
0.5 Yel X2, B3 0.8 100 Blk Splice, E7
0.5 Yel/Blu X25, Y4
0.8 110 Blk Splice, E8
0.5 Blk/Wht X25, Splice 0.8 120 Blk Splice, X12
0.5 Blk/Wht Splice, W2 0.8 130 Blk Splice, E5
0.5 Blk/Wht X25, Splice
2.0 140 Blk X12, X23
0.5 Brn X25, X22 0.5 150 Blk Splice, E6
0.5 Blk/Wht X25, Splice
2.0 400 Yel X12, E7
0.5 Blk/Yel Splice, B4 0.8 420 Yel X12, E5
0.5 Blk/Yel Splice, B5 2.0 592 Pnk X12, S10
0.5 Blk/Yel Splice, B6
2.0 593 Pnk S10, X23
0.5 Yel/Red X25, Y5 0.8 800 Pur X12, E8
0.5 Org X25, X22 0.8 820 Pur X12, E6
0.5 Red X25, X22

0.5 Blk X25, X24 W5 PTO Option Wiring Harness Color Codes
0.5 Red/Blu X25, B6 Size/No./Color Wire Connection Points
0.5 Wht X25, Splice 0.8 520 Yel X6, S8
0.5 Wht Splice, X25 0.8 740 Blu X6, S7
0.5 Wht Splice, Y4 0.8 742 Blu X6, S8
0.5 Wht Splice, Y5 0.8 790 Tan X6, S7
0.5 Tan X25, B6

0.5 Grn X25, B5

0.5 Blu X25, B4

Electrical Schematics and Harnesses - 216

 ELECTRICAL OPERATION AND DIAGNOSTICS
Operation and Diagnostics • S9 light switch - 400 Yel/Blu
• S6 brake switch - 501 Yel and (767 SN 30001-)/765 Pur
Power Circuit Operation - X465 • S5 PTO/RIP switch - 765 and 789 Pur, and 705 Pnk/Blk
Function: • S3 seat switch - 502 Yel
To provide unswitched and switched power to the primary • A3 PTO interlock module (option) - X8 connector J4-C
electrical components whenever the battery is properly terminal, 789 Pur
connected. The power circuits are divided among the • S4 RIO switch - 505 Yel
unswitched power circuit, switched power circuits (key
switch in run position), and secondary power circuits. The • Instrument panel - X3 connector 17 terminal, 503 Yel
secondary power circuits become energized when • S8 mid PTO switch (option) - 520 Yel
switched power circuits energize relays, providing current
• H8 brake light (pin 6 at X3 instrument panel connector)
paths to the secondary circuits. The secondary power
circuits will not be energized if the relays controlling the These circuits are controlled by the key switch and are
current path(s) fail. protected by the fusible links F2 - F3 and the F4 and F5
fuses.
Operating Conditions, Unswitched Circuits:
With power now available at various locations on the
Voltage must be present at the following components with machine, the electrical system is ready to perform the
the key switch in the off position. different functions of starting and running the engine,
• G1 battery positive terminal engine monitoring lights, the PTO clutch and the PTO
system interlocks, and the headlights.
• M1 starter - B terminal
The ground circuit is equally important as the power circuit
• S1 key switch - B terminal connections. Proper systems operation depends on good
• G2 Stator wires and connections in order to carry the current needed
to operate the various relays, solenoids and lights.
• F2 and F3 fusible links
• F1 fuse Operating Conditions, Secondary Switched Circuits:
• S10 accessory switch Secondary switched voltage must be present at the
following components during the following conditions: Key
• N1 voltage regulator/rectifier switch in run position, transmission in neutral, PTO in off
The positive battery cable connects the battery to the position, brake locked, and operator off seat:
starting motor. The starting motor bolt is used as the 12 volt • A1 ignition interlock module - X5 connector H-F
DC tie point for the rest of the electrical system. These terminal, 652 Blu
circuits are protected by the F2 and F3 fusible links and the
F1 fuse. The battery cables and the starting motor tie point • S5 PTO/RIP switch - 650 Pnk/Blk and 652, 750, and 786
connections must be good for the machine’s electrical Blu
system to work properly. Proper starting motor operation • Y2 fuel shutoff solenoid - 650 Pnk/Blk and Yel/Wht
depends on the battery cables to carry high current. The
ground cable connection is equally as important as the • A1 ignition interlock module - X4 connector F-5 terminal,
positive cable connection in maintaining electrical system 750 and 751 Blu
integrity. • A1 interlock module components - PTO relay common
and normally open terminals and ignition relay common
Operating Conditions, Switched Circuits: terminal
With the key switch in run position, PTO switch in off • S6 brake switch - 751 Blu
position, brake locked, and operator off the seat, switched
voltage should be present at the following components: • A3 PTO interlock module (option) - X7 connector J5-A
terminal, 786 Blu
• S1 key switch - terminal “A”
• A3 PTO interlock module (option) components - brake
• A1 ignition interlock module - X4 connector F-2, F-3 and lock relay normally open terminal
F-6 terminals
These circuits are controlled by the key switch and are
• A1 interlock module components - F4 and F5 fuse, start protected by the F3 fusible link and the F4 and F5 fuses.
relay common terminal and coil, ignition relay normally
open terminal and coil, magneto relay coil, and E1 Grn seat
LED.

Electrical Operation and Diagnostics - 217

 ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Wiring Schematic - X465
592 Blu

Wht
S2
Wht
592 X5 H-B A1 Ignition Interlock Module
S1
Blu S2
S1
S1 S2 X4
Red A F4 Fuse -15 A F-2
B A
A X4
20A F1 M
Wht F5 Fuse -15 A F-6
Fuse G M M X4
F-3
Start
X5
202 Run
Red H-F
S1 Key Off
Switch X4
X1 F-5
E1 Grn K5
K2 Magneto LED Ignition
200 K1 K6
Red Start Relay Start Relay Seat Relay
PTO Relay X5

H-C
X5
H-D
X5
X4
H-A
F-1 K3 RIO
E2 Red
X4
Latch Relay
K4 RIO LED
201 F-4
Unlatch Relay PTO
Red N1 X5
Rectifier/
X2 Regulator H-G
X5 H-E X5 H-H
+
U
F2 F3 -
Fusible Fusible
Link X2
Link
503 Yel
203 600
Blk 205 Brn
Lt Blu
14
X3
Red
503 Yel X3
17
H2 Engine H3 P1
B S Hourmeter
Oil Service
H1 Pressure Indicator
+ _ Discharge Light (SN -30000)
Light
M
M1 X3
X2
Starting Y1 620 Tan
Starting A2 Service
Motor Motor
Blu/ 15
Light Timer
Red
Solenoid Module
G1 B1 Engine Oil
P
Battery Pressure
Switch (NC)

Unswitched Power Switched Power Secondary Power

Unswitched Ground Control Panel Wiring Harness

MIF

Electrical Operation and Diagnostics - 218

 ELECTRICAL OPERATION AND DIAGNOSTICS

592 Blu
592
Blu
S9 Light
On
Switch On
X12
S5 PTO/RIP
Off S10 Accessory
400 Yel/Blu Switch 400 Yel/Blu
Switch Off
RIP* Yel/
Wht On
On
500 Yel X2 Y2 Fuel 592 Pnk
Off
Shutoff Neutral/
3 6 Solenoid 505
Forward
705 Pnk/Blk Yel
5 Reverse
750 Blu 2
786 Blu
8 650 Pnk/Blk S4 RIO
652 Blu 652 Blu
705 Pnk/Blk 1
4 Switch
7 765 Pur

750 Blu
A3 PTO Interlock Module
X7
751 Blu
789 J5-C
Pur
S3 Seat K7 Brake
Lock Relay
Switch
786 Blu X7
(Off) J5-A
S6 Brake
(On) Switch X7
502 Yel Off K8 Off
J5-B
Seat
Relay
751 Blu On X8 742
X8 Blu/Wht
J4-A
J4-B
765 Pur K9 S8
Mid Mid
501 Yel PTO X6
Relay
PTO
789 Pur X8 Switch
J4-C
X9
J6-A K10 Rear

On
Off
767 PTO Relay
Pur X9 X8 X6
520
J6-B J4-D Yel
503 Yel 520 Yel

P2 Fuel
Gauge 6

8 X3 H8
Brake
900
Blk/Wht
Light (SN 30001-)

X10

B2 Fuel
Q Gauge
Sensor

MIF

Electrical Operation and Diagnostics - 219

 ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Operation - X475 and X575 • S3 seat switch - 502 Yel
• A3 PTO interlock module (option) - X8 connector J4-C
Function: terminal, 789 Pur
To provide unswitched and switched power to the primary
• S4 RIO switch - 505 Yel
electrical components whenever the battery is properly
connected. The power circuits are divided among the • N1 voltage rectifier/regulator - 504 Yel
unswitched power circuit, switched power circuits (key • Instrument panel - X3 connector 17 terminal, 503 Yel
switch in run position), and secondary power circuits. The
secondary power circuits become energized when • S8 mid PTO switch (option) - 520 Yel
switched power circuits energize relays, providing current These circuits are controlled by the key switch and are
paths to the secondary circuits. The secondary power protected by the fusible links F2 - F3 and the F4 and F5
circuits will not be energized if the relays controlling the fuses.
current path(s) fail.
With power now available at various locations on the
Operating Conditions, Unswitched Circuits: machine, the electrical system is ready to perform the
different functions of starting and running the engine,
Voltage must be present at the following components with engine monitoring lights, the PTO clutch and the PTO
the key switch in the off position. system interlocks, and the headlights.
• G1 battery positive terminal The ground circuit is equally important as the power circuit
• M1 starter - B terminal connections. Proper systems operation depends on good
wires and connections in order to carry the current needed
• S1 key switch - B terminal
to operate the various relays, solenoids and lights.
• N1 voltage regulator/rectifier
Operating Conditions, Secondary Switched Circuits:
• F1 fuse
Secondary switched voltage must be present at the
• S10 accessory switch following components during the following conditions: Key
The positive battery cable connects the battery to the switch in run position, transmission in neutral, PTO in off
starting motor. The starting motor bolt is used as the 12 volt position, brake locked, and operator off seat:
DC tie point for the rest of the electrical system. These • A1 ignition interlock module - X5 connector H-F
circuits are protected by the F2 and F3 fusible links and the terminal, 652 Blu
F1 fuse. The battery cables and the starting motor tie point
connections must be good for the machine’s electrical • S5 PTO/RIP switch - 650 Pnk/Blk and 652, 750, and 786
system to work properly. Proper starting motor operation Blu
depends on the battery cables to carry high current. The • Y2 fuel shutoff solenoid - 650 Pnk/Blk and Yel/Wht
ground cable connection is equally as important as the
positive cable connection in maintaining electrical system • M2 fuel pump - 651 Pnk/Blk
integrity • A1 ignition interlock module - X4 connector F-5 terminal,
750 and 751 Blu
Operating Conditions, Switched Circuits:
• A1 interlock module components - PTO relay common
With the key switch in run position, PTO switch in off and normally open terminals and ignition relay common
position, brake locked, and operator off the seat, switched terminal
voltage should be present at the following components:
• S6 brake switch - 751 Blu
• S1 key switch - terminals “A”
• A3 PTO interlock module (option) - X7 connector J5-A
• A1 ignition interlock module - X4 connector F-2, F-3 and terminal, 786 Blu
F-6 terminals
• A3 PTO interlock module (option) components - brake
• A1 interlock module components - F4 and F5 fuse, start lock relay normally open terminal
relay common terminal and coil, ignition relay normally
open terminal and coil, magneto relay coil, and E1 Grn seat These circuits are controlled by the key switch and are
LED. protected by the F3 fusible link and the F4 and F5 fuses.

• S9 light switch - 400 Yel/Blu

• S6 brake switch - 501 Yel, 765 and (767 SN 30001-)Pur
• S5 PTO/RIP switch - 765 and 789 Pur, and 705 Pnk/Blk

Electrical Operation and Diagnostics - 220

 ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Electrical Schematic - X475 and X575

592 Blu

Wht
S2
Wht
592 X5 H-B A1 Ignition Interlock Module
S1
Blu S2
S1
S1 S2 X4
A
Red F4 Fuse -15 A F-2
B A
A X4
20A F1 M
Wht F5 Fuse -15 A F-6
Fuse G M M X4
F-3
Start
X5
202 Run
Red H-F
S1 Key Off
Switch X4
X1 F-5
E1 Grn K5
K2 Magneto LED Ignition
200 K1 K6
Red Start Relay Start Relay Seat Relay
PTO Relay X5

H-C
X5
H-D
X5
X4
H-A
F-1 K3 RIO
E2 Red
X4
Latch Relay
K4 RIO LED
201 F-4
Unlatch Relay PTO
Red X5
H-G
X5 H-E X5 H-H
+ N1
U Rectifier/
Regulator
F2 F3 -
Fusible Fusible 600 504
Link Link Brn Yel
500 Yel
203
205
Blk
Lt Blu

Red
503 Yel X3
X3
14 17
H2 Engine H3 P1
B S H1
Discharge Oil Service Hourmeter
Light Pressure Indicator
Light (SN -30000)
M + _

M1 X3
X2
Starting Y1 620 Tan
Starting A2 Service
Motor Motor
Blu/ 15
Light Timer
Red
Solenoid Module
G1 B1 Engine Oil
P
Battery Pressure
Switch (NC)

Unswitched Power Switched Power Secondary Power

Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 221

 ELECTRICAL OPERATION AND DIAGNOSTICS

592 Blu 592

Blu
S9 Light
On
Switch On
X12
S5 PTO/RIP
Off S10 Accessory
400 Yel/Blu
Switch 400 Yel/Blu
Switch Off
RIP* Yel/
Wht On
500 Yel On
X2 Y2 Fuel 592 Pnk
Off
Shutoff
3 6 Solenoid
705 Pnk/Blk 655
Pnk
5
750 Blu 2
8 650 Pnk/Blk
786 Blu
652 Blu 4 652 Blu
705 Pnk/Blk 1
7 765 Pur

750 Blu
789 A3 PTO Interlock Module
Pur
X7
751 Blu
J5-C

S3 Seat K7 Brake
Lock Relay
Switch
786 Blu
X7
(Off) J5-A
S6 Brake
(On)
Switch X7
502 Yel Off K8 Off
J5-B
Seat
Relay
751 Blu On X8 742
X8 Blu/Wht
J4-A
501 Yel J4-B
765 Pur K9 S8
Mid Mid
PTO X6
Relay
PTO
789 Pur X8 Switch
S4 RIO** Neutral/ J4-C
Switch
Forward
767
X9
Reverse Pur 655 J6-A K10 Rear

On
Off
505 Yel Pnk PTO Relay
X9 X8 X6
520
J6-B J4-D Yel
500 Yel

X21
P2 Fuel
P3 Engine Coolant Gauge
651
Temperature Gauge X3 Pnk
Q 900 Blk/Wht
/Blk 767
8
t0 X10
Pur
X10
X3 6
2 310 H8
B2 Fuel Brake
Org/ M M2 Fuel
Wht Gauge Q Light (SN 30001-)
Sensor Pump
X2

B3 Engine Coolant
t0 Temperature
Sensor

Electrical Operation and Diagnostics - 222

 ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Diagnosis - X465, X475 and X575

Test Conditions:
• Key switch off.

Test/Check Point Normal If Not Normal

1. Starting motor solenoid Battery voltage Test battery and cable connections.

2. Key switch Battery voltage Test F3 fusible link. Check 200 Red wire and connections.

3. Voltage rectifier/regulator Battery voltage Test F3 fusible link. Check 201 Red wire and connections.

4. Accessory switch Battery voltage Test F1 fuse and F2 fusible link. Check 202 Red, 592 Blu
and 592 Pnk wires and connections.

Test Conditions:
• Key switch in run position, engine not running.
• Brake locked.
• PTO off.
• Transmission in neutral.
• Operator off seat.

Test/Check Point Normal If Not Normal

5. Ignition interlock module Continuity to ground Check 130 and 100 Blk wires and connections.

6. Ignition interlock module Battery voltage Test F4 fuse. If ok, replace ignition interlock module.

7. Light switch Battery voltage Check 400 Yel/Blu wire and connections.

8. Ignition interlock module Battery voltage Test F5 fuse. If ok, replace ignition interlock module.

9. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

10. PTO/RIP switch Battery voltage Check 765 Pur wire and connections. If ok, replace brake
switch.

11. PTO interlock module Battery voltage Check 789 Pur wire and connections. If ok, replace brake
(option) switch.

12. Ignition interlock module Battery voltage Check 705 Pnk/Blk wire and connections. If ok, replace
PTO/RIP switch.

13. Ignition interlock module Battery voltage, green Replace ignition interlock module.
LED illuminated

14. Fuel pump Battery voltage Check 652 Blu, 650, and 651 Pnk/Blk wires and
connections.

15. Brake switch Battery voltage Check 750 and 751 Blu wires and connections. If ok,
replace PTO/RIP switch.

16. PTO interlock module Battery voltage Check 786 Blu wires and connections. If ok, replace PTO/
(option) RIP switch.

17. Seat switch Battery voltage Check 500 and 502 Yel wires and connections.

Electrical Operation and Diagnostics - 223

 ELECTRICAL OPERATION AND DIAGNOSTICS
Test/Check Point Normal If Not Normal

18. RIO switch Battery voltage Check 500 and 505 Yel wires and connections.

19. Voltage rectifier/regulator (not Battery voltage Check 500 and 504 Yel wires and connections.
on X465)

20. X3 instrument panel Battery voltage Check 500 and 503 Yel wires and connections.
connector

21. Mid PTO switch (option) Battery voltage Check 500 and 520 Yel wires and connections.

Electrical Operation and Diagnostics - 224

 ELECTRICAL OPERATION AND DIAGNOSTICS

M1 Starting S10 Accessory Switch

Motor
F2 Fusible Link 202 Red
F1 Fuse X12
592 Blu

N1 Voltage 592
201 Red Pnk
Regulator/Rectifier
F3 Fusible 200 Red
1 Link
4

19
A1 Ignition
Interlock Module 504 Yel
2 200 3
G1 Battery 201 Red
Red

X3 Instrument
S1 S2
500 Yel
Panel Connector
503 Yel

A1
8
12 M
S6 Brake
M
751 Blu Switch
A1 15 20
S2
501
5 Yel
6
13 S1

130 Blk S5 PTO/RIP

S3 Seat 9
Switch Switch
100 650
Blk 17 Pnk
/Blk
502 Yel 10

652 Blu
400
765 Pur
Yel/
Blu 705 Pnk/Blk
786
750 Blu
S9 Light Blu
Switch
S4 RIO 650
7
Pnk
S8 Mid PTO Switch Switch
/Blk
520 18
Yel Y2 Fuel
505 Yel
Shutoff
A3 PTO Interlock Module 21
Solenoid
16
651 655
786 Blu X21
14 Pnk/Blk Pnk

M2 Fuel
789 Pur Pump

11

Electrical Operation and Diagnostics - 225

 ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Operation - X485 and X585 • S6 brake switch - 501 Yel, 765 (767 SN 30001-) Pur
• S5 PTO/RIP switch - 765 and 789 Pur, and 705 Pnk/Blk
Function:
• S3 seat switch - 502 Yel
To provide unswitched and switched power to the primary
electrical components whenever the battery is properly • A3 PTO interlock module (option) - X8 connector J4-C
connected. terminal, 789 Pur
The power circuits are divided among the unswitched • S4 RIO switch - 505 Yel
power circuit, switched power circuits (key switch in run • N1 voltage rectifier/regulator - 504 Yel
position), and secondary power circuits. The secondary
power circuits become energized when switched power • Instrument panel - X3 connector 17 terminal, 503 Yel
circuits energize relays, providing current paths to the • K12 EFI module power relay - 86 terminal, 560 Red/Yel
secondary circuits. The secondary power circuits will not be
• S8 mid PTO switch (option) - 520 Yel
energized if the relays controlling the current path(s) fail.
These circuits are controlled by the key switch and are
Operating Conditions, Unswitched Circuits: protected by the fusible links F2, F3 and F6, and the F4,
Voltage must be present at the following components with F5, and F7 fuses.
the key switch in off position. With power now available at various locations on the
• G1 battery positive terminal machine, the electrical system is ready to perform the
different functions of starting and running the engine,
• M1 starter - B terminal engine monitoring lights, the PTO clutch and the PTO
• S1 key switch - B terminal system interlocks, and the headlights.
• N1 voltage regulator/rectifier The ground circuit is equally important as the power circuit
connections. Proper systems operation depends on good
• F1 fuse
wires and connections in order to carry the current needed
• S10 accessory switch to operate the various relays, solenoids and lights.
• K12 EFI module power relay - 87 terminal, 221 Red
Operating Conditions, Secondary Switched Circuits:
The positive battery cable connects the battery to the Secondary switched voltage must be present at the
starting motor. The starting motor bolt is used as the 12 volt following components during the following conditions: Key
DC tie point for the rest of the electrical system. These switch in run position, transmission in neutral, PTO in off
circuits are protected by the F2, F3 and F6 fusible links and position, brake locked, and operator off seat:
the F1 and F7 fuses.
• A1 ignition interlock module - X5 connector H-F
The battery cables and the starting motor tie point terminal, 652 Blu
connections must be good for the machine’s electrical
system to work properly. Proper starting motor operation • S5 PTO/RIP switch - 650 Pnk/Blk and 652, 750, and 786
depends on the battery cables to carry high current. The Blu
ground cable connection is equally as important as the • Y2 fuel shutoff solenoid - 650 Pnk/Blk and Yel/Wht
positive cable connection in maintaining electrical system
integrity. • K11 EFI module ground relay - 86 terminal 650 Pnk/Blk
• K12 EFI module power relay - 30 terminal, 230 Red
Operating Conditions, Switched Circuits:
• K13 Fuel pump relay - 87, 86, and 30 terminals, 231,
With the key switch in run position, PTO switch in off 232 Red and 655 Pnk
position, brake locked, and operator off the seat, switched
voltage should be present at the following components: • M2 fuel pump - 651 Pnk/Blk

• S1 key switch - terminals “A” • A1 ignition interlock module - X4 connector F-5 terminal,
750 and 751 Blu
• A1 ignition interlock module - X4 connector F-2, F-3 and
F-6 terminals • A1 interlock module components - PTO relay common
and normally open terminals and ignition relay common
• A1 interlock module components - F4 and F5 fuse, start terminal
relay common terminal and coil, ignition relay normally
open terminal and coil, magneto relay coil, and E1 Grn seat • S6 brake switch - 751 Blu
LED. • Y4 fuel injector - Wht
• S9 light switch - 400 Yel/Blu • Y5 fuel injector - Wht

Electrical Operation and Diagnostics - 226

 ELECTRICAL OPERATION AND DIAGNOSTICS
• A4 electric fuel injector module - P and M terminals, 240
Red and 950 Wht
• Instrument panel - X3 connector 16 terminal, 785 Grn
• A3 PTO interlock module (option) - X7 connector J5-A
terminal, 786 Blu
• A3 PTO interlock module (option) components - brake
lock relay normally open terminal
These circuits are controlled by the key switch and are
protected by the F3 and F6 fusible links and the F4, F5 and
F7 fuses.

Electrical Operation and Diagnostics - 227

 ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Electrical Schematic - X485 and X585

Wht
S2
Wht
592 X5 H-B A1 Ignition Interlock Module
S1
Blu S2
S1
S1 S2 X4
Red A F4 Fuse -15 A F-2
B A
A X4
20A F1 Wht
M
F5 Fuse -15 A F-6
Fuse G M X4
M
F-3
Start
X5
202 Run
Red H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
X1 K2 Magneto LED Ignition
K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X5
200 H-C
Red
X5
H-D
X5
X4
H-A
F-1 K3 RIO
E2 Red
X4
Latch Relay
K4 RIO LED
F-4
Unlatch Relay PTO
X5
H-G
201 X5 H-E X5 H-H
Red

+ N1
F2
Fusible
F3
Fusible
U Rectifier/
Regulator
Link Link -
600 504
203 205 Brn Yel
Blk Lt Blu
215 Gry 215 Gry

503 Yel X3
17
Red H2 Engine H3 P1
X3 Oil Service Hourmeter
B S 14
H1 Pressure Indicator
Discharge Light (SN -30000)
Light

M + _ X2 620 Tan
X3
Blu/Red
M1 A2 Service
15
Starting Y1 Light Timer
Motor Starting B1 Engine Oil Module
Motor P Pressure
Solenoid
Switch (NC)
G1
Battery

Unswitched Power Switched Power Secondary Power

Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 228

 ELECTRICAL OPERATION AND DIAGNOSTICS

592
S9 Light Blu
On
Switch X12
On
S5 PTO/RIP Off S10 Accessory
Switch
400 Yel/Blu
RIP* 400 Yel/Blu
Switch Off
On On
500 Yel Off 592 Pnk

3 6 86 87 87a K11 EFI

705 Pnk/Blk
Module
750 Blu 2
5
85 30 Ground
8 650 Pnk/Blk Relay
786 Blu
4 652 Blu
652 Blu 705 Pnk/Blk 1
7 765 Pur S6 Brake
Switch
789 Off
750 Blu Pur A3 PTO Interlock Module
On X7
751 Blu 751 Blu
J5-C
501 Yel
765 Pur K7 Brake
S3 Seat Lock Relay
Switch
786 Blu
X7
(Off) J5-A
767
(On)
Pur
X7
502 Yel K8 Off
J5-B
Seat
Relay
X8 742
X8 Blu/Wht
J4-A
J4-B
S4 RIO** Neutral/ K9 S8
Forward Mid Mid
Switch PTO X6
Reverse
Relay
PTO
505 Yel 789 Pur X8 Switch
J4-C
X9
J6-A K10 Rear

On
Off
PTO Relay
X9 X8 X6
520
J6-B J4-D Yel

F6 Fusible Link F7 Fuse

215 Gry 220 Red
560
K12 EFI Red
221 /Yel
P3 Engine Coolant P2 Fuel Module Red 230 Red 233 Red/Blu X23 Wht
767
Temperature Gauge Gauge Pur Power
87a 87 86 231
X3 Relay Red 232
t 0 Q Red
8 30 85 87a 87 86
K13
X3 B2 Fuel Fuel
230
2 310 Gauge 6 Red Pump
30 85
Org/ Sensor Relay
Wht 655
651 Pnk/Blk X21 Pnk
900
Blk/Wht
Yel
X2
X10 X10
H8
B3 Engine Coolant Brake
t0 Temperature Light (SN 30001-) M M2 Fuel
Sensor Q
Pump

Electrical Operation and Diagnostics - 229

 ELECTRICAL OPERATION AND DIAGNOSTICS

X26
A
B
C
Y4 #1 Cylinder X25 D
Fuel Injector Yel/Blu Yel/Blu A 160 Blk
Solenoid E
B
F
C A4
G
D Electric
H
Yel/Red E 610 Tan Fuel
I Injection
Y5 #2 Cylinder Wht F
Fuel Injector Yel/Red G
J Module
K
Solenoid H
L
Red I 950 Wht
M
J
N
K
O
Wht Wht L 240 Red
P
Tan M 470 Yel
N
Grn O 515 Blu
Blu P 615 Tan
Blu

B4 Engine
Coolant
X22 to Temperature
785 Grn Red
Sensor
Grn

B5 Air
to Temperature
Sensor

Tan
Wht
B6 Vacuum
m Pressure
Sensor
785
Grn

X3
16

H8 Circuit
Integrity
Bulb

Unswitched Power Switched Power Secondary Power

Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 230

 ELECTRICAL OPERATION AND DIAGNOSTICS
Power Circuit Diagnosis - X485 and X585
Test Conditions:
• Key switch off.

Test/Check Point Normal If Not Normal

1. Starting motor solenoid Battery voltage Test battery and cable connections.

2. Key switch Battery voltage Test F3 fusible link. Check 200 Red wire and connections.

3. Voltage rectifier/regulator Battery voltage Test F3 fusible link. Check 201 Red wire and connections.

4. Accessory switch Battery voltage Test F1 fuse and F2 fusible link. Check 202 Red, 592 Blu
and 592 Pnk wires and connections.

5. K12 EFI module power relay Battery voltage Test F7 fuse and F6 fusible link. Check 220 and 221 Red
wires and connections.

Test Conditions:
• Key switch in run position, engine not running.
• Brake locked.
• PTO off.
• Transmission in neutral.
• Operator off seat.

Test/Check Point Normal If Not Normal

6. Ignition interlock module Continuity to ground Check 130 and 100 Blk wires and connections.

7. Ignition interlock module Battery voltage Test F4 fuse. If OK, replace ignition interlock module.

8. Light switch Battery voltage Check 400 Yel/Blu wire and connections.

9. Ignition interlock module Battery voltage Test F5 fuse. If OK, replace ignition interlock module.

10. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

11. PTO/RIP switch Battery voltage Check 765 Pur wire and connections. If OK, replace brake
switch.

12. PTO interlock module Battery voltage Check 789 Pur wire and connections. If OK, replace brake
(option) switch.

13. Ignition interlock module Battery voltage Check 705 Pnk/Blk wire and connections. If OK, replace
PTO/RIP switch.

14. Ignition interlock module Battery voltage, green Replace ignition interlock module.
LED illuminated

15. K11 EFI module ground relay Battery voltage Check 652 Blu and 650 Pnk/Blk wires and connections.

16. Brake switch Battery voltage Check 750 and 751 Blu wires and connections. If OK,
replace PTO/RIP switch.

17. PTO interlock module Battery voltage Check 786 Blu wires and connections. If OK, replace PTO/
(option) RIP switch.

Electrical Operation and Diagnostics - 231

 ELECTRICAL OPERATION AND DIAGNOSTICS
Test/Check Point Normal If Not Normal

18. Seat switch Battery voltage Check 500 and 502 Yel wires and connections.

19. RIO switch Battery voltage Check 500 and 505 Yel wires and connections.

20. Voltage rectifier/regulator Battery voltage Check 500 and 504 Yel wires and connections.

21. X3 instrument panel Battery voltage Check 500 and 503 Yel wires and connections.
connector

22. Mid PTO switch (option) Battery voltage Check 500 and 520 Yel wires and connections.

23. K12 EFI module power relay Battery voltage Check 500 Yel and 560 Red/Yel wires and connections.

24. #1 Cylinder fuel injector Battery voltage Check 230 Red, 231 Red/Blu, and Wht wires and
connections. If OK, replace EFI module power relay.

25. #2 Cylinder fuel injector Battery voltage Check 230 Red, 231 Red/Blu, and Wht wires and
connections. If OK, replace EFI module power relay.

26. EFI module Battery voltage Check 230 Red, 231 Red/Blu, Wht, and 240 Red wires and
connections. If OK, replace EFI module power relay.

27. X3 instrument panel Battery voltage Check 785 Grn, Red, and 950 Wht wires and connections.
connector If OK, replace EFI module.

Electrical Operation and Diagnostics - 232

 ELECTRICAL OPERATION AND DIAGNOSTICS

M1 Starting F2 Fusible 202 Red F1 Fuse X12 S10 Accessory Switch

Motor Link 592 Blu

N1 Voltage
F3 Fusible Link
Regulator/Rectifier
K12 EFI Module X475/X575/X485/X585 592
F6 Fusible Pnk
Link Power Relay
1

4
221 Red X465

20
560 Red/Yel 5
504 Yel
A1 Ignition 3
201 Red
Interlock Module
G1 Battery 2
200
Red
X3 Instrument
S1 S2
500 Yel
Panel Connector
503 Yel

A1
9
13 M
751 Blu
M S6 Brake
A1
Switch
21
16
S2

6 7 501
14 S1
Yel
130 Blk
S3 Seat
100 Switch 10
Blk 18 S5 PTO/RIP
Switch
502 Yel
11
652 Blu
400 650 Pnk/Blk
Yel/ 765 Pur
Blu
705 Pnk/Blk

S9 Light 750 Blu

Switch
786 Blu
8
S8 Mid PTO Switch
K11 EFI Module
520 Ground Relay
Yel
15

A3 PTO Interlock Module 22 650 Pnk/Blk

17
786 Blu

789 Pur S4 RIO

Switch
12 19

505 Yel

Electrical Operation and Diagnostics - 233

 ELECTRICAL OPERATION AND DIAGNOSTICS

M1 Starting
Motor
F3 Fusible Link
K12 EFI Module
Power Relay
F6 Fusible
Link
560 Red/Yel 23
1

230 Red
221 Red

A1 Ignition
Interlock Module
G1 Battery
200
Red
X3 Instrument
S1 S2
500 Yel
Panel Connector
503 Yel
785 Grn
A1

M
M

A1

27
S2

S1

130 Blk
X23
100
Blk Y4 #1 Cylinder Y5 #2 Cylinder
Fuel Injector Solenoid Fuel Injector Solenoid
Wht

X22
Wht Wht

24 25

Wht
Red

X25

X25

26

240 Red

950 Wht

Electrical Operation and Diagnostics - 234

 ELECTRICAL OPERATION AND DIAGNOSTICS
Cranking Circuit Operation - All Models Current on the 721 Pur wire is used to illuminate the H4
RIO defeat light and indicate that the starting circuit through
Function: the A1 interlock module is functional. If the Y1 starting
motor solenoid does not engage but the H4 RIO defeat light
To energize the starting motor solenoid and engage the
is illuminated, then the cranking circuit is functional and the
starting motor to crank the engine.
starting motor solenoid may be tested. If the Y1 starting
Operating Conditions: motor solenoid does not engage and the H4 RIO defeat
light is not illuminated, then either the operating conditions
• Key switch in start position. have not been met, or there is a fault within the cranking
• Brake locked, switch closed. circuit.
• PTO/RIP switch in off position. Additionally, the E1 Grn LED on the A1 ignition interlock
module will be illuminated when the cranking circuit
Theory of Operation: operating conditions have been met and are functional.
NOTE: The key switch is connected to the printed
circuit board (A1 Interlock Module) by soldered wire
connections. Components are solid state and are not
serviced separately except for the 15 amp fuses. Lines
within border of the Interlock Module (A1) except for
key switch connections are circuit paths on the circuit
board and are not wires in the harness.
The starting motor is a solenoid shift design. The power
circuit provides current to the S1 key switch and protects
the cranking circuit with the F3 fusible link. Current flows
from the battery positive (+) terminal to the starter solenoid
battery terminal, F3 fusible link, 200 Red wire, X1
connector, Red wire and key switch.
With the key switch in the start position, current flows
through the Red wire to the A1 interlock module and to the
start relay common terminal and the F5 fuse. From the F5
fuse current flows to the 500 and 501 Yel wire, and the S6
brake switch.
With the brake pedal depressed, the brake switch is
engaged and current flows across the switch to the 765 pur
wire and the S5 PTO/RIP switch. From the PTO/RIP switch
current flows to the 705 Pnk/Blk wire back to the A1
interlock module and the start relay coil. The ground path
for the start relay is provided through the key switch S1 and
S2 contacts.
The start relay is energized and shifts to the normally open
contact allowing current to flow to the 720 Pur wire to the
Y1 starting motor solenoid and the 721 Pur wire to the H4
RIO defeat light on the instrument panel.
The Y1 starting motor solenoid is engaged by current
flowing through the coil windings, pulling the plunger
inward. The plunger closes the solenoid main contacts.
Current flows through the hold-in windings, keeping the
solenoid engaged.
With the solenoid main contacts closed, high current from
the battery flows across the main contacts to the M1 starter
motor causing it to turn.

Electrical Operation and Diagnostics - 235

 ELECTRICAL OPERATION AND DIAGNOSTICS
Cranking Circuit Electrical Schematic - All Models

Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4
Red A F4 Fuse -15 A F-2
B A
A X4 500 Yel
M F-6
Wht F5 Fuse -15 A
G M M X4
F-3 705
Start Pnk
X5 /Blk
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X5
H-C
X1
X5
200
Red H-D
X5
720 Pur X4
H-A
F3 F-1 K3 RIO X4
E2 Red
Fusible 721 Latch Relay
K4 RIO LED
Link Pur Unlatch Relay PTO
F-4
X5
205
Lt Blu H-G
X5 H-E X5 H-H
130
Blk
Red

721 Pur X3 S5 PTO/RIP

B S 11
Switch
RIP*
On
S6 Brake
M Off Switch
M1 3 6 Off
Starting Y1
Motor Starting 2
5 On
Motor H4 RIO 8
501
Solenoid Defeat 4
705 Pnk/Blk 1 Yel
7 765 Pur

G1
Battery X3
20 135
Blk Blk
100 Blk

W1
Frame Ground
Unswitched Power Switched Power Secondary Power
Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 236

 ELECTRICAL OPERATION AND DIAGNOSTICS
Cranking Circuit Diagnosis - All Models

Test Conditions:
• Key switch in run position, engine not running.
• Brake locked.
• PTO off.

Test/Check Point Normal If Not Normal

1. Ignition interlock module Continuity to ground Check 130 and 100 Blk wires and connections.

2. Key switch Battery voltage Test F3 fusible link. Check 200 Red wire and connections.

3. Ignition interlock module Battery voltage Test F5 fuse. If OK, replace ignition interlock module.

4. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

5. PTO/RIP switch Battery voltage Check 765 Pur wire and connections. If OK, replace brake
switch.

6. Ignition interlock module Battery voltage Check 705 Pnk/Blk wire and connections. If OK, replace
PTO/RIP switch.

7. Ignition interlock module Battery voltage, green Replace ignition interlock module.
LED illuminated

Test Conditions:
• Spark plug wires removed and grounded to engine.
• Key switch in start position.
• Brake locked.
• PTO off.

Test/Check Point Normal If Not Normal

8. Starting motor solenoid Battery voltage Check 720 Pur wire and connections. If OK, replace ignition
interlock module.

Electrical Operation and Diagnostics - 237

 ELECTRICAL OPERATION AND DIAGNOSTICS

720 Pur

F3 Fusible Link

M1 Starting
Motor

A1 Ignition
Interlock Module
G1 Battery 2
200
Red

S1 S2
500 Yel

A1
3
6 M
M

A1

S2

1
S1
7
720 Pur

130 Blk

100
Blk S6 Brake
Switch

501
Yel

4
S5 PTO/RIP
Switch

5
765 Pur

705 Pnk/Blk

Electrical Operation and Diagnostics - 238

 ELECTRICAL OPERATION AND DIAGNOSTICS
Charging Circuit Operation - All Models
Function:
To maintain battery voltage between 12.4 volts DC or
higher.

Operating Conditions:
The key switch must be in the run position, with the engine
running, for the charging system to operate.

Theory of Operation:
The main charging system components are the battery, G2
alternator and the N1 voltage regulator/rectifier. Charging
output is controlled by the regulator/rectifier. The status of
the charge rate is indicated by the H1 discharge light.
X475/X575/X485/X585 - With the key switch in the run
position, battery sensing circuit current flows from battery
positive terminal to the starting motor terminal, F3 fusible
link, 200 Red wire, S1 key switch, F5 fuse, 500 and 504 Yel
wire, and the N1 voltage regulator/rectifier. The battery
sensing circuit allows the voltage regulator/rectifier to
monitor battery voltage.
X465 - With the key switch in the run position, battery
sensing current flows from the battery positive terminal to
the starting motor terminal, F3 fusible link, 201 Red wire to
the N1 voltage regulator/rectifier.
With the engine running, a rotating permanent magnet in
the alternator induces AC current in the alternator stator
coils. The AC current flows to the voltage regulator/rectifier.
The voltage regulator/rectifier converts AC current to DC
current needed to charge the battery.
Current flows from the voltage regulator/rectifier to the
battery positive (+) terminal through the 201 Red wire and
F3 fusible link. When the battery is fully charged, the
voltage regulator/rectifier halts current flow to the battery.
If the voltage on the sensing circuit falls below system
usage or is insufficient to maintain a preset voltage, the
regulator/rectifier provides current to turn on the H1
discharge light.
The ground circuit 125 Blk provides a path to ground for the
voltage regulator/rectifier and the 136/100 Blk for the
discharge light.

Electrical Operation and Diagnostics - 239

 ELECTRICAL OPERATION AND DIAGNOSTICS
Charging Circuit Electrical Schematic - All Models

Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4
A
Red F4 Fuse -15 A F-2
B A
A X4 500 Yel
M
Wht F5 Fuse -15 A F-6
G M M X4
F-3
Start
X5
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X5

H-C
X1
200 X5
Red
H-D
X5
X4
H-A
F-1 K3 RIO
E2 Red
X4
Latch Relay
K4 RIO LED
F3 Unlatch Relay
F-4
PTO
Fusible X5
Link
H-G
X5 H-E X5 H-H

205
Lt Blu X2
G Blk
504
Red Yel
Blk
G2
B S Alternator
590 595
201
Red
Brn/ Brn/ G2
Yel Wht
Alternator G
M + 201
Red
X2
M1 X3 U
Starting Y1
Starting
14
-
Motor Motor 600
125 N1
Solenoid Blk Brn
Rectifier/ +
Regulator
+ _ U
H1
X475/X575/X485/
-
G1 Discharge 600 X2 N1
Light X585 Brn
Rectifier/
Battery X3
Regulator
3
Blk 136 X465
100 Blk Blk

W1
Frame Ground Unswitched Power Switched Power Secondary Power
Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 240

 ELECTRICAL OPERATION AND DIAGNOSTICS
Charging Circuit Diagnosis - All Models

Test Conditions:
• Key switch in run position, engine not running.
• Brake locked.
• PTO off.

Test/Check Point Normal If Not Normal

1. Voltage rectifier/regulator Continuity to ground Check 125 (not X465) and 100 Blk wires and connections.

2. Voltage rectifier/regulator Battery voltage Test F3 fusible link. Check 201 Red wire and connections.

3. Key switch (X465 - skip to step Battery voltage Test F3 fusible link. Check 200 Red wire and connections.
6)

4. Ignition interlock module Battery voltage Test F5 fuse. If OK, replace ignition interlock module.
(X465 - skip to step 6)

5. Voltage rectifier/regulator Battery voltage Check 500 and 504 Yel wires and connections.
(X465 - Skip to step 6)

6. X3 Instrument panel connector Battery voltage Check 600 Brn wire and connections.

Test Conditions:
• Key switch in run position, engine running at slow idle.
• Brake locked.
• PTO off.
• Engine speed increased from slow idle to fast idle during test.

Test/Check Point Normal If Not Normal

7. Battery positive terminal 12.0 volts raising to 15.0 Test voltage rectifier/regulator. Test stator. See appropriate
volts procedures in Tests and Adjustments in this section.

Electrical Operation and Diagnostics - 241

 ELECTRICAL OPERATION AND DIAGNOSTICS

M1 Starting
X475/X575/X485/X585 N1 Voltage Regulator/
Motor Rectifier
125 Blk
F3 Fusible Link
100
1 Blk

590 Brn/Yel
600 Brn
595 Brn/Wht

504 Yel 5
A1 Ignition
201 Red
Interlock Module
G1 Battery 3
200 2
Red

S1 S2
500 Yel

A1
4

M
M

A1

S2

S1

130 Blk
G2 Alternator Blk (X465)
100
Blk
595 Brn/Wht
590 Brn/Yel

X465 Blk (X465)

N1 Voltage
Regulator/Rectifier

X3 Instrument
Panel Connector
600 Brn 600
Brn

201 Red
Blk

Blk 6

Electrical Operation and Diagnostics - 242

 ELECTRICAL OPERATION AND DIAGNOSTICS
Ignition Circuit Operation - X465, X475 and Theory of Operation, Running Engine
X575 The key switch is connected to the A1 ignition interlock
module by soldered wire connections. The components are
Function: solid state and are not serviced separately except for the
To control the ignition coils ability to create a spark while 15 amp fuses. Lines within the border of the A1 ignition
also controlling the fuel supply to the engine. interlock module except for key switch connections are
circuit paths on the circuit board and are not wires in the
Operating Conditions, Stopping Engine: harness.
• Key switch in off position, The ignition system is a transistor-controlled magneto
design. Ignition timing is controlled by the transistor and is
or,
not adjustable. As the engine turns over the flywheel
• Operator off seat with PTO engaged, magnet induces current into the magneto ignition coil,
and, which in turn produces current high enough to jump the
spark plug(s) gap, creating spark to ignite the engine fuel/
• Park braked unlocked. air mixture.
Theory of Operation, Stopping Engine
The engine is shut off by grounding the T1 and T2 ignition
coils. With the ignition primary coil grounded, a spark
cannot be produced.
When the S1 key switch is in the off position, a path to
ground is created through the key switch Wht wire (M)
solder connection and back to the interlock module through
the Wht wire (S2) solder connection. In addition the power
circuit current flow is stopped at the key switch. This de-
energizes the magneto relay providing a path to ground for
ignition coil through the magneto relay.
The magneto relay coil is energized by current from the
seat switch circuit or brake circuit. If the operator gets off
the seat (seat switch opens) with the PTO engaged without
the park brake locked, current flow to the magneto relay coil
is stopped.
The seat switch or brake switch also energize the ignition
relay. Whenever the ignition relay is de-energized, the fuel
shutoff solenoid is also de-energized and fuel flow to the
carburetor is stopped.

Operating Conditions, Running Engine:

• Key switch in run or start position,
• Operator on seat,
or,
• Key switch in run or start position,
• Operator off seat,
• Park braked locked.

Electrical Operation and Diagnostics - 243

 ELECTRICAL OPERATION AND DIAGNOSTICS
Ignition Circuit Electrical Schematic - X465, X475 and X575

Wht
940 Wht 940 Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4 X2
A
Red F4 Fuse -15 A F-2 Blk
B A
A X4 500 Yel
M F-6
Wht F5 Fuse -15 A
G M M X4 705 Pnk/Blk
F-3
Start
X5 652 Blu
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
X1 Start Relay Start Relay Seat Relay
PTO Relay X5

200 H-C
Red
X5 800 Pnk
H-D
X5
F3 X4
H-A
Fusible
Link F-1 K3 RIO
E2 Red
X4
Latch Relay
K4 RIO LED
F-4
Unlatch Relay PTO
205
Lt Blu
X5
H-G
X5 H-E X5 H-H

605
Tan
605 Tan

Red

B S

130
M Blk Wht Wht
M1 Blk Blk
Starting Y1
Motor Starting E9 E10
Motor Spark Spark
Solenoid Plug Plug

T1 Ignition T2 Ignition
Coil Coil
G1
Battery

Blk
100 Blk 100 Blk

W1
Frame Ground Unswitched Power Switched Power Secondary Power
Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 244

 ELECTRICAL OPERATION AND DIAGNOSTICS

S5 PTO/RIP RIP* X475 and X575 Only

Switch On
Off

3 6

500 Yel
2
5
650 Pnk/Blk
X21
8 650 Pnk
4 652 Blu
705 Pnk/Blk 705 Pnk/Blk 1
7 765 Pur
789
X2
652 Blu Pur 651
S6 Brake Y2 Fuel Pnk/Blk
Switch Shutoff Yel/
Off
Solenoid Wht
On

S3 Seat X10
Switch 501 Yel
765 Pur

(Off)

(On)
800 Pnk 502 Yel M
Q

820
Pnk M2 Fuel
A3 PTO Interlock Module Pump
X7
J5-C

K7 Brake
Lock Relay
X7
X10
J5-A

605 Tan 605 Tan

X7
K8 Off 120
J5-B
Seat Blk
Relay
820 Pnk X8
X8
J4-A
742
J4-B
Blu/Wht
K9 Mid
PTO Light
Relay
X6
789 Pur X8
J4-C
S8
X9 Mid
J6-A K10 Rear PTO
On
Off

PTO Light Switch

X9 Relay X8 140 X6
Blk
520
J6-B J4-D Yel

100 Blk

Electrical Operation and Diagnostics - 245

 ELECTRICAL OPERATION AND DIAGNOSTICS
Ignition Circuit Diagnosis - X465, X475 and X575

Test Conditions:
• Key switch off.

Test/Check Point Normal If Not Normal

1. Ignition interlock module Continuity to ground Check 130 and 100 Blk wires and connections.

2. Ignition interlock module Continuity to ground Replace ignition interlock module.

3. X2 connector Continuity to ground Check 940 Wht wire and connections.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO off.
• Operator off seat.

Test/Check Point Normal If Not Normal

4. Key switch Continuity to ground Replace ignition interlock module.

5. Ignition interlock module No continuity to ground Replace ignition interlock module.

6. Ignition interlock module Battery voltage Test F3 fusible link and F5 fuse. Check 200 Red wire and
connections. If OK, replace ignition interlock module.

7. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

8. PTO/RIP switch Battery voltage Check 765 Pur wire and connections. If OK, replace brake
switch.

9. Ignition interlock module Battery voltage Check 705 Pnk/Blk wire and connections. If OK, replace
PTO/RIP switch.

10. Ignition interlock module Battery voltage Replace ignition interlock module.

11. Fuel pump (X475 and X575 Battery voltage Check 652 Blu, 650 Pnk/Blk, 655 Pnk, and 651 Pnk/Blk
only) wires and connections.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake unlocked.
• PTO off.
• Operator on seat.

Test/Check Point Normal If Not Normal

12. Seat switch Battery voltage Check 500 and 502 Yel wires and connections.

13. Ignition interlock module Battery voltage Check 800 Pnk wire and connections. If OK, replace seat
switch.

Electrical Operation and Diagnostics - 246

 ELECTRICAL OPERATION AND DIAGNOSTICS
Test/Check Point Normal If Not Normal

14. Ignition interlock module Battery voltage Replace ignition interlock module.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO on.
• Operator off seat.

Test/Check Point Normal If Not Normal

15. Mid PTO switch Battery voltage Check 500 and 520 Yel wires and connections.

16. PTO interlock module Battery voltage Check 742 Blu/Wht wire and connections. If OK, replace
(option) mid PTO switch.

17. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

18. PTO interlock module Battery voltage Check 765 and 789 Pur wires and connections. If OK,
(option) replace brake switch.

19. Ignition interlock module Battery voltage Check 605 Tan wire and connections. If OK, replace PTO
interlock module.

20. Ignition interlock module Battery voltage Replace ignition interlock module.

Electrical Operation and Diagnostics - 247

 ELECTRICAL OPERATION AND DIAGNOSTICS

A1 Ignition M1 Starting
Interlock Module Motor

200 Red F3 Fusible Link

S1 S2
500 Yel
6
9
1 13 A1
T2 Ignition
5
2 M Coil
M

A1

T1 Ignition
Blk
S2 Coil
19 S1
4

G1 Battery
10 Blk
14
20 940 Wht X2

3
130 Blk S6 Brake
Switch
100
Blk
501
S3 Seat Yel
Switch
12 7
17
S5 PTO/RIP
502 Yel 650
Switch
Pnk
820 Pnk
800 Pnk /Blk
652 Blu
765 Pur
789 Pur

705 Pnk/Blk

8
Y2 Fuel
650 Shutoff
S8 Mid PTO Switch 520
Pnk Solenoid
Yel
/Blk
15

655
A3 PTO Interlock Module Pnk
651
X21
605 Tan 11 Pnk/Blk

16 M2 Fuel
Pump (not on X465)
18 742 Blu/Wht
789 Pur
820 Pnk

140
Blk

Electrical Operation and Diagnostics - 248

 ELECTRICAL OPERATION AND DIAGNOSTICS
Ignition Circuit Operation - X485 and X585 Theory of Operation, Running Engine
The key switch is connected to the A1 ignition interlock
Function: module by soldered wire connections. The components are
To control the ignition coils ability to create a spark while solid state and are not serviced separately except for the
also controlling the fuel supply to the engine. 15 amp fuses. Lines within the border of the A1 ignition
interlock module except for key switch connections are
Operating Conditions, Stopping Engine: circuit paths on the circuit board and are not wires in the
• Key switch in off position, harness.

or, The ignition system is a transistor-controlled magneto

design. Ignition timing is controlled by the transistor and is
• Operator off seat with PTO engaged, not adjustable. As the engine turns over the flywheel
and, magnet induces current into the magneto ignition coil,
which in turn produces current high enough to jump the
• Park braked unlocked.
spark plug(s) gap, creating spark to ignite the engine fuel/
Theory of Operation, Stopping Engine air mixture.

The engine is shut off by grounding the T1 and T2 ignition Fuel is supplied to the intake manifold through the fuel
coils. With the ignition primary coil grounded, a spark injectors. The fuel injectors are controlled by the electric
cannot be produced. fuel injector (EFI) module. The ground circuit for the EFI
module is controlled through the ignition interlock module. If
When the S1 key switch is in the off position, a path to the operating conditions are not met, the K11 EFI module
ground is created through the key switch Wht wire (M) ground relay will not be energized and the EFI module will
solder connection and back to the interlock module through not receive a ground path. This will stop the fuel supply,
the Wht wire (S2) solder connection. In addition the power thereby stopping the engine.
circuit current flow is stopped at the key switch. This de-
energizes the magneto relay providing a path to ground for
ignition coil through the magneto relay.
The magneto relay coil is energized by current from the
seat switch circuit or brake circuit. If the operator gets off
the seat (seat switch opens) with the PTO engaged without
the park brake locked, current flow to the magneto relay coil
is stopped.
The seat switch or brake switch also energize the ignition
relay. Whenever the ignition relay is de-energized, the fuel
shutoff solenoid is also de-energized and fuel flow to the
carburetor is stopped.

Operating Conditions, Running Engine:

• Key switch in run or start position,
• Operator on seat,
or,
• Key switch in run or start position,
• Operator off seat,
• Park braked locked.

Electrical Operation and Diagnostics - 249

 ELECTRICAL OPERATION AND DIAGNOSTICS
Ignition Circuit Electrical Schematic - X485 and X585

940 Wht 940 Wht

Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4
A
Red F4 Fuse -15 A F-2
B A
A X4 500 Yel
M F-6
Wht F5 Fuse -15 A
G M M X4 705 Pnk/Blk
F-3
Start
X5 652 Blu
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
X1 Start Relay Start Relay Seat Relay
PTO Relay X5

200 H-C
Red
X5 800 Pnk
H-D
X5
F3 X4
H-A
Fusible
Link F-1 K3 RIO
E2 Red
X4
Latch Relay
K4 RIO LED
F-4
205 Unlatch Relay PTO
Lt Blu X5
H-G
X5 H-E X5 H-H
130 605 Tan 605 Tan
Blk

Red 215 Gry 215 Gry

B S

M
M1
Starting Y1
Motor Starting
Motor
Solenoid

G1
Battery
Blk
100 Blk 100 Blk

W1 Unswitched Power Switched Power Secondary Power

Frame Ground Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 250

 ELECTRICAL OPERATION AND DIAGNOSTICS

940 Wht 940 Wht

S5
RIP*
PTO/RIP 650 670 Pur
On
Switch Pnk
Off /Blk

3 6 86 87 87a K11 EFI

Module
500 Yel
2
5
85 30 Ground
8 650 Pnk/Blk Relay
138
4 652 Blu
705 Pnk/Blk 705 Pnk/Blk 1 Blk 139
7 765 Pur Blk
789
Pur
652 Blu
A3 PTO Interlock Module
X7
J5-C
S6 Brake
Switch K7 Brake
S3 Seat Off Lock Relay
Switch X7
On
(Off) J5-A
501
(On) 765 Pur
Yel
605 Tan
X7
K8 Off
800 Pnk 502 Yel J5-B
Seat
Relay
820 Pnk X8 742
820 Pnk X8 Blu/Wht
J4-A
J4-B
K9
Mid
S8
PTO X6 Mid
X8 Relay PTO
789 Pur
Switch
J4-C
X9
J6-A K10 Rear

On
Off
605 Tan PTO Relay
X9 X8 140 X6
Blk
520
J6-B J4-D Yel 560 Red/Yel

215 Gry F6 Fusible Link F7 Fuse

220 Red 221 Red

100 Blk 100 Blk

Electrical Operation and Diagnostics - 251

 ELECTRICAL OPERATION AND DIAGNOSTICS

940 Wht
X2 Blk

Blk

670 Pur 670 Pur X22 Org

Blk Blk
Blk Blk
X24 E9 E10
Spark Spark
Plug Plug

T1 Ignition T2 Ignition
Coil Coil
X26
W2 Ground
A
B
C
Y4 #1 Cylinder X25 D
Fuel Injector Yel/Blu Yel/Blu A 160 Blk
Solenoid E
Blk/Wht B 330 Org
F
Brn C 460 Yel A4
G
Blk/Yel D 510 Blu Electric
H
Yel/Red E 610 Tan Fuel
Wht I Injection
Y5 #2 Cylinder Blk/Wht F 710 Pur
Fuel Injector
J Module
Yel K
Solenoid /Red Org H 860 Pnk
L
I
M
Blk J 170 Brn
N
Red/Blu K 340 Grn
O
Wht Wht L 240 Red
P
Tan M 470 Yel

Blk/Yel

Wht
B6 Vacuum
Red/Blu
560 Red/Yel X23 m Pressure
Sensor
221 Red
Tan

K12 EFI
87a 87 86 Module 651
233
Power Red Pnk
/Blu Brn /Blk
30 85 Relay
230 150 B2 Fuel
X22 X10 X10
Red Blk 230 Red Gauge
Sensor
231
232
Red M
RedK13 Q
87a 87 86 Fuel
Pump M2 Fuel
30 85 Relay Pump
655 910 Wht X10
Pnk
X21 120
Blk

100 Blk

Electrical Operation and Diagnostics - 252

 ELECTRICAL OPERATION AND DIAGNOSTICS
Ignition Circuit Diagnosis - X485 and X585
Test Conditions:
• Key switch off.

Test/Check Point Normal If Not Normal

1. Ignition interlock module Continuity to ground Check 130 and 100 Blk wires and connections.

2. Ignition interlock module Continuity to ground Replace ignition interlock module.

3. X2 connector Continuity to ground Check 940 Wht wire and connections.

4. EFI module Continuity to ground Check Blk and 170 Brn wires and connections.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO off.
• Operator off seat.

Test/Check Point Normal If Not Normal

5. Key switch Continuity to ground Replace ignition interlock module.

6. Ignition interlock module No continuity to ground Replace ignition interlock module.

7. Ignition interlock module Battery voltage Test F3 fusible link and F5 fuse. Check 200 Red wire and
connections. If OK, replace ignition interlock module.

8. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

9. PTO/RIP switch Battery voltage Check 765 Pur wire and connections. If OK, replace brake
switch.

10. Ignition interlock module Battery voltage Check 705 Pnk/Blk wire and connections. If OK, replace
PTO/RIP switch.

11. Ignition interlock module Battery voltage Replace ignition interlock module.

12. K11 EFI module ground relay Battery voltage Check 652 Blu and 650 Pnk/Blk wires and connections.

13. K12 EFI module power relay Battery voltage Test F6 fusible link and F7 fuse. Check 220 and 221 Red
wires and connections.

14. K12 EFI module power relay Battery voltage Check 500 and 560 Red/Yel wires and connections.

15. K13 Fuel pump relay Battery voltage Check 230 and 231 Red wires and connections. If OK,
replace K12 EFI module power relay.

16. Fuel pump Battery voltage Check 655 Pnk and 651 Pnk/Blk Red wires and
connections. If OK, replace K13 fuel pump relay.

17. Fuel injector(s) Battery voltage Check 230 Red, 233 Red/Blu and Wht wires and
connections. If OK, replace K12 EFI module power relay.

18. Electric fuel injection module Battery voltage Check 230 Red, 233 Red/Blu, Wht, and 240 Red wires and
connections. If OK, replace K12 EFI module power relay.

Electrical Operation and Diagnostics - 253

 ELECTRICAL OPERATION AND DIAGNOSTICS

A1 Ignition M1 Starting
Interlock Module Motor

200 Red F3 Fusible Link

F6
Fusible
S1
Link
S2
500 Yel
7
10 1
1
A
T2 Ignition
6
2 M Coil
M

A1

T1 Ignition
S2 Coil Blk
S1
5

G1 Battery
500 Blk
11
Yel

940 Wht
X2 Blk

3
130 Blk 560 Red/Yel

100
Blk S6 Brake
Switch
S3 Seat
Switch
501 650
Yel S5 PTO/RIP
Pnk Switch
502 Yel /Blk
820 Pnk 8
800 Pnk
652 Blu
765 Pur
789 Pur
705 Pnk/Blk

S8 Mid PTO Switch

520 650 K11 EFI Module

Yel Pnk
Ground Relay
/Blk
A3 PTO Interlock Module
138 Blk
605 Tan
139 Blk
140 Blk
742 Blu/Wht 12
789 Pur
820 Pnk 670
Pur
X22 Org
100
Blk

Electrical Operation and Diagnostics - 254

 ELECTRICAL OPERATION AND DIAGNOSTICS

K12 EFI Module

Power Relay

560 Red/Yel 14

230 Red
221 Red
221 Red

13
150
Blk

100
Blk K13 Fuel
Pump Relay
232 Red

230
Blk
Red

231 Red
560 Red/Yel
233
Red
15
/Blu
910
X23 Wht
Y4 #1 Cylinder Y5 #2 Cylinder
Fuel Injector Solenoid Fuel Injector Solenoid X22
Wht

Blk Brn
Wht Wht
X24
17 17
X25
Wht

170
Blk 655
X25 Pnk

X21

18 651
4
Pnk/Blk
240 Red 16
170 Blk M2 Fuel
A4 Pump
Electric 860 Pnk
Fuel
Injection 460 Yel
Module

Org X2 860 Pnk

Electrical Operation and Diagnostics - 255

 ELECTRICAL OPERATION AND DIAGNOSTICS

Test Conditions:
• Key switch in run position, engine not running.
• Park brake unlocked.
• PTO off.
• Operator on seat.

Test/Check Point Normal If Not Normal

19. Seat switch Battery voltage Check 500 and 502 Yel wires and connections.

20. Ignition interlock module Battery voltage Check 800 Pnk wire and connections. If OK, replace seat
switch.

21. Ignition interlock module Battery voltage Replace ignition interlock module.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO on.
• Operator off seat.

Test/Check Point Normal If Not Normal

22. Mid PTO switch Battery voltage Check 500 and 520 Yel wires and connections.

23. PTO interlock module Battery voltage Check 742 Blu/Wht wire and connections. If OK, replace
(option) mid PTO switch.

24. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

25. PTO interlock module Battery voltage Check 765 and 789 Pur wires and connections. If OK,
(option) replace brake switch.

26. Ignition interlock module Battery voltage Check 605 Tan wire and connections. If OK, replace PTO
interlock module.

27. Ignition interlock module Battery voltage Replace ignition interlock module.

Electrical Operation and Diagnostics - 256

 ELECTRICAL OPERATION AND DIAGNOSTICS

A1 Ignition M1 Starting
Interlock Module Motor

200 Red F3 Fusible Link

F6
Fusible
S1
Link
S2
500 Yel

20 A1
T2 Ignition
M Coil
M

A1

T1 Ignition
S2 Coil Blk
S1

26
G1 Battery
500 Blk
21
Yel
27
940 Wht X2 Blk

130 Blk 560 Red/Yel

100
Blk S6 Brake
Switch
S3 Seat
Switch
19 501
Yel S5 PTO/RIP
650 Switch
502 Yel Pnk
820 Pnk 24 /Blk
800 Pnk

652 Blu
765 Pur
789 Pur

705 Pnk/Blk

520
S8 Mid PTO Switch Yel

22
650 K11 EFI Module
Pnk
Ground Relay
/Blk
A3 PTO Interlock Module
138 Blk
605 Tan
139 Blk
140 Blk
25 742 Blu/Wht
23
789 Pur
820 Pnk 670
Pur
X22 Org
100
Blk

Electrical Operation and Diagnostics - 257

 ELECTRICAL OPERATION AND DIAGNOSTICS

K12 EFI Module

Power Relay

560 Red/Yel

230 Red
221 Red
221 Red

150
Blk

100
Blk K13 Fuel
Pump Relay
232 Red

230
Blk
Red

231 Red
560 Red/Yel
233
Red
/Blu
910
X23 Wht
Y4 #1 Cylinder Y5 #2 Cylinder
Fuel Injector Solenoid Fuel Injector Solenoid X22
Wht

Blk Brn
Wht Wht
X24
X25
170
Blk Wht

655
X25 Pnk

X21

651
Pnk/Blk
240 Red
170 Blk M2 Fuel
A4 Pump
Electric 860 Pnk
Fuel
Injection 460 Yel
Module

Org X2 860 Pnk

Electrical Operation and Diagnostics - 258

 ELECTRICAL OPERATION AND DIAGNOSTICS
PTO/RIP Circuit Operation - All Models With the S5 PTO/RIP switch on, current flow from the S6
brake switch to the S5 PTO/RIP switch and into the A1
Function: ignition interlock module to energize the K5 ignition relay is
stopped. The S3 seat switch circuit must keep the K5
To provide power to energize the PTO clutch solenoid.
ignition relay energized. If the operator gets off the seat
Operating Conditions: with the S5 PTO/RIP switch on, the S3 seat switch de-
energizes the K5 ignition relay and K2 magneto relay,
• Key switch in run position, which grounds the ignition system and stops current flow to
• PTO/RIP switch on, the fuel supply circuit and the K6 PTO relay. The result is
that the engine will stop and the PTO clutch solenoid will be
• Operator on seat,
de-energized.
or,
Circuit Function - RIO:
• Park brake locked.
To provide a safety interlock with the machine being
Theory of Operation: repositioned in reverse while the PTO is engaged, by
The key switch is connected to the A1 interlock module by disengaging the PTO circuit. An operator who deems it
soldered wire connections. The components are solid state necessary, and chooses to keep the PTO engaged while
and are not serviced separately except for the 15 amp backing up, must take a deliberate action to actuate the
fuses. Lines within border of the interlock module except for PTO/RIP switch, by pulling up on the PTO/RIP switch
key switch connections are circuit paths on the circuit board momentarily while pressing the reverse pedal.
and are not wires in the harness.
Operating Conditions - RIO:
With the PTO/RIP switch off, current flows from the A1
• Key switch in the run position,
ignition interlock module to the 652 Blu wire, S5 PTO/RIP
switch (PTO disengaged), 750 and 751 Blu wire, S6 brake • Operator on the seat,
switch (unlocked position), 770 Pur and 772 Blu wires, S4 • PTO/RIP switch in the RIO (momentary) position while
RIO switch (neutral/forward position), 735 Org wire into the placing the machine in reverse.
interlock module to energize the K6 PTO relay coil.
The PTO relay contacts close, supplying power to the 750 Theory of Operation - RIO:
and 751 Blu wires. The 751 Blu wire connects back to the The RIO circuit is powered by either the S4 RIO switch or
brake switch to the 770 Pur wire. This creates a loop to the S5 PTO/RIP switch. With the machine in neutral or
energize the PTO relay. Power is now available at the PTO/ forward, the S4 RIO switch supplies power to the K4 RIO
RIP switch to energize the RIO circuit and the PTO clutch unlatch relay and the K6 PTO relay which in turn supplies
solenoid when the PTO/RIP switch is moved to the on power to the S5 PTO/RIP switch to be used when the Y3
position. PTO clutch solenoid is engaged.
With the S5 PTO/RIP switch in the on position, power is If the machine is placed in reverse the S4 RIO switch is
supplied from the 750 Blu wire across the S5 PTO/RIP released and its contacts are opened, breaking the circuit
switch contacts to the 754 and 755 Blu wires. The 755 Blu to the K6 PTO relay and the K4 RIO unlatch relay. This in
wire supplies power to the Y3 PTO clutch solenoid and is turn breaks the circuit to the 750 Blu wire back to the S5
grounded through the 115 and 100 Blk wires. PTO/RIP switch and the 751 Blu wire back to the S6 brake
At the same time the 755 Blu wire supplies power to the Y3 switch where it connects to the 770 Pur wire to continue the
PTO clutch solenoid the 754 Blu wire supplies power to the loop back to the S4 RIO switch. Because the 750 Pur wire
momentary contacts of the S5 PTO/RIP switch. This circuit is now de-energized, there is no power for the PTO/RIP
is part of the RIO circuit to allow for repositioning of the switch to energize the PTO clutch solenoid.
machine in reverse with the PTO engaged. To reenergize these circuits, the machine must be placed in
If the machine is repositioned in reverse without pulling the neutral or forward, and the PTO/RIP switch must be placed
PTO/RIP switch into the Reverse Implement Position (RIP) in the OFF position. The operator can then energize the
the PTO will be disengaged. The PTO/RIP switch will then PTO again if desired.
need to be placed back to the off position to energize the
PTO relay and then pulled back to the on position if
desired.

Electrical Operation and Diagnostics - 259

 ELECTRICAL OPERATION AND DIAGNOSTICS
If the operator chooses to reposition the machine in reverse
while the PTO is engaged, the operator must pull up on the
PTO/RIP switch while placing the machine in reverse. Once
the machine is traveling in reverse the operator can release
the PTO/RIP switch. The K3 RIO latch relay feeds itself
across the K4 RIO unlatch relay contacts as well as
supplying power to the K6 PTO relay and the PTO loop.
Power to create this condition comes from the S5 PTO/RIP
switch momentary contacts. Wire 754 Blu is connected to
the 730 Grn and 731 Pur wires. The 730 Grn wire connects
to the interlock module to energize the K3 RIO latch relay
coil. The K3 RIO latch relay takes the place of the S4 RIO
switch during reverse movement with the RIP circuit
activated. The 731 Pur wire connects to the instrument
panel to illuminate the H4 RIO defeat light to warn the
operator that the RIO circuit is activated.
When the machine is placed back into neutral or forward,
the K4 RIO unlatch relay is energized and breaks the loop
to the K3 RIO latch relay. This prepares the machine for the
next reverse operation with the PTO engaged.

Electrical Operation and Diagnostics - 260

 ELECTRICAL OPERATION AND DIAGNOSTICS
PTO Circuit Electrical Schematic - All Models

Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4
A
Red F4 Fuse -15 A F-2
B A
A X4 500 Yel
M
Wht F5 Fuse -15 A F-6
G M M X4 705 Pnk/Blk
F-3
Start
X5 652 Blu
Run
H-F
S1 Key Off 750 Blu
Switch X4 751 Blu

F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X5

H-C
X5 800 Pnk

X1 H-D
X5 735 Org
X4
H-A
200 772 Blu
Red F-1 K3 RIO
E2 Red
X4 770 Pur
Latch Relay
K4 RIO LED
F-4
Unlatch Relay PTO
X5 730 Grn
F3
Fusible X5 H-E X5 H-H
H-G
Link
130
Blk
205
Red
Lt Blu

B S

M
M1
Starting Y1
Motor Starting
Motor
Solenoid

G1
Battery

Blk
100 Blk 100 Blk

W1
Frame Ground Unswitched Power Switched Power Secondary Power
Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 261

 ELECTRICAL OPERATION AND DIAGNOSTICS

S5 PTO/RIP
Switch
RIP*
On
Off
731 Pur
6 730 Grn
754 Blu 3
756 Blu 754 Blu
5 755 Blu
750 Blu 2
8 650 Pnk/Blk To Fuel
500 Yel 4 652 Blu Circuit
705 Pnk/Blk 1
7 765 Pur

705 Pnk/Blk

S6 Brake
652 Blu Switch
Off
750 Blu
751 Blu On
751 Blu
770 Pur
501 Yel
S3 Seat 765 Pur
Switch
(Off) S4 RIO** Neutral/
Forward
(On)
Switch
Reverse
800 Pnk 502 Yel 505 Yel
735 Org
772 Blu

735 Org

772 Blu
770 Pur

730 Grn

755
Blu
731
Pur X11
X6 740 Blu 758 Y3 PTO
X3 Blu
756 Blu V1 Clutch
1 Solenoid
Diode
X9
757
Yel

116
X3 Blk X11
5 H4 RIO
H6 Mid Defeat
115
Blk
PTO Light

X3
20 135
Blk
100 Blk

Electrical Operation and Diagnostics - 262

 ELECTRICAL OPERATION AND DIAGNOSTICS
PTO Circuit Diagnosis - All Models

Test Conditions:
• Key switch in run position, engine not running.
• Operator on seat.
• PTO off.
• Park brake unlocked.
• Transmission in neutral.

Test/Check Point Normal If Not Normal

1. Ignition interlock module Continuity to ground Check 130 and 100 Blk wires and connections.

2. Ignition interlock module Battery voltage Test F3 fusible link and F5 fuse. Check 200 Red wire and
connections. If OK, replace ignition interlock module.

3. Seat switch Battery voltage Check 500 and 502 Yel wires and connections.

4. Ignition interlock module Battery voltage Check 800 Pnk wire and connections. If OK, replace seat
switch.

5. Ignition interlock module Battery voltage Replace ignition interlock module.

6. PTO/RIP switch Battery voltage Check 652 Blu wire and connections.

7. Brake switch Battery voltage Check 750 and 751 Blu wires and connections. If OK, replace
PTO/RIP switch.

8. RIO switch Battery voltage Check 770 Pur and 772 Blu wires and connections. If OK,
replace brake switch.

9. Ignition interlock module Battery voltage Check 735 Org wire and connections. If OK, replace RIO
switch.

Test Conditions:
• Key switch in run position, engine not running.
• Operator on seat.
• PTO on.
• Park brake unlocked.
• Transmission in neutral.

Test/Check Point Normal If Not Normal

10. Ignition interlock module Battery voltage. Red Check that test conditions have been set properly. If OK,
LED illuminated replace ignition interlock module.

11. PTO/RIP switch Battery voltage Check 750 Blu wire and connections.

12. PTO clutch solenoid Battery voltage Check 755 Blu wire and connections. If OK, replace PTO/RIP
switch.

13. X3 Instrument panel Battery voltage. Rear Check 754, 756 Blu, and 757 Yel wires and connections. If
connector PTO light illuminated OK, replace PTO/RIP switch. Test rear PTO light bulb.

Electrical Operation and Diagnostics - 263

 ELECTRICAL OPERATION AND DIAGNOSTICS

Test Conditions:
• Key switch in run position, engine not running.
• Operator off seat.
• PTO in RIP position.
• Park brake unlocked.
• Transmission in neutral.

Test/Check Point Normal If Not Normal

14. X3 Instrument panel Battery voltage Check 754, 756 Blu, and 757 Yel wires and connections. If
connector OK, replace PTO/RIP switch.

15. X3 Instrument panel Battery voltage. RIO Check 731 Pur wire and connections. If OK, replace PTO/RIP
connector defeat light illuminated switch. Test RIO defeat light bulb.

16. Ignition interlock module Battery voltage Check 730 Grn wire and connections. If OK, replace PTO/
RIP switch.

Test Conditions:
• Key switch in run position, engine not running.
• Operator off seat.
• PTO in RIP position.
• Park brake unlocked.
• Transmission in reverse.

Test/Check Point Normal If Not Normal

17. Ignition interlock module Battery voltage. Red Check that test conditions have been set properly. If OK,
LED illuminated replace ignition interlock module.

18. Ignition interlock module Less than 0.2 volts Test RIO switch. See “RIO Switch Test” on page 314. If OK,
replace ignition interlock module.

Electrical Operation and Diagnostics - 264

 ELECTRICAL OPERATION AND DIAGNOSTICS

A1 Ignition M1 Starting
Interlock Module Motor
G1 Battery
200 Red F3 Fusible Link

S1 S2

500 Yel
17 2
10
1
A

4
M
501
M
Yel

S6 Brake
A1
Switch
7
S2
751
5 1 Blu
9 S1
770
18 Pur
16 S3 Seat
Switch
765
735 Pur
Org 730 X3 Instrument
502 Yel 503
Grn 652 Yel Panel Connector
Blu 130
800 Pnk
Blk 705 3 S4 RIO 757
Pnk Switch Yel
/Blk 772
Blu 750
Blu
505 Yel 13
772 Blu 731
Pur 15 14
735 Org 8

756 Blu X9
12

755 Blu
Y3 PTO Clutch
Solenoid 115 758
Blk 116 Blu

Blk
S5 PTO/RIP
Switch

115 Blk 755

754 Blu Blu
V5 6
Diode
652 Blu
11
765 Pur
754 Blu
756 Blu
730 Grn 650
Pnk
731 Pur /Blk
100
705 Pnk/Blk
Blk
To Fuel
750 Blu Circuit

Electrical Operation and Diagnostics - 265

 ELECTRICAL OPERATION AND DIAGNOSTICS
Instrument Panel Circuit Operation - All The engine coolant temperature sensor resistance is
Models approximately 40 - 700 ohms.

Function - Instrument Panel: Function - Fuel Gauge:

To inform the operator of various machine operating Inform the operator of the fuel level in the fuel tank.
conditions.
Theory of Operation - Fuel Gauge:
Operating Condition - Instrument Panel: The fuel level in the fuel tank is measured by the B2 fuel
The key switch must be in run or start position. gauge sensor. The sensor is a variable resistor. The
resistance is set by movement of a mechanical linkage
Theory of Operation - Instrument Panel: connected to a float in the fuel tank. The 5 to 95 ohm
variable resistance creates a variable voltage difference
The instrument panel receives current from the power across the P2 fuel gauge. The voltage difference ranges
circuit. Power is supplied to the instrument panel from the from approximately 5.72 VDC (fuel tank FULL) to
battery positive (+) terminal to the F3 fusible link, S1 key approximately 0.87 VDC (fuel tank EMPTY). The fuel
switch, A1 ignition interlock module F5 fuse, and 500 and gauge is part of the instrument panel.
503 Yel wires. The circuit traces on the instrument panel
then supply current to the individual lights and gauges. Function - Hourmeter and Service Timer Light:
The ground path for the instrument panel is completed by Hourmeter and Service Timer Light Circuit (SN -30000)
the 135 and 100 Blk wires.
To record the number of hours the key switch is in the run
Function - Engine Oil Pressure Light: position. To inform the operator that the machine is within
the service time limit.
To alert operator of low engine oil pressure.
Theory of Operation - Hourmeter and Service Timer
Theory of Operation - Engine Oil Pressure Light: Light:
The engine oil pressure light circuit uses a pressure
The P1 hourmeter not only counts the total number of
activated switch to provide a path to ground for the engine
hours the key switch is in the run position, it is also tied into
oil pressure light. The switch is closed when engine oil
the A2 service light timer module. The service light timer
pressure is at or below 98 kPa (14.2 psi).
module is also tied into the engine oil pressure light circuit.
If the engine is not running or engine oil pressure is at or While the hourmeter counts time when the key is in the run
below 98 kPa (14.2 psi), the B1 engine oil pressure switch position, the service light timer module is activated when
will be closed. The engine oil pressure switch completes the engine has enough oil pressure to open the engine oil
the path to ground and the engine oil pressure light comes pressure switch.
on.
The H3 service light will illuminate automatically 2 hours
When the engine starts and engine oil pressure increases before scheduled maintenance. The light will stay
above 98 kPa (14.2 psi), the engine oil pressure switch illuminated until the S2 service timer reset switch has been
opens, breaking the path to ground and the light goes out. pressed. The service light circuit is automatic and
nonadjustable. When the scheduled maintenance has been
Function - Engine Coolant Temperature Gauge (not on
preformed, the service technician will press and release the
X465):
S2 service timer reset switch to start the next service
Inform the operator of engine and coolant operating interval cycle. The key must be in the run or start position
temperature. for the A2 service light timer module to be reset.

Theory of Operation - Engine Coolant Temperature The P1 hourmeter will continue to count the total hours of
Gauge (not on X465): operation and will not reset to zero with the reset switch.
The P1 hourmeter, A2 service light timer module and H3
The engine coolant temperature sensor is a variable service light receive power from the switched power circuit.
resistor, providing a ground circuit path for the temperature
gauge. As the engine coolant heats, the resistance
decreases. As the resistance decreases, more current is
allowed to flow across the engine coolant temperature
gauge causing the needle raise and indicate a higher
temperature. The temperature gauge is part of the
instrument panel.

Electrical Operation and Diagnostics - 266

 ELECTRICAL OPERATION AND DIAGNOSTICS
Function - Brake Light (SN 30001-)
Inform the operator that the brake pedal is depressed or the
park brake is engaged.

Theory of Operation - Brake Light

The brake light will illuminate whenever the brake pedal is
depressed or the park brake is engaged with the key switch
in the on position. It is activated by the S6 brake switch and
receives its power from the 767 Pur wire to the H13 brake
light on the instrument panel. A path to ground is provided
by the 135 Blk wire on the instrument panel and to frame
ground.

Electrical Operation and Diagnostics - 267

 ELECTRICAL OPERATION AND DIAGNOSTICS
Instrument Panel Circuit Electrical Schematic - All Models (SN -30000)

Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4
A
Red F4 Fuse -15 A F-2
B A
A X4 500 Yel
M F-6
Wht F5 Fuse -15 A
G M M X4
F-3
Start
X5
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X5
H-C

X1 X5
H-D
200
Red X5
X4
H-A
F-1 K3 RIO
E2 Red
X4 503
F3 Latch Relay
K4 RIO Yel
LED
Fusible Unlatch Relay PTO
F-4
Link X5 X3
17
205 H-G
X5 H-E X5 H-H
Lt Blu
Red
H2 Engine
Oil H3 P1 P3 Engine
B S Coolant
Pressure Service Hourmeter
Light Indicator Temperature
Gauge P2 Fuel
(SN -30000) Gauge
(Not on X465)
M X3
M1 t0 Q
X3 8
Starting 620 Tan X3
A2 Service
Motor 15
X3 Light Timer 2
900 Blk/Wht
850 7
Module
Pnk
X2 310 X10 X10
Org/
Wht
Blu/
Red S2 Service Timer B2 Fuel
X2 M
Reset Switch Gauge Q
(SN -30000) Sensor
Reset

Off

G1 P X3 Yel
B3 Engine M2 Fuel
Battery 20 135
151
Coolant Pump
Blk Blk
Blk B1 Engine Oil Temperature X10 (Not on
Pressure t0 X465)
Sensor 120
Switch (NC) (Not on X465) Blk
100 Blk

W1 Unswitched Power Switched Power Secondary Power

Frame Ground Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 268

 ELECTRICAL OPERATION AND DIAGNOSTICS
Instrument Panel Circuit Schematic - All Models (SN 30001-)

Wht
S2
Wht
A2 Control Module
S1
S2
S1
S1 S2 X6
Red A F5 Fuse -15 A F-2
B A
A X6 500 Yel
M F6 Fuse -15 A F-6
Wht
G M M X6
F-3
Start
X7
Run
H-F
S1 Key Off
Switch X6
F-5
E1 Grn K5
K2 Magneto LED Ignition
X1 K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X7
200
Red H-C

F3 X7
Fusible H-D
Link
X7
Red
X6
H-A
205
Lt Blu F-1 K3 RIO
E2 Red
X6 503
Latch Relay
B S K4 RIO LED
F-4
Yel
Unlatch Relay PTO
X7
17
H-G
M X7 H-E X7 H-H

M1
Starting
Motor P1 P3 Engine
Hourmeter Coolant
To S6 Temperature
H9 H10 P2 Fuel
Brake Switch Gauge
EFI Oil (not on X465) Gauge
767
Diagnostic Pressure Pur
Light Light 15 t0 Q
H8/H9
(X485/X585) 6
(X485/X585) X3
16
Brake 2 8
620
785 Tan Light
310 900
Grn 451 Yel/Wht
Org/ Blk/Wht
G1 To A4
Wht to Light Switch
Battery Electric X2
Fuel Blu/
Injection Red B3 Engine X28
Module Coolant 19 H12
B4 Engine Temperature Light
P X3 Q
Oil Sensor
20
Pressure 135
Yel (not on X465)
Switch
Blk B2 Fuel
Blk
t0 Gauge
Sensor
X28
120 Blk
100 Blk 135 Blk

W1 Unswitched Power Switched Power Secondary Power

Frame Ground
Unswitched Ground Control Panel Wiring Harness
MIF

Electrical Operation and Diagnostics - 269

 ELECTRICAL OPERATION AND DIAGNOSTICS
Instrument Panel Circuit Diagnosis - All Models

Test Conditions:
• Key switch in off position.
• X3 connector to instrument panel disconnected.
• Service timer reset switch depressed (SN -30000).

Test/Check Point Normal If Not Normal

1. X3 Instrument panel connector Continuity to ground Check 135 and 100 Blk wires and connections.

2. Service timer reset switch Continuity to ground Check 135 and 100 Blk wires and connections.
(SN -30000)

3. X3 Instrument panel connector Continuity to ground Check 850 Pnk wire and connections. If OK, replace
(SN -30000) service timer reset switch.

Test Conditions:
• Key switch in off position.
• X3 connector to instrument panel disconnected.

Test/Check Point Normal If Not Normal

4. Fuel gauge sensor Continuity to ground Check 120 and 100 Blk wires and connections.

5. X3 Instrument panel connector Resistance between Check 900 Blk/Wht wire and connections. Test fuel gauge
6 ohms - empty sensor.
to 200 ohms - full

6. X3 Instrument panel connector Continuity to ground Check 620 Tan wire and connections. If OK, replace engine
oil pressure switch.

7. X3 Instrument panel connector Resistance between Check 310 Org/Wht wire and connections. If OK, replace
(not on X465) 700 ohms - cold engine coolant temperature sensor.
40 ohms - hot

Test Conditions:
• Key switch in run position, engine not running.
• X3 connector to instrument panel connected.

Test/Check Point Normal If Not Normal

8. Ignition interlock module Battery voltage. Test F3 fusible link and F5 fuse. If OK, replace ignition
interlock module.

9. Engine oil pressure switch Less than 0.2 volts. Test engine oil pressure light bulb. Check 200 Red and 500
Engine oil pressure light Yel wires and connections. If OK, replace instrument panel.
illuminated.

10. Engine coolant temperature 7.0 - 6.0 volts Test engine coolant temperature sensor. If OK, replace
sensor (not on X465) instrument panel.

11. Fuel gauge sensor 0.87 - 5.72 volts Test fuel gauge sensor. If OK, replace instrument panel.

Electrical Operation and Diagnostics - 270

 ELECTRICAL OPERATION AND DIAGNOSTICS
M1 Starting
Motor

200 Red
F3 Fusible
Link

A1 Ignition
Interlock Module
200
G1 Battery 135 Blk
Red
900 Blk/Wht
X3 Instrument
850 Pnk Panel Connector
S1 S2
500 Yel 503 Yel
620 Tan
A1
310 Org/Wht
M 1
M

5
A1
3
S2
6
S1 7
130 Blk 8
B3 Engine Coolant
Temperature Switch
S2 Service Timer (not on X465)
Reset Switch
(SN -30000)
10
310 Org/Wht
X2
Yel

850 Pnk
B1 Engine Oil
Pressure Switch
2
151 Blk
9

620 Tan X2 Blu/Red

4
120 Blk 11

B2 Fuel
Gauge Sensor

100
Blk

Electrical Operation and Diagnostics - 271

 ELECTRICAL OPERATION AND DIAGNOSTICS
Lights Circuit Operation - All Models
Function:
Provides current to the headlights, tail lights, backup lights,
and instrument panel lights, in combinations depending
upon the position the light switch or transmission (RIO
switch).

Operating Conditions:
• Light switch in on or on with backup lights position,
or,
• Transmission in reverse.

Theory of Operation:
Power is provide to the S9 light switch through the A1
ignition interlock module and is protected by the F3 fusible
link and the F4 fuse. The 400 Yel/Blu wire connects to the
S9 light switch.
With the S9 light switch in the on position, current is
provided to the 450 Yel/Wht wire which splices into the 451,
455, and 459 Yel/Wht wires.
The 451 Yel/Wht wire supplies current to the X3 connector
to illuminate the H7 dash lights. The 135 and 100 Blk wires
provide the ground from the instrument panel.
The 455 Yel/Wht wire supplies current to the X13 connector
and the 170 and 171 Blk wires to illuminate the E3 and E4
headlights. The ground is provided by the 172 and 173 Blk
wires, X13 connector to the 110 Blk wire.
The 459 Yel/Wht wire supplies current to the X12 connector
and the 400 and 420 Yel wires to illuminate the E5 and E7
tail lights. The ground is provided by the 100, 130 and 120
Blk wires, X12 connector to the 122 and 100 Blk wires.
With the light switch in the on with backup lights position, in
addition to the H7 dash light, E3 and E4 headlights, and the
E5 and E7 tail lights, current is provided to the to the E6
and E8 backup lights. The 810 Pnk with receives current
and connects through the X12 connector to the 800 and
820 Pur wires and the E6 and E8 backup lights. The ground
is provided by the 110, 150, and 120 Blk wires, X12
connector to the 122 and 100 Blk wires.
The backup light can also be powered by the S4 RIO
switch. Power is provide to the S4 RIO switch through the
A1 ignition interlock module and is protected by the F3
fusible link and the F5 fuse. The 500 and 505 Yel wires
connect to the S4 RIO switch. When the transmission is in
reverse, the switch is released and the 505 Yel wire is
connected to the 830 Gry wire. The 830 Gry wire supplies
current to the X12 connector to the 800 and 820 Pur wires
and the E6 and E8 backup lights. The ground is provided
by the 110, 150, and 120 Blk wires, X12 connector to the
122 and 100 Blk wires.

Electrical Operation and Diagnostics - 272

 ELECTRICAL OPERATION AND DIAGNOSTICS
Lights Circuit Electrical Schematic - All Models
Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4 400 Yel/Blu
A
Red F4 Fuse -15 A F-2
B A
A X4 500 Yel
M
Wht F5 Fuse -15 A F-6
G M M X4
F-3
Start
X5
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X5

H-C

505 Yel

X1 S4 RIO
Switch
200 Neutral/ S9 Light
On
Red Forward Switch On
Reverse Off 810 Pnk
505 Yel 830 Gry
400 Yel/Blu
F3 450 Yel/Wht
Fusible 455
Link 459 Yel/
Yel/ Wht
205 451 Yel/Wht Wht
Red
Lt Blu

B S
X12 E5 RH
Tail Light X13
420 Yel X16 130 Blk E3 RH Headlight
M 171 Blk X14
451 X16
M1 E6 RH 172
Yel/ X14
Starting Y1 Wht Backup Light
Blk

Motor Starting E4 LH Headlight

Motor 820 Pur X17 150 Blk
Solenoid X3
19 X15
X17 170 Blk 173 Blk

H7 E7 LH X15
Dash Tail Light
X13
Light 400 Yel X18 100 Blk

X18
X3 E8 LH
G1
20 Backup Light
Battery X19
135 800 Pur 110 Blk
Blk
Blk X19
100 Blk 100 Blk
X12 120 Blk
110 Blk 110 Blk

W1 Unswitched Power Switched Power Secondary Power

Frame Ground
Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 273

 ELECTRICAL OPERATION AND DIAGNOSTICS
Lights Circuit Diagnosis - All Models

Test Conditions:
• Key switch in run position, engine not running.
• Light switch in on position.
• Transmission in neutral.
• X3 connector to instrument panel disconnected.

Test/Check Point Normal If Not Normal

1. Light switch Battery voltage Test F3 fusible link and F4 fuse. Check 400 Yel/Blu wires
and connections. If OK, replace ignition interlock module.

2. X3 Instrument panel connector Battery voltage Check 450 and 451 Yel/Wht wires and connections. If OK,
replace light switch.

3. E5 and E7 tail lights Battery voltage Check 450, 459 Yel/Wht wires, X12 connector, and 400 and
420 Yel wires and connections. If OK, replace light switch.

4. E3 and E4 headlights Battery voltage Check 450, 455 Yel/Wht wires, X13 connector, and 170 and
171 Blk wires and connections. If OK, replace light switch.

Test Conditions:
• Key switch in run position, engine not running.
• Light switch in on with backup lights position.
• Transmission in neutral.

Test/Check Point Normal If Not Normal

5. E6 and E8 backup lights Battery voltage Check 810 Pnk wire, X12 connector, and 800 and 820 Pur
wires and connections. If OK, replace light switch.

Test Conditions:
• Key switch in run position, engine not running.
• Light switch off.
• Transmission in reverse.

Test/Check Point Normal If Not Normal

6. RIO switch Battery voltage Test F3 fusible link and F5 fuse. Check 500 and 501 Yel
wires and connections. If OK, replace ignition interlock
module.

7. E6 and E8 backup lights Battery voltage Check 810 Pnk wire, X12 connector, and 800 and 820 Pur
wires and connections. If OK, replace light switch.

Electrical Operation and Diagnostics - 274

 ELECTRICAL OPERATION AND DIAGNOSTICS

M1 Starting
Motor

F3 Fusible
Link
200 Red
S4 RIO
Switch
6

505 Yel

A1 Ignition
830
Interlock Module
200 Gry
G1 Battery
Red

X3 Instrument
451 Yel/Wht Panel Connector
S1 S2
500 Yel 503 Yel

A1

M
M

A1
2

S2

S1

130 Blk

400 Yel/Blu
S9 Light
110 Blk X13 173 Blk
Switch
1 E4 LH
Headlight
450 Yel/Wht 455 Yel/Wht X13 170 Blk
4
172 Blk E3 RH
Headlight
810 171 Blk
Pnk 4

E7 LH E8 LH E6 RH E5 RH
Tail Light Backup Light Backup Light Tail Light

459 7
7
Yel/ 3 5 5 3
Wht
400 Yel
X12
420 Yel
830 Gry 800 Pur
X12
820 Pur
100 110 150 130
X12 Blk Blk Blk Blk
122 Blk 120 Blk

100 Blk 110

Blk

Electrical Operation and Diagnostics - 275

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Pump and Fuel Shutoff Circuit Operation If the PTO/RIP switch is in the on position and the operator
- X465, X475 and X575 is off the seat then the 789 Pur wire which receives power
from the brake switch will supply current to the A3 PTO
Function: interlock module.
To provide power to the fuel shutoff solenoid and the fuel With the operator off the seat, the K8 off seat relay on the
pump to supply fuel to the engine. A3 PTO interlock module is deenergized and its normally
closed and common terminals and connected. The S8 mid
Operating Conditions: PTO switch has energized the K9 mid PTO relay and
current flows from the 789 Pur wire across the K9 mid PTO
• Key switch in run or start position,
relay and the K8 off seat relay and to the 605 Tan wire. The
• Operator on seat, 605 Tan wire supplies current into the A1 ignition interlock
or, module to energize the K5 ignition relay. With the relay
energized, current flows across the ignition relays normally
• Key switch in run or start position, open contacts to the 652 Blu wire. The 652 Blu wire
• Operator off seat, connects to the 650 Pnk/Blk and 655 Pnk wires. The 650
Pnk/Blk wire supplies current to the Y2 fuel shutoff solenoid
• Park braked locked.
while the 655 Pnk wire supplies current to the M2 fuel
Theory of Operation: pump.

NOTE: The X465 model circuit does not have the M2

electric fuel pump (655 Pnk wire and M2 fuel pump).
See Engine section.
The fuel shutoff solenoid and fuel pump circuit is powered
by the K5 ignition relay on the A1 ignition interlock module.
Current from the switched power circuit is supplied to the
S3 seat switch from the 500 and 502 Yel wires. When the
operator is on the seat, current flows across the seat switch
to the 800 Pnk wire and into the A1 ignition interlock
module to energize the K5 ignition relay. With the relay
energized, current flows across the ignition relays normally
open contacts to the 652 Blu wire. The 652 Blu wire
connects to the 650 Pnk/Blk and 655 Pnk wires. The 650
Pnk/Blk wire supplies current to the Y2 fuel shutoff solenoid
while the 655 Pnk wire supplies current to the M2 fuel
pump.
With both the fuel pump and fuel shutoff solenoid
energized, fuel is now able to flow to the carburetor and into
the combustion chamber.
Current can also be supplied to the K5 ignition relay
through the brake switch.
Current from the switched power circuit is supplied to the
S6 brake switch from the 500 and 501 Yel wires. When the
brake is on, current flows across the brake switch to the
765 and 789 Pur wires. The 765 Pur wire supplies current
to the S5 PTO/RIP switch. With the PTO/RIP switch in the
off position current flows across the PTO/RIP switch to the
705 Pnk/Blk wire and into the A1 ignition interlock module
to energize the K5 ignition relay. With the relay energized,
current flows across the ignition relays normally open
contacts to the 652 Blu wire. The 652 Blu wire connects to
the 650 Pnk/Blk and 655 Pnk wires. The 650 Pnk/Blk wire
supplies current to the Y2 fuel shutoff solenoid while the
655 Pnk wire supplies current to the M2 fuel pump.

Electrical Operation and Diagnostics - 276

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Pump and Fuel Shutoff Circuit Electrical Schematic - X465, X475 and X575

Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4
Red A F4 Fuse -15 A F-2
B A
A X4 500 Yel
M
Wht F5 Fuse -15 A F-6
G M M X4 705 Pnk/Blk
F-3
Start
X5 652 Blu
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
X1 Start Relay Start Relay Seat Relay
PTO Relay X5

200 H-C
Red
X5 800 Pnk
H-D
X5
F3
X4
Fusible H-A
Link F-1 K3 RIO X4
Latch Relay E2 Red
K4 RIO LED
F-4
Unlatch Relay PTO
X5
H-G
X5 H-E X5 H-H

205 605
Lt Blu Tan 605 Tan

Red

B S

M 130
Blk
M1
Starting Y1
Motor Starting
Motor
Solenoid

G1
Battery

Blk
100 Blk 100 Blk

W1
Frame Ground Unswitched Power Switched Power Secondary Power
Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 277

 ELECTRICAL OPERATION AND DIAGNOSTICS

S5 PTO/RIP RIP*
Switch On X475 and 575 Only
Off

3 6

500 Yel 5
2 650 Pnk/Blk 655 Pnk
8
4 652 Blu 655
705 Pnk/Blk 705 Pnk/Blk 1 Pnk
7 765 Pur

X2
652 Blu X21
S6 Brake
Switch Yel/
Off
789 Wht
Pur
On Y2 Fuel 651
Shutoff Pnk
S3 Seat Solenoid /Blk
Switch 501 Yel
765 Pur

(Off)

(On)
B2 Fuel
800 Pnk 502 Yel Gauge X10 X10
Sensor
820
Pnk M
Q
A3 PTO Interlock Module
X7
J5-C
M2 Fuel
Pump
K7 Brake
Lock Relay X10
X7
J5-A

605 Tan 605 Tan

X7
K8 Off 120
J5-B
Seat Blk
Relay
820 Pnk X8 742
X8 Blu/Wht
J4-A
J4-B
K9 Mid
PTO Light X6
Relay
X8
789 Pur S8
J4-C Mid
X9 PTO
J6-A K10 Rear Switch
On
Off

PTO Light
X9 Relay X8 140 X6
Blk
520
J6-B J4-D Yel

100 Blk

Electrical Operation and Diagnostics - 278

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Pump and Fuel Shutoff Circuit Diagnosis - X465, X475 and X575
NOTE: The X465 model circuit does not have the M2 electric fuel pump (655 Pnk wire and M2 fuel pump). See
Engine section.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO off.
• Operator off seat.

Test/Check Point Normal If Not Normal

1. Ignition interlock module Battery voltage Test F3 fusible link and F5 fuse. Check 200 Red wire and
connections. If OK, replace ignition interlock module.

2. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

3. PTO/RIP switch Battery voltage Check 765 Pur wire and connections. If OK, replace brake
switch.

4. Ignition interlock module Battery voltage Check 705 Pnk/Blk wire and connections. If OK, replace
PTO/RIP switch.

5. Ignition interlock module Battery voltage Replace ignition interlock module.

6. Fuel pump (not X465) Battery voltage Check 652 Blu, 650 Pnk/Blk, 655 Pnk, and 651 Pnk/Blk
wires and connections.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake unlocked.
• PTO off.
• Operator on seat.

Test/Check Point Normal If Not Normal

7. Seat switch Battery voltage Check 500 and 502 Yel wires and connections.

8. Ignition interlock module Battery voltage Check 800 Pnk wire and connections. If OK, replace seat
switch.

9. Ignition interlock module Battery voltage Replace ignition interlock module.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO on.
• Operator off seat.

Electrical Operation and Diagnostics - 279

 ELECTRICAL OPERATION AND DIAGNOSTICS

Test/Check Point Normal If Not Normal

10. Mid PTO switch Battery voltage Check 500 and 520 Yel wires and connections.

11. PTO interlock module Battery voltage Check 742 Blu/Wht wire and connections. If OK, replace
(option) mid PTO switch.

12. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

13. PTO interlock module Battery voltage Check 765 and 789 Pur wires and connections. If OK,
(option) replace brake switch.

14. Ignition interlock module Battery voltage Check 605 Tan wire and connections. If OK, replace PTO
interlock module.

15. Ignition interlock module Battery voltage Replace ignition interlock module.

Electrical Operation and Diagnostics - 280

 ELECTRICAL OPERATION AND DIAGNOSTICS

A1 Ignition M1 Starting
Interlock Module Motor

200 Red F3 Fusible Link

S1 S2
500 Yel
1
4
8 A1

M
M

A1

S2

14 S1

G1 Battery
5
9
15

130 Blk S6 Brake

Switch
100
Blk
501
S3 Seat Yel
Switch
7 2 S5 PTO/RIP
12 650 Switch
502 Yel
Pnk
820 Pnk /Blk
800 Pnk
652 Blu
765 Pur
789 Pur

705 Pnk/Blk

3
Y2 Fuel
650 Shutoff
S8 Mid PTO Switch 520
Pnk Solenoid
Yel
/Blk
10

655
A3 PTO Interlock Module Pnk
651
Pnk/Blk X21
605 Tan 6
11 M2 Fuel
Pump (X475 and X575 only)
13 742 Blu/Wht
789 Pur
820 Pnk

140
Blk

Electrical Operation and Diagnostics - 281

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Pump and Fuel Injector Circuit Operation With the fuel pump, fuel injectors, and the EFI module
- X485 and X585 energized, fuel is now able to be delivered into the
combustion chamber.
Function: Current can also be supplied to the K5 ignition relay
To provide power to the fuel pump and fuel injectors to through the S6 brake switch.
supply fuel to the engine. Current from the switched power circuit is supplied to the
S6 brake switch from the 500 and 501 Yel wires. When the
Operating Conditions:
brake is on, current flows across the brake switch to the
• Key switch in run or start position, 765 and 789 Pur wires. The 765 Pur wire supplies current
to the S5 PTO/RIP switch. With the PTO/RIP switch in the
• Operator on seat,
off position current flows across the PTO/RIP switch to the
or, 705 Pnk/Blk wire and into the A1 ignition interlock module
• Key switch in run or start position, to energize the K5 ignition relay. With the relay energized,
current flows across the ignition relay’s contacts to the 652
• Operator off seat, Blu wire. The 652 Blu wire connects to the 650 Pnk/Blk
• Park braked locked. wire. The 650 Pnk/Blk wire supplies current to the K11 EFI
module ground relay.
Theory of Operation:
If the PTO/RIP switch is in the on position and the operator
The fuel pump and fuel injector circuit is powered by the A4 is off the seat then the 789 Pur wire, which receives power
electric fuel injection (EFI) module which is controlled from the brake switch, will supply current to the A3 PTO
through the K5 ignition relay on the A1 ignition interlock interlock module.
module.
With the operator off the seat, the K8 off seat relay on the
Current from the switched power circuit is supplied to the A3 PTO interlock module is deenergized and its normally
S3 seat switch from the 500 and 502 Yel wires. When the closed and common terminals are connected. The S8 mid
operator is on the seat, current flows across the seat switch PTO switch has energized the K9 mid PTO relay and
to the 800 Pnk wire and into the A1 ignition interlock current flows from the 789 Pur wire across the K9 mid PTO
module to energize the K5 ignition relay. With the relay relay and the K8 off seat relay and to the 605 Tan wire. The
energized, current flows across the ignition relays normally 605 Tan wire supplies current into the A1 ignition interlock
open contacts to the 652 Blu wire. The 652 Blu wire module to energize the K5 ignition relay. With the relay
connects to the 650 Pnk/Blk wire. The 650 Pnk/Blk wire energized, current flows across the ignition relays normally
supplies current to the K11 EFI module ground relay. The open contacts to the 652 Blu wire. The 652 Blu wire
K11 EFI module ground relay closes and provides a path to connects to the 650 Pnk/Blk wire. The 650 Pnk/Blk wire
ground for the A4 EFI module through the 860 Pnk, Org, supplies current to the K11 EFI module ground relay.
and 670 Pur wires, K11 EFI module ground relay, 139, and
100 Blk wires.
At the same time power is being supplied to the A4 EFI
module through the K12 EFI power relay. With the key in
the run position, switched power is provided to the K12 EFI
module power relay from the 500 Yel and 560 Red/Yel
wires. This energizes the K12 EFI module power relay to
supply unswitched power from the F6 fusible link, 220 and
221 Red wires to the 230, 231 Red and 233 Red/Blu wires
to the X23 connector to the Wht wire in the W2 engine
wiring harness (X485 and X585). The Wht wire provides
power to the Y4 and Y5 fuel injector solenoids and the 240
Red wire to the A4 EFI module. With power to the A4 EFI
module, internal circuitry provides a ground circuit for the
K13 fuel pump relay. The power input for the for the K13
fuel pump relay is provided from the K12 EFI module relay
and 230 and 231 and 232 Red wires. With the K13 fuel
pump relay energized, current flows from the 231 Red wire
to the 655 Pnk and 651 Pnk/Blk wires to the M2 fuel pump.

Electrical Operation and Diagnostics - 282

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Pump and Fuel Injector Circuit Electrical Schematic - X485 and X585

Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4
A
Red F4 Fuse -15 A F-2
B A
A X4 500 Yel
M
Wht F5 Fuse -15 A F-6
G M M X4 705 Pnk/Blk
F-3
Start
X5 652 Blu
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
X1 Start Relay Start Relay Seat Relay
PTO Relay X5

200 H-C
Red
X5 800 Pnk
H-D
X5
F3 X4
H-A
Fusible
Link F-1 K3 RIO
E2 Red
X4
Latch Relay
K4 RIO LED
F-4
205 Unlatch Relay PTO
Lt Blu X5
H-G
X5 H-E X5 H-H

605 Tan 605 Tan

Red 215 Gry 215 Gry

B S

130
Blk
M
M1
Starting Y1
Motor Starting
Motor
Solenoid

G1
Battery

Blk
100 Blk 100 Blk

W1 Unswitched Power Switched Power Secondary Power

Frame Ground Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 283

 ELECTRICAL OPERATION AND DIAGNOSTICS

S5
RIP*
PTO/RIP 650 Pnk/Blk
On
Switch
Off

3 6

500 Yel 5
2
8 650 Pnk/Blk
4 652 Blu
705 Pnk/Blk 705 Pnk/Blk 1
7 765 Pur
789
Pur
652 Blu
A3 PTO Interlock Module
X7
J5-C
S6 Brake
Switch K7 Brake
S3 Seat Off Lock Relay
Switch X7
On
(Off) J5-A

(On) 765 Pur 605 Tan

X7
501 K8 Off
800 Pnk 502 Yel Yel J5-B
Seat
Relay
820 Pnk X8 742
820 Pnk X8 Blu/Wht
J4-A
J4-B
K9
Mid
S8
PTO X6 Mid
X8 Relay PTO
789 Pur
Switch
J4-C
X9
J6-A K10 Rear

On
Off
605 Tan PTO Relay
140 X6
X9 X8 Blk
520
J6-B J4-D Yel 560 Red/Yel

F6 Fusible Link F7 Fuse

215 Gry 220 Red 221 Red

100 Blk

Electrical Operation and Diagnostics - 284

 ELECTRICAL OPERATION AND DIAGNOSTICS

650 670 Pur 670 Pur X22 Org

Pnk
/Blk
86 87 87a K11 EFI
Module
Ground
85 30
138 Relay
Blk 139
Blk

X26
W2 Ground
A
B
C
Y4 #1 Cylinder X25
Fuel Injector Yel/Blu D
Yel/Blu A 160 Blk
Solenoid E
Blk/Wht B 330 Org
F
Brn C 460 Yel A4
G
Electric
H
Yel/Red E 610 Tan Fuel
Wht I Injection
Y5 #2 Cylinder Blk/Wht F 710 Pur
Fuel Injector
J Module
Yel K
Solenoid /Red Org H 860 Pnk
L
Red I 950 Wht
M
N
O
Wht Wht L 240 Red
P

Wht
Red
X22 785 Grn 16
X23
H9 X3
Circuit Integrity
Light
560 Red/Yel 503 Yel
Control
221 Red
X3 Panel

K12 EFI 17
87a 87 86
Module 651
Power Pnk
Brn /Blk
30 85 Relay 233
230 150 Red B2 Fuel
X22 X10
Red Blk 230 Red /Blu Gauge
Sensor
231
232
Red M
RedK13 Q
87a 87 86 Fuel
Pump M2 Fuel
30 85 Relay Pump
655
Pnk
910 Wht X10
X21 120
Blk

100 Blk

Electrical Operation and Diagnostics - 285

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Pump and Fuel Injector Circuit Diagnosis - X485 and X585

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO off.
• Operator off seat.
• Confirm that the EFI fault light illuminates for approximately two seconds when the key is first turned to the run
position.

Test/Check Point Normal If Not Normal

1. Ignition interlock module Battery voltage Test F3 fusible link and F5 fuse. Check 200 Red wire and
connections. If OK, replace ignition interlock module.

2. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

3. PTO/RIP switch Battery voltage Check 765 Pur wire and connections. If OK, replace brake
switch.

4. Ignition interlock module Battery voltage Check 705 Pnk/Blk wire and connections. If OK, replace
PTO/RIP switch.

5. Ignition interlock module Battery voltage Replace ignition interlock module.

6. K11 EFI module ground relay Battery voltage Check 652 Blu and 650 Pnk/Blk wires and connections.

7. K12 EFI module power relay Battery voltage Test F6 fusible link and F7 fuse. Check 220 and 221 Red
wires and connections.

8. K12 EFI module power relay Battery voltage Check 500 and 560 Red/Yel wires and connections.

9. K13 Fuel pump relay Battery voltage Check 230 and 231 Red wires and connections. If OK,
replace K12 EFI module power relay.

10. Fuel pump Battery voltage Check 655 Pnk and 651 Pnk/Blk wires and connections. If
OK, replace K13 fuel pump relay.

11. Fuel injector(s) Battery voltage Check 230 Red, 233 Red/Blu and Wht wires and
connections. If OK, replace K12 EFI module power relay.

12. Electric fuel injection module Battery voltage Check 230 Red, 233 Red/Blu, Wht, and 240 Red wires and
connections. If OK, replace K12 EFI module power relay.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake unlocked.
• PTO off.
• Operator on seat.
• Confirm that the EFI fault light illuminates for approximately two seconds when the key is first turned to the run
position.

Electrical Operation and Diagnostics - 286

 ELECTRICAL OPERATION AND DIAGNOSTICS

Test/Check Point Normal If Not Normal

13. Seat switch Battery voltage Check 500 and 502 Yel wires and connections.

14. Ignition interlock module Battery voltage Check 800 Pnk wire and connections. If OK, replace seat
switch.

15. Ignition interlock module Battery voltage Replace ignition interlock module.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO on.
• Operator off seat.
• Confirm that the EFI fault light illuminates for approximately two seconds when the key is first turned to the run
position.

Test/Check Point Normal If Not Normal

16. Mid PTO switch Battery voltage Check 500 and 520 Yel wires and connections.

17. PTO interlock module Battery voltage Check 742 Blu/Wht wire and connections. If OK, replace
(option) mid PTO switch.

18. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

19. PTO interlock module Battery voltage Check 765 and 789 Pur wires and connections. If OK,
(option) replace brake switch.

20. Ignition interlock module Battery voltage Check 605 Tan wire and connections. If OK, replace PTO
interlock module.

21. Ignition interlock module Battery voltage Replace ignition interlock module.

Electrical Operation and Diagnostics - 287

 ELECTRICAL OPERATION AND DIAGNOSTICS

A1 Ignition M1 Starting
Interlock Module Motor

200 Red F3 Fusible Link

F6
Fusible
S1
Link
S2
500 Yel
1
4
14 A1
T2 Ignition
M Coil
M

A1

T1 Ignition
S2 Coil Blk
S1

20
G1 Battery
500 Blk
5
Yel
15
21 940 Wht X2 Blk

130 Blk 560 Red/Yel

100
Blk S6 Brake
Switch
S3 Seat
Switch
13 501
Yel S5 PTO/RIP
Switch
502 Yel 650
820 Pnk 2 Pnk
800 Pnk 18 /Blk

652 Blu
765 Pur
789 Pur

705 Pnk/Blk

3
520
S8 Mid PTO Switch Yel

16
650 K11 EFI Module
Pnk Ground Relay
/Blk
A3 PTO Interlock Module
138 Blk
605 Tan
139 Blk
140 Blk
19 742 Blu/Wht 6
17
789 Pur
820 Pnk
670
Pur X22 Org
100
Blk

Electrical Operation and Diagnostics - 288

 ELECTRICAL OPERATION AND DIAGNOSTICS

K12 EFI Module

Power Relay

560 Red/Yel 8

230 Red
221 Red
221 Red

7
150
Blk

100
Blk K13 Fuel
Pump Relay
232 Red

230
Blk
Red

231 Red
560 Red/Yel
233
Red
9
/Blu
910
X23 Wht
Y5 #2 Cylinder
Y4 #1 Cylinder Fuel Injector
Fuel Injector Solenoid Solenoid X22
Wht

Blk Brn
Wht Wht
X24
11 11
X25
170
Blk Wht

655
X25 Pnk

X21
12
651
Pnk/Blk
240 Red 10
M2 Fuel
A4 170 Blk
Pump
Electric 860 Pnk
Fuel
Injection
Module 460 Yel

Org X2 860 Pnk

Electrical Operation and Diagnostics - 289

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Injection Sensor and Diagnostic Circuit components that change the voltage to the EFI module.
Operation - X485 and X585 The fault codes for these components are based on the EFI
module reading either a open or shorted circuit. This
Function: means that the EFI is receiving either battery voltage or no
voltage from the sensors.
Provides the inputs to the EFI module which in turn
provides the proper output to the injectors. Diagnostic Circuit Operation:
The H9 circuit integrity light flashes in specific sequences During normal operation the circuit integrity light will
of flashes to provide a visual indication of fault diagnostic illuminated for approximately 2 seconds when the key is
codes. These fault codes will aid in the diagnosis of turned ON as part of a self test, then the light will not be
operational problems that may occur. illuminated. The status indicator light will begin to flash a
specific fault code when the input from any one or more
Operating Conditions: sensors is not operating properly. If more than one fault
• Key in run or start position, exists, each fault will be displayed before the controller
repeats the fault codes.
• Engine running.
The EFI module has 4 different fault codes available to
Theory of Operation: assist with diagnostics. Each fault code is a combination of
Power is supplied to the electric fuel injection module when long and short flashes. A fault code of 1 long and 2 short
the key is in the run or start positions and the K12 EFI flashes would be signaling that the air temperature sensor
module power relay has been energized. At the same time circuit is malfunctioning. This means that the EFI is
the ground circuit is controlled by the K11 EFI module receiving either battery voltage or no voltage from the
ground relay which is controlled by the ignition interlock sensor.
circuit. The long flash is approximately 1.0 second, the short flash
When the operating conditions have been met, the fuel is approximately 0.5 second and the OFF period is
injector sensors provide the input to the EFI module so that approximately 4 seconds. The flash code begins after the
the EFI module will provide the ground path for the injectors off period. Whenever reading a fault flash code be sure to
at the correct time and duration. let the code cycle several times while reading the code to
be sure you are at the beginning of the code. Once a code
The EFI module also has a self diagnostic light that will has been read, it can be matched to the fault code chart.
flash a fault code if any of the three input sensors is not
operating properly. The fault codes are shown by a series EFI Module Fault Code Chart
of long and short flashes of the H8 circuit integrity light.
The long flash “ - ” = 1.0 second
When the circuit is operating normally, the light will be off. If
a fault exists, the light will flash all the fault codes that are The short flash “•” = 0.5 second
detected by the EFI module starting with the lowest
OFF period = 3 to 4 seconds.
numbered code. When all the fault codes have been
displayed, the light will be off for a long period of time and The flash code begins after the off period.
then the fault codes will repeat. Let the code cycle several times while reading the code to
The B4 coolant temperature, B5 Air Temperature and B6 be sure you are at the beginning of the code.
vacuum pressure sensors are all resistance operated
FAULT FLASH TEST POINT FAULT CAUSE
CODE SEQUENCE

12 - •• Air temperature sensor B5 air temperature sensor circuit malfunctioning. Circuit either
open or shorted.

13 - ••• Coolant temperature sensor B4 coolant temperature sensor circuit malfunctioning. Circuit
either open or shorted.

21 - - • Vacuum pressure sensor B6 vacuum pressure sensor circuit malfunctioning. Circuit

either open or shorted.

22 - - •• N/A EFI module air/fuel pressure calculation error. To reset: Stop

engine, wait for fault indicator light to go off and fuel pump to
stop (approximately 0.5 to 1 second). Start engine.

Electrical Operation and Diagnostics - 290

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Injection Sensor and Diagnostic Circuit Electrical Schematic - X485 and X585

Wht
S2
Wht
X5 H-B A1 Ignition Interlock Module
S1
S2
S1
S1 S2 X4
Red Red A F4 Fuse -15 A F-2
B A
A X4 500 Yel
M
Wht F5 Fuse -15 A F-6
G M M X4 705 Pnk/Blk
F-3
Start
X5 652 Blu
Run
H-F
S1 Key Off
Switch X4
F-5
E1 Grn K5
K2 Magneto LED Ignition
K1 K6
Start Relay Start Relay Seat Relay
PTO Relay X5

H-C
X1 X5 800 Pnk
H-D
X5
X4
H-A
F-1 K3 RIO
E2 Red
X4
200 Latch Relay
Red K4 RIO LED
F-4
Unlatch Relay PTO
X5
F3 H-G
Fusible X5 H-E X5 H-H
Link
605 Tan 605 Tan
205 130
Lt Blu Blk

Red 215 Gry 215 Gry

B S

M
M1
Starting Y1
Motor Starting
Motor
Solenoid

G1
Battery

Blk
100 Blk 100 Blk

W1 Unswitched Power Switched Power Secondary Power

Frame Ground
Unswitched Ground Control Panel Wiring Harness

Electrical Operation and Diagnostics - 291

 ELECTRICAL OPERATION AND DIAGNOSTICS

S5 PTO/RIP
Switch
RIP*
On
Off

3 6

500 Yel 5
2
8 650 Pnk/Blk 650 Pnk/Blk
4 652 Blu
705 Pnk/Blk 705 Pnk/Blk 1
7 765 Pur
789
652 Blu Pur

A3 PTO Interlock Module

S6 Brake X7
Switch J5-C
Off
S3 Seat K7 Brake
On Lock Relay
Switch
X7
(Off) 501 Yel
765 Pur J5-A
(On)
605 Tan
X7
800 Pnk 502 Yel K8 Off
J5-B
Seat
Relay
820 Pnk X8 742
820 Pnk X8 Blu/Wht
J4-A
J4-B
K9 S8
Mid Mid
PTO X6
Relay
PTO
789 Pur X8 Switch
J4-C
X9
J6-A K10 Rear

On
Off
605 Tan PTO Relay
X9 X8 140 X6
Blk
520
J6-B J4-D Yel
215 Gry 503 Yel

F6 Fusible Link F7 Fuse

220 Red

560
221 Red
Red /Yel
K12 EFI
87a 87 86
Module
Power
30 85
Relay
230
Red 230 Red

150
Blk

100 Blk 100 Blk

Electrical Operation and Diagnostics - 292

 ELECTRICAL OPERATION AND DIAGNOSTICS

X26
A
650
Pnk/Blk 670 Pur W2 Ground B
C
X25 D
86 87 87a K11 EFI X22 E
Module Blk/Wht B 330 Org
F
Ground Org
C 460 Yel A4
85 30 Brn
G
138 Relay Blk/Yel D 510 Blu Electric
H
Blk 139 Fuel
Blk I Injection
Blk/Wht F 710 Pur
J Module
K
Org H 860 Pnk
785 Grn
X22 Red Red I
L
950 Wht
M
N
Red/Blu K 340 Grn
X23 O
230 Red 233 Red/Blu Wht Wht L 240 Red
P
Tan M 470 Yel
231
Red 232
Red K13 Grn O 515 Blu
X3 87a 87 86
Fuel Blu P 615 Tan
16
Pump Grn
30 85 Relay
H9 EFI 655
Pnk B5 Air
Diagnostic Blu
B4 Engine to Temperature
Light X22 Sensor
910 Wht Brn Coolant
X3
to Temperature
17 Blk/Yel
Sensor
X21 Blk/Yel

503 Yel Blk/Yel

B6 Vacuum
Red/Blu
m Pressure
Sensor
651 Tan
Pnk
/Blk

X10 X10

B2 Fuel
M M2 Fuel
230 Gauge Q
Red Sensor Pump

X10
120
Blk
100 Blk

Electrical Operation and Diagnostics - 293

 ELECTRICAL OPERATION AND DIAGNOSTICS
Fuel Injection Sensor and Diagnostic Circuit Diagnosis - X485 and X585

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO off.
• Operator off seat.
• Confirm that the EFI fault light illuminates for approximately two seconds when the key is first turned to the run
position.

Test/Check Point Normal If Not Normal

1. Ignition interlock module Battery voltage Test F3 fusible link and F5 fuse. Check 200 Red wire and
connections. If OK, replace ignition interlock module.

2. Brake switch Battery voltage Check 500 and 501 Yel wires and connections.

3. PTO/RIP switch Battery voltage Check 765 Pur wire and connections. If OK, replace brake
switch.

4. Ignition interlock module Battery voltage Check 705 Pnk/Blk wire and connections. If OK, replace
PTO/RIP switch.

5. Ignition interlock module Battery voltage Replace ignition interlock module.

6. K11 EFI module ground relay Battery voltage Check 652 Blu and 650 Pnk/Blk wires and connections.

7. K12 EFI module power relay Battery voltage Test F6 fusible link and F7 fuse. Check 220 and 221 Red
wires and connections.

8. K12 EFI module power relay Battery voltage Check 500 Yel wire, 560 Red/Yel wire, and connections.

9. Fuel injector(s) Battery voltage Check 230 Red, 233 Red/Blu and Wht wires and
connections. If OK, replace K12 EFI module power relay.

10. Electric fuel injection module Battery voltage Check 230 Red, 233 Red/Blu, Wht, and 240 Red wires and
connections. If OK, replace K12 EFI module power relay.

Test Conditions:
• Key switch in run position, engine not running.
• Park brake locked.
• PTO off.
• Measure voltage between test point and 510 Blu wire (terminal L) at EFI module.
• Confirm that the EFI fault light illuminates for aproximately two seconds when key is first turned to the run position.

Test/Check Point Normal If Not Normal

11. Coolant temperature sensor 2.26 - 2.5 volts Check Blu and 615 Tan wires and connections. Test coolant
temperature sensor. See “Coolant Temperature Sensor
Test - X485 and X585” on page 322.

Electrical Operation and Diagnostics - 294

 ELECTRICAL OPERATION AND DIAGNOSTICS
Test/Check Point Normal If Not Normal

12. Air temperature sensor 2.26 - 2.5 volts Check Grn and 515 Blu wires and connections. Test air
temperature sensor. See “Air Temperature Sensor Test -
X485 and X585” on page 322.

13. Vacuum pressure sensor 4.75 - 5.25 volts Check Red/Blu and 340 Grn wires and connections. Test
vacuum pressure sensor. See “Vacuum Pressure Sensor
Test - X485 and X585” on page 321.

14. Vacuum pressure sensor 3.5 - 3.8 volts Check Tan and 470 Yel wires and connections. Test vacuum
pressure sensor. See “Vacuum Pressure Sensor Test -
X485 and X585” on page 321.

NOTE: If above tests do not solve problem, replace EFI

control module with a known good unit.

Electrical Operation and Diagnostics - 295

 ELECTRICAL OPERATION AND DIAGNOSTICS

A1 Ignition M1 Starting
Interlock Module Motor

200 Red F3 Fusible Link

F6
Fusible
S1
Link
S2
500 Yel
1
4
A1
T2 Ignition
M Coil
M

A1

T1 Ignition
500
S2
Yel Coil Blk
S1

G1 Battery
5 Blk

940 Wht X2 Blk

130 Blk 560 Red/Yel

100
Blk S6 Brake
Switch
S3 Seat
Switch
501
Yel
S5 PTO/RIP
Switch
502 Yel
650
820 Pnk 2 Pnk
800 Pnk /Blk

652 Blu
765 Pur
789 Pur
705 Pnk/Blk

3
520
S8 Mid PTO Switch Yel

650 K11 EFI Module

Pnk
Ground Relay
/Blk
A3 PTO Interlock Module
138 Blk
605 Tan
139 Blk
140 Blk
742 Blu/Wht 6
789 Pur
820 Pnk 670
Pur
X22
100 Org
Blk

Electrical Operation and Diagnostics - 296

 ELECTRICAL OPERATION AND DIAGNOSTICS

K12 EFI Module

Power Relay

560 Red/Yel 8

230 Red
221 Red
221 Red
230
Red 7
150
Blk

100
233
Blk
Red
/Blu

X23
Blk Y5 #2 Cylinder
Y4 #1 Cylinder Fuel Injector
Fuel Injector Solenoid Solenoid
Wht
560 Red/Yel

Wht Wht
B5 Air
9 9 Temperature
Sensor
Blk Wht

X24 12
170 X25 X25
515 Blu Grn
Blk

Blk/Yel

B4 Engine
Coolant
Temperature
Sensor
240
11
Red

170 X25
615 Tan Blu
10 Blk
11
12
13 X25
14 510 Blu Blk/Yel

A4 B6 Vacuum
Electric Pressure Sensor
Fuel
Injection
Module 14

470 Yel
X25 Tan

Org X2 860 Pnk 860 Pnk 340 Grn X25 Red/Blu 13

Blk/Yel

Electrical Operation and Diagnostics - 297

 ELECTRICAL TESTS AND ADJUSTMENTS
Tests and Adjustments 3. Put meter red lead on ground terminal of circuit or
component to be tested that is closest to the battery
negative terminal. Resistance reading must be very close
Common Circuit Tests to or the same as the battery negative terminal reading.
Work backwards from the battery on the ground side of the
Shorted/Grounded Circuit:
problem circuit until the resistance reading increases above
A shorted circuit on the ground side of a component (i.e. 0.1 ohms. The problem is between the last two test points.
improper wire-to-wire or wire to ground contact) may result If a problem is indicated, disconnect the wiring harness
in improper component operation. connector to isolate the wire or component and check
A shorted circuit on the power side of a component or resistance again. Maximum allowable resistance in the
contact of two power circuits (i.e. improper wire-to-wire or circuit is 0.1 ohms. Check both sides of connectors closely
wire to ground contact) may result in blown fusible link and as disconnecting and connecting may temporarily solve
fuses. problem.

To test for a shorted or improperly wired circuit: Voltmeter Procedure:

1. Turn component switch ON. 1. Put transmission in neutral. Lock park brake. Put PTO
2. Start at the controlling switch of the component that switch in off position. Turn key switch to on position.
should not be operating. 2. Connect voltmeter negative (black) lead to negative
3. Follow the circuit and disconnect wires at connectors terminal of battery.
until components stop operating. 3. Put meter positive (red) lead on ground terminal of
4. Shorted or improper connections will be the last two component to be tested. Be sure the component circuit is
wires disconnected. activated (key in run position, switches closed) so voltage
will be present at the component. Record voltage. Voltage
HIgh Resistance or Open Circuit: must be greater than 0 but less than 1 volt. Some
components will have a very small voltage reading on the
High resistance or open circuits usually result in slow, dim,
ground side and still be operating correctly.
or no component operation (i.e. poor, corroded, or severed
connections). Voltage at the component will be low when Results:
the component is in operation.
• If resistance is above 0.1 ohms, check for open wiring,
To test for high resistance and open circuits: loose terminal wire crimps, poor connections, or corrosion
1. Check all terminals and ground connections of the in the ground circuit.
circuit for corrosion. • If voltage is 0.0, the component is open.
2. If terminals are not loose or corroded, the problem is in • If voltage is greater than 1 volt, the ground circuit is bad.
the component or wiring. Check for open wiring, loose terminal wire crimps, poor
connections, or corrosion in the ground circuit.
Ground Circuit Tests
Reason:
To check for opens, loose terminal wire crimps, poor
connections, or corrosion in the ground circuit. The
voltmeter method checks ground connections under load.

Equipment:
• Ohmmeter or Voltmeter

Ohmmeter Procedure:
1. Turn key switch to OFF position. Lock park brake.
2. Connect ohmmeter negative (black) lead to negative (-)
terminal of battery. Put meter positive (red) lead on
negative terminal of battery and record reading. Reading
should be 0.1 ohm or less.

Electrical Tests and Adjustments - 298

 ELECTRICAL TESTS AND ADJUSTMENTS
Battery Voltage and Specific Gravity Test
Reason: D.C. AMPS D.C. VOLTS

To check voltage and determine condition of battery.

Equipment:
• Voltmeter or JTO5685 Battery Tester
• Hydrometer Procedure
• Clean battery terminals and top of battery

Procedure: MIF

5. Check battery voltage with voltmeter or JTO5685

c CAUTION: Avoid injury! Sulfuric acid in

battery electrolyte is poisonous. It is strong
battery tester.

enough to burn skin, eat holes in clothing,

and cause blindness if splashed into the
eyes.
Avoid the hazard by:
Filling batteries in a well-ventilated area,
Wearing eye protection and rubber gloves,
Avoiding breathing fumes when electrolyte
is added.
Avoid spilling or dripping electrolyte.
Use proper jump-start procedure.
If you spill acid on yourself:
Flush your skin with water.
Apply baking soda or lime to help neutralize
the acid. MIF
Flush your eyes with water for 10 - 15
minutes. Get medical attention immediately. 6. Use an hydrometer to check for a minimum specific
gravity of 1.265 with less than 50 point variation in each cell
If acid is swallowed: at full charge at 26.7°C (80°F).
Drink large amounts of water or milk.
Then drink milk of magnesia, beaten eggs, Results:
or vegetable oil.
• Battery voltage less than 12.4 VDC, charge battery.
Get medical attention immediately.
• Battery voltage more than 12.4 VDC, test specific
1. Park machine safely with park brake locked. gravity.
2. Inspect battery terminals and case for breakage or • All cells less than 1.175, charge battery at 10 amp rate.
cracks.
• All cells less than 1.225 with less than 50 point variation,
3. Check electrolyte level in each battery cell. Add clean, charge battery at 10 amp rate.
soft water as needed. If water added, charge battery for 20
minutes at 10 amps. • All cells more than 1.225 with less than 50 point
variation, load test battery.
4. Remove surface charge by placing a small load on the
battery for 15 seconds. • More than 50 point variation: replace battery.

Specifications:
Minimum battery voltage . . . . . . . . . . . . . . . . .12.4 volts
Minimum specific gravity
. . . . . . . . . . . . . . 1.225 with less than 50 point variation

Electrical Tests and Adjustments - 299

 ELECTRICAL TESTS AND ADJUSTMENTS
Battery - Charge • More than 50 point variation between cells: replace
battery
Reason: • Less than 50 point variation between cells: go to
To increase battery charge after battery has been steps 6 and 7
discharged.
6. Continue charging battery until specific gravity is
1.230 - 1.265 points.
Equipment:
7. Load test battery.
• Battery charger (variable rate)

Procedure: Battery - Load Test

Reason:
To check condition of battery under load.
NOTE: Charge battery before performing load test.

Equipment:
Battery Charger
and Booster
• JTO5685 Battery Tester
NOTE: Use the procedures given with the tester.
MIF
Connections:
1. Connect variable rate charger to battery.
NOTE: Maximum charge time at boost setting is 10
minutes. Allow an additional 5 minutes for each 10
degrees below 70 degrees F.
B D E
2. Start charger at slow rate. Increase charge rate one
setting at a time. Check charger ammeter after 1 minute at C
each setting. Maintain 10 amp charge rate. Use boost
setting as necessary.
3. Check if battery is accepting a 10 amp charge after 10
A
minutes at boost setting.
• Battery will not accept 10 amp charge after 10
minutes at boost setting: replace battery
• Battery is accepting 10 amp charge after 10 minutes
at boost setting, and battery did not need water: go to M49597
steps 6 and 7 1. Turn load knob (A) of tester counter-clockwise to off.
• Battery is accepting 10 amp charge after 10 minutes 2. Connect tester positive cable (B) to battery positive
at boost setting, but battery did need water or all cells terminal.
were below 1.175: go to steps 4 and 5
3. Connect tester negative cable (C) to battery negative
IMPORTANT: Avoid damage! Decrease charge terminal.
rate if battery gases or bubbles excessively or
Procedure:
becomes too warm to touch.
1. Turn load knob of tester clockwise until amperage
4. Set charger at 15 - 25 amps. reading is equal to:
5. Check specific gravity after 30 minutes (60 minutes for • Cold cranking amperage rating (blue scale).
maintenance-free battery).
or
NOTE: If battery was discharged at slow or unknown
• Three times ampere hour rating (black scale).
rate, charge at 10 - 15 amps for 6 - 12 hours
(Maintenance-free battery: 12 - 24 hours). If battery was 2. Hold for 15 seconds and turn load knob of tester off.
discharged at fast rate, charge at 20 - 25 amps for 2 - 4 3. Read battery voltage.
hours (Maintenance-free battery: 4 - 8 hours).

Electrical Tests and Adjustments - 300

 ELECTRICAL TESTS AND ADJUSTMENTS
Results:
IMPORTANT: Avoid damage! Perform these tests
• If the battery does not indicate 9.6 volts or more, replace quickly to prevent damage to battery tester. DO
battery NOT apply full load to battery for more than 5 - 10
seconds.
Regulated Amperage and Voltage Test
5. Turn load knob clockwise (in) until voltage on voltage
Reason: tester scale reads 11 volts for 5 seconds only to partially
drain battery.
To determine the regulated charging output of the
alternator. 6. Quickly turn load knob completely counter-clockwise
(out) to off position.
NOTE: Battery must be in a good state of charge.
7. Start and run engine at high idle. Battery voltage should
Equipment: read between 14.2 - 14.8 VDC.

• JTO5712 Current Gun 8. Turn load knob (A) clockwise (in) until voltage on tester
voltage scale (B) reads 11 volts and look at current gun for
• Voltmeter a minimum reading of 13.0 amps.
• JTO5685 Battery Tester 9. Quickly turn load knob (A) completely counter-
clockwise (out) to off position.
Procedure:
[Link] load test, battery voltage (B) should return to the
1. Park machine safely with park brake locked. voltage level prior to test.
2. Raise hood.
Results:
IMPORTANT: Avoid damage! Turn load knob (A) • If current gun amp reading is below specification, test for
fully counterclockwise (out) into OFF position unregulated voltage output. If unregulated voltage output
BEFORE making any test connections. test meets specifications and you have verified voltage to
ground to regulator/rectifier, replace regulator/rectifier.
B • If at any time voltage increase exceeds 14.8 VDC,
A replace regulator/rectifier.
D.C. AMPS D.C. VOLTS

Specifications:
High Idle Voltage . . . . . . . . . . . . . . . . . . 14.2 - 14.8 VDC
Minimum High Idle Amperage. . . . . . . . . . . . 13.5 Amps

MIF

3. Connect JTO5712 Current Gun to voltmeter and put

around red wire going to voltage rectifier/regulator. Set
current gun for DC current.
4. Connect battery tester to battery.

Electrical Tests and Adjustments - 301

 ELECTRICAL TESTS AND ADJUSTMENTS
Regulated Voltage Test Voltage Regulator/Rectifier Test - X465
Reason: Reason:
To determine regulated voltage output of the regulator/ To verify proper operation capability of the voltage
rectifier. regulator/rectifier.

Equipment: Equipment:
• Voltmeter • Multimeter

Procedure: Procedure:
1. Park machine with park brake locked. 1. Disconnect stator connector from the voltage regulator/
rectifier.
2. Raise hood.
2. Set the multi-meter to the Ohms scale.
3. Remove surface charge from battery by placing a small
load on the battery for 15 seconds.
4. Set voltmeter to DC volts scale.
E
A

B
F

D
A
B
C
MIF

3. Measure resistance between each point as shown in the

MIF
chart.

5. Connect meter red lead (A) to positive battery terminal. A B C D E F

6. Connect meter black lead (B) to negative battery A OL OL OL 19 - 3k 3k - OL
terminal. B OL 0 500 - OL OL
OL
7. Start and run engine at low idle.
C OL 0 500 - OL OL
8. Read meter while increasing engine speed to fast idle. OL
Voltage should increase from battery voltage at low idle to D 7.5k - 925 - 925 - 10k - 10k -
maximum regulated voltage at fast idle. OL OL OL OL OL
E 330 - OL OL OL 1.2k -
IMPORTANT: Avoid damage! Do not allow the 10k OL
battery voltage to exceed 15.5 volts or the F 14k - OL OL OL 110 -
battery and charging system will be damaged. OL OL

Specifications: 4. If resistance is not within specification, replace voltage

regulator/rectifier.
Regulated voltage (maximum) . . . . . . . . . . . . .15.0 VDC

Results:
• If the DC voltage stays below the minimum specification,
test unregulated voltage output. If ok, replace the voltage
rectifier/regulator.
• If the DC voltage goes above the maximum
specification, replace the regulator.

Electrical Tests and Adjustments - 302

 ELECTRICAL TESTS AND ADJUSTMENTS
Unregulated Voltage Test - X465 Unregulated Voltage Test - X475, X575, X485,
and X585
Reason:
To measure AC voltage output of stator and verify correct Reason:
resistance of stator. To determine charging output of the alternator stator.

Equipment: Test Equipment:

• Multimeter • Voltmeter

Procedure: Procedure:
1. Disconnect connector from stator. 1. Park machine with park brake locked.
2. Set multimeter for AC volts. 2. Raise hood.
3. Attach red test lead to either pin on stator side of stator
connector.
4. Attach black test lead to other pin.
A
5. Lock parking brake, start engine and run at full throttle.
6. Check output.

Results: B

• Output will be approximately 30 - 32 volts.

• If no or low output is found, replace stator.

Specifications:
MIF
AC output at full throttle . . . . . . 26 volts AC (minimum)
X475/X575/X485/X585
3. Disconnect connector (A) from voltage rectifier/
regulator.
4. Set voltmeter to AC volts.
5. Connect voltmeter to stator terminals (B).
6. Start and run engine at 3000 rpm.
7. Record stator voltage.

Specifications:
Unregulated voltage (minimum) . . . . . . . . . . . . . 26 VAC

Results:
• If voltage is less than specification, replace stator.

Electrical Tests and Adjustments - 303

 ELECTRICAL TESTS AND ADJUSTMENTS
Stator Resistance Test Starting Motor Condition
Reason: 1. The starting motor overheats because of:

To determine if stator windings are open or grounded. • Long cranking.

• Armature binding.
Equipment:
2. The starting motor operates poorly because of:
• Voltmeter
• Armature binding.
Procedure: • Dirty or damaged starter drive.
1. Park machine safely with engine off and park brake • Badly worn brushes or weak brush springs.
locked.
• Excessive voltage drop in cranking system.
2. Raise hood.
• Battery or wiring defective.
• Shorts, opens, or grounds in armature.
NOTE: Starting motor repair is limited to brushes, end
A caps, and starter drive. Fields in starting motor are
permanent magnets and are not serviceable. If housing
or armature is damaged, replace starting motor.
B

X475/X575/X485/X585

B
X465

MIF

3. Disconnect connector (A) from voltage rectifier/

regulator.
4. Set voltmeter to ohms.
5. Connect meter across terminals (B) of alternator.
6. If reading is not within specification, replace stator.
7. Connect meter to either terminal of alternator connector
and to frame ground.
8. If meter does show continuity, replace stator.

Specifications:
Stator Resistance . . . . . . . . . . . . . . . . . .0.11 - 0.18 ohms

Electrical Tests and Adjustments - 304

 ELECTRICAL TESTS AND ADJUSTMENTS
Starter Solenoid Test Starting Motor Amp Draw Test
Reason: Reason:
To determine if starter solenoid or starting motor is To determine the amperage required to crank the engine
defective. and check starter motor operation under load.

Equipment: Equipment:
• Jumper wire • JTO5685 Battery Tester

Procedure: Procedure:
1. Put transmission in neutral. Lock park brake. Move key 1. Put transmission in neutral. Lock park brake. Put key
switch to off position. switch in off position.
2. Raise hood. 2. Raise hood.
3. Disconnect and ground spark plug leads. 3. Disconnect and ground spark plug leads.

IMPORTANT: Avoid damage! Turn load knob (A)

fully counterclockwise before making any test
connections

D.C. AMPS D.C. VOLTS

B
C

MIF
MX14279 4. Connect JTO5685 Battery Tester to battery.
4. Disconnect 720 Pur wire from starter solenoid terminal 5. Crank engine and read voltage.
(A).
6. Turn key switch to off position. Adjust load knob until
5. Connect jumper wire to positive battery terminal and battery voltage reads the same as when cranking.
briefly jump to starter solenoid terminal (A).
7. Read amperage on meter.
• Starting motor runs: solenoid is good, check cranking
circuit. 8. Turn load knob fully counterclockwise.

• Starting motor does not run: go to next step. Specifications:

6. Remove red and black rubber boots from starter Starter amp draw (maximum) . . . . . . . . . . . . . . .85 amps
solenoid terminals (B and C).
Results:
7. Connect jumper wire between starter solenoid large
terminals (B and C). • If amperage is above specification, check starting motor
no load amperage draw to determine if starting motor is
• Starter runs: Replace solenoid.
binding or damaged.
• Starting motor does not run: Check battery cables
• If starting motor is good, check internal engine
then replace starting motor.
components for binding or damage.

Electrical Tests and Adjustments - 305

 ELECTRICAL TESTS AND ADJUSTMENTS
Starting Motor No-load Amperage and RPM Field Windings Test
Test NOTE: Field winding case is a tie point for many
separate field coils. It may be difficult to detect one bad
Reason:
coil. If rpm was slow and armature tests are normal,
To determine if starting motor is binding or has excessive replace field coil assembly.
amperage draw under no-load.

Equipment: B
A
• JTO5712 Current Gun
• JTO5719 Photo Tachometer

Procedure:
1. Remove starter from engine.
NOTE: Check that battery is fully charged and of
proper size to ensure accuracy of test. C

2. Connect jumper cables to battery.

D

M57356
A A - Field Brushes (Continuity between brushed
and to case)
B - To Solenoid
C - Armature Brushes (Continuity between
M45864a brushes and solenoid lead. Open to case.)
3. Put screwdriver between gear and bendix drum (A) and D - Starter Case
pull outward. Install reflective tape on drum. Replace field coil if not according to specifications.
4. Connect negative cable to starter body.
5. Connect positive cable to solenoid battery terminal.
6. Attach current gun to positive jumper cable.

IMPORTANT: Avoid damage! Complete this test

in 20 seconds or less to prevent starter damage.

7. Use jumper wire to briefly connect solenoid battery

terminal and solenoid engagement terminal.
8. Measure starter amperage and rpm.

Specifications:
Starter amperage (maximum) . . . . 50 amps at 6000 rpm
Starter rpm (minimum) . . . . . . . . . . . . . . . . . . . .6000 rpm

Results:
• If amperage or rpm is out of specification, check for
binding or seizing bearings, sticking brushes, dirty or worn
commutator. Repair or replace starter.

Electrical Tests and Adjustments - 306

 ELECTRICAL TESTS AND ADJUSTMENTS
Starter Armature Test

IMPORTANT: Avoid damage! Do not clean

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

M24861

1. 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.
2. Shorts between bars are sometimes caused by dirt or
copper between bars. Inspect for this condition.
3. If test indicates short circuited windings, clean the
commutator of dust and fillings. Check armature again. If
test still indicates short circuit, replace armature.

(A) (B)
M50112/M50113

A - Test for grounds

B - Test for open
4. Using an ohmmeter, test each individual armature
windings for grounded or open circuits.
NOTE: Armature windings are connected in parallel, so
each commutator bar needs to be checked.
5. If either test fails, armature must be replaced.

Electrical Tests and Adjustments - 307

 ELECTRICAL TESTS AND ADJUSTMENTS
Ignition Interlock Test
Reason:
To make sure the ignition interlock module has input and 2
output voltage at the correct terminals for proper operation.
This test determines if the ignition interlock module is
defective or the input circuit is defective. A
13S1 S2
11 8
Equipment: 5
10 A1 B
• Voltmeter 7
M
• Ohmmeter M12
4
Procedure: 3 A1

1. Park machine safely with park brake locked. 1

S2

2. Set test conditions as described before each test. 9 6 S1

3. Connect meter negative (black) lead to battery negative

terminal. MIF

4. Check battery voltage. 5. Check fuses (A) and (B) to be sure they are not open.
6. Put meter positive (red) lead at terminals as indicated in
the test table.
7. Check the terminals for input and output battery voltage
or good ground.

Test Conditions:
• Key switch in off position.

Test/Check Point Normal Condition If Not Normal

1. Terminal E. Maximum 0.1 ohms Check battery negative cable and harness ground
resistance. connection, and 100, 130 Blk wires.

Test Conditions:
• Key switch in run position.
• Park brake locked.
• PTO off.
• Operator on seat.

Test/Check Point Normal Condition If Not Normal

2. Key switch power connector. Battery voltage - input. Check 200 Red and 205 Lt Blu wires.

3. Terminal 2. Battery voltage - output. Check fuses; if OK, replace ignition interlock module.

4. Terminal 6. Battery voltage - output. Check fuses; if OK, replace ignition interlock module.

5. Terminal 3. Battery voltage - input. Check cranking circuit test points.

6. Terminal D. Battery voltage - input. Check seat switch, 800 Pnk, 502 and 500 Yel wires.

7. Terminal F. Battery voltage - output. Replace ignition interlock module.

Electrical Tests and Adjustments - 308

 ELECTRICAL TESTS AND ADJUSTMENTS

Test Conditions:
• Key switch in run position.
• Park brake unlocked.
• PTO off.
• Operator on seat.

Test/Check Point Normal Condition If Not Normal

8. Terminal 4. Battery voltage - input. Check PTO circuit test points.

9. Terminal A. Battery voltage - input. Check RIO switch, 735 Org and 772 Blu wires. If OK,
Red LED on. replace ignition interlock module.

10. Terminal F. Battery voltage - output. Replace ignition interlock module.

Test Conditions:
• Key switch in run position.
• Park brake unlocked.
• Operator on seat.
• PTO switch in on position then put machine in reverse.

Test/Check Point Normal Condition If Not Normal

11. Terminal 5. 0.0 volts - output. Check PTO switch and RIO switch. If switches and wires
are good, replace ignition interlock module.

Test Conditions:
• Key switch in run position.
• Machine in forward then cycle the PTO switch to off and then to the RIP position.

Test/Check Point Normal Condition If Not Normal

12. Terminal G. Battery voltage - input. Check PTO switch, 730 Grn and 754 Blu wires.

Test Conditions:
• Key switch in off position.
• While holding PTO switch in RIP position, place machine in reverse then release PTO switch to the on position.

Test/Check Point Normal Condition If Not Normal

13. Terminal 5. Battery voltage - output. Check PTO switch, 730 Grn and 754 Blu wires. If PTO
switch and wires are good, replace ignition interlock
module.

Test Conditions:
• Key switch in off position.
• Place machine in forward and back to reverse.

Electrical Tests and Adjustments - 309

 ELECTRICAL TESTS AND ADJUSTMENTS

Test/Check Point Normal Condition If Not Normal

14. Terminal 3. 0.0 volts - output. Replace ignition interlock module.

Test Conditions:
• Key switch in off position.
• Park brake locked.
• PTO switch in off position.
• Starting motor solenoid wire disconnected.
• Key switch in start position.

Test/Check Point Normal Condition If Not Normal

15. Terminal 5. Battery voltage - output. Replace ignition interlock module.

Results:
• If terminal does not have input voltage or voltage is low,
check proper circuit before the ignition interlock module.
• If terminal does not have output voltage, replace the
ignition interlock module.
A

Engine Coolant Temperature Sensor Test -

X475, X575, X485, and X585
Reason:
To verify coolant temperature sensor is functioning
properly. M91295

7. Place sensor (A) in antifreeze solution heated to

Equipment: approximately 110°C (230°F). Measure resistance while
• Ohmmeter sensor is heated.
8. If resistance does not meet specification, replace
Procedure:
coolant temperature sensor.
NOTE: Perform test with engine at room temperature.
Specifications:
1. Park machine safely in neutral with park brake locked.
Variable Resistance . . . . . . . . . . . . . . . . . 40 - 700 ohms
2. Raise hood.
3. Disconnect 310 Org/Wht wire from engine coolant
temperature sensor.
4. Measure resistance between terminal and sensor body.
5. If resistance does not meet specification, replace
coolant temperature switch.
6. Drain engine coolant and remove coolant temperature
switch.

Electrical Tests and Adjustments - 310

 ELECTRICAL TESTS AND ADJUSTMENTS
Engine Oil Pressure Switch Test 1. Start and run engine.
2. Measure resistance between terminal and engine block.
Reason:
To determine the proper operation of the oil pressure Results:
switch. There should be no continuity between switch terminal and
ground with the engine running.
Equipment:
• If the switch does have continuity to engine block
• Ohmmeter
(ground) with engine running, check engine oil pressure.
Procedure: • If oil pressure meets specification; replace the oil
pressure switch.
NOTE: Perform test with engine at room temperature.
1. Park machine safely in neutral with park brake locked. Lights Switch Test
2. Raise hood.
Reason:
To verify terminal continuity is correct for each switch
position.

Equipment:
• Ohmmeter or continuity tester
A
Procedure:
1. Park machine safely in neutral with park brake locked.
2. Raise hood.
3. Remove left side panel.
4. Disconnect lights switch connector.
5. Put light switch in off position.
MX14287

Picture Note: X485 shown

3. Disconnect Blu/Red wire from engine oil pressure switch
(A) located near oil filter. B
4. Connect black lead of ohmmeter to engine block and red
lead of ohmmeter to terminal of switch.
5. Measure resistance between terminal and engine block. C
A
Results: MIF

• There should be continuity between terminal and 6. Use and ohmmeter to test switch continuity in off,
ground. headlights on, and backup lights on positions.
• If there is no continuity between terminal and ground; Specifications:
replace the oil pressure switch.
Switch Position . . . . . . . . . . . . . . . . Terminal Continuity
NOTE: Be sure to apply Pipe Sealant with TEFLON® to Off . . . . . . . . . . . . . . . . no continuity between terminals
threads of switch anytime it is installed.
Headlights On . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B
TEFLON® is a registered trademark of the DuPont Backup lights on . . . . . . . . . . . . . . . . . . . . . . . . . A and B
Company. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and C
IMPORTANT: Avoid damage! Do not allow
connector of wire to contact the engine or frame Results:
as there will be voltage on it during the test. • If continuity is not correct, replace lights switch.

Electrical Tests and Adjustments - 311

 ELECTRICAL TESTS AND ADJUSTMENTS
PTO/RIP Switch Test Relay Test
Reason: Reason:
To verify terminal continuity is correct for each switch To check relay terminal continuity in the energized and de-
position. energized condition.

Equipment: Equipment:
• Ohmmeter or continuity tester • Ohmmeter or continuity tester

Procedure: Procedure:
1. Park machine safely in neutral with park brake locked. 1. Park machine safely in neutral with park brake locked.
2. Raise hood. 2. Raise hood.
3. Disconnect PTO switch connector. 3. Disconnect relay connector.
4. Put PTO switch in the off position. 4. Check terminal continuity using an ohmmeter or
continuity tester.

B
D

B A

C
A C E
F
D (D)86 (B)30

H G

MIF
(C)85 (E)87 (A)87a
5. Use and ohmmeter to test switch continuity in off, on, M56817
and momentary (RIP) positions.
5. There should be continuity between terminals 87A (A)
Specifications: and 30 (B), and 85 (C) and 86 (D).
Switch Position. . . . . . . . . . . . . . . . . Terminal Continuity 6. There should not be continuity between terminals 87 (E)
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and C and 30 (B).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and F 7. Connect a jumper wire from battery positive (+) terminal
On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and B to relay terminal 85 (C). Connect a jumper wire from relay
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and E terminal 86 (D) to ground (-).
Momentary (RIP) . . . . . . . . . . . . . . . . . . . . . . . . . .A and B 8. There should be continuity between terminals 87 (E)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and E and 30 (B).
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G and H
Results:
Results:
• If continuity is not correct, replace relay.
All other possible combinations have infinite resistance. If
any continuity is NOT correct, replace switch.

Electrical Tests and Adjustments - 312

 ELECTRICAL TESTS AND ADJUSTMENTS
Seat Switch Test Brake Switch Test and Adjustment
Reason: Reason:
To verify proper operation of seat switch. To make sure the brake switch has continuity when the
brake pedal is depressed.
Equipment:
Equipment:
• Ohmmeter
• Ohmmeter
Procedure:
Procedure:
1. Park machine safely in neutral with park brake locked.
1. Park machine safely in neutral with park brake locked.
2. Disconnect seat switch connector.
3. Depress the seat switch plunger. NOTE: Brake switch is located on left side of frame
under footrest.
2. Remove footrest.
3. Disconnect brake switch connector.

A
B
MIF

4. Check continuity across seat switch connector terminals

(A). There should be continuity. A
B
5. Release the seat switch plunger.
A
6. Check continuity across connector terminals. There
MIF
should not be continuity.
4. Check continuity across terminals (A). Check continuity
Specifications: across terminals (B).
Seat switch plunger depressed. . . . . . . . . . . . continuity NOTE: Be sure actuator (C) contacts switch plunger
Seat switch plunger released . . . . . . . . . . no continuity (plunger depressed) and not switch body.

Results:
• If the seat switch does not have continuity with the C
operator on the seat, check the seat switch bracket and
spring for damage.
• If the seat switch does not have continuity with the
plunger depressed, replace the switch.

MIF

NOTE: Side view shown

5. Release park brake pedal.
6. Check continuity across terminals. Be sure actuator
does not contact switch plunger (plunger released).

Electrical Tests and Adjustments - 313

 ELECTRICAL TESTS AND ADJUSTMENTS
Specifications: Specifications:
Brake pedal depressed Plunger depressed)
(plunger depressed) continuity between terminals . . . . . . . . . . . . . . . (A) only
continuity between terminals . . . . . . . . . . . . . . . (A) only Plunger released)
Brake pedal released continuity between terminals . . . . . . . . . . . . . . . (B) only
(plunger released)
continuity between terminals . . . . . . . . . . . . . . . (B) only Results:
• If continuity is not correct, replace switch.
Results:
• Adjustment switch to specification if needed.
• If continuity is not correct, replace switch.
• If actuator position is not correct, loosen cap screw (D). RIO Switch Adjustment
Depress brake pedal and lock park brake. Rotate actuator
(C) until the switch plunger is depressed, but not bottomed Reason:
out. The actuator must not contact the switch body. Hold
actuator in position and tighten cap screw. To set the proper air gap so that the RIO switch is activated
at the proper time.

RIO Switch Test Equipment:

Reason: • Ruler

To make sure the RIO switch has proper continuity. • Continuity tester

Equipment: Procedure:

• Ohmmeter 1. Stop engine and lock park brake.

2. Remove fender deck.
Procedure:
1. Park machine safely in neutral with park brake locked.
NOTE: RIO switch is located on right side of frame
under footrest.
2. Remove footrest.
3. Disconnect RIO switch connector.

A
B
D C
E
B
MX16074

3. Measure the gap between the bottom edge (A) of the

A spring and the bottom edge (B) of the RIO switch body.
B
• The gap should be 12 mm (0.47in.).
A
4. The bottom edge of the switch should be in line with the
MIF
bottom edge of the spring.
4. Press switch plunger and check continuity across
5. Slightly loosen the back nut (C) and then the front nut
terminals (A) and then check continuity across terminals
(D).
(B).
6. Position the RIO switch at the proper angle with a 12
5. Press switch plunger and check continuity across
mm (0.47 in.) gap.
terminals.
7. Tighten the nuts to 13.5 N•m (10 lb-ft) while maintaining
the position of the switch.

Electrical Tests and Adjustments - 314

 ELECTRICAL TESTS AND ADJUSTMENTS
8. Perform RIO switch test. Fuse Test
9. Install the fender deck.
Reason:
Specifications: To verify that fuse has continuity.
Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.47 in.)
Equipment:
Torque . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 N•m (10 lb-ft)
• Ohmmeter or continuity tester
Service Timer Reset Switch (SN -30000) Procedure:
Reason: 1. Park machine safely in neutral with park brake locked.
To determine proper operation of service timer reset switch. 2. Raise hood.
3. Remove fuse from fuse holder.
Equipment:
• Ohmmeter

Procedure:
A
1. Park machine safely in neutral with park brake locked.
2. Raise hood.
3. Remove service timer reset switch connectors.

M49391

4. Check visually for broken filament (A).

B
5. Connect ohmmeter or continuity tester to each end of
A fuse.

MIF
6. Check for continuity.

4. Connect meter leads to switch terminals (A) and (B) and Results:
compare to specification.
• If continuity is not indicated, replace the fuse.
5. Press and release plunger (C) of switch.

Specifications:
Switch plunger not pressed
. . . . . . . . . . . . . . . . . . . . no continuity between A and B
Switch plunger pressed
. . . . . . . . . . . . . . . . . . . . . . . continuity between A and B

Results:
If service timer reset switch does not pass both tests,
replace switch.

Electrical Tests and Adjustments - 315

 ELECTRICAL TESTS AND ADJUSTMENTS
Instrument Panel Light Test
Reason: D

To verify that bulb has continuity.

Equipment:
• Ohmmeter or continuity tester

Procedure:
1. Park machine safely in neutral with park brake locked.
2. Raise hood.
3. Remove side panels.
8. Turn bulb sockets (D) counterclockwise to remove.

E
A

MX13632

4. Disconnect wire harness (A) from instrument panel.

M49392
5. Remove capscrews (B) on both sides of instrument
panel. 9. Check visually for broken filament (E).
6. Lift instrument panel bottom tabs out of holder, and pivot [Link] ohmmeter or continuity tester to each terminal
panel to remove from machine. of bulb.
[Link] for continuity.
C
Results:
• If continuity is not indicated, replace bulb.

MX13633

7. Push down on tabs and remove panel back (C).

Electrical Tests and Adjustments - 316

 ELECTRICAL TESTS AND ADJUSTMENTS
PTO Solenoid Test Short to Case Test
1. Check for grounds or shorts by connecting tester to one
Reason: coil terminal and the other to bare metal of coil case or
To verify that the solenoid is operating properly. frame.

Equipment: Results:
• Ohmmeter or continuity tester • Replace fuel shutoff solenoid if continuity is present
from either terminal to coil case.
Procedure:
Audibility Test:
1. Park machine safely in neutral with park brake locked.
1. Connect PTO solenoid connector (A).
2. Listen for click when PTO solenoid pulls in.

Results:
• If click when PTO solenoid pulls in is not heard, replace
solenoid.
A
PTO Switch Test (optional)
Reason:
To verify that mid and rear PTO switches function properly.
MX14285
Equipment:
2. Disconnect PTO solenoid connector (A) at rear of
• Ohmmeter or continuity tester
machine.
Procedure:
1. Park machine safely in neutral with park brake locked.

M91222
C
3. Using an ohmmeter or continuity tester, check if
continuity exists between solenoid terminals. B

Results:
• If resistance does not meet specifications, replace A
solenoid. MX14286

PTO Solenoid Continuity: 2. Locate rear PTO switches at rear left side of transaxle
and disconnect mid PTO switch connector (A) and rear
B to C . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 - 10.0 ohms PTO switch connector (B).
3. Move PTO selector lever (C) to top position.

Electrical Tests and Adjustments - 317

 ELECTRICAL TESTS AND ADJUSTMENTS
Fuel Shutoff Solenoid Test - X465, X475 and
X575
Reason:
To determine if the fuel shutoff plunger retracts when the
solenoid is energized.

Equipment:
• 2 jumper wires
D
Procedure:
MIF
1. Park machine safely in neutral with park brake locked.
4. Check for continuity between switch terminals (D) and
compare to specification. 2. Raise hood.
5. Move PTO selector lever (C) to middle position.
6. Check for continuity between switch terminals (D) and
compare to specification.
c away
CAUTION: Avoid Injury! Keep gasoline
from sparks, flame, or hot engine
7. Move PTO selector lever (C) to bottom position. parts or personal injury can result.

8. Check for continuity between switch terminals (D) and 3. Remove drain screw and spring to drain gasoline from
compare to specification. float bowl.
Replace switch if correct continuity can not be obtained. 4. Disconnect fuel shutoff solenoid connector.
5. Remove fuel shutoff solenoid, washer and float bowl.
Mid PTO Switch Continuity:
PTO Lever Position . . . . . . . . . . . . Terminal Continuity
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Continuity
Middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity A
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity
B
Rear PTO Switch Continuity:
PTO Lever Position . . . . . . . . . . . . Terminal Continuity C
Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity
M82845
Middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity
6. Connect a jumper wire from the battery positive (+)
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Continuity
terminal to solenoid terminal (C). It may be necessary to
push plunger (A) inward slightly for plunger to retract.
NOTE: It may be necessary to push plunger (A) inward
slightly for plunger to retract.
7. Connect a jumper wire from the battery negative (-)
terminal to solenoid threads (B). Plunger should now
retract with the solenoid energized.
8. Remove jumper wire from the battery negative (-)
terminal. Plunger should extend.

Results:
If plunger does not move, replace solenoid.

Electrical Tests and Adjustments - 318

 ELECTRICAL TESTS AND ADJUSTMENTS
Diode Test Fuel Tank Sensor Test
Reason: Reason:
To verify that diode has proper continuity. To make sure the fuel tank sensor resistance changes as
the float is raised or lowered.
Equipment:
Equipment:
• Ohmmeter or continuity tester
• Ohmmeter
Procedure:
Procedure:
1. Park machine safely in neutral with park brake locked.
1. Park machine safely in neutral with park brake locked.
2. Raise hood.
3. Remove diode from connector. 2. Remove fender deck.
3. Disconnect fuel tank sensor connector.
4. Remove fuel tank sensor.

A B
MIF

4. Connect ohmmeter red (+) lead to pin (A) of diode.

5. Connect ohmmeter black (-) lead to pin (B) of diode.
Check for continuity.
A
6. Reverse test leads. Check for continuity.

Results:
Diode must have continuity in one direction only. Replace A
defective diode.

M46303a

5. Measure resistance across fuel tank sensor terminals

with black and black/white wires (A).
6. Move sensor float arm up and down.
7. Meter must show resistance increase and decrease as
float moves up and down. Resistance is the lowest when
the float is in the lowest (empty) position.

Specifications:
Sensor resistance (approximately) . . . . . . 6 - 103 ohms

Results:
If the resistance does not change or does not meet the
specifications, replace the fuel tank sensor.

Electrical Tests and Adjustments - 319

 ELECTRICAL TESTS AND ADJUSTMENTS
Fuel Injector Test - X485 and X585 Fuel Injection Module Test - X485 and X585
Reason: Reason:
To verify fuel injector continuity and operation. To determine if fuel injection module is defective.

Equipment: Procedure:
• Ohmmeter

Procedure:
1. Park machine safely in neutral with park brake locked.
2. Raise hood.
3. Remove air cleaner assembly.
4. Disconnect fuel injector connector.

MIF

5. Measure resistance across fuel injector terminals (A).

MX16071
6. Connect a jumper wire from battery negative terminal to
one of the fuel injector terminals. The fuel injection module (A) is very sensitive to the type of
meter used to check resistance. Due to variations in the
7. Briefly and repeatedly connect a jumper wire from
meters, the best way to determine if the fuel injection
battery positive terminal to the other fuel injector terminal.
module is good is to replace the questionable fuel injection
8. The fuel injector must click each time the jumper wire module with a known good module.
contacts the terminal.
Results:
Specifications:
• If the new fuel injection module does not solve the
Resistance at 20° C (68° F) . . . . . . . . . . . . . . .13.8 ohms problem, check the other fuel injection components.

Results:
• If resistance does not meet specifications, check fuel
injector operation before replacing the fuel injector. The
tested resistance values may vary from the specifications
due to type of meter used or temperature.
• If the fuel injector does not click, replace the fuel
injector.

Electrical Tests and Adjustments - 320

 ELECTRICAL TESTS AND ADJUSTMENTS
Vacuum Pressure Sensor Test - X485 and
X585
Reason:
To verify vacuum pressure sensor continuity and operation.

Equipment:
• Ohmmeter
• Voltmeter G

Procedure:
E
1. Park machine safely in neutral with park brake locked. F
H
2. Raise hood.
3. Remove air cleaner assembly.
MX14288

7. Disconnect air pressure sensor hose (E).

8. Turn key switch to run position.
NOTE: It will be necessary to remove the rubber seals
around the wires to take the voltag e readings.
9. Connect voltmeter negative lead to wire terminal (F).
A [Link] voltmeter positive lead to wire terminal (G).
[Link] input voltage. Voltage should be about 5 volts.
[Link] voltmeter positive lead to wire terminal (H).
[Link] output voltage. Voltage should be something
less than 5 volts depending on air pressure.
[Link] slight air pressure to sensor hose. Voltage should
MX14288
increase.

4. Disconnect air pressure sensor connector (A). [Link] slight vacuum to hose and voltage should
decrease.

Specifications:

Terminal resistance (Approximation):

Left (B) and center (C) . . . . . . . . . . . . . 2986 - 3034 ohms
Left (B) and right (D) . . . . . . . . . . . . . . . . 773 - 787 ohms
Center (C) and right (D) . . . . . . . . . . . . 3774 - 3798 ohms
C

B D Input voltage (G). . . . . . . . . . . . . . . . . . . . . .about 5 volts

Output voltage (H) . . . . . . . . . . . . . . . . . . . 0.5 - 4.9 volts
. . . . . . . . . . . . . . . . . . . . . . . . depending on air pressure

Results:
MX14289
• If resistance does not meet specifications, check output
5. Measure resistance between left (B), center (C), and voltage before replacing the air pressure sensor. The
right (D) terminals on vacuum sensor. tested resistance values may vary from the specifications
6. Connect wire harness to air pressure sensor. due to type of meter used or temperature.
• If the output voltage does not increase or decrease,
replace the air pressure sensor.

Electrical Tests and Adjustments - 321

 ELECTRICAL TESTS AND ADJUSTMENTS
Air Temperature Sensor Test - X485 and X585 Specifications:
Resistance at 20°C (68°F) . . . . . . . . . 2.21 - 2.69 k-ohms
Reason:
Resistance at 0 - 30°C (32 - 86°F)
To verify air temperature sensor continuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.88 - 1.65 k-ohms

Equipment: Results:
• Ohmmeter • If resistance does not meet specifications, replace the
air temperature sensor. The tested resistance values may
Procedure: vary from the specifications due to type of meter used or
1. Park machine safely in neutral with park brake locked. temperature.
2. Raise hood.
Coolant Temperature Sensor Test - X485 and
3. Remove air cleaner assembly.
X585
Reason:
To verify coolant temperature sensor continuity.

Equipment:
• Ohmmeter

Procedure:
A
1. Park machine safely in neutral with park brake locked.
2. Raise hood.
3. Remove air cleaner assembly.

MX14290

4. Disconnect air temperature sensor connector (A).

MX14288

4. Disconnect coolant temperature sensor connector (A).

5. Measure resistance across coolant temperature sensor
terminals.

B Specifications:
Resistance at 20°C (68°F) . . . . . . . . . 2.21 - 2.69 k-ohms
MX14291 Resistance at 0 - 30°C (32 - 86°F)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.88 - 1.65 k-ohms
5. Measure resistance across air temperature sensor
terminals (B).

Electrical Tests and Adjustments - 322

 ELECTRICAL TESTS AND ADJUSTMENTS
Results:
• If resistance does not meet specifications, replace the
coolant temperature sensor. The tested resistance values
may vary from the specifications due to type of meter used
or temperature.

Spark Plug Gap Test

Spark plugs should not be burned, blistered, or have
cracked insulator tips or badly eroded electrode.
Make sure the plug is correctly gapped.

Specifications: M48364
X475/X485/X575/X585 - Spark Plug (NGK BPR4ES) 4. Measure resistance across spark plug cap terminals.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) Resistance should be about the same as marked on the
X465 - Spark Plug (Champion RCJ8Y) spark plug cap.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.)
Specifications:
NOTE: Bending center wire or hitting plug with
Spark plug cap resistance. . . . . . . . . . . . marked on cap
gapping tool can break insulator.
John Deere recommended plug is the best heat range for Results:
the engine application. • If resistance does not meet specification, replace spark
If hotter plug is used, go no more than (1) one range hotter. plug cap.
• For NGK plugs: the lower the number the hotter the
plug. Spark Plug Gap Adjustment
• For Champion Plugs: The higher the number the hotter Reason:
the plug.
To maintain the correct gap between the center electrode
If spark plugs are burning improperly: and the tab needed to produce a good spark.
• Use known good grade and source of fuel.
Equipment:
• Test fuel for alcohol content. Tester is available at an
auto parts stores. Alcohol content should be a maximum of • Feeler gauge
10%. This rating should be listed on service station pumps.
Procedure:
• Try a different grade (octane) fuel, or a different fuel
manufacturer. IMPORTANT: Avoid damage! Do not clean spark
• With electronic ignition, check ground connections, plug with sand paper or abrasives. Engine
ignition components, and a possible sheared flywheel key scoring can result.
(unlikely). 1. Scrape or wire brush deposits from spark plug.
Reason: 2. Inspect spark plug for:
To determine if spark plug cap is defective. • Cracked porcelain.
• Pitted or damaged electrodes.
Equipment:
• Ohmmeter A

Procedure:
1. Park machine safely in neutral with park brake locked.
2. Raise hood.
MIF
3. Disconnect spark plug cap.
3. Check spark plug gap (A) using a feeler gauge. Set gap
to specifications.

Electrical Tests and Adjustments - 323

 ELECTRICAL TESTS AND ADJUSTMENTS
4. Install and tighten spark plug to specifications. Spark Test
Specifications: Reason:
Spark Plug Gap X465 . . . . . . . . . . . . . 1.0 mm (0.040 in.) Check overall condition of ignition system.
Spark plug torque . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Spark plug gap Equipment:
X475, X575, X485, and X585. . . . . . . 0.75 mm (0.030 in.) • D-05351ST Spark Tester
Spark plug torque . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
Connections:
Ignition Coil Test 1. Brake locked. PTO disengaged.

Reason:
A
To determine condition of ignition coil windings.

Equipment: C
• Ohmmeter

Procedure: B
1. Put transmission in neutral. Put key switch in off D
position.
2. Remove spark plug cap from spark plug wire.
3. Disconnect wires from ignition coil terminal.

MIF

2. Remove high tension lead (A) from spark plug and

connect to spark tester (B).
3. Connect spark tester to spark plug.
4. Adjust spark tester gap to 4.2 mm (0.166 in.) with screw
(C).
C
NOTE: Do not adjust spark tester gap beyond 5.0 mm
B (0.200 in.) as damage to ignition system components
could occur.

A Procedure:
1. Turn key switch to start position and watch spark (D) at
spark tester. If engine will start, watch spark with engine
MX16073 running.
4. Measure primary coil resistance between laminations
(A) and terminal (B). Specifications:

5. Measure secondary coil resistance between laminations • Steady, strong, blue spark.
(A) and spark plug wire (C).
Results:
Specifications: • If spark is weak, or if no spark, install a new spark plug
Primary coil resistance . . . . . . . . . . . . . 2.2 - 3.6 k-ohms and test again.
Secondary coil resistance . . . . . . . . . . . . 13 - 21 k-ohms • If spark is still weak, or still no spark, run tests on
individual components to find cause of malfunction.
Results:
• If resistance does not meet specifications, replace the
ignition coil.

Electrical Tests and Adjustments - 324

 ELECTRICAL REPAIR
Repair Adjustment:

B B
Ignition Coil Replacement A A

Remove:
1. Park machine safely. See Parking Machine Safely in
SAFETY SECTION.
B B

A A

MX14236

1. Place feeler gauge between ignition coil legs (A) and

flywheel.
2. Hold ignition coil in place and tighten the mounting
A capscrews (B) to 3.4 N•m (30 lb-in.).
3. Check air gap again after tightening. Readjust if needed.
B

Specification:
Air Gap . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.)

MX16073 Capscrew Torque . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.)

2. Disconnect plug wire from spark plug.
3. Disconnect ignition lead from primary coil terminal (A).
4. Remove ignition coil mounting capscrews (B).

Install:

MX16073

1. Align ignition coil with mounting holes on crankcase.

2. Loosely install mounting capscrews (A).
3. Connect ignition lead from primary coil terminal (B).
4. Connect plug wire to spark plug.

Electrical Repair - 325

 ELECTRICAL REPAIR
Stator Replacement Installation:

NOTE: The charging system is a permanent magnet 1. Place stator over crankshaft and onto crankcase.
and stator design. As the flywheel rotates, a permanent Align the four mounting holes with the threaded holes in the
magnet in the flywheel induces AC current in the stator crankcase and the stator wires routed towards the clamp.
windings. This current flows to the regulator-rectifier
2. Install and tighten the four capscrews.
where it is converted to DC current needed to charge
the battery. Component may differ from illustration. 3. Install and tighten the wire clamp.
4. Align the flywheel keyway with the key on the crankshaft
Removal:
and install flywheel.
1. Park machine safely. See “Park Machine Safely” on
page 3 in Safety section.
NOTE: For X465 machines - See “Flywheel Removal
and Installation” on page 79 in Engine section.
A
2. Remove engine from machine. See engine removal in
appropriate engine section.

B
MX16079

5. Install spring washer (A) as shown.

6. Install and tighten the flywheel bolt.
MX16077 7. Install engine into machine.
3. Hold flywheel with strap and remove flywheel bolt (A).
Specification:
4. Thread a flywheel puller into the pulling holes (B) and
remove the flywheel. Stator Capscrew . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.)

Wire Clamp Capscrew . . . . . . . . . . . . 3.4 N•m (30 lb-in.)

Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . 56 N•m (41 lb-ft)

D
D

MX16078

5. Remove the wire clamp (C).

6. Remove the four mounting capscrews (D) and remove
stator from crankcase.

Electrical Repair - 326

 POWER TRAIN - HYDROSTATIC TABLE OF CONTENTS
Repair............................................................ 368
Power Train - Hydrostatic

Table of Contents
Foot Control Linkage Removal and
Installation.................................................. 368
Specifications ...............................................329 Shift Lever Linkage (MFWD) Removal and
General Specifications ...............................329 Installation.................................................. 371
Test And Adjustment Specifications...........329 Oil Cooler Removal and Installation .......... 372
Repair Specifications..................................329 Control Arm and Damper Removal and
Special or Essential Tools ..........................330 Installation ................................................. 374
Other Materials...........................................330 Differential Lock Linkage Inspection .......... 375
Component Location....................................331 Charge Pump Removal and Installation .... 375
Hydrostatic Power Train .............................331 Charge Pump Disassembly and Assembly 376
Final Drive (MFWD)....................................333 Directional Control Valves ......................... 377
Front Axle Gear Case (MFWD) ..................334 Hydrostatic Pressure Relief Valve (45 Loader)
Front Axle Assembly (MFWD)....................336 Installation.................................................. 378
Rear PTO Gear Case Assembly ................337 Drive Shaft Removal and Installation ........ 378
MFWD Output Shaft ...................................339 PTO Solenoid Valve .................................. 379
Theory of Operation .....................................340 PTO Relief Valve Removal and
Center Section and Directional Control Valves Installation.................................................. 381
- Reverse System Operation ......................340 PTO Relief Valve Disassembly, Inspection
Transaxle Oil Flow System Operation........343 and Assembly ............................................ 381
External Power Train System Operation ....346 PTO Brake Removal and Installation......... 381
Transaxle Internal System Operation.........347 PTO Brake Disassembly, Inspection and
Rear PTO Component Location and Operation Assembly ................................................... 382
- Optional....................................................351 PTO Drive Train (Mid-PTO) Removal and
540 Rear PTO ............................................352 Installation ................................................. 383
Diagnostics ...................................................353 PTO Drive Train (Mid and Rear PTO) Removal
Hydrostatic Transmission Diagnosis ..........353 and Installation........................................... 384
Mid-PTO System Diagnosis .......................355 Rear PTO Removal and Installation .......... 387
Transaxle Diagnosis...................................355 Transaxle Removal and Installation........... 390
Hydrostatic Transmission Test ...................356 Differential Lock Shaft Disassembly and
Mid-PTO System Test ................................358 Assembly ................................................... 392
Transaxle Test............................................359 Differential (2-Wheel Drive) Disassembly and
Tests and Adjustments ................................360 Assembly ................................................... 393
Hydraulic Oil Warm-Up Procedure .............360 Differential (MFWD) Disassembly and
Charge Pump Pressure Test......................360 Assembly ................................................... 394
Charge Pump Flow and Pressure Test - At PTO Clutch Disassembly, Inspection and
Charge Pump .............................................361 Assembly ................................................... 395
Mid-PTO Engagement Pressure and Brake MFWD Output Shaft Removal and
Test ............................................................363 Installation.................................................. 396
Transaxle Neutral Adjustment ....................364 Hydrostatic Transmission 2-WD and
Transaxle Control Linkage Adjustment ......365 MFWD ....................................................... 399
Transaxle Linkage Full Forward Hydrostatic Pump Inspection ..................... 406
Adjustment .................................................366 Transaxle Disassembly.............................. 407
Cruise Control Linkage Check and Transaxle (Right Cover) Disassembly and
Adjustment ................................................366 Assembly ................................................... 410
Transaxle Case Inspection ........................ 411
Transaxle Assembly .................................. 411

Power Train - Hydrostatic Table of Contents - 327

 POWER TRAIN - HYDROSTATIC TABLE OF CONTENTS
Rear Axle Assembly (Two Wheel Steer
Models) Removal and Installation ..............413
Rear Axle Assembly (Two Wheel Steer
Models) Disassembly and Assembly..........414
Rear Axle Assembly (All Wheel Steer)
Removal and Installation ............................415
Rear Axle Assembly (All Wheel Steer)
Disassembly and Assembly .......................416
Knuckle Assembly (All Wheel Steer)
Removal and Installation ............................417
Knuckle Housing Disassembly and
Assembly....................................................417
Final Drive Cover Removal and Installation -
(MFWD)......................................................418
Final Drive Housing Removal and Installation -
(MFWD)......................................................420
Spindle Housing - (MFWD) ........................422
Drive Shaft Removal and Installation -
(MFWD)......................................................423
Mechanical Front Wheel Drive Removal and
Installation - (MFWD) ................................423
Differential Input Housing - (MFWD) ..........425
Front Axle Housing Disassembly and
Assembly....................................................426

Power Train - Hydrostatic Table of Contents - 328

 POWER TRAIN - HYDROSTATIC SPECIFICATIONS
Specifications

General Specifications
Transaxle Capacity:
Two-Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 L (7.0 qt)
All-Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 L (6.0 qt)
Four-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 L (7.0 qt)
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J20D Low Viscosity HY-GARD

Front Axle:
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere GL5 Gear Lubricant (80W-90
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 L (2.5 qt)

Test And Adjustment Specifications

Hydrostatic Transmission:
Pump and Motor Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 mL (0.6 oz)/rev

Charge Pump:
Displacement (2-WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mL/rev (0.2 oz)/rev
Displacement (MFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mL/rev (0.27 oz)/rev
Charge Pressure Control Valve (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1958 kPa (284 psi)
Charge Pressure Relief Valve (Implement Pressure) (minimum). . . . . . . . . . . . . . . . . . . . . . . . . . 63710 kPa (924 psi)
Charge Pump Flow 2-WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm)
Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 L/m (3.4 gpm)
Charge Pump Flow (MFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 L/m (6.0 gpm)
Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm)

PTO:
PTO Pressure Control Valve (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14698 kPa (213 psi)
PTO Circuit Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L/m (0.5 gpm)

Repair Specifications
Control Arm Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft)
PTO Solenoid Armature Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
PTO Solenoid Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 N•m (43 lb-in.)
Transaxle Cover Cap Screws:
Used Transaxle Case Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
New Transaxle Case Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
PTO Output Shaft Retaining Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
PTO Shifter Shaft Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
PTO Ball Switches Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft)
PTO Clutch Pack Wear Clearance Between Plate and Bottom
of Gear/Hub Groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 mm (0.106 in.) maximum
Charge Pump Cap Screws: Short Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
Long Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
Hydrostatic Motor Seal Cap Depth below Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 mm (5/32 in.)
Hydrostatic Center Valve Block: Directional Control Valves Torque. . . . . . . . . . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft)

Power Train - Hydrostatic Specifications - 329

 POWER TRAIN - HYDROSTATIC SPECIFICATIONS
Bottom Suction Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Charge Pressure Relief Valve Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
Mounting Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
Axle Housing Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
King Pin Cap Screws Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Transaxle to Frame Mounting Cap Screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 - 106 N•m (52 - 78 lb-ft)
Differential Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)
Drive Shaft Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Hydraulic Line Fittings Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (212 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).

Special or Required Tools

Tool Name Tool No. Tool Use
Temperature Gauge JDG282 Used to test the hydraulic oil temperature.
Solenoid Valve Socket JDG757A Used to install solenoid armature.
Transmission Gear Spacer JDT39 Used to disassemble and assemble PTO
clutch assembly.
Bushing, Bearing and Seal Driver Set Used to service bearings and seals.
Press Used to remove and install axle shaft and
bearings.
Snap Ring Pliers Set Used to remove snap rings.
Knife-Edge Puller Used to remove bearings.
Jack Stands Used to support machine.
Lift Brackets or 8 mm Eyebolts Used to remove and install transaxle.
Hoist Used to remove and install transaxle.

Other Materials

Other Material
Part No. Part Name Part Use
TY15130 John Deere Form-in-Place Gasket Seal mating surfaces of transaxle.
TY6305/TY9485/ Cure primer Clean thread of sealing surfaces.
#764
TY9370/TY9477/ Thread Lock and Sealer (Medium Strength) To seal threads on control valve screws, spool
#242 detent, and small plugs.

Power Train - Hydrostatic Specifications - 330

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
Component Location

Hydrostatic Power Train

B
C

G H
E

S J

K
Q

P
L

O
N

MX14200

Power Train - Hydrostatic Component Location - 331

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
A - Cruise Control Latch
B - Forward Pedal
C - Reverse Pedal
D - RIO Switch
E - Charge Pump
F - Control Rod
G - Control Valves
H - Oil Fill Tube
I - PTO Brake Cover
J - PTO Solenoid
K - Control Arm Damper
L - Control Valve
M - Differential Lock Shaft
N - Rear Cover Plate
O - Differential Lock Arm
P - Brake Arm
Q - Center Valve Block
R - Motor Case Assembly
S - Center PTO Shaft
T - Drive Shaft

Power Train - Hydrostatic Component Location - 332

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
Final Drive (MFWD)

H I

G D
F

L
K
E
D

C
A

B
A

B
C

D
L
L

E
K

D
G

I H

MX14348 F - Case
A - Spindle G - Gasket
B - Sleeve H - Final Gear
C - Seal I - Snap Ring
D - Snap Ring (4 used) J - Ball Bearing
E - Ball Bearing K - Gearbox
L - Drain Plug

Power Train - Hydrostatic Component Location - 333

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
Front Axle Gear Case (MFWD)

C
D
B

F
A E

K
L

M
N
G
O
M

P
H
Q J

G
I

R
S

T
U

V
W

X
Y
AD
Z

AA
H
AB

AC

MX14349

Power Train - Hydrostatic Component Location - 334

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
A - Washer
B - Nut
C - Cap Screw
D - Cap Screw
E - Bracket, Left
F - Bracket, Right
G - Gear Case, Front
H - Stud
I - Gear Box, Front Right
J - Cap Screw (12 used)
K - Sleeve
L - Seal
M - Ball Bearing
N - Snap Ring
O - Washer
P - Gear
Q - Shaft
R - Sleeve
S - Collar
T - Seal
U - Snap Ring
V - Washer
W - Bearing Race
X - Needle Bearing
Y - Washer
Z - Snap Ring
AA- Pinion, Final
AB- Ball Bearing
AC- Gear Box, Front Left
AD- Pin (4 used)

Power Train - Hydrostatic Component Location - 335

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
Front Axle Assembly (MFWD)
N O
M

Q P

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

H
S V
T
U
W
X

AH
AF AE Y

Q
AC
P AD Z
AB AA
AG
N
O

MX14350 W - Seal
A - Bolt X - Cover
B - Bushing (2 used) Y - Bolt
C - Washer Z - Bolt
D - Lock Nut AA- Ball Bearing
E - Ball Bearing AB- Gear
F - Gear, Differential (2) AC- Snap Ring
G - Shaft, Differential AD- Ball Bearing
H - Pinion, Differential (2) AE- Dowel Pin
I - Gear, Differential AF- Drive Pinion
J - Ball Bearing AG- Differential Housing
K - Shaft, Right AH- Shaft, Left
L - O-Ring (2)
M - Axle Housing, Right
N - O-Ring
O - Ball Bearing
P - O-Ring
Q - Gear, Front
R - Cap Screw (6 used)
S - Ball Bearing
T - Gear
U - Input Shaft
V - Bearing

Power Train - Hydrostatic Component Location - 336

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
Rear PTO Gear Case Assembly

A
C D
E

F
G

H
L
K
I
M N
J J

O
Q
P
R

M
S
T U

AL V
W X
T

M Y
Z
AK

AJ
AI
AA
AH
AG
AB
AF
AE
AD
AC Y
Z

MX14322

Power Train - Hydrostatic Component Location - 337

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
A - Snap Ring
B - Spacer
C - Snap Ring
D - Bearing
E - PTO Gear
F - Needle Bearing
G - Spline Collar
H - Snap Ring
I - Bushing
J - Bolt
K - O-Ring
L - Cap
M - Bearing (3 used)
N - Gear, Rear PTO (35T)
O - Bushing
P - Snap Ring
Q - Ball Bearing
R - Seal
S - PTO Shaft
T - Washer
U - Gear, Rear PTO (29T)
V - Idle Shaft, Rear PTO
W - Gear, Rear PTO (14T)
X - Cover
Y - Bushing
Z - Cap Screw
AA- Pin
AB- Cap Screw
AC- Ball Bearing
AD- Shaft, Rear PTO
AE- Ball Bearing
AF- Snap Ring
AG- PTO Gear (20T)
AH- Shift Collar
AI - Snap Ring
AJ- Cap Screw
AK- Case, Rear PTO
AL- O-Ring

Power Train - Hydrostatic Component Location - 338

 POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
MFWD Output Shaft

B
C

G
E
F
AB
J

Y
I

AA
H
K
W

Y
V O
X U
T P
S

O N
M

MX14346

Power Train - Hydrostatic Component Location - 339

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
A - Spacer When the direction is reversed to provide forward direction,
B - Strainer charge oil will then pressurize the reverse side of the
C - Motor Housing closed loop.
D - Motor Shaft The variable displacement hydrostatic pump pressurizes
E - Spring Pin the reverse side loop, causing the fixed displacement motor
to rotate. The reverse directional check valve blocks the
F - Pin
closed loop pressure oil from entering the charge circuit.
G - Arm
H - Strap The reverse directional check valve cartridge has a leak-off
orifice. This orifice bleeds off a small amount of high
I - Screw
pressure oil from the reserve closed loop back into the
J - O-Ring charge circuit. This provides for a wider neutral band to
K - Shaft help prevent creep. This small leakage does not slow down
L - Shifter reverse.
M - Spline Collar
Free-Wheeling:
N - Shift Collar
O - Ball When the free-wheeling push pins are pushed down, the
pins unseat the closed loop check valves, allowing oil flow
P - Spring
created by the motor to escape into the charge circuit. This
Q - Front Drive Shaft
prevents oil pressure from building between the pump and
R - Ball Bearing motor, allowing the machine to be pushed.
S - Washer
T - Sleeve Anti-Cavitation Valves:
U - Seal These valves prevent cavitation of the motor during free-
V - Gasket wheeling or when the motor overruns the pump (machine
W - Locating Sleeve (2 used) going down hill).
X - Front Cover During free-wheeling, the free-wheeling valves are
Y - Lock Washer depressed and the engine is not turning the charge pump
that supplies the charge oil. The hydrostatic motor pumps
Z - Bolt
the closed loop oil out into the charge circuit; the anti-
AA- Cap Screw cavitation valves open, letting oil from the transaxle sump
AB- Bolt into the closed loop, preventing motor cavitation.
When the machine goes down a hill, the motor becomes
Theory of Operation the pump, going into a braking mode, and tries to overrun
the pump. Closed loop pressure increases higher than the
Center Section and Directional Control Valves charge pressure, closing off the charge oil. Anti-cavitation
- Reverse System Operation valve then opens to make up oil lost through the pump,
preventing pump cavitation.
NOTE: Hydrostatic theory is not covered. See FOS
Series Manuals.

Function:
The center section contains the closed loop passages
between the variable displacement pump and the bi-
directional, fixed displacement motor. It also contains the
directional control valves. These valves control the flow of
charge oil into the closed loop and block closed loop
pressure from the charge circuit oil.

System Operation:
Charge oil from the charge pump enters the center section
at port (C). Charge oil will open the closed loop check valve
and enter the forward side of the closed loop when the
reverse side has been pressurized by the hydrostatic pump.

Power Train - Hydrostatic Theory of Operation - 340

POWER TRAIN - HYDROSTATIC THEORY OF OPERATION

D
B C
E

R
F

Q G

P
H

I
N

Reverse Pressure Oil

K J
Charge Pressure Oil
Engagement Circuit Oil
Pressure Free Oil
L

MIF

Power Train - Hydrostatic Theory of Operation - 341

POWER TRAIN - HYDROSTATIC THEORY OF OPERATION

U
S

AA

W
Z

AB
X

AK
Y

AI

AJ AH

AC

AG

AF

AD

Charge Pressure Oil

Clutch Engagement Pressure Oil

AE
Lube Pressure Oil

Pressure Free Oil

MIF

Power Train - Hydrostatic Theory of Operation - 342

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
A - Charge Pressure Relief Sump Passage of the pump. Three valves control the flow and pressure
B - Reverse Directional Control Valve from the pump.
C - Pressure Oil From Charge Pump
Charge Pressure Control Valve:
D - Freewheeling Manual Push Pins
If charge pressure is below 1910 kPa (277 psi), the charge
E - Forward Directional Control Valve
pressure control valve will block oil flow from leaving the
F - Closed Loop Check Valve "OUT" port to the steering valve. This will insure priority oil
G - Hydrostatic Pump flow to the lube reduction valve for transmission lubrication.
H - Inlet To Charge Pump
When charge pressure is at a minimum of 1958 kPa (284
I - Forward Side Loop psi), it will allow oil flow out the "OUT" port to steering and
J - Anti-Cavitation Check Valves hydraulic control valve.
K - Screen
L - Plugs Charge Pressure Relief Valve:
M - Motor Charge pressure relief valve protects the hydraulic system
N - Reverse Loop and charge pump from excessive pressure. High pressure
in the hydraulic circuit can be caused by an excessive load
O - Valve Plate Cooling Passage
on the hydraulic outlets, or with nothing connected to the
P - Return From Oil Cooler outlets when the control lever is moved.
Q - Reverse Leakoff Orifice
R - To PTO Engagement Solenoid Lube Reduction Valve:
S - Clutch Piston The lube reduction valve has two functions:
T - PTO Pressure Test Port
1. If pressure in the lube and charge port exceeds 586 kPa
U - PTO Engagement Solenoid (85 psi), it will close off the flow to the port, reducing lube
V - PTO Brake and charge pressure.
W - Charge Pressure Relief Valve 2. This valve also has a small orifice that allows a small
X - Charge Pressure Test Port flow of oil to the engagement solenoid. Oil is available for
Y - Lube Reduction Valve clutch and brake engagement when PTO is engaged.
Z - Directional Valve - Forward
AA- PTO Pressure Control Valve
AB- Hydrostatic Motor
AC- Directional Valve - Reverse
AD- Return From Steering Valve and Control Valve
To Sump
AE- Transaxle Case
AF- Hydraulic Oil Filter
AG- Outlet To Steering Control Unit
AH- Charge Pressure Control Valve
AI - PTO Flow Orifice
AJ- Charge Pump
AK- Hydrostatic Variable Pump

Transaxle Oil Flow System Operation

Function:
Provide pressure oil to charge and lubricate the hydrostatic
transmission, operate the hydraulic system and engage the
PTO clutch and brake.

System Operation:
The charge pump draws oil from the transaxle case,
through the filter and provides pressure oil to outlet galley

Power Train - Hydrostatic Theory of Operation - 343

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION

C
D

E
F
G

AA I
J
Z

N
X

O
W

P
V

S
U T

Charge Pressure Oil

Clutch Engagement Pressure Oil

Lube Pressure Oil

Pressure Free Oil

MIF

Power Train - Hydrostatic Theory of Operation - 344

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION

W
B

Charge Pressure Oil

Clutch Engagement Pressure Oil

Lube Pressure Oil

Pressure Free Oil

I

D
N M
J

MIF N - Out to Steering

A - Clutch and Brake Pressure Test Port O - Charge Pressure Control Valve
B - PTO Engagement Solenoid Valve P - Charge Pump
C - PTO Pressure Control Valve Q - Hydrostatic Motor
D - Passage to Solenoid R - To Charge Pump
E - Directional Valve - Forward S - Filter
F - Charge Pressure Relief Valve T - Inlet From Case
G - Directional Valve - Reverse U - Transaxle Case
H - Center Section V - Clutch Lube Passage
I - Charge Pressure Test Port W - Clutch Piston
J - Lube Reduction Valve X - Brake Shoe
K - PTO Flow Orifice Y - Brake Piston
L - Return From Cooler To Sump Z - Brake Spring
M - Lube Passage To Hydrostatic Pump AA- PTO Brake

Power Train - Hydrostatic Theory of Operation - 345

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
External Power Train System Operation
System Operation:
The transaxle is a combination of a hydrostatic
transmission, differential and axle assemblies. It also
contains a hydraulic operated PTO clutch and brake with all
associated drive train gears.
The drive shaft connects the engine to the input shaft of the
transaxle. The input shaft rotates the charge pump,
hydrostatic pump and PTO clutch drive hub. These
components provide the power to operate the transaxle
The transaxle is controlled by foot operated forward and
reverse pedals. The pedal linkage is connected to the
swash plate control lever that operates the internal swash
plate shaft, controlling the direction and amount of output of
the hydrostatic pump to the hydrostatic motor. The damper
(shock absorber) provides for a smooth operation of the
control linkage and also provides the pedal "feel".
The differential lock pedal and linkage are located on the
left-hand side of the transaxle. When the pedal is
depressed, the linkage holds the internal differential lock
lever, collar and pins under spring tension. This is done
because if the lock pins do not line up with the holes in the
differential, the lock will not engage. When the holes do line
up with the pins, the spring will force the pins to engage.
The free-wheeling linkage is accessible from the right rear
of the machine. When the linkage is moved up, the
directional control valves are depressed, allowing the
closed loop circuit to by-pass, allowing the machine to be
pushed.

Power Train - Hydrostatic Theory of Operation - 346

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
Transaxle Internal System Operation
C
I

D
B
J

E K

F
L

G
M
H
A

U Q

S
T

MX11457 F - PTO Drive Gear

Side View Shown G - Neutral Centering Spring
A - PTO Electrical Engagement Solenoid H - Swash Plate
B - PTO Clutch Hub and Gear I - Hydrostatic Pump
C - Dip Stick J - Charge Pressure Relief Valve
D - PTO Piston K - Charge Pressure Test Port
E - PTO Clutch L - Lube Reduction Valve

Power Train - Hydrostatic Theory of Operation - 347

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
M - Charge Pump R - Ring Gear
N - Input Shaft S - PTO Output Shaft
O - Hydrostatic Motor T - Left Axle
P - Anti-Cavitation Valves U - PTO Driven Gear
Q - Input Pinion Gear V - PTO Idler Gear

A
E

MX14458 Rear View Shown

Power Train - Hydrostatic Theory of Operation - 348

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
A - Brakes
B - PTO Output Shaft
C - Swash Plate Shaft
D - Swash Plate Control Lever
E - Differential Input Gear
F - Differential Ring Gear
G - Differential Bevel Pinions
H - Differential Side Gears
I - Differential Shift Collar and Pin
J - Left Axle

Transaxle Operation:
The transaxle consists of an internal hydrostatic pump and
external hydrostatic motor, differential assembly and a
hydraulic PTO clutch and gearing to the PTO output shaft.
Whenever the engine is running, the drive shaft is turning
the input shaft, charge pump and PTO drive gear.
The charge pump provides charge and lubrication oil for
the hydrostatic pump, motor and PTO clutch lube. It also
provides pressure oil to operate the PTO clutch and supply
oil for the steering valve and hydraulic control valve. (See
Steering and/or Hydraulics sections.)
The hydrostatic pump, controlled by the foot control linkage
and swash plate, provides direction and speed of the
closed loop pressure oil to the hydrostatic motor. The motor
drives the input pinion gear. Power is then transmitted
through the ring gear, differential input gear and differential
ring gear. Differential action to the rear axles and wheels is
provided through the bevel pinions and side gears.
When the differential lock is engaged, the differential collar
and pins lock the left-hand axle and side gear to the
differential carrier, turning both axles at the same rate.

PTO Operation:
When the PTO is engaged, the electrical engagement
solenoid allows pressure oil, supplied by the charge pump,
to engage the PTO clutch and release the PTO brake. The
PTO clutch is applied when pressure oil moves the PTO
piston, squeezing the clutch disk together. With the disks
locked together, power is then transmitted by the PTO
clutch hub and gear, through the idler gear and driven gear
and out the case through the output shaft.
The PTO brake is released at the same time the clutch is
applied. Pressure oil moves the brake piston out against
brake spring pressure, releasing the brake. When the PTO
is shut off, the engagement solenoid blocks the pressure oil
and the brake springs push the piston and brake shoe
against the PTO clutch hub and gear. Frictional force stops
the rotation of the PTO drive train. See “Transaxle Oil Flow
System Operation” on page 343.

Power Train - Hydrostatic Theory of Operation - 349

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION

A B C E F F G
D H

P O N M L

M55426a

A - PTO Pressure Control Valve

B - PTO Clutch, Hub and Gear
C - PTO Clutch
D - Hydrostatic Pump
E - Charge Pressure Relief Valve
F - Directional Control Valves
G - Charge Pressure Test Port
H - Lube Reduction Valve
I - Input Shaft
J - Charge Pressure Control Valve
K - Neutral Centering Spring
L - Neutral Adjustment Eccentric
M - PTO Brake Piston
N - PTO Brake Springs
O - PTO Brake
P - PTO Pressure Test Port
Q - Damper (Shock Absorber)

Power Train - Hydrostatic Theory of Operation - 350

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
Rear PTO Component Location and Operation
- Optional
Function:
To provide 540 rear PTO drive.

Theory of Operation:
The mid-PTO and the rear PTO kits, use a common power
flow up to the shift collar. To have power to either or both
PTO's the operator must be on the seat and PTO clutch
must be engaged. Power is then transmitted from the input
shaft through the clutch disks and out the clutch hub and
gear, idler gear, PTO drive gear and into shift collar. The
shift collar has three detented positions. It is moved by the
shift fork that is controlled by the external shift lever.

Rear PTO:
When the shift collar is positioned in the rear detent (shift
lever up), the collar connects and drives only the rear PTO
drive gear. Power then flow through the reduction gear set
and PTO output gear, out the rear coupler. A boss on the
shift fork depresses the mid-PTO switch, turning off the
mid-PTO indicator light on the dash.

Mid- and Rear PTO:

When the shift collar is in the middle detent position, the
shift collar picks up both the rear and mid-PTO drive gears.
Both PTO output shafts are powered. The shift fork boss is
not depressing either of the PTO switches, leaving both
PTO indicator lights on.

Mid-PTO:
When the collar is positioned in forward detent (shift lever
down) the collar connects and drives only the mid-PTO
shaft. A boss on the shift fork depresses the rear PTO
switch and turns the indicator light on the dash off.

Stationary PTO Operation:

For the rear PTO to operate with operator off seat, a start-
up sequence must be followed:
1. Engine off. PTO switch off. PTO drive line connected
and shields in place.
2. Park brake set.
3. Rear PTO lever positioned up for rear PTO operation.
4. Engine can be started with operator on or off seat.
5. Operator off seat. Pull PTO switch on.
NOTE: If seat switch is activated by touching or sitting
on seat, PTO will disengage. Repeat procedure to
engage PTO.

Power Train - Hydrostatic Theory of Operation - 351

 POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
540 Rear PTO
E F G

L
N
M

MX16044 M - Mid-PTO Drive Gear

A - Rear PTO Power Flow N - Shift Collar
B - Rear PTO Shaft O - Rear PTO Drive Gear
C - PTO Output Gear P - Rear PTO Switch
D - Idler Gear Q - Reduction Gear Set
E - Clutch and Hub Gear
F - Clutch Disk
G - PTO Clutch Gear
H - Input Shaft
I - Common Power Flow to Shift Collar
J - Mid-PTO Power Flow
K - Mid-PTO Shaft
L - PTO Drive Gear

Power Train - Hydrostatic Theory of Operation - 352

 POWER TRAIN - HYDROSTATIC DIAGNOSTICS
Diagnostics Symptom: Hydrostatic Transmission Problems
Yes - Free-wheeling linkage set for push or partially
Hydrostatic Transmission Diagnosis set.
Symptom: Hydrostatic Transmission Problems Yes - Linkage damper (shock absorber) failed.
(1) Machine will not move on its own power? Yes - Directional control valves leaking or stuck
down.
No - Go to next step.
Yes - Pump or motor valve plates scored or worn.
Yes - Free-wheeling linkage set for push or partially
set. (5) Slow forward under load, or speed drops when
load is applied?
Yes - Control pedal linkage bent, binding or
disconnected. No - Go to next step.
Yes - Directional control valves leaking or stuck Yes - Forward pedal height needs to be adjusted.
down.
Yes - Free-wheeling linkage set for push or partially
Yes - Brakes set or not releasing. See Brakes set.
section.
Yes - Control pedal linkage bent, binding or
Yes - Anti-cavitation valves leaking or stuck open. disconnected.
Yes - Charge pump scored or worn. Yes - Directional control valves leaking or stuck
down.
Yes - Pump or motor valve plates scored or worn.
Yes - Drive shaft not turning pump input shaft or
Yes - Filter pugged or suction side air leak. Check
charge pump key sheared.
filter, charge pump or case seal.
Yes - Anti-cavitation valves leaking or stuck open.
Yes - Charge pressure relief valve leaking. Seat valve
or spring damaged. Yes - Directional valve in wrong location.
Yes - Drive shaft not turning pump input shaft or Yes - Charge pump scored or worn.
charge pump key sheared.
Yes - Pump or motor valve plates scored or worn.
(2) Machine will not move. Wheels locked up. Can
Yes - Filter pugged or suction side air leak. Check
not be pushed?
filter, charge pump or case seal.
No - Go to next step.
Yes - Engine performance is poor or not operating or
Yes - Brakes set or not releasing. See Brakes set at correct operating speeds. See Engine
section. diagnosis.
(3) Will not move in one direction? (6) Erratic speed?
No - Go to next step. No - Go to next step.
Yes - Free-wheeling linkage set for push or partially Yes - Free-wheeling linkage set for push or partially
set. set.
Yes - Control pedal linkage bent, binding or Yes - Linkage damper (shock absorber) failed.
disconnected.
Yes - Control pedal linkage bent, binding or
Yes - Directional control valves leaking or stuck disconnected.
down.
Yes - Brakes set or not releasing. See Brakes
Yes - Directional valve in wrong location. section.
Yes - Anti-cavitation valves leaking or stuck open. Yes - Directional control valves leaking or stuck down
Yes - Pump or motor valve plates scored or worn. Yes - Drive shaft not turning pump input shaft or
charge pump key sheared.
(4) Too aggressive in reverse?
Yes - Anti-cavitation valves leaking or stuck open
No - Go to next step.
Yes - Charge pump scored or worn

Power Train - Hydrostatic Diagnostics - 353

 POWER TRAIN - HYDROSTATIC DIAGNOSTICS
Symptom: Hydrostatic Transmission Problems Symptom: Hydrostatic Transmission Problems
Yes - Pump or motor valve plates scored or worn Yes - Anti-cavitation valves leaking or stuck open.
Yes - Filter pugged or suction side air leak. Check Yes - Charge pump scored or worn.
filter, charge pump or case seal
Yes - Pump or motor valve plates scored or worn.
Yes - Charge pressure relief valve leaking. Seat valve
Yes - For mid or rear PTO problems or complaints,
or spring damaged
see “Mid-PTO System Diagnosis” on page 355.
Yes - Swash plate control shaft or bushing worn.
(11) Hydraulic noise?
Yes - Engine performance is poor or not operating or
No - Go to next step.
set at correct operating speeds.. See Engine
diagnosis Yes - Free-wheeling linkage set for push or partially
set.
(7) Machine will not stop?
Yes - Brakes set or not releasing. See Brakes
No - Go to next step.
section.
Yes - Free-wheeling linkage set for push or partially
Yes - Neutral adjustment not correct.
set.
Yes - Drive shaft not turning pump input shaft or
Yes - Control pedal linkage bent, binding or
charge pump key sheared.
disconnected.
Yes - Directional control valves leaking or stuck
Yes - Brakes set or not releasing. See Brakes
down.
section.
Yes - Anti-cavitation valves leaking or stuck open.
Yes - Neutral adjustment not correct.
Yes - Charge pump scored or worn.
Yes - Anti-cavitation valves leaking or stuck open.
Yes - Pump or motor valve plates scored or worn.
Yes - Swash plate control shaft or bushing worn.
Yes - Filter pugged or suction side air leak. Check
(8) PTO problem or complaint?
filter, charge pump or case seal.
No - Go to next step.
Yes - Charge pressure relief valve leaking. Seat valve
Yes - For mid or rear PTO problems or complaints, or spring damaged.
see “Mid-PTO System Diagnosis” on page 355.
Yes - Swash plate control shaft or bushing worn.
(9) Transaxle or differential lock problem or
Yes - For mid or rear PTO problems or complaints,
complaint?
see “Mid-PTO System Diagnosis” on page 355.
No - Go to next step.
(12) Gear noise, dependant on speed, direction of
Yes - See “Hydrostatic Transmission Test” on travel or during turn?
page 356.
No - Go through procedures in “Hydrostatic
(10) Transmission operating hot? Transmission Test” on page 356 for additional tests.
No - Go to next step. Yes - Brakes set or not releasing. See Brakes
section.
Yes - Free-wheeling linkage set for push or partially
set. Yes - Drive shaft not turning pump input shaft or
charge pump key sheared.
Yes - Control pedal linkage bent, binding or
disconnected. Yes - Charge pump scored or worn.
Yes - Brakes set or not releasing. See Brakes Yes - Pump or motor valve plates scored or worn.
section.
Yes - Filter pugged or suction side air leak. Check
Yes - Neutral adjustment not correct. filter, charge pump or case seal.
Yes - Oil cooler may be plugged with debris. Yes - For mid or rear PTO problems or complaints,
see “Mid-PTO System Diagnosis” on page 355.
Yes - Directional control valves leaking or stuck
down.

Power Train - Hydrostatic Diagnostics - 354

 POWER TRAIN - HYDROSTATIC DIAGNOSTICS
Mid-PTO System Diagnosis Symptom: Mid PTO Speed Problems
Symptom: Mid PTO Engagement Problems (1) PTO shaft slows down?
(1) PTO will not engage? No - Go to next step.
No - Go to next step. Yes - Excessive load on PTO output. Remove load.
Yes - Check engagement solenoid circuit. See Yes - Use higher engine rpm. Check engine
Electrical section. performance.
Yes - PTO switch not working. Yes - PTO lube reduction valve orifice plugged.
Yes - PTO lube reduction valve orifice plugged. Yes - Low charge pump output.
Yes - Engagement valve installed incorrectly. Yes - PTO pressure control valve faulty.
Yes - PTO pressure control valve faulty. Yes - PTO clutch piston leaking, input shaft seal
leaking or clutch disk worn.
Yes - PTO clutch piston leaking, input shaft seal
leaking or clutch disk worn. (2) PTO shaft will not stop, or slow to stop?
Yes - Low charge pump output. No - Go through procedures in “Mid-PTO System
Test” on page 358 for additional tests.
Yes - PTO shaft, gear or bearing failure.
Yes - Check engagement solenoid circuit. See
(2) Engine stalls when PTO is engaged? Electrical section.
No - Go to next step. Yes - Engagement valve installed incorrectly.
Yes - Excessive load on PTO output. Remove load. Yes - PTO brake not releasing. Check brake piston,
Yes - Use higher engine rpm. Check engine O-Rings.
performance.
Yes - Excessive load on PTO output. Remove load.
Yes - Hydraulic circuit in relief. Remove restriction or
Yes - PTO brake springs faulty.
load.
Yes - PTO brake not releasing. Check brake piston,
Transaxle Diagnosis
O-Rings.
Yes - PTO shaft, gear or bearing failure. Symptom: Transaxle Engagement Problems
(3) PTO will not stay engaged? (1) PTO complaint?

No - Go to next step. No - Go to next step.

Yes - Check engagement solenoid circuit. See Yes - See Mid-PTO or rear PTO diagnosis.
Electrical section. Yes - See Transaxle Repair.
Yes - Engagement valve installed incorrectly. (2) Hydrostatic transmission complaint?
Yes - PTO clutch piston leaking, input shaft seal No - Go to next step.
leaking or clutch disk worn.
Yes - Brakes are applied or mis-adjusted. See Brakes
Yes - PTO lube reduction valve orifice plugged. section.
Yes - Low charge pump output. (3) Rear drive wheel are locked up; will not move
Yes - PTO pressure control valve faulty. directional pins down?

(4) Gear or bearing noise with PTO engaged? No - Go to next step.

No - See “Mid-PTO System Test” on page 358. Yes - Brakes are applied or mis-adjusted. See Brakes
section.
Yes - PTO brake not releasing. Check brake piston,
O-Rings. Yes - Differential lock collar, pin or differential carrier
failure.
Yes - PTO brake springs faulty.

Power Train - Hydrostatic Diagnostics - 355

 POWER TRAIN - HYDROSTATIC DIAGNOSTICS
Symptom: Transaxle Engagement Problems Symptom: Transaxle Noise Problems
Yes - Check axle or differential gear failure. See axle Yes - Check axle or differential gear failure. See axle
or differential repair. or differential repair.
Yes - See “Transaxle Test” on page 359. Yes - See “Repair” on page 368 for repair
procedures.
Yes - See “Repair” on page 368.
(2) Ratcheting noise as machine turns?
(4) Rear wheel free-wheel; no transaxle drive;
hydraulic control valve pins are up? No - Go through procedures in “Transaxle Test” on
page 359 for additional tests.
No - Go to next step.
Yes - Differential lock linkage is mis-adjusted.
Yes - Check axle or differential gear failure. See axle
or differential repair. Yes - Differential is engaged. Check adjustment.
Adjustment ok = repair differential lock.
Yes - Differential lock collar, pin or differential carrier
failure. Yes - Differential lock collar, pin or differential carrier
failure.
Yes - See “Transaxle Test” on page 359.
Yes - Check axle or differential gear failure. See axle
Yes - See “Repair” on page 368.
or differential repair.
(5) Differential lock will not engage?
Yes - See Repair section for repair procedures.
No - Go to next step.
Yes - Differential lock linkage is mis-adjusted. Hydrostatic Transmission Test
Yes - Differential lock collar, pin or differential carrier
Engine NOT running:
failure.
Yes - See “Repair” on page 368. Test Conditions:
(6) Differential lock will not disengage? • Park brake disengaged.
No - See “Transaxle Test” on page 359. • Engine not running.
Yes - Brakes are applied or mis-adjusted. See Brakes • Machine on hard level surface.
section.
Yes - Differential lock linkage is mis-adjusted. System: Hydrostatic Transmission
Yes - Differential is engaged. Check adjustment. (1) When checking transmission dipstick, correct
Adjustment ok = repair differential lock. type, viscosity of oil, and oil level? No signs of
leaks from transaxle?
Yes - Differential lock collar, pin or differential carrier
failure. Yes - Go to next step.

Yes - See Repair section for repair procedures. No - Add or change hydraulic oil. Repair all external
leaks.
Symptom: Transaxle Noise Problems (2) Oil cooler/radiator intake screen and cooler fins
(1) Ratcheting noise as machine moves? free of debris and clean? Fins not bent?

No - Go to next step. Yes - Go to next step.

Yes - Brakes are applied or mis-adjusted. See Brakes No - Clean as required.

section. (3) Hydraulic control levers return to neutral
Yes - Differential lock linkage is mis-adjusted. position?

Yes - Differential is engaged. Check adjustment. Yes - Go to next step.

Adjustment ok = repair differential lock. No - Hydraulic control levers not in neutral; hydraulic
Yes - Differential lock collar, pin or differential carrier system could be in relief. See Hydraulics section and
failure. check linkage for binding.

Power Train - Hydrostatic Diagnostics - 356

 POWER TRAIN - HYDROSTATIC DIAGNOSTICS
System: Hydrostatic Transmission System: Hydrostatic Transmission
(4) With free-wheeling lever disengaged (DOWN), Yes - Go to next step.
machine free-wheels in both directions?
No - Inspect linkage for bent, binding or looseness
No - Go to next step.
No - If pedals do not return to neutral, disconnect
Yes - Free-wheeling linkage not releasing directional damper (shock). Pedals should return sharply.
control valve pins
No - Disconnect control rod from swash plate arm.
Yes - Directional control pins stuck down. Check linkage for binding and repair.
(5) With free-wheeling lever disengaged (DOWN), No - Linkage not binding - check swash plate shaft for
machine pushes in reverse but not forward? binding or internal return/centering spring or swash
plate bushing binding.
No - Go to next step.
(10) Transmission control pedals and linkage: With
Yes - Directional control valves are installed in wrong
brake pedal engaged, forward and reverse pedal
ports. Switch valves around
should be locked in neutral? (Engage free-
Yes - Forward valve is leaking. Replace forward valve wheeling lever and push machine to verify.)
(6) With free-wheeling lever disengaged (DOWN), Yes - Go to next step.
machine free-wheels with brakes applied?
No - Pedals not locked in neutral. (See “Transaxle
No - Go to next step. Control Linkage Adjustment” on page 365.)
Yes - Adjust brakes. (See Brakes section.) No - Brakes not holding machine. See Brakes section
and adjust.
Yes - If brakes do not stop machine, check for the
following (NOTE: Push machine until differential lock (11) To check cruise control lever and linkage (if
engages: Failed brake shaft or bearing, failed equipped), push forward pedal slightly and set
differential input gear or differential carrier, or check cruise. (Brake pedal released.) Does cruise control
differential bevel gears. release when forward pedal is pressed and
released or brake pedal is depressed?
(7) With free-wheeling lever disengaged (DOWN),
machine stops after differential lock engages? Yes - Hydrostatic transmission (engine OFF) checks
completed.
No - Go to next step.
No - Check linkage for bent, binding or disconnected
Yes - Differential bevel gears or axles will not push in
links.
either direction.
No - Check cam teeth for wear if cruise will not stay
Yes - Brakes are on or dragging.
engaged.
Yes - Reverse orifice is plugged.
Engine running:
(8) With free-wheeling lever engaged (UP), machine
pushes easily forward and backward?
Test Conditions:
Yes - Go to next step.
• Start engine.
No - Free-wheel lever is bent, disconnected from
Left-Hand bracket, or not pushing directional control • Release park brake.
valve pins. Repair linkage. • Move machine to open area for driving test.
No - Check directional control valve pins for dirt or
corrosion that would bind pins. System: Hydrostatic Transmission
No - Check brakes for dragging. (1) With parking brake applied, does machine have
excessive noise when operated?
(9) Transmission control pedals (brakes
disengaged) and linkage move smoothly with No - Go to next step.
slight resistance to movement? (NOTE: Linkage Yes - Transmission neutral return linkage bolt is out
will return slower at colder temperatures.) No free- of adjustment.
play in linkage between pedals and swash plate
shaft?

Power Train - Hydrostatic Diagnostics - 357

 POWER TRAIN - HYDROSTATIC DIAGNOSTICS
System: Hydrostatic Transmission System: Hydrostatic Transmission
(2) Test forward and reverse pedals. Drive machine Yes - See “Charge Pump Flow and Pressure Test - At
forward, then stop. Reverse and stop. Does Charge Pump” on page 361.
machine respond to pedal movement? (Gradual
Yes - Extreme wear of valve plates or rotating groups.
increase in speed FORWARD up to 13.2 km/h (8.2
mhp). Should stop within 2.2 - 4 m (7 - 10 ft) without
using brake. Gradual speed increase; speed in Mid-PTO System Test
REVERSE to 8.8 km/h (5.5 mph). Should stop
within 1.2 - 1.8 m (4 - 8 ft).)
Test Conditions:
Yes - Go to next step.
• Park brake disengaged.
No - Check free-wheeling linkage if machine will not
move or if hydrostatic is jerky. • Engine running approximately half throttle.
• Deck or PTO driven implement installed.
No - If machine still will not move, continue testing
sequence. If machine does not stop within distance, • PTO switch off.
check linkage for binding, replace dampener and
retest.
No - Check swash plate shaft for binding, or neutral
return spring weak or broken.
(3) Are drive shaft cap screws tight? No wear or
damage to splines? Drive shaft turning input
shaft?
Yes - Go to next step.
No - Tighten cap screws. Repair or replace as
A
necessary
(4) Test charge pump pressure port. Is there charge
pressure? M55440

Yes - Go to next step. System: Mid-PTO

No - Check hydraulic oil level. (1) Is PTO shaft (A) turning?
No - Replace hydraulic filter. No - Go to next step.
No - Check vent for plugging. Yes - Perform “Mid-PTO Engagement Pressure and
Brake Test” on page 363.
No - Check charge pump seal.
Yes - Check brake springs, brake shoes, solenoid
No - Check for sheared pump drive key.
valve and clutch return spring.
No - Check charge pressure relief valve for broken
(2) With PTO switch on, brake off, and being on the
spring or debris.
seat, is PTO engaging?
(5) Test charge pump pressure port. Is there charge
Yes - Go to next step.
pressure, but no drive?
No - Perform PTO engagement pressure test. (See
No - Hydrostatic transmission (engine running) tests
“Mid-PTO Engagement Pressure and Brake Test” on
completed.
page 363.)
Yes - Replace directional control valves.
Yes - Lube reduction valve stuck.
Yes - Inspect pump and motor for wear.
Yes - See “Hydrostatic Transmission Diagnosis” on
page 353.
Yes - Anti-cavitation valve stuck open.

Power Train - Hydrostatic Diagnostics - 358

 POWER TRAIN - HYDROSTATIC DIAGNOSTICS
System: Mid-PTO System: Transaxle
No - If there is no engagement, and/or no (3) Differential lock engages within a short distance
engagement pressure check: Electrical solenoid in when differential lock pedal is depressed?
Electrical section; PTO pressure control valve leaking (Machine wants to continue in a straight line.
to sump; Lube reduction valve orifice plugged; For no Differential lock will disengage when you release
charge pressure. (Perform “Charge Pump Flow and the traction pedal.)
Pressure Test - At Charge Pump” on page 361.);
Yes - Go to next step.
Clutch or brake packing leaking; Packing on end of
clutch hub shaft missing or leaking. No - Check linkage springs and all linkage
connections. Inspect differential and lock collar and
(3) Observe PTO shaft. (Engine at full rpm; PTO on,
pins. Check for broken differential shift fork return
then off.) Does PTO shaft and implement stop
spring.
within four seconds?
(4) Check differential and axles (jack one wheel off
Yes - Go to next step.
ground). During a turn, any noise from axles or
No - Check brake springs and brake facing. Repair differential? (AWS wheel hubs in knuckle housing
PTO inertia brake. should have movement (wobble)).
(4) Observe PTO shaft. (Engine at full rpm; PTO No - Go to next step.
on.) Is PTO driving implement satisfactory under
Yes - Noise in the turn: Check all bearings then
load? PTO clutch not slipping? No vibration?
differential side gears and bevel pinions.
Yes - Mid-PTO test completed.
(5) Check brake pedals. Any noise in differential
No - PTO pressure low; adjust pressure control valve. when brakes are released and rear wheels are
rotated?
No - Check clutch disk for wear. (NOTE: Check lube
passage in input shaft and in clutch input gear for No - Transaxle test completed.
blockage.)
Yes - Ratcheting noise: See “Brake/Differential
No - Vibration: Disconnect implement drive shaft and Linkage Adjustment” on page 485 in the Brakes
operate PTO. Check shaft U-joints or implement for section.
vibration.
Yes - Brakes adjusted properly - disassemble and
repair transaxle.
Transaxle Test

Test Conditions:
• Park brake engaged.
• Engine not running.

System: Transaxle
(1) When checking dipstick, oil at proper level and
viscosity?
Yes - Go to next step.
No - Add or change hydraulic oil and filter.
(2) Check transaxle (drive machine). No leaks?
Transaxle engages in 0.5 - 1. 0 seconds?
Yes - Go to next step.
No - Replace leaking and worn seals.

Power Train - Hydrostatic Diagnostics - 359

 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
Tests and Adjustments
c under
CAUTION: Avoid Injury! Escaping fluid
Hydraulic Oil Warm-Up Procedure pressure can penetrate the skin
causing serious injury. Avoid the hazard by
Reason: relieving pressure before disconnecting
When making hydraulic tests the oil must be heated to hydraulic or other lines. Tighten all
normal operating temperature for the tests to be accurate. connections before applying pressure.
Search for leaks with a piece of cardboard.
Test Equipment: Protect hands and body from high pressure
fluids.
• JDG282 Temperature Gauge • If an accident occurs, see a doctor
immediately. Any fluid injected into the skin
Procedure:
must be surgically removed within a few
1. Install JDG282 Temperature Gauge on transmission oil hours or gangrene may result. Doctors
filter. unfamiliar with this type of injury should
reference a knowledgeable source. Such
IMPORTANT: Avoid damage! DO NOT overheat information is available from the Deere &
engine. Company Medical Department in Moline,
Illinois, U.S.A. In the United States and
2. Apply park brake. Start engine and run at full throttle. Canada only, this information may be
3. Move and hold hydraulic lever in implement raise obtained by calling 1-800-822-8262.
position.
4. Periodically cycle all hydraulic functions to distribute
heated oil.
5. Heat oil to operating temperature before performing
tests.

Charge Pump Pressure Test

A
B
Reason:
To determine charge pressure control valve operation and
help determine condition of hydraulic charge pump. This
also checks charge pump pressure relief valve operation
and determines if there is sufficient pressure to operate
implements. MX14307

Test Equipment: 4. Install connector, hose and pressure gauge to charge

pressure test port (A).
• JT05489 Connector, 7/16-20 x M 37° 1/2-20 M ORB
5. Start engine and run at high idle. Do not operate
• JT03017 Hose steering or hydraulic control valves.
• JT03117-13790 kPa (2000 psi) Pressure Gauge 6. Observe gauge reading. This is charge pressure.
Pressure Test Procedure: 7. Move hydraulic control lever to raise or lower position.
Hold until pump pressure is in relief.
Warm hydraulic oil to operating temperature before
performing this test. When done “cold” or at shop 8. Observe gauge reading and release control. This is
temperature, most machines (especially when new) will charge pressure relief pressure (implement operation
likely be close to 3450 kPa (500 psi). pressure).
1. Park machine safely. See “Park Machine Safely” in the Specification:
Safety section.
Charge Pressure (minimum) . . . . . . 19588 kPa (284 psi)
2. Remove seat and fender deck.
Charge Relief (Implement) Pressure (minimum)
3. Attach seat switch and set up machine so engine can be . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi)
run.

Power Train - Hydrostatic Tests and Adjustments - 360

 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
Results: • JT03342 Coupler, 3/4" F NPT x 9/16-18 F 37°
• If charge pressure is to specifications, 1958 kPa (284
Procedure:
psi) minimum, in transaxle, charge pressure control valve
is operating properly. NOTE: To save time and help with diagnosis, perform
charge pump flow and pressure test at hydraulic
• Note: Charge pressure gauge reading may be higher
control valve quick disconnect fittings before
than specification due to cold oil temperature. Warm oil
performing this test. See “Charge Pump Pressure and
and retest.
Flow Quick Test at Couplers” on page 444 in the
• If charge pressure is too high, and oil is at operating Hydraulics section.
temperature, there is a potential problem with the charge
pressure control valve, or a restriction in the system. See 1. Remove fender deck. Support fuel tank to one side.
“Charge Pump Flow and Pressure Test - At Charge Pump”
in the Hydraulic Power Train section.”
• If relief pressure is within charge relief (implement)
c under
CAUTION: Avoid Injury! Escaping fluid
pressure can penetrate the skin
pressure specifications, 6371 kPa (924 psi) minimum, causing serious injury. Avoid the hazard by
pump and charge pressure relief valve are in good relieving pressure before disconnecting
condition. 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
B 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 source. Such
information is available from the Deere &
Company Medical Department in Moline,
Illinois, U.S.A. In the United States and
MX14228
Canada only, this information may be
• If relief pressure is below 5881 kPa (853 psi), check obtained by calling 1-800-822-8262.
charge pressure relief valve (B), shim relief pressure
spring. If pressure cannot be increased, check charge 2. Disconnect the pressure and return line from the charge
pump for damage. pump housing.

Charge Pump Flow and Pressure Test - At

Charge Pump
Reason:
To check condition of charge pump and setting of the
charge pump relief valve. Isolates possible restrictions of
flow in the steering control valve and/or hydraulic control
valve.

Test Equipment:
• JT01765 Consumer Products Hydraulic Fitting Kit
• JT05469 Flowcharter Kit
• JT03216 Connector, 9/16-18 M 37° x 9/16-18
M ORB M55420
• JT03341 Elbow, 90° 9/16-18 M 37° x 9/16-18
F 37°

Power Train - Hydrostatic Tests and Adjustments - 361

 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
• If there is no pump flow, check for:
D • Drive shaft not turning input shaft
• Sheared charge pump drive key
• Charge pressure control valve (E) stuck closed
• If pump flow is below 13 L/m (3.4 gpm) for 2-WD
A machines, OR 17 L/m (4.5 gpm) for MFWD machines,
C foamy or erratic, match specifications by checking:
B
D • If O-Ring is damaged.
• Hydraulic oil level; replace filter and repeat test.
M55421 • Transaxle vent not plugged, filter seal for leaks.
A - ORB Connectors (removed from charge pump) • Oil ring at inlet of charge pump for leak in case
B - JT03216 Connector, 9/16 - 18 M 37° x 9/16 - 18 F passage between filter and charge pump.
37°
• If dipstick is loose.
C - JT03341 90° Elbow, 9/16 - 18 M 37° x 9/16 - 18 F
37°
D - JT03342 Coupler, 3/4” F NPT x 9/16 - 18 F 37°
3. Remove the ORB fittings and install JT03216 and
JT03341.

IMPORTANT: Avoid damage! After connecting F

flowmeter, keep disconnected lines away from
drive shaft.

4. Connect flowmeter inlet hose to pump outlet (right-hand

side).
5. Connect return hose of flowmeter to return port (left-
MX14228
hand side).
• If pump flow is still below 13 L/m (3.45 gpm) for 2-WD
Flow Test Procedure: machines, OR 17 L/m (4.5 gpm) for MFWD machines,
1. Open flowmeter control valve. match specifications by checking charge pressure relief
valve (F) for damage or debris that could be holding valve
2. Start engine and run at wide open throttle. Oil must be open.
at normal operating temperature.
• Replace pump and repeat test.
3. Observe flowmeter reading.
Pressure Test Procedure:
Results:
1. Flowmeter still connected as in flow test.
• If pump flow is between 13 - 17 L/m (3.4 - 4.5 gpm) for
2-WD machines OR 17 - 22.7 L/m (4.5 - 6 gpm) for MFWD 2. Start engine and run at wide open throttle.
machines, pump is in good condition. 3. Slowly close flowmeter valve until maximum pressure is
reached. Observe pressure reading.
E
Results:
• If pressure is 6371 kPa (924 psi) minimum, pump and
valve are in good condition.
• If pressure is below 5881 kPa (853 psi), shim charge
pressure relief pressure spring. If pressure cannot be
increased, check charge pump for damage.

M55428

Power Train - Hydrostatic Tests and Adjustments - 362

 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
Procedure:
1. Remove hex-plug upper right-hand port on rear
transmission case.

G
IMPORTANT: Avoid damage! Do not overtighten
fittings.

MX14180
B
• If pump seems in good condition, check condition of
lube reduction valve modulation orifice (G) for plugging.
• Replace charge pump and repeat test. C

Specifications:
Charge Pump Flow (2-WD) . 13 - 17 L/m (3.4 - 4.5 gpm)
D
Charge Pump Flow (MFWD) 17 - 22.7 L/m (4.5 - 6 gpm)
Charge Pressure Relief Pressure (minimum) 6371 kPa
(924 psi)

Mid-PTO Engagement Pressure and Brake M55461

Test
2. Install JT05486 (B) and JT05483 (C) Connectors.
PTO Engagement Pressure Test 3. Install JT03017 Hose (D) with JT03115, 2758 kPa (400
psi) Pressure Gauge (A).
Reason:
4. Run engine at wide open throttle.
To check for adequate clutch engagement pressure and
brake release pressure. 5. With brake pedal released and operator on seat, engage
PTO switch.
Test Equipment:
6. Observe pressure gauge.
• JT05486 Connector, 1/4 M NPT x 7/16-20 M 37°
Results:
• JT05483 Connector, 90° elbow, 7/16-20 M 37°,
7/16-20 F 37° Swivel • If pressure is at or above 1420 - 1517 kPa (206 - 220
psi) engagement valve is operating and engagement
• JT03017 Hose
pressure is OK. If there is a PTO engagement complaint,
• JT03115 2758 kPa (400 psi) Pressure Gauge inspect clutch disk for wear.
• If there is no pressure on gauge, see Electrical Section
to check engagement solenoid and circuit. Inspect PTO
engagement valve for proper installation, scoring, or
damage to solenoid shaft. If solenoid is operating, check
lube reduction valve orifice for plugging. Perform “Charge
Pump Flow and Pressure Test - At Charge Pump” on
page 361.

Power Train - Hydrostatic Tests and Adjustments - 363

 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
- Weak or broken clutch piston return spring.
- Engagement solenoid valve not releasing pressure,
keeping clutch engaged.

Transaxle Neutral Adjustment

Reason:
F
To ensure that machine does not creep when pedals are in
neutral.
E

Test Equipment:
• Hoist
• Jackstands (2)
NOTE: If creep is intermittent, inspect transmission
control linkage for binding or damage. Repair linkage
M55462
before adjusting transmission neutral.
• If pressure is low, perform same test on left-hand port
opposite test port checked above and compare pressure Procedure:
differential. If different, check solenoid valve (F) for sticking
or shim missing, or solenoid not functioning. If both
pressures are low, check PTO pressure control valve (E). c rotate
CAUTION: Avoid Injury! Rear wheels will
during adjustment or if transaxle is
• If pressure is low, inspect PTO pressure control valve
out of adjustment. Always support rear
spring or seat for damage and valve for scoring. Add shims
wheels with jackstands. Be cautious of
to increase pressure. If shims will not increase pressure,
rotating wheels.
check lube reduction valve orifice. Perform “Charge Pump
Flow and Pressure Test - At Charge Pump” on page 361. 1. Lift machine with a hoist and support rear wheels off the
Mid-PTO Brake Test ground.
2. Support rear axle with jackstands.
Reason:
PTO brake is not stopping implement within five seconds.
Also, insure PTO shaft does not rotate when PTO is off.

Procedure:
1. With implement installed, PTO on and engine at wide
open throttle.
2. Shut PTO off.
3. Observe the time it takes for implement to come to
complete stop.

Results:
• Implement stops within five seconds and stays stopped,
PTO brake is OK.
• Implement takes longer than specified time to stop or
M55443
continues to run, check the following:
NOTE: Fender deck was removed to illustrate
- Size of the implement may be too large or requires its own
adjustment location. Adjustment can be made
brake.
through right-hand side frame cutout.
- Weak or broken brake springs.
- Worn brake shoe or scored PTO clutch hub and gear
assembly.

Power Train - Hydrostatic Tests and Adjustments - 364

 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
Transaxle Control Linkage Adjustment

A B Reason:
To insure transmission returns to neutral and control pedals
are locked in neutral when brake is set.

Procedure:
1. Park machine safely.
2. Check transmission neutral adjustment and readjust if
not correct. (See “Transaxle Neutral Adjustment” on
M55442 page 364.)
3. Loosen lock nut (A).

c caution
CAUTION: Avoid Injury! Use extreme
when doing this adjustment. Drive
wheels are free to rotate. A B

4. Have someone activate seat safety switch, or use a

jumper wire to bypass the seat switch. C
D
5. Start engine and run at low idle.
6. With brakes disengaged, turn eccentric nut (B) forward
and backward until rear wheels stop turning.
7. Tighten lock nut. Make sure adjustment did not change. E
If adjustment changes, use wrench from rear of machine to
tighten lock nut.
8. Depress both forward and reverse speed pedals then
release to verify adjustment. Repeat adjustment as
necessary. MX14384

9. Lower machine to the ground. Remove seat switch

jumper wire if used.

Results: F
G
• If neutral will not hold, turn eccentric 180° and repeat
adjustment.
• If drive wheels continue to rotate, check for worn or
H
binding control linkage. Disconnect linkage and repeat
adjustment. I
J
• Wheels rotate after adjustment with control linkage
disconnected. Check swash plate shaft bushing for binding
or wear. Check neutral return spring, pump and motor valve
plate wear.
K

c wire
CAUTION: Avoid Injury! Remove jumper
from seat switch if installed. M
N

MX14163

Power Train - Hydrostatic Tests and Adjustments - 365

 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
3. Press brake pedal (A) and pull up on lever (B) to set Results:
parking brake. Be sure that brake pin (C) on brake shaft is
in latch (D) and forward shaft (H) pin (N) aligns in slot (E).
4. Press forward (F) and reverse (G) pedals and check for
movement. Pedals should remain locked in position. D

5. Remove spring pin holding pivot onto forward shaft (H),

and loosen jam nuts (M) on pivot (I), until pivot can be C
moved freely into slot on forward shaft (H).
6. Tighten jam nuts (M) on brake rod (K) to pivot (I),
making sure leaf spring (J) is positioned correctly to press E
against RIO switch (L).

Transaxle Linkage Full Forward Adjustment

F
Reason:
To set forward pedal height to insure maximum forward
speed. MX14269

• If forward pedal (E) is not within specifications, loosen

Procedure:
nuts (F) and move slotted front side (toward front of
1. Turn engine off. machine) of pedal up or down as needed. Tighten nuts.
• If reverse pedal (D) is not within specifications, loosen
nuts (C) and move slotted front side of pedal up or down as
needed. Tighten nuts.

Cruise Control Linkage Check and

Adjustment
Reason:
To ensure that cruise control will engage and disengage
A
properly.
B
First Procedure:
1. Put service-park brake in disengaged position, transaxle
in neutral.
MX13638

2. Measure the distance (A) between the front side of

forward pedal and top of pedestal and distance (B)
between the front side reverse pedal and top of pedestal.

Specifications:
Forward pedal to pedestal (A) . . . . . . 101.6 mm (4.0 in.) A
Reverse pedal to pedestal (B) . . . . . . 57.2 mm (2.25 in.)

MX14396

2. With engine not running, push down forward drive pedal

and engage cruise control lever (A) in several locations and

Power Train - Hydrostatic Tests and Adjustments - 366

 POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
with forward pedal all the way down. Release cruise control Results:
lever. • Forward drive pedal should disengage.
Results: • If cruise control does not disengage, check hydrostatic
control linkage adjustment or for a disconnected cruise
• Drive pedal should remain in down position.
control disconnect rod (F).

Third Procedure:

A
1. Reset cruise control.
2. Tap forward pedal down and release.

Results:
F • Cruise should disengage.
• If cruise does not disengage check for binding pivots.
E Inspect linkage component for wear or damaged
conditions. Replace as necessary.

MX14163

A - Cruise Control Lever

B - Control Rod
C - Return Spring
D - Cruise Control Stop
E - Cruise Control Latch
F - Cruise Control Disconnect Rod
• If pedal will not stay engaged, check condition of teeth
on cruise control latch (E) and stop (D). Replace if worn.

Second Procedure:
1. Reset cruise control.
2. Engage service-park brake.

Power Train - Hydrostatic Tests and Adjustments - 367

 POWER TRAIN - HYDROSTATIC REPAIR
Repair

Foot Control Linkage Removal and Installation

F
A
B C
D

G
H
AR B

AS AT
L
AR
AQ

I J
AO AK
AP K M
N
O

AM
AN
AJ
AL L
AK AB
AA

Q
AC
AD
Z
AF R P
X
AE
AF

Y S
X AD
AI L

U X
W R
V T

AG U
AH

L S

MX14417

Power Train - Hydrostatic Repair - 368

 POWER TRAIN - HYDROSTATIC REPAIR
A - Knob Removing:
B - Spring Pin
C - Washer
D - Coupling
A
E - Screw
F - Rod, Cruise Control
G - Plug
H - Screw F
I - Seal
J - Bushing K
K - Latch, Cruise Control AS
L - Flange Nut
M - Extension Spring
N - Pad
O - Pedal, Forward AL
P - Flange Nut G AJ
Q - Screw
R - Screw
S - Bracket M
Z
T - Pad AK
U - Pedal, Reverse
V - Washer (6 used)
W - Ball Bearing MX14163
X - Bearing Support
1. Block machine wheels and release parking brake.
Y - Cotter Pin
Z - Shaft, Forward NOTE: Remove cruise control linkage. Then,
AA- Carriage Bolt disassemble foot control linkage.
AB- Stop 2. Remove extension spring (M) from forward shaft (Z) and
AC- Ball Bearing cruise control latch (K).
AD- Flange Nut 3. Remove handle (A), and cotter pin holding cruise control
AE- Washer rod (F) in position on machine. Lower rod assembly from
AF- Carriage Bolt under machine frame.
AG- Bracket (welded to frame) 4. Remove spring locking pin (AK) and disconnect control
AH- Shaft, Reverse Pedal rod (AL) from transaxle control arm (AJ).
AI - Bearing Housing 5. To remove cruise control latch (K), remove plug (G) and
AJ- Arm, Transaxle cap screw/lock nut and associated parts holding it onto
AK- Spring Locking Pin machine frame.
AL- Rod, Control 6. Remove spring locking pin and pivot (AS) from forward
AM- Cap Screw shaft (Z), and remove control rod (AL) and pivot from
AN- Strap machine.
AO- Switch, Stop
AP- Lock Nut
AQ- Leaf Spring
AR- Nut
AS- Pivot
AT- Washer

Power Train - Hydrostatic Repair - 369

 POWER TRAIN - HYDROSTATIC REPAIR
[Link] remove stop (AB), remove lock nut (L), and inspect
stop for broken or worn teeth. Replace, as necessary.
[Link] remove bearing housing (AI), remove lock nut (AD),
U
and inspect housing for wear or damage. Replace, as
necessary.
P
Installing:
S O

P Z
S W
L
L AD
MX14269
AI
7. Remove nuts (P) and bolts holding forward (O) and Y
reverse (U) pedals onto brackets (S). S
8. Loosen nuts (L) and remove brackets (S) from both
Y X W
forward and reverse shafts.
V

AB AG
AH
L S

MX14305

W AC Z 1. After replacing all worn/damaged parts, install forward

AD shaft (Z) and reverse shaft (AH) through welded frame
bracket (AG).
AI 2. Making sure all bearings (W) and supports (X and AI)
Y are in place, install washer(s) (V) and cotter pins (Y)
S securing both forward and reverse shafts in place.
AD

Y X W
V

U
AG
AH
S P

MX14305 O
S
9. Remove cotter pin (Y), washer(s) (V), and remove
reverse (AH) and/or forward (Z) shaft.
[Link] bearings (W), and inspect for damage or wear.
Replace as necessary.
[Link] supports (X) are press fit into welded frame P
S
bracket (AG). If worn or damaged, replace. Press new L
support onto bracket. L AD

[Link] remove bearing (AC), remove lock nut (AD), and MX14269
inspect bearing for wear or damage. Replace, as 3. Install brackets (S) onto forward and reverse shafts, and
necessary. tighten nuts (L) securing brackets to shafts.

Power Train - Hydrostatic Repair - 370

 POWER TRAIN - HYDROSTATIC REPAIR
4. Install forward (O) and reverse (U) pedals onto brackets Shift Lever Linkage (MFWD) Removal and
(S), and secure with nuts (P) and bolts. Installation

A
A
B

C
F

D G
K
AS
E

H
F

AL J K
P
G AJ I

L
M

M O
Z L
AK N

MX14347

MX14163 A - Cap
5. Raise control rod (AL) into position, and secure pivot B - Lock Nut
(AS) onto forward shaft (Z) with spring locking pin. C - Knob
D - Lever
6. Raise control rod (AL) onto transaxle control arm (AJ),
E - Torsion Spring
and secure with spring locking pin (AK).
F - Bolt
7. Secure cruise control latch (K), with associated G - Cap Screw
hardware, with cap screw and lock nut. Install plug (G). H - Pivot
8. Raise cruise control rod (F) into position, and secure I - Lock Nut
onto end of cruise control latch (K) with cotter pin. Install J - Linkage
handle (A). K - Spring Locking Pin
9. Install extension spring (M) onto forward shaft (Z) and L - Washer (2 used)
cruise control latch. M - Stud
N - Nut
[Link] parking brake, and adjust foot control linkage. (See
“Transaxle Control Linkage Adjustment” on page 365.) O - Lever
P - Flange Nut
1. Pull off cap (A), and remove nut (B) and knob (C).
2. Remove fender deck. (See “Fender Deck Removal and
Installation” on page 552 in the Miscellaneous section.)
3. Remove spring pin (K) and washer (L), and remove pin
(M) from shift arm on hydrostatic transmission motor.
4. Remove lock nut (I), cap screw (G), and pivot (H)
holding components to top of frame.
5. Disassemble components as necessary. Replace worn
or defective parts and reassemble in reverse order.

Power Train - Hydrostatic Repair - 371

 POWER TRAIN - HYDROSTATIC REPAIR
Oil Cooler Removal and Installation

N
L

A
I J J O

B
H

G
B
F
E

MX14392

A - Selective Control Valve Q

B - Fitting
C - Hydraulic LIne
D - Hose Clamp P
E - Clamp
F - Screw
G - Hydraulic LIne
H - Hose
I - Power Steering Control Valve
J - Hose Clamp
K - Oil Cooler
L - Retainer
M - Hose
N - Hose Clamp MX14393
O - Adapter 3. Remove side panel from instrument panel assembly,
1. Loosen and move clamp (D) slightly to remove hose (H) and pull handle (P) to remove screen (Q).
from hydraulic line (C), and drain transaxle (cooler) fluid
into a clean container.
2. Loosen and move clamp (N) slightly to remove hose (M)
from adapter (O) on transaxle, and drain transaxle (cooler)
fluid into the same clean container as in step 1.

Power Train - Hydrostatic Repair - 372

 POWER TRAIN - HYDROSTATIC REPAIR

R K

J
M

MX14394

4. Loosen and move clamps (J) on both sides of cooler

and remove lines (M and H) from cooler (K).
5. Pull and turn fasteners (L) so that cooler assembly can
be removed from radiator coolant frame (R).

Installation is done in the reverse order of removal.

• If removed, tighten fittings on selective control valve (A)
and power steering control valve (I) to 38 N•m (28 lb-ft).
• Fill transaxle fluid up to appropriate level.

Power Train - Hydrostatic Repair - 373

 POWER TRAIN - HYDROSTATIC REPAIR
Control Arm and Damper Removal and Installation
NOTE: Fuel tank can be removed for easier access to control arm and damper.

A
B D

H
E G
F F

MX14183 5. Remove control arm.

A - Control Arm 6. Install control arm the same as removal, and install
B - Washer washer and cap screw. Tighten cap screw (C) to 73 N•m
C - Main Cap Screw (54 lb-ft).
D - Foot Control Rod NOTE: If removed, use medium strength thread lock
E - Spring Locking Pin and sealer on pivot stud (H) threads.
F - Washer
7. Install damper with open end of clamp facing down.
G - Damper
8. Install remaining washers and spring locking pins.
H - Pivot Stud
I - Clevis Pin
J - Spring Locking Pin
1. Remove spring locking pins (E) and washers (F) from
both sides of damper (G).
2. Slide damper off of pivot stud (H) and clevis pin (I).
Inspect and, if defective, replace damper as an assembly.
3. To remove control arm (A), remove spring locking pin (J)
and disconnect foot control rod (D) from control arm.
NOTE: Access to cap screw (C) is through hole in right
frame.
4. Remove cap screw (C) and washer (B) from control
arm.

Power Train - Hydrostatic Repair - 374

 POWER TRAIN - HYDROSTATIC REPAIR
Differential Lock Linkage Inspection

D
E
H
G
B

A
F

MX14418
C
A - Pin
B - Washer
B D
C - Rear Differential Lock Rod
A
D - Differential Lock Arm
E - Bushing
F - Spring Locking Pin
G
G - Torsion Spring
H - Bushing
E
I - Differential Lock Pedal Rod
J - Knob
G
K - Screw F

1. Disassemble parts from differential lock linkage. MX14308

2. Inspect linkage components for wear or damaged 4. Disconnect hose (A) and loosen clamp for hose (F) from
conditions. Replace as necessary. pump housing (C).
3. Install short leg of spring to the rear of arm. 5. Remove tube adapter (E) and adapter (B).
6. Remove two short (G) and one long (D) cap screw.
Charge Pump Removal and Installation
IMPORTANT: Avoid damage! Do not drop pump
NOTE: Approximate capacity of hydrostatic powertrain gerotor (H) or lose key (I). Damage to machined
is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt) surfaces will cause poor performance and
for all-wheel steering. premature failure.
1. Remove fender deck. (See “Fender Deck Removal and
Installation” on page 552 in the Miscellaneous section.)
2. Remove drain plug to drain oil from transaxle.
3. Remove drive shaft. (See “Drive Shaft Removal and
Installation” on page 378.)

Power Train - Hydrostatic Repair - 375

 POWER TRAIN - HYDROSTATIC REPAIR
• Tighten long cap screw (D) to 39 N•m (29 lb-ft).
• Tighten tube adapter (E) and adapter (B) to 24 - 35 N•m
H
I (18 - 26 lb-ft).
• Tighten hose (A) to 24 - 35 N•m (18 - 26 lb-ft).

M81188

Installation is done in the reverse order of removal.

• Tighten two short cap screws (G) to 25 N•m (18 lb-ft).

Charge Pump Disassembly and Assembly

A B G

C F
E H
D
Y
I
X

J
W
K
L

M
V

N
L
S R J
T
O
U Q
P

MX14321 G - O-Ring
A - Cap Screw (2 used), M10 x 65 H - Plug
B - Plug I - Shims
C - O-Ring J - Pin
D - Pump Body K - O-Ring
E - Pressure Valve L - O-Ring
F - Spring M - O-Ring

Power Train - Hydrostatic Repair - 376

 POWER TRAIN - HYDROSTATIC REPAIR
N - Outer Rotor Directional Control Valves
O - Key
P - Inner Rotor Removal and Installation:
Q - O-Ring 1. Remove fuel tank. (See “Fuel Tank Removal and
R - Plug Installation” on page 553 in the Miscellaneous section.)
S - Reducing Valve
T - Spring
U - Reducing Plug
A
V - O-Ring
W - Bushing
X - Seal
Y - Cap Screw, M10 x 105
NOTE: Charge pressure control valve and pressure B
reducing valve can be removed when the charge pump
is in the machine. To inspect valve seats and bores, the
pump must be removed. M81180

1. Disassemble all parts of charge pump (D). 2. Remove free-wheeling control lever (A).
2. Inspect O-rings (C, K, L, M, and Q) for cuts or damage. 3. Remove directional control valves (B).
Replace as necessary.
Installation is done in the reverse order of removal.
NOTE: Pump gerotor (N and P), seal (X), body (D), and
• Tighten directional control valves to 35 N•m (26 lb-ft).
pressure reducing valve (S) parts must be replaced as
a set. Disassembly, Inspection and Assembly:
3. Inspect gerotor charge pump parts (N- P). Replace
parts if worn, chipped, scored or damaged.
B
A
4. Remove plug (U) to remove pressure reducing valve
parts (V, S, and T). C
5. Inspect parts for scoring, wear or damage.
6. Check small orifice in reducing valve (S) spool for D
D
obstruction.
7. Replace parts if necessary. E

8. Remove plug (H) to remove charge pressure relief valve E

parts (E, F, G, and I). F

9. Inspect parts for scoring, wear or damage.

M81181ae
[Link] parts if necessary.
A - Reverse Control Valve (with orifice)
[Link] seal (X) and bushing (W) for wear or damage. B - Orifice
[Link] bushing is removed, apply clean hydraulic oil to C - Forward Control Valve
bushing and use a disk driver to install bushing to bottom of D - O-Ring
bore.
E - Backup Ring
[Link] seal is replaced, apply clean hydraulic oil to new seal. F - O-Ring
Install seal with open side into pump body. Push seal to
bottom of bore. 1. Disassemble parts from directional control valves.

[Link] clean hydraulic oil to all machined surfaces before 2. Inspect O-rings and backup rings for damage.
assembly. 3. Plunger pin must move freely.
4. Internal valve must move freely when valve is shaken.
5. Make sure orifice and all passages are free of any
obstruction.

Power Train - Hydrostatic Repair - 377

 POWER TRAIN - HYDROSTATIC REPAIR
Drive Shaft Removal and Installation
IMPORTANT: Avoid damage! The reverse control
valve must be installed in the left port. The Removing:
control valve can be identified by a small orifice
drilled into a land between the two sets of valve 1. Remove fuel tank. (See “Fuel Tank Removal and
passageways. Installation” on page 553 in the Miscellaneous section.)

6. Assemble parts.

Hydrostatic Pressure Relief Valve (45 Loader)

Installation
B

IMPORTANT: Avoid damage! The 45 loader is

shipped complete with a hydrostatic pressure A
relief valve which must be installed in place of
the transaxle’s forward control valve. The relief
valve limits the peak hydrostatic pressures in
the transaxle. This protects the transaxle from
unnecessary stress for longer life. Operation of
a front end loader on a machine without the
transaxle hydrostatic pressure relief valve will
void the machine warranty. If a 45 loader is taken MX14307
off one machine and used on another, or another
brand of loader is used, it is important that the 2. Loosen cap screws (A).
loader machine be equipped with the transaxle
relief valve.

M81174

3. Remove three cap screws (C) to remove drive shaft (B)

from under machine frame.

M81183

1. Remove forward control valve and replace with

hydrostatic pressure relief valve (A).
2. Tighten valve to 35 N•m (26 lb-ft).

Power Train - Hydrostatic Repair - 378

 POWER TRAIN - HYDROSTATIC REPAIR
Disassembly, Inspection and Assembly: PTO Solenoid Valve
Removal and Installation:
A

E IMPORTANT: Avoid damage! Do not bend, twist

or damage solenoid armature. Do not damage
machined surfaces or sharp edges of spool or
sleeve. PTO will not function or will function
B erratically if spool, sleeve or armature is
damaged.

D F
C

M81172ae

A - Cap Screws (2 used) A

B - Drive Shaft
C - Cap Screws (3 used)
M55442
D - Isolator
E - Lube Fitting 1. Disconnect solenoid connector (F) from wiring harness.

1. Disassemble drive shaft. 2. Remove nut (A) and O-ring (B).

2. Inspect U-joint for wear.

3. Inspect isolator for cracks or wear.
4. Install isolator with bosses toward drive shaft.
5. Assemble drive shaft.

Installing:
1. Install drive shaft from under frame and attach to
transaxle pump shaft.
2. Raise front of drive shaft to engine pulley and tighten
cap screws (C) to 40 N•m (30 lb-ft).
3. Tighten two cap screws (A).
M81115a

NOTE: Nut (A) and O-ring (B) were already removed

in step 2.
3. Remove solenoid cover (C), O-ring (D), and solenoid
coil (E). Note order and direction of valve components for
reassembly.
4. Remove solenoid armature assembly using JDG757A
Solenoid Valve Socket (N).
5. Carefully remove valve components from PTO cover.
NOTE: Check bottom of bore for “wave” washer.
6. Clean and inspect parts for damage. Replace if

Power Train - Hydrostatic Repair - 379

 POWER TRAIN - HYDROSTATIC REPAIR
necessary.
7. Place wave washer in case cover.
F
Disassembly, Inspection and Assembly:
NOTE: Sleeve and spool must be replaced as a set.

IMPORTANT: Avoid damage! Be sure large land

(H) on sleeve and oil hole in spool are facing
away from PTO case cover. K

A D E
C
B
M81123
F
7. Use JDG757A Solenoid Valve Socket (K) to tighten
solenoid armature (A) to 22 N•m (195 lb-in.).

L
J H G
I

M78316a

A - Wave Washer M
N
B - Spool
C - Sleeve M78310

D - O-Ring 8. Slide solenoid coil (N) onto solenoid armature. Install O-

E - Flats ring (L) and plastic nut (M) (do not tighten plastic nut at this
time.)
F - Solenoid Armature
G - Gasket
H - Large Land on Sleeve
I - Oil Hole
J - Spring
1. Disassemble PTO solenoid valve.
2. Inspect parts for wear or damage.
P
3. Install spool into sleeve so the end with the oil hole is
toward the large land on the sleeve.
4. Place spring into recess in end of spool.
5. Install sleeve assembly so smaller lands go into the PTO O
cover first.
6. Install gasket and O-ring. M55442

9. Position solenoid coil wire leads (P) to the right and

approximately 45° above horizontal.

IMPORTANT: Avoid damage! When tightening

plastic nut be sure to tighten nut to exact
specifications. Nut has a very low torque. Any
overtightening will damage the armature coil.

[Link] plastic nut (O) to 4.9 N•m (43 lb-in.).

Power Train - Hydrostatic Repair - 380

 POWER TRAIN - HYDROSTATIC REPAIR
PTO Relief Valve Removal and Installation PTO Brake Removal and Installation
NOTE: Approximate capacity of hydrostatic powertrain
is 6.6 L (7.0 qt) for two-wheel steering and 5.7 L (6.0 qt)
for all-wheel steering.

A
c cool
CAUTION: Avoid Injury! Allow transaxle to
before draining fluid. Hot fluid can
cause serious burns.

B
M81189a A

1. Remove relief valve plug.

2. Install relief valve plug (A) and tighten to 25 N•m (19 lb-
ft).
C
PTO Relief Valve Disassembly, Inspection and
Assembly

A B C D
D

MX14167

1. Remove plug to drain oil from transaxle.

2. Remove fuel tank (A). (See “Fuel Tank Removal and
Installation” on page 553 in the Miscellaneous section.)
3. Remove hitch plate (D).
M78309

1. Disassemble PTO relief valve. NOTE: If rear PTO is installed, remove necessary rear
PTO components before rear transaxle cover removal.
2. Check relief valve plunger and bore for scoring, nicks or (See “Rear PTO Removal and Installation” on
burrs. Replace if necessary. page 387.)
3. Install spring (B), gasket (C), relief valve plunger (A),
4. Remove PTO solenoid harness (B) and rear transaxle
and plug (D) in PTO cover.
cover (C). (If optional rear PTO is installed (not shown
above), remove rear PTO. See “Rear PTO Removal and
Installation” on page 387.)
5. Remove control arm damper, to gain access to three
cap screws holding PTO brake cover to transaxle side
cover. (See “Control Arm and Damper Removal and
Installation” on page 374.)

c spring
CAUTION: Avoid Injury! PTO brake cover is
loaded. Remove cap screws evenly
to release spring force.

6. Installation is reverse of removal.

Power Train - Hydrostatic Repair - 381

 POWER TRAIN - HYDROSTATIC REPAIR
PTO Brake Disassembly, Inspection and Assembly

G
F
E
B
D
H
A C
D

MX14331 2. Remove PTO clutch assembly (N) and brake shoe (M)
A - Collar, Brake Pin together.
B - O-Ring NOTE: PTO brake pin, piston, springs, and O-Rings,
C - Pin, PTO Brake etc., (parts C through I), must be replaced as a set.
D - Snap Ring (2 used) 3. Check pin and piston for burrs, scoring or wear.
E - Piston
4. Replace brake shoe if grooves in shoe contact surface
F - Stopper
are not visible.
G - Spring, Inner
5. Inspect O-rings for cuts or damage.
H - Spring, Middle
I - Spring, Outer 6. Inspect springs for cracks or damage.
J - Cover 7. Apply petroleum jelly to O-rings and seal on end of PTO
K - Cap Screw (3 used) clutch shaft.
L - O-Ring 8. Install piston assembly and clutch assembly.
M - PTO Brake Shoe 9. Clean mating surface of cover and case. Be sure
N - PTO Clutch Assembly threaded holes are clean.
1. Carefully pull piston assembly from case using a pliers. [Link] a bead of John Deere Form-in-Place Gasket to
Do not damage pin. cover mating surface.

Power Train - Hydrostatic Repair - 382

 POWER TRAIN - HYDROSTATIC REPAIR
1. Remove plug to drain oil from transaxle.
IMPORTANT: Avoid damage! Be sure cover is
aligned with transaxle case and installed within
3 mm (1/8 in.) of case before tightening cap Q
P
screws. Major damage can occur to cover and/or
case if cover is not installed properly before
tightening cap screws.

Transaxle Cover Cap Screw Torque Specifications: R

Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)

PTO Drive Train (Mid-PTO) Removal and

Installation
NOTE: Approximate capacity of hydrostatic powertrain T
is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt) S
for all-wheel steering. MX14167

Removing: 2. Remove fuel tank (P).

3. Remove hitch plate (S).

c cool
CAUTION: Avoid Injury! Allow transaxle to
before draining fluid. Hot fluid can
4. Disconnect PTO solenoid harness (Q).
5. Remove rear transaxle cover (R) or transaxle cover
cause serious burns. plate (T).

D E
A

I C
N B

M
O P
I

F
K
G
H
J
I

MX16046 E - Seal
A - PTO Clutch Assembly F - Needle Bearing
B - Snap Ring G - Washer
C - Needle Bearing H - Cap Screw
D - Washer I - Ball Bearing

Power Train - Hydrostatic Repair - 383

 POWER TRAIN - HYDROSTATIC REPAIR
J - Snap Ring 5.6L (6 qts) for all-wheel steering models using JOHN
K - Mid-Mount PTO Gear DEERE LOW VISCOSITY HY-GARD™ (J20D as required)
L - PTO Output Shaft to cross-hatched area of dipstick.
M - Snap Ring Rear Cover Cap Screw Torque Specifications:
N - PTO Idler Gear
Used Transaxle Case . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
O - PTO Idler Shaft
New Transaxle Case. . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
P - Washer
Internal Cap Screws. . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
6. Remove PTO clutch assembly.
PTO Drive Train (Mid and Rear PTO) Removal
IMPORTANT: Avoid damage! When removing
snap ring (B), be sure not to lose needle bearing and Installation
(C) or washers (D). NOTE: Approximate capacity of hydrostatic powertrain
7. Remove PTO idler gear assembly. is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt)
for all-wheel steering.
8. Remove PTO gear.
9. Left axle must be removed to remove PTO output shaft Removing:
assembly. (See “Rear Axle Assembly (Two Wheel Steer
Models) Removal and Installation” on page 413.)
[Link] ball bearings and needle bearing for smooth
c cool
CAUTION: Avoid Injury! Allow transaxle to
before draining fluid. Hot fluid can
rotation. cause serious burns.
NOTE: Idler gear and shaft must be replaced as a set. 1. Remove plug to drain oil from transaxle.
[Link] gears and splines for missing or chipped teeth,
wear or damage. Replace parts if necessary. W

Installing:
V
1. If replaced, install new needle bearing from inside case
with bearing identification marks toward the inside of the
case. Push bearing tight against shoulder in bore.
2. Install new seal with the open, spring side towards the
inside of the case.
3. Push seal against shoulder in bore.
X
4. Install mid-mount PTO gear so side with the longer Y
center hub is towards bearing. AB
5. Clean mating surfaces of rear cover and case. Be sure
Z
threaded holes are clean and two O-rings are in position in AA AA
rear cover. MX14332
6. Apply petroleum jelly to seal on shaft of PTO clutch 2. Remove fender deck and fuel tank (V).
assembly.
3. Remove roll pin and rear PTO control rod (AB).
7. Apply a bead of John Deere Form-in-Place Gasket to
4. Remove rear PTO shield (X).
cover mating surface.
5. Remove hitch plate (Z).
IMPORTANT: Avoid damage! Be sure cover is 6. Disconnect two PTO switch connectors (AA).
aligned with transaxle case and installed within
3 mm (1/8 in.) of case before tightening cap 7. Remove rear PTO cover (Y).
screws. Major damage can occur to cover and/or 8. Disconnect PTO solenoid harness (W).
case if cover is not installed properly before
tightening cap screws.

8. Install transaxle drain plug. Refill transaxle with

approximately 6.6L (7 qts) for two-wheel steer models and

Power Train - Hydrostatic Repair - 384

 POWER TRAIN - HYDROSTATIC REPAIR
9. Remove cap screws (AC) (9 used) to remove rear cover
(AD).

AC

AD

MX16048

A
D E

U S
C
B

T
P
Q
S

R
O

N
S
M

L
I
K J

MX16047 C - Needle Bearing

A - PTO Clutch Assembly D - Washer
B - Snap Ring E - Seal

Power Train - Hydrostatic Repair - 385

 POWER TRAIN - HYDROSTATIC REPAIR
F - Snap Ring
G - Spacer
H - Ball Bearing
I - Mid-Mount and Rear-Mount PTO Gear
J - Needle Bearing
AC
K - Spline Collar
L - Snap Ring
M - Cap Screw (2 used)
N - Washer
O - Needle Bearing
P - Washer AD
Q - PTO Idler Shaft
R - PTO Output Shaft
S - Ball Bearing MX16048
T - Snap Ring 1. Clean mating surfaces of rear cover (AD) and transaxle
U - PTO Idler Gear case. Be sure threaded holes are clean and two O-rings
[Link] PTO clutch assembly. are in position in rear cover.
2. Apply petroleum jelly to seal on shaft of PTO clutch
IMPORTANT: Avoid damage! When removing assembly.
snap ring (B), be sure not to lose needle bearing
3. Apply a bead of John Deere Form-in-Place Gasket to
(C) or washers (D).
rear cover mating surface.
[Link] PTO idler gear assembly.
IMPORTANT: Avoid damage! Be sure rear cover
[Link] snap ring (L), spline collar (K), and remove
(AD) is aligned with transaxle case and installed
mid-mount and rear-mount PTO gear assembly (I).
within 4 mm (1/8 in.) of case before tightening
[Link] axle must be removed to remove PTO output shaft cap screws (AC). Major damage can occur to
assembly. Inspect ball bearings and needle bearings for cover and/or case if cover is not installed
smooth rotation. properly before tightening cap screws.
[Link] gears and splines for missing or chipped teeth, 4. Carefully position the rear cover (AD) on the transaxle
wear or damage. Replace parts if necessary. and onto the lower dowel pin. Use a pry bar between the
PTO and frame to carefully move the PTO approximately
Installing:
1.5 mm (1/16-in.) to the right to align the top of the cover
with the upper dowel pin. Secure with cap screws (AC) (9
IMPORTANT: Avoid damage! Be careful not to
used).
get too much sealant in area of two upper O-
rings in rear cover (AD). Sealant should be Rear Cover Cap Screw Torque Specifications:
applied outside of the grooves surrounding each
O-ring. DO NOT fill groove with sealant. Purpose Used Transaxle Case . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
of groove is to stop excess sealant from moving New Transaxle Case. . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
O-ring during reassembly.
Internal Cap Screws. . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)

Power Train - Hydrostatic Repair - 386

 POWER TRAIN - HYDROSTATIC REPAIR
Rear PTO Removal and Installation
W
NOTE: Approximate capacity of hydrostatic powertrain
is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt)
V for all-wheel steering.

Removing:

c cool
CAUTION: Avoid Injury! Allow transaxle to
before draining fluid. Hot fluid can
X cause serious burns.
Y 1. Remove plug to drain oil from transaxle.
AB

Z
AA AA
MX14332

5. Apply a bead of John Deere Form-in-Place Gasket to

PTO gear case (Y) mating surface.
D
6. Shift PTO lever (AB) to the middle position
7. Carefully position the PTO gear case assembly (Y) on
the transaxle. C

E
IMPORTANT: Avoid damage! Be sure PTO B
gearbox cover (Y) is aligned with rear cover and F
installed within 4 mm (1/8 in.) of cover before A
tightening cap screws. Major damage can occur
H G
to both covers and transaxle case, if PTO cover H
is not installed properly before tightening cap MX14332
screws. 2. Remove roll pin and rear PTO control rod (A).
8. Secure PTO to transaxle with cap screws. 3. Remove rear PTO shield (E).

Rear PTO Gear Case Cap Screw 4. Remove hitch plate (G).
Torque Specifications: 5. Disconnect two PTO switch connectors (H).
Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft) NOTE: Remember to install three different sized cap
New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) screws in original holes as removal.
6. Remove four M12 x 40 (D), two M8 x 110 (C), and three
9. Install shifter (AB), PTO shield (X), and hitch plate (Z).
M8 x 50 (B) cap screws and PTO assembly (F).
[Link] PTO switch connectors (AA)
[Link] PTO solenoid harness (W).
[Link] transaxle drain plug. Refill transaxle with
approximately 6.6L (7 qts) for two-wheel steer models and
5.6L (6 qts) for all-wheel steering models using JOHN
DEERE LOW VISCOSITY HY-GARD™ (J20D as required)
to cross-hatched area of dipstick.
[Link] any additional items removed prior to PTO.

MX16048

Power Train - Hydrostatic Repair - 387

 POWER TRAIN - HYDROSTATIC REPAIR
7. Remove snap ring (I) and drive gear set (J). Inspect 5. Inspect rear PTO case (C) components. Replace as
parts and replace as necessary. necessary.
6. Apply clean hydraulic oil to O-ring (D) before installation.
Disassembly and Assembly:
7. If shifter fork (N) was disassembled, install spring (O)
and ball (P) in fork. While compressing ball and spring,
C
install fork shaft (M). Be sure ball fits into grooves of shaft.
8. With fork groove of shift collar away from case, install
B shifter fork and collar. Be sure arm of shifter shaft (E) fits
A into slot of shifter fork.
NOTE: Install bearings with writing/numbers facing
gears in cover assembly.

Q
E
D

AV G
L M MX16059

I 9. Remove bearing (Q) and bearing (R), noting markings

on outer bearing races.
H

U
W
J V

L
T
S

MX14325

1. Remove cover from PTO gear case (C). X

2. Remove cap screw (A) and plate (B), and pull shifter Y
shaft (E) from PTO gear case (C). Replace O-Ring (D). R
3. Remove shift collar (F) and shifter fork (N) assembly
AB Z
together.
AC AA
4. Remove tow relief valve (L) if necessary. Remove and
AD
replace O-rings (G through L).
MX16060
NOTE: If shift collar replacement is necessary, the rear
PTO idler gear and rear PTO input gear (in the rear PTO [Link] rear PTO gear (S), and collar (T) from PTO
cover) must be replaced also. The three gears are shaft (U).
available as a set.

Power Train - Hydrostatic Repair - 388

 POWER TRAIN - HYDROSTATIC REPAIR
NOTE: If rear PTO input gear (AB) replacement is
necessary, the shift collar (F) (in the rear PTO case)
and rear PTO idler gear (X) must be replaced also. The W
three gears are available as a set. Rear PTO gear (S)
and rear PTO idler pinion (AC) must be replaced as a
set.
[Link] washer (AD), PTO idler pinion (AC), PTO input
gear (AB). Remove idle shaft (AA), and bearing (Y) from M78313
cover. Press bearing from shaft.
• If removed, install O-rings and ball switches (W). DO
[Link] snap ring (Z), and PTO idler gear (X) from rear NOT overtighten. Tighten to 34 N•m (25 lb-ft).
PTO shaft (V).
[Link] necessary, remove ball switch (W) and O-Ring. Installing:
1. Clean mating surface of cover and gear case. Be sure
U threaded holes are clean.
AG

AF

AE A

AJ

AH
B

V AI
C

MX16061 MX16048
[Link] snap ring (AE) and press bearing (AF) from 2. If removed, install drive gear set (C) and snap ring (B).
PTO shaft (U). Inspect shaft for wear or damage, and
replace if necessary. 3. Apply a bead of John Deere Form-in-Place Gasket to
PTO cover to gear case, and gear case to transaxle (A)
[Link] and replace oil seal (AG) from cover. Install mating surfaces.
new seal into cover with the closed side of the seal into the
bore first. Use a disk driver to push seal to bottom of bore. IMPORTANT: Avoid damage! Carefully lower
NOTE: Recall writing/numbers on all outer bearing cover assembly onto case, making sure
races, and install bearings in reverse order as removal. bearings fit into bores and gears mesh properly.
Be sure cover is installed within 3 mm (1/8 in.) of
[Link] snap ring (AJ), and remove rear PTO input case before tightening all cap screws to 25 N•m
shaft (U) from cover. Remove bearing (AH) and large (18 lb-ft). Major damage can occur to cover and/
bearing (AI) from shaft. or case if cover is not installed properly before
[Link] all parts and replace as necessary. Assembly is tightening cap screws.
reverse order of disassembly.
• Install bearings (AI and AH) on rear PTO input shaft
(V) tight against shoulder.

Power Train - Hydrostatic Repair - 389

 POWER TRAIN - HYDROSTATIC REPAIR
Transaxle Removal and Installation
NOTE: Approximate capacity of hydrostatic powertrain
is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt)
for all-wheel steering.
1. Park machine safely, and disconnect negative battery
G cable.

F c cool
CAUTION: Avoid Injury! Allow transaxle to
before draining fluid. Hot fluid can
H
E cause serious burns.
I
D 2. Remove plug to drain oil from transaxle.

K J
K
MX14332

4. Install PTO assembly (I) on the two alignment bushings, A

and tighten four M12 x 40 (G), two M8 x 110 (F), and three
M8 x 50 (E) cap screws to specification below.
5. Connect two PTO switch connectors (K).
6. Install rear PTO control rod (D), and roll pin.
7. Install rear PTO shield (H), and secure with four cap
screws to specification below. B
8. Install hitch plate (J).
9. Install transaxle drain plug. Refill transaxle with C
approximately 6.6L (7 qts) for two-wheel steer models and E
5.6L (6 qts) for all-wheel steering models using JOHN D D
DEERE LOW VISCOSITY HY-GARD™ (J20D as required) MX14332
to cross-hatched area of dipstick. 3. Remove fuel tank (A). (See “Fuel Tank Removal and
Installation” on page 553 in the Miscellaneous section.)
Specifications:
4. If equipped, remove rear PTO shield (B), disconnect
PTO Shield Cap Screws . . . . . . . . . . . . 54 N•m (40 lb-ft)
rear PTO control rod (C), and the two (2) PTO switch
M8 Bolts. . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft) connectors (D).
M12 Bolts. . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
5. Remove hitch plate (E).

MX14307

6. Disconnect charge pump-to-steering valve hose (H) and

Power Train - Hydrostatic Repair - 390

 POWER TRAIN - HYDROSTATIC REPAIR
oil cooler-to-charge pump hose (F).
N
7. Remove drive shaft (G) from transaxle. (See “Drive N
O
Shaft Removal and Installation” on page 378.) M

I T

S R

MX16048
J
Optional rear PTO removed in photo; rear PTO
MX16087
does not need to be removed for transaxle
8. Disconnect brake linkage (I). removal.
9. For AWS machines only, remove nut (J) and disconnect [Link] rear of machine, and install jack stands.
rear intermediate linkage. [Link] rear tires (Q).
[Link] lift cylinder pin (R), snap rings (M) and
bushings (N) to remove rockshaft (P).
[Link] PTO solenoid connector (O).
[Link] transaxle to a hoist.
[Link] four cap screws (T) and lock nuts (S) on both
sides of transaxle, and carefully remove transaxle.
K
[Link] transaxle as necessary.

Installation is done in the reverse order of removal.

• Connect drive shaft while installing transaxle.
• Tighten four transaxle mounting lock nuts (S) to 71 - 106
MX16090 N•m (52 - 78 lb-ft).
[Link] below hydraulic lift cylinder, remove spring locking
pin and washer, and disconnect differential lock linkage (K).

MX16051

[Link] foot control linkage (L).

Power Train - Hydrostatic Repair - 391

 POWER TRAIN - HYDROSTATIC REPAIR
Differential Lock Shaft Disassembly and 3. Inspect shaft (E) and fork for wear or damage. Replace
Assembly parts as necessary.
Installation is reverse of removal.

c compression.
CAUTION: Avoid Injury! Springs are under
Carefully remove roll pin and
NOTE: Install long hub of fork towards transaxle.

release spring force slowly to prevent

personal injury.

G
C
F
E
D

B C
H
A
A

N O

M
I

K
J

MX14317

A - Snap Ring (2 used)

B - Spring
C - Sleeve (2 used)
D - Fork
E - Shaft
F - Spring
G - Washer
H - Roll Pin
I - Shift Collar
J - Cap Screw
K - Plate
L - Fulcrum, Differential Lock
M - Washer
N - Cotter Pin
O - Seal
1. Remove roll pin (H), washer (G), and spring (F).
2. Remove snap rings (A), sleeves (C), spring (B), shaft
(E), and fork (D).

Power Train - Hydrostatic Repair - 392

 POWER TRAIN - HYDROSTATIC REPAIR
Differential (2-Wheel Drive) Disassembly and Assembly

B
G

A
I
E
J
K

H
J

N
O

MX14340 1. Use a puller to remove left ball bearing from differential

A - Ball Bearing holder.
B - Bevel Input Gear 2. Inspect differential components.
C - Final Pinion Shaft 3. Bearings must rotate free and smoothly. Replace as
D - Ball Bearing necessary.
E - Right Ball Bearing 4. Check differential components for wear or damage. If
F - Final Gear replacement is necessary, all parts must be replaced as
G - Right Differential Gear set.
H - Differential Carrier 5. Inspect differential lock collar for wear or loose or
I - Pins (2 used) sheared off pins.
J - Pinion Gear (2 used) 6. Check differential holder (L) and carrier (H) for wear,
K - Left-Notched Differential Gear cracks or damage.
L - Differential Holder
7. Inspect final gear (F) for worn or damaged teeth.
M - Cap Screws w/Washers (8 used)
N - Differential Lock Collar NOTE: Pinion gears (J) (2 used) and pins (I) (2 used)
must be replaced as a set.
O - Left Ball Bearing

Power Train - Hydrostatic Repair - 393

 POWER TRAIN - HYDROSTATIC REPAIR
8. Inspect ball bearings (A and D) for smooth rotation. the deeper offset of gear center away from the holder.
Tighten eight differential cap screws (M) to 88 N•m (65 lb-
NOTE: Final pinion shaft (C) and final gear (F) must be ft).
replaced as a set. Bevel input gear (B) and bevel input
pinion (not shown) must be replaced as a set. [Link] differential lock collar (N) and left bearing (O).
Push bearing tight against shoulder of differential holder.
9. Check bevel input gear (B) and final pinion shaft (C) for
worn or damaged condition. Replace parts as necessary. [Link] remaining components.

[Link] final gear on differential holder and carrier with NOTE: Use medium strength thread lock and sealer.

Differential (MFWD) Disassembly and Assembly

i G
B

A H
J

E
L
G

F
K

I
M

N
O
Q
E
P

MX14341 I - Washer (2 used)

A - Ball Bearing J - Pinion Gear (2 used)
B - Bevel Input Gear K - Differential Pinion Shaft
C - Final Pinion Shaft L - Left-Notched Differential Gear
D - Ball Bearing M - Final Gear
E - Ball Bearing (2 used) N - Differential Holder, Left
F - Differential Holder, Right O - Washers (8 used)
G - Liner (2 used) P - Cap Screws (8 used)
H - Right Differential Gear Q - Differential Lock Collar

Power Train - Hydrostatic Repair - 394

 POWER TRAIN - HYDROSTATIC REPAIR
1. Use a puller to remove ball bearings (E) from differential 8. Inspect ball bearings (A and D) for smooth rotation.
holders (F and N).
NOTE: Final pinion shaft (C) and final gear (M) must be
2. Inspect differential components. replaced as a set. Bevel input gear (B) and bevel input
3. Bearings must rotate free and smoothly. Replace as pinion (not shown) must be replaced as a set.
necessary. 9. Check bevel input gear (B) and final pinion shaft (C) for
4. Check differential components for wear or damage. If worn or damaged condition. Replace parts as necessary.
replacement is necessary, all parts must be replaced as [Link] final gear on differential holder and carrier with
set. the deeper offset of gear center away from the holder.
5. Inspect differential lock collar for wear or loose or Tighten eight differential cap screws (P) to 88 N•m (65 lb-
sheared off pins. ft).
6. Check differential holders (F and N) and differential [Link] differential lock collar (Q) and left and right
pinion shaft (K) for wear, cracks or damage. bearings (E). Push bearing tight against shoulder of
differential holder.
7. Inspect final gear (M) for worn or damaged teeth.
[Link] remaining components.
NOTE: Pinion gears (J) (2 used), washers (I) (2 used),
and differential pinion shaft (K) must be replaced as a NOTE: Use medium strength thread lock and sealer.
set.

PTO Clutch Disassembly, Inspection and Assembly

1. Remove PTO clutch assembly. (See “PTO Brake Removal and Installation” on page 381.)

I
H
G
F
J
E
K
D

A
L

Q
M

T S
N
O
P

M81113ae D - Needle Bearing

A - Ball Bearing E - Washer
B - Snap Ring F - O-Ring
C - Clutch Shaft G - Piston
H - Spring

Power Train - Hydrostatic Repair - 395

 POWER TRAIN - HYDROSTATIC REPAIR
I - Washer [Link] input shaft collar for burrs, wear or damaged
J - Snap Ring teeth or splines.
K - Input Shaft Collar [Link] clutch pack wear. Assemble parts.
L - Snap Ring
M - Thick Steel Plate
N - Friction Plate
O - Spring
P - Pin
Q - Steel Plate
R - Clutch Gear/Hub
S - Washer
T - Seal Ring
2. Remove large snap ring and thick steel plate.
3. Remove parts.
NOTE: Friction plates, springs, steel plates and pins
must be replaced as a set.
4. Replace clutch gear/hub if brake surface is badly scored
or teeth are chipped or damaged. M81186

[Link] clutch gear/hub on bench so steel and friction plates

c spring
CAUTION: Avoid Injury! Piston is under
force. Use care during disassembly.
are against snap ring. Measure clearance between inner
steel plate and bottom of clutch gear/hub.
[Link] clearance measures 2.7 mm (0.106 in.) or more,
replace PTO clutch plates.
[Link] clean hydraulic oil to all parts.
U Installation is done in the reverse order of removal.
V
W MFWD Output Shaft Removal and Installation
X
Removal:
1. Park machine safely, and remove negative battery cable.
NOTE: Approximate capacity of hydrostatic powertrain
is 6.6L (7.0 qt) for two-wheel steering and 5.6L (6.0 qt)
for all-wheel steering.
M81124 2. Remove front drive shaft assembly.
5. Remove piston from clutch gear/hub. Use JDT39
Transmission Gear Spacer (X) to compress spring (U) and
washer (V) in a vise. Remove snap ring (W) and slowly
c cool
CAUTION: Avoid Injury! Allow transaxle to
before draining fluid. Hot fluid can
release force of spring.
cause serious burns.
6. Remove remaining clutch parts.
3. Drain transaxle.
7. Check bearings for smooth rotation.
8. Inspect clutch gear for worn or damaged teeth.
9. Check inner piston bore for scoring or wear.
[Link] steel plates for scoring, discoloration, warping or
wear.
[Link] worn or damaged springs.

Power Train - Hydrostatic Repair - 396

 POWER TRAIN - HYDROSTATIC REPAIR
C
B H

A
D

G
F
I

MX16020

MX16018
2. Remove shift collar (I), detent balls, spring, and bearing
(H) from front wheel drive output shaft.
4. Remove spring pin (B) and washer, and remove end of
linkage (A) off of shift arm (G). NOTE: Flat end of shift collar goes toward bearing.
5. Remove two long cap screws (C) and washers, cap 3. Clean bearings in a suitable solvent. Dry with
screw (E) and washer, and three short cap screws (D) compressed air.
holding cover assembly (F) onto motor case.
IMPORTANT: Avoid damage! DO NOT spin
Disassembly and Assembly: bearing using compressed air. Damage to
bearing balls, cage, and races could result.

4. Inspect bearings for discolored, burned, balls and/or

races. Check balls and races for spalling or cracking. Roll
bearing by hand to check for rough turning or excessive
looseness or play between balls and races. Replace
bearings as required.

MX16019

1. Remove front wheel drive output shaft assembly from MX16034

front wheel drive housing by driving assembly into housing
from the front. 5. Measure OD of bearing surface. If not within
specifications, replace front wheel drive output shaft.
NOTE: Front wheel drive output shaft has two spring
6. Measure ID of pilot hole. If not within specifications,
loaded detent balls located under shift collar. Use care
replace front wheel drive output shaft.
when removing shift collar from front wheel drive
output shaft. Note that flat end of shift collar goes 7. Inspect sleeve (J) for wear. Replace, as necessary.
toward bearing. 8. Inspect spines on front wheel drive output shaft and shift
collar for damage. Replace as required.
9. Inspect groove in shift collar for scoring or damage.
Replace as required.

Power Train - Hydrostatic Repair - 397

 POWER TRAIN - HYDROSTATIC REPAIR
Specifications:
P
Front Wheel Drive Output Shaft: M O Q
OD at Bearing . . . . . . 24.98 - 25.0 mm (0.983 - 0.984 in.) N R
ID Pilot Hole . . . . . . . . 17 - 17.02 mm (0.669 - 0.670 in.)

U
L
K T

MX16037

[Link] drift to drive out spring pin (S) and roll pin (T)
securing pivot (U) to shaft.
[Link] shaft (R) from housing and pivot (U).
[Link] O-Ring (Q) on shaft.
[Link] washer (P) and inspect seal (O) for wear or
MX16035
damage. Replace, as necessary.
[Link] bearing block (K) from pin (L) on shift arm.
[Link] shaft bore in housing. If not in specifications,
Replace if damaged or worn.
replace housing.
[Link] OD of shaft in bearing area. If not in
M specifications, replace shaft.

Specifications:
Shaft OD . . . . . . . . . . . 16.93 - 17 mm (0.667 - 0.669 in.)
Housing Shaft Bore ID 17 - 17.043 mm (0.669 - 0.671 in.)

Assembly & Installation:

Assembly and installation of the front MFWD output
N
assembly is carried out in reverse order of disassembly and
removal.
Replace the gasket, or use a thin bead of RTV silicone
MX16036 gasket maker between center case and front PTO output
[Link] cap screw (M) securing keeper (N) to housing. housing.
Tighten cap screws to specification.

Torque Specification:
Cap Screws. . . . . . . . . . . . 16 - 22 N•m (144 - 192 lb-in.)

Power Train - Hydrostatic Repair - 398

 POWER TRAIN - HYDROSTATIC REPAIR
Hydrostatic Transmission 2-WD and MFWD Hydrostatic Transmission Motor Removal:

Hydrostatic Transmission Removal:

1. Remove transaxle. (See “Transaxle Removal and
Installation” on page 390.)
2. Remove charge pump. (See “Charge Pump Removal
and Installation” on page 375.)

IMPORTANT: Avoid damage! Do not drop or

damage pump valve plate when removing center
valve block assembly. Do not nick or scratch
lapped or machined surfaces of the valve plates
or cylinder block components. The slightest A
damage can cause poor performance.
B

B
C
C

M81104

2-Wheel Drive Shown

1. Remove retaining ring (B), bevel input pinion (C), and
ball bearing (A).
2. Inspect bearing for smooth rotation.
NOTE: Bevel input pinion and bevel input gear must be
A replaced as a set.
3. Check pinion for wear or damage.
4. Replace retaining ring if ring is distorted during removal.

M81182

2-Wheel Drive Shown (MFWD similar)

3. Remove cap screws (A) and carefully remove center
valve block (B) and motor assembly from transaxle.
4. Replace gasket (C) if torn or damaged.

Power Train - Hydrostatic Repair - 399

 POWER TRAIN - HYDROSTATIC REPAIR
Hydrostatic Transmission Motor Disassembly and Assembly (2-Wheel Drive):

B C
D E

F G
I

J
H

X S J
R
W Q
K

N O
V P
N M
U L

MX14345 U - Thick Thrust Plate

A - Cap Screw V - Thrust Bearing
B - Seal Cap W - Bushing
C - Snap Ring X - Thin Thrust Plate
D - Snap Ring
E - Washer IMPORTANT: Avoid damage! Do not drop or
damage motor valve plate when removing motor
F - Ball Bearing
assembly. Do not nick or scratch lapped or
G - Motor Case machined surfaces of the valve plate or cylinder
H - Locating Sleeve (2 used) block components. The slightest damage can
I - Motor Shaft cause poor performance.
J - Center Valve Block Assembly
1. Remove two cap screws (A).
K - Locating Pin
L - Motor Valve Plate IMPORTANT: Avoid damage! Keep pistons (S)
M - Snap Ring matched with bore of cylinder block (P). Do not
N - Washer interchange motor pistons and valve plate (L)
O - Spring with pump pistons and valve plate. Pistons and
P - Cylinder Block cylinder blocks are a matched set.
Q - Shim 2. Remove cylinder block assembly.
R - Piston Spring
NOTE: Motor rotating components must be replaced as
S - Piston a set.
T - Gasket

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 POWER TRAIN - HYDROSTATIC REPAIR
3. Inspect rotating components: NOTE: Apply John Deere Form-in-Place Gasket to
outer edge of new seal cap. Install seal cap until cap is
NOTE: Scoring is fine scratches or grooves cut into the approximately 4 mm (5/32 in.) below surface of motor
highly machined surface. When the scratches can be case.
detected by feel using a lead pencil or fingernail, the
part must be replaced. [Link] parts in reverse order of removal.
4. Check valve plate and cylinder block for grooves, NOTE: Use petroleum jelly to hold valve plate in
scoring, discoloration or pitting. position.
5. Check for free movement of pistons in cylinder bore. • Put motor valve plate (L) on center valve block. Make
6. Check pistons for flat areas, scoring or discoloration. sure bronze surface is away from valve block and notch
in valve plate fits on locating pin of valve block.
7. Thrust bearing (V) must rotate freely.
NOTE: Thin thrust plate (X), bushing (W) and motor IMPORTANT: Avoid damage! Apply clean
case (G) must be replaced as a set. hydraulic oil to all mating surfaces.

8. Inspect thin thrust washer for wear or damage. Replace

IMPORTANT: Avoid damage! Pump and motor
as necessary.
valve plates are not interchangeable. The pump
valve plate has two leading grooves into two of
IMPORTANT: Avoid damage! Do not damage ball
the slotted ports. The motor valve plate (L) has
bearing (F) when removing seal cap (B).
no leading grooves.
9. Remove seal cap (B) and snap ring (C) to remove shaft
assembly components. NOTE: Motor case will seem springy because the
springs inside the cylinder block are being
[Link] bushing (W), thrust bearing (V) and shaft (I) for compressed.
wear or damage. Replace if necessary.

Hydrostatic Transmission Motor Disassembly and Assembly (MFWD):

B C D E
A G

F
V Q
J
P
O I
U
N
M
T L
K
L
S J
MX14344

Power Train - Hydrostatic Repair - 401

 POWER TRAIN - HYDROSTATIC REPAIR
A - Cap Screw 6. Check for free movement of pistons in cylinder bore.
B - Snap Ring 7. Check pistons for flat areas, scoring or discoloration.
C - Snap Ring
8. Thrust bearing (T) must rotate freely.
D - Ball Bearing
E - Motor Case NOTE: Thin thrust plate (V), bushing (U) and motor
case (E) must be replaced as a set.
F - Locating Sleeve (2 used)
G - Motor Shaft 9. Inspect thin thrust plate (V) for wear or damage.
H - Center Valve Block Assembly Replace as necessary.
I - Locating Pin
J - Motor Valve Plate IMPORTANT: Avoid damage! Do not damage ball
bearing (D) when removing snap ring (B).
K - Snap Ring
L - Washer [Link] snap ring (B) to remove shaft assembly
M - Spring components.
N - Cylinder Block [Link] bushing (U), thrust bearing (T) and shaft (G) for
O - Shim wear or damage. Replace if necessary.
P - Piston Spring
Q - Piston IMPORTANT: Avoid damage! Apply clean
hydraulic oil to all mating surfaces.
R - Gasket
S - Thick Thrust Plate [Link] parts in reverse order of removal.
T - Thrust Bearing NOTE: Use petroleum jelly to hold valve plate in
U - Bushing position.
V - Thin Thrust Plate
• Put motor valve plate (J) on center valve block. Make
1. Remove front drive shaft assembly. (See “Removal:” on sure bronze surface is away from valve block and notch
page 396.) in valve plate fits on locating pin of valve block.

IMPORTANT: Avoid damage! Do not drop or IMPORTANT: Avoid damage! Pump and motor
damage motor valve plate when removing motor valve plates are not interchangeable. The pump
assembly. Do not nick or scratch lapped or valve plate has two leading grooves into two of
machined surfaces of the valve plate or cylinder the slotted ports. The motor valve plate (J) has
block components. The slightest damage can no leading grooves.
cause poor performance.
NOTE: Motor case will seem springy because the
2. Remove two cap screws (A). springs inside the cylinder block are being
compressed.
IMPORTANT: Avoid damage! Keep pistons (Q)
matched with bore of cylinder block (N). Do not
interchange motor pistons and valve plate (J)
with pump pistons and valve plate. Pistons and
cylinder blocks are a matched set.

3. Remove cylinder block assembly.

NOTE: Motor rotating components must be replaced as
a set.
4. Inspect rotating components:
NOTE: Scoring is fine scratches or grooves cut into the
highly machined surface. When the scratches can be
detected by feel using a lead pencil or fingernail, the
part must be replaced.
5. Check valve plate and cylinder block for grooves,
scoring, discoloration or pitting.

Power Train - Hydrostatic Repair - 402

 POWER TRAIN - HYDROSTATIC REPAIR
Center Valve Block Disassembly and Assembly:

K
I

J L
H

M G
I N
F
H O E
P
G
D
F Q
C
E
R
B
D
T
C A

AF W
U
V

V
X

AB
AA

AE Y
AD
AC
Z

MX14326

Power Train - Hydrostatic Repair - 403

 POWER TRAIN - HYDROSTATIC REPAIR
A - Holder valve block.
B - Spring 5. Inspect anti-cavitation valve assemblies.
C - Ball
NOTE: Screens may be located in bores of transaxle
D - Push Pin
case.
E - O-Ring
F - Seal 6. Check suction screens for blockage.
G - O-Ring 7. Carefully pull anti-cavitation valve body from center
H - Back-up Ring valve block so as not to lose parts.
I - O-Ring 8. Replace parts as necessary.
J - Forward Check Valve 9. Apply oil to O-rings and push assembly to bottom of
K - Top Plug bore.
L - O-Ring [Link] center valve block where charge pump contacts
M - O-Ring block for scoring.
N - Washer
[Link] center valve block if necessary.
O - Shim (0.5)
P - Shim (0.2) NOTE: Scoring is fine scratches or grooves cut into the
highly machined surface. When the scratches can be
Q - Spring
detected by feel using a lead pencil or fingernail, the
R - Charge Pressure Relief Valve Plunger part must be replaced.
S - Reverse Check Valve
T - Seat [Link] valve plate for grooves, scoring, discoloration or
pitting.
U - Center Valve Block
V - Needle Bearing (2 used)
IMPORTANT: Avoid damage! Pump and motor
W - Locating Pin (2 used) valve plates are not interchangeable. The pump
X - Pump Valve Plate valve plate has two leading grooves into two of
Y - Anti-Cavitation Valve Body the slotted ports. The motor valve plate has no
Z - Backup Ring leading grooves.
AA- O-Ring [Link] pump valve plate on center valve block. Make sure
AB- Ball bronze surface is away from valve block and notch in valve
AC- Ball Holder plate fits on locating pin of valve block.
AD- Spring NOTE: Use petroleum jelly to hold valve plate in
AE- Retainer position.
AF- Motor Valve Plate
[Link] plug to inspect charge pressure relief valve
NOTE: Remove motor assembly if necessary to inspect parts.
needle bearing. (See “Hydrostatic Transmission Motor
[Link] plunger for nicks, wear or damage.
Removal:” on page 399.)
[Link] plunger seat in center valve block. Remove any
1. Remove and inspect directional check valves. obstructions and replace center valve block if seat is worn
or damaged.
IMPORTANT: Avoid damage! The reverse check
valve must be installed in the left port. The check
valve can be identified by a small orifice drilled
into a land between the two sets of valve
passageways.

2. Replace locator pins if missing or damaged.

3. Inspect needle bearings for wear or damage. If bearings
are replaced, install new bearings with the stamped end
away from center valve block.
4. Push bearings into bore until end of bearing is
approximately 3 mm (7/64 in.) above the surface of the

Power Train - Hydrostatic Repair - 404

 POWER TRAIN - HYDROSTATIC REPAIR
Hydrostatic Transmission Motor Installation:
NOTE: Replace retaining ring (D) if ring is distorted B
during removal.
C

A
C

M81182

E 2-Wheel Drive Shown (MFWD similar)

F 1. Install gasket (C).

M81104
2. Install center valve block (B) and motor assembly to
transaxle housing and secure with cap screws (A).
2-Wheel Drive Shown
• Tighten cap screws (A) to 39 N•m (29 lb-ft).
1. Secure motor housing assembly (A) and gasket (F) to
center valve block (B) and install ball bearing (C) and bevel 3. Install charge pump. (See “Charge Pump Removal and
input pinion (E). Secure with retaining ring (D). Installation” on page 375.)
4. Install transaxle. (See “Transaxle Removal and
Hydrostatic Transmission Installation: Installation” on page 390.)

IMPORTANT: Avoid damage! Do not drop or

damage pump valve plate when removing center
valve block assembly. Do not nick or scratch
lapped or machined surfaces of the valve plates
or cylinder block components. The slightest
damage can cause poor performance.

Power Train - Hydrostatic Repair - 405

 POWER TRAIN - HYDROSTATIC REPAIR
Hydrostatic Pump Inspection

B
C

D
E
F
G

H
I
J

MX16066 NOTE: Pump rotating components must be replaced as

A - Washer a set. Thin thrust plate must be replaced as a set with
the pump swash plate and bushing.
B - Piston Spring (7 used)
C - Snap Ring 3. Check cylinder block for grooves, scoring, discoloration
D - Cylinder Block or pitting.
E - Washer NOTE: Scoring is fine scratches or grooves cut into the
F - Spring highly machined surface. When the scratches can be
G - Piston (7 used) detected by feel using a lead pencil or fingernail, the
H - Thick Thrust Plate part must be replaced.
I - Thrust Bearing 4. Check for free movement of pistons in cylinder bores.
J - Thin Thrust Plate 5. Check pistons for flat areas, scoring or discoloration.
Thrust bearing must rotate freely.
IMPORTANT: Avoid damage! Keep pistons
matched with bore of cylinder block. Do not For inspection of pump valve plate, refer to “Center Valve
interchange motor pistons and valve plate with Block Disassembly and Assembly:” on page 403.
pump pistons and valve plate. Pistons and
cylinder blocks are a matched set.

1. Spring is compressed. Apply an external force to

compress spring farther before removing snap ring. Then
slowly remove external force.
2. Remove parts from transaxle as necessary.

Power Train - Hydrostatic Repair - 406

 POWER TRAIN - HYDROSTATIC REPAIR
Transaxle Disassembly
1. For AWS models, remove rear steering linkage. (See
“Rear Steering Linkage - All Wheel Steering” on page 477 A B
in the Steering section.)
2. Remove control arm damper. (See “Control Arm and
Damper Removal and Installation” on page 374.)
3. Remove hydrostatic transmission and pump. (See
“Hydrostatic Transmission 2-WD and MFWD” on
page 399.)
4. Remove axle housings. (See “Rear Axle Assembly (Two
Wheel Steer Models) Removal and Installation” on
C
page 413, and “Rear Axle Assembly (Two Wheel Steer
Models) Disassembly and Assembly” on page 414, or
“Rear Axle Assembly (All Wheel Steer) Disassembly and
Assembly” on page 416.)
5. Remove brakes. (See “Brakes Removal and Installation”
on page 495 in the Brakes section.) D

A
E
M81089

With Rear PTO Option

6. Remove PTO idler shaft assembly (C), snap ring (E),
B
PTO gear (D) (or rear drive gear set).
7. Remove PTO brake shoe (B) and clutch (A). (See “PTO
C Brake Removal and Installation” on page 381.)

M81088

Without Rear PTO option

Power Train - Hydrostatic Repair - 407

 POWER TRAIN - HYDROSTATIC REPAIR

G
F H
I

L
K

MX16068

8. Remove large snap ring (H) and input shaft assembly.

9. Remove large snap ring (L), small snap rings (G and K),
washers (M and J), and ball bearing (I) from input shaft (F).

Power Train - Hydrostatic Repair - 408

 POWER TRAIN - HYDROSTATIC REPAIR
[Link] final gear and differential assembly and differential
N lock shaft from transaxle case together as an assembly.
[Link] final pinion shaft assembly.

M81095

[Link] transaxle on left side and remove sixteen (16) cap

screws (N) attaching right cover assembly (O).

IMPORTANT: Avoid damage! Bearing, washer

and differential pinion located on top of
differential assembly are loose. Do not drop or
lose parts.

M98231

[Link] final pinion shaft ball bearing. Bearing may

remain in cover assembly.

Power Train - Hydrostatic Repair - 409

 POWER TRAIN - HYDROSTATIC REPAIR
Transaxle (Right Cover) Disassembly and Assembly

G
F

E
H

A
B J
C K
L
D

B
M
A
Q

P N

MX16069 3. Inspect transaxle cover components.

A - Swash Plate Bearing 4. Check bushing, bearing and swash plate contact
B - Washer surfaces for wear or damage. Replace as necessary.
C - Bushing 5. Inspect O-rings on swash plate and eccentric adjust
D - Spring fulcrum for cuts or damage.
E - Cover 6. Install spring so legs are crossed and each leg of spring
F - Snap Ring fits into a groove of the fulcrum cap screw.
G - Washer
7. If swash plate bearing was removed, install new bearing
H - Cap Screw until end of bearing is even with the inside surface of the
I - Washer cover.
J - Control Arm 8. Put petroleum jelly on all O-rings. Install swash plate
K - Nut assembly and remaining components.
L - Washer
NOTE: Use medium strength thread lock and sealer.
M - Pivot Stud
N - O-Ring
O - Eccentric Adjust Fulcrum
P - Swash Plate
Q - Fulcrum Cap Screw
1. Remove snap ring, nut and washers.
2. Pull swash plate from cover.
NOTE: Pump swash plate, bushing, and thin thrust
plate must be replaced as a set.

Power Train - Hydrostatic Repair - 410

 POWER TRAIN - HYDROSTATIC REPAIR
Transaxle Case Inspection
F

B E
A

M81099
M81097
7. Inspect PTO brake pin sleeve (E) for scoring or damage.
1. Remove front PTO shaft seal (B).
Replace if necessary.
2. Inspect needle bearing (A) for wear or damage. Remove
8. Push sleeve out from inside of case.
if necessary. Install new needle bearing from inside case
with bearing identification marks toward the inside of the 9. Install new sleeve into case until flange of sleeve is tight
case. Push bearing tight against shoulder in bore. against case.
3. Install new seal with the open, spring side towards the [Link] swash plate bearing (G) for wear or damage.
inside of the case. Replace if necessary.
4. Push seal against shoulder in bore. [Link] new bearing using a disk driver. Push bearing to
bottom of bore.
[Link] vent cap (F) for damage or obstructions.
Replace as necessary.
C

Transaxle Assembly

M81098

5. Replace differential lock shaft seal (C).

NOTE: Differential lock plate (D) may have to be
removed to install new seal.
6. Install new seal with the open, spring side towards
inside of case. Push seal tight against bottom of bore.

M98231

1. Apply clean hydraulic oil to all internal components.

2. Install final pinion shaft assembly into transaxle case
with bevel gear end in first.

IMPORTANT: Avoid damage! Bearing and

washer on top of differential assembly are loose.
Do not drop or lose parts.

Power Train - Hydrostatic Repair - 411

 POWER TRAIN - HYDROSTATIC REPAIR
3. Put fork of differential lock shaft into groove of collar on
differential assembly. Install differential assembly and
differential lock shaft together into transaxle case.
C
4. Install ball bearing.

M81088

Without Rear PTO Option

M81095 C
D
5. Apply a bead of John Deere Form-in-Place Gasket to
mating surface of transaxle case.
6. Carefully lower right transaxle cover assembly (B) onto
case while making sure bearings and shafts fit into bores
properly. Make sure washer on swash plate does not fall
out of position. Secure with sixteen (16) cap screws (A),
and tighten to specification below.

Transaxle Case Cap Screw E

Torque Specifications:
Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)

7. Assemble bearing, washers and snap rings on input

shaft. F

8. Install input shaft assembly and large snap ring.

G
M81089

With Rear PTO Option

Power Train - Hydrostatic Repair - 412

 POWER TRAIN - HYDROSTATIC REPAIR
9. Install PTO brake shoe (D) and PTO clutch assembly [Link] hydrostatic transmission and pump.
(C). (See “PTO Brake Removal and Installation” on [Link] control arm damper. (See “Control Arm and
page 381.) Damper Removal and Installation” on page 374.)
[Link] PTO idler shaft assembly (E), PTO gear (F) (or
[Link] AWS models, install rear steering linkage. (See
rear PTO gear on rear PTO option machines), and snap
“Rear Steering Linkage- Installation” in the Steering
ring (G).
section.)
[Link] PTO drive train. (See “PTO Drive Train (Mid and
Rear PTO) Removal and Installation” on page 384.) Rear Axle Assembly (Two Wheel Steer
[Link] brakes. (See “Brakes Removal and Installation” Models) Removal and Installation
on page 495 in the Brakes section.)
1. Loosen rear wheel lugs and raise rear of machine by the
[Link] axle housings. (See “Rear Axle Assembly (Two frame.
Wheel Steer Models) Removal and Installation” on
page 413.) 2. Remove lugs and rear wheel.

G H

F
E

D
C
B
I

A
J

L K

MX16043 L - Washer
A - Shaft 3. Remove two bolts (G) and nuts (I) holding axle housing
B - Snap Ring (H) to frame.
C - Sleeve NOTE: Note position of two locator bushings (J) when
D - Seal removing axle housing.
E - Ball Bearing
4. Remove six cap screws (K) holding axle housing to
F - Snap Ring
transaxle housing, and remove axle assembly.
G - Cap Screw (2 used)
5. Clean axle housing and transaxle mating surfaces.
H - Axle Housing
Apply a bead of John Deere Form-in-Place Gasket to
I - Lock Nut (2 used) mating surface.
J - Bushing (2 used)
6. Repeat for other side if necessary.
K - Cap Screw (6 used)
Installation is done in the reverse order of removal.

Power Train - Hydrostatic Repair - 413

 POWER TRAIN - HYDROSTATIC REPAIR
Rear Axle Assembly (Two Wheel Steer
Models) Disassembly and Assembly

A B

M81197

9. Install axle shaft assembly into axle housing using a

C press. Press shaft only until a rapid increase in pressure is
M81196
noticed

1. Remove large snap ring (C) from groove of axle housing

(A).
2. Use a press to remove axle shaft (B) from axle housing.
3. Remove remaining snap ring to remove axle shaft
components.
4. Inspect axle shaft and housing for wear or damage.
Replace parts as necessary.
5. Inspect bearing for smooth rotation. Replace if
necessary. D
NOTE: Ball bearing is not pressed into housing. When C
placed in axle housing it may be loose. A clearance up
to 0.38 mm (0.015 in.) is normal.
E
6. Install bearing, seal and snap ring into axle housing. Put
spring-side of seal into housing first.
7. Apply petroleum jelly to lips of seal and inner diameter
of sleeve.
8. Install snap ring, washer and sleeve on axle shaft. Use a
piece of pipe with a minimum inside diameter of 31 mm (1-
3/16 in.) to push sleeve and washer tight against shoulder
of shaft.

IMPORTANT: Avoid damage! Do not use

MX14320
excessive force to install axle shaft. Axle
housing may be cracked or damaged if too much [Link] washer (E) and snap ring (C) on axle shaft.
force is used. [Link] a piece of pipe (D) with a minimum inside diameter
of 31 mm (1-3/16 in.), maximum outer diameter of 43 mm
(1-11/16 in.) and approximately 330 mm (13 in.) long to
install snap ring.

Power Train - Hydrostatic Repair - 414

 POWER TRAIN - HYDROSTATIC REPAIR
Rear Axle Assembly (All Wheel Steer) Removal and Installation
Removing:

B
A
H

G
D F

E J

K
C
L

M
N
P
O
M

L
K I

MX14233 Steering section.)

A - Link Rod, Middle 1. Remove transaxle. (See “Transaxle Removal and
B - Bearing Housing Installation” on page 390.)
C - Pivot Arm 2. Remove left (D) and/or right (F) rear axle assemblies.
D - Left-Hand Axle
E - Cap Screws NOTE: For AWS models, longer caps screws (E) are
installed in the bottom three holes.
F - Right-Hand Axle
G - Axle Shaft 3. Clean axle housing and transaxle mating surfaces.
H - Ball Bearing 4. Repeat for other side if necessary.
I - Drive Shaft, U-Joint
J - Ball Bearing Installing:
K - Case, Wheel Bearing NOTE: Apply a bead of John Deere Form-in-Place
L - Steering Arm Gasket to mating surfaces.
M - Tie Rod (2) Installation is done in the reverse order of removal.
N - Cap, Pivot
O - Pivot Plate
P - Link Rod, Rear
NOTE: For AWS models, remove rear steering linkage
before removing transaxle. (See “Rear Steering
Linkage - All Wheel Steering” on page 477 in the

Power Train - Hydrostatic Repair - 415

 POWER TRAIN - HYDROSTATIC REPAIR
Rear Axle Assembly (All Wheel Steer) Disassembly and Assembly

C
D
E
F

M81121 8. Install large snap ring.

1. Remove inner seal (C). 9. Apply multi-purpose grease to lips of seal. Install seal so
2. Remove large snap ring (D) to remove axle shaft (G) open, spring side of seal is towards bearing. Push seal
with ball bearing (F) and snap ring (E). Remove snap ring against snap ring using a tube type driver.
(E) if bearing or shaft must be replaced.
3. Inspect axle components for cracks, wear or damage.
Replace if necessary.
4. If bushing (A) and/or washer (B) was replaced, use a
disk driver to install bushing until end of bushing is even
with machined surface of axle housing (K). Apply
multipurpose grease to inside diameter of bushing.
5. If ball bearing was replaced, push bearing to bottom of
bore.
6. Install new lower king pin seal (I) with open side of seal
away from ball bearing (J). Use a disk driver to push seal
into bore until even with surface of axle housing. Apply
multi-purpose grease to seal lips.
NOTE: Do not lose locator sleeves (H) from axle
housing.
7. Install axle shaft with bearing and snap ring in axle
housing.

Power Train - Hydrostatic Repair - 416

 POWER TRAIN - HYDROSTATIC REPAIR
Knuckle Assembly (All Wheel Steer) Removal A - Lock Washer
and Installation B - Cap Screw
C - Lubrication Fitting
B D - King Pin
E - Knuckle Housing
C F - Seal
A
D G - Hub
H - Washer
I - Ring
E J - Cap
K - Cap Screw
F
G L - Lock Washer
1. Remove upper and lower king pins.
H
I 2. Pull knuckle housing from axle housing.

Installation is done in the reverse order of removal.

• Apply medium strength thread lock and sealer to
threads of cap screws and washers.
L
J • Tighten cap screws (B and K) to 54 N•m (40 lb-ft).
K
• Apply multi-purpose grease to lube fitting until grease
M81120 begins to appear at upper joint.

Knuckle Housing Disassembly and Assembly

B
C
D

L G

M81122

Power Train - Hydrostatic Repair - 417

 POWER TRAIN - HYDROSTATIC REPAIR
1. Remove seal cap (A), washer (B), snap ring (C) and U-
joint drive shaft (I).
2. Remove wheel hub (D) to disassemble remaining
components. B
3. Inspect knuckle housing (E) components for cracks,
wear or damage. Replace as necessary.
NOTE: Inner ball bearing (F) is not press fit.
4. If inner ball bearing (F) was replaced, push new bearing
to bottom of bore. Fill bearing and cavity with multipurpose
grease.
5. Install snap ring (G).
6. Install bushing (K) against inner ball bearing (F). A

7. Push outer ball bearing (J) tight against bushing (K). C

MX14359
IMPORTANT: Avoid damage! Open lip side of 3. Drain the differential and remove drain plug (C) to drain
seal must face outward to prevent dust and either final drive housing.
moisture from getting into bearings. Push only
on outer surface of seal. NOTE: Use a rubber hammer to loosen the cover (B).
Do not force the cover off as damage may result.
8. Use a disk driver to push outer seal (L) (lip facing
outward) into bore until even with the surface of knuckle 4. Remove six cap screws (A). Remove the final drive
housing (E). cover (B) and hub shaft from the final drive housing.

IMPORTANT: Avoid damage! Lip on seal must D

not be damaged or rolled over.

9. Use a disk driver to push inner seal (H) (seal lip facing
outward) to bottom of bore.
[Link] multi-purpose grease to seal lips.
[Link] wheel hub while installing into knuckle housing.
Check while installing that seal lip is not rolled over.
[Link] Dubois MPG-2 (M79292) grease (water repellent)
to splines of U-joint drive shaft and slide into knuckle
housing assembly.
[Link] remaining components.
[Link] all threads of knuckle housing and cap screws
with clean and cure primer. E

Final Drive Cover Removal and Installation - MX14362

(MFWD) 5. Remove the snap ring (E) from the hub shaft (D), and
press hub shaft from the ring gear.
Final Drive Cover Removal and Inspection:
NOTE: The oil wear sleeves in the front axle assembly
1. Raise and safely support the front of the machine. are lined with rubber. Using heat to remove the sleeves
2. Remove the wheel and tire from the final drive requiring will damage the rubber linings and will require
service. replacement of the sleeves.

NOTE: To service both of the front final drive

assemblies, see “Front Wheel Removal and
Installation” on page 561 in Miscellaneous section.

Power Train - Hydrostatic Repair - 418

 POWER TRAIN - HYDROSTATIC REPAIR

MX14365 MX14364
6. Inspect the oil seal wear sleeve (F) on the hub shaft for 8. Press the ring gear (H) from the inner race of the ball
wear or damage. Inspect the seal, hub shaft, and cover. bearing inside the final drive cover (B).
Replace any unserviceable parts.
I

K
J
G

MX14366

9. Remove the outer (I) and inner (J) snap rings on both
sides of bearing (K), and press bearing out of final drive
cover (B).

Final Drive Cover Installation:

MX14363 1. Install the inner snap ring (J) onto the final drive cover
7. Remove the seal (G) from the cover. (B). Press bearing (K) into housing and until it is seated
against snap ring (J). Install second, outer snap ring (I) on
NOTE: Use the correct puller and carefully remove and the other side of bearing.
install the seal from the cover.

Power Train - Hydrostatic Repair - 419

 POWER TRAIN - HYDROSTATIC REPAIR

MX14362

MX14363 4. Install the hub shaft (D) and snap ring (E).
2. Install the seal (G) onto the cover. 5. Install the cover to the final drive case. Tighten six (6)
cap screws in a cross pattern. Tighten to 16 - 22 N•m (144
- 192 lb-in.).
6. Fill the housing with approved gear lube.

H
NOTE: The final drives and axle housing fill very
slowly. It may be necessary to open a drain plug to
allow for a faster fill. BE CERTAIN to tighten the drain
plug as soon as the gear lube reaches the drain hole.
Allow the entire amount of gear lube to fill the housing.

Final Drive Housing Removal and Installation

- (MFWD)
Removal and Inspection:
B
C E

MX14367
B
3. Press the ring gear (H) onto the inner race of the ball D
bearing inside the final drive cover (B).
NOTE: Press the gear flush with the ball bearing inner
race. DO NOT force the gear any further. F
G
A

H
I

J
MX14359

1. Drain the differential and final drive housing (I), and

remove the final drive cover (J). (See “Final Drive Cover
Removal and Installation - (MFWD)” on page 418.)

Power Train - Hydrostatic Repair - 420

 POWER TRAIN - HYDROSTATIC REPAIR
2. Remove cotter pin and castle nut (F) on machine tie rod
(H) and remove tie rod from spindle arm (C). N
3. Remove cotter pin and castle nut (E) and remove end of
O
steering cylinder (G) from spindle arm (C).
4. Remove cap screw (B), long cap screw (D), and nuts/
washers (A). Remove the front spindle arm (C) from top
spindle housing.
5. Remove seal and bearing from top of spindle housing,
and, using a punch, tap top of drive shaft (M) to remove
final drive housing assembly (I) from spindle housing.
Q
M

MX14369

8. Remove snap ring (Q), washer (P), and bearing race

(N), and inspect needle bearing (O) for wear or damage. If
damaged, remove bearing and replace.
L

K
R

MX14368

6. Carefully remove collar (K), and seal (L) from final drive
housing (I).
NOTE: Note position of writing/numbers on bearings
during removal and replace with same orientation.
MX14371
7. Remove drive shaft (M) from final pinion and bearing
seated in bottom of housing. 9. Remove the ring gear bearing (R) from the housing.
[Link] all the components of the final drive housing.
Replace any unserviceable parts.

Installation:
1. Press the ring gear bearing (R) into the housing.
2. With needle bearing (O) in place, install bearing and
final pinion into bottom of final drive housing (I).

Power Train - Hydrostatic Repair - 421

 POWER TRAIN - HYDROSTATIC REPAIR
[Link] the housing cover (J). (See “Final Drive Cover
M Installation:” on page 419.)

I
[Link] the housing with approved gear lube.
NOTE: The final drives and axle housing fill very
slowly. It may be necessary to open a drain plug to
allow for a faster fill. BE CERTAIN to tighten the drain
plug as soon as the gear lube reaches the drain hole.
Allow the entire amount of gear lube to fill the housing.

Spindle Housing - (MFWD)

L
Disassembly and Inspection:
K 1. Remove the steering arm and final drive housing, along
with spindle shaft. (See “Final Drive Housing Removal and
Installation - (MFWD)” on page 420.)
2. Remove six cap screws holding spindle housing to
differential housing.

A
MX14368
C
3. Seat bearing into bottom of housing, and press shaft (M)
into bearing. B
4. Install seal (L) and collar (K) onto housing opening.
5. Raise assembly through spindle housing, while
simultaneously orienting gear in spindle housing so final
drive housing (I) mates fully with spindle housing.
6. Install bearing and seal on top of spindle housing. D
F E
C E
MX14372
B
D 3. Remove snap ring (C), washer (B), and bearing (D) from
top of spindle housing (A).
4. Remove gear (E) through the final drive opening of the
G housing.
F
A 5. Inspect the sleeve (F) on spindle housing for wear or
damage. Replace as needed.

H G
I

J
MX14359

7. Install the spindle arm (C) onto spindle housing. Secure

assemblies with cap screw (B), long cap screw (D), and
nuts/washers (A).
8. Install tie rod (H) onto end of spindle arm (C), and
secure with castle nut (F) and cotter pin.
9. Install end of steering cylinder (G) onto arm of spindle,
and secure with castle nut (E) and cotter pin.
MX14373

Power Train - Hydrostatic Repair - 422

 POWER TRAIN - HYDROSTATIC REPAIR
6. Inspect the steering arm and oil wear sleeve (G) for 1. Remove nuts (C) and bolts.
wear or damage. Replace as required.
2. Slide the drive shaft (A) toward the front of the machine,
removing the rear drive shaft yoke from the differential drive
Assembly:
shaft (B).
A 3. Slide drive shaft toward rear of machine to remove shaft
from the differential input shaft.
C 4. Inspect all parts for wear or damage. Replace any
B
unserviceable parts.
NOTE: The U-joint yokes are not serviced separately. If
either yoke is damaged, replace the drive shaft.

Installing:
1. Install front drive shaft yoke into differential input shaft
D as far forward as it will go.
F E 2. Slide rear drive shaft yoke onto differential drive shaft
MX14372
(B), until bolts can be installed.

1. Install bearing (D), washer (B), and snap ring (C) 3. Install both bolts and tighten nuts (C).
through top of spindle housing (A).
2. Install gear (E) through the final drive opening of the Mechanical Front Wheel Drive Removal and
housing, with the gear teeth facing toward the bottom of the Installation - (MFWD)
spindle housing.
Removal:
3. Install the spindle shaft, final drive housing, and steering
arm. (See “Final Drive Housing Removal and Installation - 1. Remove the MFWD drive shaft. (See “Drive Shaft
(MFWD)” on page 420.) Removal and Installation - (MFWD)” on page 423.)

4. Fill the housing with approved gear lube. 2. Loosen front wheels and raise the front of the machine
by the frame to allow front axle removal.
NOTE: The final drives and axle housing fill very
3. Remove both front wheels.
slowly. It may be necessary to open a drain plug to
allow for a faster fill. BE CERTAIN to tighten the drain
plug as soon as the gear lube reaches the drain hole. A
Allow the entire amount of gear lube to fill the housing.

Drive Shaft Removal and Installation -

(MFWD)
C
Removing: B

A B D
E
C

MX14359

4. Remove cotter pin and castle nut (B) from tie rod (D).
Remove tie rod from steering arm (E). Repeat for other side
of machine.
5. Remove cotter pin and castle nut (A) from steering
cylinder (C) end. Remove steering cylinder end from
steering arm.
MX14379

Power Train - Hydrostatic Repair - 423

 POWER TRAIN - HYDROSTATIC REPAIR

A
G

H
C
B

D
E

C MX14359
MX16000 5. Install steering cylinder (C) end to steering arm (E) and
6. Remove the cotter pin and castle nut (H) from the secure with castle nut (A) and cotter pin.
steering cylinder end and lower cylinder (C), with hydraulic 6. Install tie rod (D) to steering arm and secure with castle
lines attached to cylinder. nut (B) and cotter pin. Repeat for other side of machine.
7. Support the front axle (F) with a floor jack, and remove 7. Install the tires. Tighten lugs to specification below.
nut (G), washer, and bolt securing axle to frame.
8. Install the MFWD drive shaft. (See “Drive Shaft Removal
8. Lower the axle from the frame with the floor jack. Set the and Installation - (MFWD)” on page 423.)
axle on a workbench or blocks to drain and disassemble
transaxle. 9. Lower the front of the machine.
[Link] MFWD with approved gear lube.
Installation:
NOTE: The MFWD and axle housing fill very slowly. It
1. Set the axle on a floor jack beneath the machine.
may be necessary to open the drain plug to allow for a
2. Raise the axle into position. faster fill. BE CERTAIN to tighten the drain plug as
soon as the gear lube reaches the drain hole. Allow the
entire amount of gear lube to fill the housing.
G

Torque Specifications:
F Tire Lugs . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)
Tie Rod Ends . . . . . . . . . . . . . . . . . . . . . 53 N•m (39 lb-ft)
H

C
MX16000

3. Slide the axle bolt through the frame and axle (F), and
install washer and nut (G).
4. Raise steering cylinder (C) onto axle and secure with
castle nut (H) and cotter pin.

Power Train - Hydrostatic Repair - 424

 POWER TRAIN - HYDROSTATIC REPAIR
Differential Input Housing - (MFWD) 6. Remove the bearing (O) and transfer gear (M) from the
input pinion shaft.
Disassembly: 7. Remove the snap ring (P), the large bearing (L) and
NOTE: This procedure can be performed with the pinion drive shaft (K) from the differential housing (H).
differential on the machine. Remove the drive shaft and NOTE: Note location of writing/numbers on large
follow the steps in this section. bearing (L) during removal procedure. Assemble with
writing/numbers toward transfer gear (M).
E
8. Remove the large bearing (L) from the input pinion shaft
(K).
9. Remove cap screws (I) and separate right axle housing
(J) from differential housing (H) (for installation procedure).
D
[Link] all parts for wear or damage and replace as
required.
C
B Assembly:
F
A
G E

MX16005
D
1. Remove the differential input drive housing (E).
2. Push the input shaft (C) out of the housing.
C
3. Remove bearing (A) and the transfer gear (B) from the B
F
input shaft.
A
NOTE: Note location of writing/numbers on bearing (D) G
during removal procedure. Assemble with writing/
numbers toward transfer gear (B).
4. Remove bearing (D) from input shaft (C). MX16005
5. Remove washer (G) and seal (F) from inside housing. 1. Invert the input housing (E) and install a new seal (F).
NOTE: Note flange (N) on transfer gear (M), and install 2. Place the transfer gear (B) and press the 2 bearings (A
with flange toward the pinion drive shaft (K). and D) onto the input shaft.
3. Place the thrust washer (G) on the upper bearing.
4. Install the input shaft (C) to the housing. The upper
bearing must seat inside fully in the input housing.
I

J
P K

L
O

M
N
MX16006

Power Train - Hydrostatic Repair - 425

 POWER TRAIN - HYDROSTATIC REPAIR
Front Axle Housing Disassembly and
Assembly

I Disassembly/Inspection:
1. Drain the differential and final drive housings, and
H remove the MFWD from the machine. (See “Mechanical
Front Wheel Drive Removal and Installation - (MFWD)” on
page 423.)
J
P K
B
D

L A
O

C
M
N
E
MX16006
L
5. Install the bearing (L) to the input pinion shaft (K), with J
writing/numbers facing the transfer gear (M).
K F
6. Install the input pinion shaft (K) to the differential
housing (H).
7. Install the large snap (P) ring to the differential housing. I
J G
8. Install transfer gear (M), with raised flange (N) towards H
input pinion shaft (K).
MX16008

2. Separate the right axle housing (D) from the differential

O
housing (B).
M
3. Remove the bevel pinion gears (J), bevel pinion shaft (I)
and bevel gear (K) from the left axle (C).
K
H 4. Remove the ring gear (G) and bevel gear (H) from right
axle housing (D).
5. Remove O-Ring (L) from right axle housing.
NOTE: Note any writing/numbers on bearings and
assemble with correct orientation.

MX16007

9. Install the upper bearing (O) to the input pinion shaft (K)
until it contacts the splines of the input pinion shaft. Support
the bottom of the input pinion shaft during installation.
[Link] the bearings and gears. Seal the input
housing.
B
[Link] the input housing (I) to the differential housing
(H).
[Link] the housing with approved gear lube.
NOTE: The MFWD and axle housing fill very slowly. It C
may be necessary to open the drain plug to allow for a N
O
M
faster fill. BE CERTAIN to tighten the drain plug as
soon as the gear lube reaches the drain hole. Allow the MX16009
entire amount of gear lube to fill the housing.

Power Train - Hydrostatic Repair - 426

 POWER TRAIN - HYDROSTATIC REPAIR
6. To remove right (F) and left (C) axles, remove spindle 3. Install bearing (N) onto gear (M), and install onto shaft
assemblies from axle housings. (See “Spindle Housing - (C) through differential housing (B). Repeat for right axle
(MFWD)” on page 422.) Remove gear (M) and bearing (N) housing.
on outside of shafts (C and F). Remove bearing from gear.
4. Install the inner axle bearing (E) to the right axle
7. Remove O-Ring (O) on both housing ends. housing.
8. Remove the left axle (C) with inner bearing (A) from the 5. Install the bevel gear (K) to the left axle (C).
differential housing (B). Remove bearing (A) from axle (C).
6. Install new O-Ring (L) onto right axle housing.
9. Remove the right axle inner bearing (E) and axle (F)
7. Install bevel gear (H) and ring gear (G) to the right axle.
from the right axle housing (D).
8. Install the bevel pinion gears (J) to the bevel pinion shaft
[Link] all parts for wear or damage. Replace as
(I).
necessary.
9. Install the bevel pinion shaft and gears to the differential.
Assembly:
NOTE: Be certain the differential gear assembly
remains intact during this installation. Some
adjustment may be required to mesh the gears so the
housings will match up.
[Link] the right axle housing (D) to the differential
housing (B).
[Link] spindle assemblies to axle housings. (See
“Spindle Housing - (MFWD)” on page 422.)
[Link] the housing with approved gear lube.
B
NOTE: The MFWD and axle housing fill very slowly. It
may be necessary to open the drain plug to allow for a
faster fill. BE CERTAIN to tighten the drain plug as
C soon as the gear lube reaches the drain hole. Allow the
O
entire amount of gear lube to fill the housing.
N
M

MX16009

1. Install new O-Ring (O) on both housing ends.

B
D

E
L
J

K F

I
J G
H

MX16008

2. Press bearing (A) onto shaft (C), and install shaft

through differential housing (B).

Power Train - Hydrostatic Repair - 427

POWER TRAIN - HYDROSTATIC REPAIR

Power Train - Hydrostatic Repair - 428

 HYDRAULICS TABLE OF CONTENTS
Hydraulics

Table of Contents

Specifications ...............................................431
General Specifications ...............................431
Test and Adjustment Specifications ...........431
Repair Torque Specifications .....................432
Special or Essential Tools ..........................432
Other Materials...........................................432
Schematics....................................................433
Hydraulic Schematic - Power Train ............433
Component Location....................................434
Hydraulic System .......................................434
Operation and Diagnostics ..........................435
Hydraulic System .......................................435
Hydraulic Control Valve Operation -
Neutral........................................................436
Hydraulic Control Valve Operation - Raise.437
Hydraulic Control Valve Operation - Float..438
Hydraulic Control Valve Operation -
Regen.........................................................439
Lift Cylinder Shut-off Valve - Optional ........440
Hydraulic Diagnostics.................................440
Preliminary Hydraulic System Inspection ...442
Hydraulic System Tests..............................443
Tests and Adjustments ................................444
Hydraulic Oil Warm-Up Procedure .............444
Charge Pump Pressure and Flow Quick
Test at Couplers .........................................444
Charge Pump Pressure Test......................445
Lift Cylinder Leakage Test..........................447
Control Valve Leakage Test .......................447
Repair.............................................................448
Hydraulic Control Valve Removal and
Installation ..................................................448
Hydraulic Control Valve .............................449
Lift Cylinder Removal and Installation ........450
Hydraulic Control Levers and Linkage .......451

Hydraulics Table of Contents - 429

HYDRAULICS TABLE OF CONTENTS

Hydraulics Table of Contents - 430

 HYDRAULICS SPECIFICATIONS
Specifications

General Specifications
Transaxle
Hydraulic Oil J20D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Viscosity HY-GARD
Oil Capacity (Two-Wheel Steer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 L (7.0 qt)
Oil Capacity (All-Wheel Steer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 L (6.0 qt)
Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use original John Deere filters
Charge Pressure Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1958 kPa (284 psi)

Charge Pump (Two-Wheel Drive)

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cc/rev.
Charge Pressure Relief Valve (Implement Pressure) (minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924psi)
Rated Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm)
Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 L/m (3.4 gpm) @ 3200 rpm

Charge Pump (MFWD Machines)

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 cc/rev.
Charge Pressure Relief Valve (Implement Pressure) (minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi)
Rated Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 L/m (6.0 gpm)
Minimum Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm) @ 3200 rpm

Hydraulic Control Valve

Leakage (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 cc/minute @ 6895 kPa (0.135 oz/minute @ 1000 psi)
Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.635 cm (1/4 in.) ISO

Hydraulic Lift Cylinder

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 mm (4.0 in.)
Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4 mm (1.0 in.)

Test and Adjustment Specifications

NOTE: Make sure engine idle and wide-open throttle speeds are correct before performing any of the hydraulic
tests.
Charge (Implement) Pressure Relief (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi)
Charge Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1958 kPa (284 psi)

Lift Cylinder Leakage Test:

Hydraulic Oil Temperature (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43°C (110°F)
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slow idle
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No leakage

Control Valve Leakage Test:

Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slow idle
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No more than a drip from "out" port of control valve

Hydraulics Specifications - 431

 HYDRAULICS SPECIFICATIONS
Repair Torque Specifications
Control Valve Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16 N•m (8 - 12 lb-ft)
End Cap Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.)
Spring Retainer Retaining Screw (Under End Cap). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.)
Detent Ball Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.)
Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (36 lb-in.)
Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Lift Check Valves Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft)

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).

Special or Required Tools

Tool Name Tool No. Tool Use
Temperature Gauge JDG282 Used to measure hydraulic oil temperature.
Quick Coupler AM102420 Used to connect to pressure and flow test
equipment.
9/16-18 M x 7/16-20 M 37° Orb JT031111 Used to connect pressure and flow test
equipment.
Hose JT03017 Used to connect pressure gauge to couplers
during pressure tests.
Pressure Gauge - 13790 kPa (2000 psi) JT03117 Used to measure hydraulic oil pressure.
Consumer Products Hydraulic Fitting Kit JT01765 Used for Charge Pump Flow and Pressure
Quick Test at Couplers.
Flowmeter Kit JT05469 Used to measure flow rate of hydraulic oil.
1/4 Male Quick-Coupler AM102420 Used to connect flowmeter to work ports.
Connector and 9/16-18 M 37° x 9/16-18 JT03216 Used to connect flowmeter to work ports.
M Orb
Coupler and 3/4” F NPT x 9/16-18 F 37° JT03342 Used to connect flowmeter to work ports.
Orb

Other Materials

Other Material
Part No. Part Name Part Use
TY9370/TY9477/ Loctite ® Products Thread Lock and Sealer Used to seal threads on control valve screws,
#242 (Medium Strength) spool detent and small plugs.
AM132341 Control Valve Seal Kit
AM100201 Load Check Valve Kit
AM132340 Spool Spring Center Kit
AM132338 Spool Detent Float Kit

Hydraulics Specifications - 432

 HYDRAULICS SCHEMATICS
Schematics Hydraulic Schematic - Power Train

X PTO Pressure Test Port

PTO Clutch PTO Shutoff Solenoid
1469 kPa
(213 psi)

PTO Pressure Regulator Valve

Anti-Cavitation
Check Valve
PTO Brake 19 L/minimum Anti-Cavitation
(0.5 gpm) Pressure
6371 kPa Screen
(924 psi)
Constant Reduction
Valve
Charge Pressure Forward Directional
Relief Valve Test Port
(Implement Pressure) Control Valve
Charge Charge
Pump Pressure
18 mL/rev 18 mL/rev Hydrostatic Fixed
Hydrostatic Variable (0.6 oz/rev) (0.6 oz/rev) Displacement Motor
Displacement Pump
19588 kPa
(284 psi)
Reverse Directional
2-WD 6 mL/rev Control Valve
(0.2 oz/rev)
MFWD 8 mL/rev Charge
(0.27 oz/rev) Pressure
Control Valve

Hydraulic Oil Filter

Oil Cooler
Hydraulic
Control Valve Steering
Valve
Housing
Auxiliary Control
Spool Valve
P B T
T P
Manual
Steering
Check
Valve

A
Lift Cylinder
Shutoff Valve
(Option)
B
Steering
Control
Valve
C
Metering
Pump

D R L

Lift Control Regen Kit Spool

Lift Cylinder Spool Valve Extension (Option)
Steering Cylinder
MIF

Hydraulics Schematics - 433

 HYDRAULICS COMPONENT LOCATION
Component Location Hydraulic System

K J
N
M
L I

H
G

A - Lift Cylinder
B - Auxiliary Control Valve Lever
C - Lift Control Valve Lever
D - Oil Cooler
E - Link Rods
F - Hydraulic Couplers
G - Hydraulic Control Valve
H - Steering Cylinder
I - Steering Valve
J - MFWD Drive
K - Hydrostatic Motor
L - Charge Pump
M - Oil Filter
N - Transaxle

Hydraulics Component Location - 434

 HYDRAULICS OPERATION AND DIAGNOSTICS
Operation and Diagnostics the hydraulic control valve at or above the charge pressure
control valve setting. When the steering and/or hydraulic
control valves are activated, restrictions in the system
Hydraulic System cause the charge pressure to increase until the charge
pressure relief valve opens. The charge pressure relief
Function:
valve opening pressure is the implement operation
The hydraulic system provides fluid power to charge the pressure.
hydrostatic pump and operate the power steering, lift
The charge pressure relief valve maintains sufficient
cylinder and any optional auxiliary hydraulic attachments.
system pressure, 6371 kPa (924 kPa) minimum, to operate
System Operation: implements.

The hydraulic systems is an "open center" type system. In Charge oil in the transmission will open the closed loop
this type of system the charge pump provides a continuous check valve and enter the forward side of the closed loop
flow of oil through a circuit that connects all of the when the reverse side has been pressurized by the
controlling valves. If the valves are not operated, the flow of hydrostatic pump. When the direction is reversed to provide
oil passes through the "open center" of each valve and then forward direction, charge oil will then pressurize the reverse
returns to the transmission case. In an open center circuit, side of the closed loop.
the first controlling valve takes priority over the next valve The variable displacement hydrostatic pump pressurizes
downstream in the circuit. the reverse side loop, causing the fixed displacement motor
The charge pump draws hydraulic oil from the transaxle to rotate. The reverse directional check valve blocks the
case, through the filter, then supplies a constant flow of oil closed loop pressure oil from entering the charge circuit.
to the steering valve and control valve. The reverse directional check valve cartridge has a leak-off
Return oil from the steering valve and hydraulic control orifice. This orifice bleeds off a small amount of high
valve is routed through the oil cooler then back to the pressure oil from the reserve closed loop back into the
transaxle case. charge circuit. This provides for a wider neutral band to
help prevent creep. This small leakage does not slow down
The hydraulic control valve is controlled by two levers on reverse.
the steering column. The top lever controls the lift spool
that controls the flow of oil to and from the lift cylinder. The Steering Valve Operation:
lower lever operates the auxiliary control spool valve, used
The steering valve is an open center type valve. This valve
to operate hydraulic implement equipment attached to the
consists of a self-centering fluid control valve (spool and
machine. An optional shutoff valve can be installed in the
sleeve) and a metering pump. The valve and pump are
line running to the lift cylinder. When in the off position, the
hydraulically and mechanically interconnected inside the
lift cylinder is blocked out of the system, allowing
valve.
attachments requiring dual function controls to be operated
without the deck or hitch moving up or down. Pressure oil comes into the steering valve body at the inlet
port from the charge pressure control valve. The oil then
See this section for operation, test and repair of the
flows through inlet passage to a series of grooves,
hydraulic control valve and charge pressure tests.
passages, and slots in the valve body, sleeve, and spool to
See Power Train section for operation, test and repair of come out the power beyond passage and power beyond
charge pump and valves. port to go on to the lift system. The amount of oil that flows
See Steering section for operation and test of the steering this way varies with the speed of the turn. All the oil will
valve and cylinder. follow this path when the steering valve is in neutral. There
will be some oil when a slow turn is made, and there will be
NOTE: Couplers are optional on some models but the less oil when a fast turn is made. No oil is available to the
auxiliary spool valve is functional, standard power beyond port when the steering is dead headed.
equipment.
When the valve is in neutral, the turn passages are closed.
Hydraulic Pump and Motor Operation: The oil in the steering cylinder and lines is trapped oil. The
small amount of internal leakage oil will go out the return
The charge pump draws oil from the transaxle sump and port as return oil back to the sump.
provides charge oil to the center section. The charge
pressure control valve maintains a minimum oil pressure,
1958 kPa (284 psi), in the center section.
If the implements or steering are not activated, the charge
pump circulates oil through the steering control valve and

Hydraulics Operation and Diagnostics - 435

 HYDRAULICS OPERATION AND DIAGNOSTICS
Hydraulic Control Valve Operation - Neutral

F B
A

C
B A

A
T P C
D C D

I
A H

B D

Charge Pressure Oil

C Return Oil
G
Trapped Oil
D

MIF open-center spools (the lift cylinder spool and the auxiliary
A - Return Springs spool). The lift spool (D) has three positions in the standard
configuration, controlling the raising and lowering of the lift
B - Load Check Valve
cylinder. It is spring-centered and is automatically returned
C - Auxiliary Spool
to the neutral position when the lever is released. The
D - Lift Spool fourth position is for the bucket regenerative function, which
E - Inlet is available as a kit. (See “Hydraulic Control Valve
F - Hydraulic Control Valve Housing Operation - Regen” on page 439.)
G - Lift Cylinder When in the neutral position, charge oil passes through the
H - Load Check Valve "open center" passage and exits the valve housing at the
I - Outlet Port Location "OUT" port. The auxiliary spool (C) is four-position,
controlling the raise, lower, and neutral functions of the
Function: couplers connected to auxiliary equipment. It is spring-
centered and automatically returns to neutral, except when
The hydraulic control valve controls oil flow to the lift
placed into the “float” position. (See “Hydraulic Control
cylinder and the auxiliary hydraulic outlets (if equipped).
Valve Operation - Float”.)
When both spool valves are in the neutral position they
block oil flow to the lift cylinder and to any attachments, In neutral, the passages are blocked by the spools, there is
holding them in the desired position. no oil flow entering the work ports. No oil is allowed to enter
or leave, hydraulically locking the lift cylinder or attached
System Operation: implement in position.
The hydraulic control valve housing contains two separate,

Hydraulics Operation and Diagnostics - 436

 HYDRAULICS OPERATION AND DIAGNOSTICS
Hydraulic Control Valve Operation - Raise

E B
A

C
B A

D C D
F A
F
C
T P
H

B
Charge Pressure Oil

Return Oil
C
G
D
D

MIF System Operation:

A - Return Springs As the control lever and linkage moves either of the spools
B - Load Check Valves toward the lift position, the open center passage is closed
C - Auxiliary Spool off, increasing inlet pressure at work port. When inlet
D - Lift Spool pressure overcomes the pressure of the work port, and oil
flow starts to move the load, the lift check valve opens. The
E - Hydraulic Control Valve Housing
lift check valve prevents the load from dropping before inlet
F - Inlet pressure overcomes the load or if the hydraulic system
G - Lift Cylinder should lose pressure. High pressure oil acting against the
H - Load Check Valve cylinder, makes the cylinder extend. The oil from the rod
end of the cylinder returns though the work port to return oil
Function: and exits the control valve.
Controls the flow of pressure oil to the piston side of lift
cylinder and allows return oil from the cylinder to exit the
valve housing.

Hydraulics Operation and Diagnostics - 437

 HYDRAULICS OPERATION AND DIAGNOSTICS
Hydraulic Control Valve Operation - Float
E B
A

B A C

A D C D

F F

T P H

B Charge Pressure Oil

Return Oil

C Trapped Oil
G
D

MIF System Operation:

A - Return Springs When the shift linkage moves the control spool (C) into the
B - Load Check Valve "float" position (lever fully forward), it is held there by detent
C - Auxiliary Spool balls. The spool will remain in this position until it is
D - Lift Spool manually brought back out of the detents. In the float
position, the open center circuit is still open, allowing oil
E - Hydraulic Control Valve Housing
flow to exit the control valve and also to be available for the
F - Inlet operation of the lift cylinder. Both pressure and return work
G - Lift Cylinder ports are open to the return circuit. As the cylinder extends
H - Load Check Valve or retracts, oil is drawn from the return circuit.
I - Detent Balls

Function:
In "float" position, the spool equalizes the pressure
between both work ports, allowing oil to freely enter or
leave the auxiliary cylinder. This allows the implement to
follow or "float" with the contour of the ground.

Hydraulics Operation and Diagnostics - 438

 HYDRAULICS OPERATION AND DIAGNOSTICS
Hydraulic Control Valve Operation - Regen
B

E
A

B A C

A D C D
I
F F

T P H

J A

B
Charge Pressure Oil

Return Oil
C
G Trapped Oil
D
D

MIF optional regen end cap (I), included in the regen kit. Going
A - Return Springs into regen, the charge pressure is going into area “C”.
Return flow from area “D” gets blocked and is rerouted
B - Load Check Valve
across the load check bridge (H) to area “C”.
C - Auxiliary Spool
D - Lift Spool System Operation:
E - Hydraulic Control Valve Housing The shift linkage moves the control spool (D) into the
F - Inlet "regen" position (lever fully forward). The auxiliary outlet
G - Lift Cylinder spool will not remain in this position unless held, and
H - Load Check Valve should return from regen position without locking.
I - Regen Bucket Kit (Option) The lift cylinder shutoff valve (J) would typically be closed.
J - Shutoff Valve (Option) The regen function would be used with the loader to
increase the speed of the bucket dump. The bucket
Function: cylinders are connected to the C and D ports.
In "regen" position the spool moves fully forward into the

Hydraulics Operation and Diagnostics - 439

 HYDRAULICS OPERATION AND DIAGNOSTICS
Lift Cylinder Shut-off Valve - Optional Symptom: Hydraulic Problems
Function: Yes - Air leak on suction side of charge pump.
The shutoff valve is supplied with the front hitch kit. Its Yes - Transmission case vent plugged.
purpose is to lock the lift cylinder in a set position so when
Yes - Hydraulic oil contaminated. Flush, change oil
using the front coupler work ports, the deck or rear hitch will
and filter.
not move. This will provide a positive movement of the
attachment. (3) Slow hydraulic functions?
No - Go to next step.
Hydraulic Diagnostics
Yes - Check hydraulic oil level. Replace filter.
Symptom: Hydraulic Problems Yes - See “Charge Pump Pressure and Flow Quick
(1) Mower will not lift? Test at Couplers” on page 444.

No - Go to next step. Yes - Tapered crankshaft sheave slipping on engine

crankshaft.
Yes - Shutoff valve is installed and is shut off.
Yes - Hydraulic line damaged, causing a restriction.
Yes - LIft linkage is binding or disconnected. Deck
height adjustment is all the way up. Yes - Coupler tips worn or damaged. Replace
couplers.
Yes - Check hydraulic oil level. Replace filter.
Yes - Charge (implement) pressure relief valve
Yes - See “Charge Pump Pressure and Flow Quick setting incorrect.
Test at Couplers” on page 444.
Yes - Hydraulic control spool valve scored.
Yes - Hydraulic line damaged, causing a restriction.
Yes - See “Control Valve Leakage Test” on page 447.
Yes - Charge (implement) pressure relief valve
setting incorrect. Yes - Control valve spool not neutralizing. Check
linkage for binding or repair valve.
Yes - Hydraulic control spool valve scored.
Yes - Lift cylinder leaking. See “Lift Cylinder Leakage
Yes - See “Control Valve Leakage Test” on page 447. Test” on page 447.
Yes - Lift cylinder leaking. See “Lift Cylinder Leakage Yes - Implement lift or operating cylinder is leaking.
Test” on page 447.
Yes - Air leak on suction side of charge pump.
Yes - Air leak on suction side of charge pump.
Yes - Lift cylinder not locked out.
Yes - Transmission case vent plugged.
Yes - Transmission case vent plugged.
(2) Hydraulic system inoperative?
Yes - Hydraulic oil contaminated. Flush, change oil
No - Go to next step. and filter.
Yes - Optional shutoff valve is installed and is shut Yes - Excessive load.
off.
(4) Low lift capacity?
Yes - LIft linkage is binding or disconnected. Deck
height adjustment is all the way up. No - Go to next step.

Yes - Check hydraulic oil level. Replace filter. Yes - See “Charge Pump Pressure and Flow Quick
Test at Couplers” on page 444.
Yes - See “Charge Pump Pressure and Flow Quick
Test at Couplers” on page 444. Yes - Charge (implement) pressure relief valve
setting incorrect.
Yes - Hydraulic line damaged, causing a restriction.
Yes - Lift cylinder leaking. See “Lift Cylinder Leakage
Yes - Charge (implement) pressure relief valve Test” on page 447.
setting incorrect.
Yes - Implement lift or operating cylinder is leaking.
Yes - Lift cylinder leaking. See “Lift Cylinder Leakage
Test” on page 447. Yes - Hydraulic oil contaminated. Flush, change oil
and filter.

Hydraulics Operation and Diagnostics - 440

 HYDRAULICS OPERATION AND DIAGNOSTICS
Symptom: Hydraulic Problems Symptom: Hydraulic Problems
Yes - Excessive load. Yes - Tapered crankshaft sheave slipping on engine
crankshaft causing chirping sound.
(5) Erratic operation of implement attached to
couplers? Yes - Charge (implement) pressure relief valve
setting incorrect.
No - Go to next step.
Yes - Control valve spool not neutralizing. Check
Yes - Check hydraulic oil level. Replace filter.
linkage for binding or repair valve.
Yes - See “Charge Pump Pressure and Flow Quick
Yes - Air leak on suction side of charge pump.
Test at Couplers” on page 444.
Yes - Transmission case vent plugged.
Yes - Coupler tips worn or damaged. Replace
couplers. Yes - Hydraulic oil contaminated. Flush, change oil
and filter.
Yes - Charge (implement) pressure relief valve
setting incorrect. Yes - Excessive load.
Yes - See “Control Valve Leakage Test” on page 447. (8) Control levers stick, hard to operate, do not
align?
Yes - Control valve spool not neutralizing. Check
linkage for binding or repair valve. No - Go to next step.
Yes - Lift cylinder leaking. See “Lift Cylinder Leakage Yes - Optional shutoff valve is installed and is shut
Test” on page 447. off.
Yes - Implement lift or operating cylinder is leaking. Yes - LIft linkage is binding or disconnected. Deck
height adjustment is all the way up.
Yes - Air leak on suction side of charge pump.
Yes - Check hydraulic oil level. Replace filter.
Yes - Lift cylinder not locked out.
Yes - See “Charge Pump Pressure and Flow Quick
Yes - Transmission case vent plugged.
Test at Couplers” on page 444.
Yes - Hydraulic oil contaminated. Flush, change oil
Yes - Hydraulic line damaged, causing a restriction.
and filter.
Yes - Coupler tips worn or damaged. Replace
Yes - Excessive load.
couplers.
(6) Mower deck or attachment drops with control
Yes - Charge (implement) pressure relief valve
valve in neutral?
setting incorrect.
No - Go to next step.
Yes - Hydraulic control spool valve scored.
Yes - Hydraulic control spool valve scored.
Yes - See “Control Valve Leakage Test” on page 447.
Yes - See “Control Valve Leakage Test” on page 447.
Yes - Control valve spool not neutralizing. Check
Yes - Control valve spool not neutralizing. Check linkage for binding or repair valve.
linkage for binding or repair valve.
Yes - Lift cylinder leaking. See “Lift Cylinder Leakage
Yes - Lift cylinder leaking. See “Lift Cylinder Leakage Test” on page 447.
Test” on page 447.
Yes - Implement lift or operating cylinder is leaking.
Yes - Implement lift or operating cylinder is leaking.
Yes - Air leak on suction side of charge pump.
Yes - Air leak on suction side of charge pump.
Yes - Lift cylinder not locked out.
(7) Hydraulic noise?
Yes - Hydraulic oil contaminated. Flush, change oil
No - Go to next step. and filter.
Yes - Check hydraulic oil level. Replace filter. (9) Hydraulic oil foams?
Yes - See “Charge Pump Pressure and Flow Quick No - Go to next step.
Test at Couplers” on page 444.
Yes - Check hydraulic oil level. Replace filter.
Yes - Hydraulic line damaged, causing a restriction.

Hydraulics Operation and Diagnostics - 441

 HYDRAULICS OPERATION AND DIAGNOSTICS
Symptom: Hydraulic Problems System: Hydraulic System - Engine OFF
Yes - See “Charge Pump Pressure and Flow Quick
(Preliminary Checks)
Test at Couplers” on page 444. Yes - Go to step 2.
Yes - Air leak on suction side of charge pump. No - Add John Deere Low Viscosity HY-GARD
Yes - Hydraulic oil contaminated. Flush, change oil Transmission and Hydraulic Oil (J20D). Drain and
and filter. replace.

(10) Frequent failure of hydraulic line or O-Rings? (2) John Deere Low Viscosity HY-GARD
Transmission and Hydraulic Oil: Foamy, milky,
No - Go to next step. metal particles noted, discolored or burned?
Yes - See “Charge Pump Pressure and Flow Quick No - Go to next step.
Test at Couplers” on page 444.
Yes - Check for air leak and use of correct fluid.
Yes - Charge (implement) pressure relief valve
setting incorrect. Yes - Check for water in oil.

Yes - Hydraulic oil contaminated. Flush, change oil Yes - Check for mechanic failure.
and filter. Yes - Check for causes of overheating: Plugged
Yes - Excessive load. radiator, hydraulic control valve stuck, charge
pressure relief valve malfunction.
(11) Hitch drops or will not hold implement up?
(3) Oil Leakage?
No - Go to next step.
No - Go to next step.
Yes - Hydraulic control spool valve scored.
Yes - Repair cause.
Yes - See “Control Valve Leakage Test” on page 447.
(4) Radiator screen, cooler, and radiator free of dirt
Yes - Control valve spool not neutralizing. Check and debris?
linkage for binding or repair valve.
No - Clean as required.
Yes - Lift cylinder leaking. See “Lift Cylinder Leakage
Yes - Engine OFF preliminary checks completed.
Test” on page 447.
Yes - Implement lift or operating cylinder is leaking.
Test Conditions:
(12) Mower will not lower?
• Start engine.
No - Go through procedures in “Preliminary Hydraulic
System Inspection” on page 442. • Operate ALL hydraulic functions.

Yes - Optional shutoff valve is installed and is shut System: Hydraulic System - Engine Running
off. (Preliminary Checks)
Yes - LIft linkage is binding or disconnected. Deck (1) Quick and positive steering response? Full
height adjustment is all the way up. right to full left with only slight effort? Steering
Yes - Hydraulic line damaged, causing a restriction. wheel does not drift when driving in straight line?
Yes - Go to next step.
Preliminary Hydraulic System Inspection No - See the Steering section for steering system
diagnosis.
Test Conditions: (2) Lift cylinder control lever: Implement should
• Engine off. raise and lower. Holds implement up for a
reasonable time (4 minutes) when in neutral?
• Machine on hard level surface.
Yes - Go to next step.
System: Hydraulic System - Engine OFF
(Preliminary Checks)
(1) Hydraulic oil between marks on dipstick?

Hydraulics Operation and Diagnostics - 442

 HYDRAULICS OPERATION AND DIAGNOSTICS
System: Hydraulic System - Engine Running System: Hydraulics
(Preliminary Checks) (2) Transmission drive shaft is turning hydrostatic
No - See “Charge Pump Pressure and Flow Quick transmission input shaft?
Test at Couplers” on page 444 and “Control Valve Yes - Go to next step.
Leakage Test” on page 447. If lift cylinder rod leaked
down 25.4 mm (1 in.) in the 1 - 2 minute range, check No - Repair as necessary.
for cylinder leakage first, then proceed with tests. (3) Constant, foam free flow from charge pump?
(3) Auxiliary hydraulic control lever: Adequate Pump flow within specification? Pressure relief
pressure and flow out of front couplers. Holds valve in specification?
pressure to attachment when in neutral? Yes - Go to next step.
Yes - Go to next step. No - Perform “Charge Pump Pressure and Flow
No - See “Control Valve Leakage Test” on page 447. Quick Test at Couplers” on page 444.
(4) Positive transmission speed control response: (4) Steering is responsive and turns quickly full
control forward, neutral, and reverse? right and left?
Yes - Go to next step. Yes - Go to next step.
No - See the Power Train section for transmission No - See the Steering section for steering system
and speed control linkage diagnosis. diagnosis.
(5) Hydraulic oil filter replaced at normal service (5) Hydraulic control valve (deck lift): Lifts and
intervals or replaced to verify filter is not holds deck and hitch in the raised position?
restricted? Control lever returns to neutral?
Yes - Go to next step. Yes - Go to next step.
No - Change hydraulic filter. No - Perform “Control Valve Leakage Test” on
page 447. Check linkage for binding. Repair or
(6) All hydraulic system checks normal?
replace control valve.
No - Complaint not found and unable to duplicate
(6) Hydraulic cylinders lift and hold implement in a
complaint. Factory assistance for a dealer is available
raised position? No leakage at rod seal or
through the Dealer Technical Assistance Center
connectors?
(DTAC).
Yes - Go to next step.
No - Perform all the steps in “Hydraulic Diagnostics”
on page 440. Perform tests and adjustments to No - Perform “Lift Cylinder Leakage Test” on
isolate and repair the malfunction. page 447. Replace cylinder.
Yes - Engine running preliminary checks completed. (7) Auxiliary couplers: Relief pressure within
specification? Hydraulic flow within specification?
Spool leakage within specification?
Hydraulic System Tests
Yes - Go to next step.

Test Conditions: No - Perform “Charge Pump Pressure and Flow

Quick Test at Couplers” on page 444 and/or perform
• Park brake engaged. “Control Valve Leakage Test” on page 447.
• Engine not running. (8) Hydrostatic transmission operates in forward and
reverse? Returns to neutral and does not creep?
System: Hydraulics
No - See the Power Train section for hydrostatic
(1) Hydraulic/transmission dipstick has proper system diagnosis
level, viscosity, type and condition per the
preliminary hydraulic checks? Yes - Hydraulic checks completed.

Yes - Go to next step.

No - Drain and replace fluid and filter.

Hydraulics Operation and Diagnostics - 443

 HYDRAULICS TESTS AND ADJUSTMENTS
Tests and Adjustments Orb
• JT03342 Coupler and 3/4" F NPT x 9/16-18 F 37° Orb
Hydraulic Oil Warm-Up Procedure
Pressure Test:
Reason:
When making hydraulic tests the oil must be heated to
normal operating temperature for the tests to be accurate.

Test Equipment:
• JDG282 Temperature Gauge

Procedure:
1. Install JDG282 Temperature Gauge on transmission oil
A
filter.

IMPORTANT: Avoid damage! DO NOT overheat

engine.

2. Apply park brake. Start engine and run at full throttle.

3. Move and hold hydraulic lever in implement raise
position. MIF

4. Periodically cycle all hydraulic functions to distribute 1. Locate hydraulic control valve on right side of machine
heated oil. frame. Install JT03117 pressure gauge into coupler (A).
5. Heat oil to operational temperature [38 - 49° C (100 - 2. Start and run engine at high idle.
120° F) typical].
3. Move the auxiliary hydraulic control lever to the raise or
lower position.
Charge Pump Pressure and Flow Quick Test 4. Observe pressure gauge reading.
at Couplers
Results:
Reason:
• If pressure is to charge relief (implement) pressure
To check condition of the charge pump and the charge specifications, 6371 kPa (924 psi) minimum, pump and
pressure relief valve setting (implement operation charge pressure relief valve are in good condition.
pressure). This determines if there is sufficient oil pressure
and flow to operate implements. • If there is no pressure, repeat test using different
coupler. If pressure exists, replace coupler and repeat test.
NOTE: This test can be misleading if there is a
• If pressure is below 5881 kPa (853 psi), See “Charge
malfunction of the steering valve, hydraulic control
Pump Pressure Test” on page 445.
valve or lift cylinder.
Flow Test:
Pressure Test Equipment:
1. If machine is not equipped with quick-couplers, install
• AM102420 Quick Coupler)
couplers.
• JT031111 9/16-18 M x 7/16-20 M 37° Orb
• JT03017 Hose
• JT03117-13790 kPa (2000 psi) Pressure Gauge

Flow Test Equipment:

• JT01765 Consumer Products Hydraulic Fitting Kit
• JT05469 Flowmeter Kit
• AM102420 1/4 Male Quick-Coupler
• JT03216 Connector and 9/16-18 M 37° x 9/16-18 M

Hydraulics Tests and Adjustments - 444

 HYDRAULICS TESTS AND ADJUSTMENTS
• Leak in case passage between filter and charge
pump
• If problem cannot be found, perform flow and pressure
test at charge pump to eliminate the possibility of the
steering valve or hydraulic control valve malfunctioning,
giving false test results. (See the Hydrostatic Power Train
section.)

A
• Check charge pump for damage.

Charge Pump (Two-Wheel Drive)

B
Rated Flow . . . . . . . . . . . . . . . . . . . . . 17 L/m (4.5 gpm)
Minimum Flow . . . . . . . . 13 L/m (3.4 gpm) @ 3200 rpm

Charge Pump (MFWD Machines)

Rated Flow . . . . . . . . . . . . . . . . . . . . 22.7 L/m (6.0 gpm)
MIF
Minimum Flow . . . . . . . . 17 L/m (4.5 gpm) @ 3200 rpm
2. Connect flowmeter to work ports (A and B).

Flow Test Procedure:

Charge Pump Pressure Test
1. Open flowmeter control valve. Reason:
2. Start engine and run at high idle. Oil must be at normal To determine charge pressure control valve operation and
operating temperature. help determine condition of hydraulic charge pump. This
3. Move cylinder lift control lever to get oil flow through also checks charge pump pressure relief valve operation
meter in correct direction. and determines if there is sufficient pressure to operate
implements.
4. Observe flowmeter reading.
Test Equipment:
Results:
• JT05489 Connector, 7/16-20 x M 37° 1/2-20 M ORB
• If pump flow is between minimum and rated flow
specification, pump is in good condition. • JT03017 Hose

• If there is no pump flow, check: • JT03117-13790 kPa (2000 psi) Pressure Gauge

• Drive shaft not turning input shaft Pressure Test Procedure:

• Sheared charge pump drive key Warm hydraulic oil to operating temperature before
• Charge pressure control valve stuck closed performing this test. When done “cold” or at shop
temperature, most machines (especially when new) will
• If pump flow is below minimum flow specification, foamy likely be close to 3450 kPa (500 psi). See “Hydraulic Oil
or erratic, check: Warm-Up Procedure” on page 444.
• Hydraulic oil level 1. Park machine safely. See “Park Machine Safely” in the
• Charge pressure Safety section.
• Filter, replace and repeat test 2. Remove seat and fender deck.
• Transaxle vent for plugging 3. Attach seat switch and set up machine so engine can be
run.
• Filter seal for leaks
• Charge pressure relief valve for damage or debris
that could be holding valve open
• Charge pressure control valve for scoring or debris
that could be holding valve closed
• If pump flow is still below minimum flow specification,
check:
• O-ring at inlet of charge pump leaking

Hydraulics Tests and Adjustments - 445

 HYDRAULICS TESTS AND ADJUSTMENTS
Results:
c under
CAUTION: Avoid Injury! Escaping fluid
pressure can penetrate the skin
• If charge pressure is to specifications, 1958 kPa (284
psi) minimum, in transaxle, charge pressure control valve
causing serious injury. Avoid the hazard by is operating properly.
relieving pressure before disconnecting • Note: Charge pressure gauge reading may be higher
hydraulic or other lines. Tighten all than specification due to cold oil temperature. Warm oil
connections before applying pressure. and retest.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure • If charge pressure is too high, and oil is at operating
fluids. temperature, there is a potential problem with the charge
• If an accident occurs, see a doctor pressure control valve, or a restriction in the system. See
immediately. Any fluid injected into the skin “Charge Pump Flow and Pressure Test - At Charge Pump”
must be surgically removed within a few in the Hydraulic Power Train section.”
hours or gangrene may result. Doctors • If relief pressure is to charge relief (implement) pressure
unfamiliar with this type of injury should specifications, 6371 kPa (924 psi) minimum, pump and
reference a knowledgeable source. Such charge pressure relief valve are in good condition.
information is available from the Deere &
Company Medical Department in Moline,
Illinois, U.S.A. In the United States and
Canada only, this information may be
obtained by calling 1-800-822-8262.

A MX14228
B
• If relief pressure is below 5881 kPa (853 psi), check
charge pressure relief valve (B), shim relief pressure
spring. If pressure cannot be increased, check charge
pump for damage.

MX14307

4. Install connector, hose and pressure gauge to charge

pressure test port (A).
5. Start engine and run at high idle. Do not operate
steering or hydraulic control valves.
6. Observe gauge reading. This is charge pressure.
7. Move hydraulic control lever to raise or lower position.
Hold until pump pressure is in relief.
8. Observe gauge reading and release control. This is
charge pressure relief pressure (implement operation
pressure).

Specification:
Charge Pressure (minimum) . . . . . . . 1958 kPa (284 psi)
Charge Relief (Implement) Pressure (minimum)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi)

Hydraulics Tests and Adjustments - 446

 HYDRAULICS TESTS AND ADJUSTMENTS
Lift Cylinder Leakage Test
IMPORTANT: Avoid damage! Hold control lever
Reason: in the raised position before starting engine.
Also be ready to shut off engine. If valve leaks,
To determine if lift cylinder is leaking. oil will flow out open port.

c under
CAUTION: Avoid Injury! Escaping fluid
pressure can penetrate the skin
4. Move hydraulic control valve lever to "lift" position.
5. Start engine. Operate at slow idle.
causing serious injury. Avoid the hazard by 6. Observe cylinder rod-end line (A) for continuous oil
relieving pressure before disconnecting leakage.
hydraulic or other lines. Tighten all
connections before applying pressure. Results:
Search for leaks with a piece of cardboard. • If hydraulic oil continually leaks out of fitting, replace lift
Protect hands and body from high pressure cylinder.
fluids.
• If no leakage, go to Second Procedure.
• If an accident occurs, see a doctor
immediately. Any fluid injected into the skin Second Procedure:
must be surgically removed within a few
hours or gangrene may result. Doctors 1. Shut off engine and connect line (B).
unfamiliar with this type of injury should 2. Start engine and lower (retract) cylinder.
reference a knowledgeable source. Such
3. Shut off engine. Remove line (B).
information is available from the Deere &
Company Medical Department in Moline, 4. Hold control lever in the lower position.
Illinois, U.S.A. In the United States and 5. Start engine and observe flow from line.
Canada only, this information may be
obtained by calling 1-800-822-8262. Results:
• No leakage, cylinder is good.
First Procedure:
• Leakage, replace cylinder.
1. Remove any attachment that is mounted, including
mower deck.
2. With deck lift arms in raised position, shut off engine.
Control Valve Leakage Test
Reason:
To determine the condition of spool valves and housing.

Test Equipment:
• Measuring tape or ruler

Mower Deck Lift Spool Procedure:

1. Heat hydraulic oil to specifications. (See “Hydraulic Oil
Warm-Up Procedure” on page 444.)
2. Make sure mower deck is properly installed.
A 3. Make sure that mower deck lift stop is at 1.0 inch
(lowest) cut height position.
B
4. Move lift cylinder to maximum raise position (pull top
MX14432 lever fully back).
3. Disconnect lift cylinder rod-end line (A) from control 5. Shut off engine.
valve. 6. Measure height from level ground to mower deck
attaching pin (the pin engaged in “V” slot at the end of the
lift arms).
7. Wait approximately 12 minutes.

Hydraulics Tests and Adjustments - 447

 HYDRAULICS REPAIR
8. Measure pin height again. Repair
Results:
Hydraulic Control Valve Removal and
• Mower deck should drop no more than 25 mm (1.0 in.)
Installation
in 12 minutes.
Removing:
Front Quick Hitch Lift Cylinder Procedure:
1. Remove hood.
1. Heat hydraulic oil to specifications. (See “Hydraulic Oil
Warm-Up Procedure” on page 444.)
2. Make sure front hitch is properly installed. A
3. Whatever front implement is on machine (blade, broom, B
snowblower, etc.) can remain mounted.
C
4. Move hitch lift cylinder to maximum raise position (pull
bottom lever fully back).
5. Shut off engine.
6. Measure height from level ground to quick pull pin at the
front/top of the quick hitch.
7. Wait approximately 7 minutes. B B
8. Measure pin height again.
MX11895
Results: NOTE: Engine removed in photo for clarity.
• Attachment should drop no more than 25 mm (1.0 in.) in 2. Remove hydraulic lines at fittings (B).
7 minutes.
3. Remove bolt (C) connecting lower half of control valve to
frame.

D E

F
H
G

MX11896

Note: Some models have couplers instead of

plugs.
4. Remove spring pin (E) from control arm (D).
5. Remove spring pin (F) from control arm (G).
6. Remove bolt and nut (A) connecting upper half of
control valve to frame.
7. Remove and make repairs to valve as necessary. (See
“Hydraulic Control Valve” on page 449.)

Hydraulics Repair - 448

 HYDRAULICS REPAIR
Installing: • Tighten large straight fitting (E) to 33 - 49 N•m (24 - 36
lb-ft).
Installation is done in the reverse order of removal.
• Tighten drain plugs to 38 N•m (28 lb-ft); 25 HP EFI
engine (FD711D): tighten couplers to 33 - 49 N•m (24 - 36
IMPORTANT: Avoid damage! Do not overtighten
lb-ft).
valve mounting bolts, valve spools may stick.

• Tighten mounting bolt (C), and lock nut (A) to mounting Load Check Valve:
bolt (I), to 11 - 16 N•m (8 - 12 lb-ft).
J
• Tighten hydraulic line fittings (B) to 24 - 30 N•m (18 - 22
lb-ft).
• Install lower control arm (G) and hardware before
I
installing upper control arm (D) and hardware onto valve
assembly.

Hydraulic Control Valve

H K
A
B
A
MX11931

1. Disassemble check valve assembly, which includes a

C cap (J) and O-rings (I) (4 used), spring (K), and check valve
poppet (H).

D Installation is done in the reverse order of removal.

• Tighten cap to 24 N•m (18 lb-ft).
G B NOTE: The quick-coupler assembly is serviced as a
F C separate assembly and is replaced as a kit only.
E
Up/Down Spool Assembly:
MX11929

IMPORTANT: Avoid damage! Always use new O- IMPORTANT: Avoid damage! Always use new O-
rings. Damaged or used O-rings will leak. rings. Damaged or used O-rings will leak.

Disassembly: O

1. Remove two load check valves (B) and O-rings (2 used).

2. Remove two small straight fittings (C) with O-rings.
3. Remove one large straight fitting (E) with O-ring. N

4. Remove 90° fitting (D) with O-ring.

M
NOTE: All machines have couplers installed, except
465 and 475, instead of drain plugs (A). P

5. Remove drain plugs (A) with O-rings (4 used). Q

6. Remove up/down float spool assembly (G).
R
7. Remove up/down spool assembly (F).
L
Installation is done in the reverse order of removal. S

• Tighten 90° fitting (D) to 33 - 49 N•m (24 - 36 lb-ft).

T
• Tighten small straight fittings (C) to 24 - 30 N•m (18 - 22
lb-ft). MX11932

Hydraulics Repair - 449

 HYDRAULICS REPAIR
1. Disassemble up/down float spool assembly. 4. Apply multi-purpose grease to two springs (V) and balls
(AB).
NOTE: O-rings (O) are located in spool bore at each
end of control valve. The O-rings are serviced as a Installation is done in the reverse order of removal.
separate assembly and replaced as a kit only. The
remaining parts (gasket (N), end cap (M), spring (R), • Tighten detent ball retaining screws and detent plugs to
spring retainer (S), and screw (T), except the spool (P) 4 N•m (36 lb-in.).
and washers (Q), are serviced as a separate assembly
and are replaced as kits only. Lift Cylinder Removal and Installation
Installation is done in the reverse order of removal. 1. Remove fuel tank. (See “Fuel Tank Removal and
Installation” on page 553 in the Miscellaneous section.)
• Tighten screws (L and T) to 4 N•m (36 lb-in.).
NOTE: Remove cylinder with hoses attached.
Up/Down Float Spool Assembly:
E
IMPORTANT: Avoid damage! Spool and housing
are matched and must be replaced as an
assembly. Make sure spool is installed in
original bore to ensure proper operation. Always
use new O-rings. Damaged or used O-rings will C D
leak.

1. Apply thread lock and sealer (medium strength) to

B
threads of screws.
NOTE: O-rings are located in spool bore at each end of
control valve. The O-rings (Y) are serviced as a
separate assembly and replaced as a kit only. The steel
ball is serviced and the end cap is serviced. The
remaining parts, except the spool (Z), end cap (W) and
A
steel ball (AB), are serviced as a separate assembly
and are replaced as kits only. MX14179

2. Remove cap screw (E) and nut holding hose clamp to

2. Apply multi-purpose grease to spring (AA) after installed
frame.
on spool.
3. Disconnect hoses from hydraulic line at connections (D).
Y 4. Remove spring clip (C) and pin.
5. Remove spring clip and pin (A).
6. Remove lift cylinder (B).

Installation is done in the reverse order of removal.

U Z • Tighten fittings (D) to 24 - 30 N•m (18 - 22 lb-ft).

X
W • If removed, tighten hose fittings attached to lift cylinder
V
(B) to 16 N•m (12 lb-ft).
AA

AB

AC

MX11933

3. Apply thread lock and sealer (medium strength) to

threads of screws (AC) and two detent plugs (U).

Hydraulics Repair - 450

 HYDRAULICS REPAIR
Hydraulic Control Levers and Linkage

B
C

E
D

L H E

K J

I
I

MIF I - Spring Locking Pin

Viewed from frame side of valve J - Link
A - Knob K - Spool Valve
B - Spring Pin L - Quick Coupler (If installed)
C - Lift Control Valve Lever M - Dust Cap
D - Auxiliary Control Valve Lever 1. Remove dash panels to access controls levers.
E - Pivot 2. Inspect linkage for bent or damage parts.
F - Screw
3. Repair or replace.
G - Carriage Bolt
H - Lock Nut

Hydraulics Repair - 451

HYDRAULICS REPAIR

Hydraulics Repair - 452

 STEERING TABLE OF CONTENTS
Steering

Table of Contents

Specifications ...............................................455
General Specifications ...............................455
Test and Adjustment Specifications ...........455
Repair Specifications..................................455
Special or Essential Tools ..........................455
Component Location....................................456
Steering Components - Front Wheel Steer 456
Steering Components - All Wheel Steer.....457
Steering Components - All Wheel Steer
Rear Axle....................................................458
Theory of Operation .....................................459
Steering System Operation ........................459
Steering Valve Operation - Neutral ............460
Steering Valve Operation - Turning............461
Steering Valve Operation - Manual ............462
Diagnostics ...................................................463
Steering Diagnosis .....................................463
Steering System Tests ...............................464
Steering Link Checks .................................464
Tests and Adjustments ................................465
Hydraulic Oil Warm-Up Procedure .............465
Steering Valve and Cylinder Leakage Test 465
Toe-In Adjustment Front Wheels................466
Toe-In Adjustment All Wheel Steering .......467
Repair.............................................................468
Steering Column Removal and Installation 468
Steering Valve Removal and Installation ...469
Steering Valve Disassembly and
Assembly....................................................471
Steering Cylinder Removal and
Installation ..................................................474
Front Axle Removal and Installation...........474
Front Axle Disassembly and Assembly ......475
Rear Steering Linkage - All Wheel
Steering ......................................................477
Steering Intermediate Linkage - AWS ........479
Front and Rear Pivots ................................480

Steering Table of Contents - 453

STEERING TABLE OF CONTENTS

Steering Table of Contents - 454

 STEERING SPECIFICATIONS
Specifications

General Specifications
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power
Tilt Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard

Test and Adjustment Specifications

Steering System Leakage:
Oil Temperature (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43°C (110°F)
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fast Idle
Maximum Turns with Constant Torque of 6.8 N•m (60 lb-in.) in Either Direction . . . . . . . . . . . . . . . . . . . . . . . . . 4 rpm
Charge Pressure Control Valve (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1958 kPa (284 psi)
Steering Valve System Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6371 kPa (924 psi)

Toe-in Adjustment:
Front Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6 mm (0.04 - 0.24 in.)
Rear Tires (All Wheel Steer): Front-to-back difference from frame for each tire . . . . . . . . . . . . 0 - 10 mm (0 - 0.4 in.)

Repair Specifications
Steering Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Steering Valve End Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.)
Check Ball Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.)
Front Axle Pivot Cap Screw and Lock Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 N•m (150 lb-ft)
Tie Rod Lock Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N•m (45 lb-ft)
Rear Steering Link Lock Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 N•m (125 lb-ft)
Adjusting Nut Jam Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Rear Steering Side Pivots Pivot Lock Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N•m (80 lb-ft)
Rear Axle Pivot Bracket Cap Screws Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 N•m (67 lb-ft)
2WD Pivot Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 ± 40 N•m (147.5 ± 29.5 lb-ft)
4WD Pivot Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 ± 73 N•m (271 ± 53.8 lb-ft)
2WD Steering Cylinder Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.5 ± 6.8 N•m (38 ± 5 lb-ft)
4WD Steering Cylinder Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.2 ± 9.5 N•m (40 ± 7 lb-ft)

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).

Special or Required Tools

Tool Name Tool No. Tool Use
Bushing, Bearing and Seal Driver Set Used to install seals and bushings.

Steering Specifications - 455

 STEERING COMPONENT LOCATION
Component Location

Steering Components - Front Wheel Steer

A D

A
D

F E

MX14265 G - Steering Arm

A - Steering Cylinder
B - Front Axle (Rear Wheel Drive)
C - Front Axle (All Wheel Steering)
D - Steering Control Unit (SCU)
E - MFWD Drive Shaft
F - Tie Rod

Steering Component Location - 456

 STEERING COMPONENT LOCATION
Steering Components - All Wheel Steer

B C

N
M
O
L J
E

K F

H
G

MX14231

A - Steering Cylinder
B - Front Axle (2 Wheel Drive Only on AWS)
C - Tie Rod
D - Steering Control Unit (SCU)
E - Rear Tie Rod Pivot
F - Rear Wheel Steering Arm
G - Tie Rod (2)
H - Link Rod, Rear
I - Pivot Arm
J - Bearing Housing
K - Link Rod, Middle
L - Bearing Housing
M - Steering Arm, Front
N - Link Rod, Front
O - Steering Arm

Steering Component Location - 457

 STEERING COMPONENT LOCATION
Steering Components - All Wheel Steer Rear Axle

B
A
E

H
C
I

J
M

L K

I
H F

MX14233

A - Link Rod, Middle

B - Bearing Housing
C - Pivot Arm
D - Axle Shaft
E - Ball Bearing
F - Drive Shaft, U-Joint
G - Ball Bearing
H - Case, Wheel Bearing
I - Steering Arm
J - Tie Rod (2)
K - Cap, Pivot
L - Pivot Plate
M - Link Rod, Rear

Steering Component Location - 458

 STEERING THEORY OF OPERATION
Theory of Operation
6371 kPa
Steering System Operation (924 psi)

Function:
Offer hydraulic all wheel power steering for ease of
operation.
1958 kPa
(284 psi)
System Operation:
Pressure oil is supplied by the charge pump of the Transaxle
hydrostatic transmission to the inlet port of the steering
valve. When the steering wheel is not turned, the oil flows
directly through the valve and out to the hydraulic control
valve. When the steering wheel is turned to make a left
turn, the pressure oil is routed through the steering valve T
and out the left turn port.
Hydraulic
The oil then flows down left turn line to the rod end of the Control Valve
steering cylinder. The cylinder rod is pushed out, rotating P
the front steering arm to the right which pulls the left tie rod
and spindle and pushes the right tie rod and spindle. This
turns the front wheels to the left. The return oil from the
head end of the cylinder is routed through right turn line to
the right turn port of the steering valve. The oil is routed P B T
through the valve to the return port.
Steering
On all wheel steer machines, linkage connects the front Valve
steering arm to the rear pivot, which allows the front and
rear sets of wheels to pivot in opposite directions. When the
front steering arm is rotated counterclockwise, the front link
rod is pushed to the right which rotates the front steering
arm clockwise. This moves the middle link rod, rear pivot
arm, and rear link rod rearward. The rear pivot is rotated
counterclockwise, which pushes the left rear tie rod, rear
steering arm, rear spindle housing, and rear spindle hub
and pulls the right side link. This turns the rear wheels to
the right. With the front wheels turned to the left and the
rear wheels turned to the right, a short turning radius is
accomplished.
R L
When the steering wheel is turned to make a right turn, the
pressure oil is routed the opposite way through the valve.
The oil comes out the right port of the valve to the head end
of the cylinder. The cylinder rod is pushed out and the front
pivot plate rotates the opposite way. The return oil flows
Steering Cylinder
through the lines to the left port of the valve and out the
return port.
Left Turn Shown
The steering valve is designed to allow manual steering if
the engine is not running or if there is a failure of the
hydraulic pump.
The tilt steering assembly allows the steering wheel to be
adjusted for operator comfort. A spring loaded rod locks the
steering column in different positions.

Steering Theory of Operation - 459

 STEERING THEORY OF OPERATION
Steering Valve Operation - Neutral

B
F

G
A

N I

M L
J
K
Pressure Oil Return Oil Trapped Oil

MIF sleeve) and a metering pump. The valve and pump are
A - Check Valve hydraulically and mechanically interconnected inside the
valve.
B - Return Port
C - Valve Body Pressure oil comes into the steering valve body at the inlet
D - Sleeve port. The oil then flows through inlet passage to a series of
grooves, passages, and slots in the valve body, sleeve, and
E - Sleeve Inlet Groove
spool to come out the power beyond passage and power
F - Spool Inlet beyond port to go on to the lift system. The amount of oil
G - Spool that flows this way varies with the speed of the turn. All the
H - Power Beyond Slot oil will follow this path when the steering valve is in neutral.
I - Power Beyond Groove There will be some oil when a slow turn is made, and there
J - Feed Holes will be less oil when a fast turn is made. No oil is available
to the power beyond port when the steering is dead
K - Inlet Passage
headed.
L - Power Beyond Passage
When the valve is in neutral, the turn passages are closed.
M - Inlet Port
The oil in the steering cylinder and lines is trapped oil. The
N - Power Beyond Port small amount of internal leakage oil will go out the return
port as return oil back to the sump.
Function:
Charge oil enters the steering valve at normal charge
Controls oil flow to and from the steering cylinder. In
pressure of 1958 kPa (284 psi) minimum, passes through
neutral, the steering valve blocks oil flow to the cylinder,
the open center valve, then the oil cooler to return to sump.
holding the wheels in a fixed position and allows oil to flow
If the steering wheel is turned, oil restriction occurs, and the
to the hydraulic system.
charge pressure increases. The charge pressure relief
System Operation: valve will open when the hydraulic pressure reaches 6371
kPa (924 psi) and pass excess oil to the sump.
The steering valve is an open center type valve. This valve
consists of a self-centering fluid control valve (spool and

Steering Theory of Operation - 460

 STEERING THEORY OF OPERATION
Steering Valve Operation - Turning
B C D E
F G
H

I
A
J
K

Z N

Y O

P
Q

X R
Pressure Oil Return Oil Trapped Oil W S
V T
U

MIF Y - Return Port

A - Center of Spool Z - Left Turn Port
B - Valve Body
Function:
C - Spool
D - Sleeve Controls pressure oil flow to the proper end of the steering
cylinder to turn the front wheels.
E - Spool Left Turn Slot
F - Left Turn Passage System Operation:
G - Left Turn Groove Pressure oil comes into the steering valve body at the inlet
H - Right Turn Passage port. The oil then flows through inlet passage to a series of
I - Right Turn Groove grooves, holes, slots, and passages to the gerotor. The
J - Spool Outlet Slot steering wheel is turning which turns the gerotor gear in the
K - Sleeve Outlet Holes gerotor body so that some of the cavities are enlarging in
volume and the oil fills them. At the same time, some of the
L - Valve Body Passages
gerotor cavities are reducing in volume which feeds the
M - Spool Right Turn Slot pressure oil out to another series of passages, grooves,
N - Sleeve Inlet Holes slots and holes. They provide a path to one of the steering
O - Gerotor Cavity (Reducing Volume) ports (in this drawing the right turn port) and on to the
P - Gerotor Body steering cylinder. The gerotor controls the rate at which oil
Q - Gerotor Cavity (Enlarging Volume) flows to the steering cylinder. The return oil coming back
from the steering cylinder is routed into the other steering
R - Sleeve Inlet Groove
port (in this case, left turn) to the center of the spool. From
S - Spool Inlet Groove the center of the spool the oil goes out the return port back
T - Gerotor Gear to sump.
U - Right Turn Port
Smooth turning is insured by the design of the gerotor. Its
V - Feed Holes geometry causes it to fill and empty its cavities 6 times as
W - Inlet Passage fast as the steering wheel is being turned.
X - Inlet Port

Steering Theory of Operation - 461

 STEERING THEORY OF OPERATION
Steering Valve Operation - Manual
C
B
D E

A F
G
H
I
Z
J
K

Y L

X
N
W O
Return Oil Trapped Oil

Pressure Oil Suction Oil V

P

Q
U R
T S

MIF Z - Left Turn Port

A - Left Turn Passage
Function:
B - Valve Body
C - Spool Provides manual steer operation to make a left or right turn
if hydraulic oil pressure and flow is not available.
D - Sleeve
E - Spool Left Turn Slot System Operation:
F - Left Turn Groove When the hydraulic system is not operating, engine not
G - Right Turn Groove running or hydraulic pump failure, it is still possible to steer
H - Spool Outlet Slot the machine. The gerotor must create the pressure and
I - Sleeve Outlet Holes flow necessary to move the steering cylinder as the
J - Spool Right Turn Slot steering wheel is being turned. As some of the gerotor
cavities reduce in volume, pressure oil is forced out of the
K - Sleeve Inlet Holes
cavities through a series of passages, holes, grooves, and
L - Valve Body Passages slots in the valve body, sleeve, and spool to one of the
M - Gerotor Cavity (Reducing Volume) steering ports (in this drawing right turn). The pressure oil
N - Gerotor Body is then routed to the steering cylinder. The return oil from
O - Gerotor Gear the steering cylinder returns in the other port (in this case
P - Gerotor Cavity (Enlarging Volume) the left turn port) through another series of passages,
grooves, slots, and holes to the center of the spool. From
Q - Sleeve Inlet Groove
the center of the spool the oil is routed to the return port.
R - Spool Inlet Groove The return port is connected to the inlet port through the
S - Right Turn Port check valve. The check valve allows the oil from return port
T - Inlet Holes to be drawn back into the system. This suction oil is routed
U - Inlet Passage through the valve body, sleeve, and spool to gerotor
V - Inlet Port cavities that are enlarging in volume. As the steering wheel
is turned the enlarging volume cavities become the
W - Check Valve
reducing volume cavities and the oil is transferred.
X - Return Port
Y - Return Passage

Steering Theory of Operation - 462

 STEERING DIAGNOSTICS
Diagnostics Symptom: Steering Function Problems
Yes - Front steering arm, rear pivot arm, or middle
Steering Diagnosis link rod binding.
Symptom: Steering Noise or Vibration Yes - Front tie rods bent, loose, or toe-in not correct.
(1) Steering shimmy or vibration? Yes - Rear tie rods bent, loose, or toe-in not correct.
No - Go to next step. Yes - Link rods bent, loose, or adjusted incorrectly.
Yes - Front axle spindles or front pivot plate binding; (2) Steers hard or no steering in ONE direction?
not lubricated.
No - Go to next step.
Yes - Front steering arm, rear pivot arm, or middle
Yes - Steering cylinder has external or internal oil
link rod binding.
leakage.
Yes - Front tie rods bent, loose, or toe-in not correct.
Yes - Steering valve has external or internal oil
Yes - Rear tie rods bent, loose, or toe-in not correct. leakage.
Yes - Link rods bent, loose, or adjusted incorrectly. Yes - Steering cylinder lines restricted or leaking.
(2) Noise during turning? Yes - Front axle spindles or front pivot plate binding;
not lubricated.
No - For additional procedures go to “Steering
System Tests” on page 464. Yes - Rear spindle housing and rear pivot plate
binding; not lubricated.
Yes - Steering cylinder has external or internal oil
leakage. Yes - Front steering arm, rear pivot arm, or middle
link rod binding.
Yes - Steering cylinder lines restricted or leaking.
(3) Steering pulls in one direction?
Yes - Return lines to transmission and oil cooler
restricted or leaking. No - Go to next step.
Yes - Front axle spindles or front pivot plate binding; Yes - Steering cylinder has external or internal oil
not lubricated. leakage.
Yes - Rear spindle housing and rear pivot plate Yes - Steering valve has external or internal oil
binding; not lubricated. leakage.
Yes - Front tie rods bent, loose, or toe-in not correct.
Symptom: Steering Function Problems
Yes - Rear tie rods bent, loose, or toe-in not correct.
(1) Steers hard or no steering in BOTH directions?
Yes - Middle link rod bent, loose, or adjusted
No - Go to next step.
incorrectly.
Yes - Charge pressure relief valve not opening within
(4) Steering wheel creeps?
specification.
No - Go to next step.
Yes - Steering cylinder has external or internal oil
leakage. Yes - Steering cylinder has external or internal oil
leakage.
Yes - Steering valve has external or internal oil
leakage. Yes - Steering valve has external or internal oil
leakage.
Yes - Steering cylinder lines restricted or leaking.
(5) Wheels turn on engine start-up?
Yes - Return lines to transmission and oil cooler
restricted or leaking. No - Go to next step.
Yes - Front axle spindles or front pivot plate binding; Yes - Charge pressure relief valve not opening within
not lubricated. specification.
Yes - Rear spindle housing and rear pivot plate Yes - Steering cylinder has external or internal oil
binding; not lubricated. leakage.

Steering Diagnostics - 463

 STEERING DIAGNOSTICS
Symptom: Steering Function Problems System: Steering
(6) Slow steering response? No - See Charge Pump Flow and Pressure Test in
the Hydraulic section.
No - For additional procedures go to “Steering
System Tests” on page 464. (3) Check steering cylinder. No external/internal oil
leakage?
Yes - Charge pressure relief valve not opening within
specification. Yes - Go to next step.
Yes - Steering cylinder has external or internal oil No - See “Steering Valve and Cylinder Leakage Test”
leakage. on page 465.
Yes - Steering valve has external or internal oil (4) Check steering valve. No external/internal oil
leakage. leakage?
Yes - Steering cylinder lines restricted or leaking. Yes - Go to next step.
Yes - Return lines to transmission and oil cooler No - See “Steering Valve and Cylinder Leakage Test”
restricted or leaking. on page 465.
Yes - Front axle spindles or front pivot plate binding; (5) Check steering lines. Not pinched, cracked or
not lubricated. leaking?
Yes - Rear spindle housing and rear pivot plate Yes - Go to next step.
binding; not lubricated.
No - Replace as necessary.
Yes - Front steering arm, rear pivot arm, or middle
(6) Check return lines to transmission and oil
link binding.
cooler. Not restricted, pinched, cracked or leaking?
Yes - End of steering tests.
Steering System Tests
No - Replace as necessary.

Test Conditions:
Steering Link Checks
• Machine parked on level surface.
• Park brake engaged.
Test Conditions:
• Steering cylinder (A) disconnected.
• Key switch in OFF position.
• Hydraulic oil at room temperature.
• Front link rod disconnected.
• Engine running at fast idle.
• Rear link rod disconnected.
System: Steering • Front wheels off ground for front axle check.
(1) Steering wheel turns smoothly with no • Rear wheels off ground for rear axle check.
binding? Steering cylinder extends and retracts?
(Maximum of 3 revolutions of steering wheel to System: Steering Links
fully extend cylinder. Compare steering effort with
(1) Front axle spindles and front pivot plate turns
cylinder connected.)
with little resistance? Axle bushings lubricated, no
Yes - Go to next step. side freeplay?
No - Steering cylinder does not move or wheel Yes - Go to next step.
revolutions are more than 3, see “Steering Valve and
No - Repair axle, spindle, or plate.
Cylinder Leakage Test”. Steering wheel binds or will
not lock in place, go to step 14. (2) Rear spindle housing and rear pivot plate turns
with little resistance? Bearings lubricated, no side
(2) Hydraulic checks: Pressure relief valve test port
freeplay?
pressure setting to minimum specification 6371
kPa (924 psi)? Yes - Go to next step.
Yes - Go to next step. No - Repair spindle housing or pivot plate.

Steering Diagnostics - 464

 STEERING TESTS AND ADJUSTMENTS
System: Steering Links Tests and Adjustments
(3) Front steering arm, rear pivot arm and middle
link rod turns with little resistance? Bearings not Hydraulic Oil Warm-Up Procedure
rough, no side freeplay?
Reason:
Yes - Go to next step.
When making hydraulic tests the oil must be heated to
No - Repair steering arm, pivot arm, or link rod. normal operating temperature for the tests to be accurate.
(4) Front tie rods are not bent? Rod ends are tight? Test Equipment:
Toe-in is 1 - 6 mm (0.04 - 0.24 in.)?
• JDG282 Temperature Gauge
Yes - Go to next step.
Procedure:
No - Replace if necessary. Adjust toe-in.
1. Install JDG282 Temperature Gauge on transmission oil
(5) Rear tie rods are not bent? Rod ends are tight?
filter.
Wheels are straight with pin through rear pivot
plate?
IMPORTANT: Avoid damage! DO NOT overheat
Yes - Go to next step. engine.
No - Replace if necessary. Adjust toe-in. 2. Apply park brake. Start engine and run at full throttle.
(6) Steering cylinder ball joint is tight, not worn and 3. Move and hold hydraulic lever in implement raise
properly lubricated? Rod not bent? position.
Yes - Go to next step. 4. Periodically cycle all hydraulic functions to distribute
heated oil.
No - Replace if necessary.
5. Heat oil to operational temperature [38 - 49° C (100 -
(7) Steering column and tilt assembly: Steering
120° F) typical].
column not binding? Snap rings in place?
Universal joint not binding or worn? Tilt assembly
not binding? Spring holds latch rod in notch? Steering Valve and Cylinder Leakage Test
Yes - Go to next step. Reason:
No - Tilt steering wheel will not lock in place, or may To check the steering valve and cylinder for internal
lock in only one position or will not hold position, see leakage.
tilt steering rod repair. Replace if necessary.
Test Equipment:
(8) Tires and wheels are correct size, matched
circumference, and proper air pressure? Rims not • Torque Wrench
bent? Tires running true (no wobble)? No • JT03375, 9/16 - 18 M ORFS x 7/16 - 20 M 37° Fitting
excessive play in wheel hubs? Wheel bearings
lubricated and not rough? • JT05484, 7/16 - 20 F 37° Cap

Yes - Go to next step. Procedure:

No - Replace as needed. Inflate tires to 1. Remove steering wheel cap.
recommended pressure. 2. Turn wheels for a complete right turn.
(9) Rear weights or wheel weights have proper rear
ballast?
Yes - End of steering link tests.
No - Add or subtract weights. See Operator's Manual.

Steering Tests and Adjustments - 465

 STEERING TESTS AND ADJUSTMENTS
Results:
c under
CAUTION: Avoid Injury! Escaping fluid
pressure can penetrate the skin
• If steering wheel rpm is more than 4 rpm, and there is
leakage (steady stream) from the cylinder return connector,
causing serious injury. Avoid the hazard by the steering cylinder is leaking. Replace cylinder. Repeat
relieving pressure before disconnecting test.
hydraulic or other lines. Tighten all • If steering wheel rpm is still more than 4 rpm, repair or
connections before applying pressure. replace steering valve.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids. Toe-In Adjustment Front Wheels

If an accident occurs, see a doctor Reason:

immediately. Any fluid injected into the skin Correct toe-in adjustment prevents tire wear and steering
must be surgically removed within a few wander.
hours or gangrene may result. Doctors
unfamiliar with this type of injury may call Procedure:
the Deere & Company Medical Department
NOTE: Toe-in cannot be adjusted with wheels off the
in Moline, Illinois, or other knowledgeable
ground or on an uneven surface.
medical source.
1. Park machine on level surface.
NOTE: Measuring point should be from center of tire,
hub height.
A

B
E C G
A
B
H

MX11934
F
3. Disconnect return hose (A) from the steering cylinder
(B). MIF

4. Cap return hose with JT03375 Fitting and JT05484 Cap. 2. Inspect tie rod (A), front axle (B), and steering cylinder
(C) for damage.
5. Heat hydraulic oil to approximately 43°C (110°F). (See
“Hydraulic Oil Warm-Up Procedure” on page 465.)
D
6. Run engine at fast idle.
7. Using a torque wrench on steering wheel nut, turn
steering wheel right with a constant torque of 6.8 N•m (60
lb-in.).
8. Observe the number of rotations of the steering wheel
that occurs in one minute. Also observe leakage from
cylinder return connector. Compare results to
I
specifications.
MIF
9. Reinstall hose and tighten to 16 N•m (144 lb-in.).
I. Side View

Steering Tests and Adjustments - 466

 STEERING TESTS AND ADJUSTMENTS
3. Mark the center (D) on the front of the tires.
D
4. Measure distance between marks (E) from front (F) of
right front tire to front of left front tire. Record distance.
5. Rotate the tires 180 degrees so the marks on the front
of the tires are now on the rear of the tires. Measure
distance between marks (G) from back of right front tire to
back of left front tire. Record distance.
6. Distance (E) should be 1 - 6 mm (0.04 - 0.24 in.) less I
than distance (G). MIF
7. Loosen tie rod nuts (H) and adjust tie rods equally to I. Side View
achieve the specified toe-in.
3. Mark the center (D) on the front of the tires.
Specifications: 4. Measure distance between marks (E) from front (F) of
Toe-In . . . . . . . . . . . . . . . . . . . . . 1 - 6 mm (0.04 - 0.24 in.) right front tire to front of left front tire. Record distance.
5. Rotate the tires 180 degrees so the marks on the front
Toe-In Adjustment All Wheel Steering of the tires are now on the rear of the tires. Measure
distance between marks (G) from back of right front tire to
Reason: back of left front tire. Record distance.
Correct toe-in adjustment prevents tire wear and steering 6. Distance (E) should be 1 - 6 mm (0.04 - 0.24 in.) less
wander. than distance (G).
7. Loosen tie rod nuts (H) and adjust tie rods equally to
Front Wheel Procedure:
achieve the specified toe-in.
NOTE: Toe-in cannot be adjusted with wheels off the
ground or on an uneven surface. Be sure the jam nut Rear Wheel Procedure:
and cotter pin are tight. Add washers if needed. 1. Set toe-in on front wheels.
1. Park machine on level surface. NOTE: The 10 mm cap screw must be perpendicular to
rear pivot plate and mounting plate when installed.
NOTE: Measuring point should be from center of tire,
hub height.

I
E C G L
A
Front
B
H

F MX14233

2. Turn steering wheel until a 10mm cap screw can be

MIF
installed through pivot plate and frame holes (I).
2. Inspect tie rod (A), front axle (B), and steering cylinder
(C) for damage.

Steering Tests and Adjustments - 467

 STEERING REPAIR
Repair

Steering Column Removal and Installation

Removing:

I
D

M
C

J K
B
L E
A

MIF
Z H
3. Measure from the center “bead” of left rear tire - from
front of tire to machine frame (J) and then from back of tire Q
F G
to machine frame (K). Record measurements.
O
4. Front measurement (J) should be 0 - 10 mm (0 - 0.4 in.) I
N
less then rear measurement (K).
X Y
5. If necessary, adjust linkage. J

• Loosen jam nuts (L). L

W V
• Rotate adjustment nut (M) until measurement M K
difference meets specification.
N
• Tighten jam nuts to 68 N•m (50 lb-ft).
U O
6. Repeat exact procedure for right rear tire.
Q
Specifications: P

Front Toe-In. . . . . . . . . . . . . . . . 1 - 6 mm (0.04 - 0.24 in.)

Rear Toe-In (each tire parallel to frame) 0 - 10 mm (0 -
R
0.4 in.)

MIF

A - Shroud
B - Lever
C - Snap Ring
D - Steering Wheel
E - Washer
F - Cap Screw
G - Sector
H - Tilt Return Spring
I - Lock Nut
J - Pawl

Steering Repair - 468

 STEERING REPAIR
K - Compression Spring 9. Make repairs to steering column as necessary.
L - Spacer
Installing:
M - Cap Screw
N - Bushing (2 used) 1. Apply multipurpose grease to slotted end of steering
column shaft (R).
O - Washer
P - Lock Nut 2. If removed, drive bushings (N) into steering column (Y)
Q - Snap Ring with a hammer and driver fixture.
R - Steering Shaft 3. Place steering shaft into steering column and install
S - Bushing washer (O) and snap ring (Q).
T - Steering Valve 4. Lower steering column and shaft into position and install
U - Lock Nut spring (K) and pawl (J) into place on steering column (Y).
V - Thrust Washer 5. Install spacers, bolts (M and X), and nuts holding
W - Spacer steering column (Y) onto pedestal frame.
X - Cap Screw 6. Install compression spring (Z).
Y - Steering Column 7. Install instrument panel and shroud (A).
Z - Compression Spring
8. Install tilt steering lever (B), washer (E), and snap ring
1. Remove steering wheel cover, nut, and steering wheel (C).
(D).
9. Install steering wheel (D), nut and steering wheel cover.
2. Remove snap ring (C), washer (E), and tilt steering lever
(B). Specifications:
3. Remove all components necessary to remove Steering Wheel Nut . . . . . . . . 34 - 41 N•m (25 - 30 lb-ft)
instrument panel and shroud (A) and access steering
assembly. (See “Instrument Panel Removal and
Steering Valve Removal and Installation
Installation” in the Miscellaneous section.)
Removing:

A B
C
D
Z
E

X
M
G F
H G

Y
R

MX14429
MX14427
4. Remove compression spring (Z).
1. Remove two cap screws (G).
5. Remove bolts (M and X), spacers, and nuts holding
steering column (Y) onto pedestal frame. 2. Move separator plate (F) just enough to remove
hydraulic lines.
6. Raise steering column and steering shaft (R) from
machine, being careful not to lose spring (K) and pawl (J). 3. Remove nut (A) holding clamp and remove steering
valve to cooler line (C) from steering valve.
7. Remove snap ring (Q) and washer (O) from end of
steering shaft (R). 4. Remove steering valve to cylinder rod end hose (B),
pump to steering valve hose (H), and steering valve to
8. If necessary, remove bushings (N) from end of steering
cylinder head end hose (D).
column (Y).

Steering Repair - 469

 STEERING REPAIR
5. Remove steering valve to control valve line (E). 2. Lower steering column and steering shaft (K) into top
slotted sleeve of steering valve.
6. Loosen two cap screws holding steering valve to
machine frame. 3. Install bolts (I) and nuts holding steering column (J) onto
pedestal frame.
7. Remove steering wheel.
8. Remove all components necessary to remove IMPORTANT: Avoid damage! Always use new O-
instrument panel and access steering assembly. rings. Damaged or used O-rings will leak.

A B
C
D

I
I
G F
H G

J
K

MX14429 MX14427

9. Remove bolts (I) and nuts holding steering column (J) 4. Install separator plate (F) loosely into position.
onto pedestal frame. 5. Install steering valve to control valve line (E).
[Link] steering column and steering shaft (K), just 6. Install steering valve to cylinder rod end hose (B), pump
enough to clear steering valve from under machine. to steering valve hose (H), and steering valve to cylinder
[Link] two cap screws holding steering valve to head end hose (D).
machine frame, and make repairs to valve as necessary. 7. Install steering valve to cooler line (C) and clamp and
nut (A) holding line in position (to machine frame).
Installing:
8. Install separator plate (F) into position and install and
NOTE: When installing steering valve, install cap tighten two cap screws (G) to 30 N•m (22 lb-ft).
screws finger-tight until all hydraulic lines are in place.
9. Tighten two cap screws, holding steering valve to
1. Raise steering valve into position and finger-tighten cap machine frame.
screws holding valve to machine frame.
[Link] all components necessary to re-install instrument
panel.
[Link] steering wheel.

I
I

J
K

MX14429

Steering Repair - 470

 STEERING REPAIR
Steering Valve Disassembly and Assembly
G

F
E

C D
B
A

I
J
K

L
N

M81128 K - Spacer
A - Steering Valve Housing L - O-Ring
B - O-Ring M - Plug
C - Wear Plate N - O-Ring
D - Drive Shaft O - Check Ball
E - Gerotor Set 1. Remove cap screws to remove components from
F - Seal Ring housing.
G - End Cover 2. Remove manual steering check components.
H - Cap Screw
3. Check ball, O-ring, and plug.
I - O-Ring
J - O-Ring

A Q

M81129

Steering Repair - 471

 STEERING REPAIR
4. Pull spool and sleeve assembly (S) from steering valve
housing (A). W
5. Remove quad seal (Q), thrust bearing race (R), and
thrust bearing (T) components.
V
IMPORTANT: Avoid damage! Use care not to U
damage seal bore during removal.

6. Pry dust seal (P) from housing.

X
Y
W
Z
M81130

V [Link] retaining ring (Z).

U
[Link] two flat leafs of springs (V) in slot of spool (Y).
Then install curved leafs between flat leafs, three at a time.
Install retaining collar (U) over springs.
X [Link] clean hydraulic oil to spool and install spool in
Y
sleeve (W). Springs must fit into notches of sleeve.
Z
[Link] pin (X).
M81130

7. Remove pin (X) to separate sleeve (W) from spool (Y).

8. Remove retaining collar (U).

c removing
CAUTION: Avoid Injury! Use care when
springs because springs (V) are
under tension.

9. Remove retaining ring (Z).

[Link] all machined mating surfaces for scratches or
burrs. Clean all parts in clean solvent and air dry.

R
A
W

M81131ae

[Link] one bearing race (R) and sleeve (W) into valve
housing (A).
[Link] holding sleeve and bearing race tightly into
housing, install quad seal (Q) into groove between bearing
race and housing. Make sure the seal is not twisted.
[Link] sleeve and bearing race.

Steering Repair - 472

 STEERING REPAIR

A Q

P
T

M81129
AA
[Link] dust seal (P) with open side of seal away from
housing (A). Use a disk driver to push seal to bottom of
bore. Apply petroleum jelly to seal lips and quad seal (Q). A

Q R
T

A
R

P
M81134
S
[Link] housing (A) in a vise (AA) with the gerotor end up.
[Link] parts in housing.
[Link] holes of wear plate with housing holes.
M81133ae [Link] sure drive shaft slot fits on pin and holes of wear
[Link] thrust bearing race (R), thrust bearing (T), and plate align with holes of housing.
second thrust bearing race (R) components. [Link] holes of gerotor with holes of wear plate.
[Link] clean hydraulic oil to spool and sleeve assembly [Link] cap screws and tighten in a criss-cross pattern to
(S). Carefully install assembly into housing (A) so not to 17 N•m (150 lb-in.).
damage seals.
[Link] steering valve from vise. Install ball, O-ring and
IMPORTANT: Avoid damage! Tighten vise only plug. Tighten plug to 17 N•m (150 lb-in.).
enough to hold housing or damage may occur to
housing and sleeve.

Steering Repair - 473

 STEERING REPAIR
Steering Cylinder Removal and Installation Front Axle Removal and Installation
1. Engage park brake.
A 2. Remove hood. (See “Hood Removal and Installation” in
the Miscellaneous section.)
3. Remove battery.

MX11934

1. Disconnect hydraulic hose (C) and loosen hose (A) from

steering cylinder (B).

B
A
B MX11936

4. Lift front of machine until front wheels (B) are off the
ground. Install jack stands.
5. Remove two front wheels.
6. Remove steering cylinder (A) without disconnecting
hydraulic lines. (See “Steering Cylinder Removal and
Installation” on page 474.)

E
D D

MX11935 C

2. Remove cotter pin (E) and nut (D) from each end of
steering cylinder.
NOTE: Cylinder ball joint ends are tapered. Use a
forked tool or soft-faced hammer to loosen stud ends.
3. Remove steering cylinder and disconnect cylinder (B)
from hose (A).
4. Replace steering cylinder if necessary.
5. Connect steering cylinder (B) to hose (A) and tighten
hose to 16 N•m (144 lb-in.).
MX11937
6. Install steering cylinder (B) to spindle arm and through
axle housing. 2-Wheel steer Shown; All wheel steer similar
7. Install nuts (D) and tighten to 33 N•m (24 lb-ft). Tighten 7. Install a lift or hoist on axle. Remove lock nut (D) and
nut to insert cotter pins (E). bolt to remove front axle assembly (C).
8. Connect hydraulic hose (C) and tighten to 16 N•m (144 8. Repair or replace axle assembly.
lb-in.). 9. Apply multi-purpose grease to pivot bushings in axle
9. Bleed the steering system. assembly.
[Link] axle assembly into position, while making sure
machine frame fits between head of guide bolts and axle.

Steering Repair - 474

 STEERING REPAIR
[Link] bolt and lock nut (D). Tighten cap screw and lock
nut to 203 N•m (150 lb-ft). A
[Link] steering cylinder. (See “Steering Cylinder D
B C
Removal and Installation” on page 474.)
[Link] front wheels and lower machine to the ground. F
[Link] and adjust axle toe-in. A
G

Front Axle Disassembly and Assembly D C

NOTE: All axle repair can be done while on the E
machine except for the axle pivot bushings (C).
H
K

C G
I

J C

B J
G
H I

MIF

2-Wheel Steering Shown

A - Bushing
B - Snap Ring
C - Bushing
D - Grease Fitting
E - Front Axle
MX11938 F - Front Spindle, Right
2-Wheel Steer Axle Shown G - Nut
1. Remove nut (G) from both sides of axle and remove tie H - Ball Joint
rod (J). I - Nut
2. Remove snap ring (B) to remove spindle. J - Tie Rod
K - Front Spindle, Left
3. Repeat steps for other spindle.
NOTE: Remove components from axle and replace as
necessary.

Steering Repair - 475

 STEERING REPAIR
7. Install spindles (F and P), snap rings (B).
B
8. Attach tie rod to ends of spindles and tighten nuts (G) to
C 61 N•m (45 lb-ft).
D A
B
9. Check length of tie rod from center of stud to center of
stud. Adjust rod length to approximately 292 mm (11-1/2
in.).
F
[Link] and adjust axle toe-in after axle is installed.

A C
E
D
R G
Q S
T
H

I
P J
G
K
H
L
J
K

O G
G
N M

MIF

All Wheel Steering Shown

A - Bushing
B - Snap Ring
C - Bushing
D - Grease Fitting
E - Front Axle
F - Front Spindle, Right
G - Nut
H - Ball Joint
I - Tie Rod
J - Nut
K - Ball Joint
L - Steering Rod
M - Shaft
N - Cotter Pin
O - Nut
P - Front Spindle, Left
Q - Cotter Pin
R - Washer
S - Nut
T - Steering Cylinder
4. Install four flanged bushings (A) into axle until flange is
tight to 1 mm (0.04 in.) maximum gap to casting.
5. Install two bushings (C) into axle bore until end of
bushing is even with casting surface.
6. If removed, install three grease fittings (D).

Steering Repair - 476

 STEERING REPAIR
Rear Steering Linkage - All Wheel Steering
Components:

B
A
D

C
E

H
R
I

L
M
N
O
P
Q
A
B
Q

O M

MX14246 J - Washer
A - Cotter Pin (4 used) K - Castle Nut
B - Castle Nut (4 used) L - Cap
C - Pivot Plate M - Tie Rod End
D - Pivot Bracket N - Nut, LH Thread
E - Seal O - Nut, Adjuster
F - Tapered Roller Bearing P - Nut
G - Spacer Q - Tie Rod
H - Snap Ring R - Lock Nut
I - Roller Bearing S - Link Rod, Rear

Steering Repair - 477

 STEERING REPAIR
Removal: G - Cotter Pin
H - Cap Seal
I - Grease Fitting
C J - Snap Ring
B
K - Spacer
1. Pry cap seal (H) from pivot plate.
2. Remove cotter pin (G), castle nut (F), washer (E) and
pivot plate assembly parts.
NOTE: Outer race of two tapered bearings (D) is slip fit.
D 3. Remove pivot plate components.
A 4. Inspect bearings and ball joints for wear. Replace as
MX14386 necessary.
1. Remove lock nut (A) to disconnect rear link rod (B) from
Assembly:
pivot plate assembly (C).
1. Apply extreme pressure grease to rollers of bearings.
2. Remove left and right tie rod assemblies by removing
hardware parts (C) from knuckle arm end and parts from 2. Install snap ring, upper bearing and seal into pivot plate.
pivot plate end of tie rods. Install seal with closed side into bore first and even with top
of pivot plate.
3. Remove cap screws and washers to remove pivot
assembly (D). 3. Install pivot plate, spacer, lower bearing, washer and
nut. Tighten nut while making sure slot of nut aligns with
Disassembly: hole in pivot shaft.

B
4. Install cotter pin. Fill cavity with extreme pressure
grease and install cap seal.
A
C Installation:
1. Install pivot assembly using cap screws and washers.
Tighten cap screws to 91 N•m (67 lb-ft).
K
2. Install right and left tie rods with castle nuts (A) and
cotter pins.
3. Check and adjust rear axle toe-in. (See “Toe-In
D
Adjustment All Wheel Steering” on page 467.)

A
E

G F
H
B
MX14254
C
A - Seal
B - Pivot Bracket
MX14386
C - Pivot Plate
4. Connect rear rod (A) to pivot plate (B) using lock nut (C).
D - Tapered Roller Bearing (2 used)
Tighten lock nut to 170 N•m (125 lb-ft).
E - Washer
F - Castle Nut

Steering Repair - 478

 STEERING REPAIR
Steering Intermediate Linkage - AWS

F
F

J E
K

H G
E C
D B

MX14231 Installation:
A - Lock Nut - 170 N•m (125 lb-ft) 1. Install pivot.
B - Rear Intermediate Link Rod
2. Install link rods. Make sure front and rear steering
C - Lock Nut - 170 N•m (125 lb-ft) assemblies are centered. Tighten lock nut to 170 N•m (125
D - Rear Pivot lb-ft).
E - Lock Nut - 68 N•m (50 lb-ft) 3. Connect front end of middle link rod (F) to front pivot
F - Cap Screw - 84 N•m (62 lb-ft) using lock nut. Tighten lock nut to 68 N•m (50 lb-ft).
G - Middle Link Rod
H - Front Pivot
I - Lock Nut - 170 N•m (125 lb-ft)
J - Front Intermediate Link Rod
K - Lock Nut - 170 N•m (125 lb-ft)
NOTE: Rear (B) intermediate link is not adjustable. Ball
joint ends are peened to rod. Complete link must be
replaced if any part is worn or damaged.

Removal:
1. Remove lock nut (A and C) from each end of link.
2. Remove front pivot (H) or rear pivot (D) by removing cap
screws (F) and nuts.

Steering Repair - 479

 STEERING REPAIR
Front and Rear Pivots
D

W
E

V
M
G J
L

I E K

U
L G
H

O
S
R
Q
O N

MIF L - Ball Bearing (2 used)

A - Ball Bearing M - Pivot Arm
B - Spacer N - Link Rod, Rear
C - Snap Ring O - Snap Ring
D - Pivot Lock Nut P - Tie Rod End
E - Flange Nut Q - Jam Nut
F - Screw (4 used) R - Adjustment Nut
G - Lock Nut S - Jam Nut
H - Pivot Lock Nut T - Link Rod, Middle
I - Screw U - Tie Rod End
J - Housing, Rear Pivot V - Shaft, Pivot Arm
K - Spacer W - Housing, Front Pivot

Steering Repair - 480

 STEERING REPAIR
Removing:
1. Remove nut and snap ring. Replace parts as necessary.

Installing:
1. Install one bearing at a time in a press, making sure to
include spacer between bearings. Seat snap ring after
removing assembly from press.
2. Install pivot arm shaft and lock nut. Tighten lock nut to
specification.

Specifications:
2WD Pivot Lock Nut . . 200 ± 40 N•m (147.5 ± 29.5 lb-ft)
4WD Pivot Lock Nut . . . . 367 ± 73 N•m (271 ± 53.8 lb-ft)
Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Flange Nuts . . . . . . . . . . . . . . . . . . . . . . 80 N•m (59 lb-ft)
Lock Nuts . . . . . . . . . . . . . . . . . . . . . 170 N•m (125 lb-ft)

Steering Repair - 481

STEERING REPAIR

Steering Repair - 482

 BRAKES TABLE OF CONTENTS
Brakes

Table of Contents

Specifications ...............................................485
General Specifications ...............................485
Test and Adjustment Specifications ...........485
Repair Specifications..................................485
Special or Essential Tools ..........................485
Other Materials...........................................485
Component Location....................................486
Brake System Component Location...........486
Brake/Differential Linkage (Exploded)........487
Theory of Operation .....................................488
Brake System Operation ............................488
Diagnostics ...................................................489
Brakes ........................................................489
Tests and Adjustments ................................491
Brake/Differential Linkage Adjustment .......491
Repair.............................................................493
Brake/Differential Linkage Removal and
Installation ..................................................493
Brakes Removal and Installation................495

Brakes Table of Contents - 483

BRAKES TABLE OF CONTENTS

Brakes Table of Contents - 484

 BRAKES SPECIFICATIONS
Specifications

General Specifications
Brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal wet disk

Test and Adjustment Specifications

Brake/Differential Linkage Adjustment
With 45 N (10 lb force) applied to brake and differential lock arm just contacting differential lock shaft,
adjust differential lock link outward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 turns

Repair Specifications
Transaxle Brake Cover Cap Screws Torque - Used Transaxle Case . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
Transaxle Brake Cover Cap Screws Torque - New Transaxle Case. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Brake Switch Striker Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (108 lb-in.)
Brake Adjustment Gap (Pin and Brake Rod Spring Retainer) . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 mm (0.12 - 0.35 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).

Special or Required Tools

Tool Name Tool No. Tool Use
Gauge F67-10-61505 For measuring gap between roll pin and brake
rod spring retainer (brake adjustment).

Other Materials

Other Material
Part No. Part Name Part Use
TY15130 John Deere Form-in-Place Gasket Seal mating surfaces of transaxle
TY6305/TY9485/#764 Cure primer Clean thread of sealing suraces
TY9370/TY9477/#242 Thread Lock and Sealer (Medium Strength) Retain brake mounting cap screws

Brakes Specifications - 485

 BRAKES COMPONENT LOCATION
Component Location Brake System Component Location

O
N D

K
L

H G F

MX14415 H - Differential Lock Link

A - Pad, Brake Pedal I - Brake Arm and Cam
B - Handle, Park Brake Rod J - Rod, Brake Arm
C - Park Brake Rod K - Brake Rod
D - Latch L - Brake Return Spring
E - Mid-Lift Shaft M - Brake Shaft
F - Differential Lock Shaft N - Brake Spring Retainer
G - Differential Lock Arm O - Brake Pedal

Brakes Component Location - 486

 BRAKES COMPONENT LOCATION
Brake/Differential Linkage (Exploded)
D
B C
E

F
A

G I

AO J
K
AN

AM
AL L P
M
O
AK
N
AJ

Q
AI

R
S
T
U
O V
AH W

AG

X
Y

AE AD
AF

AC

Y
AA
AB

MIF

Brakes Component Location - 487

 BRAKES THEORY OF OPERATION
A - Rod, Parking Brake Theory of Operation
B - Washer
C - Coupling Brake System Operation
D - Cotter Pin
NOTE: See “Component Location” on page 486.
E - Screw
F - Handle Function:
G - Brake Pedal
Provide a means of stopping the machine and also prevent
H - Pad, Brake Pedal movement when not in use.
I - Strip
J - Screw System Operation:
K - Bushing When the brake pedal is depressed, the brake spring
L - Latch retainer is pulled forward. The brake spring is compressed
M - Washer and spring tension pulls the brake rods and the brake arm
and cam forward. As the brake arm and cam rotates, the
N - Rod, Cruise Control Disconnect
cam plate rotates, rolling three balls up a ramp. When the
O - Bearing balls move up the ramp, the cam plate pushes against the
P - Washer brake plates, forcing the brake plates and brake discs
Q - Screw together.
R - Spring Pin The brake plates are attached to the transaxle housing
S - Bolt through external tangs on the plates. The brake plates
T - Guide cannot rotate. Brake discs that are splined to the reduction
U - Compression Spring shaft are located between the brake plates. The brake
V - Washer discs rotate whenever the reduction shaft rotates. The
pressure of the brake plates against the brake discs stops
W - Cotter Pin
the reduction shaft rotation.
X - Yoke
At the same time the brake arm and cam is engaged, the
Y - Spring Locking Pin
differential lock is also engaged to provide braking to both
Z - Pin rear wheels. The brake arm and cam pushes the differential
AA- Brake Arm and Cam lock link and arm rearward. The differential lock shaft and
AB- Rod, Rear Brake fork move into the transaxle and engage the differential lock
AC- Mid-Lift Shaft pins to lock both axles together.
AD- Retainer, Brake Spring When the brake pedal is released, the brake return spring
AE- Pin pulls the brake pedal and linkage to the disengaged
AF- Extension Spring position. The linkage pulls the cam plate away, releasing
AG- Cap Screw the pressure against the plates and disk.
AH- Striker The brake pedal can be locked in the engaged position to
AI - Brake Shaft be used as a parking brake. When the park brake rod is
engaged, the park brake pawl contacts a tab on the brake
AJ- Spring Locking Pin
pedal to hold the pedal in the engaged position.
AK- Lock Nut
AL- Washer
AM- Spring
AN- Foam Pad
AO- Bushing

Brakes Theory of Operation - 488

 BRAKES DIAGNOSTICS
Diagnostics Symptom: Brake Problems
Yes - Brake arm and cam bent, binding, or worn.
Brakes
Yes - Brake plates and disks warped, grooved, or
Symptom: Brake Problems worn.
(1) Poor or no brakes? Yes - Transaxle internal brake components binding or
worn.
No - Go to next step.
Yes - Transaxle internal differential lock components
Yes - Brake pedal or linkage bent, binding or worn.
binding or worn.
Yes - Brake spring broken or collapsed.
(4) Brakes noisy or chatter?
Yes - Brake linkage freeplay adjustment incorrect.
No - Go to next step.
Yes - Brake arm and cam bent, binding, or worn.
Yes - Brake pedal or linkage bent, binding or worn.
Yes - Differential lock arm bent, binding, or worn.
Yes - Brake spring broken or collapsed.
Yes - Brake plates and disks warped, grooved, or
Yes - Park brake rod and pawl bent or binding.
worn.
Yes - Brake arm and cam bent, binding, or worn.
Yes - Transaxle internal differential lock components
binding or worn. Yes - Differential lock arm bent, binding, or worn.
Yes - Transaxle internal brake components binding or Yes - Brake plates and disks warped, grooved, or
worn. worn.
(2) Brakes binding or brake effort excessive? Yes - Transaxle internal brake components binding or
worn.
No - Go to next step.
Yes - Transaxle internal differential lock components
Yes - Brake pedal or linkage bent, binding or worn.
binding or worn.
Yes - Brake spring broken or collapsed.
(5) Excessive brake wear?
Yes - Brake linkage freeplay adjustment incorrect.
No - Go through diagnostic procedures or go back to
Yes - Park brake rod and pawl bent or binding. steps 1-5.
Yes - Brake arm and cam bent, binding, or worn. Yes - Brake pedal or linkage bent, binding or worn.
Yes - Differential lock arm bent, binding, or worn. Yes - Brake return spring broken or stretched.
Yes - Brake plates and disks warped, grooved, or Yes - Brake linkage freeplay adjustment incorrect.
worn.
Yes - Brake arm and cam bent, binding, or worn.
Yes - Transaxle internal brake components binding or
Yes - Differential lock arm bent, binding, or worn.
worn.
Yes - Brake plates and disks warped, grooved, or
Yes - Transaxle internal differential lock components
worn.
binding or worn.
Yes - Transaxle internal brake components binding or
(3) Brakes will not release?
worn.
No - Go to next step.
Yes - Transaxle internal differential lock components
Yes - Brake pedal or linkage bent, binding or worn. binding or worn.
Yes - Brake spring broken or collapsed.
Symptom: Parking Brake Problems
Yes - Brake return spring broken or stretched.
(1) Parking brake will not engage?
Yes - Brake linkage freeplay adjustment incorrect.
No - Go to next step.
Yes - Park brake rod and pawl bent or binding.
Yes - Brake pedal or linkage bent, binding or worn.
Yes - Differential lock arm bent, binding, or worn.
Yes - Brake spring broken or collapsed.

Brakes Diagnostics - 489

 BRAKES DIAGNOSTICS
Symptom: Parking Brake Problems Symptom: Parking Brake Problems
Yes - Brake return spring broken or stretched. Yes - Transaxle internal differential lock components
binding or worn.
Yes - Brake linkage freeplay adjustment incorrect.
Yes - Park brake rod and pawl bent or binding.
Yes - Brake arm and cam bent, binding, or worn.
Yes - Differential lock arm bent, binding, or worn.
Yes - Brake plates and disks warped, grooved, or
worn.
Yes - Transaxle internal brake components binding or
worn.
Yes - Transaxle internal differential lock components
binding or worn.
(2) Park brake will not release?
No - Go to next step.
Yes - Brake pedal or linkage bent, binding or worn.
Yes - Brake return spring broken or stretched.
Yes - Brake linkage freeplay adjustment incorrect.
Yes - Park brake rod and pawl bent or binding.
Yes - Brake arm and cam bent, binding, or worn.
Yes - Differential lock arm bent, binding, or worn.
Yes - Brake plates and disks warped, grooved, or
worn.
Yes - Transaxle internal brake components binding or
worn.
Yes - Transaxle internal differential lock components
binding or worn.
(3) Parking brake will not engage?
No - Go through diagnostic procedures or go back to
steps 1-5.
Yes - Brake pedal or linkage bent, binding or worn.
Yes - Brake spring broken or collapsed.
Yes - Brake linkage freeplay adjustment incorrect.
Yes - Park brake rod and pawl bent or binding.
Yes - Brake arm and cam bent, binding, or worn.
Yes - Differential lock arm bent, binding, or worn.
Yes - Brake plates and disks warped, grooved, or
worn.
Yes - Transaxle internal brake components binding or
worn.

Brakes Diagnostics - 490

 BRAKES TESTS AND ADJUSTMENTS
Tests and Adjustments A - Cap Screw
B - Striker
Brake/Differential Linkage Adjustment C - Brake Rod Yoke
D - Retainer, Brake Spring
Reason: E - Roll Pin
To adjust brake linkage for proper braking and differential F - Brake Arm Rod
lock engagement when the brake pedal is applied. Machine G - Link Rod
creeps when on a slope with park brake engaged. Brakes H - Brake Arm
may not stop machine completely when operating on an
I - Differential Lock Arm
incline.
J - Differential Lock Shaft
Test Equipment: 2. Disconnect brake arm rod (F) from brake arm (H). This
• Spring Scale is easiest if done from left underside of machine by pulling
the cotter pin from the brake arm rod end.
Procedure:
3. Disconnect the forward end of link rod (G) from brake
1. Release brake pedal. arm (H).
4. Connect spring scale to bottom of brake arm (H) and
c brakes
CAUTION: Avoid Injury! Do not pre-load
as excessive wear of brake
pull forward with 45 N (10 lb. force).
5. Push link rod (G) rearward until differential lock arm (I)
components will result. contacts the differential lock shaft (J).
6. Check alignment of link rod (G) and brake arm (H) as
shown below.

C
K

A F
B G
L
G

I J
MX14281
MX14384 7. Front of link rod (G) should be flush or up to 2 mm
(0.08 in.) behind front edge of brake arm (H) hole (K).

Brakes Tests and Adjustments - 491

 BRAKES TESTS AND ADJUSTMENTS
NOTE: It may be necessary to move link rod (G) into
rear hole (as shown above), if linkage cannot be
adjusted enough for proper function of brake arm.
8. Adjust rod by turning inward or outward (link has left
hand threads), one full turn at a time, up to 6 turns.
9. Remove spring scale slowly to relieve tension.
[Link] link rod, brake arm rod and cotter pins. D

[Link] brake rod yoke (C) until there is no freeplay in the

brake linkage with the brake pedal released. Check linkage E
for binding after adjustment. If rear wheels are rotated and
brakes drag, linkage is too tight. Rotate rear wheels to be
sure differential lock is not engaged and brakes do not
drag.

B
MX14384

• With the park brake locked, and using a F67-10-61505

A Gauge, the brake rod roll pin (E) must be 3 - 9 mm (0.12 -
0.35 in.) away from brake rod spring retainer (D). If not,
MIF
shorten brake rod by rotating brake rod yoke (C) in either
NOTE: Side view shown direction.
[Link] cap screw (A). • Engage brake. See if it holds on slope in question.
[Link] brake pedal and engage park brake lock. • If brakes don’t hold, this indicates that linkage is
“bottoming out” on differential lock, preventing “full” brake
NOTE: The actuator must not contact the switch body. engagement, OR brake service is required.
[Link] actuator (B) until the switch plunger is
depressed, but not bottomed out.
[Link] actuator in position and tighten cap screw (A) to 12
N•m (108 lb-in.).
[Link] machine on slope with park brake engaged.
[Link] machine will not hold on slope without tires creeping,
repeat above steps until machine will hold.

Results:
If the brake/differential linkage adjustment is correct:
• The brake linkage should not have any freeplay with the
brake pedal released and the differential lock should not be
engaged.
• The differential lock will be engaged when the brakes
are engaged.
NOTE: Brake arm rod (F) may have to be relocated to
rear hole (L) if yoke (C) cannot be adjusted to pivot.

Brakes Tests and Adjustments - 492

 BRAKES REPAIR
Repair K - Link Rod
L - Brake Arm Rod
Brake/Differential Linkage Removal and M - Pin
Installation N - Brake Rod Yoke
O - Spring, Brake Return
Removing: P - Striker
1. Disconnect negative battery terminal and remove fender Q - Cap Screw
deck. (See “Fender Deck Removal and Installation” on 3. Making sure the parking brake is released, and using a
page 552 in the Miscellaneous section.) suitable spring tool, disconnect brake return spring (O)
2. Remove footrest. from mid-Lift shaft (H) and brake shaft (A) arm.
4. Remove spring pin and pin (B) holding brake spring
retainer (C) to arm on brake shaft (A).

D R
S

E
C E

B F

D
H Z
A G Y

X G
M
G V
N U
O
W
Q L
P T
F

K P
A
J

Q
MIF
I 5. Loosen nut (Q) and remove striker (P) from end of brake
MX14384 shaft.
A - Brake Shaft 6. Remove two bolts (F), washer (T), and brake pedal (D)
B - PIn from brake shaft.
C - Retainer, Brake Spring 7. Remove bushings (G) on both sides of machine and
D - Brake Pedal inspect for wear. Replace, as necessary.
E - Parking Brake Rod 8. Slide brake shaft to left of machine, while carefully
F - Bolts (2) removing cruise control disconnect rod (U) from bottom of
G - Bearing brake shaft (A).
H - Mid-lift shaft 9. Remove brake shaft and inspect for wear or damage.
I - Differential Lock Arm Replace, as necessary.
J - Brake Arm [Link] remove parking brake rod (E) and latch (Y):

Brakes Repair - 493

 BRAKES REPAIR
• Remove screw (S) and parking brake handle (R).
• Remove spring pin (W) and washer (V) from under
latch (Y). Raise parking brake rod out of hole in latch
(Y), and lower rod from beneath machine.
• Remove latch (Y), by removing nut (X), bolt (Z), and
associated hardware.

Installing: C

R B
S
H
A
E

D
Z O
Y

X G
V
U MX14384

W 6. Install brake spring retainer (C) to arm on brake shaft

T
(A), and secure with pin (B) and spring pin.
F
7. Making sure the parking brake is released, and using a
P suitable spring tool, disconnect brake return spring (O)
A
from mid-Lift shaft (H) and brake shaft (A) arm.
8. Install footrest.
G
9. Install fender deck and connect negative battery
Q
terminal. (See “Fender Deck Removal and Installation” on
MIF page 552 in the Miscellaneous section.)
1. To install parking brake rod (E) and latch (Y):
• Install latch (Y), by installing hardware, bolt (Z) and
nut (X).
• Raise parking brake rod from under machine, and
install bottom of rod into latch (Y). Install washer (V) and
spring pin (W) under latch (Y).
• Install parking brake handle (R) and screw (S).
2. Install bushings (G) on both sides of machine.
3. Raise brake shaft (A) right side end into machine frame.
Install cruise control disconnect rod (U) to bottom of brake
shaft (A).
4. Install brake pedal (D) and washer (T). Secure with two
bolts (F).
5. Install striker (P) onto end of brake shaft and secure with
nut (Q). When entire brake assembly is installed, adjust
brake switch. (See “Brake Switch Test and Adjustment” on
page 313 in the Electrical section.)

Brakes Repair - 494

 BRAKES REPAIR
Brakes Removal and Installation

C
B

A D

G
S

L K
R
Q

I
P H
O
N J
M
L

MX14424 N - Adjusting Nut

A - Snap Ring O - Nut
B - Brake Actuator Plate P - Rod
C - Friction Plate Q - Cam Lever
D - Steel Plate R - Brake Cover
E - Steel Ball S - Cap Screw
F - Clevis Pin 1. Remove transaxle. (See “Transaxle Removal and
G - Washer Installation” on page 390 in the Hydrostatic Power Train
H - Spring Lock Pin section.)
I - O-Ring
J - Interlock Plate IMPORTANT: Avoid damage! Use care not to lose
steel balls (E).
K - Cotter Pin
L - Washer 2. Inspect components on brake cover (R). Replace as
M - Rod necessary. Apply petroleum jelly to O-ring.

Brakes Repair - 495

 BRAKES REPAIR
3. Inspect plates for wear or spline damage. If groove
pattern in friction plates is no longer visible, replace plates.
4. Apply petroleum jelly to balls (E) and install balls in
cover.
5. Install steel plates (D) and friction plates (C) alternately
beginning with a steel plate.
6. Apply a bead of John Deere Form-in-Place Gasket to
brake cover mating surface of transaxle case.
7. Install brake actuator plate (B) and brake cover
assembly (R).

Brake Cover Cap Screw Torque Specifications:

Used Transaxle Case . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
New Transaxle Case . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)

8. Check brake/differential linkage adjustment. (See

“Brake/Differential Linkage Adjustment” on page 491.)

Brakes Repair - 496

 ATTACHMENTS TABLE OF CONTENTS
General Information..................................... 527
Attachments

Table of Contents
Reading Electrical Schematics .................. 527
Operation and Diagnostics ........................ 528
Diagnostic Information ............................... 528
Specifications ...............................................499 Wire Color Abbreviation Chart ................... 528
General Specifications ...............................499 Common Circuit Tests ............................... 528
Torque and Repair Specifications ..............501 Conductors For 12 Volt Circuits................. 529
Diagnostics ...................................................503 Generator Identification Numbers.............. 530
48, 54 and 62-Inch Mower Deck Diagnosis503 Generator................................................... 530
45 Loader Diagnosis ..................................506 Alternator ................................................... 530
Tests and Adjustments ................................507 Generator Component Location................. 531
Adjusting Cutting Height (48C, 54C, and 62C Generator................................................... 531
Mower Deck) ..............................................507 Alternator Components.............................. 532
Adjusting Mower Deck Wheels...................507 Control Panel ............................................. 533
Mower Deck Level Check and Adjustment.508 Generator Gear Box Components ............. 534
Adjusting Mower Level Side-to-Side ..........508 Generator Schematics and Harnesses ...... 535
Adjusting Mower Level Front-to-Rear.........509 Wiring Harness Legend ............................. 535
Adjusting Latch Rod ...................................510 Connectors ................................................ 535
Cylinder Leakage Test ...............................510 Standard Electrical Schematic................... 536
45 Loader Lubrication.................................510 Generator Operation and Diagnostics ....... 538
Repair.............................................................511 Generator Circuit Operation....................... 538
Cleaning Grass and Debris From Machine 511 Generator Circuit Diagnosis....................... 538
Mower Deck Belt and Shield Removal and Generator Tests and Adjustments ............. 540
Installation ..................................................511 Generator Stator Test ................................ 540
Mower Deck Blade Removal and Generator Rotor Test................................. 541
Installation ..................................................513 Ground Fault Circuit Interrupter (GFCI)
Mower Deck Blade - Sharpen ....................514 Checks....................................................... 541
Mower Deck Blade - Balance .....................514 Generator Ground Test.............................. 542
48C Mower Deck Spindle Removal and Generator Repair.......................................... 542
Installation ..................................................514 Stator Excitation Field Restoration ............ 542
Idlers...........................................................516 PTO Shield Removal and Installation ........ 543
Jacksheave ................................................517 Generator Removal and Disassembly ....... 543
54C Mower Deck Spindle Removal and Gear Case Removal and Disassembly...... 543
Installation ..................................................517 Rotor Bearing Removal and Installation .... 545
Jacksheave ................................................519 Rotor Fan Removal and Installation .......... 545
Idlers...........................................................520 Generator Assembly and Installation......... 546
62C Mower Deck Spindle Removal and Control Panel Removal and Installation..... 547
Installation ..................................................520
Mower Deck Drive Shaft Removal and
Installation ..................................................522
Mower Deck Drive Shaft Repair .................523
Mower Deck Gearbox Removal and
Installation ..................................................524
Mower Deck Gearbox Repair .....................526

Attachments Table of Contents - 497

ATTACHMENTS TABLE OF CONTENTS

Attachments Table of Contents - 498

 ATTACHMENTS SPECIFICATIONS
Specifications

General Specifications
Mower Deck Specifications

48-Inch Mower Deck:

Discharge Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mulch, Bag or Side
Cutting Height Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 127 mm (1 - 5 in.)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 kg (117 lb)
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 cm (48 in.)
PTO Gearbox Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 L (13.5 oz)
Belt Tension Spring Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 cm (5-7/16 in.)
Blade Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.) Higher in Rear
Blade Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 N•m (90 lb-ft)
Anti-Scalp Wheel Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.)

54-Inch Mower Deck:

Discharge Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mulch, Bag or Side
Cutting Height Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 127 mm (1 - 5 in.)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 kg (170 lb)
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137.2 cm (54 in.)
PTO Gearbox Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 L (13.5 oz)
Belt Tension Spring Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 cm (5-7/16 in.)
Blade Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.) Higher in Rear
Anti-Scalp Wheel Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.)

62-Inch Mower Deck:

Discharge Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mulch, Bag or Side
Cutting Height Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 127 mm (1 - 5 in.)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 kg (200 lb)
Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157.5 cm (62 in.)
PTO Gearbox Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 L (13.5 oz)
Belt Tension Spring Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 cm (5-7/16 in.)
Blade Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.25 in.) Higher in Rear
Anti-Scalp Roller Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Adjustable

Attachments Specifications - 499

 ATTACHMENTS SPECIFICATIONS
Loader Specifications

Loader:
Maximum Lift Height To Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1854.2 mm (73 in.)
Maximum Lift Height Under Level Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1752.6 mm (69 in.)
Maximum Clearance Under Fully Dumped Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1447.8 mm (57 in.)
Reach With Bucket Dumped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.2 mm (23 in.)
Maximum Bucket Dump Angel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
2WD: Reach with Bucket On Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1128.6 mm (44.43 in.)
4WD: Reach With Bucket On Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1098.6 mm (43.25 in.)
Bucket Roll-Back Angle On Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 degrees
Digging Depth Below Ground Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 mm (4 in.)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 kg (515 lb)

Loader Hydraulic System:

Rated Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6895 kPa (1000 psi)
Lift Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm (1.75 in.)
Bucket Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm (1.75 in.)
Break out Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 kg (770 lb)
Bucket Rollback Force at Ground Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 kg (740 lb)
Lift Capacity at 914 mm (36 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 kg (640 lb)
Lift Capacity at Full Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 kg (365 lb)

Bucket:
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1219 mm (48 in.)
Capacity (Struck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 cu. m (5.0 cu. ft)

Recommended Lubricants
Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-5 (90W)

Greases - High-Speed:
Blade Spindles (3 places) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Multi-Purpose Lithium Complex Grease
PTO Shaft Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Multi-Purpose HD Lithium Complex Grease

Greases - Other Applications:

Caster Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose HD Lithium Complex Grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Moly High Temperature EP Grease
Caster Wheel Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose HD Lithium Complex Grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Moly High Temperature EP Grease
PTO Shaft Splines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Multi-Purpose HD Lithium Complex Grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or John Deere Moly High Temperature EP Grease

NOTE: If not using any of the preferred greases, be sure to use a general purpose grease with an NLGI Grade No.
2 rating. Avoid use of John Deere Moly High Temperature EP Grease on high speed applications such as mower
spindles and rear axles.

Attachments Specifications - 500

 ATTACHMENTS SPECIFICATIONS
PTO Generator
120 VAC (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Amp, NEMA 5-20R, GFCI Protected Duplex Receptacles
240 VAC (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Amp, NEMA 6-50 Receptacle
Maximum Output (Intermittent) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10560 watts
Rated Voltage (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120/240
Continuous Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9600 watts
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single
Weight (Shipping). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 kg (247 lb)
Weight (Operating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kg (194 lb)
Height (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.1 cm (30.75 in.)
Width (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.9 cm (27.13 in.)
Length (approximate). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.4 cm (31.25 in.)
PTO Input Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Spline, 1 - 3/8 in. Diameter
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80W90 GL5 Gear Lube
Gear Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.63 L (23 oz)

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Discrete Output Thermal

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over/Under Voltage Meter
Stator Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self Exciting, Dual Output Brushless
Rotor Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self Regulating Brushless

Torque and Repair Specifications

Mower Decks

48-Inch Mulch, Bag or Side Discharge Mower Decks:

Blade Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Blade Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 N•m (90 lb-ft)
Spindle Mounting Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ± 4 N•m (230 ± 4 lb-in.)
Spindle Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 N•m (106 lb-ft)
Lower Seal Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 mm (0.31 in.) below hub flange
Gauge Wheel Roller Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Jack Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft)
Tensioning Idler Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)

54-Inch Mulch, Bag or Side Discharge Mower Decks:

Blade Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Blade Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 N•m (90 lb-ft)
Spindle Mounting Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ± 4 N•m (230 ± 4 lb-in.)
Spindle Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 N•m (106 lb-ft)
Lower Seal Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 mm (0.31 in.) below hub flange
Gauge Wheel Roller Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Jack Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft)
Tensioning Idler Sheave Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)

Attachments Specifications - 501

 ATTACHMENTS SPECIFICATIONS
62-Inch Mulch, Bag or Side Discharge Mower Decks:
Blade Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Blade Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 N•m (90 lb-ft)
Spindle Mounting Lock Nut (6 used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ± 4 N•m (18 ± 4 lb-ft)
Spindle Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 N•m (188 lb-ft)
Support Arm Pivot Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 ± 20 N•m (99 ± 20 lb-ft)
Front Caster Wheel Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N•m (60 lb-ft)
PTO Gear Box to Frame Cap Screw (4 used). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 N•m (73 lb-ft)

Loader
Hydraulic System Rated Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6895 kPa (1000 psi)
Lift Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm (1.75 in.)
Bucket Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm (1.75 in.)
Breakout Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 kg (770 lb)
Bucket Rollback Force at Ground Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 kg (740 lb)
Lift Capacity at 914 mm (36 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 kg (640 lb)
Lift Capacity at Full Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 kg (365 lb)

PTO Generator Electrical Specifications:

Watts (AC) Rated (Continuous) at power factor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9600
Watts (AC) Rated (Peak). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10560
Rated Voltage (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120/240
Rated Amperage (120 VAC) at each outlet at 40° C (104° F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rated Amperage (240 VAC) at outlet at 40° C (104° F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single

Attachments Specifications - 502

 ATTACHMENTS DIAGNOSTICS
Diagnostics System: Mower Deck Level
No - Adjust clevis (A) as needed. See “Mower Deck
48, 54 and 62-Inch Mower Deck Diagnosis Level Check and Adjustment” on page 508.

Special or Required Tools:

Tool Name Tool No. Tool Use
Leveling Gauge AM130907 To check blade level.

Test Procedure A

Test Conditions:
• Machine parked safely.
• PTO disengaged. B

System: Mower Deck Linkage MX11040a

(2) Is mower deck level front-to-back?

Yes - Go to next step.
No - Adjust linkage (B) as needed. See “Mower Deck
Level Check and Adjustment” on page 508.
A

System: Mower Deck Drive Belt

B C
A

MX11041

(1) Is the mounting hardware (A) in place and

secure?
Yes - Go to the next step.
B
No - Tighten or replace hardware. B
C

System: Mower Deck Level

MX11043a

(1) Are the drive belt (A), sheaves (B), and pulleys
(C) free of debris?
A
Yes - Go to next step.
No - Remove belt shields and remove debris.
(2) Is the drive belt slipping?
Yes - Check for worn belt or debris around sheaves
or mower plugged.
No - Go to the next step.

MX11041
(3) Is the correct belt installed?

(1) Is mower deck level side-to-side? Yes - Go to the next step.

Yes - Go to step. No - Replace belt.

Attachments Diagnostics - 503

 ATTACHMENTS DIAGNOSTICS
System: Mower Deck Drive Belt System: Spindle and Housing
(4) Is the drive belt damaged, worn, stretched or (3) Is there material wrapped around spindle or
broken? blade?
Yes - Replace belt if necessary. Yes - Remove material.
No - Go to the next step. No - Go to the next step.

A A
MX11043a

(5) Is the discharge chute (D) plugged?

Yes - Check to see if belt is installed correctly. MX11047
No - Go to the next step. (4) Is the spindle (A) properly lubricated?

System: Mower Drive Belt Tension Spring Yes - Go to the next step.
No - Apply specific grease to lube fittings at top of
spindle.
(5) Are bearing free of ware or damage and rotate
smoothly?
Yes - End test.
No - Repair or replace spindles as needed.

System: Mower Blades

A
(1) Are blades tight on spindle?
MX11047
Yes - Go to the next step.
(1) Is the tension spring (A) damaged, worn or
No - Tighten blade cap screw. See “Mower Decks” on
weak?
page 501.
Yes - Replace spring.
(2) Are the blades bent, worn or damaged?
No - Go to the next step.
Yes - Replace blades.
System: Spindle and Housing No - Go to the next step.
(1) Is the spindle sheave running straight and true,
not damaged or bent?
Yes - Go to the next step.
No - Repair or replace as needed.
(2) Is the belt off sheave?
Yes - Install or replace belt.
No - Go to the next step.

Attachments Diagnostics - 504

 ATTACHMENTS DIAGNOSTICS
System: Mower Blades Test Procedure B

Test Conditions:
• Machine parked on a clean, level surface, away from
people and objects.
• Engine running at fast idle.
• Engine at operating temperature.
• Mower deck lowered to the ground.
• PTO engaged.
M61524
System: Engine
(3) Are the blades properly sharpened and
balanced? (1) Is the engine running at the correct RPM.
Yes - Go to the next step. Yes - End test.
No - Sharpen and balance blades. No - Check engine operation. See Engine Section.
(4) Is the cut even?
System: Mower Deck Drive Shaft
Yes - Go to the next step.
No - Sharpen and balance blades.
(5) Is there too much vibration?
Yes - Balance blades.
No - Go to the next step.
(6) Does the mower load down tractor?
Yes - Check for bent blades.
A
No - Go to the next step.
(7) Are the blades scalping the grass? MX11043
Yes - Check for bent blades. (1) Is the drive shaft (A) operating smoothly,
No - End test. without any unusual noises, or vibrations?
Yes - Go to the next step.
System: Gauge Wheel Assemblies
No - Slowly reduce engine rpm and listen for problem
area. Disengage PTO and stop engine. Repair or
replace faulty or damaged components.

MX11044

(1) Are the gauge wheel assemblies properly

lubricated?
Yes - End test.
No - Apply specified grease to pivot lubrication
fittings (A) on each gauge wheel.

Attachments Diagnostics - 505

 ATTACHMENTS DIAGNOSTICS
45 Loader Diagnosis System: Hydraulic System
Test Procedure A

Test Conditions:
• Machine parked safely.

System: Hydraulic System

MX8268

(4) Is the loader operation slow or jerky?

Yes - Check to ensure that lift cylinder shut-off valve
(C) is completely closed.
No - Go to the next step.

MX12364

(1) Is the loader operation slow or jerky?

Yes - Check transaxle oil level at filler (A).
No - Go to the next step.
(2) Is the loader operation slow or jerky?
Yes - Replace transaxle filter.
No - Go to the next step.

MX13535

(5) Does the bucket or lift arms drift down from

raised position?
Yes - Check control valve (D) for damaged O-rings,
wiper seals, or internal leakage.
No - Go to the next step.

MX13537

(3) Is the loader operation slow or jerky?

Yes - Check hydraulic circuit (B) for oil leaks.
No - Go to the next step.

Attachments Diagnostics - 506

 ATTACHMENTS TESTS AND ADJUSTMENTS
System: Hydraulic System Tests and Adjustments

Adjusting Cutting Height (48C, 54C, and 62C

Mower Deck)
Mower cutting height can be adjusted from approximately
25 - 127 mm (1-5 in.), depending on the machine. When lift
lever is in highest (transport) position, cutting height is
approximately 127 mm (5 in.), 114.3 mm (4.5 in.) for AWS.
1. Stop machine on a hard, level surface.
E
2. Pull back top hydraulic lever to raise mower deck to
highest (transport) position.
3. Turn cutting height knob to desired cutting height.
Mower will be at that cutting height when it is lowered.
4. Push forward top hydraulic lever to lower mower deck.
MX12362 5. Park machine safely. (See Parking Safely in the Safety
(6) Are there oil leaks or insufficient lift capacity? section.)

Yes - Check cylinders (E) for damaged O-rings, wiper 6. Check that the actual height-of-cut matches, within 6.35
seals, or internal leakage. mm (1/4 in.), the reading on the cutting height knob. If they
do not match, adjust mower deck side-to-side and/or front-
No - Go to the next step. to-rear.

Adjusting Mower Deck Wheels

1. Inflate vehicle tires to correct pressure.
2. Raise mower deck to highest (transport) position and
adjust cutting height.
3. Lower deck to mowing position.
4. Park machine safely. (See Parking Safely in Safely
section).

MX13537

(7) Are the cylinders inoperative?

Yes - Check the connection (F) between control valve
and cylinder hoses.
No - Test complete.
A

MX11075

5. Pull gauge wheel release rod (A) and position wheel in

correct hole (B). See decal located on deck.

Attachments Tests and Adjustments - 507

 ATTACHMENTS TESTS AND ADJUSTMENTS
Mower Deck Level Check and Adjustment Results:
• The blade cutting heights should be equal side-to-side.
Adjusting Cutting Height:
• The blade height front-to-rear should be to the specified

c CAUTION:
difference.
Avoid injury! Mower blades may be
sharp. Wear heavy gloves or wrap the blade Specifications:
edges with a rag to prevent injury during
Mower Blade and Mower Deck Wheel Heights
handling.
Mower Deck Wheel
Special or Required Tools: . . . . . . . . . . . . . . . 6-13 mm (1/4-1/2 in.) from the ground
Rear Blade Tip Higher Than Front Blade Tip
Tool Name Tool No. Tool Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm ( 0.25 in.)
Leveling Gauge AM130907 To check blade level.
Adjusting Mower Level Side-to-Side
1. Park machine safely. (See Parking Safely in Safely
section).
2. Lower mower deck to the ground. c CAUTION: Avoid injury! Rotating blades are
dangerous. Before adjusting or servicing
3. Inflate vehicle tires to correct pressure.
mower:
4. Set mower deck to desired cutting height.
• Disconnect spark plug wire(s) to prevent
5. Make sure that mower deck wheels and rear hangers engine from starting accidently.
are set to the same height.
• Always wear gloves when handling
6. Adjust anti-scalp wheel to proper height specification on mower blades or working near blades.
left and right side of mower deck.

IMPORTANT: Avoid damage! Mower deck lift

c CAUTION: Avoid injury! Mower blades may be
sharp. Wear heavy gloves or wrap the blade
system can be damaged if lift arms are not
adjusted correctly. Check adjustment each time
edges with a rag to prevent injury during mower is installed to allow gap between lift arms
handling. and frame stop at full lift height.

7. Turn the blade until parallel to front axle. 1. Park machine safely. (See Parking Safely in Safely
section).
2. Inflate vehicle tires to correct pressure.
3. Pull back top hydraulic lift lever to raise mower deck to
highest (transport) position.

D
M40137

8. Measure distance (A) from tip of outside blade to the

ground using AM130907 Leveling Gauge. Repeat steps 7
and 8 for outer blade tip on opposite side of deck. A C
9. Turn outer mower blades to face front-to-rear, MX11041
perpendicular to front axle.
4. Check that the lift arm (A) does not contact frame stop. If
[Link] distance from front left and right blade tips to needed, adjust yokes (B) on both sides of mower until there
ground. Repeat step for left and right blade tips. is a slight gap of 1.6 mm (1/16 in.) on both sides.

Attachments Tests and Adjustments - 508

 ATTACHMENTS TESTS AND ADJUSTMENTS
• Remove spring locking pin (C) and drilled pin (D) Adjusting Mower Level Front-to-Rear
from each lift arm.
• Turn each yoke (B) clockwise to raise lift arm. Checking Procedure:
1. Lower mower deck to level surface.
• Turn each yoke counterclockwise to lower the lift
arm. 2. Park machine safely. (See Parking Safely in Safely
• Attach each yoke to lift arm with drilled pin (D) and section).
spring locking pin (C). 3. Inflate vehicle tires to correct pressure.
5. Lower mower deck to level surface. 4. Turn right blade so tip points straight forward.
6. Turn left blade parallel to axle and complete 5. Hold drive belt and turn left blade until blade tip also
measurement. Hold drive belt and turn right blade parallel points straight forward.
to axle and complete measurements.

E
M40137a

6. Measure from front (A) and rear of each blade tip to the
level surface.
7. The front of blade should be 6mm (0.25 in.) lower than
the rear of blade.
MIF

7. Measure from each outside blade tip (E) to the level Adjusting Procedure:
surface. 1. Lower mower deck to level surface.
8. Adjust deck side to side until measurement is equal. 2. Park machine safely. (See Parking Safely in Safely
section).

D
A

A
C

MX11041

9. Remove spring locking pin (C) and drilled pin (D) from
each lift arm (A).
C C B
[Link] yoke until deck is level side to side. B

• Turn yoke (B) counterclockwise to lower mower deck.

• Attach yoke to lift arm with drilled pin and spring
MX11040a
locking pin.
3. Measure distance (A) from end of nut to end of bolt. This
measurement should be the same on each side of the front
deck hanger.

Attachments Tests and Adjustments - 509

 ATTACHMENTS TESTS AND ADJUSTMENTS
4. Loosen two rear nuts (B) on front deck hanger.
5. Adjust two front nuts:
• Turn two front nuts (C) clockwise to raise front of
mower deck.
• Attach yoke to lift arm with drilled pin and spring
locking pin.
6. Measure distance (A) from end of nut to end of bolt. This
measurement should be the same on each side of the front
hanger.
7. Tighten rear nuts after making adjustment.
T6222AL
8. Measure blade tip again and adjust front deck hanger if
necessary. 5. Disconnect rod end hose and install a plug in hose end.
6. After oil stops dripping from cylinder port, put a
Adjusting Latch Rod measuring beaker under the cylinder port to catch oil.
7. Start engine and operate at slow idle. Actuate the
cylinder extend function for one minute.
B
A 8. Stop engine. Measure oil collected and connect hose.
9. Repeat procedure to test each cylinder.

Results
If measured oil is not within specifications, repair cylinder
as necessary.
C
Specifications
Cylinder Leakage . . . . . . . . . . . . . 5 mL/min (1/6 oz/min)
MX12365

1. Loosen jam nut (A) on end of latch rod (B). 45 Loader Lubrication
2. Turn latch rod (B) in or out to obtain require length.
3. Make sure there is at least 13 mm (0.50 in.) (C) of
thread engagement on end of latch rod (B).
A
4. Tighten jam nut.

Cylinder Leakage Test A

A A

Reason
To make sure cylinder leakage is within allowable limits,
allowing proper hydraulic circuit operation. A
A
Procedure
1. Start engine and drive machine for 5 - 10 minutes to
warm hydraulic oil. MX12362
2. Lock park brake. Lubricate six pivot points (A) on each side of loader by
3. Start engine and fully extend cylinder rod. pumping grease into grease fittings.
4. Stop engine and activate a hydraulic function to relieve
pressure in the system.

Attachments Tests and Adjustments - 510

 ATTACHMENTS REPAIR
Repair
A A
B
Cleaning Grass and Debris From Machine

IMPORTANT: Avoid damage! Clean under deck

shields and in the engine compartment before each
use to help prevent heavy grass and thatch build-up
on the machine.

A A
MX11055

Picture Note: 62C-Inch Mower Deck

3. Loosen six hex nuts (A) securing belt guard cover to
mower deck. On 62C mower deck, left belt guard has only
one hex nut to remove. Do not remove step (B).

C
C
MX8825

1. Remove belt shields (A) from mower deck.

2. Lift belt shields up off of the attaching bolts.
3. Inspect belt shields for cracks, wear or damage.
Replace if necessary.
4. Installation is done in the reverse order of removal.

Mower Deck Belt and Shield Removal and MX19469

Installation 4. Clean top of mower deck and area around all of the
sheaves (C) of debris.
Procedure:
5. Lift belt shield up off of the attaching bolts.

c CAUTION: Avoid injury! To avoid personal

injury, make sure engine is off and mower deck
6. Inspect belt shield for cracks, wear or damage. Replace
if necessary.
PTO and drive belt have stopped before
IMPORTANT: Avoid damage! To prevent damage
removing belt shields.
to mower belt:
1. Park machine on level surface. • Do not clean belt using parts cleaning solvent
2. Remove mower deck from machine. or belt dressing. They soften belt and shorten
belt life.

7. Clean and inspect belt for damage.

A A
• If belt does not need to be replaced, stop here. Install
belt shields.
• If belt needs to be replaced, continue with next step.

c CAUTION: Avoid injury! To prevent injury

when removing idler spring:
• Wear eye protection.
MX11043
• Use a locking pliers.
Picture Note: 54-Inch Mower Deck

Attachments Repair - 511

 ATTACHMENTS REPAIR

MX11047

8. Remove idler tension spring (D) to relieve tension on

belt.
MX11050

[Link] gearbox (I) forward and remove deck drive belt.

[Link] belt from all spindle sheaves. Discard belt.
E [Link] is in reverse order.

Specifications:
Gearbox-to-Deck Frame Cap Screws . . 73 N•m (54 lb-ft)
F

MX19468

9. Remove clip (E) and washer (F). Lift idler arm up to

remove belt.

MX11051

[Link] two nuts (G) on rear gearbox.

[Link] two front nuts and carriage bolts (H).

Attachments Repair - 512

 ATTACHMENTS REPAIR
Mower Deck Blade Removal and Installation
IMPORTANT: Avoid damage! Improperly
Removal: installed blades can loosen during operation. Do
not lubricate or use power tools when installing
the blade bolt or the bolt will be ineffective.
c CAUTION: Avoid injury! Service mower
blades safely.
Use a hand torque wrench and tighten bolts to
blade bolt torque of: 122 N•m (90 lb-ft).
• Disconnect spark plug wires or negative
(-) battery cable to prevent accidental
startup.
D
• Mower blades are sharp. Always wear
gloves when handling or working near
blades.
C
1. Park machine safely. (See Parking Safely in the Safety B
section.)
2. Remove mower from machine. A

3. Turn mower over and place a block of wood between

blade and mower deck to prevent blade from turning when
removing bolt. M74256

• Check that deflector cup (D) is properly seated between

D mower spindle and blade (C).
• Install blade with bent tip up.
C
• Install and hand-tighten bolt (A) with washer (B) until
mower blade is in full contact with spindle.
B
• Make sure to install blade washer with concave side
toward blade.
A • Tighten blade cap screw to specification.

Specifications:
Blade Cap Screw Torque . . . . . . . . . . . 122 N•m (90 lb-ft)
M74256

4. Remove bolt (A) with washer (B), blade (C) and

deflector (D).
5. Inspect blade for cracks, wear or damage, sharpen
balance or replace blades as necessary.
6. Tighten bolt to 122 N•m (90 lb-ft).

Installation:

c CAUTION: Avoid injury! The blade is sharp. To

help prevent personal injury, wear heavy
gloves or wrap the end of the blade with a rag.

• Installation is done in the reverse order of removal.

Attachments Repair - 513

 ATTACHMENTS REPAIR
Mower Deck Blade - Sharpen 4. Turn blade to the horizontal position (A). If the blade is
not balanced, the heavy end will drop.
Procedure: 5. Grind blade edge of heavy end. Do not alter original
blade bevel angle of 30°.
c CAUTION: Avoid injury! Wear goggles and
gloves when sharpening mower blades. 48C Mower Deck Spindle Removal and
Installation
1. Sharpen blade using grinder, file or power sharpener.
Removal 48C:
A
B
c CAUTION: Avoid injury! To help prevent
personal injury, wear heavy gloves or wrap the
end of the blade with a rag.

1. Remove drive belt. (See “Mower Deck Belt and Shield

M61830 Removal and Installation” on page 511.)
2. Do not alter original bevel (A) of 30°. Maintain blade 2. Remove mower blade.
cutting edge (B) to specification, rather than a razor-type
edge.
3. Balance blade. A

Specification:
B
Blade Cutting Edge . . . . . . . . . . . . . 0.40 mm (0.016 in.)

Mower Deck Blade - Balance

Procedure:

c CAUTION: Avoid injury! Wear gloves or wrap

blade with rag to prevent personal injury. A

IMPORTANT: Avoid damage! Balance blades after MX9609

sharpening or mower deck may vibrate excessively. 3. Remove four nuts and washers (A) and spindle (B).
1. Clean and inspect blade. 4. Make repairs as necessary. (See “Spindle Disassembly/
2. Sharpen blade. (See “Mower Deck Blade - Sharpen” on Inspection” on page 515.)
page 514.)
Installation is done in the reverse order of removal:
• Tighten spindle mounting lock nuts to 26 N•m (230 lb-
in.).

A IMPORTANT: Avoid damage! Install blade with bent

tips up. Install blade washer with concave side to
blade.

• Install blade and tighten blade cap screw to 122 N•m (90
lb-ft).

Specification:
Blade Cap Screw Torque . . . . . . . . . . . 122 N•m (90 lb-ft)
M61524 Spindle Mounting Lock Nut Torque
3. Put blade on a nail in a vise or wall stud. . . . . . . . . . . . . . . . . . . . . . . . . . 26 ± 4 N•m (230 ± 4 lb-in.)

Attachments Repair - 514

 ATTACHMENTS REPAIR
Spindle Disassembly/Inspection
G

c CAUTION: Avoid injury! To help prevent

personal injury, wear heavy gloves or wrap the
end of the blade with a rag.

IMPORTANT: Avoid damage! Do not install

hexagon end of spindle shaft in a vise to remove
spindle sheave nut. The hexagon end of the
spindle shaft will be damaged resulting in
improper blade operation. MX9612

NOTE: Remove bearings only if replacement is 7. Remove spacer (G).

necessary.

H
B
E
D A
E
H
F
C
E
D
C
I

J G

H E

L
M
K MIF
MX9610 8. Inspect all parts for wear or damage. Replace parts as
1. Install blade (K), washer (L), and cap screw (M) on necessary.
spindle shaft. If only the nut (A) or spindle sheave (B) need
to be replaced, and the spindle is still in the deck, use a Assembly 48C:
block of wood to prevent the blade from turning. If spindle is
not in the deck, put blade in a soft-jaw vise. Tighten cap B
screw (M) to 122 N•m (90 lb-ft).
A
C
2. Hold the blade with a vise or a block of wood. Remove
nut (A), spindle sheave (B), and lubrication fitting (I).
3. Remove cap screw, washer and blade.
4. Pull spindle shaft (J) out of spindle hub (F).
5. Remove seal rings (C) noting location of notched side.
6. Remove seals (D) and bearings (E) using a punch.
Bearings (E) are seated against hub shoulder (H) and D
cannot be removed with a press. MX9611

1. Install upper bearing (A) tight against spindle hub

shoulder (B) using a 1-13/16 disk and press.
2. Install upper seal (C) with lip toward bearing, tight
against bearing using a 1-13/16 disk and press.

Attachments Repair - 515

 ATTACHMENTS REPAIR

B
A

D
L
E D
M44950 G
3. Install upper seal ring (D), with grease notch (E) toward
bearing, inside seal lip. E
F

MX9610
F
I H G
8. Install spindle shaft (D).

IMPORTANT: Avoid damage! Do not install

hexagon end of spindle shaft in a vice to install
spindle sheave nut. The hexagon end of the
spindle shaft will be damaged resulting in
improper blade operation.
J 9. Install blade (G), washer (E), cap screw (F) and
deflector (L) on spindle shaft. Tighten cap screw to 122
MX9612
N•m (90 lb-ft).
4. Install spacer (G).
IMPORTANT: Avoid damage! Make sure the
IMPORTANT: Avoid damage! Do not press lower hexagon shaped hole in spindle sheave is
bearing (H) tight against hub shoulder (F). The aligned with the hexagon portion of the spindle
bearing and seal must be installed to a specific shaft.
dimension for proper sealing of spindle.
10. Hold the blade with a soft-jaw vise or if spindle is in the
5. Install lower bearing (H) in hub using a 1-13/16 in. disk mower deck, with a block of wood. Install spindle sheave
and press, just enough so the lower seal can be installed. (B), nut (A), and lubrication fitting (H). Tighten nut to 145
N•m (106 lb-ft).
I 11. Remove cap screw, washer and blade.
K 12. Lubricate spindle with multipurpose grease at
lubrication fitting.

Idlers
NOTE: Idler sheaves are welded and contain a non-
serviceable bearing. If bearing replacement is needed,
replace entire idler sheave.

MX9613

6. Install lower seal (I) with lip toward bearing using a 1-13/
16 in. disk and a press, until seal is 7.8 mm (0.31 in.) below
hub flange (K).
7. Install lower seal ring (J), with grease notch away from
bearing, inside seal lip.

Attachments Repair - 516

 ATTACHMENTS REPAIR
Jacksheave 54C Mower Deck Spindle Removal and
Installation
Disassembly 48C:
Removal 54C:
NOTE: Bearings are seated against shoulder in jack
sheave, and must be removed one at a time, from
either side.
c CAUTION: Avoid injury! To help prevent
personal injury, wear heavy gloves or wrap the
Remove bearings only if replacement is necessary.
end of the blade with a rag.

1. Remove drive belt. (See “Mower Deck Belt and Shield

Removal and Installation” on page 511.)
A B
2. Remove mower blade.

C B

A B

MIF

A - Shoulder A

B - Upper Bearing MX9609

C - Spacer 3. Remove four nuts and washers (A) and spindle (B).
1. Remove one bearing using a suitable puller, or a pin 4. Make repairs as necessary. (See “Spindle Disassembly/
punch and hammer. Inspection” on page 518.)
2. Remove spacer.
Installation is done in the reverse order of removal:
3. Remove second bearing using a press, or suitable driver
and mallet. • Tighten spindle mounting lock nuts to 26 N•m (230 lb-
in.).
4. Inspect all parts for wear or damage, replace as needed.
IMPORTANT: Avoid damage! Install blade with bent
Assembly:
tips up. Install blade washer with concave side to
• Install bearings tight against shoulder in jack sheave blade.
using a press, or suitable driver and mallet. Be sure to
install spacer between bearings. • Install blade and tighten blade cap screw to 122 N•m (90
lb-ft).

Specification:
Blade Cap Screw Torque . . . . . . . . . . . 122 N•m (90 lb-ft)
Spindle Mounting Lock Nut Torque
. . . . . . . . . . . . . . . . . . . . . . . . . 26 ± 4 N•m (230 ± 4 lb-in.)

Attachments Repair - 517

 ATTACHMENTS REPAIR
Spindle Disassembly/Inspection
G

c CAUTION: Avoid injury! To help prevent

personal injury, wear heavy gloves or wrap the
end of the blade with a rag.

IMPORTANT: Avoid damage! Do not install

hexagon end of spindle shaft in a vise to remove MX9612
spindle sheave nut. The hexagon end of the 7. Remove spacer (G).
spindle shaft will be damaged resulting in
improper blade operation. 8. Inspect all parts for wear or damage. Replace parts as
necessary.
NOTE: Remove bearings only if replacement is
necessary. Assembly 54C:

B
B
A
A
C C
E D
D
F E

D
C
I
N
MX9611
J
1. Install upper bearing (A) tight against spindle hub
shoulder (B) using a 1-13/16 disk and press.
2. Install upper seal (C) with lip toward bearing, tight
against bearing using a 1-13/16 disk and press.
K M L

MX9610

1. Install blade (K), washer (L), cap screw (M) and

deflector (N) on spindle shaft. If only the nut (A) or spindle
sheave (B) need to be replaced, and the spindle is still in
the deck, use a block of wood to prevent the blade from
turning. If spindle is not in the deck, put blade in a soft-jaw D
E
vise. Tighten cap screw (M) to 122 N•m (90 lb-ft).
2. Hold the blade with a vise or a block of wood. Remove M44950
nut (A), spindle sheave (B), and lubrication fitting (I). 3. Install upper seal ring (D), with grease notch (E) toward
3. Remove cap screw, washer and blade. bearing, inside seal lip.
4. Pull spindle shaft (J) out of spindle hub (F).
F
5. Remove seal rings (C) noting location of notched side.
I H G
6. Remove seals (D) and bearings (E) using a punch. J
Bearings (E) are seated against hub shoulder (H) and
cannot be removed with a press.

MX9612

4. Install spacer (G).

Attachments Repair - 518

 ATTACHMENTS REPAIR
9. Install blade (M), washer (N), cap screw (O) and
IMPORTANT: Avoid damage! Do not press lower deflector (S) on spindle shaft. Tighten cap screw to 122
bearing (H) tight against hub shoulder (F). The N•m (90 lb-ft).
bearing and seal must be installed to a specific
dimension for proper sealing of spindle.
IMPORTANT: Avoid damage! Make sure the
5. Install lower bearing (H) in hub using a 1-13/16 in. disk hexagon shaped hole in spindle sheave is
and press, just enough so the lower seal (I) can be aligned with the hexagon portion of the spindle
installed. shaft.

[Link] the blade with a soft-jaw vise or if spindle is in the

mower deck, with a block of wood. Install spindle sheave
(Q), nut (R), and lubrication fitting (P). Tighten nut to 145
N•m (106 lb-ft).
J I [Link] cap screw, washer and blade.
K
[Link] spindle with multipurpose grease at
lubrication fitting.

Jacksheave
Disassembly 54C:
1. Inspect all parts for wear or damage. Replace parts if
necessary.

MX9613
A
6. Install lower seal (I) with lip toward bearing using a 1-13/
16 in. disk and a press, until seal is 7.8 mm (0.31 in.) below
hub flange (K). C
B
7. Install lower seal ring (J), with grease notch away from A
bearing, inside seal lip.

Q
R E
D

P
M45998AE
L
S 2. Inspect bearing (A) for wear or damage. Replace if
necessary.
NOTE: Bearings (A) are seated against shoulder in jack
M sheave (B), and must be removed one at a time, from
either side.
N
O Remove bearings (A) only if replacement is necessary.
MX9610
3. Remove one bearing (A) using a suitable puller, or a pin
8. Install spindle shaft (L). punch and hammer.
4. Remove spacer (C).
IMPORTANT: Avoid damage! Do not install
hexagon end of spindle shaft in a vice to install 5. Remove second bearing (A) using a press, or suitable
spindle sheave nut. The hexagon end of the driver and mallet.
spindle shaft will be damaged resulting in 6. Inspect all parts for wear or damage, replace as needed.
improper blade operation.

Attachments Repair - 519

 ATTACHMENTS REPAIR
Assembly: A - Lubrication Fitting (apply grease)
• Install bearings (A) tight against shoulder in jack sheave B - Flanged Nut
(B) using a press, or suitable driver and mallet. Be sure to C - Sheave
install spacer between bearings. D - Upper Seal
• Tighten jack sheave nut (D) to 136 N•m (100 lb-ft). E - Bushing
• Tighten tensioning idler sheave nut (E) to 27 N•m (20 lb- F - Upper Bearing
ft). G - Flanged Lock Nut
H - Housing
Idlers I - Spacer
J - Lower Bearing
NOTE: Idler sheaves are welded and contain a non- K - Lower Seal Ring
serviceable bearing. If bearing replacement is needed,
L - Lower Seal
replace entire idler sheave.
M - Spindle Shaft
N - Deflector
62C Mower Deck Spindle Removal and
O - Blade
Installation
P - Blade Washer
Removal 62C: Q - Cap Screw
1. Place blade (O) in a soft-jawed vise.
IMPORTANT: Avoid damage! Always install new
bearings and seals when servicing spindles. 2. Remove flanged nut (B).
3. Remove lubrication fitting (A), sheave (C) and bushing
A (I).
B 4. Remove cap screw (Q), washer (P), deflector (N) and
blade (O).
C 5. Remove spindle shaft from housing (J).
6. Remove lower seal ring (K) and lower seal (L).
D NOTE: Remove upper bearing (F) and lower bearing (J)
G
E only if replacement is necessary.
F 7. Upper and lower bearings are seated against spindle
hub shoulder and cannot be removed with a press. Remove
H upper seal (D) and bearings using a punch.
I 8. Remove spacer (I).
9. Inspect all parts for wear or damage. Replace parts as
needed.
J
K
L

O R

P
Q

MP29544A

Attachments Repair - 520

 ATTACHMENTS REPAIR
Assembly 62C:
U
D O

B
H
L

C I

A K
N
MP29644b

1. Using a press and disk driver large enough to contact

the bearing outer race, install lower bearing (A) until it is
J
seated against the shoulder in the housing (B).
P
2. Turn the housing over.
3. Install spacer (C). Center the spacer over the lower
bearing.
Q
S
IMPORTANT: Avoid damage! Using disk drivers,
support both the inner and outer races of the upper T
and lower bearings when installing the upper
bearing. Do not support the housing by allowing it to MP29644C
rest on its end. 7. Install bushing (L).
4. Using a press and disk driver, install upper bearing (D) 8. Using a press and disk, install upper seal (H) and lower
until it rests against the bottom of the housing shoulder. seal (N) with open side toward bearing until the face of the
seal is flush with the end of the housing (I).
NOTE: The inner diameter chamfer of the seal ring is
away from the bearing. 9. Install spindle shaft (J) into housing.
[Link] bushing (K) and sheave (M).
[Link] flanged nut (O).

IMPORTANT: Avoid damage! Blade (Q) must be

properly seated on the spindle, and concave side of
blade washer (R) MUST face toward blade.

[Link] lower deflector (P), blade (Q), and washer (S) and
cap screw (T).
G E F
[Link] blade cap screw to 320 N•m (236 lb-ft).
MX2537 [Link] blade in a soft-jawed vise.
5. Using a press and disk, install lower seal (E) with open [Link] flange nut to specification.
side toward bearing until the face of the seal is at the
specified height (F) from the lower end of the housing. [Link] blade cap screw and retighten to specification.
6. Install lower seal ring (G) with the outer diameter [Link] specified grease to lubrication fitting (U).
chamfered edge toward bearing.

Attachments Repair - 521

 ATTACHMENTS REPAIR
Specifications: 3. Using care not to misplace shaft key (C), wrap a piece of
tape around shaft key and PTO gearbox input shaft.
Seal Face Distance from Lower End of Housing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.57 mm (0.10 in.)
Blade Cap Screw Torque . . . . . . . . . . 122 N•m (90 lb-ft)
Flanged Nut Torque . . . . . . . . . . . . . 255 N•m (188 lb-ft)
Recommended Grease D
John Deere Multi-Purpose SD Polyurea Grease or John
Deere Multi-Purpose Lithium Complex Grease

Mower Deck Drive Shaft Removal and

Installation E

Removal:

IMPORTANT: Avoid damage! Use of incorrect

greases can result in premature wear of parts and
component failures. MX8823

1. Lift up PTO drive shaft cover to gain access to the front 4. Inspect the universal joint (D) and lubrication fitting (E)
PTO drive shaft universal joint. for wear or damage. Replace as necessary.

Installation:
B • Installation is done in the reverse order of removal.
• Remove tape from PTO gearbox input shaft, using care
A not to misplace shaft key.
• Apply a light coat of MPG-2 Multi-Purpose Grease to
splines of drive shaft.
• Install drive shaft onto PTO gearbox input shaft. Tighten
flange head cap screw to specification.
• Apply specified grease to lubrication fitting on universal
joint. See Mower Spindle Grease in Specifications and
General Information section.

Specifications:
MX7111 Drive Shaft Flanged Head Cap Screw Torque
2. Remove flanged head cap screw (A) to remove drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 N•m (60 lb-ft)
shaft from PTO gearbox input shaft (B).

MX7109

Attachments Repair - 522

 ATTACHMENTS REPAIR
Mower Deck Drive Shaft Repair
A

T U

C
R
M
Q

P L

O
N

MX5733 N - Snap Ring

A - Lubrication Fitting O - Locking Collar
B - Yoke, with Tube P - Compression Spring
C - Yoke Q - Ball
D - Snap Ring R - Snap Ring
E - Bearing S - Universal Joint Yoke
F - Guard T - Lubrication Fitting
G - Spring Pin U - Universal Joint
H - Shaft V - Snap Ring
I - Snap Ring • Inspect all parts for wear or damage. Replace parts as
J - Universal Joint Yoke needed.
K - Universal Joint • Apply a light coat of MPG-2 Multi-Purpose Grease to
L - Lubrication Fitting splines of drive shaft. (See Anti-Corrosion Grease in
M - Snap Ring Specifications and General Information section.)

Attachments Repair - 523

 ATTACHMENTS REPAIR
Mower Deck Gearbox Removal and 4. Adjust mower height control knob to 38.1 mm (1.5 in.).
Installation 5. Push top hydraulic lever forward to lower deck to the
ground.
Removal:

MX11077

6. Reach under machine from left side and pull coupler (D)
to release deck PTO driveshaft.
MX11076
7. Put PTO driveshaft on top of deck.
1. Pull back top hydraulic lift lever (A) to raise mower deck
to highest (transport) position.
2. Park machine safely. (See Parking Safely in the Safety
section of the operator’s manual).
E

c CAUTION: Avoid injury! Rotating blades are

dangerous. Before adjusting or servicing
F

mower:
• Disconnect spark plug wire(s) to prevent
engine from starting accidently.
• Always wear gloves when handling
mower blades or working near blades.
MX11078

8. Pull out pin and pull down release latch (E) on front deck
C hanger bracket (F) to release deck. Rear of deck will slide
B
off draft arms at this step.

MX11075

3. Turn all gauge wheels to the deck removal position:

• Pull back on gauge wheel release rod (B). MX11052a
• Turn gauge wheel sideways. 9. Remove front deck hanger bracket (F) from mower deck.
• Move gauge wheel up until release rod engages in [Link] engine.
deck removal holes (C) on side of rod.

Attachments Repair - 524

 ATTACHMENTS REPAIR
[Link] back top hydraulic lever to raise draft arms to
highest position.
[Link] off engine.

G K
K

MX11051
MX11055 [Link] two nuts (K) on rear of gearbox.
[Link] each belt guard cover (G). [Link] four bolts (L) from front of gearbox and remove
belt.

MX11047
N
[Link] idler tension spring (H) to relieve tension on
belt.

M
I
J
MX5735

[Link] cap screw (M) to remove drive sheave (N) from

gearbox.
[Link] drive sheave for wear or damage. Replace if
necessary.

Installation:
MX11048
• Installation is done in the reverse order of removal.
[Link] clip (I) and washer (J). Lift idler arm up to
remove belt. • Install drive sheave to gearbox and tighten cap screw to
specification.
• Wrap belt around drive sheave and install gearbox onto
mower deck frame. Tighten cap screws to specification.
• Install tension spring, and adjust belt tension to
specification.

Attachments Repair - 525

 ATTACHMENTS REPAIR
• Install belt shield. J - Bearing
• Remove tape from gearbox input shaft, using care not to K - Pipe Plug (2 used)
misplace shaft key. L - Snap Ring
• Apply a light coat of MPG-2 Multi-Purpose Grease to M - Bearing Cup
gearbox input shaft. N - Bearing
O - Shim
• Install drive shaft onto gearbox input shaft and tighten
cap screw to specification. P - Snap Ring
Q - Shaft Seal
• Install drive shaft onto PTO output shaft.
R - Shaft Seal
Specifications: S - Snap Ring
T - Shim
Tightening Torques:
U - Bearing Cup
Drive Sheave Cap Screw . 129 ± 9.5 N•m (95 ± 9.5 lb-ft) V - Bearing
Gearbox-to-Frame Cap Screw . . . . . . . 99 N•m (73 lb-ft) W - Input Shaft
Drive Shaft Cap Screw . . . . . . . . . . . . . 81 N•m (60 lb-ft) X - Keyway
Y - Gear
Mower Deck Gearbox Repair Z - Housing
• Inspect all parts for wear or damage. Replace seals or
A plugs as needed. If gears are worn or damaged, replace
gearbox assembly.
B

IMPORTANT: Avoid damage! Do not overfill the

C gearbox with oil. Damage to internal gearbox seal
F
D will result.

E NOTE: Gearbox oil capacity is approximately 0.4 L

Z (13.5 oz).

G • Fill gearbox to proper level with approved gear oil. (See

X Y
H Oils and Lubricants in the Specifications and General
I Information section.)
J
W
K
V
L
U
M

N
P
O
T
S Q
R
MX5738

A - Plug
B - Output Shaft with Gear
C - Shim
D - Bearing
E - Bearing Cup
F - Plug
G - Snap Ring
H - Shim
I - Bearing Cup

Attachments Repair - 526

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

S1 Key On Off
Switch F2 414 Seat Seat
Wht 15 Amp Yel/ S2
Wht
B Fuse Blk Seat A
Red Red
Switch
X1 S1 800
X2 X3 Pink D
M
X3 D
6
Start C K2
Ignition
210 Run Relay
Red
Off 30 87
L K J
F3 85
15 Amp 86
Fuse
F1 K1
Fusible Start
Relay
Link X3
710
Pur

H
1
215
Org X2
721
Pur/
Wht
Red 805 Pnk/Blk
F
W3
Engine X3
Wiring X4
B S E Yel/
G T1 Harness Wht T2
I Ignition Ignition
X3 X5
G1 M1 H Coil Yel/Wht Yel/Wht Coil
Battery Starting P
M Motor
Blk B E1 Yel/ E2 Q
Spark Wht Spark
Plug Plug
W1 Wht Blk/Yel
Shielded F
E O C N
Ground 105 Blk

SE1-Power and Starting Circuit SE2-Ignition and Interlock Circuit SE3-PTO and Interlock

MIF used consistently on all diagrams in this section.

The same component name and identification code are Components can be easily cross-referenced.

Attachments General Information - 527

 ATTACHMENTS GENERAL INFORMATION
Operation and Diagnostics Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
The operation and diagnostics stories divide the electrical
Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
system into individual circuits by function. Each circuit is
isolated from the main wiring schematic and only shows the Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
components that are used in it. The story contains Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White
information on function, operating conditions, and theory of Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
operation. The circuit schematics are drawn with the Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/White
components in the operating position, with the power, or Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
battery positive, into them across the top and the ground, or
Red/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
battery negative, across the bottom.
Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Diagnostic Information
Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
The diagnostic procedure is used to test the complete Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
circuit regardless of the problem or complaint. Select a Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow/White
symptom or system from the quick check or
troubleshooting chart and follow the test procedures under
that heading. Common Circuit Tests
The diagnostic procedure lists: Shorted Circuit:
• Test conditions.
• Test sequence.
• Test location.
• Normal reading.
• Check or test to perform if reading is not normal.
When performing the test or check, be sure to set your
machine up to the test conditions listed and follow the
sequence carefully.
MIF

A shorted circuit may result in the wrong component

Wire Color Abbreviation Chart operating (i.e. improper wire-to-wire contact). To test for a
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Black shorted or improperly wired circuit:
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue 1. Turn component switch ON.
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown 2. Start at the controlling switch of the component that
Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green should not be operating.
Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray 3. Follow the circuit and disconnect wires at connectors
Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange until component stops operating.
Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink
4. Shorted or improper connections will be the last two
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple wires disconnected.
Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan High Resistance or Open Circuit:
Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White
Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
Blu/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/White
Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow MIF
Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
1. High resistance or open circuits usually result in slow,
Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green
dim or no component operation (i.e. poor, corroded, or
Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red disconnected connections). Voltage at the component will

Attachments General Information - 528

 ATTACHMENTS GENERAL INFORMATION
be low when the component is in operation. To test for high Grounded Circuit:
resistance and open circuits:
2. Check all terminals and grounds of the circuit for
corrosion.
3. If terminals are not corroded or loose, the problem is in
the component or wiring.

MIF

Grounded circuits usually result in no component operation

or a blown fuse.

Conductors For 12 Volt Circuits

Standard Conductors For 12 Volt Circuits

SAE Wire Size (Gauge) 20 18 16 14 12 10

Metric Wire Size (mm) 0.5 0.8 1.0 2.0 3.0 5.0

Typical Stranding 7 X 28 16 X 30 19 X 29 19 X 27 19 X 25 19 X 23

Minimum Conductor Area In 1072 1537 2336 3702 5833 9343

Circular Mils

Attachments General Information - 529

 ATTACHMENTS IDENTIFICATION NUMBERS
Identification Numbers

Generator

MX19672A

A - Generator Identification

Alternator

MX19203

A - Alternator Identification

Attachments Identification Numbers - 530

 ATTACHMENTS COMPONENT LOCATION
Component Location

Generator

D
C

F
G

MX19672 H - Base
A - Control Panel I - Alternator
B - Voltage Meter
C - Fan Housing
D - Transmission
E - Transmission Oil Fill Plug
F - PTO Shield
G - Mounting Pin

Attachments Component Location - 531

 ATTACHMENTS COMPONENT LOCATION
Alternator Components

G
H

E
C
B K
A

J
C K

MX19887

A - Fan Housing
B - Rotor
C - Varistor (R1 and R2)
D - Control Case
E - Bolt
F - Exciter Capacitors (C1 and C2)
G - Terminal Board
H - Air Intake Vent
I - Cap
J - Bearing
K - Diode (V1 and V2)
L - Fan Friction Collar
M - Fan
N - Air Vent

Attachments Component Location - 532

 ATTACHMENTS COMPONENT LOCATION
Control Panel

A B B A

C D C

MX19674

B
A

F
E

MIF

A - 20 Amp Circuit Breaker (F1 and F4)

B - 40 Amp Circuit Breaker (F2 and F3)
C - 120 Volt/20 Amp GFCI Protected Duplex
Receptacle (X1 and X3)
D - 240 Volt/40 Amp Receptacle (X2)
E - O-Ring

Attachments Component Location - 533

 ATTACHMENTS COMPONENT LOCATION
Generator Gear Box Components
D
C E

A
H G

I
K
J
L

MX19882

A - Seal
B - Bearing
C - Plug
D - Nut
E - Cap
F - Seal
G - Plug
H - Bearing
I - Plug (BPT)
J - Bolt
K - Cap
L - Bolt
M - Bolt

Attachments Component Location - 534

 ATTACHMENTS SCHEMATICS AND HARNESSES
Schematics and Harnesses

Wiring Harness Legend

C1 - Capacitor (SE2)
C2 - Capacitor (SE2)
F1 - Circuit Breaker - 20 Amp (SE1)
F2 - Circuit Breaker - 40 Amp (SE1)
F3 - Circuit Breaker - 40 Amp (SE1)
F4 - Circuit Breaker - 20 Amp (SE1)
G1 - Generator
L1 - Stator Coil (SE2)
L2 - Excitation Coil (SE2)
L3 - Excitation Coil (SE2)
L4 - Stator Coil (SE2)
L5 - Rotor Coil (SE2)
L6 - Rotor Coil (SE2)
P1 - Voltmeter (SE1)
R1 - Varistor (SE2)
R2 - Varistor (SE2)
V1 - Diode (SE2)
V2 - Diode (SE2)
W1 - Control Panel Internal Ground

Connectors
X1 - 120 Volt, 20 Amp, GFCI Receptacle (SE1)
X2 - 240 Volt, 40 Amp Receptacle (SE1)
X3 - 120 Volt, 20 Amp, GFCI Receptacle (SE1)

Attachments Schematics and Harnesses - 535

 ATTACHMENTS SCHEMATICS AND HARNESSES
Standard Electrical Schematic

Wht

Wht/Yel

Blk/Yel

Blk
Wht Wht/Yel

120 Wht 135 Wht

W2 U2 V2
P1
U1 V1 W1 Blk/Yel Voltmeter

Blk

515 530
Blk Red

F1 F2 F3 F4
140
Wht
525
Red

X1 (GFCI) X3 (GFCI)
130 Wht

520 535
Red Blk

125
Wht 505 Blk 540 Red

X2
540
Red

510 Blk

110 Grn 115 Grn

120 Wht

W1

SE1 - Output Section

MIF

Attachments Schematics and Harnesses - 536

 ATTACHMENTS SCHEMATICS AND HARNESSES

G1 Generator
L1 Stator Coil
Wht L4 Stator Coil
Rotor
Wht/Yel L5 L6
L2 L3
Blk/Yel
Exciter
Blk Circuits
Red Grn

C1 C2
Capacitor Capacitor
V1 V2
Diode Diode

Blk Blk/Yel

Wht/Yel
Wht R1 R2
Varistor Varistor

Wht

Wht/Yel

Blk/Yel

Blk

SE2 - Alternator

MIF

Attachments Schematics and Harnesses - 537

 ATTACHMENTS OPERATION AND DIAGNOSTICS
Operation and Diagnostics Generator Circuit Diagnosis
Test Procedure A
Generator Circuit Operation
Function: Test Conditions:
To provide circuit breaker protected 120 and 240 volt AC • Machine warmed up and running with a minimum 50
outputs. watt load applied to generator.

Operating Conditions: System: Generator AC Output

The PTO must be ON and rotating at 540 rpm for the
(1) Is the PTO running at 540 rpm to provide
generator transmission to provide a 3600 rpm output in
correct 60 Hz output from all of the AC
order to provide 60 Hz alternating current to the generator
receptacles?
outputs. The 20 amp, 120 volt duplex outlets are GFCI
protected and the unit must be connected to a suitable Yes - Test complete.
earth ground for these circuits to function properly.
No - Check to make sure that the PTO is running at
Theory of Operation: 540 rpm. Go to test procedure B.

Test Procedure B
c CAUTION: Avoid injury! The field capacitors
have the capability to store very high Test Conditions:
voltages. NEVER touch both capacitor
terminals with bare hands as this could • Key switch in the OFF position.
cause rapid discharge and result in an • Generator excitation capacitors accessible.
electrical shock. Discharge capacitors by
• All terminal block leads disconnected.
bridging the terminals with a screwdriver
shaft that has an insulated handle before
servicing.
System: Generator Internal Components
(1) Did generator provide proper output in test
The generator is a brushless design with stator self
procedure A?
excitation capability to provide a magnetic field within which
the rotor will induce voltage. Self excitation is provided by No - The excitation field capacitors may need to be
two angle shifted, in relation to the power windings, energized. See “Stator Excitation Field Restoration”
capacitors (one per 120 VAC output). These capacitors set on page 542. Low engine speed/PTO speed, faulty
up the magnetic field within which the rotor turns to windings, or defective capacitors can cause
inductively generate AC power. Proper operation of these excitation field failure.
capacitors are essential for correct generator output. As the
No - Check for continuity between one Red and one
rotor turns, power is generated in two independent 120 volt
Grn capacitor lead. If there is continuity, the stator is
sets of windings in the stator. These outputs are directed to
shorted. Replace stator.
the generator control panel wiring.
No - Disconnect the excitation capacitor leads and
To obtain a 240 volt AC output, the two 120 volt outputs are
measure the resistance between the Red wires.
combined at receptacle X2.
Repeat for the Grn pair. If the resistance is not
Unit grounding is provided by several ground straps approximately 1.2 ohms, replace the stator.
connecting the base, generator, roll guard, and ultimately, a
user installed earth ground connection. No - After discharging each capacitor, measure the
resistance across each of the capacitor’s terminals. If
The generator circuit is equipped with an over/under the resistance increases (increasing as capacitor
voltage warning meter. charges), the capacitor is OK. If not, replace the
capacitor.
No - Check for continuity between each capacitor
lead and each black stator power lead. If there is
continuity, the stator is shorted and must be replaced.

Attachments Operation and Diagnostics - 538

 ATTACHMENTS OPERATION AND DIAGNOSTICS
System: Generator Internal Components Test Procedure D

No - Measure the resistance across each of the

Test Conditions:
rotor’s diode ends. See “Generator Rotor Test” on
page 541. • Key switch in the OFF position.
No - Check continuity between each of the rotor’s
diode ends and ground. If there is continuity, the rotor
System: Generator Circuit Breakers
is shorted and must be replaced. (1) Are the individual circuit breakers tripping?
No - Check for continuity between the rotor body and Yes - Ensure that the load on the circuit does not
the stator body. If there is continuity, isolate the exceed its respective amperage rating.
source of the short and repair or replace components
as necessary. Yes - The device connected to the receptacle may be
short circuiting and causing excessive current draw
No - If generator voltage no load output is too high, on the generator.
excitation capacitors may be holding too high a
charge. Short each capacitor and recharge. See Yes - Distribute the 120 volt loads evenly across the
“Stator Excitation Field Restoration” on page 542. duplex receptacles.

No - Check for low no-load or low loaded voltage. Yes - Ensure that the frequency of the device
Possible faulty rotor diodes. See “Generator Rotor connected to the receptacle matches that of the
Test” on page 541. generator’s output.

Yes - Go to test procedure C. Yes - Remove top panel and inspect internal wiring
for problems.
Test Procedure C No - Test complete.

Test Conditions:
• Key switch in the OFF position.

System: Generator GFCI Circuit

(1) Did the GFCI circuit trip during test procedure
A?
Yes - Check to ensure the generator earth ground is
connected properly.
Yes - Check the generator to base grounds. See
“Generator Ground Test” on page 542.
Yes - Test the GFCI circuits. See “Ground Fault
Circuit Interrupter (GFCI) Checks” on page 541.
Yes - Ensure that the frequency of device connected
to the receptacle matches that of the generator’s
output.
Yes - Ensure that the load of the device connected to
the generator does not exceed the rated output of the
generator or receptacle.
No - Go to test procedure D.

Attachments Operation and Diagnostics - 539

 ATTACHMENTS TESTS AND ADJUSTMENTS
Tests and Adjustments
L1 Stator Coil L4 Stator Coil
Generator Stator Test L2 L3
Exciter
Reason: Circuits
To verify that the stator coils have proper continuity (not Red Grn
open or shorted).

Test Equipment:
• Ohmmeter C1 C2
Capacitor Capacitor
Procedure:
1. Remove the four screws securing the control panel
cover.

Wht U2 V2 Wht/Yel
C E
Blk Blk/Yel
A V1 W1 D
B

MIF

4. With the terminal wires disconnected, check the

resistance between the Blk wire (B) and Wht wire (C).
B There should be continuity.
5. With the terminal wires disconnected, check the
resistance between the Blk wire (D) and Wht wire (E).
There should be continuity.
MX19886 6. Check for continuity between the two White wires (C and
E). There should be no continuity. If there is, the stator is
2. Disconnect white and green wires (A) and ground shunt
shorted.
(B) from the terminal block, noting their positions.
7. Check for continuity between the stator housing and all
3. Disconnect the harness ground on stator housing.
wires. There should be no continuity. If there is, the stator is
shorted.

Specifications:
Blk to Wht wire resistance (approximately). . . 1.0 ohms
White wire to White wire . . . . . . . . . . . . . . Infinity ohms

• If specifications are not met, replace stator.

Attachments Tests and Adjustments - 540

 ATTACHMENTS TESTS AND ADJUSTMENTS
Generator Rotor Test 4. Repeat for second diode. The readings should meet
specifications.
Test Equipment: 5. Place lead on end of diode and one end on stator
• Ohmmeter housing. Repeat test with a one lead placed on the end of
each diode. There should be no continuity. If there is, the
Reason: rotor is shorted.
To verify that the rotor coils and components have proper
Specifications:
continuity and resistance (not open or shorted). This test
verifies circuit integrity ONLY. If specifications are not met, Resistance at each diode (approximately) . . . 1.5 ohms
rotor discrete components (diodes and varistors) can not Diode to stator housing. . . . . . . . . . . . . . . Infinity ohms
be tested individually. Diode to diode . . . . . . . . . . . . . . . . . . . . . . Infinity ohms
Procedure: • If specifications are not met, replace rotor.

Ground Fault Circuit Interrupter (GFCI)

Checks

c CAUTION: Avoid injury! The GFCI circuits

may not function unless the generator is
A properly grounded. Situations exist where
a GFCI will not afford any protection
against the hazards of electrical shock.
EXAMPLE: If a person touches two or more
conductors from a damaged cord set and is
not in direct contact with the ground, he or
she may receive a shock. Since there is no
path to ground for a ground fault current to
MX19883 flow through, the GFCI will not operate and
1. Remove the four screws securing the side cover of serious injury may result.
generator housing.
Reason:
The 20 amp, 120 VAC outlets are protected by ground fault
circuit interrupters (GFCI). The GFCI has to meet the
following operational checks.
• When the test button is pressed, the reset button must
B pop out and the voltage to the GFCI and the 5-20R duplex
receptacle must be zero.
• When the reset button is pressed back in, power must
return to the GFCI duplex receptacle.
• When a 5mA “ground fault” is applied from either
receptacle’s Hot Line to Frame Ground, the reset button
must pop out and the receptacle power must be zero. Use
tester available from electrical or building stores.
MX17383

2. Locate the diode for each of the rotor coils (B).

NOTE: The diodes are in a parallel circuit with the
varistors and the rotor windings. Do not unsolder the
diodes for testing.
3. Place an ohmmeter lead on the each end of diode.
Measure resistance.

Attachments Tests and Adjustments - 541

 ATTACHMENTS REPAIR
Generator Ground Test Procedure:

Reason:
To ensure that the generator, base, and control panel share
a common ground. A

Equipment:
• Ohmmeter

Procedure:
1. Visually inspect all ground points to ensure that wires
and cables are attached securely and are in good
condition.
2. Set VOM to RX1 setting.

MX19672a

1. Remove the four control panel cover screws (A) and

remove cover.

c CAUTION: Avoid injury! The field capacitors

have the capability to store very high
voltages. NEVER touch both capacitor
B terminals with bare hands. as this could
cause rapid discharge and result in an
electrical shock. Discharge capacitors by
bridging the terminals with a screwdriver
A shaft that has an insulated handle before
servicing.

2. Discharge the capacitors.

3. Connect one VOM lead to the ground terminal (A).

4. Connect second lead to ground test points (B).

Results:
• Resistance should not exceed 0.2 ohms.
• If resistance exceeds 0.2 ohms, check condition of
affected wires and connections. Repair or replace as
necessary.

Repair

Stator Excitation Field Restoration B

Reason: MX19885
To restore the stator self excitation capacitor charge in the 3. Using jumper wires, apply a DC power source (such as
event of no generator output. the 12 volt starting battery) across the terminals of either of
If the generator has no AC output, it is possible that the the field capacitors (B) for approximately 1 second.
excitation field has dissipated and the field capacitors will 4. Replace terminal block cover and secure with four
have to be recharged. mounting screws.

Attachments Repair - 542

 ATTACHMENTS REPAIR
PTO Shield Removal and Installation Generator Removal and Disassembly

c CAUTION: Avoid injury! Generator weighs

approximately 49 Kg (108 lbs). Use an
assistant or proper equipment to aid in
generator removal.

Procedure:
A

A
MX17182

Removal:
1. Remove the four bolts securing the protective shield to B
the transmission.
2. Remove shield.

Installation: MX19191
• Installation is in the reverse of removal. 1. Remove fan cover (A) from each side of generator.
2. Remove locknuts from two bolts (B) securing generator
to base bracket.
3. Remove locknut securing rear of generator to base
bracket.
4. Remove generator from base bracket.

Gear Case Removal and Disassembly

Procedure:

MX19191

1. Remove fan cover (A) from each side of generator.

Attachments Repair - 543

 ATTACHMENTS REPAIR

F
B
H

B
F

MX19884 E G

2. Remove four bolts (B) securing gear case to generator MX19882a

housing.
5. Remove four bolts (E) securing plate to housing.
6. Remove top and bottom plugs (F) and drain gear oil into
a suitable container.
7. Remove bolts (G) securing case halves and separate
case.
NOTE: If gears are damaged, replace entire gear case
assembly.
C
8. Remove gear shaft assemblies and inspect for damage.
Replace bearings as necessary.
9. Remove and replace seals (H) before assembly.

Assembly:
Assembly is performed in the reverse order of disassembly.
MX19883
• Replace gear shaft seals.
3. Remove the four screws (C) securing the side cover of
• Clean case halves and seal with gasket compound.
generator housing.
• Install plugs.

Gear Case Oil Fill:

1. Install gear case to generator or place gear case on flat
D work surface.
NOTE: If gear case is overfilled, oil may come out of
top vent plug during operation. If oil leaks occur during
operation, check for proper oil level.

MX17383

4. Loosen bolt (D) approximately five full turns and tap on

bolt with a soft mallet to loosen the gear case tapered shaft
from the rotor. Remove bolt and gear case.

Attachments Repair - 544

 ATTACHMENTS REPAIR

B MX17351
MX17188 2. Using a press, install bearing on shaft until it stops on
2. Remove top (A) and side (B) case plugs. bearing seat (B).
3. Fill case with 80W90 GL5 Gear Lube (approximately 16 3. Ensure that bearing rotates freely and does not bind.
oz) until gear oil comes out of side plug opening (B).
4. Install and tighten plugs. Rotor Fan Removal and Installation
Removal:
Rotor Bearing Removal and Installation
1. Clean rotor shaft and ensure that it is free of all dirt and
Removal: grease.
1. Remove gear case from generator. See “Gear Case 2. Stand rotor on a level surface with the bearing end
Removal and Disassembly” on page 543. down.
2. Remove rotor assembly from generator.

MX17345

3. Using a suitable puller (A), slowly remove fan from rotor

MX17352
shaft.

1. Stand rotor assembly upright on a level surface and

attach a suitable bearing puller (A) to rotor bearing.
2. Slowly remove bearing from rotor shaft.

Installation:
1. Place bearing evenly on rotor shaft.

Attachments Repair - 545

 ATTACHMENTS REPAIR
Generator Assembly and Installation
Assembly and Installation:
1. Assemble generator by applying medium strength
thread lock to bolts securing generator end support bracket
B
to transmission (if removed for transmission replacement).

MX17347

4. Inspect the fan friction collar (B) for deformation.

Replace as necessary.
MX19708
Installation:
2. Set end support bracket against gear case and insert
1. If removed, replace fan friction collar.
bolts (A). Tighten bolts to specification.
2. Place rotor and fan on press.
3. Wipe gear case shaft taper clean of grease and debris.

MX17348
C
3. Place a block of wood (C) on fan to allow for even
MX19709
pressure distribution.
4. Slide rotor and fan assembly (B) onto crankshaft.
4. Slowly apply pressure until fan seats on rotor shaft
flange. 5. Insert rotor to gear case retaining bolt (C) through lock
washer and rotor into crankshaft. Tighten finger tight.
6. Gently slide stator and end housing over rotor.

Attachments Repair - 546

 ATTACHMENTS REPAIR
Control Panel Removal and Installation
E Removal:
1. Remove the control panel cover.

D
F

MX19884
B
7. Slide two bolts and nuts (D) at bottom of stator housing
and tighten finger tight. Install two bolts (E) into holes at top
of stator housing, install nuts, and tighten. Tighten bolts to
specification. MX19885

8. Tighten rotor retaining bolt slowly and ensure rotor turns 2. Disconnect wires from the terminal block (A).
smoothly inside of stator.
3. Disconnect ground wires (B).
9. Ensure that rotor bearing is seated completely in stator
4. Remove control panel.
housing.
10. Tighten rotor bolt to specification. Installation:
11. Install three generator support bolts (F). • Installation is in the reverse of removal.

MX19191

12. Install generator end cover and vent covers (F).

13. Connect all wiring in the reverse of disassembly.

Specifications:
Generator support bracket to gear case
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Generator to support bracket . . . . . 21 N•m (186 lb-in.)
Rotor to rotor retaining bolt . . . . . . 21 N•m (186 lb-in.)

Attachments Repair - 547

ATTACHMENTS REPAIR

Attachments Repair - 548

 MISCELLANEOUS TABLE OF CONTENTS
Miscellaneous

Table of Contents

Specifications ...............................................551
Repair Specifications..................................551
Other Materials...........................................551
Repair.............................................................552
Fender Deck Removal and Installation ......552
Fuel Tank Removal and Installation ...........553
Fuel Pump/Fuel Gauge Sensor Removal
and Installation ...........................................554
Headlights Adjustment ...............................555
Lift Linkage Removal and Installation.........556
Hood Removal and Installation ..................559
Instrument Panel Removal and Installation 560
Front Wheel Removal and Installation .......561
Rear Wheel Removal and Installation ........561

Miscellaneous Table of Contents - 549

MISCELLANEOUS TABLE OF CONTENTS

Miscellaneous Table of Contents - 550

 MISCELLANEOUS SPECIFICATIONS
Specifications

Repair Specifications
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.6 L (6.5 gal)
Fuel Pump/Sensor Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 N•m (12 lb-in.)
Steering Wheel Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Front Wheel Cap Screw (2-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft)
Front Wheel Lugs (5 used) (4-Wheel Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)
Rear Wheel Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)

Other Materials

Other Material
Part No. Part Name Part Use
LOCTITE® Thread Lock and Sealer (Medium Strength) To seal threads on control valve screws, spool
PRODUCTS detent, and small plugs
Loctite#/U.S. #/
Canadian
TY9370/TY9477/
#242

Miscellaneous Specifications - 551

 MISCELLANEOUS REPAIR
Repair
G
Fender Deck Removal and Installation
Removing:
1. Disconnect negative battery terminal.

A
B

C
MX15401/MX15402

6. 25 HP (FD711D) EFI Engines Only: Loosen the fuel

pressure relief screw (G) to relieve the high pressure in the
return fuel hose; then tighten it.
F
D

E
MX14169

2. After disconnecting seat switch wiring connector (A),

remove wire and sheath from notched area (B) in platform
(C) and bottom of seat platform. This avoids possible
damage to wiring harness or connector when removing
platform. H I

3. MFWD machines only: Remove shift lever knob on right

side of fender deck before fender deck removal. (See “Shift MX14172
Lever Linkage (MFWD) Removal and Installation” on 7. Remove cap screws (H) and platform (I), being careful
page 371 in the Hydrostatic Power Train section.) to guide seat switch wiring through hole in bottom of
4. Remove fuel cap (F) and fuel tank support bracket, platform.
under left rear tire. 8. Disconnect tail light (E) wiring harness connector.
5. Remove cap screws (D). 9. Immediately install fuel cap, being sure to not allow dirt
or other debris to enter fuel tank.

c HP
CAUTION: Avoid Injury! Machines with 25
(FD711D) EFI engines: Release of fluids
Installing:

from pressurized fuel system can cause

serious injuries. Relieve fuel system
pressure before servicing (.

H I

MX14172

Miscellaneous Repair - 552

 MISCELLANEOUS REPAIR
1. Guide seat switch wiring connector (A) through hole in
bottom of platform before lowering platform onto machine
A
frame.
2. Connect tail light (E) wiring harness connector.
3. Remove fuel cap (F), lower platform (I) onto machine
frame, and install cap screws (H).
4. Immediately install fuel cap, being sure to not allow dirt
or other debris to enter fuel tank.
5. Install fuel tank support bracket, under left rear tire.

A MX15401/MX15402
B
1. 25 HP (FD711D) EFI Engines Only: Loosen the fuel
pressure relief screw (A) to relieve the high pressure in the
C return fuel hose; then tighten it.
2. Disconnect negative battery terminal and remove fender
deck. (See “Fender Deck Removal and Installation” on
page 552.)
F
D
D
E
B

E
MX14169

6. Guide seat wiring connector (A) through platform (C),

and connect to bottom of seat. Insert wire and sheath into H F
G
notched area (B) in platform.
D
7. Install and tighten two cap screws (D).
H
I
Fuel Tank Removal and Installation
MX14173
Removing: 3. Remove two cap screws (D) and bracket (C).

c HP
4. Remove three clips (H) holding wiring harnesses in
CAUTION: Avoid Injury! Machines with 25 place.
(FD711D) EFI engines: Release of fluids 5. Disconnect sending unit wiring harness connector (F).
from pressurized fuel system can cause
serious injuries. Relieve fuel system
pressure before servicing (.

Miscellaneous Repair - 553

 MISCELLANEOUS REPAIR
6. Install bracket (C) into position, making sure all wiring
c explosive
CAUTION: Avoid Injury! Fuel Vapors are
and flammable.
harnesses and fuel lines are not out of position. Install two
cap screws (D).
• Do not smoke while handling fuel. 7. Move headlight wiring harness (I) so it hangs off the
back of fuel tank, and seat switch connector (B), so they
• Keep fuel away from flames or sparks.
line up for fender deck installation.
• Fill fuel tank outdoors or in a well
8. Install fender deck and connect negative battery
ventilated area.
terminal. (See “Fender Deck Removal and Installation” on
• Clean up spilled fuel immediately. page 552.)
• Use clean approved non-metal container
to prevent static electric charge. Fuel Pump/Fuel Gauge Sensor Removal and
• Use clean approved plastic funnel Installation
without screen or filter, to prevent static
electric discharge. Removing:

6. Loosen hose clamp and remove drain-back hose (E).

Cap hose to keep fuel from draining. c HP
CAUTION: Avoid Injury! Machines with 25
(FD711D) EFI engines: Release of fluids
7. Squeeze tabs on end of fuel supply hose and
from pressurized fuel system can cause
disconnect hose (G) from stationary line on sending unit.
serious injuries. Relieve fuel system
Cap hose to keep fuel from draining.
pressure before servicing.
8. Remove fuel tank, taking care to move all fuel lines and
wiring harnesses, including seat switch (B) and tail light (I)
harnesses, out of the way to avoid damaging them. A

Installing:
1. Install fuel tank into position, taking care to move all fuel
lines and wiring harnesses out of the way to avoid
damaging them.

D
E
B

C MX15401/MX15402

1. 25 HP (FD711D) EFI Engines Only: Loosen the fuel

pressure relief screw (A) to relieve the high pressure in the
return fuel hose; then tighten it.
2. Disconnect negative battery terminal and remove fender
H F
G deck. (See “Fender Deck Removal and Installation” on
page 552.)
D
H
I

MX14173

2. Guide fuel supply hose (G) into position on fuel tank.

Squeeze tabs on end of hose and connect to sending unit.
3. Guide drain-back hose (E) into position on fuel tank, and
attach to sending unit. Secure with clamp on end of hose.
4. Connect sending unit wiring harness connector (F).
5. Install three clips (H) holding wiring harnesses in place.

Miscellaneous Repair - 554

 MISCELLANEOUS REPAIR
4. Tighten cap screws (A) holding fixture to hood.

To replace headlights:
C
B
D
c contains
CAUTION: Avoid Injury! Halogen light bulb
gas under pressure. The bulb may
shatter if the glass is scratched or dropped.
C
Wear eye protection and handle bulb with
care when removing or replacing.
C
C E

F E
D

MX14174

25 HP (FD711D) EFI supply hose (B) shown; 23 HP

(FD671D) engines have standard clamped hose.
3. Disconnect sending unit wiring connector (F).
4. Loosen clamp and disconnect drain-back hose (D).
5. 25 HP (FD711D) EFI Engines Only: Squeeze tabs on
end of supply hose (B) and disconnect hose. MX13624
6. Remove five bolts (C) and fuel pump/sensor (E). • Disconnect wire harness (D) from defective bulb
7. Inspect parts for wear or damage. Replace if necessary. assembly (E).
• Turn bulb assembly 1/4 turn counterclockwise to
Installing: remove.
Installation is done in the reverse order of removal. • Insert new bulb assembly into housing and turn 1/4
• Tighten five bolts (C) to 1.4 N•m (12 lb-in.), in a star turn clockwise to install.
pattern. • Connect wire harness.
5. Lower hood.
Headlights Adjustment
1. Raise hood.

MX14303

2. Loosen both cap screws (A) holding headlight fixture (B)

securely to hood.
3. To adjust headlights, loosen cap screw (C), and rotate
headlight fixture (B) up or down. Tighten cap screw (C).

Miscellaneous Repair - 555

 MISCELLANEOUS REPAIR
Lift Linkage Removal and Installation

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

S
Q

MIF Q - Pin
A - Cotter Pin R - Strap
B - Washer S - Washer
C - Mower Deck Lift Arms T - Snap Ring
D - Pin U - Mid-Lift Shaft
E - Yoke V - Hole
F - Lift Link (2 used) W - Arm
G - Cap Screw
Removing:
H - Spring Pin
I - Pin 1. Remove snap ring (T), washer (S), and strap (R) from
end of welded pin on mid-lift shaft (U).
J - Washer
K - LIft Arm
L - Bearing
M - Bearing
N - Snap Ring
O - Rockshaft
P - Spring Pin

Miscellaneous Repair - 556

 MISCELLANEOUS REPAIR

R
AC

O
Q
MX14179

Fender deck removed for clarity.

AB AA
9. Remove spring pin (P) and pin (Q) holding lift cylinder
Z (AC) to end of rockshaft (O).
[Link] snap ring (N) and bearing (M) from each side
of machine.

Y [Link] rockshaft (O).

Installing:
1. Install rockshaft (O) into position, and install bearings
(M) and snap rings (N) onto each side of machine frame.
2. Install lift cylinder (AC) end to rockshaft (O), and secure
MX14384
with pin (Q) and spring pin (P).

2. Remove spring pin from end of brake rod (Z) at 3. Install bearings (L) and mid-lift shaft (U) onto machine
transaxle arm and cam (Y), and remove brake rod from frame.
mid-lift shaft (U). 4. Mount lift arm (K) on mid-lift shaft (U) to approximately
3. Remove spring (AB) from mid-lift shaft. Remove spring 90° counterclockwise of arm (W) on mid-lift shaft. Secure
pin and pin (AA) from end of brake spring return assembly with washer (J) and cap screw (G).
rod (X), and lower end from mid-lift shaft. 5. Turn lift link (F) 45°, and install to end of lift arm (K).
4. Remove cotter pin (A), washer (B), and pin (D) from 6. Install lift arm (C), pin (I), and spring pin (H) attaching lift
machine frame. link (F) to hole (V) in lift arm (C).
5. Remove spring pin (H), pin (I), and lift arm (C) from 7. Install pin (D), washer (B), and cotter pin (A) through lift
machine. arm (C) and to machine frame.
6. Turn lift link (F) 45°, and remove from end of lift arm (K).
7. Remove cap screw (G), washer (J) and lift arm (K) from
end of mid-lift shaft.
8. Repeat procedures above on other side of machine, and
remove bearings (L) and mid-lift shaft (U) from machine
frame.

Miscellaneous Repair - 557

 MISCELLANEOUS REPAIR
5. Locate strap underneath machine (this strap is the link
that connects the rockshaft cylinder to the mid-lift welded
shaft). This strap has a slot in it pointing towards the front of
the machine. The welded pin in the mid-lift shaft travels
within this slot.

AD

AE
F
X
E
U

I
AF

AB AA H C

Z MX14280

6. The lift arms have headed pins (AD) welded to them that
support the lift links. Check to make sure the P-hooks on lift
links (F) move freely about the pins.
Y

IMPORTANT: Avoid damage! Mower deck lift

system can be damaged if lift arms are not
adjusted correctly. Check adjustment each time
mower is installed to allow gap between lift arms
and frame stop (AE) at full lift height.

7. Check that the lift arm (C) does not contact the frame
stop (AE). If needed, adjust yokes (E) on both sides of
MX14384
mower until there is a slight gap of 1.6 mm (1/16 in.) on
8. Install brake rod (Z) onto mid-lift shaft (U), and connect both sides.
end to transaxle arm and cam (Y) with spring pin.
• Remove spring locking pin (H) and drilled pin (I) from
9. Install end of return assembly rod (X) to end of mid-lift each lift arm.
shaft (U), and secure with pin (AA) and spring pin. Install
spring (AB) to mid-lift shaft. • Turn each yoke (E) clockwise to raise the lift arm.

[Link] “Lift Linkage Adjustment:” procedure below. • Turn each yoke (E) counterclockwise to lower the lift
arm.
Lift Linkage Adjustment: • Attach each yoke to lift arm with drilled pin (I) and
Reason: To make sure that lift system linkage is adjusted spring locking pin (H).
properly. NOTE: On AWS machines there is an additional
1. Inspect for bent or broken mid-shaft, height indicator, bracket (AF) mounted to the machine frame that limits
etc. Replace components if necessary. lift arm rise.
2. Remove fender deck and footrest.
3. Extend rockshaft cylinder completely (pull back on top
SCV lever).
4. Rotate the height indicator to make sure it rotates freely
at full transport height.

Miscellaneous Repair - 558

 MISCELLANEOUS REPAIR
Hood Removal and Installation
A
Removing:
1. Raise hood.

IMPORTANT: Avoid damage! Disconnect headlight

harness before removing hood.

A
MX13551

1. Position hood (A) upright.

MX13552

2. Disconnect headlight harness (A) on left side of B

machine.

MX13629

2. Install first set of rollers (B) on hood into rail.

3. Connect headlight harness on left side of machine.
4. Tilt rear of hood toward steering wheel and lift hood up
and drop second set of rollers into rail.

MX13551
5. Allow hood to roll downward on rail.

3. Pull hood forward and roll hood up and out of rail. 6. Lower hood.

Installing:

Miscellaneous Repair - 559

 MISCELLANEOUS REPAIR
Instrument Panel Removal and Installation 8. Remove steering wheel cover and steering wheel (F).
See “Steering Column Removal and Installation” on
Removing: page 468 in Steering section for steering wheel removal
procedure.
1. Raise hood and disconnect negative battery terminal.
9. Slowly raise instrument panel, being careful to remove
C all electrical connections beneath panel and guiding panel
B
past SCV lever boot (H).

Installing:

D
G

A
D
F
H
M
E

I
L J

MX14395

2. Remove throttle handle (C).

NOTE: Late model side panels do not have fasteners
(A). They pull off. K
MX14396
3. (SN -30000): Pull and turn fasteners (A) to remove side
panel (E) from instrument panel assembly (D). 1. Lower instrument panel (D) just enough to install key
switch and secure with nut (G).
4. Remove screw (B) holding instrument panel (D) onto
pedestal. NOTE: To keep the tilt cover from rubbing on the
underside of the tilt lever and drag on the return-to-
D neutral feature, ensure the plastic tabs on the bottom
G of dash are fully seated in the frame slots before
tightening the screws on the top.
2. Install instrument panel onto pedestal, being careful to
F
H guide SCV lever boot (H) past hole in panel.
M
3. Install both cruise control latch (M) and parking brake
latch (L).
I 4. Install steering wheel (F) and cover. Tighten steering
L J wheel nut to 38 N•m (28 lb-ft).
5. Turn fasteners vertical and install side panel (K). Pull
and turn fasteners (I) and install screw (J) to secure side
panel (K) onto pedestal.

MX14396

5. Pull and turn fasteners (I) and remove screw (J) to

remove side panel (K).
6. Remove cruise control latch (M) and parking brake latch
(L).
7. Remove ignition key and remove nut (G) holding key
switch onto instrument panel (D).

Miscellaneous Repair - 560

 MISCELLANEOUS REPAIR
3. Inspect bearings (C) for wear or damage. Replace if
C necessary.
B
• Remove either bearing (C) using a slide hammer and
inside puller.
• Remove bearing on opposite end using a driver set
and a press.
• Install bearings flush to wheel hub.
A
D
• Pack inside areas of wheel hub bearings with
multipurpose grease.

Installation is done in the reverse order of removal.

E
• Install wheels with valve stems (D) facing away from
machine.
• Two-Wheel Drive: tighten cap screw to 73 N•m (54 lb-
MX14395 ft).
6. Install throttle handle (C). • Four-Wheel Drive: tighten lugs to 88 N•m (65 lb-ft).
7. Turn fasteners (A) vertical and install side panel (E). Pull
and turn fasteners to secure side panel onto instrument Rear Wheel Removal and Installation
panel assembly (D).
1. Lift machine high enough to remove weight from wheels.
8. Install screw (B) to secure instrument panel (D) onto
Place jack stands under machine frame.
pedestal.
9. Connect negative battery terminal.

Front Wheel Removal and Installation A

1. Lift machine high enough to remove weight from wheels. B

Place jack stands under machine frame.

A MX11940

2. Remove five cap screws (A) and rear wheel assembly

Installation is done in the reverse order of removal.

• Install wheels with valve stems (B) facing away from
machine.
• Tighten cap screws to 88 N•m (65 lb-ft).
MX11939

2-wheel drive shown; 4-wheel drive has five lugs

securing wheel to hub
2. Remove cap screw (A) and plate (B).
NOTE: Remove bearings only if replacement is
necessary.

Miscellaneous Repair - 561

MISCELLANEOUS REPAIR

Miscellaneous Repair - 562

 INDEX
Numerics 54C Jacksheave . . . . . . . . . . . . . . . . . . . . . . .519
54C Mower Deck Spindle Removal and
48C Mower Deck Spindle Removal and Installation . . 514
Installation . . . . . . . . . . . . . . . . . . . . . .517
54C Mower Deck Spindle Removal and Installation . . 517
62C Mower Deck Spindle Removal and
62C Mower Deck Spindle Removal and Installation . . 520
Installation . . . . . . . . . . . . . . . . . . . . . .520
A Cleaning Grass and Debris from Machine . . . .511
Alternative lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Mower Deck Belt Shield Removal and
Attachments Installation . . . . . . . . . . . . . . . . . . . . . .511
Component Location Mower Deck Blade Removal and Installation .513
PTO Generator . . . . . . . . . . . . . . . . . . . . . . . . 531 Mower Deck Blade Sharpen . . . . . . . . . . . . . .514
Conductors for 12 Volt Circuits . . . . . . . . . . . . . . . 529 Mower Deck Drive Shaft Removal and
Diagnosis Installation . . . . . . . . . . . . . . . . . . . . . .522
Loader Diagnosis . . . . . . . . . . . . . . . . . . . . . . 506 Mower Deck Drive Shaft Repair . . . . . . . . . . . .523
Mower Deck Diagnosis . . . . . . . . . . . . . . . . . . 503 Mower Deck Gearbox Removal and
Electrical Installation . . . . . . . . . . . . . . . . . . . . . .524
Common Circuit Tests . . . . . . . . . . . . . . . . . . 528 Mower Deck Gearbox Repair . . . . . . . . . . . . . .526
Conductors for 12 Volt Circuits . . . . . . . . . . . . 529 Repair Specifications . . . . . . . . . . . . . . . . . . . . . . .501
Diagnostic Information . . . . . . . . . . . . . . . . . . 528 Tests and Adjustments
Reading Electrical Schematics . . . . . . . . . . . . 527 Adjusting Cutting Height . . . . . . . . . . . . . . . . .507
Theory of Operation Information . . . . . . . . . . 528 Adjusting Loader Latch Rod . . . . . . . . . . . . . . .510
Wire Color Abbreviation Chart . . . . . . . . . . . . 528 Adjusting Mower Deck Wheels . . . . . . . . . . . .507
General Specifications . . . . . . . . . . . . . . . . . . . . . 499 Adjusting Mower Level Front to Rear . . . . . . . .509
Generator Circuit Diagnosis . . . . . . . . . . . . . . . . . 538 Adjusting Mower Level Side to Side . . . . . . . .508
Identification Numbers Cylinder Leakage Test . . . . . . . . . . . . . . . . . . .510
PTO Generator . . . . . . . . . . . . . . . . . . . . . . . . 530 Loader Lubrication . . . . . . . . . . . . . . . . . . . . . .510
Loader Specifications . . . . . . . . . . . . . . . . . . . . . . 500 Mower Deck Level Check and Adjustment . . .508
Mower Deck Blade Balance . . . . . . . . . . . . . . . . . 514 Wire Abbreviation Chart . . . . . . . . . . . . . . . . . . . . .528
Mower Deck Specifications . . . . . . . . . . . . . . . . . . 499 Avoid Harmful Asbestos Dust . . . . . . . . . . . . . . . . . . . . . .4
PTO Electrical Schematic . . . . . . . . . . . . . . . . . . . 536 Avoid Injury
PTO Generator Electrical Rotating Blades, Augers And PTO Shafts . . . . . . . . .5
Control Panel Removal and Installation . . . . . 547 Axle, front
Generator Assembly and Installation . . . . . . . 546 Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . .475
Generator Circuit Diagnosis . . . . . . . . . . . . . . 538 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .474
Generator Circuit Operation . . . . . . . . . . . . . . 538 B
Generator Ground Test . . . . . . . . . . . . . . . . . 542
Generator Removal and Disassembly . . . . . . 543 Brake
Generator Rotor Test . . . . . . . . . . . . . . . . . . . 541 PTO, disassembly/inspection/assembly . . . . . . . . .382
Generator Stator Test . . . . . . . . . . . . . . . . . . . 540 PTO, removal/installation . . . . . . . . . . . . . . . . . . . .381
Ground Fault Circuit Interrupter (GFCI) Brake test, Mid-PTO . . . . . . . . . . . . . . . . . . . . . . . . . . .363
Checks . . . . . . . . . . . . . . . . . . . . . . . 541 Brake/differential linkage
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .491
PTO Shield Removal and Installation . . . . . . . 543
Brakes
Rotor Bearing Removal and Installation . . . . . 545
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489
Rotor Fan Removal and Installation . . . . . . . . 545
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .488
Standard Electrical Schematic . . . . . . . . . . . . 536
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .495
Stator Excitation Field Restoration . . . . . . . . . 542
Break-in engine oil
Wiring Harness Legend . . . . . . . . . . . . . . . . . 535
4-cycle gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
PTO Generator Gear Case Removal . . . . . . . . . . 543
PTO Generator Specifications . . . . . . . . . . . . . . . 501 C
PTO Generator Wiring Harness Legend . . . . . . . . 535
California Proposition 65 Warning . . . . . . . . . . . . . . . . . .4
Recommended Lubricants Specifications . . . . . . . 500
Center valve block, hydrostatic power train . . . . . . . . .403
Repair
Charge pressure test . . . . . . . . . . . . . . . . . . . . . 360, 445
48C Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Charge pump
48C Jacksheave . . . . . . . . . . . . . . . . . . . . . . . 517
Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . .376
48C Mower Deck Spindle Removal and
Flow quick test, at charge pump . . . . . . . . . . . . . . .361
Installation . . . . . . . . . . . . . . . . . . . . . 514
Flow quick test, at couplers . . . . . . . . . . . . . . . . . .444
54C Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520

Index - 1
 INDEX
Pressure quick test, at charge pump . . . . . . . . . . 361 Steering Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
Pressure quick test, at couplers . . . . . . . . . . . . . . 444 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .355
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . 375 Transaxle Tests . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Component Location Differential
Attachments 2-Wheel Drive
PTO Generator . . . . . . . . . . . . . . . . . . . . . . . . 531 Disassembly/Assembly . . . . . . . . . . . . . . . . . .393
Brake/Differential Linkage (Exploded) . . . . . . . . . 487 Final pinion shaft, inspection . . . . . . . . . . . . . .393
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486 MFWD
Electrical, Engine Components (FD671D) . . . . . . 184 Disassembly/Assembly . . . . . . . . . . . . . . . . . .394
Electrical, Engine Components (FD711D EFI) . . . 185 Final pinion shaft, inspection . . . . . . . . . . . . . .394
Electrical, Engine Components (FH641D) . . . . . . 183 Differential Input Housing (MFWD)
Electrical, Instrument Panel . . . . . . . . . . . . . . . . . 186 Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . .425
Electrical, Machine Left Side . . . . . . . . . . . . . . . . 182 Differential lock Linkage, inspection . . . . . . . . . . . . . . .375
Electrical, Machine Right Side . . . . . . . . . . . . . . . 181 Differential lock Shaft, disassembly/assembly . . . . . . .392
Engine - Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . 27 Directional control valves Removal/installation . . . . . . .377
Engine - Liquid-Cooled Dispose of Waste Properly . . . . . . . . . . . . . . . . . . . . . . . .5
FD671D Engine Only . . . . . . . . . . . . . . . . . . . . 95 Drain interval, gasoline engine coolant . . . . . . . . . . . . . .19
FD711D Engine Only . . . . . . . . . . . . . . . . . . . . 96 Drive Shaft (MFWD) Removal/Installation . . . . . . . . . .423
Final Drive (MFWD) . . . . . . . . . . . . . . . . . . . . . . . 333 Drive shaft
Front Axle Assembly (MFWD) . . . . . . . . . . . . . . . 336 Disassembly/inspection/assembly . . . . . . . . . . . . .379
Front Axle Gear Case (MFWD) . . . . . . . . . . . . . . 334 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .378
Hydrostatic Power Train . . . . . . . . . . . . . . . . . . . . 331 Drive train
Rear PTO (optional) . . . . . . . . . . . . . . . . . . . . . . . 351 Mid and Rear PTO, removal and installation . . . . .384
Rear PTO Gear Case Assembly . . . . . . . . . . . . . . 337 Mid-PTO, removal/installation . . . . . . . . . . . . . . . .383
Steering System
2 - Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . 456
E
All Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . 457 Electrical
All Wheel Steer Rear Axle . . . . . . . . . . . . . . . 458 Charging Circuit Diagnosis - All Models . . . . . . . . .241
Control arm damper Charging Circuit Electrical Schematic . . . . . . . . . .240
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . 374 Charging Circuit Operation - All Models . . . . . . . . .239
Control linkage adjustment, transaxle . . . . . . . . . . . . . 365 Component Location
Coolant specifications Engine Components (FD671D) . . . . . . . . . . . .184
Gasoline engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine Components (FD711D EFI) . . . . . . . . .185
Cruise control linkage, check and adjustment . . . . . . . 366 Engine Components (FH641D) . . . . . . . . . . . .183
Cylinder, Steering Instrument Panel . . . . . . . . . . . . . . . . . . . . . . .186
Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 Machine Left Side . . . . . . . . . . . . . . . . . . . . . .182
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . 474 Machine Right Side . . . . . . . . . . . . . . . . . . . . .181
Cranking Circuit Diagnosis - All Models . . . . . . . . .237
D Cranking Circuit Electrical Schematic - All Models .236
Diagnosis Cranking Circuit Operation - All Models . . . . . . . . .235
Attachments Electrical Schematic - X465 (1 of 3) . . . . . . . . . . . .191
Loader Diagnosis . . . . . . . . . . . . . . . . . . . . . . 506 Electrical Schematic - X465 (2 of 3) . . . . . . . . . . . .192
Mower Deck Diagnosis . . . . . . . . . . . . . . . . . . 503 Electrical Schematic - X465 (3 of 3) . . . . . . . . . . . .193
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489 Electrical Schematic - X475 and X575 (1 of 3) . . . .194
Engine - Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . 33 Electrical Schematic - X475 and X575 (2 of 3) . . . .195
Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . 102 Electrical Schematic - X475 and X575 (3 of 3) . . . .196
Engine Tests . . . . . . . . . . . . . . . . . . . . . . . . . 106 Electrical Schematic - X485 and X585 (1 of 4) . . . .197
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 Electrical Schematic - X485 and X585 (2 of 4) . . . .198
Preliminary Hydraulic System Inspection . . . . 442 Electrical Schematic - X485 and X585 (3 of 4) . . . .199
System Tests . . . . . . . . . . . . . . . . . . . . . . . . . 443 Electrical Schematic - X485 and X585 (4 of 4) . . . .200
Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . 353 Fuel Injection Sensor and Diagnostic Circuit
Hydrostatic transmission Tests . . . . . . . . . . . . . . . 356 Diagnosis - X485 and X585 . . . . . . . . . . . .294
Mid-PTO System . . . . . . . . . . . . . . . . . . . . . . . . . 355 Fuel Injection Sensor and Diagnostic Circuit
Mid-PTO System Tests . . . . . . . . . . . . . . . . . . . . . 358 Electrical Schematic - X485 and X585 . . .291
PTO Generator Circuits . . . . . . . . . . . . . . . . . . . . 538 Fuel Injection Sensor and Diagnostic Circuit
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 Operation - X485 and X585 . . . . . . . . . . . .290

Index - 2
 INDEX
Fuel Pump and Fuel Injector Circuit Diagnosis - Tests and Adjustments
X485 and X585 . . . . . . . . . . . . . . . . . . . . 286 Air Temperature Test - X485 and X585 . . . . . .322
Fuel Pump and Fuel Injector Circuit Electrical Battery - Charge . . . . . . . . . . . . . . . . . . . . . . . .300
Schematic - X485 and X585 . . . . . . . . . . 283 Battery - Load Test . . . . . . . . . . . . . . . . . . . . .300
Fuel Pump and Fuel Injector Circuit Operation - Battery Voltage and Specific Gravity Test . . . .299
X485 and X585 . . . . . . . . . . . . . . . . . . . . 282 Brake Switch Test and Adjustment . . . . . . . . .313
Fuel Pump and Fuel Shutoff Circuit Diagnosis - Common Circuit Tests . . . . . . . . . . . . . . . . . . .298
X465, X475 and X575 . . . . . . . . . . . . . . . 279 Coolant Temperature Sensor Test - X485 and
Fuel Pump and Fuel Shutoff Circuit Electrical X585 . . . . . . . . . . . . . . . . . . . . . . . . . .322
Schematic - X465, X475 and X575 . . . . . 277 Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
Fuel Pump and Fuel Shutoff Circuit Operation - Engine Coolant Temperature Sensor Test -
X465, X475 and X575 . . . . . . . . . . . . . . . 276 X475, X575, X485, and X585 . . . . . . .310
Ignition Circuit Diagnosis - X465, X475 and X575 246 Engine Oil Pressure Switch Test . . . . . . . . . . .311
Ignition Circuit Diagnosis - X485 and X585 . . . . . 253 Field Windings Test . . . . . . . . . . . . . . . . . . . . .306
Ignition Circuit Electrical Schematic - X465, X475 Fuel Injection Module Test - X485 and X585 . .320
and X575 . . . . . . . . . . . . . . . . . . . . . . . . . 244 Fuel Injector Test - X485 and X585 . . . . . . . . .320
Ignition Circuit Electrical Schematic - X485 and Fuel Shutoff Solenoid Test - X475 and X575 . .318
X585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Fuel Tank Sensor Test . . . . . . . . . . . . . . . . . . .319
Ignition Circuit Operation - X465, X475 and X575 243 Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315
Ignition Circuit Operation - X485 and X585 . . . . . 249 Ground Circuit Tests . . . . . . . . . . . . . . . . . . . .298
Instrument Panel Circuit Diagnosis - All Models . . 270 Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . . .324
Instrument Panel Circuit Electrical Schematic - Ignition Interlock Test . . . . . . . . . . . . . . . . . . . .308
All Models (SN -30000) . . . . . . . . . . . . . . 268 Instrument Panel Light Test . . . . . . . . . . . . . . .316
Instrument Panel Circuit Electrical Schematic - Lights Switch Test . . . . . . . . . . . . . . . . . . . . . .311
All Models (SN 30001-) . . . . . . . . . . . . . . 269 PTO Solenoid Test . . . . . . . . . . . . . . . . . . . . . .317
Instrument Panel Circuit Operation - All Models . . 266 PTO Switch Test (optional) . . . . . . . . . . . . . . .317
Lights Circuit Diagnosis - All Models . . . . . . . . . . 274 PTO/RIP Switch Test . . . . . . . . . . . . . . . . . . . .312
Lights Circuit Electrical Schematic - All Models . . 273 RIO Switch Adjustment . . . . . . . . . . . . . . . . . .314
Lights Circuit Operation - All Models . . . . . . . . . . 272 RIO Switch Test . . . . . . . . . . . . . . . . . . . . . . . .314
PTO Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . 263 Regulated Amperage and Voltage Test . . . . . .301
PTO Circuit Electrical Schematic . . . . . . . . . . . . . 261 Regulated Voltage Test . . . . . . . . . . . . . . . . . .302
PTO Generator Schematics . . . . . . . . . . . . . . . . . 536 Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
PTO/RIP Circuit Operation . . . . . . . . . . . . . . . . . . 259 Seat Switch Test . . . . . . . . . . . . . . . . . . . . . . .313
Power Circuit Diagnosis - X465, X475 and X575 . 223 Service Timer Reset Switch . . . . . . . . . . . . . . .315
Power Circuit Diagnosis - X485 and X585 . . . . . . 231 Spark Plug Gap Adjustment . . . . . . . . . . . . . . .323
Power Circuit Electrical Schematic - X465 . . . . . . 218 Spark Plug Gap Test . . . . . . . . . . . . . . . . . . . .323
Power Circuit Electrical Schematic - X475 and Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .324
X575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Starter Armature Test . . . . . . . . . . . . . . . . . . .307
Power Circuit Electrical Schematic - X485 and Starter Solenoid Test . . . . . . . . . . . . . . . . . . . .305
X585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Starting Motor Amp Draw Test . . . . . . . . . . . . .305
Power Circuit Operation - X465 . . . . . . . . . . . . . . 217 Starting Motor Condition . . . . . . . . . . . . . . . . .304
Power Circuit Operation - X475 and X575 . . . . . . 220 Starting Motor No-load Amperage and RPM
Power Circuit Operation - X485 and X585 . . . . . . 226 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .306
Repair Stator Resistance Test . . . . . . . . . . . . . . . . . . .304
Ignition Coil Replacement . . . . . . . . . . . . . . . 325 Unregulated Voltage Test - X475, X575, X485,
Stator Replacement . . . . . . . . . . . . . . . . . . . . 326 and X585 . . . . . . . . . . . . . . . . . . . . . . .303
Schematic And Wiring Harness Legend - X475 and Vacuum Pressure Test - X485 and X585 . . . .321
X575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Unregulated Voltage Test - X465 . . . . . . . . . . . . . .303
Schematic And Wiring Harness Legend - X485 and Voltage Regulator/Rectifier Test - X465 . . . . . . . . .302
X585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 W1 Main Wiring Harness - X465 (1 of 2) . . . . . . . .201
Specifications W1 Main Wiring Harness - X465 (2 of 2) . . . . . . . .202
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 W1 Main Wiring Harness - X475 and X575 (1 of 2) 204
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 W1 Main Wiring Harness - X475 and X575 (2 of 2) 205
Test and Adjustment . . . . . . . . . . . . . . . . . . . 178 W1 Main Wiring Harness - X485 and X585 (1 of 2) 207
W1 Main Wiring Harness - X485 and X585 (2 of 2) 208
W1 Main Wiring Harness Color Codes - X465 . . . .212

Index - 3
 INDEX
W1 Main Wiring Harness Color Codes - X475 and Intake Manifold Removal and Installation . . . . . . . . .50
X575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Muffler Removal and Installation . . . . . . . . . . . . . . .51
W1 Main Wiring Harness Color Codes - X485 and Oil Pickup Removal and Installation . . . . . . . . . . . . .78
X585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Oil Pump Repair Specifications . . . . . . . . . . . . . . . .24
W2 Engine Wiring Harness - X475 and X575 . . . . 206 Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . .77
W2 Engine Wiring Harness - X485 and X585 . . . . 209 Oil Pump Removal and Installation . . . . . . . . . . . . .76
W2 Engine Wiring Harness Circuit Schematic - Oil Screen Inspection/Cleaning . . . . . . . . . . . . . . . .78
X485 and X585 . . . . . . . . . . . . . . . . . . . . 210 Piston Removal and Installation . . . . . . . . . . . . . . . .59
W2 Engine Wiring Harness Color Codes - X475 and Piston and Cylinder Inspection . . . . . . . . . . . . . . . . .61
X575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
W2 Engine Wiring Harness Color Codes - X485 and Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . .24
X585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Rocker Arms Removal and Installation . . . . . . . . . .57
W2, W6 and W7 Engine Wiring Harness - X465 . 203 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
W3 Headlight Wiring Harness . . . . . . . . . . . . . . . . 211 Starting Motor
W3 Headlight Wiring Harness Color Codes . . . . . 216 Disassembly and Assembly . . . . . . . . . . . . . . . .83
W4 Rear Wiring Harness . . . . . . . . . . . . . . . . . . . 211 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
W4 Rear Wiring Harness Color Codes . . . . . . . . . 216 Removal and Installation . . . . . . . . . . . . . . . . . .82
W5 PTO Option Wiring Harness . . . . . . . . . . . . . . 211 Solenoid Tests . . . . . . . . . . . . . . . . . . . . . . . . . .82
W5 PTO Option Wiring Harness Color Codes . . . 216 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Engagement pressure and brake test, Mid-PTO . . . . . 363 Starting Motor Troubleshooting . . . . . . . . . . . . . . . .31
Engine - Air-Cooled Stator Coil Inspection . . . . . . . . . . . . . . . . . . . . . . . .81
Air cleaner Removal/Inspection/Assembly . . . . . . . 43 Test & Adjustments Specifications . . . . . . . . . . . . . .23
Breather Valve Inspection . . . . . . . . . . . . . . . . . . . . 76 Tests & Adjustments
Breather Valve Removal and Installation . . . . . . . . 75 Choke Adjustment . . . . . . . . . . . . . . . . . . . . . . .35
Camshaft Compression Test . . . . . . . . . . . . . . . . . . . . . . .37
Disassembly/Inspection . . . . . . . . . . . . . . . . . . 70 Crankcase Vacuum Test . . . . . . . . . . . . . . . . . .39
Removal/Installation . . . . . . . . . . . . . . . . . . . . . 69 Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . .40
Repair Specifications . . . . . . . . . . . . . . . . . . . . 24 Governor Adjustment . . . . . . . . . . . . . . . . . . . . .36
Carburetor Clean/Inspect/Rebuild . . . . . . . . . . . . . 50 High Idle Speed Adjustment . . . . . . . . . . . . . . .36
Carburetor Disassembly/Assembly . . . . . . . . . . . . . 45 Low Idle Speed Adjustment . . . . . . . . . . . . . . . .36
Carburetor Removal/Installation . . . . . . . . . . . . . . . 44 Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . .41
Component Location . . . . . . . . . . . . . . . . . . . . . . . . 27 Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . 74 Throttle Cable Adjustment . . . . . . . . . . . . . . . . .35
Crankcase Cover Inspection . . . . . . . . . . . . . . . . . . 67 Valve Clearance Adjustment . . . . . . . . . . . . . . .38
Crankcase Cover Removal and Installation . . . . . . 65 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . .28
Crankshaft Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . .25
Repair Specifications . . . . . . . . . . . . . . . . . . . . 24 Troubleshooting
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . 73 Engine Erratic/Loss of Power . . . . . . . . . . . . . . .31
Crankshaft Removal/Replacement . . . . . . . . . . . . . 72 Engine Hard To Start . . . . . . . . . . . . . . . . . . . . .30
Cylinder Bore Honing . . . . . . . . . . . . . . . . . . . . . . . 64 Engine Malfunctions at Low Speed . . . . . . . . . .30
Cylinder Bore Resizing . . . . . . . . . . . . . . . . . . . . . . 64 Engine Runs Erratically . . . . . . . . . . . . . . . . . . .30
Cylinder Bore, Piston & Rings Oil Consumption Is Excessive . . . . . . . . . . . . . .31
Repair Specifications . . . . . . . . . . . . . . . . . . . . 25 Valve Train Removal and Installation . . . . . . . . . . . .58
Cylinder Head Assembly Valves & Valve Lifter Repair Specifications . . . . . . .24
Repair Specifications . . . . . . . . . . . . . . . . . . . . 24 Engine - Liquid-Cooled
Cylinder Head Removal and Installation . . . . . . . . . 55 Air Cleaner Removal/Installation . . . . . . . . . . . . . .128
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Breather Valve
Engine Removal and Installation . . . . . . . . . . . . . . 52 Removal and Installation . . . . . . . . . . . . . . . . .166
Flywheel Removal and Installation . . . . . . . . . . . . . 79 Camshaft
Fuel Pump Remove & Install . . . . . . . . . . . . . . . . . 42 Disassembly/Inspection . . . . . . . . . . . . . . . . . .162
Fuel Pump and Fuel Filter Inspection . . . . . . . . . . . 43 Removal and Installation . . . . . . . . . . . . . . . . .161
Fuel/Air System Tests & Adjustments . . . . . . . . . . 24 Repair Specifications . . . . . . . . . . . . . . . . . . . . .92
General Specifications . . . . . . . . . . . . . . . . . . . . . . 23 Connecting Rod
Governor Assembly Inspection . . . . . . . . . . . . . . . . 69 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Governor Assembly Removal/Replacement . . . . . . 67 Coolant Pump Removal/Installation . . . . . . . . . . . .122
Ignition Coil Removal and Installation . . . . . . . . . . . 81 Cooling Fan and Bracket Removal/Installation . . .122

Index - 4
 INDEX
Crankcase Cover Inspection . . . . . . . . . . . . . . . . . 151 Starting Motor
Crankcase Cover Removal and Installation . . . . . 150 Disassembly/Assembly . . . . . . . . . . . . . . . . . .138
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Removal and Installation . . . . . . . . . . . . . . . . .138
Removal/Replacement . . . . . . . . . . . . . . . . . . 163 Tests & Adjustments
Repair Specifications . . . . . . . . . . . . . . . . . . . . 92 Compression Test . . . . . . . . . . . . . . . . . . . . . .111
Cylinder Bore Cooling System Test . . . . . . . . . . . . . . . . . . . .120
Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Crankcase Vacuum Test . . . . . . . . . . . . . . . . .113
Resizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Engine Oil Pressure Test . . . . . . . . . . . . . . . . .114
Cylinder Bore, Pistons and Rings Fan Belt Tension Adjustment . . . . . . . . . . . . . .117
Repair Specifications . . . . . . . . . . . . . . . . . . . . 93 Fast Idle Speed Adjustment . . . . . . . . . . . . . . .111
Cylinder Head Assembly Governor Adjustment . . . . . . . . . . . . . . . . . . . .109
Repair Specifications . . . . . . . . . . . . . . . . . . . . 92 Low Idle Speed Adjustment . . . . . . . . . . . . . . .110
Cylinder Head Removal/Installation . . . . . . . . . . . 134 Radiator Bubble Test . . . . . . . . . . . . . . . . . . . .118
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Radiator Cap Pressure Test . . . . . . . . . . . . . .118
Engine Removal and Installation . . . . . . . . . . . . . 143 Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . .118
Engine Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Throttle Cable Adjustment . . . . . . . . . . . . . . . .109
FD671D Engine Only Throttle Lever Adjustment . . . . . . . . . . . . . . . .108
Component Location . . . . . . . . . . . . . . . . . . . . 95 Valve Clearance Adjustment . . . . . . . . . . . . . .112
Repair Tests & Adjustments Specifications . . . . . . . . . . . . .92
Carburetor Removal and Installation . . . . 129 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . .97
Intake Manifold Removal/Installation . . . . 135 Thermostat Removal and Installation . . . . . . . . . . .120
Tests & Adjustments Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . .93
Choke Adjustment . . . . . . . . . . . . . . . . . . 109 Valve Train Removal and Installation . . . . . . . . . . .149
Fuel Pump Flow Test for Carburetor . . . . 115 Valves & Valve Lifter
Fuel Pump Pressure Test for Carburetor . 115 Repair Specifications . . . . . . . . . . . . . . . . . . . . .92
FD711D Engine Only Engine oil specifications
Component Location . . . . . . . . . . . . . . . . . . . . 96 4-cycle, gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Repair
Fuel Injector Removal/Installation . . . . . . 132
F
Fuel Pressure Regulator Removal and Face seal fittings torque
Installation . . . . . . . . . . . . . . . . . . 133 With inch stud ends . . . . . . . . . . . . . . . . . . . . . . . . .11
Intake Manifold Removal/Installation . . . . 136 With metric stud ends . . . . . . . . . . . . . . . . . . . . . . . .12
Throttle Body Removal/Installation . . . . . 131 Fender Deck Removal and Installation . . . . . . . . . . . . .552
Tests & Adjustments Final Drive Cover Removal/Installation (MFWD) . . . . .418
Bleed Fuel System . . . . . . . . . . . . . . . . . . 117 Final Drive Housing Removal/Installation (MFWD) . . . .420
Fuel Pump Pressure Test for Fuel Final pinion shaft
Injection . . . . . . . . . . . . . . . . . . . . 116 2-Wheel Drive
Fan belt, removal/installation . . . . . . . . . . . . . . . . 121 Differential, inspection . . . . . . . . . . . . . . . . . . .393
Flywheel Removal and Installation . . . . . . . . . . . . 146 MFWD
Fuel/Air System Tests & Adjustments . . . . . . . . . . 92 Differential, inspection . . . . . . . . . . . . . . . . . . .394
General Specifications . . . . . . . . . . . . . . . . . . . . . . 91 Foot Control Linkage, Removal/Installation . . . . . . . . .368
Governor Assembly Removal and Installation . . . 152 Front Axle Housing (MFWD) Disassembly/Assembly . .426
Muffler Removal and Installation . . . . . . . . . . . . . 127 Front Wheel Removal and Installation . . . . . . . . . . . . .561
Oil Pump Front axle
Repair Specifications . . . . . . . . . . . . . . . . . . . . 93 Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . .475
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . 167 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .474
Oil Pump Removal and Installation . . . . . . . . . . . . 166 Front pivot, disassembly/assembly . . . . . . . . . . . . . . . .480
Oil Screen Removal and Installation . . . . . . . . . . . 169 Fuel gauge sensor, removal/installation . . . . . . . . . . . .554
Piston Removal and Installation . . . . . . . . . . . . . . 154 Fuel pump, removal/installation . . . . . . . . . . . . . . . . . .554
Piston and Cylinder Fuel tank, removal/installation . . . . . . . . . . . . . . . . . . .553
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Radiator Removal/Installation . . . . . . . . . . . . . . . . 124
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . 92
Rocker Arms Removal and Installation . . . . . . . . . 147

Index - 5
 INDEX
G K
Gasoline engine coolant Knuckle assembly
Drain interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 All wheel steer, removal/installation . . . . . . . . . . . .417
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Knuckle housing, disassembly/assembly . . . . . . . . . . .417
Gasoline specifications
4-cycle engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
L
Gasoline storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Leakage test
Gear case oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . .447
Gear transmission grease . . . . . . . . . . . . . . . . . . . . . . . 18 Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447
Ground Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 298 Steering valve and cylinder . . . . . . . . . . . . . . . . . .465
Levers, Hydraulic control, inspection . . . . . . . . . . . . . .451
H Lift Linkage Removal/Installation . . . . . . . . . . . . . . . . .556
Handle Chemical Products Safely . . . . . . . . . . . . . . . . . . 5 Lift cylinder
Handling And Servicing Batteries . . . . . . . . . . . . . . . . . . 1 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447
Headlights, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 555 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .450
Hood Removal and Installation . . . . . . . . . . . . . . . . . . 559 Linkage
Hydraulic control levers and linkage inspection . . . . . 451 Brake/differential
Hydraulic control valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .491
Disassembly/inspection/assembly . . . . . . . . . . . . 449 Cruise control linkage, check and adjustment . . . .366
Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 Differential lock, inspection . . . . . . . . . . . . . . . . . . .375
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 448 Foot Control, Removal/Installation . . . . . . . . . . . . .368
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic control levers, Inspection . . . . . . . . . . . .451
Hydraulic oil warm-up procedure . . . . . . . . . 360, 444, 465 Intermediate, all wheel steer, installation . . . . . . . .479
Hydraulics Lift, Removal/Installation . . . . . . . . . . . . . . . . . . . .556
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 Rear steering
Hydraulic System Tests . . . . . . . . . . . . . . . . . 443 All wheel steer . . . . . . . . . . . . . . . . . . . . . . . . .477
Preliminary Hydraulic System Inspection . . . . 442 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . 435 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Hydrostatic power train Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Center section and directional control valves, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477
system operation . . . . . . . . . . . . . . . . . . . 340 Transaxle control, adjustment . . . . . . . . . . . . . . . .365
Center valve block . . . . . . . . . . . . . . . . . . . . . . . . 403 Transaxle, full forward adjustment . . . . . . . . . . . . .366
Transaxle oil flow . . . . . . . . . . . . . . . . . . . . . . . . . 343 Live With Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hydrostatic pressure relief valve (45 loader) Loader Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .510
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 Lubricant
Hydrostatic pump, inspection . . . . . . . . . . . . . . . . . . . 406 Alternative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Hydrostatic transmission Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Hydrostatic transmission motor
M
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 MFWD Removal/Installation . . . . . . . . . . . . . . . . . . . . .423
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399 Machine serial number locations . . . . . . . . . . . . . . . . . .20
Hydrostatic transmission motor (2-Wheel Drive) Metric fastener torque values
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 400 Grade 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Hydrostatic transmission motor (MFWD) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 401 Mid-PTO
Hydrostatic transmission oil . . . . . . . . . . . . . . . . . . . . . . 16 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .355
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
I Drive train, removal/installation . . . . . . . . . . . . . . .383
Identification Numbers Engagement pressure and brake test . . . . . . . . . .363
PTO Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 Mixing of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . . . . 325 Mower Deck Belt Shield Removal and Installation . . . .511
Illuminate Work Area Safely . . . . . . . . . . . . . . . . . . . . . . 3 Mower Deck Blade Balance . . . . . . . . . . . . . . . . . . . . .514
Inch Fastener Torque Values . . . . . . . . . . . . . . . . . . . . 10 Mower Deck Blade Removal and Installation . . . . . . . .513
Instrument Panel Removal and Installation . . . . . . . . . 560 Mower Deck Blade Sharpen . . . . . . . . . . . . . . . . . . . . .514

Index - 6
 INDEX
Mower Deck Drive Shaft Removal and Installation . . . 522 Power train, system operation, external . . . . . . . . . . . .346
Mower Deck Drive Shaft Repair . . . . . . . . . . . . . . . . . 523 Pressure relief valve, hydrostatic (45 loader) . . . . . . . .378
Mower Deck Gearbox Removal and Installation . . . . . 524 Pressure test, charge . . . . . . . . . . . . . . . . . . . . . 360, 445
Mower Deck Gearbox Repair . . . . . . . . . . . . . . . . . . . 526 Prevent Acid Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Muffler Removal and Installation Prevent Battery Explosions . . . . . . . . . . . . . . . . . . . . . . . .2
Engine - Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . 127
R
Reading Electrical Schematics . . . . . . . . . . . . . . . . . . .175
O Rear PTO
O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Drive train, removal and installation . . . . . . . . . . . .384
O-ring face seal fittings . . . . . . . . . . . . . . . . . . . . . . . . . 13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
Output Shaft (MFWD) Removal and Installation . . . . . . . . . . . . . . . . . . . .387
Removal/Installation) . . . . . . . . . . . . . . . . . . . . . . 396 Rear Wheel Removal and Installation . . . . . . . . . . . . . .561
Rear axle assembly
P All wheel steer, disassembly/assembly . . . . . . . . .416
PTO Two wheel steer, disassembly, assembly . . . . . . .414
Mid and Rear Rear axle assembly (All Wheel Steer)
Drive train, removal and installation . . . . . . . . 384 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .415
Rear Rear axle assembly (Two Wheel Steer)
Drive train, removal and installation . . . . . . . . 384 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .413
Removal and Installation . . . . . . . . . . . . . . . . 387 Rear pivot, disassembly/assembly . . . . . . . . . . . . . . . .480
Relief Valve Rear steering
Disassembly/inspection/Assembly . . . . . . . . . 381 Linkage
Removal/installation . . . . . . . . . . . . . . . . . . . . 381 All wheel steer . . . . . . . . . . . . . . . . . . . . . . . . .477
Solenoid Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Disassembly/assembly . . . . . . . . . . . . . . . . . . 380 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Removal/installation . . . . . . . . . . . . . . . . . . . . 379 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
PTO Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477
Disassembly/inspection/assembly . . . . . . . . . . . . 382 Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . .1
Removal/installation . . . . . . . . . . . . . . . . . . . . . . . 381 Remove Paint Before Welding Or Heating . . . . . . . . . . . .4
PTO Generator Repair
Alternator Components . . . . . . . . . . . . . . . . . . . . . 532 Attachments
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531 48C Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516
Control Panel Removal and Installation . . . . . . . . 547 48C Jacksheave . . . . . . . . . . . . . . . . . . . . . . .517
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535, 536 48C Mower Deck Spindle Removal and
Generator Ground Test . . . . . . . . . . . . . . . . . 542 Installation . . . . . . . . . . . . . . . . . . . . . .514
Ground Fault Circuit Interrupter (GFCI) 54C Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .520
Checks . . . . . . . . . . . . . . . . . . . . . . . 541 54C Jacksheave . . . . . . . . . . . . . . . . . . . . . . .519
Rotor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541 54C Mower Deck Spindle Removal and
Stator Excitation Field Restoration . . . . . . . . . 542 Installation . . . . . . . . . . . . . . . . . . . . . .517
Stator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 62C Mower Deck Spindle Removal and
Electrical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 538 Installation . . . . . . . . . . . . . . . . . . . . . .520
Electrical Operation Cleaning Grass and Debris from Machine . . . .511
Attachments Mower Deck Belt Shield Removal and
Generator Circuit Operation . . . . . . . . . . . 538 Installation . . . . . . . . . . . . . . . . . . . . . .511
Gear Box Components . . . . . . . . . . . . . . . . . . . . . 534 Mower Deck Blade Balance . . . . . . . . . . . . . . .514
Gear Case Removal . . . . . . . . . . . . . . . . . . . . . . . 543 Mower Deck Blade Removal and Installation .513
Generator Assembly and Installation . . . . . . . . . . 546 Mower Deck Blade Sharpen . . . . . . . . . . . . . .514
Generator Removal and Disassembly . . . . . . . . . 543 Mower Deck Drive Shaft Removal and
PTO Shield Removal and Installation . . . . . . . . . . 543 Installation . . . . . . . . . . . . . . . . . . . . . .522
Rotor Bearing Removal and Installation . . . . . . . . 545 Mower Deck Drive Shaft Repair . . . . . . . . . . . .523
Rotor Fan Removal and Installation . . . . . . . . . . . 545 Mower Deck Gearbox Removal and
PTO clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 Installation . . . . . . . . . . . . . . . . . . . . . .524
Park Machine Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mower Deck Gearbox Repair . . . . . . . . . . . . . .526
Power train, hydraulic schematic . . . . . . . . . . . . . . . . . 433 Repair Specifications . . . . . . . . . . . . . . . . . . . .501

Index - 7
 INDEX
Electrical Stator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .326
Ignition Coil Replacement . . . . . . . . . . . . . . . 325 Steering
Stator Replacement . . . . . . . . . . . . . . . . . . . . 326 Column, removal/installation . . . . . . . . . . . . . . . . .468
Engine - Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . 42 Cylinder, leakage test . . . . . . . . . . . . . . . . . . . . . . .465
Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . 120 Cylinder, removal/installation . . . . . . . . . . . . . . . . .474
PTO Generator Field Restoration . . . . . . . . . . . . . 542 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463
Replace Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
Front and rear pivots, disassembly/assembly . . . .480
S Intermediate, linkage
Schematic all wheel steer, installation . . . . . . . . . . . . . . . .479
Hydraulic, power train . . . . . . . . . . . . . . . . . . . . . . 433 Operation, all wheel steer . . . . . . . . . . . . . . . . . . . .459
Service Machines Safely . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear, linkage
Service Tires Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 All wheel steer . . . . . . . . . . . . . . . . . . . . . . . . .477
Service recommendations Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
O-ring face seal fittings . . . . . . . . . . . . . . . . . . . . . . 13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Drive, disassembly/inspection/assembly . . . . . . . 379 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477
Drive, removal/installation . . . . . . . . . . . . . . . . . . . 378 Steering valve
Shaft, differential lock, disassembly/assembly . . . . . . 392 Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . .471
Specifications Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465
Brakes Operation
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .462
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485 Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460
Test and Adjustment . . . . . . . . . . . . . . . . . . . 485 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461
Electrical Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .469
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Support Machine Properly . . . . . . . . . . . . . . . . . . . . . . . .3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Synthetic lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Test and adjustment . . . . . . . . . . . . . . . . . . . . 178
General Specifications T
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 499 Tests and Adjustments
Hydraulic Attachments
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431 Adjusting Cutting Height . . . . . . . . . . . . . . . . .507
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 Adjusting Loader Latch Rod . . . . . . . . . . . . . . .510
Test and adjustment . . . . . . . . . . . . . . . . . . . . 431 Adjusting Mower Deck Wheels . . . . . . . . . . . .507
Loader Specifications Adjusting Mower Level Front to Rear . . . . . . . .509
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Adjusting Mower Level Side to Side . . . . . . . .508
Miscellaneous Cylinder Leakage Test . . . . . . . . . . . . . . . . . . .510
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551 Loader Lubrication . . . . . . . . . . . . . . . . . . . . . .510
Mower Deck Specifications Mower Deck Level Check and Adjustment . . .508
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 499 Electrical
PTO Generator Specifications Air Temperature Test - X485 and X585 . . . . . .322
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Battery - Charge . . . . . . . . . . . . . . . . . . . . . . . .300
Power train Battery - Load Test . . . . . . . . . . . . . . . . . . . . .300
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Battery Voltage and Specific Gravity Test . . . .299
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Brake Switch Test and Adjustment . . . . . . . . .313
Test and adjustment . . . . . . . . . . . . . . . . . . . . 329 Common Circuit Tests . . . . . . . . . . . . . . . . . . .298
Recommended Lubricants Specifications Coolant Temperature Sensor Test - X485 and
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 500 X585 . . . . . . . . . . . . . . . . . . . . . . . . . .322
Repair Specifications Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Engine Coolant Temperature Sensor Test -
Steering X475, X575, X485, and X585 . . . . . . .310
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 Engine Oil Pressure Switch Test . . . . . . . . . . .311
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 Field Windings Test . . . . . . . . . . . . . . . . . . . . .306
Test and adjustment . . . . . . . . . . . . . . . . . . . . 455 Fuel Injection Module Test - X485 and X585 . .320
Spindle Housing (MFWD) Fuel Injector Test - X485 and X585 . . . . . . . . .320
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 422 Fuel Shutoff Solenoid Test - X475 and X575 . .318

Index - 8
 INDEX
Fuel Tank Sensor Test . . . . . . . . . . . . . . . . . . 319 Transaxle
Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411
Ground Circuit Tests . . . . . . . . . . . . . . . . . . . 298 Case, inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .411
Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . . . 324 Control linkage adjustment . . . . . . . . . . . . . . . . . . .365
Ignition Interlock Test . . . . . . . . . . . . . . . . . . . 308 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .355
Instrument Panel Light Test . . . . . . . . . . . . . . 316 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Lights Switch Test . . . . . . . . . . . . . . . . . . . . . 311 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407
PTO Solenoid Test . . . . . . . . . . . . . . . . . . . . . 317 Internal system operation . . . . . . . . . . . . . . . . . . . .347
PTO Switch Test (optional) . . . . . . . . . . . . . . 317 Linkage full forward adjustment . . . . . . . . . . . . . . .366
PTO/RIP Switch Test . . . . . . . . . . . . . . . . . . . 312 Neutral adjustment . . . . . . . . . . . . . . . . . . . . . . . . .364
RIO Switch Adjustment . . . . . . . . . . . . . . . . . 314 Oil flow system operation . . . . . . . . . . . . . . . . . . . .343
RIO Switch Test . . . . . . . . . . . . . . . . . . . . . . . 314 Removal/installation . . . . . . . . . . . . . . . . . . . . . . . .390
Regulated Amperage and Voltage Test . . . . . 301 Right cover, disassembly/assembly . . . . . . . . . . . .410
Regulated Voltage Test . . . . . . . . . . . . . . . . . 302 Transmission oil, hydrostatic . . . . . . . . . . . . . . . . . . . . . .16
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Seat Switch Test . . . . . . . . . . . . . . . . . . . . . . 313
U
Service Timer Reset Switch . . . . . . . . . . . . . . 315 Understand Signal Words . . . . . . . . . . . . . . . . . . . . . . . . .1
Spark Plug Gap Adjustment . . . . . . . . . . . . . . 323 Use Proper Lifting Equipment . . . . . . . . . . . . . . . . . . . . . .3
Spark Plug Gap Test . . . . . . . . . . . . . . . . . . . 323 Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Using High Pressure Washers . . . . . . . . . . . . . . . . . . . . .3
Starter Armature Test . . . . . . . . . . . . . . . . . . . 307 V
Starter Solenoid Test . . . . . . . . . . . . . . . . . . . 305
Starting Motor Amp Draw Test . . . . . . . . . . . . 305 Valve
Starting Motor Condition . . . . . . . . . . . . . . . . . 304 Hydraulic control
Starting Motor No-load Amperage and RPM Disassembly/inspection/assembly . . . . . . . . . .449
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 306 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . .447
Stator Resistance Test . . . . . . . . . . . . . . . . . . 304 Removal/Installation . . . . . . . . . . . . . . . . . . . . .448
Unregulated Voltage Test - X465 . . . . . . . . . . 303 PTO Relief
Unregulated Voltage Test - X475, X575, X485, Disassembly/inspection/assembly . . . . . . . . . .381
and X585 . . . . . . . . . . . . . . . . . . . . . . 303 Removal/installation . . . . . . . . . . . . . . . . . . . . .381
Vacuum Pressure Test - X485 and X585 . . . . 321 PTO Solenoid
Voltage Regulator/Rectifier Test - X465 . . . . . 302 Disassembly/assembly . . . . . . . . . . . . . . . . . .380
Engine - Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal/installation . . . . . . . . . . . . . . . . . . . . .379
Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . 108 Steering
Theory of Operation Disassembly/assembly . . . . . . . . . . . . . . . . . .471
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 Operation, manual . . . . . . . . . . . . . . . . . . . . . .462
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Operation, neutral . . . . . . . . . . . . . . . . . . . . . .460
Engine - Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . 28 Operation, turning . . . . . . . . . . . . . . . . . . . . . .461
Engine - Liquid-Cooled . . . . . . . . . . . . . . . . . . . . . . 97 Removal/installation . . . . . . . . . . . . . . . . . . . . .469
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 W
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Warm-up procedure
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . 444, 465
Toe-in adjustment
Warm-up procedure, hydraulic oil . . . . . . . . . . . . . . . . .360
All wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Wear Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . .2
Two wheel steer . . . . . . . . . . . . . . . . . . . . . . . . . . 466
Work In Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Torque values
Work In Ventilated Area . . . . . . . . . . . . . . . . . . . . . . . . . .4
Face seal fittings
With inch stud ends . . . . . . . . . . . . . . . . . . . . . 11
With metric stud ends . . . . . . . . . . . . . . . . . . . . 12
Inch Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Metric fastener, grade 7 . . . . . . . . . . . . . . . . . . . . . 14
Metric fasteners, standard . . . . . . . . . . . . . . . . . . . . 9
Straight fitting or special nut . . . . . . . . . . . . . . . . . . 14

Index - 9
INDEX

Index - 10